Cutting Procedure - By Copying

1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.)

2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place.

3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws.

4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad:

^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned.

^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green.





^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green.

*5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage.

NOTE:
Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.*

6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw.

7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs.

8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.)





9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws.





10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done.

NOTE:
The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose.

11. Turn on the cutter motor with the motor start switch.

[NOTICE]

^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth.

* ^ To avoid breaking the cutter bit, never back up while cutting.*

^ Wear proper eye protection (safety glasses, goggles, etc.)





12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever.

13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor.

14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor.

15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place.

16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key.

17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys.

18. Use a wire brush to smooth the cut surfaces on the new key.

19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again.

20. Depending on the type of key blank you have used, do this:

^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS).

^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator).