31
There is only one way to get good results on consistent bases. Buy a quality-built heavy-duty key
m
achine, don’t abuse it, and keep it well maintained and adjusted at all times. Keep an eye on cutter
sharpness, the integrity of the stylus, the fit of the vise jaws, the fit of the key gauge shaft to the
carriage, and the fit of the cutter shaft to the bearings. Any situations in these areas will decrease the
performance and accuracy of the machine. When parts start to wear – replace them.
In addition to a quality machine and its maintenance you need an accurate measuring tool such as a
dial caliper or key micrometer (preferably mechanical digital).
Measuring True Key Machine Accuracy
The proper way to measure key machine accuracy is to take the key you are going to duplicate from
and measure it. Measure each cut from the back edge of the blade of the key. Measure each cut
several times and record their average. After documenting the key, make a duplicate of it and measure
each cut several times and record their average. Compare the results. There is really no substitute for
the procedure if you want to make accurate duplicate keys. Generation cutting will not give you
meaningful results like this procedure.
24. Troubleshooting
Machine Always Needs Adjustment
There are several things that can
cause this situation.
1. Cutter wheel may be dull. This can cause the key to try to “float” and not cut deep enough in
the deepest cuts. Replace
or resharpen the cutter.
2.
Carriage spring may be weak or adjusted to light. Replace the
spring or resharpen the cutter.
3.
Stylus may be worn. Check it carefully; if there is a groove worn in the stylus you may get
deep and shallow cuts on different brands of keys. For example when cutting Ford doubl
e
sided keys the ignition key will be cut high on the stylus and the door key will cut low on the
stylus – Schlage C keys are cut m
ore in the middle of the stylus. This may seem
like an
extreme case – but it happens every day. Replace the stylus.
4.
Carriage shaft and bearings are worn. Check
for excess “wobble”. Replace the carriage shaft
an
d Bronze Oilite ® bearings
.
5.
Cutter shaft bearings are worn. Check for
any “wobble” or in-out play. Replace the cutter
shaft assem
b
ly.
6.
One key cuts fine and the next doesn’t. You adjust and readjust all the time. The problem
may be the carriage depth overtravel adjustment is set too high. This results in the machin
e’s
in
ability to cut the deepest cuts on a key – but shallower cuts are fine. This symptom is mo
re
com
mon than you think. Fix the problem by readjusting the Carriage Overtravel Dept
h
Adjustm
e
nt.
Agai
n – one key cuts fine and the next one doesn’t. This time it may be the key gauge
s.
Som
etimes key machine operators don’t flip down the full-function key gauges all the way
down and the left-hand key gauge CRASHES into the stylus holder and knocks the key
gauges out of position. The key they’re cutting is O.K. but the next key they duplicate won’t
work in the lock. If you ever CRASH the left-hand key gauge into the stylus holder – fix th
e
key
gauges right away. See Key Gauge Adjustment
above.
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