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OperatiOn Manual

A Member of the Kaba Group

ILCO EZ®-Code II

ILCO EZ®-Code II Operation Manual

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This manual has been produced to serve as a guide for users of the Ilco EZ®-Code II electronic key-cutting machine. Read it carefully…. This is essential for safe effec-tive operation of your machine! If necessary, you can contact Kaba Ilco Technical Assistance for further information at 1-800-334-1381 (option 8).

COnTEnTs This manual is divided into sections relating to

• Machine Description Section 1• Transport Section 2• Machine Installation and Preparation Section 3• Set Up and Use of the Machine Section 4• Operation Procedures Section 5• Error Messages/Machine Reset Section 6• Cleaning Section 7• Maintenance Section 8• Cutter Replacement Section 9• Replacement Parts and Accessories Section 10• Assistance Section 11

Ilco EZ®-Code II Design-A-Key™ Instructions Page 33

TECHnICAL TERMs Certain technical terms are used in this manual. To assist those with little experience of keys and key-cutting, below is a brief list of the terms most frequently used.

shoulder stop- Feature found on many keys used to limit how far the key enters a lock; normally located on the blade area of the key somewhat near its bow (head).

Tip stop- Some keys do not have a Shoulder Stop as described above; these keys rely upon their tip surface to limit how far they will enter a lock.

Key stop- Term used for the machine feature required to properly position Shoulder Stop and Tip Stop keys within the machine’s Vise Jaw. There are two types of Key Stops used on this machine (Key Stop Tools 1&2 and the Key Gage)

Card number- The numeric identification of specific electronic files stored within the machine’s database, used by the machine to determine the details associated with cutting various keys

Indirect Code number- The number sometimes associated with a specific lock that is used to “look up” the key cut numbers required to create a func-tional key for the lock. An example of an Indirect Code can be found on the “key tag” often accompanying keys supplied with a new motor vehicle.

Direct Code or Bitting number- Key cut numbers; example: a Direct Code for a key having six cuts along its blade will consist of six digits, each of which corresponds to one of the six cuts.

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Operation Manual ILCO EZ®-Code II

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GEnERAL

UsE: The Ilco EZ®-Code II is designed for cutting keys of non-ferrous material: brass, nickel-silver, zinc, etc. It must be installed and used according to the instructions provided in this manual. If used for pur-poses other than those described, the customer forgoes any rights they may have over Kaba Ilco Corp.

InCORRECT UsE: Improper use of this machine or failure of the operator to observe the instructions written in this manual will void all guarantees and responsibilities of the manufacturer. Furthermore, unforeseen danger to the operator or third parties may arise from incorrect use of the machine! It is therefore essential to carefully read and understand this operation manual.

VERY IMPORTAnT!SPECIAL CAUTION CONCERNING THE ELECTRICAL CONTACT FEATURE:

When decoding a key, the Ilco EZ®-Code II uses a low voltage circuit to detect key bitting information. certain rules apply regarding proper use:

• nEVER attempt to use the Ilco EZ®-Code II to duplicate from a painted or plastic pattern key! The pattern key could become damaged, and no longer function in its intended lock.

• It is recommended that anodized (colored) aluminum keys should not be cut.

MACHInE IDEnTIFICATIOn • The machine is provided with an identification label on its back panel which

shows the machine’s unique serial number.

Model #/Serial Tag


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1. MACHInE DEsCRIPTIOn

The Ilco EZ®-Code II is a two-axis electronic machine with microprocessor controlled carriage movement. The machine is designed to combine a high degree of cutting precision with efficient operation and ease of use. The Ilco EZ®-Code II can be used to cut keys in several different ways: • Making duplicate keys from a functional original• Originating automotive keys based on a key code number (indirect code).

Key codes are typically found on a tag accompanying a vehicle’s original keys and usually available to auto dealers based on vehicle VIN number.

• Originating an automotive or commercial/residential key based on bitting number (direct code)

• Interfacing with a PC equipped with Kreate-A-Key code software; this allows for cutting keys by key code for older automotive applications, as well as for padlocks, desk locks, etc. (Refer to instructions included with the Kreate-A-Key Interface Kit - BK0338XXXX.)

1.1 MAIn CHARACTERIsTICs

• Carriage Transport Movement Movement of the two axes (X-Y) by means of precision lead screws

activated by microprocessor controlled stepper motors. • Vise Jaw

“Sure Grip” two-position vise jaw, specially designed to grip most com-mercial, automotive and residential keys without the need for adapters.

• Cutter AITiN coated HSS (high speed steel), that is easy to replace. An optional car-

bide cutter is available for cutting harder key materials and longer service life• Display Rear-illuminated LCD display screen; positioned on the machine for easy

viewing. Display field is 4 rows of 20 characters each.

1.2 sAFETY

• General Safetyu Do not use your Ilco EZ®-Code II key machine for purposes not

specifically covered in this manualu Do not operate the machine in a damp environmentu Do not operate the machine with any safety enclosure or shield

removedu Do not attempt to bypass or defeat the safety shield switches or other

safety features built into the Ilco EZ®-Code IIu Do not open the main circuit box (located beneath the Touch pad and

LCD display screen). There are no user serviceable parts inside, and unfastening the lid assembly will expose the operator to hazardous voltages and sensitive electronic circuitry. Opening the circuit box assembly will void the machine warranty!

Operation Manual ILCO EZ®-Code

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• Emergency Stop Switch The red emergency shut off switch, located on the

left-hand side of the machine, is used to stop the Ilco EZ®-Code II immediately in the event of faulty opera-tion or danger to the operator (press in to activate). When the cause of the emergency has been elimi-nated, turn the button 45° clockwise to deactivate it. The button will extend further out from the machine when deactivated.

nOTE: the operator is responsible for keeping the area around the button clear so that it can be reached and activated quickly in the event of an emergency.

• Circuit Breaker A Circuit Breaker is located adjacent to the

Emergency Stop Switch, providing protection against most major overload scenarios. If the Circuit Breaker activates, its center button will protrude out from the edge of the machine circuit box. To re-set, turn the machine Power Switch to the off position, and press in on the breaker’s cen-ter button. If it again activates with the machine switched on, contact the Ilco Technical Service Dept.

• Cutter drive motor protection The cutter drive motor is protected against overheating by an internal cut-

out switch. Should the switch activate: 1) Turn the machine off and disconnect the power supply cable. Machine

will reset after motor has cooled sufficiently. 2) If machine does not reset: contact Ilco Technical Assistance at 1-800-

334-1381 (option 8)

• Protective Shield The transparent protective shield is designed to

cover the working parts of the Ilco EZ®-Code II as completely as possible, helping ensure opera-tor safety. Do not attempt to bypass the shield’s safety interlock switch or attempt to operate the machine with the shield removed.


Press in on Emergency Stop Switch to activate emergency stop.

Side view of Main Circuit Box


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1.3 MAIn WORKInG PARTs

1.4 TECHnICAL DATA

Power Requirement: 2.6 Amp. 300 WattsCutter drive motor: single speed, single phase Cutter: Standard:T-U01 (AITiN coated high speed steel) Optional: D405933ZZ (carbide cutter) Jaw: “Secure Grip” 2- position vise jaw; accommodates most commercial/

residential, automotive, and flat keysDimensions: 10.5” W X 19.5” D X 9” H (14” with shield raised) Weight:: 52 lbs (23.6 kg)

1.5 ACCEssORIEs PROVIDED

The Ilco EZ®-Code II comes with various accessories needed for its opera-tion and maintenance (tools, hex wrenches, calibration keys) comprising:

A: Cutter Spindle WrenchB: Cutter Nut WrenchC: Allen Wrench (large)D: Allen Wrench (small)E: Key Stop ToolF: Shim PinG. EZ3 Calibration Gage Keys

A G F

E

D C

B

A

C

G

F D

B

E

A: Main Power SwitchB: Emergency Stop SwitchC: Safety ShieldD: Clamping KnobE: Two-Position Vise JawF: Touch pad KeyboardG. Main Circuit BoxH: Circuit BreakerI: USB Port

H B I

Operation Manual ILCO EZ®-Code

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2 TRAnsPORT

The Ilco EZ®-Code II is not excessively heavy, but when boxed, we recom-mend that it be moved using at least two people.

2.1 PACKAGInG

The special pre-formed foam packaging and carton used to ship your Ilco EZ®-Code II is designed to protect the machine and its various components during shipment.

2.2 UnPACKInG

After removing the machine and accessories from the carton, check for the following contents:

1 Ilco EZ®-Code II key-cutting machine1 set of documents, including: an Operation Manual, a spare parts list, Quick Start Guide, Card Reference /Application Guide, 1 tool set and a warranty card. Important: The Warranty Card must be filled out and returned to Ilco in order to receive direct notification concerning new software updates!

nOTE: For maximum protection, we strongly recommend that you retain the packaging (foam and carton) to use for any future transport-ing of the machine.

2.3 CHECKInG FOR DAMAGE

The Ilco EZ®-Code II is solidly constructed, and should not become damaged if reasonable care is exercised during transit, and the unpacking and instal-lation have all been carried out according to the instructions in this manual. However, it is always advisable to visibly check for damage prior to placing any machine product in operation. Concealed damage resulting from rough handling during shipment must be reported to the appropriate delivery service immediately to preserve your rights of recovery! Kaba-Ilco will not be held responsible for damage incurred during shipment.

2.4 MACHInE HAnDLInG

When the Ilco EZ®-Code II has been unpacked, carefully place it in its intended work space. Carefully lift the machine, firmly holding the base, and no other part. Do not drag the machine, the rubberized feet could potentially become damaged.

3. MACHInE InsTALLATIOn AnD PREPARATIOn

The Ilco EZ®-Code II can be installed by the machine owner, and does not require any special skills. It is supplied ready for use and should not need any special set up. (extremely rough handling during shipment may how-ever require that the machine be recalibrated for proper performance)


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3.1 EnVIROnMEnTAL COnDITIOns

To ensure proper performance of the Ilco EZ®-Code II, it is important to place it in a well ventilated area which is not too damp. The ideal conditions for the machine are:

Temperature between 50°F (10°C) to 104°F (40°C)Relative humidity: 60% or lower

3.2 POsITIOnInG AnD InsTALLATIOn

Place the machine on a horizontal surface, solid enough to support a weight of 52 lbs. or greater.• As a practical matter, we suggest that the workbench be approximately

the height of the operator’s hip. • It is important to leave clearance of at least 8” behind the machine and

on each side to ensure proper ventilation. Be certain to maintain sufficient clearance to assure easy access to the Emergency Stop Switch on the left side of the Ilco EZ®-Code II.

• Ensure that the machine’s voltage requirement matches that of the main power supply (which must also be properly grounded). As with all elec-tronic equipment, a quality surge suppression device is highly rec-ommended… especially important when using an inverter or generator as the machine power source.

• Mobile installation involves additional considerations… all equipment installed in a mobile service vehicle must be securely fastened down to help minimize the possibility of personal injury or product damage in case of traffic accident or other mishap.

3.3 DEsCRIPTIOn OF WORK sTATIOn The machine requires only one operator, having easy access to the follow-

ing machine controls • Power switch; located on the front of the machine• Vise jaw• Keyboard• Display • Emergency shut off switch

4 sET UP AnD UsE OF THE MACHInE

4.1 KEYBOARD AnD FUnCTIOns The machine’s keyboard has 19 alphanumeric and 9 function keys. The

alphanumeric keys are used for entering the data card number and the cutting data (numbers and/or letters) according to the code on the card in use. Each of the 19 alphanumeric keys contains two characters: the main character (black) which is directly active, and an alternate character (red), which can be activated by simultaneously pressing the SHIFT key.


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FUnCTIOn KEYs: sTOP key: Stops the function in progress at any time during the opera-tion; also used to access the prior screen displayed on the LCD display. Please note that the STOP button is not an alternative to using the Emergency Shut Off Switch! Use the Emergency shut Off switch any-time there appears to be a risk of personal injury or machine damage with continued machine operation!QUIT PROCEss key: Stops machine function only.sTART key: Initiates the machine’s cutting operation. UP/DOWn keys: Scrolls curser thru screen options. sHIFT key: Provides access to RED letters on the keyboard; Press it in combination with the desired letter key to enter the red letter ALPHA/nUMERIC keys: For providing numeric and alphabetical input EnTER key: Activation of various functions in the menu, especially to con-firm input and menu screen selections. CLEAR key: deletes numerical characters. MEnU / CODE / CARD keys: Convenience “hot keys” that will immediately take user to the indicated menu screens

4.2 CLAMPInG KEYs UsInG THE ILCO EZ®-CODE II VIsE JAW

The process of clamping a key in a key machine vise jaw requires that the operator both utilize a Vise Jaw setting appropriate for gripping the key, and to position the key laterally within the jaw using an appropriate Key stop method (discussed in 4.3).

The Ilco EZ®-Code II Vise Jaw features two clamping positions (A and B), and is uniquely designed to accommodate the vast majority of keys without the need for adapters. Some keys will require the use of adapters or shim pins in order to be securely held or to be held level in the vise jaw. Examples are: the General Motors “Z” keyway and the Toyota TR47 key blank both require adapters so that the key will lay flat in the vise jaw.

• To change the vise position, first loosen the Clamping Knob several turns and then lift up on the vise jaw assembly as a unit to rotate it to the desired setting.

• In most circumstances, the machine display screen provides guidance as to which clamping position (A or B) is most suitable for the key you’ve selected to cut.

Rotation of the Vise Jaw

Touch pad Keyboard and LCD Display Screen


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• side A is generally used for clamping single sided keys, and certain double-sided types that don’t have a “milling groove”.

• side B is used to clamp the majority of double-sided keys. It features a special “V-shaped” gripping surface which is intended to grip a key by clamping into its milling groove.

• After correctly positioning a key within the Vise Jaw, re-tighten the Clamping Knob to secure it. Only moderate tightening is required… do not “over tighten” the Clamping Knob.

The Ilco EZ®-Code II Vise Jaw also features two slots on each side (identified by either a Red or White dot). These slots are used in conjunction with a removable “Key Stop” accessory to position keys that don’t feature a shoulder stop. The use of the slots is discussed in more detail in section 4.3.

IMPORTANT!!! Use the supplied chip removal brush to keep the Vise Jaw surfaces free of key shavings (chips). It is a good practice to brush off the gripping surfaces after each key to assure that chip buildup doesn’t impact performance or accuracy.

4.3 POsITIOnInG KEYs (Use of Key stops)

Once the proper jaw setting and gripping manner has been determined, the next step is clamping a key into the key machine Vise Jaw. This involves selecting the proper Key stop method (to appropriately position the key laterally within the jaw). The correct choice for a given key will appear on the LCD display screen and is also listed in the accompanying Card Reference /Application Guide. The choices available are 0, Red, and White.

Using A Position Using B Position Using A Position

Close up of vise jaw (removed for clarity)

Brushing chips from Vise Jaw surfaces

Single Sided Key Double Sided Key with Milling Groove Double Sided key w/o Milling Groove


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• Key stop 0: Used only for positioning keys that have shoulder stops. Rotate the machine’s Key Gage upward so that the shoulder of the key being clamped can be positioned against its left edge. While maintaining this contact, tighten the Clamping Knob to secure the key. Rotate the Key Gage FULLY to the down position. You should be able to feel the Key Gage reach a slight detent when it is in the down position. IMPORTAnT! If the Key Gage is not returned FULLY to the down position, the stepper motor will not allow the cutter to engage the key blank. You may receive the following error message when you attempt to decode or cut a key – ERROR OPERATIOn ABORTED TO AVOID COnTACT WITH JAW. If this happens, you will need to turn off the machine, ensure that the Key Gage is fully in the down position and re-start the machine in order to clear the error message.

Shoulder Stop

Tip Stop

Key Gage in Down position

Key Gage in Up posi-tion

Rotating Key Gage

Position Key using Key Gage

Correctly positioned. Note: Key’s shoulder must be in

contact with Key Gage

Keys with shoulder stops

Keys without shoulder stops


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• Key stop R (Red) and Key stop W (White): Used only for positioning keys without shoulder stops. Place the accessory Key Stop Tool in the appropriate vise jaw slot (refer to display screen). Position the key within the Vise Jaw so that its TIP is in contact with left edge of the Key Stop Tool (see illustration). While maintaining this contact, tighten the Clamping Knob to secure the key. 2. CAUTION! Be sure to remove the Key Stop Tool from the vise jaw before attempting to cut the key. Failure to remove the Key Stop Tool could result in personal injury and/or damage to the machine.

4.4 POsITIOnInG KEYs (Use of shim Pins)

If you are attempting to cut a single sided key that has a narrow blade width or a single sided key that requires a deep cut, you may see the following prompt on the screen – “DEEP CUT! USE SHIM PIN” (the software that drives the Ilco EZ®-Code II will determine when the Shim Pin is needed based on depth of cut). If you receive this prompt it will require the placement of a Shim Pin behind the key blade in the Vise Jaw to prevent the cutter from making contact with the Vise Jaw. Included in the accessory pack with the machine are two 1.7mm Shim Pins to be used to shim the key in the Vice Jaw. Place the Shim Pin behind the Key in the Vice Jaw and then position the key using the proper Key Stops. Once you have the key tightened in the Vise Jaw slide the Shim Pin out from behind the key. The width of the Shim Pin is programmed into the software for those cards that require its use, so it is important to use only the 1.7mm pin for shimming the keys. Use of a shim of another dimension could cause you to cut a key that will not work in the lock. The shim pin can also be used to level out keys whose profiles make it difficult to lay flat in the vise jaw. With some keys you can place the shim pin in one of the milling grooves of the key to help hold it flat in the vise jaw

CAUTIOn! If the thickness of the key prevents the removal of the shim Pin prior to cutting, make sure it does not protrude excessively from the Jaw and interfere with the travel of the spacing Carriage.

Key Stop slots on Vise Jaw

Using Key Stop Tool to position “shoulderless” Key

Shim Pin placement on single sided key

4.5 ELECTRICAL COnTACT The Ilco EZ®-Code II key-cutting machine is equipped with a low voltage electrical

contact circuit that is used for decoding keys and calibration of the machine. It is important to understand that the cutter must be free of all shavings prior to attempting to decode a key. If there are shavings hanging from the cutter’s edge it could cause contact to be detected prior to the cutter actually making contact with the key blade. As a result, the decoded depths will be too shallow and result in a non-functional key.

With the electrical contact feature, depth calibration is automatically calculated for many of the key types covered in the Ilco EZ®-Code II database when the cutter touches the key’s edge at the beginning of the cutting process. Electrical contact is assured for keys made of brass, nickel silver, or zinc (with or without nickel plating).

Improper use of electric contact • nEVER attempt to use the Ilco EZ®-Code II to duplicate from a painted

or plastic pattern key! The pattern key could become damaged and no longer function properly in its intended lock.

4.6 InTERnAL DATABAsE

The machine’s internal database includes electronic “cards” … essentially, individual data files that provide the machine with specific information on how to cut specific key types. When you select a card number prior to cutting a par-ticular key, the machine references the card’s corresponding data file to obtain information necessary for cutting the key.

The internal database also includes key codes (indirect codes) used with popu-lar automotive key applications.

The entire database is stored on an easily replaceable SD type memory card, greatly simplifying the process of updating the machine’s software… no computer or special cable required! Updates to the machine’s database are periodically offered as new locking systems enter the market. These are sold through your Kaba Ilco distributor. Updating instructions are included with each memory card update.

Once again, you are reminded that you must return the Warranty Registration Card to receive direct notification concerning the release of new software updates for your Ilco EZ®-Code II.

4.7 CUTTER

The majority of keys require that the Ilco EZ®-Code II’s standard cutter (T-U01) be used. Provisions will exist in a future software release to allow for using optional cutter configurations for specialized applications. To replace the cutter see section 4.7 and 4.8.

For increased service life when cutting harder than normal key blank materi-als, a carbide cutter is available. (Ilco part# D405933ZZ) This cutter can be substituted for the standard cutter.

To assure proper performance and prevent potential machine damage use only ILCO original replacement cutters!


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5. OPERATIOn PROCEDUREs

Introduction The Operation Guide explains below how to use the Ilco EZ®-Code II in stand-alone mode (without a Personal Computer). All of the steps required to operate the machine are explained in sequence. Refer to section 4 above for guidance pertaining to vise jaw and key blank positioning (vise position and key stop selection).

An optional way to operate the Ilco EZ®-Code II is to interface the machine with a computer running Ilco Kreate-A-Key code software (sold sepa-rately). This allows for cutting not just popular automotive keys by indirect code, but also keys for older vehicle applications and thousands of other types (padlocks, desk locks, commercial keys, etc). When operating the machine in this manner, the user will see a difference in the Ilco EZ®-Code II screen information displayed. Some procedures and functions described in this Operation Manual are eliminated, and once the computer’s data has been transmitted to the machine, it bypasses some of the normally appearing operation guide screens which the use of the Kreate-A-Key program renders unnecessary.

5.1 InITIAL OPERATIOns

When the key-cutting machine has been placed in the selected work area and connected to an appropriate power source (Ch.3.2), proceed as follows: 1) Make sure that the emergency shut off button is not activated (see

Ch.1.2). 2) Turn the machine on by means of the main power switch located on the

front of the unit.3) The LCD display screen will illuminate and display the Main Menu. The

Up/Down keyboard buttons will navigate the cursor through the menu. Selections are made by pressing the Enter button.

VERY IMPORTAnT: The balance of Chapter 5 explains how to cut keys by duplication, indirect code, and direct code. Procedures common to each method, such as how to clamp keys using the Ilco EZ®-Code II’s vise jaw, and how to properly position them using the available key stop methods (gauging), are covered in sections 4.2 and 4.3 above.

Main menu

0 Duplicate Key1 Cut by Card2 Cut by Code3 Queue from PC4 Design-A-Key5 Calibration6 Options

Operational keys: Use the arrow keys to move the main menu cursor (*) to the option required, and press ENTER or directly press the numbered key corresponding to the option number.

5.2 [0] Duplicate a Key(Refer to 4.2 and 4.3 for Vise Jaw and Key Stop information)

This function enables the user to create a duplicate key when an existing key is available … and the appropriate Ilco card number is known. The Ilco EZ®-Code II will decode the existing key, and replicate the cut pattern onto a blank key. The Ilco EZ®-Code II Card Reference/Application Guide provides a listing of all available Ilco card numbers, and the associated lock manufacturers they correspond to. Card numbers are typically very specific to a given manufacturer, and in many cases, also to specific lock products they produce. The proper card number must be selected prior to the decoding process; using an incorrect card number for a given key will result in a duplicate that will not function in the intended lock.


1. Select the “Duplicate Key” function from the Main Menu.


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Main menu

*0 Duplicate Key 1 Cut by Card 2 Cut by Code 3 Queue from PC 4 Design-A-Key 5 Calibration 6 Options

Cut by Duplication

Enter Ilco Card # For Pattern Key:


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2. Select “0” USE CARD DEPTHS to decode and cut new key to OEM speci-fications or “1” USE MEASURED DEPTHS to decode and cut new key to depths measured from the decoded key.

3. Type in the required card number (refer to Ilco EZ®-Code II Card Reference/Application Guide) and press ENTER

Note: Some card numbers require that you specify how many bittings (cuts) are on the pattern key. In these instances, step 3 applies… as indicated on the screen display

4. Use Up or Down arrow to indicate the number of bittings (cuts) on the pattern key; then press ENTER.

5. Clamp the pattern key into the machine using the specified Jaw setting and Stop Position (make sure jaw surfaces are free of key shavings).

(The display screen indicates the correct jaw setting and key stop position appropriate for the Ilco card number you entered in step 1.)

IMPORTAnT: Ensure that the cutter is clean and free of all shavings prior to starting the decoding process.

Jaw = The display will instruct you to use jaw side A or B to clamp the pattern key.

Use Up, Dn and ENTER toSelect # of bittings thePattern Key has

Insert Pattern KeyJaw: # Pos: #Press start to con-tinue

*0. Use Card Depths 1. Use Meas. Depths


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Pos. = The display screen will instruct you to use key stop position 0 (for shoulder stop keys), or either Red or White (for tip stop keys). CAUTIOn! Be sure to remove the Key stop Tool from the vise jaw before attempting to cut the key. Failure to remove the Key stop Tool could result in per-sonal injury and/or damage to the machine.

Press START to begin the decoding process

Important: You MUST use the Jaw and Key Stop position indicated by the display screen for the card number selected.

At this point, the pattern key will be decoded

6. Remove the pattern key from the vise jaw. Insert the appropriate key blank using the same jaw and key stop position (as indicated on the display).

7. Press START….the cutting process will commence

Note: If duplicating a double-sided key, you will be prompted to re-insert the blank key to complete side two.

Reading cuts on keyPlease wait ...

Remove pattern keyInsert key blankJaw # Pos. #Press START to cut

Cutting in progressSide 1 of 1 Qty. 1Bitting:Duplicate


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8. Machine finishes cutting process

Note: At this point, if you desire more than one copy of the pattern key press ENTER, if not, press STOP.

5.3 [1] CUT BY CARD(Refer to 4.2 and 4.3 for Vise Jaw and Key Stop information)

One part of the machine’s memory stores data cards for hundreds of key types. A data card is an electronic file containing information concerning cut spacing, cut depth, angles, etc. for a given key type (e.g. data card 410: Provides the Ilco EZ®-Code II with specifications for cutting Schlage pin tumbler type keys). The “Cut by Card” func-tion allows the operator to originate a cut key by typing in bitting (cut) numbers, also known as direct code, once the appropriate card number has been selected for the intended key. The number of data cards in your machine’s database will increase over time as new applications are identified, and software updates are released and you update your machine. The updates are contained on easily installed SD memory card media….no computer hook up is required!

There are two types of CARD NUMBERS:ILCO Data Card (1) :This option allows you to enter an Ilco Card Number (Example: 567 GM: used for cutting certain General Motors keys). This data card is part of the ‘spaces and depths’ database as described in the intro-duction to Ch.5 “OPERATING GUIDE”).Sources for determining which Ilco card number to use for cutting a given key include the Ilco EZ®-Code II Reference/Application Guide, supporting software such as Kreate-A-Key, Ilco Auto Truck Key Blank Reference Guide or other knowledgeable industry sources.

USER Data Card (2) :This option references a user defined card, created using the Design-A-Key menu option. Most users will never have need of this option. (Design-A-Key usage is covered in an Operation Manual supplement)

Cutting Complete!

More Copies?No= STOP Yes= ENTER

Main menu

0 Duplicate Key *1 Cut by Card 2 Cut by Code 3 Queue from PC 4 Design-A-Key 5 Calibration 6 Options


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1. Select the “Cut by Card” function from the Main Menu

2. Type in the desired card # and press ENTER to proceed to the clamping instruction screen

3. Type in the desired bitting (cut) numbers, then press ENTER

4. Clamp the appropriate blank key into the machine using the specified Jaw set-ting and Key Stop Position (make sure jaw surfaces are free of key shavings).

(the display screen indicates the correct jaw setting and key stop position appropriate for the Ilco card number you entered in step 2) Jaw = The display will instruct you to use jaw side A or B to clamp the pattern key.

Pos. = The display will instruct you to use key stop position 0 (for shoul-der stop keys), or either Red or White (for tip stop keys). CAUTIOn! Be sure to remove the Key stop Tool from the vise jaw before attempt-ing to cut the key. Failure to remove the Key stop Tool could result in personal injury and/or damage to the machine.

Select Card TypeIlco = xxxxUser = xxxx

Side 1 Ilco: xxxx------ (manufac-turer)Possible Depths:xxxxxxxxxxxx

Side 1 Cutter: U01Jaw: x Pos: xInsert key


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Important: You MUST use the Jaw and Key Stop position indicated by the display screen for the card number selected

Press START….the cutting process will commence

Note: If originating a double-sided key, you will be prompted to re-insert the blank key to complete side two

Machine finishes cutting process

Note: At this point, if you desire more than one copy of the key press ENTER, if not, press STOP.

5.4 [2] Cut by Code (Refer to 4.2 and 4.3 for Vise Jaw and Key Stop information)

This function allows the operator to originate an automotive key by typing in the appropriate key code (also called indirect code) associated with a desired key. The Ilco EZ®-Code II database contains thousands of indirect key codes, covering hundreds of different vehicle models sold by major automotive manufacturers. A listing of code series stored in the machine database can be found in the Ilco EZ®-Code II Card Reference/Application Guide.


1. Select the “Cut by Code” function from the Main Menu

Cutting in progressSide 1 of 1 Qty. 1Bitting: xxxxxxxxx

Cutting Complete!



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2. Type in the desired code # and press ENTER

3. A list of code series that conceivably contain the key code number you typed will appear on the display. Use Up/Down arrows to move cursor beside the code series associated with the key you intend to originate.

Press ENTER. If you want more detail on a specific code, move cursor beside the code then press and hold the SHIFT button while pressing the down arrow. The screen will show the specifics for that code.

4. The machine will now retrieve a match to the key code number specified in step 2 from the code series just selected.

5. Once the code number is retrieved, the screen display will show:

Ilco Card NumberBitting (cuts on key) associated with selected key codeManufacturer NamePossible Depths used in the code series involved

Code Series Manufacturer 1. xxxx-xxxx xxxx2. xxx-xxxx xxxx3. xxxxx-xxxxx xxxx

Cut by Code

Code=

Side 1 Ilco: xxxxxxxxxxxxxxx xxxxxPossible Depths: xxxxxx

Searching ForCode Book ...Code Entry ...Card File ...


22

6. Press ENTER to proceed to the clamping instruction screen

(the display screen indicates the correct jaw setting and key stop position appropriate for the code series selected in step 3)

Cutter = The display verifies the cutter number

Jaw = The display will instruct you to use jaw side A or B to clamp the pat-tern key.

Pos. = The display will instruct you to use key stop position 0 (for shoulder stop keys), or either Red or White (for tip stop keys). CAUTIOn! Be sure to remove the Key stop Tool from the vise jaw before attempting to cut the key. Failure to remove the Key stop Tool could result in personal injury and/or damage to the machine.

Important: You MUST use the Jaw and Key Stop position indicated by the display screen for the card number selected7. Clamp the appropriate key blank into the machine using the specified

Jaw setting and Stop Position (make sure jaw surfaces are free of key shavings).

8. Press START … the cutting process will commence.

Note: If originating a double-sided key, upon completion of side 1, you will be prompted to re-insert the blank key to complete side two.

Cutting in Progress ...Side x of x Qty. xBitting:xxxxxxxxxxxx

Side: x Cutter: U01Jaw: x Pos. xInsert KeyPress START to cut


23

9. Machine finishes cutting process.

Note: At this point, if you desire more than one copy of the key press ENTER, if not, press STOP.

5.5 [3] Queue from PC

This feature will allow for coupling the Ilco EZ®-Code II with a PC loaded with Kreate-A-Key code software. This will provide greatly expanded indirect code capabilities, including the ability to cut keys by indirect code for non-automo-tive applications. Kreate-A-Key Interfact Kit BK0338XXXX is required.

5.6 [4] Design-A-Key

Design-A-Key will allow users to create and save “custom data cards” into the machine database. This will require various details about the desired card application (cut depths, spacing location, angle of cut, etc.) to be load-ed into the Ilco EZ®-Code II using its Touch pad keyboard. Refer to the Ilco EZ®-Code II Design-A-Key™ Instructions (supplement) for more details.

5.7 [5] Calibration

As with all key cutting machines, the Ilco EZ®-Code II should periodically be checked for proper calibration to assure optimal cutting accuracy. Calibration is required whenever the machine’s cutter is replaced, removed and then reinstalled, or when the accuracy of the keys it cuts diminishes.With the Ilco EZ®-Code II machine, calibration is largely automated other than for clamping the special EZ3 adjustment key, and providing certain Touch pad commands. The calibration menu option (5) is dual purpose; providing for Auto-Calibration or for creating a Temporary Offset.

IMPORTANT: The EZ3 calibration key should not be used more than five times to calibrate the machine. During the calibration process the cutter will actually make slight contact to the EZ3 calibration key resulting in a slight cut to the key. Using the EZ3 calibration key more than five times will affect the accuracy of the machines calibration.

Auto-Calibration: Process used to set the Ilco EZ®-Code II depth of cut and spacing of cut adjustments.

Temporary Offset: Special feature that allows the user to make a temporary change (increase or decrease) in cut depth or cut spacing for special circum-stances. The Ilco EZ®-Code II will automatically cancel out a temporary offset when either of the following occurs…. The machine power switch is placed in the “off” position, or a different card number or code series is selected.

Cutting Complete!



24


1. Select the “Calibration” function from the Main Menu

To Auto-Calibrate the Ilco EZ®-Code II, select option 1To establish a Temporary Offset select option 2

AUTO-CALIBRATIOn (select option 1)

Follow the display screen instructions:1. Position jaw to side “A”2. Clamp the EZ3 Calibration Key into side A of vise, with its shoulder against

the machine’s Key Gage (position 0). Rotate the Key Gage FULLY to the down position. You should be able to feel the Key Gage reach a slight detent when it is in the down position. IMPORTAnT! If the Key Gage is not returned FULLY to the down position, the stepper motor will not allow the cutter to engage the key blank. You may receive the follow-ing error message when you attempt to decode or cut a key – ERROR OPERATIOn ABORTED TO AVOID COnTACT WITH JAW. If this hap-pens, you will need to turn off the machine, ensure that the Key Gage is fully in the down position and re-start the machine in order to clear the error message.

Calibration:

1. Auto-Calibration2. Temporary Offset

Main menu

0 Duplicate Key 1 Cut by Card 2 Cut by Code 3 Queue from PC 4 Design-A-Key *5 Calibration 6 Options

Set Jaw to Side AInsert EZ3 Gage KeyUse Position: 0Press START to begin


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3. Press START to continue(note: Each EZ3 Calibration Key can be used for calibration purposes up to three times; discard after three auto-calibrations)

The cutter will make very slight contact with the EZ3 key and the carriage will then reposition to “home position”.

Follow the display screen instructions:4. Position the accessory Key Stop Tool 1 into the “W” slot on side A of the vise5. Reposition the EZ3 gage key with its tip butted against the Key Stop Tool6. Tighten the clamping knob to secure the EZ3 key. Be sure to remove the

Key stop Tool from the vise jaw before proceeding the the next step.7. Press START to continue

“0“ CalibrationIn Progress ...

Positioning Calibration Key against Key Gage

Reset EZ3 Gage KeyUse Position: WLower Safety ShieldPress START to Begin

Positioning tip of Calibration Key against

Key Stop Tool 1


26

The cutter will again make very slight contact with the EZ3 Calibration Key and the carriage will then reposition to “home position”.

8. Press ENTER to save the new settings or STOP to discard. The Auto-Calibration process is concluded!

TEMPORARY OFFsET (select option 2)

Follow the display screen instructions:• Use up / down arrows to increase / decrease cut depth• Up arrow increases cut depth – Down arrow decreases cut depth• Press ENTER when desired offset amount is shown on screen

Follow the display screen instructions:• Use up / down arrows to decrease / increase distance of cuts from tip of key• Up arrow moves cuts closer to head of key • Down arrow moves cuts closer to tip of key• Press ENTER when desired offset amount is shown on screen

5.8 [6] Options

“Options” allows the operator to change certain factory default settings. These settings should not be changed unless the operator fully under-stands what the result will be. There is seldom ANY need to depart from the factory default setting.

Calibration Complete!Save New Settings?No = Stop Yes = Enter

Depth AdjustmentUse up / down arrowsTemporary: x.xxxEnter = Done

Spacing AdjustmentUse up / down arrowsTemporary: x.xxxEnter = Done


27


1. Select the “Options” function from the Main Menu

2. Use the arrow keys to move the main menu cursor (*) to the option required, and press ENTER or directly press the numbered key corre-sponding to the option number.

3. A description of each item listed in the Options Menu follows:

[0] Units - Allows the operator to input either Metric or SAE (imperial) values when using the Ilco EZ®-Code II Design-A-Key™ option.

[1] Cut style – Allows the operator to change the appearance of the cuts made on keys

• (0) Default - The machine will create keys with either normal or laser cut characteristics, based upon what the internal programming indicates is preferable for a given key. For most user purposes, Default is the recom-mended setting.

Options Menu

0 Units1 Cut style2 Edge Detect3 Taper Detect4 Macs Protection5 Preferred Manufacturer6 Cutter

Main menu

0 Duplicate Key 1 Cut by Card 2 Cut by Code 3 Queue from PC 4 Design-A-Key 5 Calibration *6 Options

Cut Style Menu

0 Default1 Normal2 Flat3 Laser4 Plunge


28

• (1) normal - Cuts will have a traditional “peak and valley” (saw tooth) cut profile

• (2) Flat - Adjacent cuts of the same depth value will appear to be a single wider cut

• (3) Laser – The machine will “blend” adjacent cuts… meaning that there is a smooth transition from cut-to-cut. This cut style is sometimes used by manufacturers to allow for smoother key insertion, resulting in less wear on keys and tumblers within a lock.

• (4) Plunge- Plunge cutting means that the cutter makes “straight in-straight out” cutting motions, and will most commonly be used for cutting safe deposit style keys.

[2] Edge Detect - Allows the operator to change the active status of the Ilco EZ®-Code II electronic key edge detection circuitry. It is strongly recom-mended that the status be left in its factory Default setting, which activates the circuit for certain classes of keys and not others.

[3] Taper Detect - Allows the operator to change the active status of the Ilco EZ®-Code II electronic taper detection circuitry. It is strongly recommended that the status be left in its factory Default setting.

[4] MACs Protection - Not activated at present! This option will automati-cally become active in conjunction with a future software update. The fea-ture will enable the operator to enable / disable MACS Protection. In simple terms…MACS (Maximum Adjacent Cut specification) Protection prevents the Ilco EZ®-Code II from accepting user input that would result in cutting certain patterns of cuts.

The reason for this is that the key bitting specifications used by some lock manufacturer’s (key cut depths, cut spacing, cut angles) won’t allow for very deep cuts next to very shallow cuts without the deeper cut “wiping out” all or part of the shallow cut. MACS Protection limits the maximum difference in cut depth between two adjacent cuts (user chosen) to those specified by the various lock manufacturers. “Enabled” will be the default setting for this feature.

[5] Preferred Manufacturer – Primarily of importance to automobile deal-ers, this feature allows a particular vehicle brand to be selected as a default. When thus designated, the various code series associated with that vehicle brand will be displayed first on the code series lookup screen for conve-nience. As shipped, the default setting is “NONE”, all brands have equal priority on the display screen.

[6] Cutter – This is a future utility that will allow for the use of optional cut-ters (slotters, profile cutters, etc.). At present, the T-U01 (U01) or its carbide equivalent (D405933ZZ) are the only recommended cutter for use on the Ilco EZ®-Code II.


29

6 ERROR MEssAGEs/MACHInE RE-sET

• In certain situations, an error message may appear on the machine’s LCD screen (e.g. “Close Safety Shield”). Usually correcting the cause for the message, and then pressing the enter button, will permit machine opera-tion to continue.

• Under rare conditions, the machine software may appear to “lock up” (won’t accept Touch Pad commands). If this occurs, it may be necessary to press the power switch to the off position and then back on to clear the error.

7 CLEAnInG

• Keep the operational parts of the machine as clean as possible by brush-ing away the chips created during cutting operations from areas where they accumulate.

• Vacuum the interior of the machine as necessary (unplug it first!) to pre-vent excessive chip buildup.

• Under no circumstances should compressed air be used to clear the work zone of chips as this may blow them onto the moving parts.

• Never use oily products or solvents for cleaning painted surfaces, jaws, keypad, or electrical and electronic components.

8 MAInTEnAnCE

The Ilco EZ®-Code II is designed to require minimal maintenance. It features permanently lubricated bearings in its cutter spindle assembly, main motor, and servo motors. Typical machine maintenance will primarily include:

• Removal of key blank cuttings (chips) – Daily brush the carriage, vise, and lead screw surfaces to remove accumulated chips. As mentioned above, NEVER USE COMPRESSED AIR for removing chips. Not only is it potentially unsafe (danger to eyes), it can also result in chips being forced past the machine’s sealing devices and lead to damage.

• Cutter replacement – Replace as required; see Chapter 9 below• Periodic Calibration – Cutters wear down over time; performing the Auto-

Calibration procedure monthly will help maintain maximum machine accuracy.

Removing key chips from mechanism

Removing key chips from vise jaw


30

• Updating Internal Database – When you obtain Ilco EZ®-Code II update software install it using the following steps:

1. Unplug the machine power cord2. Remove SD Card cover plate on left side of the control box. 3. Replace existing SD card with the newer software version and reinstall

cover plate. 4. Plug in the power cord. 5. Hold in the “sHIFT” key and turn the power switch to the on position6. When text appears on the LCD display screen, release the shift key7. The new program will begin loading to the machine8. At the conclusion of the update process, the carriage will move slightly,

and the Main Menu will appear on the display screen.9. The machine is at this point fully updated. • Lubrication – It is not necessary or advisable to lubricate the machine

mechanism! Doing so may in fact create problems if excessive chip accu-mulation on the lubricated parts results.

9 CUTTER REPLACEMEnT

9.1 When to Replace the Cutter

The cutter on your Ilco EZ®-Code II machine should be replaced if either of the following is observed:• The cutter begins making noticeably greater noise when cutting• The machine appears to “struggle” when cutting keys• There is a noticeable “burr” or “roughness” visible (or remove or identifiable

by touch) on the cut surface of keys cut using the machine

9.2 Changing the Cutter

1. Unplug the power cord! 2. Raise the safety shield. 3. Loosen the cutter nut using the supplied box end wrench, while holding the

pulley end of the shaft with the special Open End Wrench, also supplied. VERY IMPORTAnT: the thread is left-handed. (reversed).4. Replace existing cutter with new one, then tighten the cutter nut by turn-

ing it counter-clockwise. 5. Recalibrate the machine (see section section 5.7)

Removing SD Card access cover Removing SD Card (note card contacts face upward)

Inserting new SD Card


31

IMPORTAnT: You must ALWAYS recalibrate the machine after replacing a worn cutter!

10. REPLACEMEnT PARTs AnD ACCEssORIEs Below is a list of some common serviceable parts and accessories that may

be purchased for your EZ-Code Key Cutting Machine.

A: Cutter Spindle WrenchB: Cutter Nut WrenchC: Allen Wrench (large)D: Allen Wrench (small)E: Key Stop ToolF: Shim PinG. EZ3 Calibration Gage Keys

A G F

E

D

C

B

Item Description Part no. Item Description Part no.U01 Cutter (Standard) D716549ZBCarbide Cutte D405933ZZCutter Washer 132470Nut-Cutter Spindle 3/8-16 LH 151002EZ Code V-Belt SM400 132673Knob – Vise Jaw 132506Washer – Vise Jaw 1325372584 Thrush Washer 1292812584 Thrush Retainer 129282Compression Spring 132517Shield 132449Shoulder Spacer – Shield 132534Washer – Delrin – Shield 132535USB Protective Cover 132502Cover Plate – SD Card 1324896-32 x ¼ Button Head Cap 1103395P Screw (Used to attach Cover Plate - SD Card)EZ Code Calibration Gage EZ3

KeysTip Stop Gage EZ-TS11.7mm Shim Pin 132904Wrench Kit (includes Cutter EZ-WR1 Spindle and Cutter Nut Wrench)Tip Stop Gage BD0716XXXXMagnetic Accessory Tray BD0700XXXXKreate-A-Key Code Software BK0202XXXX Kreate-A-Key Interface Kit BK0338XXXX (includes USB Cable – Male A to Male A, USB Interface File CD and Interface Instruction Sheet)USB Cable (Male A to Male A) BK0334XXXXGM “Z” Key Clamping Adapter BD0699XXXXToyota TR47 Clamping BD0715XXXX Adapter Kit

32

11 AssIsTAnCEIlco provides full service to purchasers of the Ilco EZ®-Code II key-cutting machine. To ensure safety to the operator and machine, do not utilize the product for any use not specified in this manual or in a manner inconsistent with the provided instructions!

It is our hope that this Operating Manual will enable you to quickly and effi-ciently set up, and begin using your new Ilco EZ®-Code II key machine. For more detailed information, troubleshooting or common maintenance tips, please contact Ilco Technical Assistance. We strongly advise you to keep this document safe and readily available. It will prove very useful in the future as you learn to use the many features of the Ilco EZ®-Code II. Should you require addition assistance or support, please contact the Ilco Technical Assistance Dept.

Ilco Technical Assistance Dept.400 Jeffreys Road

Rocky Mount, NC 27804USA

Tel: 1-800-334-1381 (option 8)Fax: 252-446-4702

11.1 How to Request service

The Ilco EZ®-Code II warranty ensures free repair or replacement of faulty parts within 12 months from the date of purchase, subject to its stated terms and conditions. A copy of the purchase invoice is required to verify proof of purchase. Customers are responsible for freight charges when returning product for repair. It is strongly recommended that the machine’s original packaging be used when preparing the machine for shipment! Non-warranty repair support is also available. Contact the Ilco Technical Assistance Dept. for details.


33

Operation Manual ILCO EZ®-Code II Design-A-Key™

Ilco EZ®-Code II Design-A-Key™ OperationA very useful feature provided in the Ilco EZ®-Code II Key Cutting Machine’s internal software is its Design-A-Key™ function. As covered in the Operation Manual, one way in which keys may be cut on the Ilco EZ®-Code II is through use of an appropriate Ilco Data Card #. In this scenario, the user selects the Ilco Data Card # suitable for the desired type of key, and once selected, uses the machine’s keypad to input the desired cut depth values (bitting #’s). A list of the available Ilco Card #’s (and their specified applications), is contained in the machine’s Ap-plication Guidebook. Occasionally however, you may find yourself needing to cut a key for a non-supported applica-tion (no pre-existing Ilco Data Card #), and this is where the Design-A-Key™ function becomes important. This menu option allows the user to easily create, and save into machine memory, custom “user defined” data cards. These user created cards function the same as pre-loaded Ilco cards, but are generated through use of the machine’s alpha-numeric keyboard by the operator, to input detailed information concerning depth, spacing, application name, and other pertinent information regarding an unsupported locking system. This data can be saved in the machine’s internal memory as a “User Card” and recalled at any time to cut a key. As already stated, Design-A-Key™ is invaluable in situations in which an Ilco card number does not yet exist for a desired key cutting application, allowing the machine operator to create their own functional User Card number, making it possible to cut the key. Use of the Ilco EZ®-Code II Design-A-Key™ function is fully explained in the pages that follow.

The Design-A-Key™ feature offers the user unparalleled flexibility and convenience.• Existing Ilco depth and spacing information can be replicated and altered to meet

particular needs.• 255 user cards are available to create customized commercial, residential and automo-

tive keys.• User cards can be named and numbered according to their various applications, and can

be edited should a need arise.• All user card information can be added to the Ilco EZ®-Code II without the use of a

personal computer.• The Ilco EZ®-Code II unique Key Registration feature provides for enhanced accuracy when

cutting customized double-sided keys

Please take a moment to review the instructions that follow and see how easy it is to begin cre-ating your own “user defined” data cards.

TABLE OF COnTEnTs

Rules ............................................................................................... .34-35Instructions ....................................................................................... 36-39

34

ILCO EZ®-Code II Design-A-Key™ Operation Manual

RULEs

There are 9 rules that must be followed whenever a new user card is created. Please read through them carefully before attempting to create a new user card.

BAsICs:

1. Customized data cards can be created for: • Single sided shoulder stopped keys • Single sided tip stopped keys • Symmetrical double sided keys with a tip stop • Symmetrical double sided keys with a shoulder stop

Single sided key with shoulder stop

Single sided key with tip stop

Symmetrical double-sided key with shoulder stop

Symmetrical double-sided key with tip stop

2. The maximum number of cut spaces available on any key is (20).3. The maximum number of different cut depths available on any key is (20).4. Cut depth symbols may be represented by digits 0-9 or letters A-Z.5. Available Cut Types include: normal Cut – Cuts will have a traditional “peak and valley” (saw tooth) cut profile. Flat Cut – Adjacent cuts of the same depth value will appear to be a single wider cut. Laser Cut – The machine will “blend” adjacent cuts…meaning that there is a smooth

transition from cut-to-cut. This cut style is sometimes used by manufacturers to al-low for smoother key insertion, resulting in less wear on keys and tumblers in the lock.

Plunge Cut – Plunge cutting means that the cutter makes “straight in-straight out” cutting motions and will most commonly be used for cutting safe deposit style keys. (Note: Use of this cut cannot be used with the Ilco EZ®-Code II standard cutter).

6. Key Blank measurements must be within a range of 0.050 inches or 1.27mm (mini-mum) and 0.750 inches or 19.05mm (maximum). The maximum cut depth cannot be greater than the key blank’s measurement.

35


7. Cut spacing measurements must be within a range of 0.002 inches or .05mm (mini-mum) and 0.984 inches or 25mm (maximum.

8. The maximum cut depth that may be used on side A of the vise jaw is 0.150 inches or 3.8mm.

9. The cutter angle must be within a range of 80 degrees minimum and 150 degrees maximum.

Please carefully follow the instructions on pages 5 through 8 to create a user card utilizing the Design-A-Key™ feature

80° - 150°

36

ILCO EZ®-Code II Design-A-Key™ Operation Manual

1. CREATInG / EDITInG OR DELETInG A UsER CARD a. Using the down arrow on the keypad, scroll down to option 4 (Design-A-Key™) and

press ENTER.

b. To create a new user card or to edit a card you created earlier, select option 0 and press ENTER. To delete an existing card you had previously entered into the memory, select option 1 and press ENTER.

c. When creating a new user card, the screen will display the next available card in the memory. You can select this card number by pressing ENTER or you can assign a different card number by using the keypad to enter the number. If you want to Edit an existing card, simply enter the card number that you want to edit and press ENTER.

d. The screen will then ask you to enter a card name for a new user card or, if you are edit-ing an existing card, it will display the name assigned to the card you are editing. At this point, enter the desired card name using the keypad. You can enter 0-9 or A-Z to name the card. Press ENTER to save the card name. Keep a record of the cards you create that you can refer to in the future.

Next you will input the specific data for the key you wish to design.

1. Cut by Card 2. Cut by Code 3. Queue from PC *4. Design-a-key

*0. Create/Edit Card 1. Delete Card

Design-A-KeyEnter Card Number ----------> : 0 enter 0 - 255

Design-A-KeyEnter Card Name? enter 0 - 9 A-Z

37


2. ADDInG THE sPECIFIC DATA FOR “DEsIGn-A- KEY”

The next several screens will allow you to input specific data for the key that you are design-ing. There are several parameters that must be specified. It is extremely important that you input the dimension data correctly. Damage to the cutter or other parts of the machine could result if the dimension data is not input correctly.

Some parameters require a numerical response (0-9) while others require a Yes or No choice (Y or N). After each parameter has been entered, pressing the ENTER key will save your data and move you to the next screen. At any point in the process you can press the Up arrow on the key pad to return to the previous screen.

1. sInGLE sIDED (Yes or No) Choose Y for a Single Sided key or press n if the card is being created for a key with

double symmetrical sides.

2. AnGLE This indicates the cutting angle to be used. Using the keypad, enter any number from

80 to 150 to select the appropriate cutting angle.

3. MODIFY FIRsT CUT (Yes or No) On some keys, the first cut features a 90 degree angle in

the first cut location

4. nUMBER OF sPACInGs (1-20) This is the number of cuts, laterally, along the key blade.

5. REVERsE ORDER BITTInG (Yes or No) Typically the first cut in a bitting string is from the head of the key, so the default in this screen is

set for n (No). With some manufacturers the first cut in a bitting string is the cut located closest to the tip of the key. If this is the case for the key you are trying to design, then select Y (Yes)

6. sTOP POsITIOn (O, R, or W) Key stop O is used only for positioning keys that have shoulder stops. Key stop R (red) or W (white) are used for positioning keys without shoulder stops. Key

stop R is used for very short tip gauged keys (i.e. some motorcycle keys). Key stop W would be used for most standard length tip stop keys.

7. JAW sIDE (A or B) Side A is used for all commercial applications or automotive applications where there is

not a center groove. Side B is used for clamping automotive applications when clamping using the center

groove on the key.


38

IMPORTAnT! If you are designing a card that requires the use of Jaw B, you must go to the OPTIOns menu, select 2. Edge Detect and select 1. Edge Det. On in order for your key to be cut properly using this card. see Operation Manual section 5.8 for more details.

8. CUTTInG METHOD (N,F,L or P) n (normal) – Cuts will have a traditional “peak and valley” (saw tooth) cut profile. F (Flat) – Adjacent cuts of the same depth value will appear to be a single wider cut. L (Laser) – The machine will “blend” adjacent cuts…meaning that there is a smooth

transition from cut-to-cut. This cut style is sometimes used by manufacturers to allow for smoother key insertion, resulting in less wear on keys and tumbler within a lock.

P (Plunge) – Not activated at present! This cut style option will automatically become active with a future software update. Plunge cutting means that the cutter makes “straight in-straight out” cutting motions, and will most commonly be used for safe deposit style keys. This cutting method will require the use of a different cutter than is normally installed on the machine.

9. KEY BLAnK WIDTH (0-750) Enter the numerical value of the width of the key blade. The Ilco EZ®-Code does not

require leading zeros or decimal places (i.e. 319 thousandths should be entered as 319).

10. DEPTH sYMBOLs (0-9 or A-Z) Enter the symbols used to designate the depth of cuts that will be available on the card.

For example if you want to show 4 available depths, you might enter 1234 or ABCD as the depth symbols for the card.

11. DEPTH (0-9999) Enter the depth of cut for each symbol entered on the previous screen. For example, in

step 10 if you selected four depth symbols, you would input the depth of cut for each of the four symbols you selected (i.e. Depth 1, Depth 2, Depth 3 and Depth 4).

12. sPACE 01 (0-9999) On the next screens you will enter the spacing measurements. The number of spaces was

determined in step 4 above. If you selected four spaces, you will see four screens (i.e. Space 01, Space 02, Space 03 and Space 04. On a shoulder stop key the measurement for Space 01 should be the measurement from the shoulder to the center of the first cut. The measure-ment for Space 02 will be from the center of the first cut to the center of the adjacent cut (the remaining spaces will default to this measurement). On a tip-stop key the measurements should be from the tip of the key blank with Space 01 being closest to the tip of the key. As on a shoulder stop key, Space 02 is measured from the center of the first cut to the center of the adjacent cut (the remaining spaces will default to this measurement).

13. FLAT 01 (0-9999) This refers to the relative base (Flat Width) of each space. Once you have entered Flat

01, the remaining flat widths will default to this measurement.


39

At this point you have designed (or edited) your user card. Press ENTER to save your card in the Ilco EZ®-Code II database for future use, press STOP to abort (all of your infor-mation will be erased) or press the UP arrow to go back and modify your information. Re-member to keep a written record of the cards you create for ease of reference in the future.

nOTE: Installing software updates will not erase any cards you have created.

CUTTInG A KEY WITH “UsER” CARD

a. To cut a key using a card you designed simply select the “Cut by Card” option from the Ilco EZ®-Code II main menu (or press the CARD hot key).

b. On the next screen press the down arrow key to move the cursor (*) next to “USER” (option 2). Before you press ENTER you must select a card number. Using the key pad enter the card number you want to use. Once you have selected the card number, press ENTER.

c. The screen will display the card number, card name and possible cut depths that are available for this card.

d. Enter the cut depths that you wish the machine to cut: i.e. (1,2,3,4,5)e. Once the cut depths have been entered, press the ENTER key.f. The next screen will display the Jaw side and key stop position for use with the card.g. Load the key blank as described (f) and press START. The Ilco EZ®-Code II will now cut

the key blank according to the customized card’s information.

ILCO TECHNICAL ASSISTANCE DEPARTMENT400 Jeffreys Rd., Rocky Mount, NC 27804

TEL: 1-800-334-1381 (Option 8)

FAX: 252-446-4702

© KABA ILCO CORP. - January 2011

Kaba Ilco Corp.P. O. Box 2627 (27802)400 Jeffreys Rd., Rocky Mount, NC 27804Tel.: (252) 446-3321 Fax: (252) 446-4702

www.kaba-ilco.com

A Member of the Kaba Group

Code No.: 132566 REV 10/13

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