HPC CodeMax User Manual

CodeMax

Machine

Computerized

No. 1200MAXAA

Cutting

Code

No. 1200MAX

Exploded View

Parts List Inside

041013 36012_000_00

The CodeMax

Computerized Code Key Machine

This manual and the internal software and data of the CodeMax® described in this manual are copyrighted by:

HPC, Inc., Schiller Park, Illinois, U. S. A.

The internal software and data is a work fully protected by the United States Copyright Laws.

Federal Law: This manual or the internal software of the CodeMax®may not be copied, translated, photocopied, microfilmed, or reproduced in any manner to be machine readable in any form (in whole or in part), without the express written consent of the copyright holder.

CodeMax

Visit the CodeMax® web page at www.hpcworld.com/km/codemax to learn about your machine.

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Manuals and Exploded Views

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To learn the features of CodeMax® Version 10 (Upgrades are available).

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Index

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Product Packaging Checklist

1.2 Parts Designation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3 Preparation of the CodeMax

1.4 Basic Codemax Setup

1.5 Emergency Button

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2. Cutter Wheels

2.1 Cutter Wheel Descriptions

2.2 Changing Cutters

2.3 Resharpening Cutters

3. Holding And Gauging Keys

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.1 Vise Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Key Gauges

3.3 Gauging Methods

3.3.1 Standard Cylinder Key With Shoulder Gauge Using Jaw A

3.3.2 Standard Cylinder Key With Shoulder Gauge Using Jaw B

3.3.3 Red Full Short Tip Stop Gauging Using Jaw A

3.3.4 Red Middle Short Tip Stop Gauging Using Jaw A

3.3.5 Black Horseshoe Tip Stop Gauging Using Jaw B

3.3.6 Medeco Using Jaw C (optional equipment)

3.3.7 Black Horseshoe Full End Tip Stop Gauging Using Jaw A or B

4. Key Cutting Methods

4.1. Stand Alone Key Cutting

4.1.1

4.1.2 Medeco® Keys

4.1.3 After The Key Has Been Cut

4.1.4 Additional Notes

4.2 Computer Assisted Key Cutting

4.3 Micrometer Key Cutting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

. . . . . . . . . . . . . . . . . . 19

. . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

. . . . . . . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . . . . . . 25

– Standard Commercial Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Standard Keys

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5. Recalibration Of The CodeMax

5.1 Electronic Calibration

5.1.1 Depth Instructions

5.1.2 Space Instructions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.1.3 DSD Specific Instructions

5.2 Manual Calibration Space Calibration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.2.1 Cutting Too Close To The Tip On Keys Gauged From The Tip

5.2.2 Cutting Too Far From The Tip On Keys Gauged From The Tip

5.2.3 Cutting Too Far From The Shoulder

5.2.4 Cutting Too Close To The Shoulder

5.3 Depth Adjustment

6. Updates

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7. Troubleshooting

8. Glossary

9. Exploded Views

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10. Preventive Maintenance, Lubrication, Repairs, and Guarantee

CodeMax

. . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . 53

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1. Introduction

Thank you for purchasing this CodeMax® Machine; we appreciate your business.

The CodeMax® represents the latest development in the industry’s first computerized code

machine. Utilizing cutting edge technology, this version allows for electronic calibration,

DSD modification, and updates installed by your computer.

Please read this manual to become familiar with the features and operation of your CodeMax®. This machine is updated every year with new information and features. Please complete and return the enclosed warranty registration card to ensure you receive notice of future updates.

We are confident your CodeMax® will provide years of service for you. If you have any questions or comments about this machine (or any HPC products), please contact us.

Thank you,

HPC, Inc. 3999 N. 25th Avenue Schiller Park, Illinois 60176 U.S.A. Tel: 847.671.6280 Toll-free in U.S.A. and Canada: 800.323.3295 Fax: 847.671.6343 Email: hpc@hpcworld.com www.hpcworld.com

CodeMax

1.1 Product Packaging Checklist

HPC Cutter Wheel (installed) HPC Cutter Wheel HPC Cutter Wheel

(CW-14MC) (CW-1011) (CW-20FM)

HPC Cutter Wheel HPC Cutter Wheel

(CW-47MC) (CW-90MC)

Cutter Wrench Allen Wrench, 5/64" Cutter/Adjustment Wrench Red Tip Gauge (WRENCH-3) (WRENCH-2) (WRENCH-1) (CM-1054MA)

Horseshoe Tip Gauge DSD List (CM-1054R) CodeMax® Update & Restore CD

(MAX-CD)

CodeMax

CodeMax® Manual (1200MAX-MAN)

Serial Cable

(CABLE-25S)

Your CodeMax® computerized code machine comes with the following additional items (see the photos on the previous page):

Qty. Stock No. Description

1 CW-14MC HPC Cutter Wheel (Installed on Machine) 1 CW-1011 HPC Cutter Wheel 1 CW-20FM HPC Cutter Wheel 1 CW-47MC HPC Cutter Wheel 1 CW-90MC HPC Cutter Wheel 1 WRENCH-1 Cutter Shaft/Adjustment Wrench 1 WRENCH-3 Cutter Nut Wrench 1 WRENCH-2 Allen Wrench, 5/64-inch 1 CM-1054R Black Horseshoe Tip Gauge 1 CM-1054MA Red Tip Gauge

1 MAX-CD DSD List, CodeMax

1 1200MAX-MAN CodeMax

Manual

Update and Restore CD

1 — Warranty Registration Card 1 CABLE-25S Serial Cable

1.2 Parts Designation

120VAC Motor (CM-1080MA)

240VAC Motor (CM-1070)

Power Switch

120VAC (KM-1017)

240VAC (9160-SW)

Automatic Angler

Cutter Head (KM-1016)

Keypad (MAX-4)

Wing Nut (EGN-1)

Eccentric Shaft (CM-1041)

Cutter Nut (CM-1039MA)

Cutter (Wide Selection

Available)

Shoulder Gauge (CMB-FG)

Top Jaw (CM-1056MA)

Tip Gauge (CM-1054MA)

Bottom Jaw (CM-1055MA)

Emergency Stop Button (MAX-50)

Pivot Arm (CM-1024X)

CodeMax® CodeMax

1.3 Preparing To Use The CodeMax® Computerized Key Machine

Before using the CodeMax® key machine, read this manual in order to gain a thorough understanding of all of its capabilities. You will receive peak performance and efficiency from your machine by fully comprehending all of its functions.

Make sure that the power outlet that the CodeMax® will attach to is properly wired, i.e., grounded with correct hot and neutral leads. If the outlet is not wired properly or power from the available outlet is not regular (i.e., you experience frequent power brownouts), the CodeMax® may malfunction. While the CodeMax® contains an internal surge protector, it is recommended that you also use an external surge/brownout protector when operating the CodeMax®.

CodeMax

1.4 Basic CodeMax® Setup

Find a suitable location for the CodeMax® machine. This should be an area with good ventilation for the cutter motor and easy access to the front and top of the machine for use and cleaning. Plug the cord into the back of the CodeMax® and then into the appropriate electrical outlet. Turn on the CodeMax® using the switch located at the left rear of the machine.

The display will read “Emergency

Stop Depressed”. Make sure there

is nothing interfering with the

pivot arm, cutter wheel, and motor.

Push the large, red emergency stop

button located at the front of the

CodeMax® until it pops out.

The CodeMax® will go through a brief test routine to prepare itself for use. The CodeMax® display will read “CodeMax Ready”, indicating that the machine is in its main screen and ready for use.

CodeMax

CodeMax Ready

HPCSoft Version 10.0

1.5 The Emergency Stop Button

The CodeMax® has an emergency stop button installed.

Pushing the emergency stop button at any time will immediately freeze the operation in which the machine is engaged. For example, if you started the cutting process and realized

you had the wrong cutter or key blank, pushing the emergency stop button would instantly turn off the cutter motor and stop the pivot arm from traveling.

To reset the CodeMax®, after the

machine freezes, push the emergency

stop button until it pops out, and the machine will return to its Home Position. Make the necessary adjustments (e.g. put the shoulder gauge down, or install the correct cutter or key blank), and start the key cutting process again.

*Note: When the emergency stop button is pushed, the CodeMax® will clear the bittings entered, if the bittings were entered directly on the CodeMax

keypad.

If you have any questions, please call the HPC Service Dept. 1-800-323-3295.

CodeMax

2. Cutter Wheels

2.1 Cutter Wheel Descriptions

The model CodeMax®is supplied with five standard cutter wheels. The CW-1011 cutter is used for cabinet, padlock, and most vehicle applications. The CW-14MC cutter is used for cutting most standard cylinder keys. The CW90MC is similar to the CW-14MC but makes cuts with a steeper slope for special applications. The CW-20FM cutter is a 76 degree cutter used for Sargent applications. The CW-47MC is an 87 degree cutter used for certain automotive applications.

Flat steel cutters, the Medeco® cutter (CW-1012), the Emhart cutter (CW-1013), and the Assa Cutter (CW-32MC) are all optional cutter wheels that are available for use with the CodeMax®. Additionally, the Medeco® Commercial Jaw (MJ-1) is an optional jaw for cutting the Medeco® Standard Commercial Keyway (Air). The KeyMark® Jaw is available from Medeco®.

CodeMax

2.2 Replacing Cutter Wheels

The following procedure is recommended when changing cutters:

IMPORTANT NOTE: Be sure the cutter is installed for a clockwise rotation, with the arrow facing the outside, so it can be seen.

1) Turn the CodeMax® off.

3) Loosen the cutter shaft nut with the 3/4 inch WRENCH-3 by turning it clockwise (left hand thread). The cutter shaft is threaded with reverse, left-hand thread.

2) Hold the cutter shaft with the 1/2 inch end of WRENCH-1.

CodeMax

4) Remove the cutter. Slide the

replacement cutter onto the shaft.

IMPORTANT NOTE: Be sure the cutter is installed for a clockwise rotation, with the arrow facing the outside, so it can be seen.

6) Install the nut, turning

counterclockwise onto the cutter shaft with the 3/4 inch wrench. Do not overtighten the nut!

5) Hold the shaft with the 1/2 inch WRENCH-1.

CodeMax

2.3 Resharpening Cutter Wheels

One of the most important features of the CodeMax® is its capability to maintain correct depth and spacing with virtually no setup time involved, including the changing of the cutter wheels. This capability is dependent upon the use of cutters whose outside diameters are carefully calibrated. We recommend using only HPC cutter wheels.

Eventually, cutters become worn and should be replaced. We do not recommend sharpening cutters.The diameter of a resharpened

if no depth adjustment is made.

cutter is smaller and will therefore make cuts shallower

See Depth Adjustment Section (5.2) for further information.

In order to maintain matched cutter diameters, all cutters for the CodeMax® must be resharpened at the same time to account for material lost during this process.

CodeMax

3. Holding And Gauging Keys

The CodeMax® comes from the factory calibrated and ready to cut keys to manufacturers’ specifications. The necessity for special gauges and adapters has been held to a minimum. Basically, one upper Vise Jaw, which is removable and reversible, covers the greatest range of key cutting. This upper Vise Jaw (CM-1056MA) is marked “A” on one side and “B” on the other. When the A side is in use, the letter “A” faces up, in sight of the operator. The

B side is in position when the “B” is seen. Manufacturers’ data and information about the

corresponding jaws can be found on the DSD-CD.

3.1 Vise Jaws

Jaws A & B – Standard Jaws (CM-1056MA) Installed

Fig. 1A. Properly seated key in jaw A. Fig. 1B. Properly seated key in jaw B.

Vise jaw A is used for all standard keys with the deepest cut no less than .142 inches (see Fig. 1A). Jaw B is used for small keys that use cuts of such great depth that a lip on the jaw is provided to hold the key closer to the cutter. See Fig. 1B.

Some keys (Best™ for example) will tip when using Jaw A. If there is a problem holding the key in Jaw A, use Jaw B by placing the lip of Jaw B on the edge of the blank. The blank must still be positioned at the back of the bottom jaw. See Fig. 2.

Fig. 2.

CodeMax®

Jaw C – Medeco® Jaw (MJ-1) Optional Equipment Required For Cutting Medeco®

Keys (Not Required For Biaxial Keys)

Shoulder Gauge

Fig. 3A. Fig. 3B. Properly seated key in jaw C.

An optional cutter (CW-1012) and Jaw C (MJ-1) are required to cut commercial level Medeco® keys. Both parts are readily available from your HPC distributor. Biaxial keys only require the CW-1012 cutter, not MJ-1.

The optional Jaw C is a specially milled CodeMax® jaw. It is required for holding the standard Medeco® keys (see Fig. 3A). Vise Jaw C is milled to fit and firmly nest into the Medeco® commercial key grooves. The proper and firm grip provided by Jaw C is necessary due to the extremely deep cuts used on Medeco® keys. Instructions for using

Medeco’s KeyMark® Jaw are available from Medeco®.

Gauge the key from the shoulder, making sure the key grooving and special jaw milling are nested together (see Fig. 3B).

CodeMax

3.2 Key Gauges

Shoulder Gauge

Fig. 4 Fig. 5 Fig. 6 Fig. 7

Red Tip Gauge

Horseshoe Tip

Gauge

Position 1

Top View of Horseshoe Tip Gauge in Position 1

Red Tip Gauge

Top View of Red Tip Gauge in Position 2

Position 2

Fig. 8 Fig. 9 Fig. 10

Horseshoe Tip

Gauge

Position 2

Keys with shoulders are gauged by placing them squarely into the vise assembly and swinging the key Shoulder Gauge (CMB-FG) upward. The key is moved laterally, as

required, until the key’s shoulder just touches the left hand surface of the gauge (see Fig. 4).

Note: Be sure to tighten the wing nut and swing the Shoulder Gauge back down before starting the cutting process.

Keys without shoulders are properly gauged by using the Red Tip Gauge (CM-1054MA) or the black Horseshoe Tip Gauge (CM-1054R). The bottoms of these tip gauges have several grooves, allowing them to be held in different positions by a spring loaded ball bearing. These tip gauges are pulled back to the first position where they are held within the base of the lower jaw (Figs. 5 & 6) safely out of the path of the cutting wheel.

See Figs. 7, 8, 9, & 10 for tip gauge references.

CodeMax

Red Tip Gauge

Wing Nut

Fig. 11. Fig. 12. 5 Pin Ford.

Position 3

In the third position, the Red Tip Gauge is sent forward into the third groove and this is the proper setting for old, 5-pin Ford keys (see Figs. 11 & 12). To clamp and gauge double sided Ford type keys, the offset of the key is set against the face of the jaw. Slide the key to the right until the tip butts against the tip gauge and tighten the wing nut. The blank is held off the key rest by this method, thereby eliminating the need for any special blocks (see Figs. 11 & 12).

Right Leg

Position 3

Position 1

Position 2

Left Leg

Position 1

Position 4

Position 3

Position 2

Red (Plastic) Tip Gauge (CM-1054MA) (Black) Horseshoe Tip Gauge (CM-1054R)

Position 1: Out of the way Position 1: Best – Right Leg

Position 2: Best Position 2: Ford – Right Leg Position 3: Ford Position 3: Best – Left Leg (same as 2 red) Position 4: Ford – Left Leg (same as 3 red)

Note: Red Tip Gauge should be pulled back to position 1 or removed when cutting shoulder gauged keys.

Remove Black Horseshoe Tip Gauge completely when gauging or cutting shoulder gauged keys or when gauging from positions 3 and 4 prior to cutting. Positions 1 and 2 of Horseshoe Tip Gauge are designed to bring the tips of key blanks even

with the right side of the jaw. If the right leg is bent inward (so the tip gauge doesn’t enter

the jaw) or bent outward (so key blanks gauge beyond the right side of the jaw) the right leg should be gently tapped back into alignment.

CodeMax

3.3 Gauging Methods

3.3.1 Standard Cylinder Key With Shoulder Gauging Using Jaw A (Example: Schlage, DSD #60)

Shoulder Gauge

1) Place the key blank in Jaw A. Raise the Shoulder Gauge to its upright position. Position the key blank with the shoulder of the key lightly touching the left hand edge of Shoulder Gauge (avoid undue pressure – see Note below).

Note: The spacing of the key cuts can be significantly affected

by any damage incurred to the Shoulder Gauge. Handle the Shoulder Gauge with care! Damage to the Shoulder Gauge most often occurs when the gauge comes in contact with the cutter, or when undue pressure is used when gauging against

the key’s shoulder. Make sure to gently position the key blank

against the Shoulder Gauge to avoid damage.

Red Tip Gauge

Position 1

CodeMax

2) Make sure the Tip Gauge (if installed) is out of the way. The Red Tip Gauge is pulled to the rear and safely in the detent position (Position 1) before continuing, and the Horseshoe Tip Gauge is removed.

3) Tighten the Wing Nut and flip the Shoulder Gauge down before continuing.

Fig. 4. Wing Nut and Top Jaw of vise removed to show top view of the Bottom Jaw only, for key positioning.

4) Make sure the key is lying flat against the back of the Bottom Jaw before tightening the Wing Nut.

CodeMax

+ 49 hidden pages

HPC CodeMax User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual