Replacing The Cutter - JMA Berna Instruction Manual

3.3 KeY CUTTING
• Decide which side of the clamp will be used to cut the key. If necessary, turn the clamp to
change sides.
• Place the original key in the left clamp so that the start of the notches more or less coincide
with the edge of the clamp. grab the key in this position, by turning the clamp lever (b).
- If the key is clamped on "side 1 or side 2" ensure that the back of the key rests
correctly on the base of the clamp.
-If the key is clamped on "side 3 or side 4" ensure that the clamp guide is co-
rrectly inserted in the key groove.
• Insert the key blank in the right clamp and align the two keys as follows:
- lift the positioners and support them on the upper key stops. Move the lever (d)
to do so.
- grab the key blank in this position, by turning the clamp lever.
nb: both the original and blank keys must be inserted from the left of their respective clamps.
- remove the key positioners. Move the lever (d) to leave them resting under-
neath in the carriage, so that they do not obstruct key cutting.
• Release the carriage by pressing the lever (M) and bring the keys towards the cutter (F)
and the probe (P).
• Remember that you must work from left to right. Hold the original key against the probe
and start duplication by moving the carriage sideways with the carriage movement lever (u).
Try to ensure that the pressure of the original key against the probe is that required by the
spring inside the carriage.
• When you have finished cutting the key, return the carriage to its rest position. The motor
will automatically stop in this rest position. release the keys once the cutter has stopped.
nb: if cutting has produced any burrs on the duplicate key, remove them using the brush
included in the machine for this purpose.
See Figure 8
3.3.1 duPlicating narrow KeYs
to cut this type of key, and for the cutter to reach the maximum depth in the key to be cut, you
need to use "side 2" of the clamp.
3.3.2 duPlicating stoP-less KeYs
• Insert both wedges (Y) in the vertical slots (E) of the clamps.
nb: choose the wedge pairs according to the length of the key that needs duplicating.
• Insert the original key in the clamp so that the tip rests against the wedge (Y). In this posi-
tion, grab the key by turning the clamp lever (b). repeat the process for the key blank.
• Remove the wedges, release the carriage and start cutting.
See Figure 9
3.3.3 duPlicating cross KeYs
• To duplicate this type of key, "side 1" of the clamp must be used.
• Insert both wedges (X) in the vertical slots (E) of the clamps. Insert them so that the wedge
openings face towards the cutter or probe.
nb: choose the pairs of wedges according to the length of the key that needs duplicating.
• Insert the original key in the clamp until the tip rests against the wedge (X). In this position,
grab the key by turning the clamp lever (b). repeat the process for the key blank.
• Release the carriage and start cutting.
nb: this key has three blades. as a result, the same operation must be repeated another two
times for the other two blades.
See Figure 10
4.- MAINTeNANCe
when performing any maintenance operations, you must comply with the following:
• Never carry out any maintenance when the machine is switched on.
• The power cable must always be disconnected.
• Follow the manual instructions to the letter.
• Use original spare parts.
4.1 rePlacing the brush
when the brush starts losing the ability to remove burrs, it needs to be replaced with a new
one.
the procedure to do so is as follows:
1. turn the machine off and disconnect the power cable.
2. insert the blocking rod into the cutter.
3. use a 4 mm allen key, release the screw holding the brush.
4. replace the brush and hold the new one in place with the screw.
5. remove the blocking rod
See Figure 11

4.2 RePLACING THe CUTTeR

when the cutter is worn, it should be replaced. the procedure to do so is as follows:
1. turn the machine off and disconnect the power cable.
2. release the screws that are holding the clear cutter shield using the nº 4 allen key.
3. extract the cutter protection to increase the space available for working.
4. insert the blocking rod into the cutter.
5. use the 18 mm spanner to release the nut holding the cutter. remember that it unscrews
towards the left.
6. carefully clean the new cutter and all of the areas that will be in contact with it.
7. replace the cutter and screw it tight using the nut.
8. ensure that the cutter has been fastened in the correct direction, as it turns clockwise.
9. replace and fasten the cutter protection and remove the blocking rod from the cutter.
10. we recommend re-calibrating the machine (depth regulation). Please see chapter 3.1 for
the instructions on how to do so
See Figure 12
4.3 RePLACING THe DePTH PRObe
the procedure for replacing the depth probe is as follows:
1. turn the machine off and disconnect the power cable.
2. completely unscrew the screw (1) using a 3 mm allen key and remove the probe (P).
3. assemble and fasten the new probe, ensuring that the flat side of the set screw faces
upwards.
4. we recommend re-calibrating the machine (depth regulation). Please see chapter 3.1 for
the instructions on how to do so
See Figure 13
4.4 ADjUSTING THe MAXIMUM CARRIAGe DePTH
to avoid damaging the clamps and cutter, a maximum cutting depth must be established.
the distance between the cutter-probe and the clamp must be 0.1 mm. if this distance is not
exact, proceed in the following manner:
1. turn the machine off and disconnect the power cable.
2. release the carriage and move it towards the cutter-probe, until it reaches its maximum
height.
3. remove the shavings tray.
4. loosen the set screw (2), using a 10 mm spanner.
5. using a 3 mm allen key, adjust the set screw (3) until a 0.1 mm distance is achieved.
6. Fasten the set screw (3) using the nut (2) and reassemble the shavings tray
See Figure 14
4.5 RePLACING THe FUSeS
if the machine fails to start when switched on, check the fuses. Proceed as follows:
1. turn off the machine off and disconnect the power cable.
2. remove the fuse box located beside the power switch.
3. use a tester to check whether any of the fuses have blown, and if necessary replace it with
an identical fuse
See Figure 15
4.6 RePLACING THe ON/OFF SWITCH AND THe bRUSH bUTTON
Proceed as follows:
1. turn the machine off and disconnect the power cable.
2. turn the machine on its side.
3. access the bottom of the machine and remove the connectors, jotting down their position.
4. Press the tabs (5) to remove the switch or button.
5. insert the new switch or button in as far as it goes into the casing.
6. re-connect all of the connectors in the correct position
See Figure 16
4.7 RePLACING THe beLT
Follow this sequence to carry out the following operations:
1. turn the machine off and disconnect the power cable.
2. insert the blocking rod into the cutter.
3. use a 4 mm allen key to release the screw holding the brush and remove the brush.
4. remove the blocking rod from the cutter.
5. Unscrew the 2 screws (F) holding the "clear cutter shield" using a 3 mm allen key and
remove the shield. remove the led strip.
6. once you have removed the clear shield, release the motor protector. to do so, remove the
protective foam and the 10 screws (g) around the protector. See Figure 17.A
7. the belt is elastic so it is not necessary to remove or dismount the motor to change the belt.
8. remove the old belt. to do so, turn the big pulley while applying a little pressure to the side
of the belt around the small pulley until it comes out. See Figure 17.b
9. Mount the new belt. remember that the new belt is unused and is more difficult to handle
as it has not reached its operational length. First insert it on the small pulley. then, and to
insert it on the large pulley, turn the pulley with your hand (it may make it easier if you use
the 18 spanner on the cutter wingnut to easily turn the cutter axis and therefore the large
pulley - see image 2). Press sideways on the belt in this area while turning the large pulley,
until it is on the wheel.
10. check that the belt is correctly mounted on the wheel.
11. insert the blocking rod into the cutter.
12. Mount the brush and attach it with its screw.
13. remove the blocking rod from the cutter.
14. Position the motor protector and secure it with the 10 screws (g). stick down the led
lighting strip before replacing the cutter shield.
15. Position the cutter shield and secure it with the screws (F).
4.8 RePLACING THe MOTOR
Proceed as follows:
1. turn the machine off and disconnect the power cable.
2. Proceed as if you were going to replace the belt - dismount the shield, engine protector,
brush and remove the belt following the instructions of section 4.7, points 1 to 8.
3. once the shield, engine protector, brush and belt have been removed, carry out the fo-