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HPC CodeMax Manual

Computerized code cutting machine
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CodeMax
®
No. 1200MAX
No. 1200MAXAA
© 2013 HPC, Inc. • Schiller Park, IL • 60176 • USA • www.hpcworld.com
041013 36012_000_00

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  • Page 1 CodeMax ® No. 1200MAX No. 1200MAXAA © 2013 HPC, Inc. • Schiller Park, IL • 60176 • USA • www.hpcworld.com 041013 36012_000_00...
  • Page 2 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.
  • Page 3 To watch the videos showing the Watch Our important features of the CodeMax®. Other Videos Look For... To learn the features of CodeMax® Features of the Version 10 (Upgrades are available). CodeMax® Look For... To view or download the current list Depth &...

  • Page 4: Table Of Contents

    Basic Codemax Setup ........

  • Page 5: Introduction

    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. 999 N. 25th Avenue Schiller Park, Illinois 6076 U.S.A.

  • Page 6: Product Packaging Checklist

    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...
  • Page 7 ® (see the photos on the previous page): Qty. Stock No. Description CW-4MC HPC Cutter Wheel (Installed on Machine) CW-0 HPC Cutter Wheel CW-20FM HPC Cutter Wheel CW-47MC HPC Cutter Wheel CW-90MC...

  • Page 8: Parts Designation

    Keypad (MAX-4) Automatic Angler Wing Nut (EGN-) Cutter Head (KM-06) Eccentric Shaft (CM-04) Cutter Nut (CM-09MA) Top Jaw (CM-056MA) Tip Gauge (CM-054MA) Cutter (Wide Selection Available) Bottom Jaw (CM-055MA) Shoulder Gauge (CMB-FG) Emergency Stop Button (MAX-50) Pivot Arm (CM-024X) CodeMax ®...

  • Page 9: Preparation Of The Codemax

    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., ®...

  • Page 10: Basic Codemax Setup

    ® The CodeMax will go through a brief test ® routine to prepare itself for use. The CodeMax ® CodeMax Ready display will read “CodeMax Ready”, indicating HPCSoft Version 10.0 that the machine is in its main screen and ready for use.

  • Page 11: Emergency Button

    (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. -800-2-295. CodeMax ®...

  • Page 12: Cutter Wheels

    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 CW- 90MC is similar to the CW-14MC but makes cuts with a steeper slope for special applications.

  • Page 13: Changing Cutters

    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. Turn the CodeMax off. ® Hold the cutter shaft with the /2 inch end of WRENCH-. Loosen the cutter shaft nut with the /4 inch WRENCH- by turning it clockwise (left hand thread).
  • Page 14 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. Hold the shaft with the /2 inch WRENCH-. 6) Install the nut, turning counterclockwise onto the cutter shaft with the /4 inch wrench. Do not overtighten the nut! CodeMax ®...

  • Page 15: Resharpening Cutters

    See Depth Adjustment Section (5.2) for further information. if no depth adjustment is made. 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.

  • Page 16: Holding And Gauging Keys

    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.
  • Page 17 Fig. 3B. properly seated key in jaw C. An optional cutter (CW-02) and Jaw C (MJ-) are required to cut commercial level Medeco keys. Both parts are readily available from your HPC distributor. Biaxial keys ® only require the CW-02 cutter, not MJ-. The optional Jaw C is a specially milled CodeMax jaw.

  • Page 18: Key Gauges

    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, & 0 for tip gauge references. CodeMax ®...
  • Page 19 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 ®...

  • Page 20: Gauging Methods

    (if installed) is out of the way. The Red Tip Gauge is pulled to the rear and safely in the detent position (Position ) before continuing, and the Horseshoe Tip Gauge is removed. Red Tip Gauge Position  CodeMax ®...
  • Page 21 ) 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. Make sure the key is lying flat against the back of the Bottom Jaw before tightening the Wing Nut. CodeMax ®...

  • Page 22: Standard Cylinder Key With Shoulder Gauge Using Jaw B

    2) Make sure the Tip Gauge is completely out of the way, and that the Horseshoe Tip Gauge is removed. Red Tip Gauge Position  ) Make sure that the key lies in front of the lip, and flat against the lip. CodeMax ®...
  • Page 23 Tighten the Wing Nut and flip the Shoulder Gauge down before continuing. Wing Nut Shoulder Gauge in the Down Position CodeMax ®...

  • Page 24: Red Full Short Tip Stop Gauging Using Jaw A

    2) The key is gauged from the tip. Make sure the Shoulder Gauge is lowered before continuing. Fig. 3. the Wing Nut and top Jaw of the vise removed to show a top view of the Bottom Jaw only, for key positioning and tip Stop settings. ) Make sure the blank is lying flat on the ledge against the back of the Bottom Jaw before tightening the Wing Nut. Note: For Ford blanks (DSD#34), the key blank grooving edge lies directly on the face of the jaw for ignition and trunk keyways. No riser blocks are used. CodeMax ®...

  • Page 25: Red Middle Short Tip Stop Gauging Using Jaw A

    The key is gauged from the bottom stop, not the tip. Be sure the key lies flat against the back edge of the Bottom Jaw before Wing Nut tightening the Wing Nut. Jaw A Red Tip Stop Fig. 3. the Wing Nut and top Jaw of the vise partially removed to show a top view of the Bottom Jaw only for key positioning and tip Stop settings. CodeMax ®...

  • Page 26: Black Horseshoe Tip Stop Gauging Using Jaw B

    Note: Undue pressure against the right leg will cause the legs to spread, resulting in inaccurately cut keys. Note the special holding on the key milling using Jaw B. (The key must be lying flat against the back ledge of the Bottom Jaw as shown.) CodeMax ®...

  • Page 27: Medeco ® - Standard Commercial Jaw

    Be sure the key groove and jaw milling mate before tightening the Wing Nut. Position  Flip the Shoulder Gauge down and tighten the Wing Nut before proceeding. Medeco is a registered trademark of Medeco Security Locks, Inc. ® CodeMax ®...

  • Page 28: Black Horseshoe Full End Tip Stop Gauging Using Jaw A Or B

    2) The key is gauged from the tip as shown. Be sure the key lies flat against the back of the Bottom Jaw before tightening the Wing Nut. Lower the Shoulder Gauge. Note: Undue pressure against the right leg will cause the legs to spread, resulting in inaccurately cut keys. Note: On Ford blanks (DSD’s 35 and 261) the key blank grooving edge lies directly on the face of the key vise. No riser blocks are used. CodeMax ®...
  • Page 29 Look For... To watch the videos showing the important features of the CodeMax®. See it in use! Look For... To learn the features of CodeMax® Version 10 (Upgrades are available). Features of the CodeMax® Look For... To view or download the current list of DSD numbers and the key cutting Depth &...

  • Page 30: Key Cutting Methods

    4. Key Cutting Methods Stand alone Key Cutting utilizing the internal capabilities of the CodeMax ® Computer assisted Key Cutting using a computer loaded with HPC software connected to the CodeMax via a serial cable (No. CABLE-25S) attached to the back of the ® CodeMax ®...

  • Page 31: Stand Alone Key Cutting

    4.1 Stand Alone Key Cutting 4.1.1 Standard Keys The computer chip in the CodeMax contains a database of nearly 1000 DSD Numbers. DSD ® stands for Depth and Space Data, these are charts of key-cutting information. For Direct Digit keys (such as Schlage or Kwikset) or if you know the bitting needed for an indirect-coded key (such as an automotive or furniture key), you can utilize the internal DSD to cut a new key.
  • Page 32 6. In the case of “Double-Sided Different” keys, after cutting the first side, press ENTER to autoload the next DSD Number associated with the manufacturer chosen. If cutting a single-sided key or if the second side is the same as the first, pressing ENTER will return to the Main Screen. CodeMax ®...

  • Page 33: Medeco ® Keys

    Some high security keys, such as Medeco and Emhart, incorporate angles in their cuts. Both the depths and angles must be determined prior to cutting the key. Use the HPC Pocket Size Decoder (No. HKD-75) to decode the depths and angles of these high security keys, as well as standard keys.
  • Page 34 Fore, Right Aft, Left Aft, Center Aft, Right On the standard model CodeMax , use DSD Number 76. ® The bitting screen will display 12 spaces to accommodate the position of the angle relative to the depth on a 6-space key. This is accomplished by inserting a zero (0) (representing the position of the angle) before the depth for an AFT cut or after the depth for a FORE cut.
  • Page 35 C4 number 4 depth in the “Aft” position with a Center or no angle. 3L number 3 depth in the “Fore” position with a Left angle. R2 number 2 depth in the “Aft” position with a Right angle. 3L number 3 depth in the “Fore” position with a Left angle. CodeMax ®...

  • Page 36: After The Key Has Been Cut

    Press NEW CODE or CLEAR to enter a new bitting, using the same DSD. Press CLEAR twice to enter a different DSD number. Press ENTER to autoload the next DSD number associated with a “Double-Sided Different” key. If no autoload specifications are present, the CodeMax will return to ®...

  • Page 37: Additional Notes

    The CodeMax always cuts shoulder-gauged keys from bow to tip, and tip-gauge keys ® from tip to bow. However, all bittings must be entered into the CodeMax ® in bow to tip order. 2) If the original manufacturer (such as Kwikset) widens some or all of the cuts, the CodeMax will automatically do the same.

  • Page 38: Computer Assisted Key Cutting

    The ® display will read: Codemax Ready HPCSoft Ver 10.0 Follow the instructions for each software program to send data to the CodeMax . The ® computer will then perform its handshake with the CodeMax and download the data. The ®...
  • Page 39 To return to the original function press ENTER, then press HOME (7). The CodeMax will resume from the point of interruption.

  • Page 40: Micrometer Key Cutting

    4.3 Micrometer Key Cutting From the main screen press DSD#. The display shows: Enter DSD Number Press “0” to signify that you wish to use the micrometer function of the CodeMax . Press ® ENTER and the display changes to:...
  • Page 41 For our example, the value is .2, so press “2”, “”, “”, then press ENTER. The display changes to: Space 0.231 In> Depth 0.000 In Press START and the CodeMax aligns the Pivot Arm for the first cut. When the ® CodeMax stops, press “2”...
  • Page 42 “9”, “0”, then press ENTER. You will see the following display: Space 0.231 In Depth 0.290^ In Press start to make the cut. Notice that the CodeMax stays in the cut position and the ® cutter continues to spin. This allows you to widen the cut, if necessary, by using the space commands.
  • Page 43 Next, enter the cut-to-cut spacing. For our Schlage example, this is .56. Press “”, “5”, “6”, then press ENTER and START. Notice that the carriage does not move to “.56”, but to “.87”. The CodeMax totals the distances of our first and second cuts (.2 + .56 = ®...

  • Page 44: Recalibration Of The Codemax

    5.1 Electronic Calibration The CodeMax is capable of Electronic Calibration. Minor depth and space adjustments, ® as well as DSD Specific Depth adjustments, can be performed using the CodeMax keypad ® and stored in the CodeMax CPU board. These adjustments can be used to offset normal ®...

  • Page 45: Depth Instructions

    5.1.1 Depth Instructions Total Machine adjustments affect all DSD’s including keys downloaded from software. To make Total Machine electronic Depth Adjustments on the CodeMax start with the “LOAD” ® button. Press “LOAD” Enter “CC” and press the “ENTER” button Choose between Inches and Metric.
  • Page 46 Confirm 0.000 In A=Yes B=No Depth Adjustment Confirmation Screen will flash twice indicating the adjustment has been saved. The CodeMax now returns to the Main menu and is ready to use. ® (Although the adjustment will not be shown next time you access machine adjustments, CodeMax saves the adjustment in memory even after power has been turned off.)

  • Page 47: Space Instructions

    5.1.2 Space Instructions: Total Machine adjustments affect all DSD’s including keys downloaded from software. To make Total Machine electronic Space Adjustments on the CodeMax start with the “LOAD” ® button. Press “LOAD” Enter “CC” and press the “ENTER” button Choose between Inches and Metric.
  • Page 48 Press ”A” to proceed out of the Adjustment screens or “B” to return to the Space adjustment screen. Space Adjustment Confirmation Screen will flash the adjustment and that it has been saved. The CodeMax now clears and reinitializes completing the Space adjustment. ®...

  • Page 49: Dsd Specific Instructions

    Use the Up Arrow (2) keypad button or the Down Arrow (C) button to change the Depths. The display will show how much of an adjustment you are making. Use the “ENTER” button when you are done. To clear any previous adjustments just follow the above instructions until the display reads “0.000 In” CodeMax ®...
  • Page 50 You will now return to the “Ready...**ADJ**” screen and cut your key with the new adjustment. As long as the adjustment is stored all keys cut with this DSD will be offset by the selected amount. CodeMax ®...

  • Page 51: Manual Calibration

    All this distracts from successful cutting of keys by code. You may proceed after eliminating the above mentioned causes for miscut keys and checking for correct depth calibration. CodeMax ®...

  • Page 52: Cutting Too Close To The Tip On Keys Gauged From The Tip

    Select a tip-gauged, factory cut large cylinder type key, such as Best, Falcon, or Ford. Make sure that all cuts are deeper than a # depth. Install the correct cutter wheel. Turn on the CodeMax ® Select and enter the proper Depth and Spacing Data number.
  • Page 53 (see Fig. 2). With the cutter aligned opposite the cut, retighten the set screws (see Fig. ). 0) Release the Emergency Stop Button. The Pivot Arm will return to the HOME position. Note: You may have to recalibrate the Shoulder Gauge after recalibrating the tip Gauge. CodeMax ®...

  • Page 54: Cutting Too Far From The Tip On Keys Gauged From The Tip

    Select a tip-gauged, factory cut large cylinder type key, such as Best, Falcon, or Ford. Make sure that all cuts are deeper than a # depth. Install the correct cutter wheel. Turn on the CodeMax ® Select and enter the proper DSD number.
  • Page 55 With a small rawhide or plastic mallet, lightly tap the inside of the Pivot Arm to move the cutter closer to the top of the key while centering the cutter flat with the pin seat (see Fig. ). 0) Release the Emergency Stop Button. The Pivot Arm will return to the Home position. Note: You may have to recalibrate the Shoulder Gauge after recalibrating the tip Gauge. CodeMax ®...

  • Page 56: Cutting Too Far From The Shoulder

    Select a shoulder gauged, factory cut type key, such as a Schlage or Arrow. Check to see that the # space (closest to the shoulder) is greater in depth than a # cut. Install the correct cutter wheel. Turn the CodeMax ® Select and enter the proper DSD number.
  • Page 57 Turn Bar so that it remains stationary, swing the key Shoulder Gauge up against the key. The Shoulder Gauge should be just touching the shoulder of the key. Now, without rotating the Turn Bar anymore, tighten the set screw that holds the Turn Bar (see Fig. 2). CodeMax ®...

  • Page 58: Cutting Too Close To The Shoulder

    Arrow. Check to see that the # space (closest to the shoulder) is greater in depth than a # cut. Install the correct cutter wheel. Turn the CodeMax ® Select and enter the proper DSD number. Enter in a # cut for the depth. Then press ENTER to accept, and then press START to begin the cutting process.
  • Page 59 Rotate the Turn Bar to the desired position and hold it there. The Shoulder Gauge should just touch the shoulder of the key (see Fig. 2). Now, without rotating the Turn Bar any more, tighten the set screw that holds the Turn Bar. CodeMax ®...

  • Page 60: Depth Adjustment

    (see Fig. ). Tools Required: Key Micrometer or Caliper, Key Blanks, Correct Depth and Spacing Data, WRENCH- (use /8 inch end for depth adjustment). Install a key blank in the CodeMax jaw. ® Turn the CodeMax ®...

  • Page 61: Updates

    , repeat the update process. Be sure you are using the latest ® files. If CodeMax does not beep on completion of the update process, or if the update process is interrupted, or if the CodeMax ® ® screen remains dark after Send Complete, use the following correction procedure: .

  • Page 62: Troubleshooting

    Once the keyboard has been removed from the casting, attempt to turn on the machine again. If the screen starts normally, inspect the keyboard wire or call HPC to obtain a new keyboard wire.

  • Page 63: Glossary

    A red button in the front of the CodeMax used for stopping all machine movements. ® Jaw: The vise that holds the key in position for cutting on the CodeMax or any other machine. ® Jaw type: Denoted by the letters A, B, or C. Indicates the proper jaw used for cutting a specific key.
  • Page 64 In this manual, this is usually referred to as general widening or specific widening. This is a function that is specified by the manufacturer and performed automatically by the CodeMax ® CodeMax...

  • Page 65: Exploded Views

    Eccentric Shaft CM-04 Set Screw CM-5009 Set Screw CM-502 5. & 6 Turn Bar & Shoulder Gauge CMB-FG Retaining Ring CM-5005 2-56 Screw MAX-92 Shoulder Gauge Wire Assembly MAX-90 Shoulder Gauge Micro Switch Bracket MAX-9 6-2 Set Screw MAX-89 CodeMax ®...
  • Page 66 CodeMax Pivot Arm with Safety Switch Assembly ® CodeMax ®...

  • Page 67: Parts List

    CodeMax Parts List ® Description Stock # Keypad MAX-4 Pad Locator MAX-5 Keypad Display Circuit Board MAX-6 Pivot Arm Assembly CM-024X Cutter Head Assembly CM-05X Grip Spring CM-079 Belt Guard CM-04B Angle Index Pin CM-042 Belt CM-08MA Motor Pulley CM-060MA...
  • Page 68 CodeMax Primary Assembly and Circuit Connections ® CodeMax ®...

  • Page 69: Preventive Maintenance, Lubrication, Repairs, And Guarantee

    7) CALIBRATING DEPTH FOR RESHARPENED CUTTERS — Sharpening cutters changes the diameter; HPC, Inc. recommends replacing cutters instead of sharpening. The diameter of a resharpened cutter is smaller and therefore will make cuts shallower (if no depth adjustment is made).
  • Page 70 Your machine should be equipped with an HPC cutter when it is sent in for repairs. If you are sending in a Blitz ™...

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