Dimple & Wave

Key Duplicating Machine

(Part Number: BW-339C-0000)

81 Apsley Street
Hudson, MA 01749-1549 U.S.A.
1-800-434-8960

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 Table of Contents
Machine Diagram…………………………………………………………………………Page 3

Parts Included...…………………………………………………………………………...Page 4

Replacement Parts List………………………………………………………....................Page 5

Setting up Your Machine...……………………………………………….........................Page 6

Dimple Key Cutting Instructions…………………………………………………………Page 7

Sidewinder Key Cutting Instructions…………………………………………..................Page 9

Tubular Key Cutting Instructions………………………………………………………..Page 11

Rod-Style Key Cutting Instructions…………………………………………..................Page 13

Cutter/Tracer Size Identification Diagram………………………………………………Page 14

Popular Wave Keys – Cutter Size Chart………………………………………………...Page 15

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Key Duplicating
Machine Diagram
1. Power Switch
2. Light Switch
3. Table Control Handle
4. Vertical Press Handle
5. Vertical Handle Locking Knob
6. Storage Drawer
7. Vise Jaw Handle (Wing nut)
8. Key Cutter
9. Key Tracer
10. Top Cover
11. Table Locking Knob
12. Tubular Key Stabilizing Block

Figure 1
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 Parts Included
(Some Minor Assembly Required)
1. Drive Belts
2. Vise Jaw Handle Caps (Wing nut)
3. Red Handle Caps
4. Allen Wrench
5. Vertical Press Handle Rod
6. “L” Shaped Block Plate
7. Triangular Rod-Style Key Alignment Block
8. Cutter Storage Boxes
9. 5mm Cutter
10. 4mm/5mm Tracer
11. 4mm Cutter
12. 2.5mm Cutter
a. Note: This cutter is factory installed in
machine.
13. 1.5mm/2.5mm Tracer
a. Note: This tracer is factory installed in
machine with 2.5mm end exposed.
14. 3mm Cutter
15. 2mm/3mm Tracer
16. 2mm Cutter
17. Dimple Cutter
18. Dimple Tracer

Figure 2

Note: Cutters and Tracers may be color coded with paint or acid etched with size. It is consumer’s responsibility to keep size sets
together.

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 Replacement Parts List
Replacement Part Number Description
BW-CAP-339-RED Handle Cap, Red
BW-CAP-339-H-BLACK Vise Jaw Handle Cap, Black
BW-PRESSHANDLE-339 Press Handle
BW-BELT-339 Drive Belt, Orange
BW-TRIANGLE-339 Tubular Key Alignment Block, Black
BW-LBLOCK-339 "L" Shaped Block Plate Accessory
BW-ALLENWRENCH-339 Allen Wrench
BW-CUTTER-339-2MM Cutter, 2MM Diameter, 6MM Shank
BW-CUTTER-339-2.5MM Cutter, 2.5MM Diameter, 6MM Shank
BW-CUTTER-339-3MM Cutter, 3MM Diameter, 6MM Shank
BW-CUTTER-339-4MM Cutter, 4MM Diameter, 6MM Shank
BW-CUTTER-339-5MM Cutter, 5MM Diameter, 6MM Shank
BW-CUTTER-339-DIMPLE Cutter, Dimple, 339 Key Machine
BW-TRACER-339-DIMPLE Tracer, Dimple, 339 Key Machine
BW-TRACER-339-1.5MM/2.5MM Tracer, 1.5MM/2.5MM Diameter, 6MM Shank
BW-TRACER-339-2MM/3MM Tracer, 2MM/3MM Diameter, 6MM Shank
BW-TRACER-339-4MM/5MM Tracer, 4MM/5MM Diameter, 6MM Shank
BW-CUTTER-339-SET Replacement Cutter Set 339 AKA "Bag-O-Bits"
BW-TRACER-339-SET Replacement Tracer Set 339
BW-BULB-339 Replacement Light Bulb 339

Note: All replacement parts are available for order. Please refer to Replacement Part Number listed above when ordering. Call for pricing.
Cutters can be ordered in individual sizes or as a complete set of all available sizes (BW-CUTTER-339-SET).
Tracers can be ordered in individual sizes or as a complete set of all available sizes (BW-TRACER-339-SET).

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Setting up Your
Machine
1. Remove machine from box and open parts bag.
2. Thread Vertical Press Handle rod into housing.
3. Thread red handle cap onto Table Control Handle. Step 1 Step 2
4. Thread red handle cap onto Vertical Press Handle.
5. While holding left side of tracer vise in place, remove
shipping nut from right side of tracer vise, and thread
black vise jaw handle cap (wing nut) onto exposed bolt.
a. Note: It is only necessary to turn cap until vise
begins to move.
6. While holding right side of cutter vise in place, remove
shipping nut from left side of cutter vise and thread
black vise jaw handle cap onto exposed bolt.

Step 3 Step 4
Note:
Your key duplicating machine comes with a 2.5mm cutter and
a 1.5mm/2.5mm tracer factory installed in it. The 2.5mm size is
the most common and can be used for many popular
sidewinder keys.

If you need to remove the cutter and tracer to change size or

type, use the Allen Wrench provided to loosen the set screw in
the cutter and tracer housings. Slide cutter and tracer out and
replace with desired size/type.

Step 5 Step 6

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 Dimple Key
Cutting Instructions
1. Using Allen Wrench provided, loosen set screws
and remove factory installed cutter and tracer.
2. Install Dimple Cutter and Dimple Tracer.
a. Firmly tighten the Tracer pin set screw. Step 1 Step 2
Approximately 50% of the pin length should
be inside the holder. (The tracer pin holder
is spring loaded).
b. Snug the set screw on the Cutter, but do not
tighten.
3. Install original key in right vise. Move key forward
until shoulder rests up against vise jaw. Tighten vise
jaw handle cap (wing nut) on right side of machine.
a. If key does not have shoulders (tip stopped),
then use the block plate accessory to locate
the key in the vise. Slide the block plate into
one of the slots in the vise and move the tip Step 3 Step 3a
of the key against the block plate. Tighten.
4. Install blank key into left vise using same procedure
as original key. Make sure both keys have the same
side facing up.
5. Loosen the cutter set screw, and then pull the
vertical press handle downward, lowering the tracer
and cutter. Move the tracer pin downward onto any
UNCUT surface on the original key. Continue
lowering until the spring loaded tracer pin holder
has become fully compressed.

Step 4 Step 5

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Dimple Key Cutting
Instructions Continued…
6. Tighten the knurled vertical handle locking knob on
the left side of the machine to retain the tracer pin in
its position.
7. Grip the cutter pin with your fingers and slide it
downwards until it is touching the blank key.
Tighten cutter set screw firmly using Allen Wrench. Step 6 Step 7
8. Loosen knurled vertical locking knob. Move table
control handle so that 1st cut on original key is
directly below tracer. Lower tracer down into cut.
9. Note that spring loaded tracer will enter dimple cut
before cutter will touch blank. (Business card used
only to show space between cutter and key blank).
10. Flip power switch to the “ON” position. Depress
tracer into 1st cut. Continue depressing tracer until
spring loaded tracer holder bottoms out.
11. Raise tracer, move table so that tracer is roughly
above 2nd cut, and depress tracer into 2nd cut. Repeat
for all cuts on original key. Step 8 Step 9
12. Turn off power, remove keys, brush off metal
shavings, and remove burrs. Repeat on opposite
side if necessary. Make sure that both the cut side of
key and vise jaw are free of shavings before
duplicating opposite side to ensure key sits correctly
in jaw.

Step 10 Step 11

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 Sidewinder Key
Cutting Instructions
1. Open red lid on top of machine. Loosen nut, and
then tighten 14mm bolt until tracer holder spring
function is eliminated. Tighten nut and close lid.
2. Choose the correct size cutter and tracer for your
application.
a. Using Allen Wrench provided, install tracer Step 1 Step 2
(right side). Approximately ½” of the tracer
should be exposed. Tighten set screw firmly.
b. Install cutter and snug set screw (do not
tighten yet).
3. Install original key in the right vise. (See “Dimple
Key Cutting Instructions”, Step 3, for instructions
on how to install a key in the vise.)
4. Install blank key in the left vise.
5. Move table so that UNCUT surface of original key
is directly below the tracer. Lower tracer until
tracer contacts UNCUT surface.
6. Slide cutter down until it contacts key blank. Step 3 Step 4
Tighten cutter set screw firmly with Allen Wrench
provided.

Step 5 Step 6

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 Sidewinder Key Cutting
Instructions Continued…
7. Remove blank key. Lower tracer down to CUT
surface of original key. Tighten vertical handle
locking knob on left side of machine.
8. Reinstall blank key.
9. Flip motor switch to the “ON” position. Trace cut
surface of original key on the right.
a. Note: Cutter spins in clockwise direction. Step 7 Step 8
Move cutter in a direction so that cutter teeth
are revolving towards key surface.
b. For external cuts, trace in continuous
counter-clockwise direction around the key,
starting from key head, as shown.
c. For internal cuts, trace in continuous
clockwise direction around key, starting
from key tip.
d. Repeat tracing of original key at least once
to verify that blank has been cut exactly like
original.
10. Turn off power. Remove blank. Remove burrs.
Reinstall with opposite side up and repeat step 9.
Make sure that both the cut side of key and vise jaw
are free of shavings before duplicating opposite side
to ensure that key sits correctly in vise. Step 9 Step 10

Choosing the correct size cutter and tracer for your application:
• The tracer must be smaller than any radius on the cut. When you place the tracer against the cut surface on the original key, you
should not see any space between the tracer and the tangential surface of the cut.
• The 2.5mm cutter and 2.5mm tracer can be used in most applications and come factory installed in your machine.
• In most cases the 2mm cutter and the 2mm tracer can be used for inner cuts and the 3mm cutter and the 3mm tracer can be used for
outer cuts.

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Tubular Key
Cutting Instructions
1. Open red lid on top of machine and loosen 14mm
bolt, by turning counter-clockwise 5 turns, to set
tracer pin for spring activation. Tighten nut on bolt
to lock bolt in place. Step 1 Step 2
2. Choose correct cutter and tracer. In order to find
correct size, fit tracer to cuts on original key. The
tracer that fits the cuts perfectly will be the size you
need.
a. Using Allen Wrench provided, install tracer
(right side). Approximately ½” of the tracer
should be exposed. Tighten set screw firmly.
b. Install cutter and snug set screw (do not
tighten yet).
3. Loosen button head cap screws and turn stabilizing
bars to the right to allow space for the tubular keys.
4. Place original tubular key in the right vise jaw and
lightly tighten vise. Swing the leveling bar into Step 2a Step 3
position over the original key.
a. Loosen the vise jaw enough that the original
key can be moved upward so the key
touches the leveling bar. Maintain pressure
on the head of the key (against spring loaded
key square) to ensure key remains square in
vise.
b. Tighten the original key in place.
5. Swing leveling bar above the left vise jaw and
repeat step 4 with blank key.

Step 4 Step 5

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Tubular Key Cutting
Instructions Continued…
6. Move tracer pin downward onto an UNCUT
surface of the original tubular key. Continue
moving tracer downward until tracer pin holder
spring is fully compressed. Tighten vertical locking
knob on left side of machine.
7. Loosen cutter set screw and slide cutter downward
until it touches the blank key. Tighten set screw. Step 6 Step 7
8. Loosen vertical locking knob. Move tracer
downward towards a cut on original key. (Due to
spring loaded tracer pin holder, tracer will enter cut
on original key before cutter reaches blank key).
Move table around until tracer is firmly set in cut.
9. Tighten table locking knob to prevent horizontal
motion.
10. Start motor and pull downward on vertical press
handle to move tracer pin into first cut on original
key.
11. Repeat steps 8-10 for all cuts on original key.
Step 8 Step 9

Step 10 Step 11

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Rod-Style Key Cutting
Instructions
1. Open jaw fully and place the original rod-style key as deep as possible into the
vise jaw.
a. Use the black triangular rod-style key alignment block to align the head of
the key at the necessary 45 degree angle for proper alignment of each row
of cuts. Tighten vise jaw.
2. Open the jaw fully and place the blank rod-style key as deep as possible into the
vise jaw.
a. Use the black triangular rod-style key alignment block to align the head of
the key at the necessary 45 degree angle for proper alignment of each row
of cuts. Tighten vise jaw.
3. Duplicate the original key using the steps provided in previous sections. Step 1

Step 2

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Cutter/Tracer Size Identification Diagram

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 Popular Wave Keys – Cutter Size Chart
Cutter
Vehicle Key Part Number Cutter Part Number Tracer Part Number Color
Size
BMW S7BW-P BH010001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Honda & Acura HO01-PT K/L/M/N 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Hyundai Azera Dealer G0001-2500 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Infiniti Q45 INF90 0001-2000 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Kia Amanti Dealer L001-1000 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Lexus TOY40P O0001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Lexus TOY48P 40000+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Mazda Millenia LXP90-P 20001-21200 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Mercedes S48HF-P HS2001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Mercedes S48HF-P 70001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Mercedes S50HF-P HA2001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Mercedes S50HF-P HA2501+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Mercedes S34YS-P HA10001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Mercedes HU64P 3501+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Pontiac G8 Dealer 60001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Pontiac GTO Dealer 0001-3022 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Saab S32YS-P 2S001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Saab S32YS-P BC001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Saab Dealer DA001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Saab Dealer DB001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Saturn Astra Dealer Z0001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Subaru Impreza Dealer T0001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow
Volvo HU57RP DH0001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Volvo S67NN-P 1V001+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Volvo NE66T2 1AAAA+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
Volvo NE66T2 AOSAYK+ 3mm BW-CUTTER-339-3MM BW-TRACER-339-2MM/3MM Red
VW/Porsche/Audi HU66 0001+ 2mm BW-CUTTER-339-2MM BW-TRACER-339-2MM/3MM Yellow

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