Silca OLYMPIC User manual

®
Operating manual
D424321XA
vers. 2.0

KEY-CUTTING MACHINE
Operating Manual
code: D424321XA - vers. 2.0
®
OLYMPIC
GB

© 2002 SILCA S.p.A - Vittorio Veneto
This manual has been drawn up by Silca S.p.A.
All rights reserved. No part of this publication may be reproduced or used in any form or by any means (photocopying, microfilm
or other) without the written permission of Silca S.p.A.
Published: september 2002
Printed in Vittorio Veneto
by Silca S.p.A.
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy

INDEX
GUIDE TO THE MANUAL ......................................................................................................5
GENERAL INSTRUCTIONS ..................................................................................................6
1 TRANSPORT ..............................................................................................................7
1.1 Packing ............................................................................................................................7
1.2 Transport .........................................................................................................................7
1.3 Unpacking .......................................................................................................................7
1.4 Machine handling ............................................................................................................7
2 WORKING PARTS .....................................................................................................8
3 MACHINE DESCRIPTION ..........................................................................................9
3.1 Technical data .................................................................................................................9
3.2 Electrical circuit .............................................................................................................10
4 ACCESSORIES PROVIDED ....................................................................................11
5 MACHINE INSTALLATION AND PREPARATION ..................................................12
5.1 Checking for damage ....................................................................................................12
5.2 Environmental conditions ..............................................................................................12
5.3 Positioning .....................................................................................................................12
5.4 Description of work station ............................................................................................12
5.5 Graphics ........................................................................................................................13
5.6 Separate parts ...............................................................................................................13
5.7 Connection to the mains ................................................................................................13
6 REGULATION AND USE OF THE MACHINE ..........................................................14
6.1 Setting ...........................................................................................................................14
6.1.1 Adjusting the cutting depth ...............................................................................14
6.1.2 Setting the cutting spaces ................................................................................15
6.2 Cutting operations .........................................................................................................16
6.3 Key cutting .....................................................................................................................16
6.4 BIT and DOUBLE BIT keys ...........................................................................................17
6.5 PUMP keys ....................................................................................................................18
6.6 Bit key with rim ..............................................................................................................18
7 MAINTENANCE ........................................................................................................19
7.1 Cutting tool replacement ...............................................................................................19
7.2 Tracer point replacement ..............................................................................................19
7.3 Replacing the fuses .......................................................................................................20
8 DISPOSING OF MACHINE .......................................................................................21
9 AFTER-SALES SERVICE ........................................................................................22
9.1 How to request service ..................................................................................................22

Operating manual - English OLYMPIC
Copyright Silca 2002 5
GUIDE TO THE MANUAL
This manual has been produced to serve as a guide for users of the OLYMPIC key-cutting machine.
Read it carefully; it is essential if you wish to operate your machine safely and efficiently.
Consultation
The contents of the manual are divided into sections relating to:
- Transport and handling
- Description of machine and safety devices
- Proper use of the machine
- Maintenance
Technical terms
Common technical terms are used in this manual. To assist those with little experience of key cutting,
below is an illustration of the terms used for the different parts of keys:
Fig. 1
Pump key
head
double
bit
stem
bit
Bit key Double bit key

OLYMPIC Operating manual - English
6 Copyright Silca 2002
GENERAL INSTRUCTIONS
The OLYMPIC key-cutting machine has been designed according to the specifications of the Machine
Directives. From the design stage risks for the operator have been eliminated in all areas: transport,
regulation, cutting and maintenance.
The use of protective goggles is compulsory during cutting operations, as indicated on the machine itself
and in this manual.
The material used in the manufacture of this machine and the components employed during use of
the machine are not dangerous and their use complies with standards
.
Use
The OLYMPIC key-cutting machine mustbe installed and usedin the waylaid down by themanufacturer,
as illustrated in this manual.
If the machine is used differently or for purposes different from those described in this manual, the
customer will forego any rights he may have over Silca S.p.A. Furthermore, unforeseen danger to the
operator or any third parties may arise from incorrect use of the machine.
Negligence in the use of the machine or failure on the part of the operator to observe the instructions
given in this manual are not covered by the guarantee and the manufacturer declines all responsibility in
such cases.
It is therefore indispensable to read the operating manual carefully in order to make the best use
of the OLYMPIC key-cutting machine and benefit from its potential.
Further risks
There are no further risks arising from the use of the OLYMPIC key-cutting machine.
Protection and safety precautions for the operator
The OLYMPIC key-cutting machine is built entirely to standards. The operations for which it has been
designed are easily carried out at no risk to the operator.
The adoption of general safety precautions (use of protective goggles) and observation of the
instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate.
The OLYMPIC key-cutting machine is designed with features which make it completely safe in all its
parts.
• Power supply
The key-cutting machine must be supplied with electricity by means of a safety device (supplied with the
230V machines; on request for other voltages). The plug must be earthed.
• Start-up
The machine is started up by means of:
1) the main switch on the safety device (supplied with the 230V machines);
2) the ON switch, situated on the machine, which activates the machine motor.
• Maintenance
The operations to regulate, service, repair and clean the machine have been devised in the simplest and
safest way possible. There is no danger of removable parts being replaced wrongly or unsafely.
• Machine identification
The OLYMPIC is provided with an identification label which shows the serial number (fig.2).
Fig. 2
(*) see chap.8 DISPOSING OF MACHINE, page 21.

Operating manual - English OLYMPIC
Copyright Silca 2002 7
1 TRANSPORT
The OLYMPIC key-cutting machine is easily transported and is not dangerous to handle.
The packed machine can be carried by one person.
1.1 Packing
The OLYMPIC key-cutting machine comes in a strong cardboard box, the dimensions of which are
shown in fig.3, designed to protect the machine and all its parts even when it is stored for long periods.
Fig. 3
1.2 Transport
It is advisable to use the packing every time the machine is transported, as this will avoid knocks which
could cause damage to the machine, persons or things.
1.3 Unpacking
To remove the machine from the packing box:
1) cut the straps with scissors and remove,
2) open the box without damaging it as it may be used again (e.g. removals, dispatch to the
manufacturers for repairs or servicing),
3) check the contents of the box, which should comprise:
- 1 OLYMPIC key-cutting machine;
- set of documents, including: operating manual, spare parts list and guarantee;
- 1 set of accessories;
- 1 safety device (supplied with the 230V machines).
1.4 Machine handling
When the OLYMPIC key-cutting machine has been
unpacked, place it directly on its workbench.
This operation can be carried out by one person, firmly
holding the base, and no other part, to lift and carry
the machine .
Fig. 4
400 mm
600 mm
410 mm
Keep dry This side upHandle with care

OLYMPIC Operating manual - English
8 Copyright Silca 2002
2 WORKING PARTS
Fig. 5
A-Mainswitch
B - Clamp carriage
C - Carriage lever
D-Base
E - Cutter nut
F - Lateral movement lever
G-Motor
H - Cutter protection
I - Key fastening knob
L - Clamp, tracer side
M - Clamp, cutter side
N - Tracer
O - Cutter
P - Anti-rocking knob
W - Carriage locking device
X - Safety device (supplied with the 230V machines)
X1- Safety main switch
X2- Warning light
X3- Plug
NP
FLCM
A
D
H
B
X3
OGI
EI
W
X
X1
X2

Operating manual - English OLYMPIC
Copyright Silca 2002 9
3 MACHINE DESCRIPTION
OLYMPIC is a professional key-cutting machine for BIT, BOUBLE BIT and PUMP keys.
The machine comprises the following main parts:
Safety device
Device connected to a power point with a differential switch; power the key-cutting machine by pressing
the switch (X1).
The warning light (X2) illuminates to indicate voltage in the plug (X3).
ATTENTION: switch (X) is electromagnetic, in the event of a power failure it goes out automatically. When
electricity is restored it must be reset manually to power the machine again by means of the plug
(X3).
Master switch
The motor starting button is placed on the right side of the OLYMPIC key-cutting machine.
ATTENTION: the switch is illuminated to indicate that the machine is live.
Motor
The OLYMPIC has a direct drive motor (G). The transmission unit comprises the motor and cutter is
protected by a single cover (H).
Mobile unit
The mobile unit comprises a carriage (B) holding the clamps.
The carriage (B) is fitted to the translation shaft and is moved manually by the operator.
It has been designed to avoid the accumulation of cutting dust or chippings.
• Cutting tool (O)
The cutting tool is the part of the OLYMPIC machine which cuts the key blank. The tool is in hard metal
(carbide) and is protected by a special cover (H) to ensure safe operation.
• Tracer point (N)
The tracer point is housed on the left-hand side of the machine base. Its depth settings are easily
regulated.
3.1 Technical data
ELECTRICAL PROPERTIES: 230V - 50Hz 190W 2A
CUTTING TOOL: hard metal (carbide)
MOTOR: one speed single phase 230V - 50Hz 1350 rpm 0,18 kW;
CLAMP: 2 sides
CARRIAGE MOVEMENT: manual
DIMENSIONS: width: 470 mm depth: 350 mm height: 260 mm
CUTTING NOISE: Lp (A) = max. 99,7 dB (A)
WEIGHT: Kg. 26

OLYMPIC Operating manual - English
10 Copyright Silca 2002
3.2 Electrical circuit
The OLYMPIC key-cutting machine is provided with a single phase one-speed motor:
1350 rpm, consumes approximately 0.18 Kw, absorption 2A;
The main parts of the electric circuit on the OLYMPIC are listed below:
1) Safety device inlet.
2) Safety main switch
3) Warning light
4) Wiring clip
5) Machine inlet
6) Rapid 4A fuses
7) Illuminated switch
8) Motor: 230V a.c. 50Hz
9) Condenser 8
F
3
brown
light blue
yellow-green
brown
light blue
OUT
IN
4
1
2
Safety device
Machine inlet
5
6
6
78
9

Operating manual - English OLYMPIC
Copyright Silca 2002 11
4 ACCESSORIES PROVIDED
To ensure trouble-free working with the OLYMPIC it is advisable to always have certain spare parts on
hand.
It is advisable to always have a tool box containing: tools, cutting tools, and small replacement parts.
OLYMPIC is supplied with a full range of accessories. The accessories provided by Silca are all that is
necessary to carry out the operations for which the machine is designed.
code D300221ZZ
2 mm Allen key
code DMS200340
13/17/19 mm Spanner
2 pcs
code D300223ZZ
3 mm Allen key
code DEM306054
Setting up pins 6 x 50 mm
2 pcs
code D301185ZZ
Fuses 5x20 4A-rapid

OLYMPIC Operating manual - English
12 Copyright Silca 2002
5 MACHINE INSTALLATION AND PREPARATION
The OLYMPIC key-cutting machine can be installed by the purchaser and does not require any special
skills. However, some checks and preparation for use need to be carried out by the operator.
5.1 Checking for damage
The OLYMPIC is solid and compact and will not normally damage if transport, unpacking and installation
have all been carried out according to the instructions on the packing box.
However, it is always advisable to check that the machine has not suffered any damage.
5.2 Environmental conditions
To ensure that the best use is made of the key-cutting machine, certain parameters must be borne in
mind:
- damp, badly ventilated sites should be avoided.
- the conditions for the machine are:
- temperature: between 0 and 40°C
- relative humidity: approx60%
5.3 Positioning
Place the machine ona horizontal surface, solid enough to takethe weight (26 Kg). To facilitate operation
and maintenance, install the machine with a clearance of at least 200 mm on all sides (fig.6). Check that
the weight of the machine is evenly distributed over the four feet; horizontal positioning prevents
vibrations during operation.
ATTENTION: ensure that the machine voltage is the same as that of the mains, which must be properly
earthed and provided with a differential switch.
Fig. 6
5.4 Description of work station
The machine needs only one operator, who has the following controls at his/her disposal:
• Safety device (X) (supplied with the 230V machines).
• Master switch (A), placed on the left-hand side of the motor; provided with a warning light
indicating that the machine is live.
• Carriage lever handle (C).
• Lateral movement lever (F).
200mm
200mm200mm

Operating manual - English OLYMPIC
Copyright Silca 2002 13
5.5 Graphics
5.6 Separate parts
The detachable parts of the machine are packed separately and must be fitted to the OLYMPIC by the
operator, as follows:
Power cable
First connect the safety device (X) to the key-cutting machine and the power cable then connect the free
end of the power cable to the power mains (fig.7).
Fig. 7
5.7 Connection to the mains
It is extremely important for the operator’s safety to ensure that the key-cutting machine is connected to
the power mains with the right voltage and
by means of a properly earthed differential switch .
THE USE OF PROTECTIVE GOGGLES
IS COMPULSORY
X
power
mains power
cable

OLYMPIC Operating manual - English
14 Copyright Silca 2002
6 REGULATION AND USE OF THE MACHINE
The cutting tool on the OLYMPIC is used to cut the key blanks and must be periodically checked and
replaced. Periodically, and whenever the cutting tool is replaced, check thekey-cutting machine settings,
to ensure perfect machine efficiency.
6.1 Setting
6.1.1 Adjusting the cutting depth
1) Insert the supplied gauges horizontally in the clamp housings (fig.8).
2) move the carriage and make sure the tracer is well pressed against the gauge.
3) turn the cutter manually.
4) the cutting depth of the machine is correct whenthe cutter skims the gaugefreely. Otherwise proceed
as follows:
- loosen the screw (J1) (fig.9).
- turn the screw (K1) (tighten it or loosen it until the cutter skims the gauge).
- fasten the screw (J1).
Fig. 8
Fig. 9
K1
J1

Operating manual - English OLYMPIC
Copyright Silca 2002 15
6.1.2 Setting the cutting spaces
ATTENTION: first carry out depth gauging then this gauging operation.
1) Insert the supplied gauges vertically in the clamps.
2) move the clamp carriage until the tracer touches the gauge.
3) turn the cutter manually.
4) the cutting interval is correct when the cutter skims the gauge in the right clamp (M). Otherwise
proceed as follows:
- loosen the screw (N1) of the tracer unit (fig.11).
- move the tracer unit next to the gauge in the left clamp (L).
- fasten the screw (N1).
- make sure the above mentioned condition occurs before the adjustment of the machine can be con-
sidered correct.
Fig. 10
Fig. 11
L M
N1

OLYMPIC Operating manual - English
16 Copyright Silca 2002
6.2 Cutting operations
To work in complete safety, pay special attention to the following recommendations:
• Always work with dry hands.
• Check that the machine is properly earthed.
• Use the protective goggles, even if the cutting tool is fitted with a protective shield.
• Start the motor only when all the operations with the carriage have been carried out (securing
keys, etc.).
• Keep hands away from the cutting tool when in motion.
6.3 Key cutting
For cutting the various types of keys, read the following instructions and refer to the mentioned figures.
ATTENTION: each time the key is repositioned, the machine must be turned OFF.
1) Position the sample key into the left clamp and fasten it; position the key blank into the right and
fasten it.
2) turn the machine on using the switch (A) (fig. 5, page 8).
Nota bene:move the carriage by raising the knob (C), this makes it move towards the cutter with
the key tilted thus aiding the cut, using the lever (F).
3) carry out the cut.
Fig. 12
Nota bene:to position the clamp on the side required, loosen the knob (I) slightly, hold the bottom
part of the clamp, lift, turn 180° and place in position in its seat.
SIDE 2
key-cutting :
- PUMP KEYS
- CHUBB (bit key with collar)
SIDE 1
key-cutting :
- BIT KEYS
- DOUBLE BIT KEYS
I

Operating manual - English OLYMPIC
Copyright Silca 2002 17
6.4 BIT and DOUBLE BIT keys
1) Position the sample key into the left clamp (L) and fasten it; position the key blank into the right (M)
without fastening it.
2) turn device (W) and raise the carriage using lever (F) (fig.13).
3) move the bit of the key against the tracer point (fig.13).
4) place the bit of the key to be cut against the cutter and fasten it.
5) loosen the carriage and the knob (P) and turn the machine on using the (A) switch.
Nota bene:move the carriage by raising the knob (C), this makes it move towards the cutter with
the key tilted thus aiding the cut (fig.13).
6) carry out the cut.
7) round off the cuts by tilting the (C) knob from top to bottom.
Fig. 13
W
F
L P M
C

OLYMPIC Operating manual - English
18 Copyright Silca 2002
6.5 PUMP keys
1) Loosen the clamp fastening knob (I) raise it and turn it to the desired position (side 2 - fig. 12, page
16).
ATTENTION: don’t round off the cuts on pump keys.
2) stop the right clamp from tilting by fastening the knob (P) (fig. 13, page 17).
3) insert the sample key into the “V” shaped housing of the left clamp (L), make sure it presses against
the side of the clamp and fasten it.
4) in the same way fasten the key blank in the right clamp (M).
5) carry out the cut.
For flat pump keys proceed as follows:
1) place the key in the clamp without fastening it.
2) fasten the key using the screw (X) situated at the top of the clamp (fig.14).
Fig. 14
Fig. 15
6.6 Bit key with rim
1) Use side 2 of the clamp.
2) Place the key into its seat (fig.15) so that the rim is resting on the clamp. Fit the original key into the
left-hand clamp and the key blank into the right-hand clamp.
3) To trim externally the bit, don’t round off the cuts (fig. 13, page 17).
4) Stop the right clamp from tilting by fastening the knob (P).
5) To cut the bit, round off the cuts (ch. 6.4).
X

Operating manual - English OLYMPIC
Copyright Silca 2002 19
7 MAINTENANCE
ATTENTION: for repairs or replacement of parts for maintenance, the ‘CE’ mark is guaranteed only if original
spare parts provided by the manufacturer are used
Although the OLYMPIC key-cutting machine does not require special maintenance, it is advisable to
check and, if necessary, replace the parts subject to wear (cutting tool, tracer point).
Replacement is simple and can be carried out by the operator.
CLEANING : it is advisable to use a soft brush to keep the carriage and clamps free of chippings from
cutting operations.
ATTENTION: DO NOT USE COMPRESSED AIR!
ATTENTION: to keep the machine well maintained we recommend using protective oil, e.g. WD40 or similar,
applied to the burnished mechanical parts. This prevents oxidation of the parts in question
(clamps, guides, carriages, etc.).
Before starting any type of maintenance (checks or replacements), read the instructions below:
• never carry out maintenance or servicing with the machine switched on.
• always remove the mains plug.
• follow all the instructions in the manual to the letter.
• use original spare parts.
• always check that any screws or nuts removed when replacing a piece are properly tightened.
7.1 Cutting tool replacement
Using the supplied tools proceed as follows:
ATTENTION: remove the mains plug.
1) place the 13 mm spanner onto the cutter shaft.
2) place the 13 mm spanner onto the cutter fastening (E) nut.
ATTENTION: left hand thread.
3) loosen the (E) nut by turning it clockwise (fig.16).
4) remove the (E) nut, the (O) cutter and clean the shaft.
5) insert the new cutter, check its direction of rotation and screw in the (E) nut anticlockwise.
Fig. 16
7.2 Tracer point replacement
To replace the tracer point (N), proceed as follows (fig.17):
ATTENTION: unplug the machine from the mains.
1) loosen and remove the tracer point locking screw (K).
2) remove the tracer point.
3) fit the new tracer point.
4) re-gauge the machine as described in chap. 6, page 14.
Fig. 17
G
O
E
K