TRAVEL ADJ.

18. MAINTENANCE

19. TROUBLESHOOTING

20. CUSTOMER
INFORMATION

21. WARRANTY

22. PARTS
BREAKDOWN



1. INTRODUCTION

Thank you for purchasing our American Made, Rytan, Inc., Model RY200, universal key duplicating
machine. Your new key machine has been designed and built with heavy-duty components designed for
the most demanding shop and service vehicle use. As you become familiar with your new machine you
will find a new ease and confidence in key cutting. Discover the smooth and natural interaction between
machine and operator, resulting from careful design and placement of the operating controls. We are
confident you will profit greatly from this quality built versatile key machine.

Your new RY200 key duplicating machine is made similar to the RY256 RAMM semi-automatic key
machine, but with one exception: Stylus and Cutter Head cannot be rotated to cut Medeco Level-1 high
security keys. The Stylus on the RY200 key machine is 100% adjustable to better than ½-thousanths of an
inch (0.0005), and can be re-set to 0 at any time.

Use your machine to cut standard cylinder keys and U.S. and Foreign automobile keys.

2.
GETTING STARTED

Please take time now to read and understand this manual thoroughly before you start cutting keys.
Maintain this owners manual and review it often, and make it available to others who will use this
machine.


Do not attempt to operate this machine until you have read it thoroughly and understand completely

all instructions, rules, etc. contained in this manual. Failure to comply can result in accidents in-

volving fire, electric shock, or serious personal injury.

3.
SAFETY RULES

A.
Know your machine. Read the owners manual carefully. Learn its applications and limitations as
well as specific operational hazards peculiar to this machine.

B.
Guard against electrical shock by preventing body contact with grounded surfaces. Examples:
Pipes and metal work tops.

C.
Keep guards in place at all times.

D.
Keep your work area clean. Cluttered areas and benches invite accidents.

E.
Avoid dangerous environment. Dont use this machine in damp or wet locations. Keep your work
area well lit.

F.
Keep children away. All visitors should be kept a safe distance from work area. Do not let
visitors contact machine or power cord.

G.
Do not force the machine. It will do the job better and safer at the rate for which it was designed.
Always maintain a sharp cutter wheel on the machine.

H.
Use the machine for what it was designed. Dont use the machine for anything but the key blanks
for which it was intended. Cutting steel keys is not recommended.

I.
Wear proper apparel. For example: No loose clothing or jewelry to get caught in moving parts.
Operators without properly restrained long hair MUST NOT operate any type of machinery, including key
machines. Long hair can get caught in moving (rotating) machinery parts.

J.
Use safety glasses. Flying chips, improperly secured key blanks and broken cutter wheel teeth can
injure the eye if not properly protected.

K.

Dont abuse cord. Never yank cord to disconnect from receptacle. Keep cord from heat, oil and
sharp edges. Never remove the ground connection from the plug. If you use a two wore adapter
be sure to properly connect the ground wire. NEVER CUT OFF THE GROUND TERMINAL
FROM THE MACHINES POWER PLUG!

3
L.
Secure keys properly in vises. Dont hold key head for support when cutting. If it doesnt clamp
properly, dont try to cut it!

M.
Maintain a sharp cutter wheel. A dull cutter wheel is not only inefficient but dangerous. A dull
cutter wheel can produce excessive cutting force on a key blank and exceed the machines vise jaws
clamping force to a point where the key blank could be ripped out of the machine.

N.
Disconnect machine. When not in use, during servicing, or when changing cutter wheel and
accessory brush always disconnect the machine form its electrical power source.

O.
Remove servicing wrenches. Remove all service tools from the machine before turning it on.

P.
Always turn off machine. After cutting a key, turn off the machine before removing a cut key and
clamping another fresh blank.

Q.
Always lock carriage back. After cutting a key, turn off the machine and lock the carriage back to
prevent accident or injury.

R.
Outdoor use. When machine is used outdoors, use only extension cords suitable for outdoors and
that have a built-in third wire and ground terminal. NEVER CUT OFF THE GROUND TERMINAL
FROM THE MACHINES POWER PLUG!

S.
Keep hands away from cutter and key blank. Keep hands away from rotating cutter. Do not reach
underneath or around cutter or key blank when cutter is rotating. Do not attempt to remove key blank or key
blank material while cutter is rotating.

T.
Never use machine in an explosive atmosphere. For example, if your machine is in a service
vehicle with a fuel leak or spill, switching on the machine could ignite the fumes.

NOTE: A FLAMMABLE SOLVENT SPILL IN YOUR SHOP OR VAN IS EQUALLY DANGEROUS!

U.
Inspect machine cord periodically. If damaged, repair at once.

V.
Keep hands dry, clean and free from oil and grease.

W.
Stay alert. Watch what you are doing and use common sense. Do not operate machine when you
are tired.

X.
Do not use machine if switch does not turn the machine ON and OFF.

Y.
Drugs, Alcohol, Medication. Do not operate machine while under the influence of drugs, alcohol,
or any medication.

Z.
The operation of any key machine can result in foreign objects being thrown into the eyes, which
can result in severe eye damage. Always wear safety glasses or eye shields before commencing key
machine operation. We recommend wide vision safety mask for use over spectacles or standard safety
glasses.

AA.
Save these instructions.


4.
MOUNTING THE MACHINE

Drill two oversized ½ holes in your bench top to mount the machine. Use ½ 13 bolts from your local
hardware store. Carefully turn the machine up-side-down and measure the spacing of the two tapped holes
on the bottom of your machine (be careful not to set the machine on the power switch). Turn the machine
right-side-up and place the machine where you want it on your work bench. Mark the bench and drill your
holes.



4 5.
CUTTING STANDARD KEYS

A.
Most key clamping requirements use the standard jaw A configuration. Jaw requirements - to
make deeper cuts in small keys or to clamp other types of keys simply loosen the key clamp knob a few extra
turns and lift-and-turn the jaw assemblies from A to B to C to D.

B.
Keys are always gauged with the full-function flip-up key gauges. We do not recommend bottom
shoulder gauging because key blank manufacturers do not always maintain a reliable correlation between
bottom and top shoulder positions on the key blanks they make.

C.
Always remember to flip down your key gauges before cutting a key. Failure to do so will prevent
the key from being cut by the cutter wheel.

D.
Always cut keys from Bow-to-Tip. NEVER MAKE YOUR FIRST CUT FROM TIP-TO-BOW.

The RY200 is specifically designed to cut most cylinder keys and U.S. and Foreign automotive keys by
operating the machines stick-shift lever SMOOTHLY from Right-to-Left. The key will be cut properly
starting at the Bow and ending at the tip of the key. It is O.K. to make a cleanup cut back to the bow of the
key ONLY after the key has already been cut from Bow to tip.

NOTE: If an excessive amount of key blank material is removed on the cleanup cut (second cut) your cutter
may need replacing or re-sharpening. Rytan can sharpen your dull cutter.

6.
CUTTING DEEP CUTS IN SMALL KEYS

A.
Most key clamping requirements use the standard jaws A configuration. If you are making deep
cuts you may have to rotate to the B jaw configuration. You must loosen the painted key clamping knobs a
few turns, turn the vise and retighten.

Make sure your vise jaws are clean (with no chips in the way) and as you secure the vise jaw on to your key -
be sure to push the key into the jaw firmly and make sure they remain flat, and parallel into the vise jaws
when tightening the large painted key clamp knob

When clamping keys in the jaws be sure to open the jaws ONLY enough to slide the key in place.

Please see below for more Vise Jaw information.

B.
Keys are always gauged with the full-function flip-up key gauges.

C.
Always remember to Flip Down your key gauges before cutting a key. Failure to do so will not cut
the key.

D.
Switch ON your machine and operate the stick-shift lever until the stylus is right over the left edge
of the first cut closest to the bow of the key, gently press down on the carriage with the black tear-drop hand,
then reach down and pull out the carriage release (small round black knob) and release the carriage. You may
ease up on the carriage and manipulate the carriage controls to make a smooth gentle cut down the left edge
of the first V cut in the key to the last cut on the tip of the key - cutting all cuts on the key.

E.
You may want to reverse the direction of the carriage and make a clean-up cut back to the bow of
the key.

F.
Push down and lock back your carriage. Turn OFF the machine.

NOTE: CUTTING STEEL KEYS IS NOT RECOMMENDED.


Cutting steel keys will accelerate cutter wear. Some steel keys will ruin your cutter wheel with just one pass.

NOTE: Some automotive presentation keys are made of Hardened Steel and can ruin the cutter wheel instantly!
Dont be fooled by the decorative Gold, Brass, or