Keyline GYMKANA 994 User manual

COMPLETE PRODUCT REGISTRATION FORM
Complete enclosed form and fax to 216-803-0202 or e-mail to info@keyline-
usa.com. This information is required to activate your warranty and inform you
of software updates and new products.
REGISTER YOUR MACHINE ON THE WEB
Visit Customer Area on www.keyline-usa.com then select the Registration
section. Complete the online form and register each machine you own with
the respective serial numbers. Once complete your profile will be set up.
PLEASE NOTE: YOU MUST REGISTER YOUR MACHINE ONLINE TO
HAVE ACCESS TO SOFTWARE UPDATES, MANUALS & QUICK START
GUIDES.
* IMPORTANT *
REGISTERING YOUR MACHINE
Thank you for your purchase of the Keyline Gymkana 994.
Before continuing with machine setup and use, please complete the following;
1

Powering Machine OFF
Cable Connection & Powering Machine ON
1. Attach power cord to back of machine and plug into a properly grounded outlet.
2. Attached phone jack cables to console and to back of machine.
3. Rotate the red Emergency Stop/Power button towards the back right of the
machine until it releases outward. The machine will now begin to start-up.
POWERING MACHINE ON/OFF
*MOBILE USERS: YOU MUST USE A PURE SINE WAVE INVERTER WITH
1100 WATTS (or greater) TO POWER THE MACHINE OR MACHINE MOTOR
WILL NOT WORK PROPERLY
2
At MAIN MENU, select Power button Select YES to log out, then select
Power button again at Login screen
Select YES to exit

3
Select ADMINSTRATOR
LOGIN / PASSWORD ENTRY
TIP: Use included stylus with touch screen to ensure accurate selections
From Main Menu, Select SETUP, USERS and then CHANGE PASSWORD. At
the Change Password screen enter in your new password and confirm (leave
Old Password line blank) then select NEXT. Administrator password is now set.
PASSWORD CREATION (OPTIONAL) -Skip this section if you do not want a password-
Leave password screen blank, no
default password is set, Select NEXT.
To create password, see below.

4
Select ADMINSTRATOR Leave password screen blank, no
default password is set, Select NEXT.
To create password, see below.
LOGIN / PASSWORD ENTRY, cont.
TIP: Use included stylus with touch screen to ensure accurate selections

5
CALIBRATION
TIP: Use included stylus with touch screen to ensure accurate selections
Select SETUP.
Follow the steps below
Select CALIBRATIONS.
Select TRACER SETUP.PRESS START.
Loosen the tracer knob, lower the TRACER and tighten the knob. PRESS OK

6
CALIBRATION, cont.
REMOVE the V037 CUTTER. PRESS OK
Install the T00 Calibration TRACER into the cutter spindle. Tighten the set screw and
CLOSE THE SHIELD. PRESS OK
The MACHINE will START the setup
process.

7
CALIBRATION, cont.
When prompted, loosen the tracer knob, LIFT THE TRACER and MOVE IT TO THE
RIGHT.Close the shield. PRESS OK
PRESS OK.
Write down the X & Y values and PRESS THE SAVE BUTTON. PRESS YES to save
the results. PRESS THE BACK BUTTON after checking their values (see next page).

8
CALIBRATION, cont.
Run the Tracer Setup process a second time and compare the X & Y values of this
process with the previous set. The values should not change more than +/- 3.
EXAMPLE:
If during the first calibration process X= 0 and Y= -4.
In the second calibration process:
X must be between values -3 and +3
Y must be between values -7 and -1.
If the values are outside the +/- 3 variation run the calibration process a third time
and compare the second set of numbers to the third.
IMPORTANT
PRESS START.
Press TRACER ADJUSTMENT.
REMOVE CALIBRATION TRACER T00 from the cutter spindle. PRESS OK

9
CALIBRATION, cont.
Install the CUTTER V037. PRESS OK
The machine will move the tracer over
the jaw.
Loosen the tracer knob, lower the TRACER, tighten the KNOB. PRESS OK

CALIBRATION, cont.
PRESS OK and then PRESS BACK.
Press JAW SETUP and SELECT U JAW
Make note of the values of X,Y,Z.
PRESS START.
Completely remove the CHIPS from the
TRACER, the JAW and the KEY.
PRESS OK.
10

11
CALIBRATION, cont.
PRESS OK.PRESS SAVE.
Run the calibration a second time and compare the X, Y & Z values with the first
set of numbers and make sure that they do not change more than +/- 3.
EXAMPLE:
If the first calibration values are X= -44, Y= -51 and Z= -28
In the second calibration values can be:
X must be between -47 and -41
Y must be between -54 and -48
Z must be between -31 and -25
If the values are outside the +/- 3 variation run the calibration process a third time
and compare the second set of numbers to the third.
IMPORTANT

IMPORTANT
SAFETY SHIELD
The safety shield works in conjunction with the software prompts. The software, before starting some
cut and decode procedures, requires the closing of the safety shield. If it is not closed when requested,
it will continue to ask its closing. If the user opens the safety shield during an operating phase (for
example, when the machine is cutting or decoding a key) it will stop immediately and, at the closing of
the shield, the machine will reset the operation and go back to the beginning of the procedure. Make
sure to complete all parts of the process at one time, then close the shield before proceeding to the
next step. This will avoid having to replicate steps.
KEY MATERIAL
The Gymkana 994 defaults to cutting brass keys as the key material type. If you are cutting a different
type of metal key, such as steel, nickel silver or aluminum, you can make the selection in the cutting
screen. Please note the Gymkana 994 cannot cut or decode any type of plastic key, painted keys or
keys made of non-conductive materials.
USE OF AFTERMARKET SPARE PARTS
Keyline machines require the use of factory original parts. Aftermarket cutters, tracers and adaptors
are not recommended and may cause product damage that will void your machine warranty.
MACHINE PACKAGING
Please retain all machine packaging for transportation purposes. Packaging is specially designed to
safely transport the machine and it’s components. Keyline is not responsible for providing additional
packing material if original boxes are lost, damaged or discarded.
WARRANTY INFORMATION
In Warranty (within 90 days of purchase): Customer will return machine and Keyline USA will the
reimburse shipping charges. Keyline USA will pay the return shipping back to the customer
In Warranty (91+ days of purchase): Customer will pay to return the machine to Keyline USA.
Keyline USA will pay the return shipping back to the customer
Out of Warranty: Customer will pay to return the machine to Keyline USA. Customer will pay the
return shipping back to the customer
TEMPERATURE
Machine operating temperature is between 32 and 104 degrees Fahrenheit.
To change the material type, simply touch the
BRASS icon on the screen until you reach the
desired material; BRASS, STEEL, NiSi (Nickel
Silver) or ALU (aluminum)
12

CUT BY DECODE
Select : Cut by Code
when prompted
1. Select: SETUP
Select MODEL, then NEXT
Select MAKE, then NEXT
Select VEHICLES
Select DECODE, then select
NEXT
Insert key on jaw as shown
Select YEAR RANGE, then NEXT
TIP: DO NOT DECODE PLASTIC KEYS! Only metal keys can be decoded and
cut on the Gymkana 994. IMPORTANT: Make sure to clean the jaw, cutter and
tracer of all chips before decoding or cutting keys by code.
13

CUT BY DECODE, cont.
Decode complete; Select OK Depths and key code displayed
Confirm key is clamped as
shown, then select NEXT
Select NEXT, then proceed with cutting the key by code (refer to Page 8 –
CUT BY CODE, cont. to proceed with cutting
Decoding in process
14

CUT BY CODE
Select MODEL, then NEXT
Select MAKE, then NEXT
Select VEHICLES
Select CODES, then select NEXT Enter code, (ex. L527), select NEXT
TIP: Cutting a test key is also recommended on first use to verify correct key
cutting procedure. IMPORTANT: Make sure to clean the jaw, cutter and tracer
of all chips before decoding or cutting keys by code.
Select YEAR RANGE, then NEXT
15

CUT BY CODE, cont.
Confirm the key is properly installed
on the jaw and select OK
Key depths appear, select NEXT Clamp the key in the jaw, select CUT
Flip key in jaw, removing key
shavings with brush, select OK
Cut complete
16

1. Select: SETUP
Select SETUP
Select REPLACE CUTTER Current cutter installed displays,
select YES to continue
CUTTER REPLACEMENT
Select UTILITY
TO REMOVE CUTTER:
1. Insert 2.5mm Allen tool into
set screw and once initial
release, loosen ½ turn.
Remove Allen tool.
2. Remove old cutter.
17

CUTTER REPLACEMENT, cont.
TO INSTALL NEW CUTTER:
1. Insert new cutter until it stops.
2. Tighten set screw with 2.5mm
Allen tool.
Select YES once complete Select OK to reset cutter counter
Utility screen appears, select
HOME to go to Main Menu
18

1. Select: SETUP
Select SETUP
Select REPLACE TRACER Current tracer installed displays,
select YES to continue
TRACER REPLACEMENT
Select UTILITY
Remove tracer using 2.5mm allen tool, then select OK
Install new tracer until it stops and tighten down set screw with 2.5mm allen tool
19
You must perform the tracer setup, tracer adjustment and jaw calibration