Rytan RY100 User manual

INCORPORATED
1648 W 134th. St.
Gardena, CA
90249 U.S.A.
www.rytan.com
800-447-9826
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING
MACHINE
USER MANUAL
RY101 Wire Brush Kit
(Optional - must be
purchased separately)
RY10030 cutter to pair
with RY10028 stylus
RY89 and RY10047
Key-Clamping Jaws
RY10005 Complete
Carriage Assembly
RY39 Lamp Kit
(Optional - must
be purchased
separately)
READ AND UNDERSTAND THIS OPERATOR’S MANUAL AND
BECOME FAMILIAR WITH YOUR NEW MACHINE BEFORE FIRST USE

INCORPORATED
1648 W 134th. St.
Gardena, CA
90249 U.S.A.
www.rytan.com
800-447-9826
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE
TABLE OF CONTENTS
INTRODUCTION & SAFETY ...........................................................2
MOUNTING THE MACHINE ..........................................................2
VISE JAWS: STANDARD KEYS & DEEP CUTS.................................3
REPLACING VISE JAWS................................................................4
KEY CLAMPING.............................................................................5
KEY GAUGING..............................................................................5
RELEASING THE CARRIAGE..........................................................6
CUTTER SHAFT LOCK.....................................................................6
REMOVING/REPLACING THE CUTTER.........................................6
DEPTH ADJUSTMENT.....................................................................7
SPACE ADJUSTMENT....................................................................7
KEY GAUGE ADJUSTMENT............................................................9
CARRIAGE OVER TRAVEL ADJUSTMENT.....................................9
MAINTENANCE...........................................................................10
TROUBLESHOOTING...................................................................10
REPLACING PARTS......................................................................10
REPAIR INFORMATION...............................................................13
WARRANTY.................................................................................13
EXPLODED VIEW AND PARTS LIST ..............................................14
1

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE
INTRODUCTION
Thank you for purchasing our American-made Rytan, Inc. Model RY100 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.
SAFETY
- Know your machine and read this manual carefully
- Keep guards in place at all times
- Keep your work area CLEAN, DRY, and WELL-LIT. The RY39 Lamp Kit is available for purchase
from Rytan, and comes with necessary hardware to attach to your duplicating machine.
- Keep children and customers away from your machine
- Do not force the machine: It will do the job better and safer at the rate for which it was
designed. Don’t use anything but the key blanks for which it was intended. Cutting steel keys is
NOT recommended.
- Wear proper apparel: Loose clothing and jewelry, as well as long hair, can get caught in
moving parts.
- Use safety glasses: Flying chips, improperly secured keys and key blanks, and broken cutter
wheel teeth can injure the eyes if not properly protected.
- Take extra care with the machines electrical components: Never yank the cord to
disconnect. Never remove the ground connection from the plug. Be gentle with the power
switch. Regularly examine the power cord for wear and replace if necessary. Remember that
turning on the machine could ignite fumes, so use it in a safe environment.
- Secure keys properly: Do NOT hold the bow of the key for support while cutting. If it doesn’t
clamp properly, do not cut it.
- Maintain a sharp cutter wheel: This is both for efficiency and safety. A dull cutter could put
undue pressure on a key blank and compromise the vise jaw clamping. Call to inquire about
cutter sharpening.
- DISCONNECT THE MACHINE When not in use, while servicing, and while changing any parts.
- TURN OFF THE MACHINE: It is very important the machine is OFF when switching out keys and
key blanks, and OFF as soon as you finish cutting a key. If you are handling any part of the
machine near the cutting wheel, turn the machine OFF so the cutter is not spinning.
- Lock the carriage when not in use. SECURE the carriage when your machine is in transit/in a
mobile unit. This can be accomplished by releasing the carriage, inserting a small piece of
carboard between the vise jaw and cutter, and holding together with a rubberband.
2
MOUNTING YOUR MACHINE
Carefully turn the machine upside down and measure the spacing of the two tapped holes
on the bottom of your machine (take extra caution with 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 the two oversized 1/2” holes. Use 1/2” 13 bolts.

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 3
- ALWAYS gauge your keys with the full function flip-up key
gauges on the top shoulder of your key. We do not
recommend bottom shoulder gauging.
- ALWAYS remember to flip down your key gauges (RY81 Key
Gauge Assembly, pictured left) before cutting a key. Failure to
do so may damage the key gauges, key gauge shaft, and/or
cutter wheel. Purchase an RY114 Key Gauge Protector
(pictured left) if needed. Call for pricing.
VISE JAWS: CUTTING STANDARD KEYS
- Most key clamping requirements use the standard top jaw configuration.
The RY89 Top Jaw (pictured right) on your RY100 can be flipped over for
“step” jaw requirements, to make deeper cuts in small keys.
- ALWAYS cut Bow to Tip. NEVER make your first cut from tip to bow. This machine is designed
to cut keys by operating the machines “stick-shift” lever smoothly, from right to left, bow to tip.
It is okay to make a “clean up” cut from tip to bow after, but ONLY after the key has already
been cut. NOTE: if an excessive amount of key blank material is removed on the “clean up”
cut, your cutter may need to be replaced or sharpened.
RY114
RY81
RY89
VISE JAWS: CUTTING DEEP CUTS IN SMALL KEYS
- Most key clamping requirements use the standard top jaw configuration. The
RY89 Top Jaw on your RY100 can be flipped over for “step” jaw requirements, to
make deeper cuts in small keys. You must flip over both the left and right RY89
Top Vise Jaws and clamp them into place with the RY10041 Knurled Knobs
located below the painted key clamping knob. (see right)
- When clamping keys in the step jaws be sure to open the jaws ONLY enough to
slide the key in place so it will be clamped against the top vise jaws step.
Opening the vise jaw too wide will allow the key to pass the step, and the key will
be clamped improperly.
- Make sure your vise jaws are clean and free of chips as you secure the top vise
jaw in the “step” configuration. Push the back edge of the step top jaw firmly
and flat back, and parallel against the stepped face of the RY10047 bottom
vise jaw. Tighten the knurled knob the secure the top vise jaw.
- Always change both vise jaws on both sides to either the standard or the step
configuration. If you change only one, your depth of cut will be off.
NOTE: Cutting steel keys is NOT recommended. They will accelerate cutter
wear. Keep a small magnet nearby to identify steel keys.
RY10041

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 4
REPLACING VISE JAWS: RY89 TOP VISE JAW
- Either RY89 Top Vise Jaw can be replaced at any time - you do not have to buy them in pairs
or sets. Inspect your top vise jaws regularly for uneven key clamping. Replace when jaws
appear worn, or are damaged by contact with the cutter wheel. See page 3 for directions on
flipping jaws. Follow the same directions to remove and replace your RY89 Top Vise Jaw.
REPLACING VISE JAWS: RY10047 BOTTOM VISE JAW
1. Begin by removing the RY89 Top Vise Jaw.
2. Remove the RY80 Key Clamping Knob assembly, the RY82
Thrust Bearing assembly, and the RY10041 Knurled Knob.
3. Remove the RY10045 Top Plate by loosening the 4 RY9063
Cap Screws with an Allen wrench. Pay attention to the
placement of the index mark and reinstall in the same direction.
4. The bottom vise jaw is secured to the RY10046 Plunger by
two RY9062 Cap Screws. Use an Allen hex wrench to remove
the cap screws, removing the jaw.
5. Remove the RY10046 Plunger. Wipe the plunger and the
carriage with a lint-free cloth to clean.
6. Loosely install your new RY10047 bottom jaw to the plunger
using the RY9062 Cap Screws. Do not tighten yet.
7. Coat all steel sliding surfaces with grease: the back side of
the bottom vise jaw, the plunger, the hole in the RY10011
Carriage, and the threaded hole in the center of the plunger.
8. Gently insert the RY10046 Plunger with the bottom jaw
loosely attached into the carriage. Check that it slides
smoothly.
9. Reinstall the RY10045 Top Plate, but do not tighten the
RY9063 cap screws. Place the RY89 Top Jaw on top.
10. Hold the RY89 Top Jaw on top of the top plate, and raise
up the RY10047 Bottom Jaw so that the two jaws engage as
if clamping a key. With your free hand, grab the edges of the
RY10045 Top Plate so it contacts the short tabs on the open
“horseshoe” end of the RY89 Top Jaw. You want to take up as
much of the slack between the vise jaws as possible. NOW
tighten the four RY9063 Cap Screws.
RY9062
RY10045
RY9063
RY89
RY10047
RY10046
RY10041
RY82
RY80
RY10011
11. Clean the RY82 Thrust Bearing assembly and reinstall the RY10041 Knurled Knob, RY82
Thrust Bearing Assembly, and RY80 Knob assembly. Be sure to secure the RY89 top jaw with
the knurled knob.
12. Use the RY80 Key Clamp knob to close the vise jaws together with moderate force,
without a key. NOW tighten the two RY9062 Cap screws to secure the RY10047 Bottom jaw
to the RY10046 Plunger.

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 5
the vise jaw pictured below. Continue to press the blade of the key into
the vise jaws as you tighten the key clamp knob, securing the key. FOR
DOUBLE SIDED KEYS: Some keys do not have a top shoulder to gauge
from. Open the vise jaws just enough to slide in the thinnest part of the
key. Slide in the key blank and allow the full thickness “ridge” of the key
to contact the face of the vise jaw. Clamp the key into the vise jaws so
that the cuts are centered in the vise jaw. Ignition key “ridge” will contact
the face of the top vise jaw. Door and trunk key “ridge” will contact the
face of the bottom vise jaw.
key blade as shown, and with moderate force
against the key, press into the vise jaws and
gently slide left and right a few times to “seat”
the key. Remember to keep a small gap
between the bottom shoulder and the edge of
CLAMPING KEYS
Open the vise jaws only wide enough to slide the key between
the top and bottom vise jaws. Use your index finger against the
TOP SHOULDER GAUGING
Standard cylinder keys should always be top shoulder
gauged. Use the machine’s RY81 Key Gauge
assembly. We do not recommend bottom shoulder
gauging because key blank manufacturers are not
always reliable with the position of the top and
bottom shoulders correlating. Always remember to
flip your key gauges DOWN before cutting a key.
Failure to do so may damage the key gauge and/or
cutter wheel. Leave a small gap of about 1/32” between the bottom
shoulder of the key and the left edge of the vise jaw.
Door
Key
Ignition
Key
gauge shaft toward you, then pushing it
to the right. Continue to twist and push
until the key gauge slides past the actual
tip of the key. Slowly release the key
gauge shaft and allow the key gauge to
rest on the tip location behind the actual
tip of the key, as pictured to the left.
BEST AND FALCON (BEHIND THE TIP) GAUGING
These keys must be gauged from a “tip” location that is behind the actual tip of the key.
Position the key in the vise so that the “tip” edge of the key is no more than 1/32” from the right
edge of the vise jaws. Operate the RY81 Key Gauge by rotating the key

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 6
RELEASING THE CARRIAGE
Releasing the carriage requires two actions. With your right
hand, push down gently on the large teardrop-shaped knob
(RY9028) just enough to move the carriage down a small
distance. While holding the carriage down, reach around with
your thumb and index finger and grasp the small round black
knob (RY9038) and pull it out, holding it there. When the small
round knob is pulled out, gently lift up on the carriage from the
teardrop knob and then let go of the small round knob. You
have now released the carriage and can use the teardrop
knob to position the carriage how you want. NOTE: You will not
be able to pull the small black knob by itself to release the
carriage. You are required to push down on the carriage first as instructed. After you cut a key,
push DOWN on the large teardrop knob to click the carriage into the locked position.
CUTTER SHAFT LOCK
To remove the cutter you must first lock the cutter and cutter shaft into position. (See the
exploded view at the end of this manual for location of the cutter shaft lock. It is part number
44) Press down firmly on the cutter shaft lock. While pressing down, rotate the cutter by hand
until you hear the cutter shaft CLICK into the locked position - there is only one locking position
to be found. You may now proceed to change the cutter. After you change the cutter
(instructions below) do not forget to pull UP on the cutter shaft lock. This will release the cutter
and cutter shaft from the locked position. Failure to unlock the cutter will cause it not to rotate
when you turn the machine on. The motor may be powerful enough to slip the belt and
permanently damage it.
REMOVING/REPLACING THE CUTTER
The cutter wheel is secured to the cutter shaft with a LEFT-HAND NUT. You must turn the nut
clockwise to remove it. Use a 1” open-end or hex wrench to remove the RY10036 Hex Nut.
Slide off the cutting wheel. Before you reinstall your cutter
and the left-hand nut, clean off any cuttings from the
cutter shaft with a clean rag. Apply a small amount of
white grease to the cutter shaft face, shank, and threads
before installing your new cutter wheel and left hand nut.
When reinstalling, do not overtighten the cutter wheel nut.
Overtightening it may make it harder to remove later and
may result in damaging the cutter shaft lock and/or
pulley. After you change the cutter do not forget to pull
UP on the cutter shaft lock. This will release the cutter and
cutter shaft from the locked position. Failure to unlock the
cutter will cause it not to rotate when you turn the
machine on. The motor may be powerful enough to slip the belt
and permanently damage it.

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 7
DEPTH ADJUSTMENT
Depth is adjusted at the back end of the stylus. To adjust the depth you will
need a 5/32” Allen Hex Wrench, a piece of writing paper cut to approx. 1”x4”
and two identical key blanks. Measure the width of the blank blade with a
micrometer or calipers to ensure they match. Before you begin, make sure
that both RY89 top jaws are in the standard configuration (see right).
Depth of cuts is adjusted by moving the
stylus forward or backward by means of a
knurled knob located at the back of the
stylus. The stylus is secured by two #10-32
allen socket head cap screws at the top of
the stylus holder (see left). To begin, you
must loosen the two screws about one turn each with the
allen hex wrench. Use your hand to turn the knob about 1 full
turn (counter-clockwise when viewed from the front of the
machine).
Secure the two matching key blanks, one in each vise jaw. See the
section on KEY GAUGING to insert and gauge the keys properly. With the keys clamped
properly and the stylus adjusted forward about one full turn, carefully release the carriage
and and position it so the key in the left jaw LIGHTLY contacts the stylus in the middle of the
blank’s blade. The cutter wheel should NOT make contact with the blank in the right jaw. Turn
the cutter BACKWARDS (to protect the blank) and confirm they do not contact. You may
now switch ON your machine.
Take the cut piece of paper and hold it between the spinning cutter wheel and the blade of
the key blank. Use your other hand to SLOWLY and carefully back off the knurled adjustment
knob, bringing the carriage closer to the cutter. While doing so, move the paper slowly from
side to side to assist you in detecting when the cutter wheel first contacts the paper. When it
does, paper will be shaved with nearly no sound. Make sure you are moving very slowly.
Once you have the cutter wheel touching the paper, slow your movements to very small
increments, one knurl at a time as you bring the carriage closer to the cutting wheel. Stop
when the paper is cut through to the last few fibers. Turn your machine OFF. You have now
accurately adjusted the depth on your machine. Tighten the two screws moderately. Verify
that tightening the screws did not alter the adjustment by turning the machine ON. The
cutting wheel should just barely “tick” the blade of the key blank. Move the carriage lever
very slightly to make sure you still hear a faint “tick.” Turn your machine OFF.
SPACE ADJUSTMENT
Never adjust the spacing without first ajdusting the depth. Always do depth adjustment first.
Spacing is adjusted by moving the cutter wheel and its cutter shaft assembly left or right. The
cutter shaft assembly is secured to the main housing by two #10-32 Allen socket head cap
screws (see image on next page). To adjust the spacing you will need a 5/32” Allen Hex
Wrench, two identical key blanks, and a small plastic mallet. Before you begin, make sure that
both RY89 top jaws are in the standard configuration (see top right image above).

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 8
SPACE ADJUSTMENT (cont.)
Stack the two identical key blanks one on top of the other and clamp them BOTH in the right
hand vise jaw (cutter side). See the section on KEY GAUGING to insert and gauge the keys
properly. There should be NO key blank in the left vise jaw for this part of the space adjustment.
Do not forget to flip down your key gauges. Failure to do so may result in damage to the key
gauge shaft.
Switch ON your machine and carefully release the carriage. Position it so the cutting wheel
makes a cut in the middle of the key blank blades. Hold the carriage lever steady and carefully
make a straight V cut into the key blank stack about 1/8” deep. Be sure not to move the
carriage sideways. Once the cut is made, lock the carriage back and switch OFF your
machine. Remove the blanks, remembering which one was on top and which was on bottom.
Take the TOP key blank and install it in the right vise
jaw. Take the BOTTOM key blank and install it in the
left vise jaw. See the section on KEY GAUGING to
insert and gauge the keys properly. Carefully release
the carriage and align the left-hand blank’s “V” cut
with the machines stylus. The “V” cut in the right-hand
vise jaw should fall into place around the “V” profile
of the cutting wheel (see right). Manually and carefully turn the cutting wheel BACKWARDS (to
protect the blank) to verify that the cutting wheel does not touch the “V” cut in the blank.
Observe which way you must move the cutting wheel so that it falls into the “V” cut to the same
degree the stylus sits in the “V” cut on the left-hand key blank. Remember this for the next step.
Loosen the two #10-32 screws securing the cutter shaft assembly in place using your 5/32” Allen
Hex Wrench. Tighten them with LIGHT pressure. You want just enough pressure on the two
screws to keep the cutter shaft assembly in place so you can’t move it with your hand, but you
CAN move it with gentle to moderate tapping with your small plastic mallet (see below).
Use your small plastic mallet to “nudge” the cutter shaft assembly
in the direction you need it to go (see left). Verify the cutter
position in the “V” cut after every tap of the small mallet, turning
the cutting wheel backwards and ensuring it does not contact
either side of the “V” cut. Make sure the stylus says seated in the
“V” cut of the left-hand key throughout this process.
Continue this process until you are satisfied with the position of
the cutter. After you have verifiied that the cutting wheel is not
contacting either side of the “V” cut, turn ON your machine and
observe it spinning in the cut. Turn OFF your machine and tighten
the two screws using the 5/32” Allen Hex Wrench.
2 Screws
Verify that your depth adjustment is still correct, and slightly readjust if necessary.

INCORPORATED
COPYRIGHT RYTAN INC 2022 | WWW.RYTAN.COM | 800-447-9826 | [email protected]
RY100 KEY DUPLICATING MACHINE 9
KEY GAUGE ADJUSTMENT
Stack two identical key blanks one on top of the other and clamp them in the right-hand vise
jaw. Be sure to BOTTOM shoulder gauge them. Do NOT use the machine’s top shoulder gauges.
There should be NO key blank in the left vise jaw for this part of the procedure.
Switch ON the key machine and carefully release the carriage. Make a cut in the middle of the
stacked key blank blades. Steadily and carefully make a straight “V” cut into the blanks using
the carriage lever. Make a wide cut, slightly larger than 1/4”. Pull the carriage back and switch
OFF your machine. Remove the blanks from the right-hand vise jaw.
Install one key blank in the right-hand vise jaw and the other in the left-hand vise jaw. Be sure to
BOTTOM shoulder gauge them. Do NOT use the machine’s top shoulder gauge assembly.
as necessary by loosening the screws holding
the fingers to the key gauge shaft, adjusting,
and tightening. The spacing of the key gauges
now matches the spacing of the vise jaws.
Verify the machines depth and spacing. If
necessary, readjust.
the cutter wheel from cutting into the vise jaws when there are
no keys clamped in the machine. Setting the depth over travel
device too high will prevent deep cuts from being made. To
adjust the depth over travel you will need a slot head
screwdriver, a 7/16” wrench, and three pieces of writing paper
cut to approximately 1”x4” each.
Close both vise jaws without keys in them. Release the carriage
and position it so the stylus and cutter wheel are centered at the
vise jaws on both sides. Loosen the 7/6” hex jam nut on the front
of the carriage (see right). Loosen the 1/4”-20 slotted screw stud
about one full turn. Confirm that the stylus is touching the face of the closed vise jaw.
Gently turn the slotted screw stud with your screwdriver clockwise, and stop when you feel the
stud contact the machine’s main housing. The slotted screw stud will contact a 3” long
hardened roll pin. After contact is made, turn it an additional 1/4 turn. Tighten the 7/16” hex
jam nut using moderate tightness.
After tightening the hex jam nut, check the gap between the stylus and the face of the closed
vise jaws. Stacking the three pieces of paper and insert them between the tip of the stylus and
the face of the closed jaw. The combined thickness is the ideal depth. Readjust if needed.
If adjusted too low, your cutter wheel may cut into the right-hand vise jaw. If adjusted too high,
your cutter wheel may not cut deep enough when duplicating.
Once the keys are clamped and bottom gauged, flip up the machine’s key gauge assembly
and place them in the wide grooves you cut into the keys (see below). Adjust the key gauges
CARRIAGE OVER TRAVEL DEPTH ADJUSTMENT
Your machine is equipped with a device to prevent the depth from over traveling. It prevents