Kval 960-3 Operation And Service Manual

Innovation, Quality & Honesty

960-3 Strike Jamb Router

Shifting Head

960-3 Operation and Service Manual

Operation and Service Manual

Published: December 21, 2021

KVAL 960-3 Operation and Service Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual

property of KVAL Inc., and is to be used solely by Customer as an operating manual for

KVAL Inc. machines. Neither this Manual nor any of the information contained herein

may be reproduced or disclosed under any circumstances without the express written

permission of KVAL Inc. For authorization to copy this information, please call Kval

Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and

Canada, call (707) 762-7367.

Manual Part Number: 65-MV101.2

960-3 is a trademark of Kval Incorporated.

All other products are trademarks or registered trademarks of their respective holders,

or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-

rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours:

Technical Support:

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6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:

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6:30 AM to 1:30 PM Pacific Standard Time, Friday

(Other sales related inquiries: http://www.kvalinc.com)

• Email: [email protected]

Kval 960-3 Operation and Service Manual

KVAL 960-3 Operation and Service Manual

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KVAL 960-3 Operation and Service Manual

Table of Contents

KVAL 960-3 Manual

Chapter 1 Introduction to the 960-3

Chapter 1 at a Glance...........................................................................1-1

Overview of the 960-3.............................................................. 1-2

Option Y 960-3......................................................................................1-2

Available Options..................................................................................1-3

About this Manual.................................................................................1-4

Safety First!.............................................................................. 1-5

Safety Sheet Sign-Off Sheet.................................................................1-5

Safety Terminology of Labels................................................................1-5

Safety Guidelines..................................................................................1-5

Lockout-Tagout Guidelines ...................................................... 1-9

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9

Lockout Tagout Procedure....................................................... 1-10

Pre-Steps Before Lockout Tagout.......................................................1-10

Lockout Tagout Power ........................................................................1-10

Lockout Tagout Air Supply ..................................................................1-11

Start Maintenance...............................................................................1-11

Post Maintenance Steps.....................................................................1-11

Anchoring the Machine to the Floor......................................... 1-12

Standard Anchoring Instructions.........................................................1-12

Zero-Energy to Start-Up .......................................................... 1-14

Getting Help from KVAL........................................................... 1-16

KVAL Return and Warranty Policy ........................................... 1-17

Send the Item .....................................................................................1-17

Acceptance of Return .........................................................................1-17

Refund Turnaround Time ....................................................................1-17

Kval Errors..........................................................................................1-17

Customer Errors .................................................................................1-18

Shipper Errors.....................................................................................1-18

Warranty Replacement Parts..............................................................1-18

Safety Sign-Off Sheet .............................................................. 1-20

A Note to the Operator........................................................................1-20

Chapter 2 Operation of the 960-3

About the 960-3 ....................................................................... 2-2

Face Plate Types ..................................................................................2-2

Summary of the Controls on the Machine ............................... 2-3

Controls (Standard) ..............................................................................2-3

KVAL 960-3 Manual

Table of Contents

Foot Pedal ............................................................................................2-3

About the Strike Controls......................................................................2-3

Start Sequence Sensors.......................................................................2-4

Initial Powering Operations for the 960-3 Line......................... 2-5

How to Power Up the Machine .............................................................2-5

How to Power Down the Machine.........................................................2-6

Emergency Shutdown and Recovery ...................................... 2-7

To Resume Normal Operation after an E-Stop.....................................2-7

Steps to Process the Jamb...................................................... 2-8

Set-up 960-3 (Mechanical) ...................................................................2-8

Middle Control Presets .........................................................................2-8

Set the Thickness .................................................................................2-8

Process the Jamb.................................................................................2-9

How to Set the Backset ........................................................... 2-11

Pin System..........................................................................................2-12

Pin Length and Backset Correlation ...................................................2-12

How to Set a Strike Depth (Option) ......................................... 2-13

How to Adjust the Face Plate Width ........................................ 2-14

How to Set a Strike Location ................................................... 2-15

Setting the Index Stops.......................................................................2-15

Tour of the Machine ................................................................. 2-16

About the Shifting Cutter Head................................................ 2-17

About the Strike Controls......................................................... 2-18

Door Hand Selector ............................................................................2-18

Right Hand and Left Hand Cutter Head Location ...............................2-19

Lock Plate Shape Selector .................................................................2-19

Bolt Plate Shape Selector...................................................................2-20

About the Electrical Panel........................................................ 2-21

Description of the Light Tower ................................................ 2-22

Chapter 3 Maintenance of KVAL Machinery

Maintenance Schedule ............................................................ 3-2

Daily, Monthly, Six Month Maintenance ................................................3-2

Maintenance NO-GOES ......................................................... 3-4

Lubrication Schedule ............................................................... 3-5

Typical Lucubration Kit..........................................................................3-5

Lubrication Requirements........................................................ 3-6

Table of Contents

KVAL 960-3 Manual

Pillow Block Bearing Housings .............................................................3-6

Flange Bearing Housings .....................................................................3-7

Ball Rail Bearing ...................................................................................3-7

Sample of Grease Locations for 960-3.................................... 3-8

Description of Air Input System................................................ 3-9

Air Input with Lubrication .....................................................................3-9

Air Line Without Lubricator .................................................................3-10

Changing the Bit on 960-3 High Frequency Motor .................. 3-11

Initial Cut on New Chip Out Block............................................ 3-15

Appendix: Router Collet Assembly Basics............................... 3-16

Checking Collet Assembly ..................................................................3-16

Appendix: Collet Torque Values............................................... 3-17

KVAL 960-3 Manual

Table of Contents

1-1

KVAL Operation/Service Manual

CHAPTER 1 Introduction to the 960-3

This chapter provides an overview of the KVAL 960-3Strike Jamb Router. Included is important

safety Information and Lockout Tagout procedures.

Chapter 1 at a Glance

The following information is available in this chapter:

TABLE 1- 1. Summary of Chapter

Section Name Summary Page

Overview of the 960-3 This section provides an overview of the

machine. It includes a general description and

a table of available options

page 1-2

Safety First! IMPORTANT safety information is described

in this section

page 1-5

Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-9

Zero-Energy to Start-Up Procedure to power up your machine for the

first time.

page 1-14

Getting Help from KVAL This section describes the method to contact

the KVAL service center for help. The section

includes how to get information from the

specification plate tor provide to KVAL, ser-

vice center hours, and return procedures

page 1-16

Safety Sign-Off Sheet A record to track operators that are trained on

the machine.

page 1-20

Overview of the 960-3

KVAL Operation/Service Manual

1-2

Overview of the 960-3

Using the KVAL 960-3 Automatic Strike Jamb

Router, a fast operator can machine 5 jambs per

minute with a full lip strike routing pattern. The

960-3 features a fully automatic machine cycle

that includes clamp-up and ejection.

Popular options include pushbutton changeover to

a "T" strike routing pattern, and end drilling units

for sills and head jamb screws.

The 960-3 is designed so that router movements

are fully automatic. The router moves in a rectan-

gular pattern for faceplate and then moves in to

route for the deeper latch hole. Both flat jambs with stop, as well as split jambs, can be accommo-

dated.

Jambs are placed against either a right-hand or left-hand indexing stop and are clamped firmly

into position at the touch of a foot pedal. Standard set-up is for full-lip routing standard. The

machine includes a unique Hand Free operation for added safety.

Option Y 960-3

Using the KVAL 960-3 Automatic Strike

Jamb Router, a fast operator can machine

up to 4 jambs per minute with a quality

full lip strike routing pattern. The 960-3

features a fully automatic machine cycle

that includes clamp-up and ejection.

The 960-3 is designed so that router move-

ments are fully automatic. The router

moves in a rectangular pattern for face-

plate and then moves in to route for the

deeper latch hole. Both flat jambs with

stop, as well as split jambs, can be accom-

modated.

Jambs are placed against either a right-hand or left-hand indexing stop and are clamped firmly

into position at the touch of a foot pedal. Standard set-up is for full-lip routing standard. The

machine includes a unique Hand Free operation for added safety.

Overview of the 960-3

1-3

KVAL Operation/Service Manual

Available Options

TABLE 1-2. Options

Options

Option A Split Jamb Sta-

pler with Side

Clamp

Adds Split Jamb Option

Option B End Drilling Automatically drills for sill or head mounting screws on both ends.

Price includes one pair of quick-change standard pattern drill

heads with air motors.

Option D Additional Mech-

anisms and

Machine Logic

For processing either full-lip strike or "closed" deadbolt plates.

Photo eyes are affixed to jamb reference guides at the end of the

machine, so plate style is automatically detected depending on

jamb position. Important: Plates must be the same size with iden-

tical plunge profiles.

Option DH Additional Mech-

anisms and

Machine Logic

For processing either full-lip strike or "closed" deadbolt plates.

Photo eyes are affixed to jamb reference guides at the end of the

machine, so plate style is automatically detected depending on

jamb position. Important: Plates must be the same size with iden-

tical plunge profiles.If this functionality is desired and Option H:

Commercial Package is purchased, this version of Option D must

be used

Option E "T” Strike Routing Allows quick change from "T" strike routing to full-lip routing with

the turn of a switch. Cycle slows to approximately four jambs per

minute due to extended router travel path.

Option F Extra Jamb Index

Stops

Two extra jamb index stops for machining dead-bolt strikes.

Option H Commercial

Package

Four additional stops for 6’8”, 7’0” and 8’0” jambs. (Stops included

on base machine for 6/8 doors, does not include extra stops for

deadlock machining)

Option Y Dual Strike The router moves in a rectangular pattern for faceplate and then

moves in to route for the deeper latch hole.

Overview of the 960-3

KVAL Operation/Service Manual

1-4

About this Manual

This manual contains operation information and service and maintenance information.

It includes identification of machine assemblies, power-up and power-down steps, and informa-

tion about using the user interface.

The Troubleshooting and Maintenance sections are directed toward qualified ser-

vice technicians only.

Operation/ Service Manual includes the following:

Chapter Title Description

Chapter 1 Introduction Descriptions of Machine Line and

Safety Information.

Chapter 2 Operation Inter-

face

Descriptions of how to power

machine line, and operator inter-

face user screens.

Chapter 3 Maintenance Information about Maintenance of

the machines

Chapter 4 Troubleshooting Troubleshooing Tips

Safety First!

1-5

KVAL Operation/Service Manual

Safety First!

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-

teria to understand before operating the machine. It is highly recommended that personnel operat-

ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be

signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-

vide safety information to operators. Safety labels should be clearly visible to the operator and

must be replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:

• DANGER means if the danger is not avoided, it will cause death or serious injury.

• WARNING means if the warning is not heeded, it can cause death or serious

injury.

• CAUTION means if the precaution is not taken, it may cause minor or moderate

injury.

Safety Guidelines

In addition to the caution and warning labels affixed to this machine, follow the guidelines below

to help ensure the safety of equipment and personnel.

This machine is a powerful electro-mechanical motion control

system. You should test your motion system for safety under

all potential conditions. Failure to do so can result in dam-

age to equipment and/or serious injury to personnel.

Ensure that all employees who operate this machine

are aware of and adhere to all safety precautions

posted on the machine and are trained to operate this

machine in a safe manner.

Training

Safety First!

KVAL Operation/Service Manual

1-6

Never operate the machine without proper eye and

ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servo

motors can unexpectedly move quickly.

• Never clear screws or hinges out of the machine

while it is running.

• Never reach into the router area to retrieve a

hinge. The router may still be running down

after shut down.

• Never perform any maintenance unless machine

is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is

running.

When the Machine is ON

The compressed air system connected to this

machine should have a three-way air valve

for shut-off and pressure relief.

All cylinders on machine are under high

pressure and can be very dangerous when

activated. Before performing any mainte-

nance or repairs on this machine turn off the

main air disconnect. Lockout and tagout

this connection.

See “Lockout Tagout Procedure” on

page 1-10.

Compressed Air

Safety First!

1-7

KVAL Operation/Service Manual

Electrical circuitry on this

machine is protected by an

approved lockable disconnect

circuit. In addition to this equip-

ment, you must install an

approved disconnect for the

electrical power supplying this

machine.

When opening the cabinet you must first turn off the

disconnect switch. When the cabinet door is open there

is still power on the top side of the disconnect switch.

Some machines are powered by more than one supply

located at different locations. Before performing any repairs or mainte-

nance, lockout and tagout must be installed at all locations

All maintenance and repairs to electrical circuitry should only be per-

formed by a qualified electrician.

Still has power

in OFF position

Electrical

Prior to performing any maintenance, repairs,

cleaning or when clearing jammed debris, you

must disconnect, tag out, or lock out the electrical

and air pressure systems. This should be done in

accordance with applicable state and/or federal

code requirements.

Before Conducting Maintenance

Laser Warnings

On some machines, laser indicators are used to set boundaries. Follow the

manufacturers safety precautions.

Safety First!

KVAL Operation/Service Manual

1-8

KVAL advises that you request an on-site state

safety review of your installation of this

machine. This is to ensure conformance to any

additional specific safety and health regula-

tions which apply in your geographic area.

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard

Before You Report an Accident

If you believe any part or operation of this machine is in

violation of any health or safety regulation, STOP pro-

duction. It is your responsibility to immediately protect

your employees against any such hazard.

Additional detailed safety guidelines are included in the

operating instructions of this manual. KVAL will be

pleased to review with you any questions you may have

regarding the safe operation of this machine

Follow Your Company’s Safety Procedures

In addition to these safety guidelines. Your company

should have on-site and machine specific safety proce-

dures to follow.

Lockout-Tagout Guidelines

1-9

KVAL Operation/Service Manual

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On the tag, each

operator must put their own name and date.

(These locks are only to be removed by the

person who signs the tag)

• If more than one person is working on the

machine, each additional person places a lock

and tag on each disconnect.

• Only each operator may remove their own

lock and tag.

Important: When many people are all working

on the same machine you will need a multiple

lockout device, such as the one shown here.

Follow the P-R-O-P-E-R lockout rule of thumb.

P...... Process shutdown

R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)

O...... OFF! Shut off all power sources and isolating devices

P...... Place lock and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to ensure they are in the “OFF” state

Lockout Tagout Procedure

KVAL Operation/Service Manual

1-10

Lockout Tagout Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S

SB198 ruling of July 1991.

Use the following lockout procedure to secure this machine while it is

powered down. During a lockout, you disconnect all power and shut

off the air supply. Be sure to use the tagout guidelines noted below.

Pre-Steps Before Lockout Tagout

Lockout Tagout Power

1. Evaluate the equipment to fully understand all energy sources (multiple electrical

supplies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the

shutdown.

3. Obtain locks, keys, and tags from your employer’s lockout center.

4. Turn off machine. See Chapter 2 for power down and power up procedures.

5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF

position. Then push the red tab to pop it out. Place a padlock through the hole.

Place your tag on the padlock, as per the tagout guidelines below. (see illustration

below).

Power

Note: When multiple people are working on the machine, each person needs to

have a lock on the handle in the extra holes provided.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

Lockout Tagout Procedure

1-11

KVAL Operation/Service Manual

Lockout Tagout Air Supply

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operate

the machine to ensure equipment will not operate.

8. Maintenance or repairs may started.

Post Maintenance Steps

9. After maintenance is completed, the person performing the work must ensure all

tools, spare parts, test equipment, etc., are completely removed and that all guards

and safety devices are installed.

10. Before removing the locks and tags, the person who attached them shall inspect the

equipment to ensure that the machine will not be put in an unsafe condition when

re-energized.

11. The lock and tag can now be removed (only by the person(s) who placed them),

and the machine can be re-energized.

12. The tags must be destroyed and the locks and keys returned to the lockout center.

6. Turn all air valves to the OFF position and place a pad-

lock through the hole (see illustration below).

NOTE: Place your tag on the padlock, as per the

tagout guidelines.

Anchoring the Machine to the Floor

KVAL Operation/Service Manual

1-12

Anchoring the Machine to the Floor

When you have set-up and test run your machine to ensure that it is feeding the material properly

KVAL recommends anchoring the machine to the floor with ½ Red head, True Bolt Anchors in

each of the foot pads. An alternative way to bolting the machine, you may want to use Epoxy and

hardened threaded rods to prevent the bolts from vibrating loose. KVAL doesn’t require the use of

epoxy though its added fastening strength is significant.

Standard Anchoring Instructions

• With machine in place and leveled, drill 3” deep holes in the concrete using a 5/8”

dia. masonry bit, using the mounting hole as a guide.

• Clean out holes with an air compressor to ensure that the anchor heads get a firm

bite on the walls of the holes.

• Insert anchors through the mounting holes in the foot pads and into the holes you

have drilled into the concrete. If an anchor’s expansion sleeve binds inside the hole,

simply tap the bolt head with a hammer until the binding stops.

• Tighten bolts until they are snug. Avoid over tightening the bolt as this may cause

the head of the bolt to break.

Anchoring Instructions using Epoxy:

• With machine in place and leveled, drill 3” deep holes in the concrete using a 9/16”

diameter. masonry bit, using the mounting hole as a guide.

• Clean out holes with an air compressor. Complete hole preparation with use of a

nylon brush (do not use wire brush).When starting a fresh cartridge of anchoring

epoxy, epoxy must be an evenly blended light gray color. Insert nozzle into the bot-

tom of the hole. Fill hole to ½ the hole depth.

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Kval 960-3 Operation And Service Manual

Kval 960-3 Operation And Service Manual

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