Kval 990-F4 Owner's manual

Brand
Kval
Model
990-F4
Type
Owner's manual
Chipout Block Replacement
1-1
Chipout Replacement
Chipout Block Replacement
Chipout Blocks help deter tearing as the bit drills through the door. Change a block when a clean
cut is not observed. Chipout blocks are located on the Lock section and the Carriage Head section.
This technical note includes procedures to change the Chipout Blocks for both the Lock and Car-
riage Head sections.
Section Page
How to Replace the Back Section Chipout Block page 1-2
How to Replace the Front Section Chipout Block page 1-3
How to Burn a Chipout Block page 1-6
This machine is a powerful electro-mechanical motion
control system. If servicing the machine, follow the Lock-
out/Tagout. Failure to do so can result in damage to equip-
ment and/or serious injury to personnel.
Follow all safety rules.
Caution
How to Replace the Back Section Chipout Block
Chipout Replacement
1-2
How to Replace the Back Section Chipout Block
The Back Section Chipout Block is located above the
Assembly/Tools:
• 3/32 Allen Wrench
Replacement Step
Chipout Block
Location
1. Perform Lockout/Tagout. (See
Chapter 1 of the Machine Manual).
2. Loosen but do not remove the
four Clamping Plate retaining
bolts.
3. Slide out the old Chipout Block.
4. Slide in the new Chipout Block.
5. Tighten the Clamping Plate
retaining bolts.
6. Load a door into the machine
and clamp it.
7. At the Main Screen, disable the
Hinge Carriage and all functions of
the Lock except the Lock Bore.
8. Burn the Chipout.See “How to Burn a Chipout” on page 1-6
9. Run a test door to verify a clean cut.
Retaining Bolt
Location (X4) Retaining
Plates(X2)
Slide OUT Old
Slide IN New
TIP
How to Replace the Front Section Chipout Block
1-3
Chipout Replacement
How to Replace the Front Section Chipout Block
Each Carriage Head has an associated Chipout Block.
Summary of Burn Process
The burn in process for each Carriage Head Chipout is performed in 3 stages.
• The Router Assembly is moved away from the Chipout Block.
• Gradually, the assembly is moved toward the block, burning at each step.
Chipout Block Spacers
Chipout Block
Location
To lengthen the life of the blocks, spacers are used to extend the block out toward the router. The
block can be burned in a total of three times.
• First Installation: Install new
Chipout Block (No Spacer).
Perform procedure.
• Second Installation: Add
Spacer to the back of the
Chipout Block. Perform proce-
dure
• Third Installation: Stack the final Spacer
to the back of the Chipout Block. Perform
procedure
How to Replace the Front Section Chipout Block
Chipout Replacement
1-4
Procedure to Change Front Chipout Block
Assembly/Tools:
• 7/16 '' Wrench
• 1/2 '' Wrench
• 3/16 '' Allen Wrench
Replacement Steps
1. Perform Lockout/Tagout. (See Chapter 1 of the Machine Manual). (This procedure is
accomplished by alternating between Lockout/Tagout and power up)
2. Locate the Router adjustable stop on the bottom of the Hinge Carriage. For each
router, back-out 6 flats of the bolt. See the figure below
3. Remove the old Chipout Block.
Location of Router
Stop: Adjust when burn-
ing the Chipout Block.
Bottom View of Machine
Remove the 2 Bolts
and Chipout Block for
each Carriage Head.
How to Replace the Front Section Chipout Block
1-5
Chipout Replacement
4. Insert the new Chipout Block with the 2 bolts.
Note: If continuing to use the block, add spacers to the back of the block at this time.
See “Chipout Block Spacers” on page 1-3.
6. Insert a door and jamb into the machine, clamp into position.
7. Burn the Chipout.See “How to Burn a Chipout” on page 1-6 .
8. For each Hinge Carriage, screw in the stop bolt by 3 flats.
9. Burn the Chipout.See “How to Burn a Chipout” on page 1-6 .
10. For each Hinge Carriage, screw in the stop bolt all the way.
11. Remove the door and the jamb.
13. Run a test door to verify a clean cut.
5. Before burning in the block, tighten the 2 top
screws to compress the top and bottom of
the block together.
12. Loosen the Allen bolts on the Chipout
Block to a 1/16'' gap between the top and
bottom Chipout. Ensure that the heads of
the bolts do not rise above the surface of
the Chipout when it is fully compressed.
Adjust to 1/16'' Gap
How to Burn a Chipout
Chipout Replacement
1-6
How to Burn a Chipout
After the insertion of a new Chipout Block, run the Burn Chipout routine.
1. At the Main Menu, select the Manual Button.
2. At the Manual Screen select the Burn Chipout
button.
After the button is pressed, a new
pocket will be slowly drilled.
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Kval 990-F4 Owner's manual

Brand
Kval
Model
990-F4
Type
Owner's manual
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