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Kval Commander Instruction Manual

Door pre-hanging machine
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KVAL INC.
INSTRUCTION MANUAL
Commander
Door Pre-Hanging Machine
REV.1

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Summary of Contents for Kval Commander

  • Page 1 KVAL INC. INSTRUCTION MANUAL Commander Door Pre-Hanging Machine REV.1...
  • Page 3 SERIAL No._____________________________________________ DATE OF PURCHASED___________________________________ This manual is designed with safety in mind. We at KVAL want to begin FAST and SAFE production as soon as possible. It is very important that all OPERATORS and MAINTENANCE personnel read this manual thoroughly. We have included important safety information that will help prevent serious injury;...

  • Page 4: Operator's & Parts Manual

    This document, the information in this document, and all rights there to are the sole and exclusive property of Kval, are intended for use by customers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in part, without the express written permission of Kval.

  • Page 5: Table Of Contents

    T able of Contents OPERATOR’S & PARTS MANUAL......................III CUSTOMER SERVICE INFORMATION....................1 RETURNING PARTS / EQUIPMENT TO KVAL..................2 : ............................2 HEN YOU CALL : ......................2 HEN SENDING MERCHANDISE BACK GETTING STARTED............................ 3 SAFETY FIRST DANGER! .......................... 5 PROCEDURE..............................
  • Page 6 FEED (OPTION):............................29 FWD: ..............................29 REV..............................29 START SEQUENCE (FRONT/BACK) (OPTION): ................. 29 :................................ 29 RONT :................................29 FRONT SECTION ............................ 31 COMMANDER HINGE SECTION: ......................31 :............................ 31 INGE OCATIONS : ......................31 TANDARD INGE ENTER : ........................31 ETTING THE :..............................
  • Page 7 COMMANDER EXTERIOR DOOR REVEAL ADJUSTMENT ............37 HIGH FREQUENCY ROUTER DEPTH ADJUSTMENT:..............38 SETTING UP THE BACK SECTION:....................41 COMMANDER LOCK SECTION:......................41 : .......................... 41 ECTION OCATION LEFT RIGHT S (OPTIONAL): ......41 HIFT WITH ULTI TOP FOR OCKS ECTION LOCK BORE ............................

  • Page 9: Customer Service Information

    M A C H I N E Customer Service Information KVAL is happy to help its customer make the most of their investment, and help solve any problems that may occur. When you call, please have the electrical print, air print number, and the serial number of the machine ready, so that we are able to accommodate your needs efficiently.

  • Page 10: Returning Parts / Equipment To Kval

    3. Include your RMA # on the outside of the package so our shipping receiver will see it. Kval tries hard to satisfy its Customers, if you have any questions concerning merchandise purchased through KVAL, please call. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 11: Getting Started

    Please review the checklist and return “Acknowledgment Copy” to KVAL Verifying complete contents. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 12 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 13: Safety First Danger

    This section contains important safety information. Failure to follow these safety guidelines may subject the operator to physical hazards that may result in serious bodily arm, or death. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 14: Procedure

    9. The tag shall be destroyed and the lock and key returned to the lockout center. In addition to safety concerns, this policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 15: Lock Out And Tag Out Procedure

    Lock out and Tag Out Procedure This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 16 You could be caught in equipment that can move due to stored energy, even with the power off. The Solution Is Quite Simple — These Accidents Can Be Prevented Using The P-R-O-P-E-R Lock-Out Procedures. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 17: Lock Rules

    Bleed electrical capacitors if any. R Recheck Controls and Return To “OFF” Setting Recheck the start button and properly test that you have zero energy state. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 18 Release pressure and drain to achieve zero energy state. R Recheck Controls and Return “OFF” Setting Recheck line and test properly and make sure you have zero energy state. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 19 E Energy - Release Stored Energy Release, spring or tension to achieve, zero energy state. R Recheck Controls and Return To “OFF” Setting This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 20 YOUR LIFE MAY DEPEND ON IT. http://www.concrete-pipe.org/sab.htm © 2004 American Concrete Pipe Association (ACPA). All Rights Reserved. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 21: Safety Guidelines

    We will be pleased to review with you any questions you may have regarding the safe operations of this machine. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 22 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 23: Specifications

    The Commander is designed to route and bore for lock and hinges in flush or stile and rail doors up to 2-1/4” thick by 4’ wide and 9’ long and wit a minimum width of 18”. It also accommodates raised panels or molding up to ¾”...

  • Page 24: Uncrating The Commander

    Rest the off-feed end of the 555 on the leveling brackets welded to the commander’s frame. Screw in the mounting bolts from the 555 into the commander finger tight. Align and drive in the roll pins from the inside of the commander’s frame. Tighten the bolts and fasten the 555 electrical junction box back in place.
  • Page 25 The standard Commander is rated at 8 CFM. Check the spec plate if the optional H-1000 or 555 was ordered with your Commander. Air should be supplied inside the left rear leg to the Filter/ Regulator / Lubricator module. Once the machine is up and running, sight through the glass on top of the lubricator, and turn the adjustment screw so one drop every two cycles is fed to the system.
  • Page 26 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 27: Anchoring The Machine To The Floor

    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.
  • Page 28 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 29: Daily

    Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance. Daily, Monthly, Six Month Maintenance Daily Preventive Maintenance Operation Description Clean Blow off dust from the entire machine.Wipe down the outside of the machine with a clean dry cloth.
  • Page 30 Maintenance Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 3-1. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...
  • Page 31 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 32: Lubrication Requirements

    Oil change is recommended after 2000 hrs. or six months of operation. Use AGMA #8 gear lube or MOBILUBE HD 80 W-90 or equivalent. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 33: Mist Oil Lubrication

    Check the lines every week to two weeks Figure 1: This shows how to adjust the lubricators and shows the air lock out valves 1 drop every 3-4 cycles This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 34 ZERK fitting Figure 2: This shows how to adjust the lubricators and shows the air lock out valves 1 drop every 3-4 cycles This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 35 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 36: Control Panel Operations

    Bolt Drill Off/ On: The Bolt Drill selector switch controls the operation of the bolt drill. Select On for bolt drill machining. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 37: Face Plate Off/ Reg. / Extend Time

    This button begins the Commander cycle of operation. “Start Sequence” only start the machining that the operator has selected from the OPERATING CONTROLS. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 38: Door Stop

    Activates the front section with out activating the back section (lock section) Back: Activates the back section for multi positioning for deadbolt, without activating the front section (hinge routing). This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 39 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 40: Front Section

    To machine opposite swing doors, the off feed stop needs adjustment according to the formula. Off Feed Stop = First Hinge + Last Hinge + Hinge Size This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 41: Hinge Size

    (reference door thickness) will go up or down. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 42: Changing Chipout Blocks

    Setting the Jamb Stops: Just as the left hand stop is the fixed stop on the Commander, the left hand jamb stop is a fixed stop. Its normally factory set for a 1/8” header clearance. Adjust the right jamb stop by reading the tape under it against the left edge of the stop.

  • Page 43: Alternative Set Up For Pre Hangers

    3 degrees. You can even mount half hinges and then drive in the pins with door and jamb out of the machine. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 44: Dalton Torque Limiter Osd

    Guard plate connected by two 10/32 socket heads removes this plate, to access the Dayton Torque Limiter. Door Hinge Backset: Bottom Pin This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 45: Setting Up For A Cut Continued

    ∗From zero degrees to 3 degrees your overall pocket decreases 1/16". Setting Up For a Cut Continued 1 3/4" Door w/ 4" hinge 5/8" Radius This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 46: Commander Exterior Door Reveal Adjustment

    When changing either the reveal measurement, or the thickness of the door, it is necessary to adjust the position of the chip out block relative to the new thickness and reveal This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 47: High Frequency Router Depth Adjustment

    See the following pictures. Turret Bolts for the Hinge Set Collars for Depth Depth adjustments. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 48 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 49: Setting Up The Back Section

    5. Tighten the shaft collar securely. 6. Attach on the indicator arrows above the tape in line with the indictor attached to the lock section. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 50 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 51: Lock Bore

    5" LONG Push chip out block housing firmly against the stop bolt. Re tighten shaft set collars. Repeat same procedure for drill. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 52: Make Sure Chipout And Drill Are Aligned Properly

    1 3/4" thick door. MAKE SURE THE CORRECT STOP PIN IS INSTALLED FOR THE THICKNESS OF THE DOOR YOU ARE MACHINING. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 53: Face Plate Set Up

    The router ring sets plate cut depth. When the machine is set up to machine three degree bevel face plates the router needs adjustment inwards. Use pencil marks on the router motor to set square and bevel depths. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 54: Switching To Bevel Plates

    Be Certain That The Face Plate Router Depth Is Correct And That The Router Cord Is Fastened To The Router; Otherwise The Long Bit Will Eat The Router. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 55 Note: Pressing the ‘Door Clamp’ foot pedal should bring in the lock section and pivot down the jamb clamps / chip-out assemblies. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 56 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 57: Trouble Shooting

    “Click”, the switch needs to be adjusted here is how you adjust it follow the following drawings. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 58: Photo Eyes

    Note: When a machine stops for no reason it is usually the fault of dirt photo eye or a misaligned limit switch arm. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 59: General Air Circuitry Trouble Shooting

    It might be necessary to call in a specialist or check with KVAL customer service at 1-800- 553-5825 If an Air Leak is coming from an exhaust port on the air bank: This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 60: To Change Cylinder Extension Speed

    Please review this drawing as this adjustment is not done in a normal manner. To change cylinder extension speed: To change cylinder retraction speed: This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 61: Basic Electrical Trouble Shooting

    7. Check motor overloads by pressing each white button (usually at the bottom of the panel in SEQUENCE, if one is tripped there will be a slight resistance to touch and a click as it is reset. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 62 5. If a solenoid valve is suspected, and not cleared in the air checks section mentioned previously, it can be electrically jumped to check operation. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 63: Front Section Does Not Function Properly

    1. In order for any of the photo eyes or through beams to operate correctly they must be clean. Wipe off any dirt, grime, or saw dust and check for operation again. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 64 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 65: Something Is Wrong With The Cylinders That Move The Front Section

    2. Alignment can only be accomplished when the front section is up and ready to go into the pocket. Loosen the (2) ¼-20 bolts on the photo eye brackets to adjust. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 66: One Or More Through Beams Are Bad

    If the warm up time helps the problem put a heater near the machine to keep the oil from coagulating. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 67: Width Adjusts Doesn't Function Properly

    If slowing the maximum speed down does not remedy the situation, you may need to lower your minimum speed. Minimum speed should be set to a smooth crawl. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

  • Page 68: Setting Up Bolt Plate Length

    The side drill bit has a 4” long fluted section. For 5” backsets and over bored dead- bolts you’ll need to put in a 6” bit. Be certain the machine is locked out. This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 69 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 70 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 71 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 72 Our Mission: Innovation, Quality and Honesty! © Kval Inc. 825 Petaluma Blvd So. Phone (707)-762-7367 • Fax (707) 762-0485 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

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