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Kval DL-2 Instruction Manual
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Kval DL-2 Instruction Manual

Door light cutout
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KVAL INC.
Instructions Manual
DL-2
Door Light Cutout

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Summary of Contents for Kval DL-2

  • Page 1 KVAL INC. Instructions Manual DL-2 Door Light Cutout...
  • Page 2 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 3 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 personal read this manual thoroughly. We have included important safety information that will help prevent serious injury;...

  • Page 5: Customer Service Information

    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 6 2. Including Packing Slip # 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.
  • Page 7 Getting Started Your new KVAL Machine arrives at your plant crated, banded, taped and has painted set collars on all shafts; keeping all of the precision moving parts secure during shipping. 1. Move the machine as close to the area it will be stationed before removing the crate to protect against damaging the machine with the forklift.
  • Page 8 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.
  • Page 9 Responsibility It is the responsibility of each employee to maintain safe working conditions in his or her area. Failure to understand and correctly follow this procedure is direct violation of safety rules and regulations. Violations of this policy can lead to severe injury. PROCEDURE To lockout or tag out a piece of equipment, the following steps must be taken: 1.
  • Page 10 7. Before removing the lock and tag, 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. 8. The lock and tag can now be removed (only by the person who place them), and the machine can be re-energized.
  • Page 11 Lock out and Tag Out Procedure 1. P..PROCESS SHUTDOWN 2. R..RECOGNIZE ENERGY TYPE 3. O..OFF - SHUT OFF ISOLATING DEVICES 4. P..PLACE LOCK AND TAG 5. E..ENERGY RELEASE STORED ENERGY (0 ENERGY STATE) 6. R..RECHECK CONTROLS AND RETURN TO PROPER SETTING ENERGY TYPES Recognize the Types of Energy to Shut Down 1.
  • Page 12 LOCK RULES 1. Use an appropriate “Lock-Out Device”, such as Lock Tongs, or a Lock Tag. Each person must attach his or her own lock to the Lock-Out Device. 2. Identify Locks Each lock will be identified by a number or a name. A lock without a tag is not good enough. Additional information that identifies the person / persons doing the work must be on the tag.
  • Page 13 P-R-O-P-E-R HYDRAULIC AND/OR PNEUMATIC LOCK-OUT P Process Shut Down Shut down process using recommended procedures. R Recognize Energy Type Recognize all sources of energy – the electric that powers the pumps or compressors, and the air or hydraulic valves themselves. O Off! -Shut off all Power Controls Shut off each energy type.
  • Page 14 P-R-O-P-E-R MECHANICAL ENERGY LOCK-OUT Mechanical Energy may be released at the point of operation, or where two or more points of operation come together. This is where you might get caught. In most cases blocking mechanical energy is done in addition to shutting off the primary source, such as electrical, hydraulic and pneumatic.

  • Page 15: Zero Energy Start Up

    ZERO ENERGY START UP Zero Energy State to Start-up to Operating State Starting the equipment is just as important as Lock-Out/Tag-Out in terms of safety. Start-up • Inspection • Clean up • Replace guards • Check controls • Remove locks •...

  • Page 16: Safety Guidelines

    Safety Guidelines ELECTRICAL Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equipment, you must install an approved disconnect for the electrical power supplying this machine. COMPRESSED AIR The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief.
  • Page 17 Measuring from the top of the door to your height is key to the set up, due to the face bore’s location in the center of the machine. The standard DL-2 has one stop set to customer deadbolt specifications, (You may order a second stop for face bore location as an option.) Both doorstops are adjustable, and have factory pre-set measurement tapes...
  • Page 18 Turn “OFF” the AIR and ELECTRICAL SUPPLY before working in the cutter head area. Loosen the collet in the spindle holding either ½” wood or metal bits, using the wrenches included with the DL-2. Use the ” wrench on the spindle flats just above the pulley, and the second wrench on the top hex.
  • Page 19 ADJUSTING DRILL UNIT This unit comes preset from the factory with two settings to drill on the centerline of either a 1 ¾” or 1 11/16” door. Should you find you require a change of height because of the thickness of your door being under or oversize, it is just a matter of removing the two 1/8”...
  • Page 21 • Make a test cut, and adjust as necessary. If you have templates for rectangular lights. • Place the template in the DL-2. • With power off guide the carriage along the pattern. • At the four corners of the light pattern position a set collar, and tighten.
  • Page 32 Side-Lite Template Set-up 1” PLACE SIDE LITE TEMPLATE ON TABLE AND OPEN IT UP WIDER THAN THE SIDE LITE PLACE SIDE LITE INTO TEMPLATE AND POSITION THE HEAD END AGAINST THE INDEX STOPS FEED TEMPLATE WITH SIDE LITE INTO THE DL AND STAGE IT AGAINST DOOR STOP PUSH THE DOOR CLAMP BUTTON TO CLAMP THE UNIT IN PLACE...

  • Page 35: Operating Controls

    The “Push to Open Fence” button opens the movable fence. If the door is not clamped in the DL-2, the “Push to Open Fence” button will also open the fence just enough to allow the door to be pushed out when pressed momentarily.
  • Page 36 DL-2 Operating Controls Continued… Push to Close Fence: The “Push to Close” button brings the fence in for narrower size doors. Make sure to leave approximately ½” clearance between fence and door. Push to Clamp Door: The “Push to Clamp Door” button controls the clamping of the door against the locator bars, clamps the door tight against the fixed fence, and brings the template clamp down against the template.
  • Page 37 DL-2 EDGE PREP OPTION OPERATING CONTROLS Drill and Router Turn switch to the left position to start drill motor, turn it to the center to turn drill off. Turn switch to the right to turn plate router motor on. Turn it to the center to turn router off.

  • Page 39: Maintenance Schedule

    MAINTENANCE SCHEDULE DAILY 1. Blow off dust from entire machine. 2. Lubricate linear bearings and chrome shaft with silicone. 3. Wipe down machine 4. Check tooling for wear 5. Empty water filter bowl if not a self draining system 6. Photo eyes should be wiped off and checked to ensure that all fastening rings are snug. 7.

  • Page 41: Lubrication Requirements

    PD2) bearings must be re-lubricated once every 60 days. Approved Lubrication Products Chevron AW Hydraulic Oil 32 – or KVAL P/N SYSLUBG or G-C lubricants light AW R&O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32. Lubricator Adjustments Using knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.) Turn flow all the way open then reduce flow...
  • Page 42 Mist Oil Lubrication Spindle housing mist oilers require syslube lubricant, available through KVAL. Optimum flow is 3 to 5 drops per minute @ 5-10 psi. NOTE: These oils cannot be interchanged. Priming the Lubricator New and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines.
  • Page 43 DL-2 TROUBLESHOOTING PROBLEM CUTTER BIT PULLS OUT OF COLLECT SOLUTION REPLACE BIT IN COLLET AND RETIGHTEN DRAWBAR IF A BIT CONTINUES TO PULL OUT THEN REPLACE COLLET PROBLEM DRAWBAR WILL NOT SCREW INTO THE COLLET SOLUTION CHECK DRAWBAR FOR CROSS TREADS...

  • Page 45: Troubleshooting

    TROUBLE SHOOTING LIMIT SWITCHES If a machine suddenly stops in mid cycle check the limit switches, a worn limit switch arm or a misadjusted limit switch is more than likely the cause. Depending on the model of limit switch you receive the amount of “pre-travel”...
  • Page 46 PHOTO EYES The sending and receiving eyes “talk” to each other when the beam between the two is broken by either a door a moving part on the machine such as the thru beams, these beams may either stop operation or initiate operation depending on their location and function. PHOTO EYES The sending and receiving units are in one unit, these operate in the same manner as the ones described previously.
  • Page 47 GENERAL AIR CIRCUITRY TROUBLE SHOOTING IF A CYLINDER IS NOT FUNCTIONING CORRECTLY HERE ARE A COUPLE OF ITEMS TO CHECK: Most cylinders have an extend and retract port. To adjust the extend motion of a cylinder you must adjust the flow control on the retract port; this regulates the air flow exhausting from the cylinder and the opposite is true for the retract motion.
  • Page 48 It maybe is necessary to purchase a rebuild kit or a new cylinder. 6. If the valve is not receiving an electrical signal, see “Electrical Trouble Shooting” instruction. 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 solenoid air bank: Check the solenoid for the manual override.

  • Page 49: Basic Electrical Trouble Shooting

    BASIC ELECTRICAL TROUBLE SHOOTING THE FOLLOWING SHOULD ONLY BE ATTEMPTED BY TRAINED ELECTRICAL PERSONNEL. The electrical component systems are designed to expedite the troubleshooting process and minimize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT.
  • Page 50 DANGER The following checks will require the electrical panel to be energized these trouble shooting checks MUST BE PERFORMED BY A QUALIFIED ELECTRICAL TECHNICIAN. 1. Remove lock and tag outs on the main power sources 2. Manually close disconnect switches and energize the control circuit or transformer with its respective switch.
  • Page 52 NOTES This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
  • Page 66 Notes:...
  • Page 67 Notes:...
  • Page 68 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...