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Kval 990-APEX Service Manual

Door machining system
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Innovation, Quality & Honesty
990-APEX Door Machining System
Architectural, Pre-Hanging, and Exterior Doors
®
With KvalCAM
Service Manual
Published: October 24, 2022

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Summary of Contents for Kval 990-APEX

  • Page 1 Service Manual Published: October 24, 2022 Innovation, Quality & Honesty 990-APEX Door Machining System Architectural, Pre-Hanging, and Exterior Doors ® With KvalCAM...
  • Page 2 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.
  • Page 3 Kval Website Learn about Kval, order parts, get information on our array of machines (including new machine releases), learn about our machine software solutions, download machine documentation, view videos of our machines in action, contact all the departments.
  • Page 4 Licensor retains all ownership of the KvalCAM Software. Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with, Inc. The Kval- CAM Software is protected by copyright laws and treaties. Title and related rights in the content generated through the KvalCAM Software are also the property of the Licensor and are protected by applicable law.

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 990-APEX System 1 Overview of the 990-APEX ..............1-2 Architectural, Pre-Hanging, & Exterior -- All in One ......1-2 KvalCAM ......................1-3 990-APEX Summary ..................1-3 Specifications Summary ................1-4 About this Manual ..................1-5 Operation Manual ..................1-5 Service Manual ...................1-5...
  • Page 6 Shipper Errors ...................1-20 Warranty Replacement Parts ..............1-20 Safety Sign-Off Sheet ................1-22 A Note to the Operator ................1-22 Maintenance of the 990-APEX 1 Maintenance Schedule ................2-2 300 Cycle Maintenance Steps ............2-4 Clean, Clean, Clean! ..................2-4 600 Cycle Maintenance Steps ............2-5 Check Air Gauges and Inspect Water Traps ..........2-5 Inspect Tooling ....................2-5...
  • Page 7 Hinge Cutter Tray Grease Point Locations ..........2-32 Greasing Lock Carriage Bearings .............2-34 Recommended Tools ................2-34 Lock Carriage Greasing Procedure ............2-34 Lock Carriage Grease Point Locations ..........2-34 Lock Cutter Tray Grease Point Locations ..........2-35 Greasing the Feed System Bearings ..........2-37 990-APEX Service Manual...
  • Page 8 Access the Tool Config Screen ............2-55 Check the Tool Config ................2-55 Tool Length in Lock Carriage ..............2-56 Tool Length in Hinge Carriage ..............2-56 Remove and Replace the Router or Pre-Drill Bits .....2-57 Remove and Replace the Chisels .............2-59 990-APEX Service Manual...
  • Page 9 Table of Contents Remove and Replace the Screwdriver Bits ........2-60 Collet Torque Values ................2-63 Addition Collet Torque Values ..............2-64 990-APEX Service Manual...
  • Page 10 Table of Contents 990-APEX Service Manual...

  • Page 11: Introduction To The 990-Apex System

    Introduction to the 990-APEX System CHAPTER 1 This chapter provides an overview of the and important KVAL 990-APEX Door Hanging System safety information to follow when operating the machine. Chapter 1 at a Glance Overview of the 990-APEX..............page 1-2 About this Manual..................

  • Page 12: Overview Of The 990-Apex

    Overview of the 990-APEX Overview of the 990-APEX Architectural, Pre-Hanging, & Exterior -- All in One redefines door and jamb machining flexibility by bridging the interior, exterior, 990-APEX and architectural/commercial markets. Designed with 75 years of experience and proven concepts at the foundation of our legendary , the APEX easily outperforms the competition.

  • Page 13: Kvalcam

    Overview of the 990-APEX Lock Section FIGURE 1-2. Jambs - The can machine and attach 3 ½” or 4” hinges with Kval’s original patented 6- 990-APEX Shooter and 8-Shooter technology for pre-hanging interior and exterior doors. allows KvalCAM the door and jamb to be machined separately to accommodate special hinges and strikes, such as ASA strikes and three-point lock strike jambs.

  • Page 14: Specifications Summary

    • Jamb Programming fully supports hinges and strike jambs (including three-point locks Specifications Summary These values are in standard configuration, special options can be ordered to modify them. Con- tact Kval Sales for more information Height 78”-96” Width 14” – 48” (12” – 14” hinge only with option ND1) Thickness 1 3/8”...

  • Page 15: About This Manual

    Maintenance steps for the machine line KvalCAM Reference Manual KvalCAM Reference Manual includes the following: Chapter Title Description KvalCAM reference Description of the Interface KvalCAM Examples Examples of Common Door Job Features KvalCAM Common Terms Common terms associated with KvalCAM 990-APEX Service Manual...

  • Page 16: Safety First

    • 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. 990-APEX Service Manual...

  • Page 17: Safety Guidelines

    • 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. 990-APEX Service Manual...

  • Page 18: Compressed Air

    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 sup- plying this machine Electrical Box Labels FIGURE 1- 6. 990-APEX Service Manual...
  • Page 19 Some machines are powered by Do not open the cabi- more than one supply located at different locations. nets without High Voltage training or without permission from a supervisor. Still has power in OFF position 990-APEX Service Manual...

  • Page 20: Pinch Points

    This should be done in accordance with applicable state and/or federal code requirements Maintenance Warning Labels FIGURE 1-8. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the laser manufacturers safety precautions. 990-APEX Service Manual 1-10...

  • Page 21: Compliance With Codes And Regulations

    KVAL 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 procedures to follow. 990-APEX Service Manual 1-11...

  • Page 22: Lockout Tagout Guidelines

    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 990-APEX Service Manual 1-12...

  • Page 23: Lockout Tagout Procedure

    OFF position. ensure the lever is in the down position, insert Lever style Electrical Panels: lock and tag into the lever hole making sure the lever cannot move, lock as per the tagout guidelines. (see illustration below). 990-APEX Service Manual 1-13...

  • Page 24: Lockout Tagout Air Supply

    Maintenance or repairs may started. Post Maintenance Steps 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. 990-APEX Service Manual 1-14...
  • Page 25 The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. 990-APEX Service Manual 1-15...

  • Page 26: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the Service team. See “Getting Help from KVAL” on page 1-18. KVAL Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some components of the machine may start automatically when energy is restored.

  • Page 27: Close The Cage Gate

    Zero-Energy to Start-Up Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. 990-APEX Service Manual 1-17...

  • Page 28: Getting Help From Kval

    Getting Help from KVAL Getting Help from KVAL Before you seek help, first try the troubleshooting procedures. Follow the procedures below. If you are unable to resolve the problem: Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.

  • Page 29: Kval Return And Warranty Policy

    We can only accept items for a return if they are still in their original packaging and in undam- aged, resalable condition. Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc. Returns after 45 days of purchase or without a Kval Inc. issued RMA number will not be accepted.

  • Page 30: Customer Errors

    Kval provides a warranty to products that are deemed defective. Within 30 days of discovery of said defect, please notify Kval, but no more than one (1) year after delivery will the product be covered under Warranty. The repair, replacement, or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval’s warranty or for claims based upon failure...
  • Page 31 Kval Return and Warranty Policy Page Intentionally Left Blank 990-APEX Service Manual 1-21...

  • Page 32: Safety Sign-Off Sheet

    It is recommended you make a copy of this sheet for new operators. If a copy is Note: needed, you may download a PDF at the KVAL website (http:// www.kvalinc.com). You may also contact our Service Department at (800) 553- 5825 or email at service@kvalinc.com.

  • Page 33: Maintenance Of The 990-Apex

    Maintenance of the 990-APEX CHAPTER 2 . The content is geared This chapter describes preventative maintenance steps for KVAL 990-APEX to guide technicians to keep a regular maintenance schedule for your machine. Keeping KVAL your machine maintained is an important piece for successful operation of your door pro- KVAL duction process.

  • Page 34: Maintenance Schedule

    Maintenance Schedule recommends the following maintenance schedule to ensure that the machine operates prop- KVAL erly. Cycles refers to the quantity of processed doors. Cleaning curtails build up of sawdust and grime which causes issues with the operation of the machine. Inspecting, finds issues before they become problems.
  • Page 35 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). See “Lubrication Schedule” on page 2-23.

  • Page 36: 300 Cycle Maintenance Steps

    300 Cycle Maintenance Steps 300 Cycle Maintenance Steps Follow Lockout Tagout procedures. Clean, Clean, Clean! Sawdust and grime build-up can cause issues with the operation of the machine. Use pressured air to blow off dust and debris on entire machine. Use a clean rag to clean areas not affected by pressurized air.

  • Page 37: 600 Cycle Maintenance Steps

    600 Cycle Maintenance Steps 600 Cycle Maintenance Steps Follow Lockout Tagout procedures. Check Air Gauges and Inspect Water Traps Air Pressure Gages. Adjust, if necessary, to the proper PSI located on the label. Adjust only if Trained in Maintenance Note: Inspect Air Filter Water Traps.

  • Page 38: Lubricate Inside Of Hopper

    600 Cycle Maintenance Steps Lubricate inside of Hopper Lubricate the inside of the Hoppers with a light coat of dry silicone spray. Lubricate the input to the screw drop hoses. Provides an easier screw drop. Do not over-spray oil. Empty Dust Collection Units Check and empty any dust collection units.

  • Page 39: 3,000 Cycle Maintenance Steps

    3,000 Cycle Maintenance Steps 3,000 Cycle Maintenance Steps Follow Lockout Tagout procedures, Inspect Feed Belts Inspect feed belts for proper tension or damage. Check belts for cuts and nicks. Belts can stretch over time. Check for looseness. A rule of thumb is to pull belt, if belt moves too freely, then replace belt.

  • Page 40: Inspect All Photo Eyes

    3,000 Cycle Maintenance Steps Inspect all Photo Eyes Inspect all photo eyes secure and tight.Check Nut that attaches Photo Eye to Machine. Check Connection to Photo Eye Inspect Limit Switches Inspect all limit switch arms for tightness or breaks. Inspect the switch for cracks in the body and check that the switch arm actuates (clicking sound) when moved to the extreme.

  • Page 41: Inspect Airlines

    Check Hoses for kinks and rubbing, manifold connections and Air Cylinder connections. Refill Lubricators Ensure Air is turned off. Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN: SYS-LUBEG). 990 APEX Service Manual...

  • Page 42: Grease Ball Screw Bearings

    3,000 Cycle Maintenance Steps Slide locking switch down twist bowl and remove. Refill bowl. Reverse action when installing trap. Grease Ball Screw Bearings Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. For locations to lubricate, See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth.

  • Page 43: 12,000 Cycle Maintenance Steps

    12,000 Cycle Maintenance Steps 12,000 Cycle Maintenance Steps Follow Lockout Tagout procedures. Inspect Chains for Proper Tension Inspect chains for proper tension or damage. Check for sagging chains. Chains can stretch over time of use. Check for chain stiffness. Stiff chains do not provide a tight fit over the gears Chain Inspect Air Cylinders Inspect all air cylinders for air leaks.

  • Page 44: Inspect Ball Rail Shafts

    12,000 Cycle Maintenance Steps Inspect Ball Rail Shafts Inspect ball rail shafts for pitting or abrasions. Example of a Pitted Ball Rail Inspect Ball Screw Axle Inspect ball screws for pitting or abrasions. Example of a Pitted Ball Screw Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray.

  • Page 45: Clean Inside Hopper

    12,000 Cycle Maintenance Steps Clean inside Hopper ® Clean inside hopper with dry silicone oil and a 3M ScotchBrite pad (or equivalent). Wipe dry with a clean dry rag 990 APEX Service Manual 2-13...

  • Page 46: 72,000 Cycle Maintenance Steps

    Check contactors for wear. Computer Backup Right Click the Icon at the Taskbar of the screen to display this Pop-Up. Kval Select the Backup menu choice. In the text box enter any notes/ Save the zip file to the location of choice...

  • Page 47: Wash Filter And Lubricator Bowls

    72,000 Cycle Maintenance Steps Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water. • Slide lock down to unlock. • Twist bowl to remove it. • Remove filter from Air filter assembly. Inspect and clean or replace if necessary. •...

  • Page 48: Tool Changing Schedule

    Changing and inspecting the tooling on a regular basis keeps the door machining process running accurately and efficiently. recommends using the tables below for reference to change or KVAL inspect the machine tooling. Note: Depending on Machine or Option, some of these tools may vary.

  • Page 49: Maintenance No-Goes

    Maintenance NO-GOES Maintenance NO-GOES Do not perform the following. This machine is tuned an calibrated at the factory. If any of these conditions are changed, timing, accuracy, or damage may occur during the machine process. • Do not adjust air PSI above or below factory settings •...

  • Page 50: About Bearings

    About Bearings About Bearings This section describes the parts of the machine that require periodic lubrication, and specifies the lubricants. In addition, it explains how to maintain the lubrication systems on the machine. If the bearing is equipped with a grease fitting (Zerk Fitting). The Zerk fitting is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing.

  • Page 51: About Flange Bearing Housings

    About Bearings About Flange Bearing Housings A flange bearing is designed to aid in mounting and positioning. The lip of the flange helps center and align the bearing. Flanges are also used with bearings on external housings used to mount a bearing unit. A mounted bearing unit acts as a system to position the bearing securely for reliable operation.

  • Page 52: About Tapered Bearings

    About Bearings About Tapered Bearings Taper bearings are used for moving the axises of heavy loads with stability. The tapered roller bearing in combination with lubricants is extremely durable and is used in applications involving rotating axle and transmission shafts. Bearing durability is such an asset that the bearing blocks often require no main- Note: tenance for the life of the machine.

  • Page 53: Ball Screw Nut

    About Bearings Ball Screw Nut is an assembly with recirculating ball bearings that interfaces with the ball Ball Screw Nut screw. The ball screw drive and the ball screw nut create very low friction coefficients resulting in a smooth, accurate, efficient movement. Ball Screw Nut Ball Screw Nut Housing Ball Screw Drive...

  • Page 54: Pulley And Idler Shafts

    About Bearings Pulley and Idler Shafts Transport systems on the machine contain pulleys and a belt to transport the door in and out of the machine. Each pulley contains an idler shaft that has a zerk fitting to apply grease. An opening in the idler shaft dispenses grease to the inner diameter of the pulley.

  • Page 55: Lubrication Schedule

    Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block (Hub) Every 250 Hours of Machine Operation Bearing Dura-Lith Grease (KVAL P/N Lube Flange Block Bear- EP-2) Ball Screw Every 80 Hours of Machine Operation Idler Shafts (Pulley) Monthly Tapered Bearing...

  • Page 56: Kval Lubrication Kit

    Lubrication Schedule Kval Lubrication Kit Hydraulic Oil Silicone Spray Grease Gun EP-2 Multi-FAK Extension Grease Adapter Needle Nozzle E Adapter Needle Nozzle Lubrication Kit FIGURE 2- 20. 990 APEX Service Manual 2-24...

  • Page 57: Machine Lubrication Map

    Machine Lubrication Map Machine Lubrication Map This machine has multiple grease points. Figure 2- 21 shows an overview of all the grease points. The following sections describes the greasing point in detail. Lock Carriage (Purple) Frame (Red) –Including Servo Assemblies –Including Clamps Feed System (Light Blue) –Including 3 deg.
  • Page 58 Machine Lubrication Map Grease Bearing Types Links Points See “Greasing the Screw Shooters Bearings” on page 2-39. Screw Shooter Linear and Hub See “Greasing Jamb Swing Bearings” on page 2-41. Jamb Swing Linear Linear, Hub, Large Hub See “Greasing Frame Bearings” on page 2-43. Frame Pillow Block 990 APEX Service Manual...

  • Page 59: Greasing Hinge And Lock Carriage Servo Bearings

    Greasing Hinge and Lock Carriage Servo Bearings Greasing Hinge and Lock Carriage Servo Bearings This section details the greasing procedure for the servo bearings. Each and the Hinge Carriage contains an X-Axis, Y-Axis and Z-Axis Servo Motor Assembly. Lock Carriage The Y and Z axis assemblies require manual greasing while the X-Axis contains an automatic greasing assembly.

  • Page 60: Hinge Servo Assembly Locations

    Greasing Hinge and Lock Carriage Servo Bearings Hinge Servo Assembly Locations Figure 2- 22 shows the bottom view of the . Areas of the carriage have been Hinge Carriage ghosted to allow better view of the Servo assemblies. Z-Axis Servo Drive Assembly X-Axis Servo Drive Assembly Y-Axis Servo Drive Assembly Hinge Servo Assembly Locations...

  • Page 61: Z-Axis Servo Assembly Part Identification

    Greasing Hinge and Lock Carriage Servo Bearings Z–Axis Servo Assembly Part Identification Figure 2- 24 below shows a view of Z-Axis assembly.The table below shows the bearing types and the greasing schedule. Follow the steps in the “Procedure to Grease the Hinge and Lock Servo Assemblies” on page 2- Bearing Schedule Ball Nut...

  • Page 62: X-Axis Servo Assembly Part Identification

    Greasing Hinge and Lock Carriage Servo Bearings Ball Screw Ball Screw Nut Zerk Zerk Servo Motor Tapered Bearing Y-Axis Assembly FIGURE 2- 25. X–Axis Servo Assembly Part Identification Figure 2- 26 below shows a view of X-Axis assembly. The X-Axis servo assembly is greased by an automatic greaser.

  • Page 63: Greasing Hinge Carriage Bearings

    Greasing Hinge Carriage Bearings Greasing Hinge Carriage Bearings This section details greasing procedure for the and the . The illus- Hinge Carriage Hinge Cutter Tray trations show the bearings as color coded to for easy identification. For recommended greasing schedule for all assemblies, see “Lubrication Schedule”...

  • Page 64: Hinge Cutter Tray Grease Point Locations

    Greasing Hinge Carriage Bearings Hinge Carriage Bearing Information TABLE 2- 1. Bearing Location Bearing Type Bearing Total Qty. Schedule 4 (Red) H-Block Horizontal Every 250 Hours of Linear Carriage Body Horizontal 5 (Blue) Machine Operation Carriage Body Vertical 4 (Yellow) H Block Bearings (Horizontal) Carriage (Horizontal) Carriage (Vertical)
  • Page 65 Greasing Hinge Carriage Bearings Hinge Tray Bearing Information TABLE 2- 2. Bearing Location Bearing Type Bearing Total Qty. Schedule 4 (Light Blue) Chisel Assemblies Pre-Drill Spindle 2 (Green) Every 250 Hours of Linear Router Spindle 2 (Red) Machine Operation CCW Router Spindle 2 (Gray) Cutter Head Tray 4 (Dark Blue)

  • Page 66: Greasing Lock Carriage Bearings

    Greasing Lock Carriage Bearings Greasing Lock Carriage Bearings This section details greasing procedure for the and the . The illus- Lock Carriage Lock Cutter Tray trations show the bearings as color coded to for easy identification. For recommended greasing schedule for all assemblies, see “Lubrication Schedule”...

  • Page 67: Lock Cutter Tray Grease Point Locations

    Greasing Lock Carriage Bearings Tool Tray Bearings (Vertical) Bearings (Horizontal) Lock Carriage Bearings FIGURE 2- 29. Lock Cutter Tray Grease Point Locations contains the cutting tools that sits on top of the . Each tool Lock Cutter Tray Lock Carriage (spindle) and the tray have linear bearings attached to the bottom of the assembly.
  • Page 68 Greasing Lock Carriage Bearings Router Spindle Router Spindle Face Spindle Assemblies Chisel Assemblies Ball Catch Spindles 0 – 3 Degree Tilt Hinge Cutter Tray Bearing Locations FIGURE 2- 30. 990 APEX Service Manual 2-36...

  • Page 69: Greasing The Feed System Bearings

    Greasing the Feed System Bearings Greasing the Feed System Bearings This section details greasing procedure for the feed system. The feed system is located on the fixed side and the movable side of the machines. The greasing points include the idler portion of each pulley and hub bearings on each motor feed axles.
  • Page 70 Greasing the Feed System Bearings Pulley Pulley Movable Side Feeder Motor Fixed Side Feeder Motor Bearings in the Feed System FIGURE 2- 31. 990 APEX Service Manual 2-38...

  • Page 71: Greasing The Screw Shooters Bearings

    Greasing the Screw Shooters Bearings Greasing the Screw Shooters Bearings This section details greasing Six and Eight Shooter bearings. Each shooter contains 4 bearings to aid moving the shooter across the machine. Each shooter contains 2 hub bearing to aid in pivoting the shooter into the pocket.
  • Page 72 Greasing the Screw Shooters Bearings Shooter Track Shooter Track Linear Bearings Linear Bearings Hub Bearings Hub Bearings Screw Shooter Bearing Locations FIGURE 2- 32. 990 APEX Service Manual 2-40...

  • Page 73: Greasing Jamb Swing Bearings

    Greasing Jamb Swing Bearings Greasing Jamb Swing Bearings This section details greasing procedure for the Swing Jambs. Each Swing Jamb contains a stepper motor to drive the assembly across the machine.Each Jamb Swing contains 2 linear bearings to aid in the movement of the assembly.t For recommended greasing schedule for all assemblies, see “Lubrication Schedule”...
  • Page 74 Greasing Jamb Swing Bearings Jamb Swing Track Linear Bearings Jamb Swing Bearings FIGURE 2- 33. 990 APEX Service Manual 2-42...

  • Page 75: Greasing Frame Bearings

    Greasing Frame Bearings Greasing Frame Bearings This section details greasing procedure for the assemblies associated with the machine.frame. The assemblies identified on the frame are: • Door Width System • Door Up-Clamp • Door Pop Down Fence • Hinge 0–3 degree Tilt Recommended Tools Frame Greasing Procedure Use an extender to reach tight areas.
  • Page 76 Greasing Frame Bearings 0– 3 Degree Tilt 0– 3 Degree Tilt Door Fence Hub Bearings Large Hub Bearings (X2) Linear Bearing (x2) Door Up Clamp Linear Bearings (x2) Door Width Axle Door Width Track Hub Bearings Linear Bearings (X4) Frame Bearings FIGURE 2- 34.

  • Page 77: Greasing The Rts Rotary Hopper Bearing

    Greasing the RTS Rotary Hopper Bearing Greasing the RTS Rotary Hopper Bearing is a machine line configuration that replaces the on-board on the RTS Rotary Hopper Hoppers . If your line has this configuration, this section details greasing procedure for the single 990 Series bearing on the The bearing is flange-mounted at the rotation point of the machine.
  • Page 78 Greasing the RTS Rotary Hopper Bearing RTS Grease Point TABLE 2- 9. Bearing Location Bearing Type Bearing Total Qty. Schedule Rotation Bearing Flange Mount 1 (Yellow) One Pump a 4 X a Year Zerk Fitting RTS Bearing Location FIGURE 2- 36. 990 APEX Service Manual 2-46...

  • Page 79: About The Self Lubricator Module

    About the Self Lubricator Module About the Self Lubricator Module This machine contains a self lubricating gear assembly to lubricate the Carriage Rails. How the Self Lubricator Works The self-lubricator is electronic and produces nitrogen gas in the well to increase pressure to push the oil out.
  • Page 80 About the Self Lubricator Module Shutdown the machine and follow the Lockout Tagout procedure, in Chapter 1. If needed, cut the hose included in the kit to match the one on the machine. Attach the 2 hose connectors to the ends of the new hose. On the new lubricator well, set the dip switches.

  • Page 81: Description Of Air Input System

    Description of Air Input System There are two types of air inputs on machinery. Not all machines have lubricator option KVAL installed. Check your machine or Air prints to verify installation. Air Input with Lubrication The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine.

  • Page 82: Priming The Air Line Lubricator

    The approved list of oil for lubricators is as fol- lows: • P/N SYSLUBG KVAL • Chevron AW Hydraulic Oil 32 • G-C lubricants light AW R&O • Mobile DTE 24 •...

  • Page 83: Identifying Cutting Tools

    Identifying Cutting Tools Identifying Cutting Tools This section describes the tool and motor information needed to replace tools. The tools identified in this section are the most common tools supplied by Kval. Note: Some tooling may differ due to customer specifications.

  • Page 84: Tool Information Lock Cutter Tray

    Identifying Cutting Tools Tool Information Lock Cutter Tray Lock Cutter Tray Tools FIGURE 2- 42. Motor Most Common Kval Collet Spindle P/N Shaft Wrench Callout Recommended Torque Collet Wrench Tool Tool Length Sip013 (Chisels) COLER32-10 HSDY341500007 (Edge Prep) RBSC1010600-N - 2 4 5/8”...

  • Page 85: How To Access To Tooling

    How to Access to Tooling How to Access to Tooling This section describes the steps to change the pre-drill bits, router bits, and chisels. Getting Access the Hinge Carriages Always follow Lockout/Tagout Procedures Warning This machine is a powerful electro-mechanical motion control system. If servic- ing this machine follow all safety guidelines Failure to do so can result in dam- age to equipment and/or serious injury to personnel.
  • Page 86 How to Access to Tooling Step into the well and move Lock Carriage Release Air to get access to the tooling Lock Carriage Access FIGURE 2- 44. 990 APEX Service Manual 2-54...

  • Page 87: Access The Tool Config Screen

    Check the Tool Config Check the tool length data in the menus. If incorrect, enter the lengths listed in For Tool Config more information, see the 990-APEX Operation Manual. Pop-Up Menus: enter/ view tool data. List of Tools (Router, Drill and Chisels) Tool Config Screen FIGURE 2- 45.

  • Page 88: Tool Length In Lock Carriage

    Lock Carriage. Note: Common Tools in the Lock Carriage TABLE 2- 10. Most Common Tool Motor Callout Kval Recommended Tool Length Edge Prep RBSC1010600-N - 2 4 5/8” Edge Prep (CR) RBSC0808300-L-N 2.0”...

  • Page 89: Remove And Replace The Router Or Pre-Drill Bits

    Remove and Replace the Router or Pre-Drill Bits Remove and Replace the Router or Pre-Drill Bits Before performing this process, turn off all power to the machine. Follow proper Lockout/Tagout procedures as detailed in the safety section of Chapter 1 of this manual. Always follow Lockout/Tagout Procedures Warning This machine is a powerful electro-mechanical motion con-...
  • Page 90 Remove and Replace the Router or Pre-Drill Bits Lightly attach collet assembly on drill. Insert the new bit into the assembly. Before tightening the collet assembly, adjust the bit depth. Set the router bit and the drill bit depth to match the settings in the parameters Tool Config If available, use the Bit Depth Gauge that supplied with the machine.

  • Page 91: Remove And Replace The Chisels

    Remove and Replace the Chisels Remove and Replace the Chisels Always follow Lockout/Tagout Procedures Warning This machine is a powerful electro-mechanical motion con- trol system. If servicing this machine follow all safety guide- lines Failure to do so can result in damage to equipment and/or serious injury to personnel.

  • Page 92: Remove And Replace The Screwdriver Bits

    Remove and Replace the Screwdriver Bits Remove and Replace the Screwdriver Bits Always follow Lockout/Tagout Procedures Warning This machine is a powerful electro-mechanical motion control system. If servic- ing this machine follow all safety guidelines Failure to do so can result in dam- age to equipment and/or serious injury to personnel.
  • Page 93 Remove and Replace the Screwdriver Bits Locate the back slide near the air valves (see Figure 2- 51 on page 61); push slide away from you. This bypasses the stop and allows for movement of the Six-Shooter assembly away from the machine 1st: Push the Six Shooter toward the Machine.
  • Page 94 Remove and Replace the Screwdriver Bits Remove Driver Bits Bit Holder Lock Slide Bit Holder lock Back Slide Bit Out To insert screwdriver bit, reverse step 5 above, push bit holder back toward Six- Shooter assembly and hold while inserting new bit. Release holder to secure bit. Move Six-Shooter assembly back toward machine and pull the back slide toward you;...

  • Page 95: Collet Torque Values

    Collet Torque Values Collet Torque Values KVAL recommends torquing the collets. Torquing adds consistency is important for repeatable machining. Follow the torque tool manufacturers method of torquing. Collet Torque Values FIGURE 2- 52. 990 APEX Service Manual 2-63...
  • Page 96 Tips About Replacing Bits FIGURE 2- 53. Addition Collet Torque Values The table below includes additional collet torque values. Collet Torque Values TABLE 2- 12. Collet Nut Type Torque Common Kval Motors ER20 Slotted 59 ft/lbs HSDY6162Y0003 SOYUS 20 Hook 36 ft/lbs PERVS503...
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  • Page 100 Customer Service Contacting KVAL 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...

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