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Kval 960-3 Operation And Service Manual

Strike jamb router
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Operation and Service Manual
Published: March 25, 2024
Innovation, Quality & Honesty
960-3 Strike Jamb Router

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  • Page 1 Operation and Service Manual Published: March 25, 2024 Innovation, Quality & Honesty 960-3 Strike Jamb Router...
  • Page 2 Fri: 6:00 AM - 3:30 PM PST Parts Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web- site at the “Contact Us” page. email: parts@kvalinc.com KVAL 960-3 Operation and Service Manual...
  • Page 3 Kval 960-3 Operation and Service Manual Technical Support For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact Us” page. Mon-Fri:4:00 AM - 4:00 PM PST email: support@kvalinc.com Field Service Support For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the “Contact Us”...
  • Page 4 Revisions March 25 2024: Updated the controls section. Updated the Option A section. Updated the Electrical Panel section. Deleted T-Strike as it is not available on the 960-3. KVAL 960-3 Operation and Service Manual...

  • Page 5: Table Of Contents

    Set the Strike Depth (Option)........... 2-12 Set the Strike Location............. 2-13 960-3 (Option A: Split Jamb Stapler) ........2-14 960-3 Sensor Index (Option DH: Machine Logic) ....2-16 Tour of the Machine ..............2-17 About the Electrical Panel............2-19 About the Light Tower .............. 2-20...
  • Page 6 Table of Contents Sample of Grease Locations for 960-3 ........3-8 Description of Air Input System..........3-9 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 Appendix: Collet Torque Values ..........

  • Page 7: Introduction To The 960-3

    This section describes the method to contact page 1-17 Getting Help from KVAL 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 8: Overview Of The 960-3

    Kval 960-3 Automatic Strike Jamb Router up to 4 jambs per minute with an open lip strike routing pattern. The 960-3 features a fully auto- matic machine cycle that includes clamp-up and ejection onto jamb support for quick reloading.
  • Page 9 4 jambs KVAL 960-3 Automatic Strike Jamb Router, 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. is designed so that router movements are fully automatic. The router moves in a rectan- 960-3 gular pattern for faceplate and then moves in to route for the deeper latch hole.
  • Page 10 This option cannot be com- bined with Option A: Split Jamb Staplers High Voltage 3 Option HV -3 Phase High Voltage (600 volts) Kval Equipment is Option HV Phase only manufactured for 460v service 3 Phase. For customers who have 600 volt 3 phase, Option HV must be purchased.
  • Page 11 Overview of the 960-3 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.

  • Page 12: Safety First

    See “Safety Sign-Off Sheet” on page 1-21. 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.
  • Page 13 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 1-11. KVAL Operation/Service Manual...
  • Page 14 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL Operation/Service Manual...
  • Page 15 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. KVAL Operation/Service Manual...

  • Page 16: 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 KVAL Operation/Service Manual 1-10...

  • Page 17: Lockout Tagout Procedure

    Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. KVAL Operation/Service Manual 1-11...
  • Page 18 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. KVAL Operation/Service Manual 1-12...

  • Page 19: Anchoring The Machine To The Floor

    (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. KVAL Operation/Service Manual 1-13...
  • Page 20 Anchoring the Machine to the Floor • Insert 1/2”, (hardened) threaded rod into the bottom of the hole using a slow twist- ing motion. This insures the epoxy fills voids and crevices. Hardening begins in 7 minutes at room temperature. KVAL Operation/Service Manual 1-14...

  • Page 21: Zero-Energy To Start-Up

    Service team. See “Getting Help from KVAL KVAL” on page 1-17. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some com- ponents of the machine may start automatically when energy is restored.
  • Page 22 Be sure to follow the P-R-O- P-E-R lockout/tagout procedures, and that those around you do also. Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. KVAL Operation/Service Manual 1-16...

  • Page 23: 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 24: Kval Return And Warranty Policy

    KVAL Return and Warranty Policy KVAL Return and Warranty Policy 's goal is to provide customers with high quality products. If, for any reason, you are not KVAL completely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...
  • Page 25 KVAL Return and Warranty Policy Customer Errors If the item is to be returned due to customer ordering error, the customer must return the item to or the shipper of origin at its expense. A 15% restocking fee may apply to manufactured...
  • Page 26 KVAL Return and Warranty Policy Page Intentionally Left Blank KVAL Operation/Service Manual 1-20...

  • Page 27: Safety Sign-Off Sheet

    Note: It is recommended you make a copy of this sheet for new operators. If a copy is 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 28 Safety Sign-Off Sheet KVAL Operation/Service Manual 1-22...

  • Page 29: Operation Of The 960-3

    The content is geared to help operators understand the basic operation of the Router. 960-3 Chapter 2 at a Glance Section Name Summary Page General Information about the 960-3 page 2-2 About the Machine Description Of The Machine Line Controls page 2-5 Summary of Machine Controls Instructions To Powering The Machine Line...

  • Page 30: About The 960-3

    About the 960-3 About the 960-3 can machine up to 4 jambs per minute with an open Kval 960-3 Automatic Strike Jamb Router lip strike routing pattern. The features a fully automatic machine cycle that includes clamp- 960-3 up and ejection onto jamb support for quick reloading.

  • Page 31: Summary Of The Controls On The Machine

    ’s routing sequence consists 960-3 of, turning on the routers, cutting the strike plate, turning off the routers, un- clamping the jamb and ejecting the jamb.(Auto Eject must be selected for the jamb to be ejected) KVAL Operation/Service Manual...
  • Page 32 The controls are the same as the standard controls Option DH except controls are included to set the controls to auto (both cuts), closed cut only, or full cut only. “960-3 Sensor Index (Option DH: Machine Logic)” on page 2-16 for the operating procedure. Mode Select:...

  • Page 33: Initial Powering Operations For The 960-3

    Initial Powering Operations for the 960-3 Initial Powering Operations for the 960-3 This section describes how to power up and to power down the 960-3 Important: Know your machine. Before processing a jamb, see “Tour of the Machine” on page 2-17.

  • Page 34: Emergency Shutdown And Recovery

    If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved: De-activate the E-Stop switch by pulling it out. Push the button on the operator's station Start Machine KVAL Operation/Service Manual...

  • Page 35: Steps To Process A Jamb

    • Set the Strike Location on the Jamb: Power UP Make sure air, and power are ON. See “Initial Powering Operations for the 960-3” on page 2-5. Set the Thickness is located on the machine Set the switch the desired thickness. The Thickness Switch E-Box.
  • Page 36 If auto-eject is set to ON, the jamb will unclamp and be kicked out to the catch brackets. If auto-eject is set to OFF, press the pedal to unclamp and eject the Stop Sequence jamb. The process is now complete and the machine is ready for the next piece. KVAL Operation/Service Manual...

  • Page 37: Setting The Backset

    • If needed, adjust both adjustable stops to align with the turret setting. Tip: Use a practice jamb placed against both turrets and if needed, adjust the two other Adjustable Stops to fit tightly against the jamb. Adjustable Stop Adjustable Stop Turrets KVAL Operation/Service Manual...
  • Page 38 For Example: 1-3/4” Thickness setting with 1-1/2 Backset With the machine set at and has inserted. The result will be 1-3/4'' Door Thickness 7/16'' Stop Pins a jamb with a 1-1/2'' backset 7/16'' Pin Length 1-1/2'' KVAL Operation/Service Manual 2-10...

  • Page 39: Setting The Strike Width

    There are two pins located on each side of each router. Change both pins to set the hinge pocket length. The longer the pins, the Note: shorter the strike plate. The size of pins can vary by option KVAL Operation/Service Manual 2-11...

  • Page 40: Set The Strike Depth (Option)

    Flip the top spacer away from the top plunge to allow full Strike through the Jamb: plunge. • Flip the spacer under the top plunge to set a partial Partial strike through the Jamb: plunge. Top Spacer Location Partial Depth Setting Strike through the Jamb Setting. KVAL Operation/Service Manual 2-12...

  • Page 41: Set The Strike Location

    The Index Stops can be flipped up or down to place them out of used. Options include a Sensor Index version that chooses the type of strike automatically, see “960-3 Sensor Index (Option DH: Machine Logic)” on page 2-16.

  • Page 42: 960-3 (Option A: Split Jamb Stapler)

    960-3 (Option A: Split Jamb Stapler) 960-3 (Option A: Split Jamb Stapler) has the same assemblies as a standard , except it includes the inclusion of the abil- Option A 960-3 ity to staple a split sill to the jamb.
  • Page 43 960-3 (Option A: Split Jamb Stapler) About the Operation of the Jamb Stapler Stack the jamb and sill with the jamb on top. Load the jamb and the sill into the 960-3. Stack the jamb and the sill with the jamb...

  • Page 44: 960-3 Sensor Index (Option Dh: Machine Logic)

    960-3 Sensor Index (Option DH: Machine Logic) 960-3 Sensor Index (Option DH: Machine Logic) For processing either opened strike or closed deadbolt plates. Typically, photo eyes are affixed to jamb reference guides at the end of the machine. The plate style is automatically detected depend- ing on jamb position.

  • Page 45: Tour Of The Machine

    960-3 960-3 with T-Strike, with Split Jamb capabilities. 960-3 960-3 960-3 Call-Outs Cutter Head: Right Hand Index: Motor and Router Bit to rout faceplate Set the top of the jamb to pre Includes Clamps measured stop locations The cutting head moves in the X, Y and Z Axises...
  • Page 46 Y Axis (Backset) Width Plate Pin (X2): Sets The Strike Width. May be fixed Head Bearings (x4) X Axis (Width) Rear View Depth Adjust: Adjust Strike Depth. May be fixed. Backset Adjustment: Sets the backset. May be fixed. KVAL Operation/Service Manual 2-18...

  • Page 47: About The Electrical Panel

    Chapter 1. Main Controls See “Summary of the Controls on the Machine” on page 2-3. VFD Over Current Light Push to Reset Breakers Disconnect Input Output Terminals 110 V / 24 V Terminals Power Supply KVAL Operation/Service Manual 2-19...

  • Page 48: About The Light Tower

    Solid: General Error • Flashing: Not Ready to Re-Start (E-Sop Switch is Active) Green: Machine is Operational Off: No Control Power Control Power ON (Green): 24 VDC Control Power ON Ready to Work Light Tower Rev 2 KVAL Operation/Service Manual 2-20...
  • Page 49 Maintenance of KVAL Machinery CHAPTER 3 This chapter describes preventative maintenance steps for . The content is geared KVAL Machinery to guide technicians to keep a regular maintenance schedule of your machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door production KVAL process.

  • Page 50: Maintenance Schedule

    This should be done in accor- dance with applicable state and/or federal code requirements To view a video of the maintenance process, visit the KVAL website. Select the Video Tab to view videos. http://www.kvalinc.com/ Daily, Monthly, Six Month Maintenance...
  • Page 51 Clean linear bearings and the chrome shaft with a clean dry cloth, then lubricate. Clean Check all air lines & electrical wiring for kinks or rubbing. Check Refill lubricator with an ISO 32 standard hydraulic oil (KVAL part# SYSLUBG) LUBE Six Month Preventive Maintenance Operation Description Wash filter and lubricator bowls with soapy water.

  • Page 52: Maintenance No-Goes

    • Do not adjust any and all flow controls from factory settings • Do not remove shim stock • Do not Change or Alter any safety assemblies (E-Stops, Gate Locks, etc) • Do not Change programs in PLC’s or PC’s • Do not Alter Electrical Components KVAL Operation/Service Manual...

  • Page 53: Lubrication Schedule

    Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation Dura-Lith Grease (KVAL P/N Lube EP-2) Flange Block Bearing Air Line Lubricator One drop of oil every 2 or 3 cycles Either lubricant listed below is approved to use.

  • Page 54: Lubrication Requirements

    Closed Pillow Block Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 3-2. KVAL Operation/Service Manual...
  • Page 55 X,Y, or Z direction. Greasing Ball Rail Bearing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Ball Rail Bearings FIGURE 3-4. KVAL Operation/Service Manual...

  • Page 56: Sample Of Grease Locations For 960-3

    Sample of Grease Locations for 960-3 Sample of Grease Locations for 960-3 This machine is a powerful electro-mechanical Caution motion control system. If servicing this machine, fol- low the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to person- nel.

  • Page 57: Description Of Air Input System

    Once you have a steady flow, tighten knob back down until you have one drop per every other cycle. Drop will form at end of cane shaped tube visible inside glass. KVAL Operation/Service Manual...
  • Page 58 Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as follows: • KVAL P/N SYSLUBG • Chevron AW Hydraulic Oil 32 • G-C lubricants light AW R&O •...

  • Page 59: Changing The Bit On 960-3 High Frequency Motor

    Changing the Bit on 960-3 High Frequency Motor Changing the Bit on 960-3 High Frequency Motor This Service Note describes the process to change the Router Bit on high frequency motor. 960-3 The process includes removing the motor to access the bit. Follow the steps below.
  • Page 60 Changing the Bit on 960-3 High Frequency Motor Step 2 Go to the back of the machine to start to remove motor. Important: Keep one hand on the motor when removing bolts. These two bolts and the knurled top nut are the only securing hardware.
  • Page 61 Changing the Bit on 960-3 High Frequency Motor Step 4 Measure old bit Remove old bit and collet assembly inspec- tion. a.To keep consistency of drill depth, mea- sure the old bit from the base of the collet nut to the tip of the drill. Use this measurement for the replacement bit.
  • Page 62 Changing the Bit on 960-3 High Frequency Motor Step 6 Run a test door. a..After everything is secure, remove lockout/ tagout. b.Run a test door. c.Check the machining of the cut. d.If some adjustments are needed, turn off air and power.

  • Page 63: Initial Cut On New Chip Out Block

    Note: Cycle Time Is Approximately 7 Seconds KVAL P/N:CHIPOUT35 Keep Hands away from the front cutting area of the machine. Insert Chip Out Block from the back of the 960-3 to Butt up against test jamb. Tighten Chip Out Block with Thumb Screws...

  • Page 64: Appendix: Router Collet Assembly Basics

    • Clean the collet parts with a dampened rag. • Use a small brush with either nylon or brass bristles to reach into close areas. These bristles will clean the collet without damaging the metal surfaces. KVAL Operation/Service Manual 3-16...

  • Page 65: Appendix: Collet Torque Values

    Appendix: Collet Torque Values Appendix: Collet Torque Values recommends torquing the collets. Torquing adds consistency is important for repeatable KVAL machining. Follow the torque tool manufacturers method of torquing. KVAL Operation/Service Manual 3-17...
  • Page 66 Appendix: Collet Torque Values KVAL Operation/Service Manual 3-18...
  • Page 67 2, 3 six month 2 weekly 2 pillow block bearing, maintenance schedule 5 power lock out procedure 11 safety guidelines 6 Safety Sign Off Sheet Safety Concerns 21 six light panel description 19 tagout procedure 11 Kval v 960-3...
  • Page 68 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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