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Kval ON-3 Service Manual

Door lift system
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Service Manual
Published: January 23, 2025
Innovation, Quality & Honesty
ON-3 Door Lift System
Stacker
Feeder

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Summary of Contents for Kval ON-3

  • Page 1 Service Manual Published: January 23, 2025 Innovation, Quality & Honesty ON-3 Door Lift System Stacker Feeder...

  • Page 2: Proprietary Notice

    Mon-Thu:6:00 AM - 4:00 PM PST 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 ON-3 Lift Service Manual...

  • Page 3: Technical Support

    KVAL ON-3 Lift 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

    Revisions March 13 2024: Reformat of manual. June 5 2024: Added Bearing Descriptions. (Pillow Block and Rail) Jan 23 2025: Update Air Maintenance KVAL ON-3 Lift Service Manual...

  • Page 5: Table Of Contents

    Kval Website..................a-III Revisions .................... a-IV Introduction to the ON-3 Chapter 1 Chapter 1 at a Glance................1-2 Overview of the ON-3 .............. 1-1 ON-3 as a Door Feeder ................1-1 ON-3 as a Door Stacker ...............1-1 Available Options..................1-2 About this Manual ..............1-4 Operation Manual .................1-4...
  • Page 6 Check Controls ...................1-17 Remove Locks ..................1-17 Perform Visual Checks ...............1-17 Close the Cage Gate ................1-18 Getting Help from Kval............. 1-19 Kval Return and Warranty Policy ..........1-20 Send the Item ..................1-20 Acceptance of Return .................1-20 Refund Turnaround Time ..............1-20 Kval Errors ..................1-20 Customer Errors .................1-21...
  • Page 7 About Bearings ................ 2-13 About Pillow Block and Rail Bearings........2-14 About Flange Bearing Housings ............2-14 About Ball Rail Bearings ............2-15 ON-3 Machine Lubrication Map ..........2-16 Greasing ON-3 Lift Bearings........... 2-17 Recommended Tools ................2-17 Procedure to Grease Lift Bearings .............2-17 Lift Identification..................2-18...
  • Page 8 KVAL MLX Service Manual...

  • Page 9: Introduction To The

    Getting Help from Kval for help. The section Kval Service Center includes how to get information from the specification plate tor provide to Kval, service center hours, and return procedures A record to track operators that are trained on page 1-22 Safety Sign-Off Sheet the machine.

  • Page 10: Overview Of The On-3

    Overview of the ON-3 Overview of the ON-3 ON-3 as a Door Feeder Door Feeder automatically lifts individual doors from a stack and places the door Kval ON-3 onto a powered roll table where the door can be fed to the next machine manually with a 'Call Door' switch or automatically fed when the next machine in the line is ready to receive a door.

  • Page 11: Available Options

    This option is required only if Stacker the feed direction of the complete line is right to left. Option HV 3-Phase High Kval Equipment is only manufactured for 460v service Feeder Voltage 3 Phase. For customers who have 600 volt 3 phase, Stacker Option HV must be purchased.
  • Page 12 Cable Sizer is included in the pre-hanging line so the control Stacker panel for the ON-3 can be mounted next to the door pre-hanging machine control panel. NOTE: This option is required when the 558 Door Sizer is installed between the ON-3 and the door pre- hanging machine.

  • Page 13: About This Manual

    Descriptions of Machine Line and Safety Information. Operation Interface Descriptions of how to power machine line, and operator interface user screens. Tour of the Machine Locations and descriptions of key assemblies on the ON-3. Service Manual Service Manual includes the following: Chapter Title...

  • Page 14: Access Manuals And Videos Easily

    Access Manuals and Videos Easily Access Manuals and Videos Easily You can easily access a range of resources including downloadable PDF manuals, Quick Start guides, Maintenance Summaries, links to instructional videos, and Electro-Mechanical Maps. To access these valuable materials, simply follow these steps: Visit https://kvalinc.com/machine-support or scan the QR code provided in this sec-...

  • Page 15: Safety First

    Safety Terminology of Labels In addition to the nameplate, machines may have other warning labels or decals that provide Kval safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

  • Page 16: Safety Guidelines

    Safety Guidelines Safety Guidelines In addition to the caution and warning labels affixed to this machine, follow the guidelines below to help ensure the safety of equipment and personnel. Different versions of the stickers may have been applied to the machine. The Note: intent of safety is the same.

  • Page 17: Compressed Air

    Safety Guidelines • Never perform any maintenance unless machine is at zero state. • Never clean the machine while it is running. • Never walk away from the machine while it is running. • Never operate the machine without the safety guards. Machine Safety Labels FIGURE 1-4.
  • Page 18 Safety Guidelines Before performing any repairs or maintenance, lockout and tagout must be installed at all loca- tions. See “Lockout/Tagout Procedure” on page 1-14. All maintenance and repairs to electrical circuitry should only be performed by a qualified electri- cian. Warning: Lever style panels have a lock system that can Lever Style Electrical Panels:...

  • Page 19: Pinch Points

    Safety Guidelines Pinch Points A pinch point is a mechanical point where a person or part of a person's body can be caught between moving parts of a machine, between the moving and stationary parts of a machine, or between product and any part of the machine. Always be aware of the safety stickers on the machine Different versions of the stickers may have been applied to the machine.

  • Page 20: Laser Warnings

    Compliance with Codes and Regulations advises that you request an on-site state safety review of your installation of this machine. Kval This is to ensure conformance to any additional specific safety and health regulations which apply in your geographic area.

  • Page 21: Lockout Tagout Air Supply

    Safety Guidelines Lockout Tagout Air Supply Turn all air valves to the OFF position and place a padlock through the hole (see illustration below). NOTE: Place your tag on the padlock, as per the tagout guidelines. Safety Guidelines 1-12...

  • Page 22: Lockout/Tagout Guidelines

    Lockout/Tagout Guidelines Lockout/Tagout Guidelines Follow these Lockout/Tagout guidelines, • Place a tag on all padlocks. On the tag, each operator must put their own name and date. (These locks are only to be removed by the person who signs the tag) •...

  • Page 23: Lockout/Tagout Procedure

    Lockout/Tagout Procedure Lockout/Tagout Procedure This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991. Use the following lockout procedure to secure this machine while it is powered down. During a lockout, you disconnect all power and shut off the air supply.

  • Page 24: Lockout/Tagout Air Supply

    Lockout/Tagout Procedure push the red tab to pop it out. Place a pad- Disconnect style Electrical Panels: lock through the hole. Place your tag on the padlock, as per the tagout guide- lines next. (see illustration next). Turn Switch to the Insert Lock into hole.

  • Page 25: Post Maintenance Steps

    Lockout/Tagout Procedure 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. Before removing the locks and tags, 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.

  • 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 See “Getting Help from Kval” on page 1-19. Kval Technical Support. 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. Zero-Energy to Start-Up 1-18...

  • 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 next. 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

    Kval Return and Warranty Policy Kval Return and Warranty Policy goal is to provide customers with high quality products. If, for any reason, you are not com- Kval's pletely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...

  • Page 30: Customer Errors

    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 31: Safety Sign-Off Sheet

    Name (print):___________________ Signature: __________________ Date:____/____/____ Supervisor/Safety Officer/Trainer Name (print):__________________Signature: __________________ Date:____/____/___ recommends you make a copy of this sheet for new operators. If a copy is Note: Kval needed, contact our at (800) 553-5825 or email at sup- Technical Support port@kvalinc.com.

  • Page 33: Maintenance Of The

    Maintenance of the ON-3 CHAPTER 2 This chapter describes preventative maintenance steps for The content is geared to Kval ON-3 guide technicians to keep a regular maintenance schedule for your machine. Keeping your Kval machine maintained is an important piece for successful operation of your door production Kval 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 2-11.

  • Page 36: 600 Cycle Maintenance Steps

    600 Cycle Maintenance Steps 600 Cycle Maintenance Steps Follow procedures. Lockout/Tagout 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. Empty trap if necessary Slide locking switch down to unlock twist trap to remove.

  • Page 37: 3,000 Cycle Maintenance Steps

    3,000 Cycle Maintenance Steps 3,000 Cycle Maintenance Steps Follow procedures. Lockout/Tagout Inspect Feed Belts For machines with auto-feed. Note: 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 38: Inspect Limit Switches

    3,000 Cycle Maintenance Steps 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. Depending on the model of limit switch, the amount of “pre-travel” (amount of movement from the arms resting position) is either 5 or 20 degrees before the limit switch actuates.

  • Page 39: Grease Ball Screw Bearings

    3,000 Cycle Maintenance Steps Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN: SYS-LUBEG). 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).

  • Page 40: 12,000 Cycle Maintenance Steps

    12,000 Cycle Maintenance Steps 12,000 Cycle Maintenance Steps Follow procedures. Lockout/Tagout 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 41: Inspect Ball Screw Axle

    12,000 Cycle Maintenance Steps 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. 12,000 Cycle Maintenance Steps...

  • Page 42: 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 43: 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 44: Lubrication Schedule

    Shutdown the machine and follow the procedures. Lockout/Tagout Kval recommends the following lubrication schedule to ensure that the machine operates prop- erly. The table next is a compilation of all the bearings located on all machines. Note: Kval Some machine may not contain a bearing described in the table.

  • Page 45: Kval Lubrication Kit

    Lubrication Schedule Kval Lubrication Kit Silicone Spray Hydraulic Oil Lint Free Rags Grease Gun Extension Adapter Needle Nozzle EP-2 Multi-FAK Grease Lubrication Kit FIGURE 2-8. Lubrication Schedule 2-12...

  • Page 46: 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 47: About Pillow Block And Rail Bearings

    About Pillow Block and Rail Bearings About Pillow Block and Rail Bearings A pillow block is any mounted bearing where the mounted shaft is in a parallel plane to the mounting surface, and perpendicular to the center line of the mounting holes, as compared to dif- ferent types of flange blocks or flange units.

  • Page 48: About Ball Rail Bearings

    About Ball Rail Bearings About Ball Rail Bearings are linear bearings that are attached to positioning rails. In most cases, the bear- Ball Rail Bearings ings are attached to assemblies to move them in the X,Y, or Z direction. Ball Rail Bearing Ball Rail Bearings FIGURE 2-11.

  • Page 49: On-3 Machine Lubrication Map

    The following sections describe the greasing point in detail. Lift Carriage Table Lubrication Map FIGURE 2- 12. Grease Bearing Types Links Points “Greasing ON-3 Lift Bearings” on page 2-17 Lift Carriage Pillow Block “About Greasing Table Bearings” on page 2-20 Tables Hub, Idler ON-3 Machine Lubrication Map 2-16...

  • Page 50: Greasing On-3 Lift Bearings

    Greasing ON-3 Lift Bearings Greasing ON-3 Lift Bearings This section details the greasing procedure for the lift bearings. The contains a chain driven ON-3 vertical assembly and a horizontal chain driven assembly. Lift Lift Carriage For recommend greasing schedule for all assemblies, see “Lubrication Schedule”...

  • Page 51: Lift Identification

    Greasing ON-3 Lift Bearings Lift Identification Figure 2- 13 shows the locations of the Vertical Lift Horizontal Lift Carriage Vertical (Qty. 4) Lift Vertical (Qty. 4) Carriage Horizontal (Qty. 4) Lift Grease Points FIGURE 2- 13. Greasing ON-3 Lift Bearings...

  • Page 52: Servicing Lift Foam Pads

    Servicing Lift Foam Pads Servicing Lift Foam Pads applies to the and the Vacuum Lift Option V ON-3 ON-3D Feeders ON-3 Stacker Move Lift down to table level. Perform Lockout/ Tagout. Refer to original manufactures directions to service the lift pad assembly.

  • Page 53: About Greasing Table Bearings

    About Greasing Table Bearings About Greasing Table Bearings This section details the greasing procedure for the table bearings. Bearing types include hub and pulley (idler). Table styles may vary due to option ordered. However, the bearing types Note: described here are the same for all tables. For recommend greasing schedule for all assemblies, see “Lubrication Schedule”...
  • Page 54 About Greasing Table Bearings Idlers (x4) Hubs (x2) Infeed Table Bearing Locations FIGURE 2- 14. About Greasing Table Bearings 2-21...

  • Page 55: Greasing Chain Conveyor Bearings (Option)

    Greasing Chain Conveyor Bearings (Option) Greasing Chain Conveyor Bearings (Option) The Conveyor Option includes dual chain conveyor system allowing a new door stack to be posi- tioned outside the main feeder framework for immediate in-feed when required. The chains also extend under the feeder's power conveyor table to move caul boards towards the table's backside.
  • Page 56 Greasing Chain Conveyor Bearings (Option) Hubs (x2) Hubs (x2) Hubs (x2) Hubs (x2) Conveyor Bearing Locations FIGURE 2- 15. Greasing Chain Conveyor Bearings (Option) 2-23...

  • Page 57: Description Of Air Input System

    Description of Air Input System Description of Air Input System The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine. The clean dry air is diverted to blow off nozzles. The lubricator, located after the CDA filters, delivers the lubricated air to valve banks and air cylinders.

  • Page 58: Maintaining The Frl

    Maintaining the FRL Maintaining the FRL Regular maintenance of the FRL unit is crucial to keep the system functioning efficiently and to prevent costly downtimes. It is recommended to check the lines every week to two weeks. Note: Safety Precautions Before you begin maintaining your FRL unit, it is important to follow these safety precautions to avoid accidents and ensure a safe working environment: •...

  • Page 59: Step 1: Inspect The Regulator

    Maintaining the FRL Step 1: Inspect the Regulator Follow the procedure below to inspect the regulator. Before Lockout/Tagout Ensure the regulator is set to the correct pressure 1. Check the pressure settings: according to your system's requirements. Look for signs of air leaks around the regulator, includ- 2.

  • Page 60: Process

    Maintaining the FRL To manually expel debris in a pressurized system, A drain cock attached to the Note: auto drain end is tightened to the “S” side in normal operation. The drain can be discharged by loosening it to the “O” side. (Be careful, however, if pressure remains inside the bowl when the drain is discharged, the drain will blow out from the drain port.) See Figure 2-4.

  • Page 61: Step 3: Inspect And Adjust The Lubricator

    Maintaining the FRL Reverse Lockout/Tagout. Slowly open the main air sup- 9. Re-pressurize the system: ply valve to allow air to flow back into the system. Monitor the pressure gauge. Observe the FRL unit and connected pneumatic tools 10. Check for proper operation: for any signs of leaks or irregular operation.

  • Page 62: Adjusting The Air Line Lubricator Drip Rate

    Add new oil to match the level line on the bowl. See oil types below. 5. Add Oil: Oil Types KVAL P/N SYSLUBG Chevron AW Hydraulic Oil 32 G-C lubricants light AW R&O Mobile DTE 24...
  • Page 63 Maintaining the FRL Turn the adjustment knob counterclockwise to b.Decrease the drip rate: decrease the oil delivery rate. (Sight Glass). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per Adjustment Knob every other cycle.
  • Page 68 http://www.kvalinc.com...

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