Kval DL-2DH Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: 4/28/16
DL-2DH Door Light Cut-Out Machine
DL-2DH Door Light Cut-Out Machine

KVAL DL-2HD Operation/Service Manual
Proprietary Notice
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. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: 126_OPSRV_DL2_V1
The DL-2DH Door Light Cut-Out System is a trademark of Kval Incorporated.
Copyright Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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Kval Incorporated
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Petaluma, CA 94952
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• Email: [email protected]

KVAL DL-2HD Operation/Service Manual
KVAL DL-2HD Operation/Service Manual
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KVAL DL-2HD Operation/Service Manual

KVAL DL-2DH Operation/Service Manual
Table of Contents
Chapter 1 Introduction to the DL-2DH
Chapter 1 at a Glance.............................................................. 1-1
Overview of the DL-2DH.......................................................... 1-2
Options Available..................................................................................1-3
About this Manual.................................................................................1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................................1-5
Lockout-Tagout Guidelines...................................................... 1-9
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Lockout Tagout Procedure....................................................... 1-10
Pre-Steps Before Lockout Tagout.......................................................1-10
Lockout Tagout Power........................................................................1-10
Lockout Tagout Air Supply..................................................................1-11
Start Maintenance...............................................................................1-11
Post Maintenance Steps.....................................................................1-11
Zero-Energy to Start-Up........................................................... 1-12
Getting Help from KVAL........................................................... 1-14
On-Line Help.......................................................................................1-14
Product Return Procedure..................................................................1-14
How to Download the Service Application............................... 1-16
Download Application.........................................................................1-16
Safety Sign-Off Sheet.............................................................. 1-19
A Note to the Operator........................................................................1-19
Chapter 2 Operation of the DL-2DH
Operator’s Tour........................................................................ 2-2
Standard ...............................................................................................2-2
DL-2DH Second Cutter Head...............................................................2-2
Option D: Edge Prep.............................................................................2-3
Option G: About Air Nozzles.................................................................2-3
About the Electrical Panels..................................................... 2-4
Description of the Six Light Panel ........................................... 2-5

DL-2DH Door Light Machine
Quick Start Description............................................................ 2-6
Powering Up and Down the DL-2DH...................................... 2-7
To Power Up the DL-2DH.....................................................................2-7
Powering Down the DL-2DH.................................................................2-7
Momentary Stop....................................................................................2-8
To Resume Normal Operation after a Momentary Stop........................2-8
Operator Controls.................................................................... 2-9
Pneumatic Table and Edge Prep Controls..........................................2-10
Edge Prep Controls (Option) ..............................................................2-11
Motor Controls....................................................................................2-12
Head Controls.....................................................................................2-12
DL-2 Setting Up for a Cut ........................................................ 2-14
Door Stop............................................................................................2-14
Face Bore Templates..........................................................................2-14
Edge Detailing Machine......................................................................2-14
Cutter Head Stops ..............................................................................2-15
Cutter Head ........................................................................................2-15
Door Thickness...................................................................................2-15
About Set Collars and Templates ............................................ 2-16
About Y Axis Template Bar(s).............................................................2-16
About Face Bore Templates ...............................................................2-17
Y- Axis Template Bar Set-up...............................................................2-17
Adjusting a Y Template Bar ................................................................2-18
Using Templates...................................................................... 2-21
Positioning the Template.....................................................................2-22
Template Drill Jig ................................................................................2-23
Chapter 3 Maintenance of the DL-2DH
Maintenance Schedule............................................................ 3-2
Daily, Monthly, Six Month Maintenance................................................3-2
Lubrication Schedule............................................................................3-3
Lubrication Requirements........................................................ 3-4
Linear Bearings, Flange Bearing, and Pillow Blocks............................3-4
Gear Motor Lubrication Requirements..................................................3-5
Ball Screws (If Applicable)....................................................................3-5
Description of Air Input System ............................................................3-5
Adjusting the Air Line Lubricator...........................................................3-6
Priming the Air Line Lubricator .............................................................3-6
Changing or Adjusting Bits ...................................................... 3-7

KVAL DL-2DH Operation/Service Manual
Adjusting Drill Unit ................................................................... 3-8
To Adjust Horizontally...........................................................................3-8
Depth of Drilling....................................................................................3-8
Adjusting the Bolt Plate Router.............................................................3-8
Set Up for Wood Rail............................................................................3-8
Chapter 4 Troubleshooting the DL-2DH
DL-2DH Sensors...................................................................... 4-2
How Sensors Work...............................................................................4-2
Troubleshooting Sensors......................................................................4-2
Important Notice about Adjusting Cylinder Speed................... 4-3
Adjusting Cylinder Extend Speed .........................................................4-3
Adjusting Cylinder Retraction Speed....................................................4-3
About a Typical Contactor Control........................................... 4-4
About Contactor Troubleshooting.........................................................4-5
Troubleshooting Electrical Problems ...................................... 4-6
If the Power Stops During Normal Operation........................................4-6
Troubleshooting with the Status Light Panel ........................... 4-8

DL-2DH Door Light Machine

Chapter 1 at a Glance
1-1
KVAL DL-2DH Series Operation/Service Manual
CHAPTER 1 Introduction to the DL-2DH
This chapter provides an overview of the KVAL DL-2DH machine and important safety informa-
tion to follow when operating the machine.
Chapter 1 at a Glance
Chapter 1 at a Glance 1-1
Overview of the DL-2DH 1-2
Options Available 1-3
About this Manual 1-4
Safety Sheet Sign-Off Sheet 1-4
Safety First! 1-5
Safety Sheet Sign-Off Sheet 1-5
Safety Terminology of Labels 1-5
Safety Guidelines 1-5
Lockout-Tagout Guidelines 1-9
Follow the P-R-O-P-E-R lockout rule of thumb. 1-9
Lockout Tagout Procedure 1-10
Pre-Steps Before Lockout Tagout 1-10
Lockout Tagout Power 1-10
Lockout Tagout Air Supply 1-11
Start Maintenance 1-11
Post Maintenance Steps 1-11
Zero-Energy to Start-Up 1-12
Getting Help from KVAL 1-14
On-Line Help 1-14
Product Return Procedure 1-14
How to Download the Service Application 1-16
Download Application 1-16
Safety Sign-Off Sheet 1-19
A Note to the Operator 1-19
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Overview of the DL-2DH
KVAL DL-2DH Series Operation/Service Manual
1-2
Overview of the DL-2DH
KVAL's DL-2DH Door Light Cut-Out Machine produces rectangular, curved, and multi-light cut-
outs in wood or metal doors up to 16 gauge. Face boring is standard with a built-in steel template
adjustable for backsets from 2-3/8” to 2-3/4”.
Steel bars are provided to set the travel in the 'X' (Door length) and 'Y' (Door width) directions for
the cutout. The 'X' axis set up uses a fixed stop for the reference from the top of the door and an
adjustable stop to set the length of the cut. For the 'Y' axis 10 bars with collars are included to set
the width of the cutout are included with the DL-2DH. The stop collars to position the bar for dif-
ferent door widths may be set up set up so the same bar may be used for 3'0", 2-10", and 2'-8"
doors by shifting the collar bar on the holder bracket. The cutout for 2'-6" wide doors will usually
require a separate bar setup to accommodate the narrow doors that are typically used.
Two three-speed Cutter Heads are supported by cross-mounted linear bearing shafts for length
and width travel. Cutter Heads can be used for metal doors and wood doors, cutting down time or
tool change over. A Hardinge B3 1/2" ID collet is used for accurate tool holding.
This design eliminates cut-out templates for rectangular lights since adjustable stops can be
locked directly on the shaft to limit Cutter Head travel. A numeric scale and ratcheting lock han-
dles are provided to make the stops easy to adjust. For curved or multiple light cutouts, plywood
templates slide into a holder 1/4" above the door. The same template may be used for 32” or 36”
doors.
During the cutting operation, the spindle automatically oscillates up and down 3/8” every second
to guard against overheating the same part of the cutting tool, thus ensure even tool wear and lon-
ger tool life.
The standard pass line height of the DL-2DH is 33-1/2”. If the DL-2DH is to be used in a line
with a Handler Door Feeder or any Kval assembly machine option P may added specified to raise
the feed height to 38-1/2"
SPECIFICATIONS
Footprint Size: 7'x 10'
Crated Dimensions: 115"L x 84"W x 60"H
Shipping Weight: 2,000 lbs.