Kval 700-C User manual

Innovation, Quality & Honesty
Service Manual
Published: October 18, 2023
700-C Frame Assembly Machine
700-C Service Manual

KVAL 700-CService 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].
Manual Name: 700-C Service Manual
Manual Revision: 46-CS1-MV101.1, 46-CS1-MV100.2
700-C is a trademark of Kval Incorporated.
Copyright 2021 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
All other products are trademarks or registered trademarks of their respective holders, all rights
reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
Kval Incorporated.
Contacting Kval
For further information about this manual or other Kval Incorporated products, please contact us.
Mailing address:
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
call: [phone]
fax: [phone]
General Office Business Hours
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: [email protected]

KVAL 700-CService Manual
KVAL 700-CService 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: [email protected]
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.
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Sales Support
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the “Contact Us” page.
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Kval Website
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releases), learn about our machine software solutions, download machine documentation, view
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http://www.kvalinc.com

KVAL 700-CService Manual
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:
1. Visit https://kvalinc.com/machine-support or scan the QR code provided in this sec-
tion.
2. Hover your cursor over the Support option located at the top bar of the website.
3. From the drop-down menu that appears, select Machine Support.
Once you've reached the Machine Support page:
1. Enter either the machine model name or the machine serial number.
2. This will take you to the document page related to your specific machine.
3. From there, you can easily select and download the desired files and resources.
This streamlined process ensures you have quick and convenient access to the information you
need for your machine
.
FIGURE 1-1. Machine Support Page
QR Code
https://kvalinc.com/machine-support

Table of Contents
Introduction and Safety...Chapter 1
About the 700-C ........................................................................................1-1
Table Options ..............................................................................................1-1
About this Manual ....................................................................................1-3
Service Manual ...........................................................................................1-3
Quick Start ...................................................................................................1-3
Safety First! .................................................................................................1-4
Safety Sheet Sign-Off Sheet ....................................................................1-4
Safety Terminology of Labels ...................................................................1-4
Safety Guidelines .....................................................................................1-5
Training ........................................................................................................1-5
Protective Gear ...........................................................................................1-5
When the Machine is Powered and Running ........................................1-5
Lockout/Tagout Guidelines ...................................................................1-6
Follow the P-R-O-P-E-R lockout rule of thumb. ....................................1-6
Lockout/Tagout Procedure ...................................................................1-7
Before Lockout/Tagout: Inspect the Machines ......................................1-7
Lockout/Tagout Power ...............................................................................1-7
Lockout/Tagout Air Supply ........................................................................1-8
Start Maintenance ......................................................................................1-8
Post Maintenance Steps ...........................................................................1-9
Zero-Energy to Start-Up ........................................................................1-10
Inspect ........................................................................................................1-10
Clean Up ....................................................................................................1-10
Replace Guards ........................................................................................1-10
Check Controls .........................................................................................1-10
Remove Locks ..........................................................................................1-10
Perform Visual Checks ............................................................................1-10
Close the Cage Gate ...............................................................................1-11
Getting Help from Kval ...........................................................................1-12
Kval Return and Warranty Policy .......................................................1-13
Send the Item ............................................................................................1-13
Acceptance of Return ..............................................................................1-13
Refund Turnaround Time ........................................................................1-13
Kval Errors .................................................................................................1-13
Customer Errors .......................................................................................1-14
Shipper Errors ...........................................................................................1-14
Warranty Replacement Parts .................................................................1-14
Safety Sign-Off Sheet .............................................................................1-16

Table of Contents
A Note to the Operator ..........................................................................1-16
Maintenance of the 700-C...Chapter 2
Maintenance Schedule ..........................................................................2-1
Lubrication Schedule ..............................................................................2-3
Kval Lubrication Kit ....................................................................................2-4
About Bearings ..........................................................................................2-5
About Pillow Block Bearing Housings .............................................2-6
About Flange Bearing Housings ..............................................................2-6
About Ball Rail Bearings .......................................................................2-7
Machine Lubrication Map ......................................................................2-8
Greasing Staple Gun Carriage Bearings .......................................2-9
Recommended Tools .................................................................................2-9
Staple Carriage Greasing Procedure ......................................................2-9
Staple Carriage Grease Point Locations ................................................2-9
Greasing the Movable Fence Bearings ..........................................2-11
Recommended Tools ...............................................................................2-11
Movable Fence Greasing Procedure ....................................................2-11
Movable Fence Grease Point Locations ..............................................2-11
Greasing the Rack and Pinion Bearings ........................................2-13
Recommended Tools ...............................................................................2-13
Rack and Pinion Greasing Procedure ..................................................2-13
Rack and Pinion Grease Point Locations .............................................2-13
Description of Air Input System ..........................................................2-15
Air Input with Lubrication ........................................................................2-15
Adjusting the Air Line Lubricator ...........................................................2-15
Priming the Air Line Lubricator ...............................................................2-16
Air Line Without Lubricator .....................................................................2-16
Troubleshooting the 700-C...Chapter 3
Get Live Technical Help .........................................................................3-1
About a Typical Pneumatic Circuit ....................................................3-2
Typical Pneumatic Assembly ....................................................................3-3
About the Coil (Solenoid) ..........................................................................3-3
About Cylinder Operation ..........................................................................3-4
How the Pneumatic System Works ..................................................3-5
Important Notice about Adjusting Cylinder Speed ................................3-7

Table of Contents
Adjusting Cylinder Extend Speed ............................................................3-7
Adjusting Cylinder Retraction Speed ......................................................3-7
Pneumatic Assembly Locations .........................................................3-8
Description of the Light Tower ...........................................................3-9
Bottom Light (Control Power) ..............................................................3-10
Bottom Light Conditions ..........................................................................3-10
If the Bottom Light is OFF .......................................................................3-10
If the Bottom Light is ON .........................................................................3-10
Top Light (Machine Status) ..................................................................3-11
Top Light Conditions ................................................................................3-11
If the Top Light is OFF .............................................................................3-11
If the Top Light Flashing White ...............................................................3-11
If the Machine Status Light is Red .........................................................3-12
If the Machine Status Light is Yellow .....................................................3-13
If the Machine Status Light is Blue ........................................................3-13
If the Machine Top is Solid Green ..........................................................3-13
About the Three Light Panel ................................................................3-14
Control Power Light .................................................................................3-14
Start Light ..................................................................................................3-15
About Switches and Sensors ..............................................................3-16
Using Sensors to Trouble Shoot ............................................................3-17

1-2
Door Transfer System Service Manual
CHAPTER 1 Introduction and Safety
This chapter provides an overview of the Kval Door Transport System (DTS) and important safety
information to follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the DTS
System
This section provides an overview of the DTS This
section includes a general description and a table
of available options.
page 1-1
Safety! IMPORTANT safety information is described in this
section.
page 1-5
Zero-Energy to Start-
Up
Procedure to power up your machine for the first
time.
page 1-10
Getting Help from Kval This section describes the method to contact the
Kval service center for help. The section includes
how to get information from the specification plate
tor provide to Kval, service center hours, and
return procedures.
page 1-12
Safety Sign-Off Sheet A record to track operators that are trained on the
machine.
page 1-16

About the 700-C
About the 700-C
1-1
About the 700-C
The Kval 700-C Frame Assembly Machine is generally used in-line with the Commander 3 or 990
Series of machines.
The operation includes placing the strike jamb and header into the machine and clamping into
place. The door, with hinge jamb installed, is then moved into position, gently lowered into place,
and then securely clamped into position. Two-Hand control Palm Buttons activate the clamping
sequence and vertically move staple guns into position to attach the jambs to the header. Activat-
ing staple gun "fire" sequence is initiated with one palm button and the "fire guns" push-button on
the control panel on machine. The door is then raised and rolled out of the machine to the next sta-
tion to the packaging station.
The 700-C is adjustable for doors from 18" to 4', wide with a standard length capacity of 6'8" or an
optional capacity for 7'0" and 8'0" doors. The 700-C can have up to four staple guns mounted on
four corner brackets. Spot Nail Staple guns, with 7/16” crown staples are supplied with machine
as standard.
Table Options
Each table or conveyor is assigned an option.
TABLE 1-1. 700-C Options
Option Table Description
B: Reverse Feed Direction Normal direction is left to right. For right to left, add this
option.
54X: 5/4 Spacers for Thick Jambs Spacers for frame width adjust bars to accommodate
both 11/16" thick jambs and 5/4" thick jambs.
D: 7’0” and 8’.0” Door Frame Allows operator to quickly adjust end clamps from 6'8" to
7'0" or 8'0" doors. Quick changeover time of approxi-
mately one minute required.
G: 7’0” Door Frame Allows operator to quickly adjust end clamps from 6'8" to
7'0" doors. Quick changeover time of approximately one
minute required.
I: Leg Extensions For variable height applications. Customer to specify
height.
J: End Clamp Spacers For use on 6’6” doors. Jamb spacer blocks connect to
the end clamp pads. Four spacers required.
N: End Clamp Spacers For use on 6’6” doors. Jamb spacer blocks connect to
the end clamp pads. Four spacers required.
N: Narrow Jamb Via removable spacer blocks and increased cylinder
stroke, operator is able to reduce minimum jamb width
from 4-1/4" to 3-1/2".