Kval 700-DC Operation manual

KVAL INC.
Operation and Service Manual
700-DC
Frame Assembly Machine
With Hand Controls

Operator’s and Parts Manual
For further information about this manual or other Kval Incorporated products, contact the Customer Support Department,
Kval Incorporated, 825 Petaluma Boulevard South, Petaluma, CA 94952. In the U.S and Canada, call [phone] or fax (707)
762-0485. Outside the U.S. and Canada, call [phone].
Kval Incorporated welcomes your opinion regarding this document. Please send them to the Customer Support address shown
above.
Documentation Part Number: DOC-073_1-OPS
Copyright 2019 Kval Incorporated. All rights reserved.
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.
Proprietary Notice
This document contains confidential and trade secret information, which is proprietary to Kval, Inc. (“Kval”), and is protected
by laws pertaining to such materials. This document, the information in this document, and all rights there to are the sole and
exclusive property of Kval, are intended for use by customers and employees of Kval, and are not to be copied, used, or
disclosed to anyone, in whole or in part, without the express written permission of Kval. For authorization to copy this
information, please call Kval Customer Support at

ii
Copyright

2019 Kval Incorporated. All rights reserved.
825 Petaluma Blvd So.
Phone [phone] • Fax [phone]
www.kvalinc.com

Congratulations on your purchase of a new KVAL
SERIAL No._____________________________________________
DATE OF PURCHASED___________________________________
This manual is designed with safety in mind. We at KVAL want to begin FAST and SAFE
production as soon as possible. It is very important that all OPERATORS and
MAINTENANCE personal read this manual thoroughly. We have included important
safety information that will help prevent serious injury; as well as complete
maintenance, and troubleshooting instructions.
Proper operation and maintenance of your new KVAL machine will guarantee many
years of trouble-free, fast-paced production.
700-DC

TABLE OF CONTENTS
CUSTOMER SERVICE INFORMATION................................................................................... 1
PROPRIETARY NOTICE...................................................................................................................... 1
CONTACTING KVAL........................................................................................................................ 2
PRODUCT RETURN PROCEDURE ....................................................................................................... 3
GETTING STARTED ........................................................................................................................... 4
SAFETY FIRST!.............................................................................................................................. 5
SAFETY RESPONSIBILITY ....................................................................................................................... 6
PROCEDURE TO LOCK OUT TAG OUT ............................................................................................... 6
TAG TYPES....................................................................................................................................... 7
ZERO ENERGY START UP ......................................................................................................... 8
START-UP ......................................................................................................................................... 8
INSPECT............................................................................................................................................ 8
CLEAN UP........................................................................................................................................ 8
REPLACE GUARDS............................................................................................................................ 8
CHECK CONTROLS ........................................................................................................................... 9
REMOVE LOCKS ............................................................................................................................... 9
VISUAL CHECKS............................................................................................................................... 9
SAFETY GUIDELINES................................................................................................................ 11
ELECTRICAL ................................................................................................................................... 11
COMPRESSED AIR........................................................................................................................... 11
OPERATING SAFETY ....................................................................................................................... 11
COMPLIANCE WITH CODES AND REGULATIONS.............................................................................. 11
OPERATORS TRAINING ................................................................................................................... 11
OTHER HAZARD CONTROL ACTION ............................................................................................... 11
700-DC GUARD PLACEMENT AND PURPOSE..................................................................... 13
UNPACKING THE KVAL 700-DC ASSEMBLY TABLE ....................................................... 14
PROPER LIFTING TECHNIQUES............................................................................................ 15
ANCHORING THE MACHINE TO THE FLOOR .................................................................................... 16
SPECIFICATIONS........................................................................................................................ 17
AVAILABLE OPTIONS ..................................................................................................................... 18
TOUR OF THE MACHINE ......................................................................................................... 20
TOP VIEW....................................................................................................................................... 20
TOP VIEW WITH CONTROL DUAL BUTTON CONTROL..................................................................... 21
OPERATOR SIDE VIEW ................................................................................................................... 22

ELECTRICAL PANEL VIEW SIDE ..................................................................................................... 22
CONTROLS ................................................................................................................................... 23
MAIN CONTROL ............................................................................................................................. 23
ABOUT THE HANDS FREE BUTTONS ............................................................................................... 24
TURNING THE 700-DC ON AND OFF ..................................................................................... 25
POWERING UP THE 700-DC............................................................................................................ 25
POWERING DOWN THE 700-DC...................................................................................................... 25
OPERATING THE 700-DC.......................................................................................................... 26
USING CONTROL BUTTONS TO STAPLE A FRAME ........................................................................... 26
USING FOOT PEDALS TO STAPLE A FRAME..................................................................................... 28
ADJUSTMENTS OF THE LENGTH AND THE WIDTH ....................................................... 30
ABOUT LENGTH ADJUST ................................................................................................................ 30
ABOUT WIDTH ADJUST .................................................................................................................. 31
ADJUST HEAD HEIGHT ................................................................................................................... 31
ABOUT THE TOUCH SCREEN INTERFACE ........................................................................ 32
PROGRAMMING .............................................................................................................................. 32
MAINTENANCE SCHEDULE.................................................................................................... 34
LUBRICATION SCHEDULE ............................................................................................................... 36
TYPICAL LUCUBRATION KIT .......................................................................................................... 37
PRIMING THE LUBRICATOR: ........................................................................................................... 37
LIMIT SWITCHES ....................................................................................................................... 38
GENERAL AIR CIRCUITRY TROUBLE SHOOTING:......................................................... 39
BASIC ELECTRICAL TROUBLE SHOOTING: ..................................................................... 41
IF THE POWER STOPS DURING NORMAL OPERATIONS: ............................................ 41

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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Customer Service Information
KVAL is happy to help its customer make the most of their investment, and help solve any
problems that may occur. When you call, please have the electrical print, air print number,
and the serial number of the machine ready, so that we are able to accommodate your
needs efficiently.
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 (707) 762-
7367.
The 979-2 Miter Trim Saw System is a trademark of Kval Incorporated.
Copyright 2015 Kval Incorporated. All rights reserved.
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.
Chapter
1

700-DC FRAME ASSEMBLY MACHINE
2
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorporated
products, contact the Customer Support Department
• Mailing address:
Customer Support Department
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
• Phone and Fax:
In the U.S and Canada, call [phone] or fax [phone]
Outside the U.S. and Canada, call [phone] or fax [phone]
• Business hours:
Technical Support:
6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
Parts & Service Sales:
6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
(Other sales related inquiries: http://www.kvalinc.com)
• Email: [e-mail]
Your Feedback is Welcome: To help us design products that make your job easier and
your business more successful, we'd like to gain your perspective about your user
experience with our product - that is, the manual, the machinery, the software, etc. What
was easy or difficult to use or to learn? If you could change something about the design,
what would it be? Please email your comments and suggestions for improvement to
[e-mail]. (NOTE: This is not a customer support email link. For that,
please refer to the Customer Service contact information above.) Thank you!

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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Product Return Procedure
If you’ve contacted Kval for help and it is determined that a return is necessary, use the
procedure below to return the machine or part.
Note: Non-Warranty returns are subject to a 15% restocking charge.
1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a
purchase order number to cover repair costs in the event the unit is determined to be
out of warranty.
2. Reason for return: Before you return the unit, have someone from your organization
with a technical understanding of the machine and its application include answers to
the following questions:
a. What is the extent of the failure/reason for return? What are the relevant
error messages or error codes?
b. How long did it operate?
c. Did any other items fail at the same time?
d. What was happening when the unit failed (e.g., installing the unit, cycling
power, starting other equipment, etc.)?
e. How was the product configured (in detail)?
f. Which, if any, cables were modified and how?
g. With what equipment is the unit interfaced?
h. What was the application?
i. What was the system environment (temperature, spacing, contaminants,
etc.)?
3. Call Kval customer support for a Return Material Authorization (RMA). When you
call:
• Have the packing slip or invoice numbers available.
• Have the documented reason for return available.
a. Send the merchandise back to Kval.
• Make sure the item(s) you are returning are securely packaged and well
protected from shipping damage
• Include the packing slip or invoice numbers.
• Include the documented reason for return.
• Include the RMA number with the parts package.

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Getting Started
Your new KVAL Machine arrives at your plant crated, banded, taped and has painted set
collars on all shafts; keeping all of the precision moving parts secure during shipping.
1. Move the machine as close to the area it will be stationed before removing the crate
to protect against damaging the machine with the forklift.
2. Remove the machine from the crate. Be careful! Anytime the machine is lifted to
remove the skids there is a chance of the machine dropping suddenly, and damaging
the machine, or injuring people near the machine.
3. Remove all painted set collars from the shafts. Just about every shaft on the
machine has set collars to secure the moveable assembly mounted to the shafts.
4. Take off any tape securing the various buttons, switches and knobs.
5. Level your KVAL machine by putting metal shims underneath the corners of the
base. Leave a clear shot from the bolt holes in the foot pads to your shop floor.
Now, make sure the machine won’t rock back and forth.
6. Once the machine is level, anchor it to the floor so that it won’t move across the
floor during operation. KVAL recommends a ½ RED HEAD, TRUE BOLT
ANCHOR in each of the foot pads. When drilling the concrete for the anchor bolts
use a 5/8 bit.
Note:
KVAL wants to provide the industry’s safest and highest quality
wood working machines. The following page is a quality control
and safety checklist. Our technicians have already performed an
initial quality control check before shipping your machine. Please
review the checklist and return “Acknowledgment Copy” to KVAL
Verifying

700-DC FRAME ASSEMBLY MACHINE
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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Chapter
2
Safety First!
This section contains important safety information. Failure to follow these safety guidelines
may subject the operator to physical hazards that may result in serious bodily harm, or
death.

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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Safety Responsibility
It is the responsibility of each employee to maintain safe working conditions in his or her
area. Failure to understand and correctly follow this procedure is direct violation of safety
rules and regulations. Violations of this policy can lead to severe injury.
Procedure to Lock Out Tag Out
To lockout or tag out a piece of equipment, the following steps must be taken:
1. Assess the equipment to fully understand all energy sources (multiple electrical supplies
air and/or hydraulic pressures, spring tension, weight shifts, etc.)
2. Inform all affected personnel of the eminent shutdown, and the duration of the shutdown.
3. Obtain lock and tags from employer.
4. Shutdown machine(s) by normal means, i.e., disconnect switch (es), air pressure relief
valve (es), on/off button, etc. NOTE: Control power switches do not serve as adequate
shutdown devices. The main source(s) of energy must be disconnected as well. Also,
ensure that all mechanically stored energy has been released, i.e., lifting booms lowered to
bottom of travel, carriages in “HOME” position etc., No one may remove a tag or lock
installed by someone else. Only the person who attached the tag or lock is authorized to
remove it.
5. Once the lock and tag is in place, the employee must try to operate the machine to ensure
all energy sources are defeated.
6. When maintenance or repairs are completed, the person that did the work must ensure all
tools, spare parts, test equipment, etc. are completely removed and that all guards and
safety devices are installed.
7. Before removing the lock and tag, 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.
8. The lock and tag can now be removed (only by the person who place them), and the
machine can be re-energized.
9. The tag shall be destroyed and the lock and key returned to the lockout center.

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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
In addition to safety concerns, this policy is required by OSHA regulation 1910.147 and Cal
OSHA’S SB198 ruling of July 1991.
Tag Types

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ZERO ENERGY START UP
Zero Energy State to Start-up to Operating State
Starting the equipment is just as important as Lock-Out/Tag-Out in terms of safety.
Start-up
•Inspection
• Clean up
• Replace guards
• Check controls
• Remove locks
• Visual checks
Inspect
When work is finished the equipment must be inspected for proper adjustment before
starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials and old parts used
during repairs must be cleaned up.
Replace Guards
Replace all guards to the equipment. If adjustments can not be made with the guard on after
start-up, leave off only the ones to be adjusted after start-up.

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Check Controls
Make sure all switches are in the off position. In some cases the machine can start
automatically when energy is restored.
Remove Locks
Each person must remove his or her own lock or tag. This will ensure you are in a safe place
when the equipment is started.
Visual Checks
If the equipment is too large to see all around it, station personnel around the area and sound
the personnel alarm before starting the equipment. If your operation is more complex,
having many pieces of equipment and a lot of people, a comprehensive Lock-Out/Tag-Out
procedure may involve additional steps. You will need to ask your supervisor about these
procedures. A specific lock out procedure may be posted at each machine. On larger or
long term maintenance projects or installation projects, the procedures should be explained
to all participants and a copy of the procedures posted on site for the duration of the work.
Provisions which ensure protection during shift changes when contractor or outside help is
used also need to follow the Lock-0ut/Tag-Out Procedures. Comprehensive Lock-0ut/Tag-
Out may use a gang box or other system to ensure that locks are secure and not removed
without authorization.
Remember Lock-Out Tag-Out procedures work because you are the only one with the key
to your lock. Proper Lock-0ut/Tag-Out can save lives, limbs and money. Help make your
work environment safe for yourself and your fellow employees. Make sure you follow the
P-R-OP-E-R Lock-0ut/Tag-Out procedures, and that those around you do also.
YOUR LIFE MAY DEPEND ON IT.
http://www.concrete-pipe.org/sab.htm
© 2004 American Concrete Pipe Association (ACPA). All Rights Reserved.

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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

700-DC FRAME ASSEMBLY MACHINE
11
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Safety Guidelines
Electrical
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 supplying this machine
Compressed Air
The compressed air system connected to this machine should have a three-way air
valve for shut-off and pressure relief. The air supply providing the pressure to this
machine also has a three-way air valve for the supply line.
Operating Safety
Prior to changing any cutters or doing any maintenance work, you must disconnect,
tag out, or lock out the electrical, air pressure and hydraulic systems. This should be
done in accordance with the State and/or Federal code requirements.
Compliance with Codes and Regulations
It is advised that you request an on-site State safety review of your installation of
this machine. This is to ensure conformance to any additional specific safety and
health regulations which apply in your area.
Operators Training
You must ensure that all operators of this machine be trained to know the potential
electrical hazards, pressure pinch points, rotating cutters, and other similar hazards.
It is also your responsibility to train the operators, or potential operators on how to
operate the machine safely.
Other Hazard Control Action
If you believe that any part or operation of this machine is in violation of any health
or safety regulation, it is your responsibility to immediately protect your employees
against any such hazard and bring the matter to our attention for review and
correction, if deemed advisable.

700-DC FRAME ASSEMBLY MACHINE
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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
You will not that additional detailed safety guidelines are included in the operating
instructions of this manual. We will be pleased to review with you any questions
you may have regarding the safe operations of this machine.

700-DC FRAME ASSEMBLY MACHINE
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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
700-DC Guard Placement and Purpose
The in feed /out feed wheel guard’s location is over both wheel assemblies. These guards
protect the operator from getting any body parts pinched by the wheel assembly and the
frame. Possible injuries from getting any part of the body caught by the wheel assembly
may include:
•Broken Bones
•Bruises
•Cuts and Amputation
Never operate the 700 without the guards.