Kval 960-3 Operation manual

Innovation, Quality & Honesty
960-3 Strike Jamb Router
With Shifting Cutter Head
960-3 Operation and Service Manual
Operation and Service Manual
Published: 12/01/2020

KVAL 960-3 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: DOC-065-1-OPS(65-MV101.0)
960-3 is a trademark of Kval Incorporated.
Copyright 2016 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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• Business hours:
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• Email: [email protected]

KVAL 960-3 Operation/Service Manual
KVAL 960-3 Operation/Service Manual
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KVAL 960-3 Operation/Service Manual

Table of Contents
KVAL Edge-SS Manual
Chapter 1 Introduction to the 960-3
Chapter 1 at a Glance...........................................................................1-1
Overview of the 960-3.............................................................. 1-2
Available Options..................................................................................1-2
About this Manual.................................................................................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
ANCHORINGTHE MACHINE TO THE FLOOR....................... 1-12
Standard Anchoring Instructions.........................................................1-12
Zero-Energy to Start-Up .......................................................... 1-14
Getting Help from KVAL........................................................... 1-16
KVAL Return and Warranty Policy ........................................... 1-17
Send the Item .....................................................................................1-17
Acceptance of Return .........................................................................1-17
Refund Turnaround Time ....................................................................1-17
Kval Errors..........................................................................................1-17
Customer Errors .................................................................................1-18
Shipper Errors.....................................................................................1-18
Warranty Replacement Parts..............................................................1-18
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 Operation of the 960-3
About the 960-3 ....................................................................... 2-2
Face Plate Types ..................................................................................2-2
Preset the 960-3 ...................................................................... 2-3
Process the Jamb .................................................................... 2-4

KVAL Edge-SS Manual
Table of Contents
Initial Powering Operations for the 960-3 Line......................... 2-5
How to Power Up the Machine .............................................................2-5
How to Power Down the Machine.........................................................2-5
Presets for the 960-3 ............................................................... 2-6
Set the Thickness .................................................................................2-6
Set the Backset.....................................................................................2-6
Set the Strike Depth..............................................................................2-7
Set the Strike Location..........................................................................2-8
Setting the Index Stops.........................................................................2-8
Tour of the Machine ................................................................. 2-10
About the Shifting Cutter Head................................................ 2-11
Summary of the Controls on the Machine ............................... 2-12
Foot Pedal ..........................................................................................2-12
Controls (Standard) ............................................................................2-12
About the Strike Controls......................................................... 2-13
Door Hand Selector ............................................................................2-13
Lock Plate Shape Selector .................................................................2-14
Lock Plate Shape Selector .................................................................2-14
Emergency Shutdown and Recovery .................................................2-15
To Resume Normal Operation after an E-Stop ...................................2-15
About the Electrical Panel........................................................ 2-16
Description of the Light Tower ................................................ 2-17
Chapter 3 Maintenance of KVAL Machinery
Maintenance Schedule ............................................................ 3-2
Daily, Monthly, Six Month Maintenance ................................................3-2
Maintenance NO-GOES ......................................................... 3-4
Lubrication Schedule ............................................................... 3-5
Typical Lucubration Kit..........................................................................3-5
Lubrication Requirements........................................................ 3-6
Pillow Block Bearing Housings .............................................................3-6
Flange Bearing Housings .....................................................................3-7
Ball Rail Bearing ...................................................................................3-7
Sample of Grease Locations for 960-3.................................... 3-8
Description of Air Input System................................................ 3-9
Air Input with Lubrication .....................................................................3-9
Air Line Without Lubricator .................................................................3-10

Table of Contents
KVAL Edge-SS Manual
Initial Cut on New Chip Out Block............................................ 3-15
Appendix: Router Collet Assembly Basics............................... 3-16
Checking Collet Assembly ..................................................................3-16
Appendix: Collet Torque Values ............................................... 3-17

1-1
KVAL Operation/Service Manual
CHAPTER 1 Introduction to the 960-3
This chapter provides an overview of the KVAL 960-3Strike Jamb Router. Included is important
safety Information and Lockout Tagout procedures.
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the 960-3 This section provides an overview of the
machine. It includes a general description and
a table of available options
page 1-2
Safety First! IMPORTANT safety information is described
in this section
page 1-5
Lockout-Tagout Guidelines Procedures describing Lockout Tagout.. page 1-9
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-14
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, ser-
vice center hours, and return procedures
page 1-16
Safety Sign-Off Sheet A record to track operators that are trained on
the machine.
page 1-20

Overview of the 960-3
KVAL Operation/Service Manual
1-2
Overview of the 960-3
Available Options
TABLE 1-2. Options
Options
Option A Split Jamb Sta-
pler with Side
Clamp
Adds Split Jamb Option
Option B End Drilling Automatically drills for sill or head mounting screws on both ends.
Price includes one pair of quick-change standard pattern drill
heads with air motors.
Option D Additional Mech-
anisms and
Machine Logic
For processing either full-lip strike or "closed" deadbolt plates.
Photo eyes are affixed to jamb reference guides at the end of the
machine, so plate style is automatically detected depending on
jamb position. Important: Plates must be the same size with iden-
tical plunge profiles.
Option DH Additional Mech-
anisms and
Machine Logic
For processing either full-lip strike or "closed" deadbolt plates.
Photo eyes are affixed to jamb reference guides at the end of the
machine, so plate style is automatically detected depending on
jamb position. Important: Plates must be the same size with iden-
tical plunge profiles.If this functionality is desired and Option H:
Commercial Package is purchased, this version of Option D must
be used
Option E "T” Strike Routing Allows quick change from "T" strike routing to full-lip routing with
the turn of a switch. Cycle slows to approximately four jambs per
minute due to extended router travel path.
Using the KVAL 960-3 Automatic Strike Jamb Router, a
fast operator can machine 5 jambs per minute with a full
lip strike routing pattern. The 960-3 features a fully auto-
matic machine cycle that includes clamp-up and ejection.
Popular options include pushbutton changeover to a "T"
strike routing pattern, and end drilling units for sills and
head jamb screws.
The 960-3 is designed so that router movements are fully
automatic. The router moves in a rectangular pattern for
faceplate and then moves in to route for the deeper latch
hole. Both flat jambs with stop, as well as split jambs, can be accommodated.
Jambs are placed against either a right-hand or left-hand indexing stop and are clamped firmly
into position at the touch of a foot pedal. Standard set-up is for full-lip routing standard.

Overview of the 960-3
1-3
KVAL Operation/Service Manual
Option F Extra Jamb Index
Stops
Two extra jamb index stops for machining dead-bolt strikes.
Option H Commercial
Package
Four additional stops for 6’8”, 7’0” and 8’0” jambs. (Stops included
on base machine for 6/8 doors ,does not include extra stops for
deadlock machining)
TABLE 1-2. Options
Options

Overview of the 960-3
KVAL Operation/Service Manual
1-4
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.
Operation/ Service Manual includes the following:
Chapter Title Description
Chapter 1 Introduction Descriptions of Machine Line and
Safety Information.
Chapter 2 Operation Inter-
face
Descriptions of how to power
machine line, and operator inter-
face user screens.
Chapter 3 Maintenance Information about Maintenance of
the machines
Chapter 4 Troubleshooting Troubleshooing Tips

Safety First!
1-5
KVAL Operation/Service Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.
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.
There are three types of warning labels or decals:
• DANGER means if the danger is not avoided, it will cause death or serious injury.
• WARNING means if the warning is not heeded, it can cause death or serious
injury.
• CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
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.
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training

Safety First!
KVAL Operation/Service Manual
1-6
Never operate the machine without proper eye and
ear protection.
Protective Gear
• Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
• Never clear screws or hinges out of the machine
while it is running.
• Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
• 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.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
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 1-10.
Compressed Air

Safety First!
1-7
KVAL Operation/Service Manual
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the electrical
and air pressure systems. This should be done in
accordance with applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.

Safety First!
KVAL Operation/Service Manual
1-8
KVAL advises 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 regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
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.

Lockout-Tagout Guidelines
1-9
KVAL Operation/Service Manual
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)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
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

Lockout Tagout Procedure
KVAL Operation/Service Manual
1-10
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. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Power
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the
shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Power
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out

Lockout Tagout Procedure
1-11
KVAL Operation/Service Manual
Lockout Tagout Air Supply
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. 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.
10. 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.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines..

ANCHORINGTHE MACHINE TO THE FLOOR
KVAL Operation/Service Manual
1-12
ANCHORINGTHE MACHINE TO THE FLOOR
When you have set-up and test run your machine to ensure that it is feeding the material properly
KVAL recommends anchoring the machine to the floor with ½ Red head, True Bolt Anchors in
each of the foot pads. An alternative way to bolting the machine, you may want to use Epoxy and
hardened threaded rods to prevent the bolts from vibrating loose. KVAL doesn’t require the use of
epoxy though its added fastening strength is significant.
Standard Anchoring Instructions
• With machine in place and leveled, drill 3” deep holes in the concrete using a 5/8”
dia. masonry bit, using the mounting hole as a guide.
• Clean out holes with an air compressor to ensure that the anchor heads get a firm
bite on the walls of the holes.
• Insert anchors through the mounting holes in the foot pads and into the holes you
have drilled into the concrete. If an anchor’s expansion sleeve binds inside the hole,
simply tap the bolt head with a hammer until the binding stops.
• Tighten bolts until they are snug. Avoid over tightening the bolt as this may cause
the head of the bolt to break.
Anchoring Instructions using Epoxy:
• With machine in place and leveled, drill 3” deep holes in the concrete using a 9/16”
diameter. masonry bit, using the mounting hole as a guide.
• Clean out holes with an air compressor. Complete hole preparation with use of a
nylon brush (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.

ANCHORINGTHE MACHINE TO THE FLOOR
1-13
KVAL Operation/Service Manual
• 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.