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.
Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed
by Beckhoff Automation GmbH
Windows 7® is a registered trademark of Microsoft Corporation.
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
Customer Service: For further information about this manual or other Kval Incorpo-
rated 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: [email protected]

KVAL 960-3 Operation/Service Manual
KVAL 960-3 Operation/Service Manual
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 improve-
ment to [email protected]. (NOTE: This is not a customer support email
link. For that, please refer to the Customer Service contact information above.) Thank
you!
http://www.kvalinc.com

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