Kval 965X User manual

Innovation, Quality & Honesty
Service Manual
Published: June 10, 2021
965X Jamb Machining System
With KvalCAM®
Service Manual 965-X System

KVAL 965-X Service Manual
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for KVAL Inc. machines. Neither this Manual nor any of the information contained
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call Kval Customer Support at [phone] or fax [phone]. Outside the
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Manual Part Number: DOC-228-1-SRV
965-X is a trademark of Kval Incorporated.
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Copyright 2021 Kval Incorporated. All rights reserved.
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K VA L 965-X Service Manual
KVAL 965-X Service Manual
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KVAL 965-X Service Manual

Table of Contents
965X Service Manual
Chapter 1 Introduction to the 965X
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 956X System ................................................. 1-2
About this Manual.................................................................................1-4
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................................1-6
Lockout-Tagout Guidelines ...................................................... 1-10
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10
Lockout Tagout Procedure....................................................... 1-11
Pre-Steps Before Lockout Tagout.......................................................1-11
Lockout Tagout Power ........................................................................1-11
Lockout Tagout Air Supply ..................................................................1-12
Start Maintenance...............................................................................1-12
Post Maintenance Steps.....................................................................1-12
Zero-Energy to Start-Up .......................................................... 1-13
Getting Help from KVAL........................................................... 1-15
On-Line Help.......................................................................................1-16
How to Download the Service Application ............................... 1-17
Download Application .........................................................................1-17
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 System IT Administration
System IT Administration ......................................................... 2-2
About the 965X Line Computer ............................................................2-2
Connections on the PLC.......................................................................2-2
Chapter 3 Maintenance of the 965X
Maintenance Schedule ............................................................ 3-2
300 Cycle Maintenance Steps ................................................. 3-4
Clean, Clean, Clean!.............................................................................3-4
600 Cycle Maintenance Steps ................................................. 3-5
Check Air Gauges and Inspect Water Traps.........................................3-5
Inspect Tooling......................................................................................3-5

965X Service Manual
Table of Contents
Empty Dust Collection Units .................................................................3-6
3,000 Cycle Maintenance Steps .............................................. 3-7
I Inspect all Photo Eyes ........................................................................3-7
Inspect Limit Switches ..........................................................................3-7
Inspect Airlines......................................................................................3-7
Refill Lubricators...................................................................................3-8
Grease Ball Screw Bearings.................................................................3-8
Clean Bearing Shafts............................................................................3-8
12,000 Cycle Maintenance Steps............................................ 3-9
Inspect Air Cylinders .............................................................................3-9
Inspect Ball Rail Shafts and Ball Screws..............................................3-9
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts...........3-9
72,000 Cycle Maintenance Steps............................................ 3-10
Inspect Nuts and Bolts........................................................................3-10
Electrical .............................................................................................3-10
Computer Backup...............................................................................3-10
Wash Filter and Lubricator Bowls .......................................................3-10
Maintenance NO-GOES .......................................................... 3-11
Lubrication Schedule ............................................................... 3-12
Typical Lucubration Kit........................................................................3-12
Lubrication Requirements........................................................ 3-13
Pillow Block Bearing Housings ...........................................................3-13
Flange Bearing Housings ...................................................................3-14
Ball Rail Bearing .................................................................................3-14
About Taper Bearings .........................................................................3-15
Tapered Bearing Housings .................................................................3-15
Ball Screw Nut ....................................................................................3-16
Ball Screw Drive Assembly .................................................................3-16
How to Prepare the 965X for Greasing.................................... 3-17
Cutter Head Location After Park .........................................................3-17
Grease Locations for the 965X................................................ 3-18
Locations of Cutter Head Bearings.....................................................3-18
Locations of Bearings on Each Tool ...................................................3-19
Locations of Rail Bearings on the Clamp Assemblies ........................3-20
Description of Air Input System................................................ 3-22
Air Input with Lubrication ...................................................................3-22
Air Line Without Lubricator .................................................................3-23
Identifying 965X Tools.............................................................. 3-24
About the Tool Kit..................................................................... 3-25

Table of Contents
965X Service Manual
About the Tool Kit................................................................................3-25
How to Access to Bit Assemblies............................................. 3-26
Remove and Replace the Router or Pre-Drill Bits ................... 3-27
Check or Update Tool Configuration........................................ 3-29
About Chisels........................................................................... 3-30
Chisel Orientation on Machine............................................................3-30
Changing Chisels on a Machine .........................................................3-30
Replacing the Self Lubricator................................................... 3-32
Replace the Lubricator Well................................................................3-32
Process to Change an Auto-Lubricator...............................................3-33
Collet Torque Values................................................................ 3-34
Chapter 4 Troubleshooting the 965X Line
Get Live Technical Help ........................................................... 4-2
Troubleshooting Basics ........................................................... 4-3
Before you Adjust..................................................................................4-3
Analyze the Sub Systems.....................................................................4-5
About Motion Control ............................................................... 4-6
Sequencing...........................................................................................4-6
Point to Point ........................................................................................4-6
Incremental...........................................................................................4-6
Basic Control Circuit ................................................................ 4-7
About a Typical Contactor Control ........................................... 4-8
About Contactor Troubleshooting .........................................................4-9
About Typical VFD Motor Drive Control................................... 4-10
About the VFD ....................................................................................4-11
About VFD Troubleshooting................................................................4-12
About a Typical Pneumatic Circuit ........................................... 4-13
Typical Pneumatic Assembly ..............................................................4-14
About the Coil (Solenoid)....................................................................4-14
About Cylinder Operation ...................................................................4-15
How the Pneumatic System Works ....................................................4-15
Important Notice about Adjusting Cylinder Speed ..............................4-17
Adjusting Cylinder Extend Speed .......................................................4-18
Adjusting Cylinder Retraction Speed .................................................4-18
Valve Bank Locations .............................................................. 4-19
Location of Valve Banks on the 965X .................................................4-19

965X Service Manual
Table of Contents
Network System Overview....................................................... 4-20
Connections to Servo Drives ..............................................................4-20
965X Servo Motor Locations ..............................................................4-21
About Switches and Sensors................................................... 4-22
Using Sensors to Trouble Shoot .........................................................4-23
Sensor Locations on Machine ............................................................4-23
Frame Sensors ...................................................................................4-23
Cutter Head Sensors ..........................................................................4-24
Troubleshooting Electrical Problems ....................................... 4-25
If the Power Stops During Normal Operation .....................................4-25
Description of the Light Tower ................................................ 4-27

Chapter 1 at a Glance
1-1
965X Service Manual
CHAPTER 1 Introduction to the 965X
This chapter provides an overview of the KVAL 965X machine and important safety information to
follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the 965X
System
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 1-6
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-10
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-13
Getting Help from KVAL This section describes the method to con-
tact 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 1-17
Safety Sign-Off Sheet A record to track operators that are trained
on the machine.
page 1-20

Overview of the 956X System
1-2
965X Service Manual
Overview of the 956X System
The 965X processes hinge, strike and head jambs, as well as mull posts for door frames.Jamb Cut-
down functionality is reduced to jambs. With CNC functionality, the 956X allows the operator to
select hinge or lock locations on the jamb and route various types of hinge and latch-plate tem-
plates as well as pre-drill for hardware attachment. Four corner square chisels are standard for
ASA or T strike and hinge pocket squaring. The counter rotating routers can also be used to cut
jambs to length and rout angled sill gains in the jamb bottom. The 965X comes standard with four
(4) auto-chisels and three (3) hi-frequency routers, each adding unique functionality to the
machine.
CNC Functionality:
The 956X, a 3-Axis (x,y,z) CNC machine, provides the operator with the ability to dictate mortise
pattern, depth, radii, location, as well as pre-drill pattern and depth. Each variable is easily modi-
fied via our touch screen and KvalCAM program. Key components include Beckhoff® AC servo
motors, controller and industrial computer which in turn drive a gear and rack system for X-axis
and precision ball screws for Y/ Z axis router and chisel movements.
Programming:
KvalCAM is used create files for a wide variety of hardware templates and can also be used to pro-
gram end dados or cut material to length. KvalCAM offers increased supportability and trouble-
shooting capabilities. Newly developed error codes and code definitions quickly identify any
problems to the operator and or Kval support technician on-site or via a connection to our offices.