Kval 990-APEX User manual

Innovation, Quality & Honesty
Service Manual
Published: October 24, 2022
990-APEX Service Manual
990-APEX Door Machining System
Architectural, Pre-Hanging, and Exterior Doors
With KvalCAM®

KVAL 990-APEX 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].
Manual Name: 990-APEX Service Manual
Manual Revision: 233-MV100.0,233-MV100.1, 233-MV100.2, 233-MV101.0
990-APEX is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 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: pa[email protected]

KVAL 990-APEX Service Manual
KVAL 990-APEX Service Manual
Technical Service 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.
email: [email protected]
Sales Support
For machinery information, specifications, and quotes. Call, email, contact us on our website at
the “Contact Us” page.
email: [email protected]
Kval Website
Learn about Kval, order parts, get information on our array of machines (including new machine
releases), learn about our machine software solutions, download machine documentation, view
videos of our machines in action, contact all the departments.
http://www.kvalinc.com

KVAL 990-APEX Service Manual
NOTICE OF OWNERSHIP OF KvalCAM® SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES
MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KvalCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KvalCAM SOFTWARE.
, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the
purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the Machinery are licensed, not sold, to you
for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to you.
Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with, Inc. The Kval-
CAM Software is protected by copyright laws and treaties. Title and related rights in the content generated through
the KvalCAM Software are also the property of the Licensor and are protected by applicable law.
1. Definitions.
a.“KvalCAM Software” means the KvalCAM computer application installed in the Machinery
and written documentation and materials provided to you, as well as any revisions or updates of
such computer application and documentation.
b.“Install” means storing of the KvalCAM Software in the computer component of the Machin-
ery.
c.“Use” means executing the KvalCAM Software for purpose of operating the Machinery and
use of the documentation for properly operating KvalCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the Kval-
CAM Software upon payment of all amounts due for the purchase of the related Machinery.
b.Licensee will make no copies of the KvalCAM Software or alter the KvalCAM Software in
any way. Title to the KvalCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KvalCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KvalCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

990-APEX Service Manual
Table of Contents
Introduction to the 990-APEX System 1
Overview of the 990-APEX ..................................................................1-2
Architectural, Pre-Hanging, & Exterior -- All in One ..............................1-2
KvalCAM ......................................................................................................1-3
990-APEX Summary ..................................................................................1-3
Specifications Summary ............................................................................1-4
About this Manual ....................................................................................1-5
Operation Manual .......................................................................................1-5
Service Manual ...........................................................................................1-5
KvalCAM Reference Manual ....................................................................1-5
Safety First! .................................................................................................1-6
Safety Sheet Sign-Off Sheet ....................................................................1-6
Safety Terminology of Labels ...................................................................1-6
Safety Guidelines .....................................................................................1-7
Training ........................................................................................................1-7
Protective Gear ...........................................................................................1-7
When the Machine is Powered and Running ........................................1-7
Compressed Air ..........................................................................................1-8
Electrical ......................................................................................................1-8
Pinch Points ..............................................................................................1-10
Before Conducting Maintenance ...........................................................1-10
Laser Warnings .........................................................................................1-10
Compliance with Codes and Regulations ............................................1-11
Other Hazard Control Action ..................................................................1-11
Follow Your Company’s Safety Procedures .........................................1-11
Lockout Tagout Guidelines ...................................................................1-12
Follow the P-R-O-P-E-R lockout rule of thumb. ..................................1-12
Lockout Tagout Procedure ...................................................................1-13
Pre-Steps Before Lockout Tagout ..........................................................1-13
Lockout Tagout Power .............................................................................1-13
Lockout Tagout Air Supply ......................................................................1-14
Start Maintenance ....................................................................................1-14
Post Maintenance Steps .........................................................................1-14
Zero-Energy to Start-Up ........................................................................1-16
Inspect ........................................................................................................1-16
Clean Up ....................................................................................................1-16
Replace Guards ........................................................................................1-16
Check Controls .........................................................................................1-16
Remove Locks ..........................................................................................1-16
Perform Visual Checks ............................................................................1-16

990-APEX Service Manual
Table of Contents
Close the Cage Gate ...............................................................................1-17
Getting Help from KVAL .........................................................................1-18
Kval Return and Warranty Policy .......................................................1-19
Send the Item ............................................................................................1-19
Acceptance of Return ..............................................................................1-19
Refund Turnaround Time ........................................................................1-19
Kval Errors .................................................................................................1-19
Customer Errors .......................................................................................1-20
Shipper Errors ...........................................................................................1-20
Warranty Replacement Parts .................................................................1-20
Safety Sign-Off Sheet .............................................................................1-22
A Note to the Operator ..........................................................................1-22
Maintenance of the 990-APEX 1
Maintenance Schedule ..........................................................................2-2
300 Cycle Maintenance Steps ............................................................2-4
Clean, Clean, Clean! ..................................................................................2-4
600 Cycle Maintenance Steps ............................................................2-5
Check Air Gauges and Inspect Water Traps ..........................................2-5
Inspect Tooling ............................................................................................2-5
Lubricate inside of Hopper ........................................................................2-6
Empty Dust Collection Units .....................................................................2-6
3,000 Cycle Maintenance Steps ........................................................2-7
Inspect Feed Belts .....................................................................................2-7
Inspect Screw Drop Tubes on Six Shooter ............................................2-7
Inspect all Photo Eyes ...............................................................................2-8
Inspect Limit Switches ...............................................................................2-8
Inspect Screw Receiver Parts ..................................................................2-8
Inspect Airlines ............................................................................................2-9
Refill Lubricators .........................................................................................2-9
Grease Ball Screw Bearings ..................................................................2-10
Clean Bearing Shafts ...............................................................................2-10
12,000 Cycle Maintenance Steps .....................................................2-11
Inspect Chains for Proper Tension ........................................................2-11
Inspect Air Cylinders ................................................................................2-11
Inspect Hydraulic Lines ...........................................................................2-11
Inspect Ball Rail Shafts ...........................................................................2-12
Inspect Ball Screw Axle ...........................................................................2-12
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts ......2-12

990-APEX Service Manual
Table of Contents
Clean inside Hopper ................................................................................2-13
72,000 Cycle Maintenance Steps .....................................................2-14
Inspect Nuts and Bolts ............................................................................2-14
Check Door Feeding Transition .............................................................2-14
Electrical ....................................................................................................2-14
Computer Backup ....................................................................................2-14
Wash Filter and Lubricator Bowls ..........................................................2-15
Tool Changing Schedule .......................................................................2-16
Maintenance NO-GOES ........................................................................2-17
About Bearings ..........................................................................................2-18
About Pillow Block Bearing Housings ...................................................2-18
About Flange Bearing Housings ............................................................2-19
About Ball Rail Bearings .........................................................................2-19
About Tapered Bearings ..........................................................................2-20
Tapered Bearing Housings .....................................................................2-20
Ball Screw Nut ..........................................................................................2-21
Ball Screw Drive Assembly .....................................................................2-21
Pulley and Idler Shafts ............................................................................2-22
Lubrication Schedule ..............................................................................2-23
Kval Lubrication Kit ..................................................................................2-24
Machine Lubrication Map ......................................................................2-25
Greasing Hinge and Lock Carriage Servo Bearings .................2-27
Recommended Tools ...............................................................................2-27
Procedure to Grease the Hinge and Lock Servo Assemblies ...........2-27
Hinge Servo Assembly Locations ..........................................................2-28
Lock Servo Assembly Locations ............................................................2-28
Z–Axis Servo Assembly Part Identification ..........................................2-29
Y–Axis Servo Assembly Part Identification ..........................................2-29
X–Axis Servo Assembly Part Identification ..........................................2-30
Greasing Hinge Carriage Bearings ..................................................2-31
Recommended Tools ...............................................................................2-31
Hinge Carriage Greasing Procedure .....................................................2-31
Hinge Carriage Grease Point Locations ...............................................2-31
Hinge Cutter Tray Grease Point Locations ..........................................2-32
Greasing Lock Carriage Bearings .....................................................2-34
Recommended Tools ...............................................................................2-34
Lock Carriage Greasing Procedure .......................................................2-34
Lock Carriage Grease Point Locations .................................................2-34
Lock Cutter Tray Grease Point Locations ............................................2-35
Greasing the Feed System Bearings ...............................................2-37

990-APEX Service Manual
Table of Contents
Recommended Tools ...............................................................................2-37
Process to Grease Feed System Bearings ..........................................2-37
Bearing Locations on the Feed System ................................................2-37
Greasing the Screw Shooters Bearings .........................................2-39
Recommended Tools ...............................................................................2-39
Process to Grease Shooter Bearings ...................................................2-39
Bearing Locations on Screw Shooters ..................................................2-39
Greasing Jamb Swing Bearings ........................................................2-41
Recommended Tools ...............................................................................2-41
Jamb Swing Assembly Greasing Procedure ........................................2-41
Jamb Swing Grease Point Locations ....................................................2-41
Greasing Frame Bearings ....................................................................2-43
Recommended Tools ...............................................................................2-43
Frame Greasing Procedure ....................................................................2-43
Machine Frame Grease Point Locations ..............................................2-43
Greasing the RTS Rotary Hopper Bearing ....................................2-45
Recommended Tools ...............................................................................2-45
RTS Greasing Procedure ........................................................................2-45
RTS Grease Point Location ....................................................................2-45
About the Self Lubricator Module ......................................................2-47
How the Self Lubricator Works ...............................................................2-47
Replace the Lubricator Well ...................................................................2-47
Description of Air Input System ..........................................................2-49
Air Input with Lubrication ........................................................................2-49
Adjusting the Air Line Lubricator ...........................................................2-49
Priming the Air Line Lubricator ...............................................................2-50
Air Line Without Lubricator .....................................................................2-50
Identifying Cutting Tools ........................................................................2-51
Tool Information for the Cutter Tray .......................................................2-51
Tool Information Lock Cutter Tray ..........................................................2-52
How to Access to Tooling ......................................................................2-53
Getting Access the Hinge Carriages .....................................................2-53
Getting Access the Lock Carriages .......................................................2-53
Access the Tool Config Screen ..........................................................2-55
Check the Tool Config .............................................................................2-55
Tool Length in Lock Carriage ..................................................................2-56
Tool Length in Hinge Carriage ................................................................2-56
Remove and Replace the Router or Pre-Drill Bits .....................2-57
Remove and Replace the Chisels .....................................................2-59

990-APEX Service Manual
Table of Contents
Remove and Replace the Screwdriver Bits ..................................2-60
Collet Torque Values ...............................................................................2-63
Addition Collet Torque Values ................................................................2-64

990-APEX Service Manual
Table of Contents

1-1
CHAPTER 1 Introduction to the 990-APEX System
This chapter provides an overview of the KVAL 990-APEX Door Hanging System and important
safety information to follow when operating the machine.
Chapter 1 at a Glance
Overview of the 990-APEX................................................................... page 1-2
About this Manual.................................................................................. page 1-5
Safety First!............................................................................................ page 1-6
Safety Guidelines.................................................................................... ..page 1-7
Lockout Tagout Guidelines................................................................... page 1-12
Lockout Tagout Procedure........................................................................page 1-13
Zero-Energy to Start-Up....................................................................... page 1-16
Getting Help from KVAL..................................................................... page 1-18
Kval Return and Warranty Policy......................................................... page 1-19
Safety Sign-Off Sheet........................................................................... page 1-22

Overview of the 990-APEX
1-2
990-APEX Service Manual
Overview of the 990-APEX
Architectural, Pre-Hanging, & Exterior -- All in One
The 990-APEX redefines door and jamb machining flexibility by bridging the interior, exterior,
and architectural/commercial markets. Designed with 75 years of experience and proven concepts
at the foundation of our legendary 990 Series, the APEX easily outperforms the competition.
Leveraging our patented KvalCAM® software—integrated with CNC technology—the 990-APEX
provides complete control of all machine movement and precision cutting. It is the perfect
machine for those looking to serve several markets with a single high-performance solution.
Hinges - Four independent CNC router heads allow you to specify hinge location, depth, radius,
and pre-drill patterns from the control panel for the door and jamb. Use of clockwise and count er-
clockwise high-frequency spindles eliminate material chip-out without the need for chip-out
blocks. A third spindle is designated for point-to-point pre-drilling any hole pattern. Automatic
corner squaring and concealed hinge capability are standard.
FIGURE 1-1. Hinge Section
Lock Section - Routers mounted on the CNC tower in the lock section can machine the entire lock
edge, making it possible to complete preps for three-point locks, deep mortise locks, flush bolts,
and more. Face work in the lock section is completed with vertical spindles mounted on the same
CNC tower, making function holes, different size bores, and irregular shapes all possible.
Corner squaring and point-to-point pre-drilling in the lock section are standard with the 990-
APEX, and optional CNC ball-cat ch routers can be added t o both bore and route for face plates on
the door top.

Overview of the 990-APEX
1-3
990-APEX Service Manual
FIGURE 1-2. Lock Section
Jambs - The 990-APEX can machine and attach 3 ½” or 4” hinges with Kval’s original patented 6-
Shooter and 8-Shooter technology for pre-hanging interior and exterior doors. KvalCAM allows
the door and jamb to be machined separately to accommodate special hinges and strikes, such as
ASA strikes and three-point lock strike jambs.
KvalCAM
The 990-APEX is programmed and controlled by our patented KvalCAM software that has been in
development for over five years. Door files are easily created at the controller, off-line, or auto-
matically from your data system through its easy-to-use API.
No G-Code experience is necessary to program new and unique door files. Jobs can be queued for
operator or automatic bar-code reader selection, and 3D drawings can be viewed in real time as
the door file is created. All machine control, calibration, and tool management is done through the
KvalCAM intuitive UI.
990-APEX Summary
• Hi-Frequency CNC Controlled Routers increase hinge pocket quality with extreme
accuracy and long life
• Counter-Rotating Routers eliminate chip-out without the need for chip-out blocks,
changing hinge sizes is fast and done from the controller
• Point-to-point Pre-drill Spindles replace air operated “gang drills” to allow for any
pre- drill pattern
• Selectable Chisels provide perfectly square hinges or face plates automatically
• High Quality Beckhoff Control Components are used throughout the 990-APEX

Overview of the 990-APEX
1-4
990-APEX Service Manual
• Laser Encoder for real-time door thickness measurement and program adjustment
for correct hardware
• CNC Ball-catch Motors for varying size, location, face plates, pivots, and flush bolt
top/bottom plates
• Variable Run Modes of pre-hanging, door-only, and/or jamb-only are fully sup-
ported
• Jamb Programming fully supports hinges and strike jambs (including three-point
locks
Specifications Summary
These values are in standard configuration, special options can be ordered to modify them. Con-
tact Kval Sales for more
information .
Height 78”-96”
Width 14” – 48” (12” – 14” hinge only with option ND1)
Thickness 1 3/8” – 1 3/4”
Bevel 0° or 3°
Hinge Width 3” – 4 ½”
Hinge Corner ¼” Rad, 5/8” Rad, Square
Hinge Mortise Depth 0-1”
Maximum Lock Mortise Depth 4.5”
Minimum Jamb Width 4.5”
Maximum Jamb Width 7 1/4”

About this Manual
1-5
990-APEX Service Manual
About this Manual
This manual is part of a package delivered with the machine line.
Operation Manual
Operation Manual includes the following:
Service Manual
Service Manual includes the following:
KvalCAM Reference Manual
KvalCAM Reference Manual includes the following:
Chapter Title Description
1Introduction Descriptions of Machine Line and Safety Information.
2Operation Interface Descriptions of how to power machine line, and operator
interface user screens.
3Calibration Descriptions of Calibration Routines and how to use the
interfaces
3Tour of the Machine Locations and descriptions of key assemblies on the 990-
APEX
Chapter Title Description
1Introduction Safety Information.
2Maintenance Maintenance steps for the machine line
Chapter Title Description
1KvalCAM reference Description of the Interface
2KvalCAM Examples Examples of Common Door Job Features
3KvalCAM Common Terms Common terms associated with KvalCAM

Safety First!
1-6
990-APEX 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 1-22.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that provide
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.
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.

Safety Guidelines
1-7
990-APEX Service Manual
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.
Note: Different versions of the stickers may have been applied to the machine. The
intent of safety is the same.
Training
Ensure that all employees who operate this machine are aware of and adhere to all safety precau-
tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-3
shows a sample of safety labels addressing training.
Read the Manual
FIGURE 1-3. Read the Manual Labels
Protective Gear
Never operate the machine without proper eye and ear protection. Figure 1-4 shows a sample of
safety labels addressing safety gear.
FIGURE 1-4. protective Gear Labels
When the Machine is Powered and Running
Serious injury or death could occur if these general rules are not followed. Figure 1-5 shows a
sample of safety labels addressing machine safety.
•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.

Safety Guidelines
1-8
990-APEX Service Manual
• 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.
• Never operate the machine without the safety guards.
FIGURE 1-5. Machine Safety Labels
Compressed Air
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 maintenance or repairs on this machine turn off the main air disconnect.
Lockout and tagout this connection.See “Lockout Tagout Procedure” on page 1-13.
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 sup-
plying this machine
FIGURE 1- 6. Electrical Box Labels

Safety Guidelines
1-9
990-APEX Service Manual
Before performing any repairs or maintenance, lockout and tagout must be installed at all loca-
tions. See “Lockout Tagout Procedure” on page 1-13.
All maintenance and repairs to electrical circuitry should only be performed by a qualified electri-
cian.
Warning: Lever Style Electrical Panels: Lever style panels have a lock system that can
be unlocked to allow access to electrical penal that still has power applied.
High Voltage may cause injury or death. Do not open the cabinets with-
out High Voltage training or without permission from a supervisor.
Warning: Disconnect Style Panels: 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. Do not open the cabi-
nets without High Voltage training or without permission from a
supervisor.
Still has power
in OFF position

Safety Guidelines
1-10
990-APEX Service Manual
Pinch Points
A pinch point is a mechanical point where a person or part of a person's body can be caught
between moving parts of a machine, between the moving and stationary parts of a machine, or
between product and any part of the machine.
Always be aware of the safety stickers on the machine
Note: Different versions of the stickers may have been applied to the machine. The
intent of safety is the same.
FIGURE 1-7. Pinch Point Warning Labels
Before Conducting Maintenance
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
.
FIGURE 1-8. Maintenance Warning Labels
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the laser manufacturers
safety precautions.