Kval 990F-3 Service manual

Innovation, Quality & Honesty
990F-3
Pre-Hanging Door
Machine
Reference
Published:
September 8, 2006

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 thereto 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
[phone] or fax [phone]. Outside the U.S. and Canada, call [phone].
Copyright 2006 Kval Incorporated. All rights reserved.
KVAL 2006 and 990F-3 are trademarks of Kval Incorporated.
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 Incorporated products,
contact the Customer Support Department
•http://www.kvalinc.com/customer_service.html (lists all the representatives, including email
addresses and phone numbers)
•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: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Thursday
Friday Technical Support: 4:00 AM to 3:30 PM Pacific Standard Time
Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday
(Other sales related inquiries: http://www.kvalinc.com/contact_us.html)
•Email: [email protected]

4
Returning Parts or Equipment to Kval
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.
Before returning parts and/or equipment to Kval Inc., please call Kval at [phone] to
receive an RMA number (Return Merchandise Authorization number). To return parts and/or
equipment, please follow the detailed instructions found under “Returning Parts or Equipment to
Kval.”
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? If you had a problem, did the manual or software
troubleshooting tools help you out?Please email your comments and suggestions for improvement to
[email protected]. (NOTE: This is not a way to get customer support. For that, please refer
to the Customer Service contact information above.) Thank you!

Congratulations on your purchase of a new
KVAL 990F-3
This manual is designed with safety in mind. At Kval, our goal is for you to begin safe and
fast production with this machine as soon as possible. It is very important that all operators
and maintenance personnel 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.

Table of Contents
PROPRIETARY NOTICE .........................................................................................................................................1
CONTACTING KVAL............................................................................................................................................3
RETURNING PARTS OR EQUIPMENT TO KVAL.......................................................................................................4
CHAPTER 1: INTRODUCTION .......................................................................................................................1
CUSTOMER SERVICE INFORMATION .....................................................................................................................1
RETURNING PARTS /EQUIPMENT TO KVAL ........................................................................................................1
*NOTE..................................................................................................................................................................1
WHEN YOU CALL: ................................................................................................................................................1
WHEN SENDING MERCHANDISE BACK:.................................................................................................................1
GETTING STARTED..........................................................................................................................................3
CHAPTER 2: SAFETY INFORMATION........................................................................................................5
SAFETY PROCEDURES ..........................................................................................................................................5
Responsibility..............................................................................................................................................................5
Lock-out/Tag-out Procedure........................................................................................................................................5
LOCK-OUT AND TAG-OUT PROCEDURE...............................................................................................................6
ACCIDENT SITUATIONS ........................................................................................................................................7
LOCK RULES ........................................................................................................................................................7
P-R-O-P-E-R ELECTRICAL LOCK-OUT................................................................................................................8
P-R-O-P-E-R HYDRAULIC AND/OR PNEUMATIC LOCK-OUT...............................................................................8
P-R-O-P-E-R FLUIDS AND GASES LOCK-OUT.....................................................................................................9
P-R-O-P-E-R MECHANICAL ENERGY LOCK-OUT................................................................................................9
ZERO-ENERGY START UP..................................................................................................................................10
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
CHAPTER 3: SPECIFICATIONS ..................................................................................................................13
UNCRATING THE 990F-3....................................................................................................................................13
RECEIVING THE 990F-3:.....................................................................................................................................13
UNCRATING YOUR MACHINE:............................................................................................................................13
UNCRATING PROCEDURE:..................................................................................................................................14
ANCHORING THE MACHINE TO THE FLOOR.......................................................................................................15
CHAPTER 4: OPERATION............................................................................................................................17
TOUCH SCREEN PANEL OPERATIONS:................................................................................................................17
FIRST SCREEN:...................................................................................................................................................17
SECOND SCREEN:...............................................................................................................................................18
THIRD SCREEN:..................................................................................................................................................18
FOURTH SCREEN:...............................................................................................................................................19
FIFTH SCREEN:...................................................................................................................................................19
SIXTH SCREEN: ..................................................................................................................................................20
CONTROL PANEL OPERATIONS...........................................................................................................................20
Control Transformer:.................................................................................................................................................20
Start Machine:............................................................................................................................................................20
R.H. Door L.H.:.........................................................................................................................................................20
Back Section / Both / Front Selection:.......................................................................................................................20

8
Off Lock Bore/ Reg. / Deep:..................................................................................................................................... 21
BOLT DRILL ON: ................................................................................................................................................21
FACE PLATE REG /OFF /EXTEND TIME:.............................................................................................................21
FEED MODE OFF /AUTO /FEED THROUGH: .......................................................................................................21
FEED JOG FOR /JOG REV: .................................................................................................................................21
SLOW FEED:.......................................................................................................................................................21
DISABLE AUTO FEED: ........................................................................................................................................21
1-PASS FRONT ROUTERS 2PASS: .......................................................................................................................21
WIDTH-ADJUST OPEN /CLOSE:..........................................................................................................................21
DISABLE AUTO-ADJUST:....................................................................................................................................21
SHIFT ROUTERS OUT OF POCKET: ......................................................................................................................22
CENTER HINGE:..................................................................................................................................................22
START SEQUENCE: .............................................................................................................................................22
EMERGENCY STOP: ............................................................................................................................................22
OPTIONAL OPERATING CONTROLS:....................................................................................................................22
PRE-DRILL OFF/ON:...........................................................................................................................................22
PRE-DRILL ROUTER HORIZONTAL POP-UP STOP OVERRIDE:..............................................................................22
PRE-DRILL LOCK OUT: ......................................................................................................................................22
DEADBOLT SHIFT:..............................................................................................................................................22
DEADBOLT BORE:..............................................................................................................................................22
BOLT DRILL:......................................................................................................................................................22
FACE PLATE DEAD BOLT: ..................................................................................................................................23
SIDE DRILL (LATCH HOLE) ................................................................................................................................23
LOCK BORE DIAMETER:.....................................................................................................................................23
ROUTER OPERATING CONTROLS:.......................................................................................................................23
CENTER ROUTER:...............................................................................................................................................23
ROUTER ON /OFF: .............................................................................................................................................23
3- OR 4-POCKET CONFIGURATIONS:...................................................................................................................23
FOOT PEDAL OPERATING CONTROLS .................................................................................................................23
DOOR CLAMP:....................................................................................................................................................23
JAMB CLAMP:.....................................................................................................................................................23
CONTROLS ON THE ELECTRICAL BOX .................................................................................................................24
SPEED CONTROL FRONT SECTION:.....................................................................................................................24
BACK SECTION FACE PLATE CONTROL TIME: ....................................................................................................24
700-C RESET:.....................................................................................................................................................24
SIX-SHOOTER.....................................................................................................................................................24
SIX-SHOOTER OPERATING CONTROLS ...............................................................................................................25
INSERT SCREW:..................................................................................................................................................25
START SEQUENCE: .............................................................................................................................................25
RESET: ...............................................................................................................................................................25
UNCLAMP:..........................................................................................................................................................25
EMERGENCY STOP: ............................................................................................................................................25
HOPPER SLIDE VALVE:.......................................................................................................................................25
SAFETY INSERT SCREW SLIDE VALVE:...............................................................................................................25
SCREW DRIVER IN CLOSE TRAP ..........................................................................................................................25
OPTIONAL CONTROLS:.......................................................................................................................................26
LOAD /UNLOAD:................................................................................................................................................26
Six-Shooter Gear Installation and Maintenance:....................................................................................................... 26
Removing the Gear Motor: ....................................................................................................................................... 26
REMOVING THE PLUNGE CYLINDER:..................................................................................................................27
REMOVING GEARBOX: .......................................................................................................................................28
GEAR BOX MAINTENANCE:................................................................................................................................29
REINSTALLING THE GEARBOX:...........................................................................................................................31
RE-INSTALLING THE PLUNGE CYLINDER:...........................................................................................................31
RE-INSTALLING THE GEAR MOTOR:...................................................................................................................31
FRONT SECTION .................................................................................................................................................32

9
PRELIMINARY HINGE CENTER SET-UP:..............................................................................................................32
POSITION “H” BLOCKS:......................................................................................................................................32
CENTERING ROUTERS WITHIN THE “H” BLOCK:.................................................................................................33
SETTING UP THE HINGE BACKSET:......................................................................................................................33
CHANGING THE TURRET SETTINGS: ...................................................................................................................34
PLATE WIDTH:PLATE ROUTER VERTICAL TRAVEL ...........................................................................................35
PLATE ROUTER DEPTH:......................................................................................................................................35
SWITCHING THE BEVEL PLATES:........................................................................................................................35
Setting the Doorstops:................................................................................................................................................36
CHANGE-OVER BETWEEN HINGE SIZES..............................................................................................................36
Setting Up Hinge Pocket Length: ..............................................................................................................................36
Door Width Minimum / Maximum Limits: ...............................................................................................................37
Chipout Replacement / Break-In:...............................................................................................................................37
SETTING UP THE BACK SECTION ........................................................................................................................38
SETTING UP LOCK HEIGHT: ...............................................................................................................................40
SETTING UP LOCK BORE BACKSET:...................................................................................................................41
SELF –CENTERING ADJUSTMENTS:....................................................................................................................42
BOLT PLATE WIDTH ADJUSTMENTS:..................................................................................................................42
SIDE DRILL (LATCH HOLE)................................................................................................................................42
LOCK BORE DIAMETER:.....................................................................................................................................43
40” LOCK LOCATION .........................................................................................................................................43
CHAPTER 5: MAINTENANCE......................................................................................................................45
MAINTENANCE SCHEDULE.................................................................................................................................45
DAILY:...............................................................................................................................................................45
WEEKLY: ...........................................................................................................................................................45
MAY AND DECEMBER CHECK-UPS ....................................................................................................................45
LUBRICATION REQUIREMENTS...........................................................................................................................46
LINEAR BEARINGS: ............................................................................................................................................46
FLANGE BEARING: .............................................................................................................................................46
LUBRICATE SPECIAL HIGH-SPEED BEARINGS:...................................................................................................46
PERSKE HIGH-FREQUENCY MOTORS: ................................................................................................................46
APPROVED LUBRICATION PRODUCTS:................................................................................................................46
LUBRICATOR ADJUSTMENTS:.............................................................................................................................46
GEAR MOTOR LUBRICATION REQUIREMENTS:...................................................................................................46
MIST OIL LUBRICATION:....................................................................................................................................46
PRIMING THE LUBRICATOR:...............................................................................................................................46
CHAPTER 6: TROUBLESHOOTING............................................................................................................49
LIMIT SWITCHES ................................................................................................................................................49
PHOTO EYES ......................................................................................................................................................49
GENERAL AIR CIRCUITRY TROUBLE SHOOTING: ...............................................................................................50
To change cylinder retraction speed: .........................................................................................................................51
BASIC ELECTRICAL TROUBLESHOOTING:...........................................................................................................52
If the power stops during normal operations: DE-ENERGIZED:..............................................................................52
FRONT SECTION DOES NOT FUNCTION PROPERTY:............................................................................................53
Front section is not turned on at the control panel: ....................................................................................................53
The Six-Shooter is not moved fully to the right:........................................................................................................53
The through-beam lenses are dirty:............................................................................................................................53
CYLINDERS THAT MOVE THE FRONT SECTION ....................................................................................................54
Move front section to the “In Pocket Position”, then do the following:.....................................................................54
One of the cylinders is malfunctioning:.....................................................................................................................54
The alignment of the cylinder shafts is off.................................................................................................................54
There is and obstruction blocking the through beam. ................................................................................................54
Guards are misaligned: ..............................................................................................................................................54
Through-beams are misaligned:.................................................................................................................................54
Ferrous Proximity Eye that controls the router carriages movement down and to the right is out of adjustment:......54
One or more through-beams are malfunctioning: ......................................................................................................55

10
Environment too cold:............................................................................................................................................... 55
WIDTH-ADJUSTS DOESN’T FUNCTION PROPERLY................................................................................................55
Width-adjust photo eyes on back section arm on in-feed side are positioned too close to the edge of the door:....... 55
UNSATISFACTORY HINGE POCKETS ...................................................................................................................55
Fuzzy Hinge Pockets:................................................................................................................................................55
Ring around the Pocket:............................................................................................................................................ 55
Feed System Surging: ............................................................................................................................................... 55
Feed system moving doors too fast:.......................................................................................................................... 55
Setting up bolt plate length: ...................................................................................................................................... 56
Lock bore two-stage face drilling:............................................................................................................................. 56
990F-3 SIX-SHOOTER.........................................................................................................................................56
Six-Shooter keeps running after cycle is completed:................................................................................................. 56
Hopper Alignment: ...................................................................................................................................................57
Machine hinge pockets (without pre-drill)................................................................................................................ 57
Hinge Laps Side of Pocket or Screws Pulled Sideways: ........................................................................................... 58
Adjusting the screw receiver block horizontally: ...................................................................................................... 58
Bit points centered: ................................................................................................................................................... 58
Hinge Laps top or bottom of pocket:......................................................................................................................... 58
Two hinges- bit points too height or too low:............................................................................................................ 58
All four hinges-bit marks too high or too low:.......................................................................................................... 59
Hinge Laps Corners of the Pocket:............................................................................................................................59
Bit Points cocked at an Angle: .................................................................................................................................. 59
Crooked Screws:....................................................................................................................................................... 59
Split Shell Adjustments:............................................................................................................................................ 59
Screw Driver Bits:..................................................................................................................................................... 59
Speed of Six-Shooter going in: ................................................................................................................................. 60
LOOSE SCREWS ..................................................................................................................................................60
All Screws Loose:..................................................................................................................................................... 60
Loose Screws at the Top or Bottom of the Hinge:..................................................................................................... 60
Loose Screws On the Side of the Hinge:...................................................................................................................60
Stripped or Broken Screw Heads: ............................................................................................................................. 60
Kick-Out:.................................................................................................................................................................. 61
Six-Shooter Multi-Wood Density Screw Stop: ......................................................................................................... 61
Not Enough Power to Drive Screws:......................................................................................................................... 61
HOPPER TROUBLESHOOTING..............................................................................................................................61
Missing Screws:........................................................................................................................................................ 61
Avoid Stacking Screws:............................................................................................................................................ 61
Magnetized Screws: .................................................................................................................................................. 62
Not feeding Between the Hopper and Screw Feeder Slides: .....................................................................................62
Jamming of the Slide Bar:......................................................................................................................................... 62
Screws ejecting from hopper:.................................................................................................................................... 62
Screws ejecting from pick off bar: ............................................................................................................................62
Hinge and Screw Quality:......................................................................................................................................... 63
WARRANTY......................................................................................................................................................65
BILLS OF MATERIALS...................................................................................................................................67
OPTION R1 –JAMB CLAMP TUBE...............................................................................................................67
OPTION R1 –BACK SECTION.......................................................................................................................68
FRAME SECTION............................................................................................................................................69
HEAD SECTION..............................................................................................................................................71
BACK SECTION..............................................................................................................................................72
SCREW CHANGING HOPPER.......................................................................................................................74
SIX SHOOTER .................................................................................................................................................75
EIGHT SHOOTER............................................................................................................................................76
NOTES ................................................................................................................................................................79