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

1
Chapter 1: Introduction
Customer Service Information
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.
Returning Parts / Equipment to KVAL
Before returning parts and/or equipment to Kval Inc. please call KVAL at [phone] to
receive a RMA # (Return Merchandise Authorization number).
* Note
Non-Warranty returns are subject to 15% Re-stocking Charge.
When you call:
Have your Packing Slip and/or invoice #’s available
Have reason for return available
When sending merchandise back:
Make sure that the Item(s) you are returning are securely packaged and well protected from
shipping damage.
Including Packing Slip #
Include your RMA # with the parts package.
Kval tries hard to satisfy its customers; if you have any questions concerning merchandise
purchased through KVAL, please call.

3
Getting Started
Your new KVAL Machine arrives at your plant crated, banded, taped and has painted set collars
on all shafts; keeping all of the precision moving parts secure during shipping.
SEE SECTION “UNCRATING THE 990F-3” FOR INSTRUCTIONS ON UNCRATING
AND SET-UP.
NOTE
KVAL wants to provide the industry’s safest and highest quality wood working machines. The
following page is a quality control and safety checklist. Our technicians have already performed
an initial quality control check before shipping your machine. Please review the checklist and
return “Acknowledgment Copy” to KVAL verifying complete contents.

5
Chapter 2: Safety Information
This section contains important safety information. Failure to follow these safety guidelines may
subject the operator to physical hazards that may result in serious bodily harm or death.
Safety Procedures
Responsibility
It is the responsibility of each employee to maintain safe working conditions in his or her area.
Failure to understand and correctly follow this procedure is direct violation of safety rules and
regulations. Violations of this policy can lead to severe injury.
Lock-out/Tag-out Procedure
To lock out or tag out a piece of equipment, the following steps must be taken:
Assess the equipment to fully understand all energy sources (multiple electrical supplies air and/or
hydraulic pressures, spring tension, weight shifts, etc.)
Inform all affected personnel of the eminent shutdown, and the duration of the shutdown.
Obtain lock and tags from employer.
Shutdown machine(s) by normal means, i.e., disconnect switch(es), air pressure relief valve(es),
on/off button, etc. NOTE: Control power switches do not serve as adequate shutdown devices.
The main source(s) of energy must be disconnected as well. Also, ensure that all mechanically
stored energy has been released, i.e., lifting booms lowered to bottom of travel, carriages in
“HOME” position etc., No one may remove a tag or lock installed by someone else. Only the
person who attached the tag or lock is authorized to remove it.
Once the lock and tag is in place, the employee must try to operate the machine to ensure all
energy sources are defeated.
When maintenance or repairs are completed, the person that did the work must ensure all tools,
spare parts, test equipment, etc. are completely removed and that all guards and safety devices are
installed.
Before removing the lock and tag, the person who attached them shall inspect the equipment to
ensure that the machine will not be put in an unsafe condition when re-energized.
The lock and tag can now be removed (only by the person who place them), and the machine can
be re-energized.

6
The tag shall be destroyed and the lock and key returned to the lockout center.
In addition to safety concerns, this policy is required by OSHA regulation 1910.147 and Cal
OSHA’S SB198 ruling of July 1991.
Lock-Out and Tag-Out Procedure
1. P .... PROCESS SHUTDOWN
2. R .... RECOGNIZE ENERGY TYPE
3. O .... OFF - SHUT OFF ISOLATING DEVICES
4. P .... PLACE LOCK AND TAG
5. E .... ENERGY RELEASE STORED ENERGY (0 ENERGY STATE)
6. R .... RECHECK CONTROLS AND RETURN TO PROPER SETTING

7
ENERGY TYPES—Recognize the Types of Energy to Shut Down
1. Electrical Energy
2. Hydraulic and/or Pneumatic Energy
3. Fluids and Gases
4. Mechanical Energy
Accident Situations
• Accidental Start Up
Equipment can accidentally be turned on and your hands may be in the point of operation or while you
are inside.
• Electrical Shock
You can be accidentally electrocuted if the power is still on or if it is accidentally turned on.
• Hazardous Materials
If released can go into confined areas or the work area.
• Stored Energy
You could be caught in equipment that can move due to stored energy, even with the power off.
The Solution Is Quite Simple — These Accidents Can Be Prevented Using The P-R-O-P-E-R
Lock-Out Procedures.
Lock Rules
1. Use Locks and Tags
Use an appropriate “Lock-Out Device”, such as Lock Tongs, or a Lock Tag. Each person must attach
his or her own lock to the Lock-Out Device.
2. Identify Locks
Each lock will be identified by a number or a name. A lock without a tag is not good enough.
Additional information that identifies the person / persons doing the work must be on the tag. Also the
type of work that is being performed should be on the tag.
3. Sign The Tag
In some instances one tag is enough, however, the tag must be signed by each worker. In some
circumstances a supervisor will also need to sign the tag.
4. One Key Per Lock
5. Never give your key to anyone else.

8
P-R-O-P-E-R Electrical Lock-Out
P Process Shut Down
Open disconnect before pulling the plug. Shut down process or equipment.
R Recognize Energy Type
Recognize the correct power source.
O Off! -Shut Off all Power Controls
Shut off machine and electrical energy at both machine and main power switch. There may be more
than one source of power and all must be shut off. If necessary, electrical drawings and a supervisor
may need to be involved.
P Place Lock-Out Device, Lock and Tag
Each person working on equipment needs to put his or her lock on the switches and sign the tag.
E Energy - Release Stored Energy
Bleed electrical capacitors if any.
R Recheck Controls and Return To “OFF” Setting
Recheck the start button and properly test that you have zero-energy state.
P-R-O-P-E-R Hydraulic And/Or Pneumatic Lock-Out
P Process Shut Down
Shut down process using recommended procedures.
R Recognize Energy Type
Recognize all sources of energy – the electric that powers the pumps or compressors, and the air or
hydraulic valves themselves.
O Off! -Shut off all Power Controls
Shut off each energy type.
P Place Lock-Out Device, Lock and Tag
The shape or location on some valves may be difficult to lock out. If there is not a specific lock out tag
out procedure in place you should ask your supervisor.
E Energy - Release Stored Energy
Bleed the stored energy by bleeding the air line and draining the compressor, or by using other
prescribed methods. Keep in mind that when bleeding stored energy
it could cause some parts of the equipment to move, as it is being held by the stored energy.
R Recheck Controls and Return To “OFF” Setting
Return controls to proper settings.

9
P-R-O-P-E-R Fluids And Gases Lock-Out
P Process Shut Down
Shut down process using recommended procedures.
R Recognize Energy Type
Recognize the material and its hazards. If material is hazardous, use the proper protective equipment.
Even water can become a hazardous fluid under high
pressure.
O Off! -Shut Off all Isolating Valves
If a job requires breaking in to a line close off isolating device, blanking if necessary. Some valves
may be difficult to lock out. A locking bar or chains may be
needed. Check with supervisor.
P Place Lock-Out Device, Lock and Tag
Sign tag.
E Energy - Release Stored Energy
Release pressure and drain to achieve zero energy state.
R Recheck Controls and Return “OFF” Setting
Recheck line and test properly and make sure you have zero energy state.
P-R-O-P-E-R Mechanical Energy Lock-Out
Mechanical Energy may be released at the point of operation, or where two or more points of
operation come together. This is where you might get caught. In most cases
blocking mechanical energy is done in addition to shutting off the primary source, such as electrical,
hydraulic and pneumatic. Some examples include inserting restraining pins or bars in the point of
operation or block under a lift. In cases where these blocks to mechanical energy are not locked in
place, they should not be the primary means of
shutting off energy. Mechanical energy can also be stored.
1 Gravity
Things that are up can fall of their own weight. Pins or blocking may be required.
2 Springs
BOING! can spell DEATH. Release tension or compressed springs by using methods prescribed by the
equipment manufacturer.
3 Tensions
Things under tension can spring in. Release tension by using prescribed method by equipment
manufacturer.
P Process Shut Down
Shut down the process.
R Recognize Energy Type
Recognize all forms of energy – Need to be shut off, such as electrical and mechanical. Mechanical is
usually a secondary energy source closest to point of operation.
O Off! -Shut Off all Power Controls
Such as switches, valves and other isolating devices.

10
P Place Lock-Out Device, Lock and Tag
Place lock on the isolating device and sign tag.
E Energy - Release Stored Energy
Release, spring or tension to achieve, zero energy state.
R Recheck Controls and Return To “OFF” Setting
Zero-Energy Start Up
Zero-Energy State to Start-up to Operating State
Starting the equipment is just as important as Lock-Out/Tag-Out in terms of safety.
Start-up
• Inspection
• Clean up
• Replace guards
• Check controls
• Remove locks
• Visual checks
Inspect
When work is finished the equipment must be inspected for proper adjustment before starting
equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials and old parts used during
repairs must be cleaned up.
Replace Guards
Replace all guards to the equipment. If adjustments can not be made with the guard on after start-up,
leave off only the ones to be adjusted after start-up.
Check Controls
Make sure all switches are in the off position. In some cases the machine can start automatically when
energy is restored.
Remove Locks
Each person must remove his or her own lock or tag. This will ensure you are in a safe place when the
equipment is started.
Visual Checks
If the equipment is too large to see all around it, station personnel around the area and sound the
personnel alarm before starting the equipment. If your operation is more complex, having many pieces
of equipment and a lot of people, a comprehensive Lock-Out/Tag-Out procedure may involve
additional steps. You will need to ask your supervisor about these procedures. A specific lock out
procedure may be posted at each machine. On larger or long term maintenance projects or installation
projects, the procedures should be explained to all participants and a copy of the procedures posted on
site for the duration of the work. Provisions which ensure protection during shift changes when
contractor or outside help is used also need to follow the Lock-Out/Tag-Out Procedures.
Comprehensive Lock-Out/Tag-Out may use a gang box or other system to ensure that locks are secure
and not removed without authorization.
Remember Lock-Out Tag-Out procedures work because you are the only one with the key to your
lock. Proper Lock-Out/Tag-Out can save lives, limbs and money. Help make your work environment