Kval 994-X Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: 11/20/2017
994-X Pre-Hanging Door System
994-X Pre-Hanging Door System

KVAL 994-X Operation/Service Manual
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This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and is to be used solely by Customer as an operating manual
for KVAL Inc. machines. Neither this Manual nor any of the information contained
herein may be reproduced or disclosed under any circumstances without the express
written permission of KVAL Inc. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC-204_2-OPS (Start at SN 025)
The 994-X Door Hanging System is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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• Business hours:
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(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL 994-X Operation/Service Manual
KVAL 994-X Operation/Service Manual
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KVAL 994-X Operation/Service Manual

KVAL 994-X Operation / Service Manual
Chapter 1 Intro to the 994-X Door Hanging System
Overview of the 994-X Door Hanging System......................... 1-2
Available Options..................................................................................1-3
About this Manual.................................................................................1-5
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................................1-6
Lockout-Tagout Guidelines...................................................... 1-10
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10
Lockout Tagout Procedure....................................................... 1-11
Pre-Steps Before Lockout Tagout.......................................................1-11
Lockout Tagout Power........................................................................1-11
Lockout Tagout Air Supply..................................................................1-12
Start Maintenance...............................................................................1-12
Post Maintenance Steps.....................................................................1-12
Zero-Energy to Start-Up........................................................... 1-13
Getting Help from KVAL........................................................... 1-15
On-Line Help.......................................................................................1-15
Product Return Procedure..................................................................1-15
How to Download the Service Application............................... 1-17
Download Application.........................................................................1-17
Safety Sign-Off Sheet.............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 Operation of the 994-X
Operator’s Tour........................................................................ 2-2
Options Available..................................................................................2-2
The 994-X will:......................................................................................2-2
Machine Components...........................................................................2-2
Overview of Machine............................................................... 2-3
Operator Controls.................................................................... 2-4
Operator’s Station.................................................................................2-4
Machine Control....................................................................................2-4
Door/Jamb Foot Pedal..........................................................................2-5
In-Feed Section ....................................................................... 2-6
Door Stops............................................................................................2-7

994-X Door Hanging System
Opt N: Weather Strip Brackets..............................................................2-7
Front Section ........................................................................... 2-8
Hinge Carriage......................................................................................2-9
Option: Securing Split Jambs..............................................................2-11
About the Six /Eight Shooter System....................................... 2-12
Option K: Eight Shooter......................................................................2-13
About the Six/Eight Shooter Controls.................................................2-14
About the Hopper................................................................................2-15
Driver Assembly..................................................................................2-17
Option: Quick Change Knuckle Assembly..........................................2-18
About the Overhead Track..................................................................2-19
Option V: Narrow Door Support..........................................................2-20
Back Section:........................................................................... 2-21
Front View of Rear Section.................................................................2-21
Back View of Rear Section................................................................2-22
Opt SB: Back View of Rear Section....................................................2-23
Opt BC: Ball Catch Motors..................................................................2-24
Out-Feed:................................................................................. 2-25
Option O: Air Blow Off ........................................................................2-26
Option IL: Left Hand / Right Hand Door Indicator...............................2-26
About the Electrical Panels...................................................... 2-27
Main Electrical Panel..........................................................................2-27
High Frequency Panel........................................................................2-28
Description of the Six Light Panel ........................................... 2-29
About Sensors......................................................................... 2-30
Quick Start............................................................................... 2-31
Powering Operations for the 994-X ......................................... 2-33
How to Power Up the 994-X...............................................................2-33
Home the 994-X..................................................................................2-34
How to Power Down the 994-X...........................................................2-34
Emergency Shutdown and Recovery .................................................2-35
Description of User Interface Screens..................................... 2-36
Screen Selection Menu Map...............................................................2-36
Machine Feed Back............................................................................2-36
Controlling Access to User Screens...................................................2-36
Menu Maps of the Operator Screens....................................... 2-37
About the Main Screen ............................................................ 2-39
About the Setup Screens......................................................... 2-43
AR-HQ2 Option...................................................................................2-39

KVAL 994-X Operation / Service Manual
About the Setup Hinges 1-4 Screens .................................................2-45
About the Pre-Drill Screen..................................................................2-47
About the Manual Operation Screens...................................... 2-49
About the Diagnostic Screen................................................... 2-52
Option SB: About the CNC Back Section Operator Screens... 2-53
Option SB: Main Menu Screen..........................................................2-53
Option SB: Lock Calibration Screen...................................................2-54
Option SB: Lock Access Buttons........................................................2-55
Chapter 3 Calibration of 994-X
About Calibration..................................................................... 3-2
Before you Calibrate.............................................................................3-2
Flow Chart of Calibration .....................................................................3-3
About the KVAL Calibration Routine........................................ 3-4
Calibration Slot Drilling Specifications ..................................................3-5
Run the Calibration Routine..................................................... 3-6
Select Calibration..................................................................................3-6
Select Door Parameters .......................................................................3-6
Load the Door and Start the Cut...........................................................3-6
Check Specifications of the Front Section............................... 3-7
Enter a Positive or Negative Number? .................................................3-7
General Instructions to Adjust Parameters...........................................3-8
Step 1: Hinge Carriage Calibration.......................................................3-9
Step 2: Router Calibrations.................................................................3-12
Step 3: Pre-Drill Calibration ................................................................3-13
Step 4: (Option CH) Chisel Calibration...............................................3-15
Calibration of the Back Section................................................ 3-17
Lock Location Calibration ...................................................................3-17
Fast and Slow Lock Plate Timing .......................................................3-18
Option SB: CNC Back Section Calibration .........................................3-19
Chapter 4 System IT Administration
System IT Administration......................................................... 4-2
About the 994-X Computer...................................................................4-2
Connections on the PLC.......................................................................4-2
Backing up the Computer.....................................................................4-3
About Remote Connection to KVAL Service.........................................4-3
About the Machine Calibration Screen ...............................................2-43

994-X Door Hanging System
Chapter 5 Maintenance of the 994-X
Maintenance Schedule............................................................ 5-2
300 Cycle Maintenance Steps................................................. 5-4
Clean, Clean, Clean!.............................................................................5-4
600 Cycle Maintenance Steps................................................. 5-5
Check Air Gauges and Inspect Water Traps ........................................5-5
Inspect Tooling......................................................................................5-5
Lubricate inside of Hopper....................................................................5-6
Empty Dust Collection Units.................................................................5-6
3,000 Cycle Maintenance Steps.............................................. 5-7
Inspect Feed Belts................................................................................5-7
Inspect Screw Drop Tubes on Six Shooter...........................................5-7
Inspect all Photo Eyes..........................................................................5-7
Inspect Limit Switches..........................................................................5-8
Inspect Screw Receiver Parts...............................................................5-8
Inspect Airlines .....................................................................................5-9
Refill Lubricators...................................................................................5-9
Grease Ball Screw Bearings...............................................................5-10
Clean Bearing Shafts..........................................................................5-10
12,000 Cycle Maintenance Steps............................................ 5-11
Inspect Chains for Proper Tension......................................................5-11
Inspect Air Cylinders...........................................................................5-11
Inspect Hydraulic Lines.......................................................................5-11
Inspect Ball Rail Shafts.......................................................................5-12
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........5-12
Clean inside Hopper...........................................................................5-12
72,000 Cycle Maintenance Steps............................................ 5-13
Inspect Nuts and Bolts........................................................................5-13
Check Door Feeding Transition..........................................................5-13
Electrical.............................................................................................5-13
Computer Backup...............................................................................5-13
Wash Filter and Lubricator Bowls.......................................................5-13
Tool Changing Schedule.......................................................... 5-14
Maintenance NO-GOES.......................................................... 5-16
Lubrication Schedule............................................................... 5-17
Lubrication Requirements........................................................ 5-18
Linear Bearings, Flange Bearing, and Pillow Blocks..........................5-18
Gear Motor Lubrication Requirements................................................5-19
Ball Screws (If Applicable)..................................................................5-19

KVAL 994-X Operation / Service Manual
Description of Air Input System ..........................................................5-19
Adjusting the Air Line Lubricator.........................................................5-20
Priming the Air Line Lubricator ...........................................................5-20
Replacing Tooling in the Front Section.................................... 5-21
Replacing Bits in the Front Section.....................................................5-21
.How to Access to Bit Assemblies ......................................................5-22
Remove and Replace the Router or Pre-Drill Bits..............................5-22
Remove and Replace the Chisels ......................................................5-24
Remove and Replace the Screwdriver Bits........................................5-24
Replacing Tooling in the Back Section..................................... 5-26
Option SB (CNC Back Section)..........................................................5-26
Changing the Bore Drill.......................................................................5-26
Changing the Bolt Drill........................................................................5-27
Collet Torque Values................................................................ 5-28
Types of Torque Tool Heads...............................................................5-28
Chapter 6 Troubleshooting the 994-X
About Motion Control............................................................... 6-2
Basic Control Circuit.............................................................................6-2
Typical Positioning Systems.................................................................6-4
Troubleshooting Basics .......................................................... 6-7
Before you Adjust .................................................................................6-7
Analyze the Sub Systems.....................................................................6-8
About a Typical Contactor Control........................................... 6-10
About Contactor Troubleshooting.......................................................6-11
About Typical VFD Motor Drive Control................................... 6-12
About the VFD....................................................................................6-13
About VFD Troubleshooting ...............................................................6-14
About a Typical Pneumatic Circuit........................................... 6-15
Typical Pneumatic Assembly..............................................................6-16
About the Coil (Solenoid)....................................................................6-16
About Cylinder Operation ...................................................................6-17
How the Pneumatic System Works ....................................................6-17
Important Notice about Adjusting Cylinder Speed..............................6-19
Adjusting Cylinder Extend Speed .......................................................6-20
Adjusting Cylinder Retraction Speed.................................................6-20
Using Sensors to Trouble Shoot.............................................. 6-21
Location of Sensors on 994-X ................................................. 6-22
Z Axis and Y Axis Front Section Sensors...........................................6-23

994-X Door Hanging System
X Axis Sensors Front Section.............................................................6-24
Troubleshooting Electrical Problems ....................................... 6-25
If the Power Stops During Normal Operation......................................6-25
Troubleshooting with the Status Light Panel ......................................6-26
Network System Overview....................................................... 6-31
Connections to Servo Drives..............................................................6-32
Connections to VFD’s (High Freq Panel)............................................6-33
Symptoms and Possible Causes............................................. 6-34

1-1
CHAPTER 1 Intro to the 994-X Door Hanging System
This chapter provides an overview of the KVAL 994-X Door Hanging System and important
safety information to follow when operating the machine.
Chapter 1 at a Glance
TABLE 1- 1.
Section Name Summary Page
Overview of the 994-X System This section provides an overview of the 994-X. This section
includes a general description and a table of available options Page 1-2
Safety! IMPORTANT safety information is described in this section Page 1-6
Zero-Energy to Start-Up Procedure to power up your machine for the first time. Page 1-13
Getting Help from KVAL This section describes the method to contact the KVAL service center
for help. The section includes how to get information from the speci-
fication plate tor provide to KVAL, service center hours, and return
procedures
Page 1-15
Safety Sign-Off Sheet A record to track operators that are trained on the machine. Page 1-20

Overview of the 994-X Door Hanging System
KVAL 994-X Operation/Service Manual
1-2
Overview of the 994-X Door Hanging System
KVAL's 994-X offers a high-speed pre-hanging line with the additional flexibility of servo con-
trolled hinge routing sections. This includes high frequency spindles and programmable point to
point pre-drilling.
The 994-X is designed for both interior, exterior doors and jambs. It will accommodate 1-3/8" and
1-3/4" thick doors with a minimum width of 18" and a maximum width of 42”. Door lengths of 6'
8" or 8' 0" can both be machined. Hinge locations automatically shift between two pre-determined
factory set locations to accommodate both three hinge pockets (6’-8”) and four hinge pockets (8’).
Changeover does however require manual repositioning of the jamb clamp fixtures but can easily
be accomplished in under two minutes without the use of tools.
The door is power-fed into the machine and clamped into position. After the hinges are attached,
and machining is finished, the door and jamb automatically is off-feed as the next door enters the
machine
Hinge routing sections are completely servo controlled for pocket height, width, and depth. Each
hinge routing section is equipped with two 1-1/2 HP High Frequency spindle motors, one for rout-
ing and one for pre drilling on both the door and jamb. Servo motors allow the hinge router to
accelerate out of and decelerate into hinge corners eliminating over travel. Changeover from 3-1/
2” to 4” hinges is accomplished by selecting the desired size on the touch-screen.Our Point to
Point Pre-Drill system can be programmed to drill all common hinge patterns automatically.
Additionally, the use of servo motors allows you to machine both 1/4” and 5/8” radius corners
without changing out tooling.
Hinges may be attached manually or with the optional Six-Shooter to install 3-1/2" X 3-1/2"
hinges, or the optional Eight-Shooter for attaching 4" X 4" hinges while the door and jamb remain
clamped in position. Door-to-door productivity, including hinge mounting, is typically 35-55 sec-
onds. However, this varies depending on the operator and material flow.
The lock machining assembly will be positioned with a single servo driven ball screw. This is
controlled by the touch screen, and will allow settings for standard lock and dead bolt locations
based on the lock bore location. A third dead bolt bore may easily be added by entering the posi-
tion on the touch screen. The servo driven system will automatically position the lock boring
assembly when the door hand is changed. Lock detailing includes 2-1/8” face boring with push
button change over between 2-3/8” and 2-3/4” back sets; 1” bolt drill and face plate routing. Face
plate routing will be accomplished with a 1-1/2 hp Hi-Frequency spindle motor.
The 994-X will accommodate doors with raised molding one or both sides up to 3/4" high, and a
minimum of 4" between the raised molding and the edge of the door.
This machine is equipped with a solid state touch screen that replaces many of the mechanical
switches for the machine functions. The touch screen also includes the capability to view the sta-
tus of the various photo eyes and switches for quick diagnosis when needed, without having to
open the electrical panel or for the operator to leave his work station. The Touch Screen logic also
includes management functions such as Daily and Lifetime Totals.

Overview of the 994-X Door Hanging System
1-3
KVAL 994-X Operation/Service Manual
About the Six Shooter
The 6- Six-Shooter screw gun will attach 3-1/2" X 3-1/2" hinges to the door and jamb, # 9 X 3/4"
long flat head screws are automatically sorted and fed, six at a time, to the screw gun. The opera-
tor manually places the hinge onto the magnetic indexing fixture and then rolls and pivots the Six
Shooter into an "H" block at each hinge location to attach the hinges. Pressing the 'Reset' switch
then raises the Six Shooter and feeds a set of six screws for the attachment of the next hinge.
The Six Shooter, which is supported on ball bearing equipped steel wheels and is mounted on an
overhead track. The track and the Six Shooter are precisely aligned to ensure the hinge is properly
position into the pocket at each hinge location.
Available Options
For detailed information about available options, please contact our KVAL Sales and Service
department.
Option Title Description
Option A Six Shooter Gun for 3-1/2'' X 3-1/2'' To attach 3-1/2" X 3-1/2" hinges to the door and jamb, No. 9 by 3/4"
long flat head screws are automatically sorted and fed, six at a time, to
the screw gun. Operator manually places the hinge onto the magnetic
indexing fixture and then rolls and pivots the Six Shooter into an "H"
block at each hinge location to attach the hinges. Pressing the 'Reset'
switch then raises the Six Shooter and feeds a set of six screws for the
attachment of the next hinge. 
NOTE: Requires Option D: Pre-Drill System for Six Shooter. 
The Six Shooter, which is supported on ball bearing equipped steel
wheels, is mounted on an overhead track that is precisely aligned to
ensure the hinge is properly position into the pocket at each hinge
location.
Option
AC: Metal Door Sensing Proximity Switch Allows operator to do the edge prep on a steel door without acciden-
tally doing a face bore into the door.
Option BC Ball Catch Drills Drill assemblies are mounted onto the lock boring section for drilling
left hand and right hand doors for drive-in ball catches. When selected
the proper drill automatically pivots in to drill into the top of the door.
Note, minimum door width for drilling is 18".
OptionCH Corner Square Chisels Corner Square Option adds automatic corner squaring to the hinge
routing sequence in both the door and jamb. Option includes two
chisel mounting blocks per head, each one containing two chisels. As
one chisel is operating, the inactive chisel is in the reveal between the
door and jamb. For instance, when you are squaring the upper right
corner in the jamb, the lower right chisel will be in the reveal. When
the lower right chisel is squaring the lower right corner in the door, the
upper right chisels in the reveal. Although two chisels are paired
together in one mounting block, each one is independently calibrated
for vertical and horizontal travel as well as depth.
Option CR Counter Rotating Routers The standard 994X relies on automatic chip-out blocks clamped
between door and jamb to protect the door face and jamb edges from
chipping during hinge routing. This option eliminates the chip-out
blocks by adding four extra routers to the hinge detailing section with
left hand rotation. As hinge pockets are routed, the left hand rotating
routing tool is used to minimize chipping of the door face or jamb
edge.

Overview of the 994-X Door Hanging System
KVAL 994-X Operation/Service Manual
1-4
Option E Two-Stage Drilling Allows changeover for two different face bore sizes with a selection
on the control panel.
Customer to specify 1-1/2” or 1-5/8” for dead bolt face bore when
ordering. Standard lock boring bit is 2/1/8".
Option IL Door Hand Indicator Light Light will be mounted on the out-feed end of the 990-F4 that can be
seen by the 700-C Assembly Table operator. The light will be on when
the door in the 994-X is being machined as a right hand door and off
for a left hand door.
Option K Eight-Shooter Screw Gun for 4" X
4" Hinge To attach 4" X 4" hinges to the door and jamb, No. 10 by 3/4" long flat
head screws are automatically sorted and fed, eight (8) at a time, to the
screw gun. Operator manually places the hinge onto the magnetic
indexing fixture and then rolls and pivots the Eight Shooter into an
"H" block at each hinge location to attach the hinges. Pressing the
'Reset' switch then raises the Eight Shooter and feeds a set of eight (8)
screws for the attachment of the next hinge.
Option O Door Blow-Off System Air blow-off tube cleans dust and chips from top of door as it feeds out
of the 994-X.
Option N Weatherstrip Retaining Brackets Isolates Weather Strips during the routing process. A protective bar
across top of H block keeps the strip up and away from the routers.
Option SB Servo Backsection with Corner
Squaring The 994-X system combines very high quality hardware detailing,
with high speed productivity. Unique features include computer con-
trolled ball screw movements for all router and chisels, complete with
square lock face plates. Backsection will have the ability to machine a
face plate at both "0" and "3" degree. Operator can select widths from
1" to 1-1/4" wide and up to 2-3/4" in length.
Option R1 Zero & Three Degree Hinge Rout-
ing Price includes PLC logic and controls to allow front hinge routing sec-
tion to rout on either a 0 degree or 3 degree angle.
Hinges will be flush mounted when installed on doors with either
square edge or 3 degree bevel on hinge side
OptionUH Top Hinge Dimension Different for
6'-8" and 8'-0" Door In-feed door and jamb stops will be movable. Door stop will be cylin- der actuated.
NOTE: Specifications for hinge locations must be provided in order to
prepare quotation.
Option W Hinge Stops for 6'8", 7'0" & 8'0"
Doors This option is limited to certain hinge pocket locations. Hinge location specifications need to be submitted in order to determine if they can be
accommodated with the 994-X.
Option Z Screw-Changing Hopper for Six
Shooter Screw-changing hopper for changing screw colors.
Option Z1 Quick-Change Hopper for Eight
Shooter Screw changing hopper for 8-Shooter allows for rapid change of
screw colors.
Quick Change Knuckle Hinge Switch located on the 8-shooter hinge applicator which provides the
ability to switch from a standard (narrow barrel) knuckle hinge to a
wide spring-knuckle hinge. Changeover time between knuckle sizes is
1 second.
Option Title Description

Overview of the 994-X Door Hanging System
1-5
KVAL 994-X Operation/Service Manual
About this Manual
This manual contains operation information and service and maintenance information.
It includes identification of machine assemblies, power-up and power-down steps, and informa-
tion about using the user interface.
The Troubleshooting and Maintenance sections are directed toward qualified service
technicians
TABLE 1- 2.
Title Part Number
994-X Operation and Service Manual DOC-204_2-OPS
Narrow Door Support Supports doors between 12" - 16”
Structure utilizes air cylinders and 7 pairs of industrial wheels for sup-
port - mechanism is automatically put in and out of position via a
selection
Split Jamb Staplers Two 1/4" crown staple guns are mounted onto the jamb clamp brack-
ets. While clamped in the machine, staples will be driven into the back
side of the split jamb to keep the male and female together.
The staple guns are fired with a single valve that is interlocked with a
safety switch to disable the staple guns unless there is a jamb clamped
in the machine.
Two staple guns with remote fires are required and are not included in
the price of the option.
Option Title Description

Safety First!
KVAL 994-X Operation/Service Manual
1-6
Safety First!
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 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 1-20.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide 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.
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.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training

Never operate the machine without proper eye and
ear protection.
Protective Gear
• 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.
• 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.
When the Machine is ON
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 mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-11.
Compressed Air
Safety First!
1-7
KVAL 994-X Operation/Service Manual

Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
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. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
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.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.
Safety First!
KVAL 994-X Operation/Service Manual
1-8

KVAL advises that you request an on-site state
safety review of your installation of this
machine. This is to ensure conformance to any
additional specific safety and health regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety proce-
dures to follow.
Safety First!
1-9
KVAL 994-X Operation/Service Manual

Lockout-Tagout Guidelines
KVAL 994-X Operation/Service Manual
1-10
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On the tag, each
operator must put their own name and date.
(These locks are only to be removed by the
person who signs the tag)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
O...... OFF! Shut off all power sources and isolating devices
P...... Place lock and tag
E...... ENERGY: Release stored energy to a zero-energy state
R ...... Recheck controls and test to ensure they are in the “OFF” state