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Congratulations on your purchase of a new KVAL

555

SERIAL
No

._____________________________________________

DATE OF
PURCHASED

___________________________________

This manual is designed with safety in mind. We at KVAL want to begin
FAST and SAFE production as soon as possible. It is very important that
all OPERATORS and MAINTENANCE personal 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.

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Summary of Contents for 555

Page 1: ... KVAL INC INSTRUCTION MANUAL 555 Door Sizer REV 2 ...

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Page 3: ...l rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated 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 there to are the sole and exclusive pr...

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Page 5: ... begin FAST and SAFE production as soon as possible It is very important that all OPERATORS and MAINTENANCE personal 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 p...

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Page 7: ...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 HOURS 6 30 AM to 4 30 PM Pacific Standard Time Monday thru Friday Phone 800 553 5825 Fax 707 762 0485 www kvalinc com 6 ...

Page 8: ...ve your Packing Slip and or invoice s available 2 Have reason for return available When sending merchandise back 1 Make sure that the Item s you are returning are securely packaged and well protected from shipping damage 2 Including Packing Slip 3 Include your RMA on the outside of the package so our shipping receiver will see it Kval tries hard to satisfy its Customers if you have any questions c...

Page 9: ...ted to the shafts 4 Take off any tape securing the various buttons switches and knobs 5 Level your KVAL machine by putting metal shims underneath the corners of the base Leave a clear shot from the bolt holes in the foot pads to your shop floor Now make sure the machine won t rock back and forth 6 Once the machine is level anchor it to the floor so that it won t move across the floor during operat...

Page 10: ...afetyFirstDanger 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 arm or death 9 ...

Page 11: ...mployer 4 Shutdown machine s by normal means i e disconnect switch s air pressure relief valve s 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 remo...

Page 12: ...fe condition when re energized 8 The lock and tag can now be removed only by the person who place them and the machine can be re energized 9 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 11 ...

Page 13: ...Mechanical Energy ACCIDENT SITUATIONS Accident 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 equip...

Page 14: ... key to anyone else Recheck controls and return to proper setting 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 powe...

Page 15: ... 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 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 wa...

Page 16: ...p 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 manufacture 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 energ...

Page 17: ... 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 s...

Page 18: ...ite state safety review of your installation of this machine This is to ensure conformance to any additional specific safety and health regulations which apply in your area OPERATORS TRAINING You must ensure that all operators of this machine be trained to know the potential electrical hazards pressure pinch points rotating cutters and other similar hazards It is also your responsibility to train ...

Page 19: ... door inserted into the 555 far enough to activate the first limit switch Press once to Start Variable Speed Control The variable speed control switches allow the operator to change the speed of the 555 feed system Index ON OFF The Index switch is located on the carriage handle it locks and unlocks the indexing clamp Clamp ON OFF The Clamp switch is located next to the Index switch on the carriage...

Page 20: ...r as possible 4 Tighten one of the bolts to hold the Outfeed Easer Guide in place 5 Loosen the two bolts securing the Infeed Easer Guide in for less depth of cut and out for more depth of cut 6 Re tighten the two fastening bolts and the lock nut on the Jackscrew 7 PLUG IN THE ROUTERS 8 To check the amount eased run a door into the 555 and ease about 3 from the top of the door then press the Emerge...

Page 21: ...arely if ever needs adjustment 1 UNPLUG THE ROUTERS 2 Roll 1 3 8 door into the 555 until the door is between the two Easer Guides 3 Easers should open approximately 1 4 when the 1 3 8 door is between the two Easers 4 Turn the Jackscrew out to decrease the space between the Easers NOTE If the Easers are properly adjusted for a 1 3 8 door the 555 will also accommodate 1 3 4 doors Adjusting for 2 1 4...

Page 22: ...nside of the cutter carriage in or out until proper angle is attained Adjusting How Much the 555 Sands The sanding belt tension determines the amount sanded If the sanding belt is loose the sander will sand off more of the door edge Tightening the sanding belt decreases the amount sanded Refer to the Training the Sanding Belt section for more sanding belt adjusting information The Sizer Setting th...

Page 23: ...ft end of the frame The Index Clamp Lock Rings hold their position on the Indexing Shaft with two socket head cap screws that pinch the lock ring onto the shaft By positioning the lock rings at the normal door width increments that you normally use changeovers become quick and easy The Lock Ring Fine Adjustment shifts the Indexing Shaft in and out when the Lock Ring fine adjustment wheel is turned...

Page 24: ...of the 555 frame shows the measurement you want turn the Allen wrench locking the adjustment shaft in place Operating Instructions 1 SETUP THE 555 TO DESIRED SPECIFICATIONS 2 ROLL THE DOOR INTO THE 555 FEED WHEELS ACTIVATING THE LIMIT SWITCHES 3 PRESS THE START FOOT PEDAL THIS ACTIVATES THE 555 CYCLE OF OPERATION 4 THE 555 AUTOMATICALLY SHUTS OFF AFTER THE DOOR HAS BEEN MACHINED AND THE AUTOMATIC ...

Page 25: ...s Check Check the air filter water trap Empty if full Weekly Preventive Maintenance Op Operation Description Check Check the machine for smooth motion through a complete door cycle Clean Clean linear bearings and the chrome shaft with a clean dry cloth then lubricate Check Check all air lines electrical wiring for kinks or rubbing LUBE Refill lubricator with an ISO 32 standard hydraulic oil KVAL p...

Page 26: ...ra Lith Grease KVAL P N Lube EP 2 Pillow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear Box 2000 ...

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Page 28: ...ime PD2 KVAL P N Lube PD2 bearings must be re lubricated once every 60 days Approved Lubrication Products Chevron AW Hydraulic Oil 32 or KVAL P N SYSLUBG or G C lubricants light AW R O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32 Lubricator Adjustments Using knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Turn flow all ...

Page 29: ... air lines Usually 4 drops of oil every 3 cycles is a good rule of thumb To prime the lubricator find an air line on the Front Section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back...

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Page 33: ...mit switch you receive the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Clicks on a Acro all the limit switches have 20 degrees of pre travel If the arm is moved to the full extent of its travel and you do not hear the limit switch Click the switch needs to be adjusted here is how you adjust it follow the followin...

Page 34: ...the thru beams these beams may either stop operation or initiate operation depending on their location and function PHOTO EYES The sending and receiving units are in one unit these operate in the same manner as the ones described previously Note When a machine stops for no reason it is usually the fault of dirty photo eye or a misaligned limit switch arm ...

Page 35: ...ctly and to the proper specifications 3 Check for and obstructions to the cylinders such as screws or a misplaced tool etc FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS 4 Check the solenoid air valves The solenoid valves can be manually operated by pushing the slotted button on the end of the valve If you wish to keep the valve open the push button assembly can be removed using an ope...

Page 36: ...eak is coming from an exhaust port on the solenoid air bank Check the solenoid for the manual override If the solenoid has a manual override you can push each of the buttons one at a time When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty Adjusting the flow controls to change the cylinder extension speed is done by the fo...

Page 37: ...r terminal strips This will indicate power supply from the respective circuits Idec controllers also have lights on them for the input and output functions You can easily find out which circuits are failing by watching the lights turn on or off Compare the lights on the IDEC controller to the electrical diagram to determine what systems are being affected IF THE POWER STOPS DURING NORMAL OPERATION...

Page 38: ...n computer controlled units make sure that the POWER and RUN lights are lit at the lower left of the computer 4 Most electrical problems are related to mechanical malfunction i e stuck motors jammed chain non tripped limit switches etc The most common failure is an improperly adjusted limit switch To check a limit switch manually operate the limit switch If the computer terminal strips lights the ...

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Page 40: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...

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