Kval 990-APEX Page 13 Service Manual Download

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Overview of the 990-APEX

1-3

990-APEX Service Manual

FIGURE 1-2.

Lock Section

Jambs -

The

990-APEX

can machine and attach 3 ½” or 4” hinges with Kval’s original patented 6-

Shooter and 8-Shooter technology for pre-hanging interior and exterior doors.

KvalCAM

allows

the door and jamb to be machined separately to accommodate special hinges and strikes, such as

ASA strikes and three-point lock strike jambs.

KvalCAM

The

990-APEX

is programmed and controlled by our patented

KvalCAM

software that has been in

development for over five years. Door files are easily created at the controller, off-line, or auto

matically from your data system through its easy-to-use API.
No G-Code experience is necessary to program new and unique door files. Jobs can be queued for

operator or automatic bar-code reader selection, and 3D drawings can be viewed in real time as

the door file is created. All machine control, calibration, and tool management is done through the

KvalCAM

intuitive UI.

990-APEX Summary

• Hi-Frequency CNC Controlled Routers increase hinge pocket quality with extreme

accuracy and long life

• Counter-Rotating Routers eliminate chip-out without the need for chip-out blocks,

changing hinge sizes is fast and done from the controller

• Point-to-point Pre-drill Spindles replace air operated “gang drills” to allow for any

pre- drill pattern

• Selectable Chisels provide perfectly square hinges or face plates automatically
• High Quality Beckhoff Control Components are used throughout the

990-APEX

Summary of Contents for 990-APEX

Page 1: ...Innovation Quality Honesty Service Manual Published October 24 2022 990 APEX Service Manual 990 APEX Door Machining System Architectural Pre Hanging and Exterior Doors With KvalCAM ...

Page 2: ...ered trademark of Kval Incorporated Copyright 2022 Kval Incorporated All rights reserved Beckhoff TwinCAT and EtherCat are registered trademarks and are licensed by Beckhoff Automation GmbH All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporat...

Page 3: ...ice Call email contact us on our website at the Contact Us page email service kvalinc com Sales Support For machinery information specifications and quotes Call email contact us on our website at the Contact Us page email sales kvalinc com Kval Website Learn about Kval order parts get information on our array of machines including new machine releases learn about our machine software solutions dow...

Page 4: ...ed through the KvalCAM Software are also the property of the Licensor and are protected by applicable law 1 Definitions a KvalCAM Software means the KvalCAM computer application installed in the Machinery and written documentation and materials provided to you as well as any revisions or updates of such computer application and documentation b Install means storing of the KvalCAM Software in the c...

Page 5: ...achine is Powered and Running 1 7 Compressed Air 1 8 Electrical 1 8 Pinch Points 1 10 Before Conducting Maintenance 1 10 Laser Warnings 1 10 Compliance with Codes and Regulations 1 11 Other Hazard Control Action 1 11 Follow Your Company s Safety Procedures 1 11 Lockout Tagout Guidelines 1 12 Follow the P R O P E R lockout rule of thumb 1 12 Lockout Tagout Procedure 1 13 Pre Steps Before Lockout Ta...

Page 6: ...Steps 2 5 Check Air Gauges and Inspect Water Traps 2 5 Inspect Tooling 2 5 Lubricate inside of Hopper 2 6 Empty Dust Collection Units 2 6 3 000 Cycle Maintenance Steps 2 7 Inspect Feed Belts 2 7 Inspect Screw Drop Tubes on Six Shooter 2 7 Inspect all Photo Eyes 2 8 Inspect Limit Switches 2 8 Inspect Screw Receiver Parts 2 8 Inspect Airlines 2 9 Refill Lubricators 2 9 Grease Ball Screw Bearings 2 1...

Page 7: ...n Kit 2 24 Machine Lubrication Map 2 25 Greasing Hinge and Lock Carriage Servo Bearings 2 27 Recommended Tools 2 27 Procedure to Grease the Hinge and Lock Servo Assemblies 2 27 Hinge Servo Assembly Locations 2 28 Lock Servo Assembly Locations 2 28 Z Axis Servo Assembly Part Identification 2 29 Y Axis Servo Assembly Part Identification 2 29 X Axis Servo Assembly Part Identification 2 30 Greasing Hi...

Page 8: ...Recommended Tools 2 45 RTS Greasing Procedure 2 45 RTS Grease Point Location 2 45 About the Self Lubricator Module 2 47 How the Self Lubricator Works 2 47 Replace the Lubricator Well 2 47 Description of Air Input System 2 49 Air Input with Lubrication 2 49 Adjusting the Air Line Lubricator 2 49 Priming the Air Line Lubricator 2 50 Air Line Without Lubricator 2 50 Identifying Cutting Tools 2 51 Too...

Page 9: ...990 APEX Service Manual Table of Contents Remove and Replace the Screwdriver Bits 2 60 Collet Torque Values 2 63 Addition Collet Torque Values 2 64 ...

Page 10: ...990 APEX Service Manual Table of Contents ...

Page 11: ...when operating the machine Chapter 1 at a Glance Overview of the 990 APEX page 1 2 About this Manual page 1 5 Safety First page 1 6 Safety Guidelines page 1 7 Lockout Tagout Guidelines page 1 12 Lockout Tagout Procedure page 1 13 Zero Energy to Start Up page 1 16 Getting Help from KVAL page 1 18 Kval Return and Warranty Policy page 1 19 Safety Sign Off Sheet page 1 22 ...

Page 12: ...adius and pre drill patterns from the control panel for the door and jamb Use of clockwise and count er clockwise high frequency spindles eliminate material chip out without the need for chip out blocks A third spindle is designated for point to point pre drilling any hole pattern Automatic corner squaring and concealed hinge capability are standard FIGURE 1 1 Hinge Section Lock Section Routers mo...

Page 13: ...s easy to use API No G Code experience is necessary to program new and unique door files Jobs can be queued for operator or automatic bar code reader selection and 3D drawings can be viewed in real time as the door file is created All machine control calibration and tool management is done through the KvalCAM intuitive UI 990 APEX Summary Hi Frequency CNC Controlled Routers increase hinge pocket q...

Page 14: ...b only are fully sup ported Jamb Programming fully supports hinges and strike jambs including three point locks Specifications Summary These values are in standard configuration special options can be ordered to modify them Con tact Kval Sales for more information Height 78 96 Width 14 48 12 14 hinge only with option ND1 Thickness 1 3 8 1 3 4 Bevel 0 or 3 Hinge Width 3 4 Hinge Corner Rad 5 8 Rad S...

Page 15: ... Safety Information 2 Operation Interface Descriptions of how to power machine line and operator interface user screens 3 Calibration Descriptions of Calibration Routines and how to use the interfaces 3 Tour of the Machine Locations and descriptions of key assemblies on the 990 APEX Chapter Title Description 1 Introduction Safety Information 2 Maintenance Maintenance steps for the machine line Cha...

Page 16: ...ay have other warning labels or decals that provide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious inju...

Page 17: ...1 3 shows a sample of safety labels addressing training Read the Manual FIGURE 1 3 Read the Manual Labels Protective Gear Never operate the machine without proper eye and ear protection Figure 1 4 shows a sample of safety labels addressing safety gear FIGURE 1 4 protective Gear Labels When the Machine is Powered and Running Serious injury or death could occur if these general rules are not followe...

Page 18: ...a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performing any maintenance or repairs on this machine turn off the main air disconnect Lockout and tagout this connection See Lockout Tagout Procedure on page 1 13 Electrical Electrical circuitry on this machine is protected by an approved lockable...

Page 19: ...ow access to electrical penal that still has power applied High Voltage may cause injury or death Do not open the cabinets with out High Voltage training or without permission from a supervisor Warning Disconnect Style Panels When opening the cabinet you must first turn off the disconnect switch When the cabinet door is open there is still power on the top side of the disconnect switch Some machin...

Page 20: ... the stickers may have been applied to the machine The intent of safety is the same FIGURE 1 7 Pinch Point Warning Labels Before Conducting Maintenance Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the electrical and air pressure systems This should be done in accordance with applicable state and or federal code requirem...

Page 21: ...rt or operation of this machine is in violation of any health or safety regula tion STOP production 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 Foll...

Page 22: ...on 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 de...

Page 23: ... energy sources multiple electrical supplies air supply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center Lockout Tagout Power Note When multiple people are working on the machine each person needs to have a lock on the handle in the extra holes prov...

Page 24: ...lustration below NOTE Place your tag on the padlock as per the tagout guidelines Start Maintenance 6 Once the locks and tags are in place and all personnel are clear attempt to operate the machine to ensure equipment will not operate 7 Maintenance or repairs may started Post Maintenance Steps 8 After maintenance is completed the person performing the work must ensure all tools spare parts test equ...

Page 25: ...d them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 10 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 11 The tags must be destroyed and the locks and keys returned to the lockout center ...

Page 26: ...s started Perform 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 your com pany s comprehensive safety procedure may involve additional steps You will need to ask your supervisor about these procedures The company s lockout procedure should be posted at e...

Page 27: ...Zero Energy to Start Up 1 17 990 APEX Service Manual Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 28: ... the serial number 3 phase volts electrical print number and air print number 2 Contact our customer support team 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 address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Air D...

Page 29: ...A _______________ Send the Item Return the item to this address Kval Inc RMA ______ Kval Parts 825 Petaluma Blvd South Petaluma CA 94952 USA Acceptance of Return We can only accept items for a return if they are still in their original packaging and in undam aged resalable condition Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc Returns after 45 days of p...

Page 30: ...ore than one 1 year after delivery will the product be covered under Warranty The repair replacement or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval s warranty or for claims based upon failure of or defect in the products regardless of when the failure or defect arises and whether a claim however described is based upon contract warranty indemnity...

Page 31: ...Kval Return and Warranty Policy 1 21 990 APEX Service Manual Page Intentionally Left Blank ...

Page 32: ... my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical ...

Page 33: ...ES page 2 17 About Bearings page 2 18 Lubrication Schedule page 2 23 Machine Lubrication Map page 2 25 Greasing Hinge and Lock Carriage Servo Bearings page 2 43 Greasing Hinge Carriage Bearings page 2 31 Greasing Lock Carriage Bearings page 2 34 Greasing the Feed System Bearings page 2 37 Greasing the Screw Shooters Bearings page 2 39 Greasing Jamb Swing Bearings page 2 41 Greasing Frame Bearings ...

Page 34: ...es Clean Use pressured air to blow off dust and debris on entire machine Clean Blow out dust collection cans 600 Cycles Inspect Air Pressure Gages Adjust if necessary to the proper PSI located on the label Adjust only if Trained in Maintenance Inspect Inspect Air Filter Water Traps Empty if necessary Inspect Inspect the Tooling for wear Drill Bits Cutting Tools Screw Driver Bits Lubricate Lubricat...

Page 35: ...ation Schedule on page 2 23 Clean Clean all bearing shafts with clean dry cloth 12 000 Cycles Inspect Inspect chains for proper tension or damage Inspect Inspect all air cylinders for air leaks Replace if seal is leaking Inspect Inspect hydraulic lines for loose fittings leaks and cracks Inspect Inspect ball rail shafts for pitting or abrasions Lubricate Clean and lubricate all slides and cylinder...

Page 36: ...with the operation of the machine Use pressured air to blow off dust and debris on entire machine Use a clean rag to clean areas not affected by pressurized air Blow out any dust collection units Loose screws could cause bearing damage Check vertical bearings for loose screws Front Section Underneath Carriage Heads Jamb Clamp area High Dust Accumulation Areas Lock Carriage Area ...

Page 37: ... PSI located on the label Note Adjust only if Trained in Maintenance Inspect Air Filter Water Traps Empty trap if necessary Slide locking switch down to unlock twist trap to remove Reverse action when installing trap Inspect Tooling Inspect the Tooling for wear Drill Bits Cutting Tools Screw Driver Bits See Remove and Replace the Router or Pre Drill Bits on page 2 57 and see Collet Torque Val ues ...

Page 38: ... the input to the screw drop hoses Provides an easier screw drop Do not over spray oil Empty Dust Collection Units Check and empty any dust collection units Clean any dust filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units FIGURE 2 9 Typical Dust Collection Unit Filters Dust Collection Containers ...

Page 39: ...ge Check belts for cuts and nicks Belts can stretch over time Check for looseness A rule of thumb is to pull belt if belt moves too freely then replace belt Belts can become slick from use lessoning traction on door Check belts for slickness or door slippage Inspect Screw Drop Tubes on Six Shooter Inspect screw drop tubes for kinks cracks wear from rubbing ensure tube clamps are tight ...

Page 40: ...for cracks in the body and check that the switch arm actuates clicking sound when moved to the extreme Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Inspect Screw Receiver Parts Inspect screw receiver parts on six shooters for cracks or breaks Replace any parts that are br...

Page 41: ...hose connectors Check all airline connections assemblies air valves and hoses Check from source to end assembly Refill Lubricators Ensure Air is turned off Refill all lubricators Replace fluid if milky or discolored Use ab ISO 32 standard hydraulic oil KVAL PN SYS LUBEG Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections ...

Page 42: ...ble of lubrication types to use Lubrication Schedule For locations to lubricate See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt Slide locking switch down twist bowl and remove Refill bowl Reverse action when installing trap ...

Page 43: ...time of use Check for chain stiffness Stiff chains do not provide a tight fit over the gears Inspect Air Cylinders Inspect all air cylinders for air leaks Replace the cylinder if seal is leaking Symptoms include a cylinder not extracting or retracting to the limits Cylinders not holding their position Inspect Hydraulic Lines Inspect hydraulic lines for loose fittings leaks and cracks Inspect hydra...

Page 44: ...rail shafts for pitting or abrasions Inspect Ball Screw Axle Inspect ball screws for pitting or abrasions Clean and Lubricate Slides Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray Example of a Pitted Ball Rail Example of a Pitted Ball Screw ...

Page 45: ...12 000 Cycle Maintenance Steps 2 13 990 APEX Service Manual Clean inside Hopper Clean inside hopper with dry silicone oil and a 3M ScotchBrite pad or equivalent Wipe dry with a clean dry rag ...

Page 46: ...tion Check that there is a smooth transition with a door feeding into and out of machine Feed door in and out to verify smooth transition is repeatable Electrical Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Computer Backup 1 Right Click the Kval Icon at the Taskbar of the screen to display this Pop Up 2 Select the Ba...

Page 47: ... Manual Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water Slide lock down to unlock Twist bowl to remove it Remove filter from Air filter assembly Inspect and clean or replace if necessary Clean bowls and reassemble them ...

Page 48: ... cycles 1 8 Pre Drill Bit 10 000 20 000 cycles Lock Section Tooling Edge Prep 2 500 cycles Edge Prep CR 2 500 cycles A Side Face Spindle 2 500 cycles B Side Face Spindle 2 500 cycles Chisel Inserts 2 500 cycles Ball Catch 2 500 cycles Screw Receiver and 6 Shooter Tooling Screwdriver Bits 1 500 cycles Steel Rings 7 500 cycles Rubber Rings 7 500 cycles Screw Receivers 30 000 cycles Split Shells 30 0...

Page 49: ...onditions are changed timing accuracy or damage may occur during the machine process Do not adjust air PSI above or below factory settings Do not adjust any and all flow controls from factory settings Do not remove shim stock Do not Change or Alter any safety assemblies E Stops Gate Locks etc Do not Change programs in PLC s or PC s Do not Alter Electrical Components ...

Page 50: ... ball is almost flush with the surface of the fitting so that it can be wiped clean to reduce the amount of debris carried with the grease into the bearing Note Bearings without grease fittings have been pre lubricated at the factory and do not require further lubrication Note Clean excess grease to avoid contact with feed belts clamping areas or the door FIGURE 2 10 Zerk Fitting About Pillow Bloc...

Page 51: ... housings used to mount a bearing unit A mounted bearing unit acts as a system to position the bearing securely for reliable operation FIGURE 2 12 Flange Bearings About Ball Rail Bearings Ball Rail Bearings are linear bearings that are attached to positioning rails In most cases the bear ings are attached to assemblies to move them in the X Y or Z direction FIGURE 2 13 Ball Rail Bearings Flange Be...

Page 52: ... is such an asset that the bearing blocks often require no main tenance for the life of the machine FIGURE 2 14 Sample of Tapered Bearing Tapered Bearing Housings The taper bearings differ from other machine bearing assemblies in that they are in a sealed envi ronment To identify a Tapered Bearing Housing look at the enclosure and verify there are seals between the screw and the housing FIGURE 2 1...

Page 53: ...ficients resulting in a smooth accurate efficient movement FIGURE 2 16 Example of a Typical Ball Nut Ball Screw Drive Assembly Including the Ball Screw Nut other types of bearings may be included on the assembly The figure below shows a typical Ball Screw Drive Assembly FIGURE 2 17 Ball Screw Drive Assembly Ball Screw Nut Housing Ball Screw Drive Ball Screw Nut Servo Motor Tapered Bearing Housing ...

Page 54: ...ulley contains an idler shaft that has a zerk fitting to apply grease An opening in the idler shaft dispenses grease to the inner diameter of the pulley Important It is important not to overfill the Idler Shaft to avoid getting excess grease on the belts FIGURE 2 18 Pulley in Action FIGURE 2 19 Exploded View of the Pulley Pulley Idler Shaft Grease Out Grease IN Pulley Exploded View ...

Page 55: ...rge Hub Bearinga a Includes Rotation Bearing on the RTS and 0 3 Degree Bearings on the 990 Series Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles 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 Harm...

Page 56: ...tion Schedule 2 24 990 APEX Service Manual Kval Lubrication Kit FIGURE 2 20 Lubrication Kit Hydraulic Oil Grease Gun Extension Adapter Needle Nozzle E Adapter Needle Nozzle EP 2 Multi FAK Grease Silicone Spray ...

Page 57: ...o Bearings on page 2 27 Linear See Greasing Hinge Carriage Bearings on page 2 31 Lock Carriage Ball Nut Tapered See Greasing Hinge and Lock Carriage Servo Bearings on page 2 27 Linear and Hub See Greasing Lock Carriage Bearings on page 2 34 Feed System Pulleys Idler Shafts and Hub See Greasing the Feed System Bearings on page 2 37 Lock Carriage Purple Including Servo Assemblies Feed System Light B...

Page 58: ...ew Shooter Linear and Hub See Greasing the Screw Shooters Bearings on page 2 39 Jamb Swing Linear See Greasing Jamb Swing Bearings on page 2 41 Frame Linear Hub Large Hub Pillow Block See Greasing Frame Bearings on page 2 43 Grease Points Bearing Types Links ...

Page 59: ...easing servo motor assembly components see About Tapered Bearings on page 2 20 and see Ball Screw Nut on page 2 21 Recommended Tools Procedure to Grease the Hinge and Lock Servo Assemblies Use an extender to reach tight areas Important Grease the tapered bearings carefully The taper bearings are in a sealed environment Too much grease can breach the seal and cause damage to the bearing 1 Perform L...

Page 60: ...assemblies FIGURE 2 22 Hinge Servo Assembly Locations Lock Servo Assembly Locations Figure 2 23 below shows the bottom view of the Lock Carriage Areas of the carriage have been ghosted to allow better view of the Servo assemblies FIGURE 2 23 Lock Servo Assembly Locations Z Axis Servo Drive Assembly X Axis Servo Drive Assembly Y Axis Servo Drive Assembly Z Axis Servo Drive Assembly X Axis Servo Dri...

Page 61: ...URE 2 24 Z Axis Assembly Y Axis Servo Assembly Part Identification Figure 2 25 shows a view of Y Axis assembly The table below shows the bearing types and the greasing schedule Follow the steps in the Procedure to Grease the Hinge and Lock Servo Assemblies on page 2 27 Bearing Schedule Ball Nut Every 80 Hours of Machine Operation Tapered Bearing One Pump a 4 X a Year Bearing Schedule Ball Nut Ever...

Page 62: ...xis servo assembly is greased by an automatic greaser The Auto Greaser is replaced as a unit A message close to the replacement time will be fed back to the Operator Interface For information about replacing automatic greas ers see Replace the Lubricator Well on page 2 47 FIGURE 2 26 X Axis Assembly Zerk Zerk Servo Motor Tapered Bearing Ball Screw Nut Ball Screw Servo Motor Auto Greaser Gear Conne...

Page 63: ...cedure Use an extender to reach tight areas 1 Perform Lockout Tagout 2 Find the linear bearings identified in Figure 2 27 on page 2 32 and Figure 2 28 on page 2 33 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Hinge Carriage Grease Point Locations The H...

Page 64: ... attached to the bottom of the assembly Table 2 2 describes the bearings that are identified in Figure 2 28 Follow the steps in the Hinge Carriage Greasing Procedure on page 2 31 TABLE 2 1 Hinge Carriage Bearing Information Bearing Location Bearing Type Bearing Total Qty Schedule H Block Horizontal Linear 4 Red Every 250 Hours of Machine Operation Carriage Body Horizontal 5 Blue Carriage Body Vert...

Page 65: ...ocation Bearing Type Bearing Total Qty Schedule Chisel Assemblies Linear 4 Light Blue Every 250 Hours of Machine Operation Pre Drill Spindle 2 Green Router Spindle 2 Red CCW Router Spindle 2 Gray Cutter Head Tray 4 Dark Blue Router Spindle Chisel Assembly Pre Drill Spindle CCW Router Spindle Cutter Head Tray Chisel Assembly Pre Drill Spindle CCW Router Spindle ...

Page 66: ...identified in Figure 2 29 on page 2 35 and Figure 2 30 on page 2 36 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Lock Carriage Grease Point Locations The Lock Carriage bearings provide a smooth movement in all axis directions Each axis contains linear ...

Page 67: ...are part of the 0 3 degree tilt assembly Table 2 4 describes the bearings that are identified in Figure 2 30 Follow the steps in the Lock Carriage Greasing Procedure on page 2 34 TABLE 2 4 Cutter Tray Bearing Information Bearing Location Bearing Type Bearing Total Qty Schedule Chisel Assemblies Linear 4 Yellow Every 250 Hours of Machine Operation Router Spindle 3 Light Purple Router Spindle 4 Ligh...

Page 68: ...Lock Carriage Bearings 2 36 990 APEX Service Manual FIGURE 2 30 Hinge Cutter Tray Bearing Locations Chisel Assemblies Ball Catch Spindles 0 3 Degree Tilt Hub Face Spindle Assemblies Router Spindle Router Spindle ...

Page 69: ...s Important Do not overfill the idler shaft to avoid getting excess grease on the belts 1 Perform Lockout Tagout 2 Find the idler and hub bearings identified in Figure 2 31 on page 2 38 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Bearing Locations on ...

Page 70: ...Greasing the Feed System Bearings 2 38 990 APEX Service Manual FIGURE 2 31 Bearings in the Feed System Hub Movable Side Feeder Motor Fixed Side Feeder Motor Hub Pulley Pulley ...

Page 71: ...ge 2 19 Recommended Tools Process to Grease Shooter Bearings Use an extender to reach tight areas 1 Perform Lockout Tagout 2 Find the linear and hub bearings identified in Figure 2 32 on page 2 40 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Bearing Lo...

Page 72: ...Greasing the Screw Shooters Bearings 2 40 990 APEX Service Manual FIGURE 2 32 Screw Shooter Bearing Locations Hub Bearings Shooter Track Linear Bearings Hub Bearings Shooter Track Linear Bearings ...

Page 73: ...ded Tools Jamb Swing Assembly Greasing Procedure Use an extender to reach tight areas 1 Perform Lockout Tagout 2 Find the linear bearings identified in Figure 2 33 on page 2 42 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Jamb Swing Grease Point Locati...

Page 74: ...Greasing Jamb Swing Bearings 2 42 990 APEX Service Manual FIGURE 2 33 Jamb Swing Bearings Jamb Swing Track Linear Bearings ...

Page 75: ...n page 2 44 3 Identify zerk fittings on the bearings 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease 6 Reverse Lockout Tagout Machine Frame Grease Point Locations Table 2 8 describes the bearings that are identified in Figure 2 34 Follow the steps in the Frame Greasing Procedure TABLE 2 8 Frame Grease Points Bearing Loc...

Page 76: ...X Service Manual FIGURE 2 34 Frame Bearings Door Width Axle Hub Bearings 0 3 Degree Tilt Hub Bearings Door Fence Linear Bearing x2 Door Up Clamp Linear Bearings x2 0 3 Degree Tilt Large Hub Bearings X2 Door Width Track Linear Bearings X4 ...

Page 77: ...tation point of the machine FIGURE 2 35 Flange Mounted Bearing Recommended Tools RTS Greasing Procedure If needed use an extender to reach the bearing 1 Perform Lockout Tagout 2 Find the bearing identified in Figure 2 36 on page 2 46 3 Identify zerk fittings on the bearing 4 Apply approximatively 1 Gram one pump from grease gun of EP 2 grease 5 After lubrication is completed clean up excess grease...

Page 78: ...er Bearing 2 46 990 APEX Service Manual FIGURE 2 36 RTS Bearing Location TABLE 2 9 RTS Grease Point Bearing Location Bearing Type Bearing Total Qty Schedule Rotation Bearing Flange Mount 1 Yellow One Pump a 4 X a Year Zerk Fitting ...

Page 79: ...ll sends a 30 day replacement alert to the operator interface when oil is low 5 It is recommended to change it as soon as possible after the alert is displayed Refer to Electrical Drawing to see connection points FIGURE 2 37 Location of Gear and Lubricator Replace the Lubricator Well The kit contains lubricator well hose with oil and its connectors bracket and sensor Follow the instructions on the...

Page 80: ... Attach the new hose to the new well and the applicator 10 Bracket the new well against the machine 11 Slide the black and red wires into the connector Secure with a small screw driver 12 Polarity is not an issue but for consistency replace wires as they were 13 Route sensor wires to the corresponding node and connect to the correct terminals 14 After lubricator well is secured on machine perform ...

Page 81: ...ers the lubricated air to valve banks and air cylinders FIGURE 2 39 Typical Air Line Filter and Lubrication System Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Shop Air Input Air On Off Knob Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator...

Page 82: ...ony 32 To prime the lubricator find an air line on the carriage 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 section and other trouble areas It is recommended to check the...

Page 83: ... Callout Most Common Tool a a Most Common Tools Some bits may differ due to special cutting processes Kval Recommended Tool Lengthb b Before changing tools always measure the tool bit Length of the bit measured is from the base of tool at the collet to the tip This measurement is entered into the Tool Config menus see Access the Tool Config Screen on page 2 55 Collet Torque Spindle P N Shaft Wrenc...

Page 84: ...red into the Tool Config menus see Access the Tool Config Screen on page 2 55 Collet Torque Spindle P N Shaft Wrench Collet Wrench A Chisels Sip013 N A N A N A N A B Edge Prep RBSC1010600 N 2 4 5 8 COLER32 10 ER32 slotted 100 ft lbs HSDY6162Y00019 HSDY341500007 COLER32 CW7 C Edge Prep CR RBSC0808300 L N 2 0 COLER25 04 ER25 04 slot 77 ft lbs HSDY6162Y00071 HSDH3415H0076 COLER25 CW7 Dc A Side Face S...

Page 85: ...s the bit assemblies FIGURE 2 43 Hinge Carriage Access Getting Access the Lock Carriages 1 Shutdown the machine and follow the Lockout Tagout procedures 2 After machine is locked and tagged out release the air by opening the push connec tion 3 Climb in to the well and move the Lock Carriage to allow access to the tooling Always follow Lockout Tagout Procedures This machine is a powerful electro me...

Page 86: ...How to Access to Tooling 2 54 990 APEX Service Manual FIGURE 2 44 Lock Carriage Access Release Air Step into the well and move Lock Carriage to get access to the tooling ...

Page 87: ... Tool Config tab and choose the desired tool At this screen specifications of the tool is entered and saved to the database This information is valuable to compute and provide the most precise cut available To check Tool Configurations 1 From the Tool Menu select the desired tooling 2 Verify the specifications before inserting the new tooling 3 Insert the new tooling matching the specifications in...

Page 88: ...e of the tool from the collet to the tip of the tool Make sure the length value matches the value in the Tool Length box in the Tool Config menus Note Table 2 11 shows the most common tools that are used in the Hinge Carriage TABLE 2 10 Common Tools in the Lock Carriage Motor Callout Most Common Tool a a Most Common Tools Some bits may differ due to special cutting processes Kval Recommended Tool ...

Page 89: ...Use the shaft wrench and the collet wrench to remove the bit on the pre drill or router assemblies FIGURE 2 46 Removing Pre Drill or Router Bit 3 Inspect and clean collet assembly FIGURE 2 47 Collet Assembly Always follow Lockout Tagout Procedures This machine is a powerful electro mechanical motion con trol system If servicing this machine follow all safety guide lines Failure to do so can result...

Page 90: ... the drill bit depth to match the settings in the Tool Config parameters1 Note If available use the Bit Depth Gauge that supplied with the machine 7 Lightly tighten and torque to correct value See Collet Torque Values on page 2 63 FIGURE 2 48 Setting the Bit Depths 8 Tighten the collet assembly 9 Inspect and verify the work Clean the work area 1 If using bits for the first time establish Tool Conf...

Page 91: ...nel grips to remove the bracket 4 Slide the old chisel out of the assembly Note the orientation of the chisel FIGURE 2 49 Replacing the Chisels 5 Slide in the new chisels 6 Tighten bolts back and forth until the bracket is tight 7 Inspect and verify the work Clean the work area 8 If maintenance is completed replace dust cover and tighten bolts Always follow Lockout Tagout Procedures This machine i...

Page 92: ...r air to be released FIGURE 2 50 Disconnect Air 2 Push the Six Shooter assembly toward the machine it will move slightly Always follow Lockout Tagout Procedures This machine is a powerful electro mechanical motion control system If servic ing this machine follow all safety guidelines Failure to do so can result in dam age to equipment and or serious injury to personnel Warning Receiver Slide Locat...

Page 93: ... the slide is moved pull the Six Shooter assembly away from the machine it will move about 1 inch This provides room for hands to access the screwdriver bit holders Remove and Replace the Screw Driver Bits 5 To remove screwdriver bit push the bit holder see images back toward the Six Shooter assembly and hold pull bit out of holder 1st Push the Six Shooter toward the Machine Machine 2nd Push the S...

Page 94: ...toward Six Shooter assembly and hold while inserting new bit Release holder to secure bit 7 Move Six Shooter assembly back toward machine and pull the back slide toward you then move assembly away from machine to restore assembly to original start ing position Remove Driver Bits Bit Holder Lock Bit Slide Bit Holder lock Back Slide Bit Out ...

Page 95: ... APEX Service Manual Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing FIGURE 2 52 Collet Torque Values ...

Page 96: ...nal collet torque values TABLE 2 12 Collet Torque Values Collet Nut Type Torque Common Kval Motors ER20 Slotted 59 ft lbs HSDY6162Y0003 SOYUS 20 Hook 36 ft lbs PERVS503 ER25 Slotted 77 ft lbs HSDY6162Y0071 SOYUS 25 Hook 90 ft lbs PERKRSV51 14 2D ER32 Slotted 100 ft lbs A6161H0824 GC90E1683 7 5D HSDY6162Y0019 HSK F63 Slotted 130 ft lbs HSDH6161H0992s ...

Page 97: ......

Page 98: ...Notes ...

Page 99: ...Notes ...

Page 100: ...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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Kval 990-APEX, Service Manual

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