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KVAL 990-F4 Service Manual

Table of Contents

Ball Screw Drive Assembly

.................................................................3-21

Pulley and Idler Shafts

........................................................................3-22

Sample of Grease Locations for the Back Section

.................. 3-23

Back Section Servo Motor Assembly

..................................................3-23

Back Section Carriage

........................................................................3-24

Sample of Grease Locations for the Front Section

.................. 3-25

About Carriage Head Grease Locations

.............................................3-25

About Carriage Head Grease Locations

.............................................3-26

Carriage Head Bearings

.....................................................................3-26

Tool Bearings

......................................................................................3-27

Front Section Assemblies

...................................................................3-28

Frame Grease Points

............................................................... 3-29

Sample of Grease Locations for Ball Catch Option

................. 3-30

Description of Air Input System

................................................ 3-31

Air Input with Lubrication

...................................................................3-31

Air Line Without Lubricator

.................................................................3-32

Replacing Tooling in the Front Section

.................................... 3-33

Tool Locations in the 990-F4 Carriage Head

......................................3-33

How to Access to Bit Assemblies

........................................................3-34

Remove and Replace the Router or Pre-Drill Bits (Point to Point)

.....3-34

Remove and Replace Pre-Drill Bits (Block)

........................................3-36

Remove and Replace the Screwdriver Bits

........................................3-37

Replacing Tooling in the Back Section

..................................... 3-40

Location of Assemblies on Back Section

............................................3-40

Changing the Bore Drill

.......................................................................3-41

Changing the Bolt Drill

........................................................................3-42

Changing the Face Plate Router

........................................................3-42

How to Replace the Back Section Chipout Block

.................... 3-43

Assembly/Tools:

..................................................................................3-43

Replacement Step

..............................................................................3-43

How to Replace the Front Section Chipout Block

.................... 3-44

Summary of Burn Process

..................................................................3-44

Chipout Block Spacers

.......................................................................3-44

Assembly/Tools:

..................................................................................3-45

Replacement Steps

............................................................................3-45

Collet Torque Values

................................................................ 3-47

About Motion Control

............................................................... 4-2

Basic Control Circuit

.............................................................................4-2

Typical Positioning Systems

.................................................................4-4

Summary of Contents for 990-F4

Page 1: ...Innovation Quality Honesty Service Manual Published November 12 2021 990 F4 Door Pre Hanging System 990 F4 Service Manual ...

Page 2: ...ered trademark of Microsoft Corporation 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 Incorpo rated products contact the Customer Support Depart...

Page 3: ...rience 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 Please email your comments and suggestions for improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information above Thank y...

Page 4: ...KVAL 990 F4 Service Manual ...

Page 5: ...aintenance 1 12 Post Maintenance Steps 1 12 Zero Energy to Start Up 1 13 Getting Help from KVAL 1 15 KVAL Return and Warranty Policy 1 16 Send the Item 1 16 Acceptance of Return 1 16 Refund Turnaround Time 1 16 Kval Errors 1 16 Customer Errors 1 17 Shipper Errors 1 17 Warranty Replacement Parts 1 17 How to Download the Service Application 1 18 Download Application 1 18 Safety Sign Off Sheet 1 21 A...

Page 6: ...Maintenance Steps 3 11 Inspect Chains for Proper Tension 3 11 Inspect Air Cylinders 3 11 Inspect Hydraulic Lines 3 11 Inspect Ball Rail Shafts 3 12 Clean and Lubricate Slides Cylinder Rods and Bearing Shafts 3 12 Clean inside Hopper 3 12 72 000 Cycle Maintenance Steps 3 13 Inspect Nuts and Bolts 3 13 Check Door Feeding Transition 3 13 Electrical 3 13 Computer Backup 3 13 Wash Filter and Lubricator...

Page 7: ... Replacing Tooling in the Front Section 3 33 Tool Locations in the 990 F4 Carriage Head 3 33 How to Access to Bit Assemblies 3 34 Remove and Replace the Router or Pre Drill Bits Point to Point 3 34 Remove and Replace Pre Drill Bits Block 3 36 Remove and Replace the Screwdriver Bits 3 37 Replacing Tooling in the Back Section 3 40 Location of Assemblies on Back Section 3 40 Changing the Bore Drill 3...

Page 8: ...out Cylinder Operation 4 17 How the Pneumatic System Works 4 17 Important Notice about Adjusting Cylinder Speed 4 19 Adjusting Cylinder Extend Speed 4 20 Adjusting Cylinder Retraction Speed 4 20 About the Machine Sensors 4 21 Sensor Locations 4 21 Using Sensors to Trouble Shoot 4 22 Troubleshooting the Air Cylinders 4 23 Adjusting Cylinder Extension Speed 4 24 Adjusting Cylinder Retraction Speed 4...

Page 9: ...n overview of the 990 F4 It includes a general description and a table of available options page 1 2 Safety First IMPORTANT safety information is described in this section page 1 1 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 ge...

Page 10: ...ch screen In addition custom lock bore and dead bolt locations may be entered on the touch screen for any position within the travel of the servo driven screw The servo driven system will also automatically position the lock boring assembly when the door hand is changed This machine is equipped with a solid state touch screen that replaces many of the mechanical switches for the machine functions ...

Page 11: ...lt Option B Pushbutton Changeover from 3 1 2 to 4 Hinge Pockets Interior Exterior option 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 Option C Pushbutton Sel...

Page 12: ...lows hinge jamb and door to be routed at 3 degrees Eliminates the capability of 0 degrees Six Shooter or Eight Shooter is also tilted to compensate for this Requires Option D Pre Drill System for Six Shooter or Option K1 Pre Drill System for Eight Shooter 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 deg...

Page 13: ... following Chapter Title Description 1 Introduction Descriptions of Machine Line and Safety Information 2 Operation Descriptions of how to power machine line and operator inter face user screens Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descriptions of the PLC system and computer system 3 Maintenance Maintenance steps for the machine line 4 Troubleshoo...

Page 14: ...d 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 foll...

Page 15: ... 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 p...

Page 16: ...ed 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 th...

Page 17: ... 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 operatio...

Page 18: ...nd 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...

Page 19: ...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 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop it...

Page 20: ...re completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags 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 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and ...

Page 21: ...when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is 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 company s compre...

Page 22: ...key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 23: ...ord 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 Ai...

Page 24: ...RMA _______________ 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...

Page 25: ...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 how ever described is based upon contract warranty indemnit...

Page 26: ... 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google we...

Page 27: ...ogram is ready to allow technicians to access machine computer Your Name Field Enter your name The KVAL tech nician will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support ...

Page 28: ...How to Download the Service Application KVAL 990 F4 Service Manual 1 20 Page Intentionally Left Blank ...

Page 29: ...ow 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 electrica...

Page 30: ...Safety Sign Off Sheet KVAL 990 F4 Service Manual 1 22 ...

Page 31: ...ller is an on board computer that sup plies the user interface and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 2 at a Glance Section Name Summary Page About the PLC This chapter describes the basic parts of the operation of the PLC in the machine page 2 2 ...

Page 32: ...and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 3 at a Glance Section Name Summary Page System IT Administration This chapter describes the basic parts of the operation of the PLC in the machine Such as About the PLC Connections on the PLC Backing up the Computer About Remote Connection to KVAL Service page 2 3 ...

Page 33: ...e chipset the module also contains internal main memory The computer has a removable Compact Flash card from which it boots The controller uses a Windows 7 oper ating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages A DV...

Page 34: ...currence The KVAL service team would be happy to help If any questions occur contact our service team at 800 553 5825 or at www kvalinc com About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 990 F4 machine With the remote access our KVAL service technician is able to observe your user screen in real time read and adjust programming code ...

Page 35: ...lowing information is available in this chapter Maintenance Schedule This section describes the assemblies to schedule for maintenance page 3 2 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Motor Lubrication Requirements Ball Screws Description o...

Page 36: ...cles 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 Lubric...

Page 37: ...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 rods with dry silicone spray Lubricate Lubricate all bearing shafts with ...

Page 38: ...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 Also blow out any dust collection units Check vertical bearings for loose screws Loose screws could cause bearing damage Front Section Underneath Car riage Heads Jamb Clamp area High Dust Accumulation Areas Lock Bore Area build up can occur and...

Page 39: ...ges Adjust if nec essary to the proper PSI located on the label 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 the Tooling for wear Drill Bits Cutting Tools Screw Driver Bits See Replacing Tooling in the Front Section on page 3 33 and see Replacing Tool...

Page 40: ...t filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units FIGURE 3 Typical Dust Collection Unit Lubricate the inside of the Hoppers with a light coat of dry silicone spray Lubricate the input to the screw drop hoses Provides an easier screw drop Do not over spray oil Filters Dust Collection Containers ...

Page 41: ... tension or damage 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 lesson ing traction on door Check belts for slickness or door slippage Inspect screw drop tubes for kinks cracks wear from rubbing Ensure tube clamps are tight Inspect all photo eyes secure and t...

Page 42: ...e switch arm actuates clicking sound when moved to the extreme Note 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 on six shooters for cracks or breaks Inspect 1 Screw Receiver 2 Spring 3 Split Shell 4 Steel Ring 5 Rubber Ring 6 Steel Ring Repla...

Page 43: ...rline connections assem blies air valves and hoses Check from source to end assembly Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections Ensure Air is turned off Refill all lubricators Replace fluid if milky or discolored Use ab ISO 32 stan dard hydraulic oil KVAL PN SYS LUBEG Slide locking switch down twist bowl and remove Refill bowl Reverse action when installing...

Page 44: ... bearings if applicable For a table of lubrication types to use see Lubrication Schedule on page 3 17 For locations to lubricate see Description of Air Input System on page 3 31 Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 45: ...ce 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 chains for proper tension or damage Check for sagging chains Chains can stretch over time of use Check for chain stiffness Stiff chains do not provide a tight fit over the gears Inspect hydraulic lines for loose fittings leak...

Page 46: ...Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray Clean inside Hopper Inspect ball rail shafts for pitting or abrasions Example of a Pitted Ball Rail Clean inside hopper with dry sili cone oil and a 3M ScotchBrite pad or equivalent Wipe dry with a clean dry rag ...

Page 47: ...Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Computer Backup Backup computer software Wash Filter and Lubricator Bowls Check that there is a smooth transition with a door feeding into and out of machine Feed door in and out to verify smooth tran sition is repeatable Wash filter and lubricator bowls with soapy water Sl...

Page 48: ... Inserts 1500 cycles Chip Out Block 10 000 20 000 cycles 9 64 Pre Drill Bit 10 000 20 000 cycles 1 8 Pre Drill Bit 10 000 20 000 cycles Lock Section Tooling Face Plate Router Bit 2 500 cycles 2 1 8 Face Bore Bit 2 500 cycles 2 1 8 Face Bore Bit Inserts 2 500 cycles Insert Scoring Spur for 2 1 8 Bit 2 500 cycles Face Bore Chip Out Block 2 500 cycles 1 Bolt Drill Bit 2 500 cycles Prior to performing...

Page 49: ...15 KVAL 990 F4 Service Manual 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 30 000 cycles Springs 30 000 cycles ...

Page 50: ...conditions 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 51: ...Bearing Idler Shaft Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Tapered Bearing Once 4 X a Year 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 Sh...

Page 52: ...tting is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing When the pressure stops the ball returns to its closed position The ball excludes dirt and functions as a check valve to prevent grease escaping back out of the fitting The ball is almost flush with the surface of the fitting so that it can be wiped clean to...

Page 53: ...eliable operation FIGURE 3 2 Flange Bearings Ball Rail Bearing 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 3 3 Ball Rail Bearings Greasing Flange Bearing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 2...

Page 54: ...y is such an asset that the bearing blocks often require little maintenance for the life of the machine FIGURE 3 4 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 ...

Page 55: ...al 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 3 7 Ball Screw Drive Assembly Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 80 hours of operation Ball Screw Nut Housing Ball Screw Drive Greasing Ball Screw Nut Se...

Page 56: ...of the machine Each pulley 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 FIGURE 4 Pulley Exploded View Pulley in Action Breakout of Pulley Assembly Grease IN Grease Out Note It is important not to overfill the Idler Shaft Avoid get ting excess grease on the belts Idler Shaft ...

Page 57: ...greasing schedule see Lubrication Schedule on page 3 17 FIGURE 3 1 Back View of 990 F4 Servo Motor Assembly This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Shutdown the machine and follow the Lock Out Tag Out procedures Caution Tapered B...

Page 58: ... Carriage Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For rec ommended greasing schedule see Lubrication Schedule on page 3 17 Zerk fitting may be located on th bottom of the bearing FIGURE 3 2 Back View Carriage of 990 F4 Closed Pillow Block Quantity 12 ...

Page 59: ...to reach tight areas Make sure to Lockout Tagout before maintenance For recommended greasing schedule see Lubrication Schedule on page 3 17 FIGURE 3 3 Front View Carriage Head This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Shutdown the ...

Page 60: ...edule see Lubrication Schedule on page 3 17 The figure below shows the Carriage Head Bearings These bearings move the entire head in the X Horizontal and Y Vertical axises Note The Carriage Head Spring has been removed for better identification of the bearings Carriage Head Bearings FIGURE 4 Carriage Bearings To get access to the bearings the Hinge Covers will have to be removed Carriage Head X Ax...

Page 61: ...nce For recom mended greasing schedule see Lubrication Schedule on page 3 17 FIGURE 5 Tool Set Bearings To get access to the bearings the Hinge Covers will have to be removed Predrill Z Axis Moves the predrill in and out of the door and frame 2 rails 2 bearings per rail Tool Box X Axis Moves the tool box in the horizontal Axis directions 2 rails 2 bearings per rail Router Z Axis Moves the router i...

Page 62: ... Assemblies Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For rec ommended greasing schedule see Lubrication Schedule on page 3 17 Look under the assembly for the 4 FIGURE 3 1 Back of Front Section 990 F4 Hub Quantity 1 Hub Located under assembly Quantity 4 ...

Page 63: ... tight areas Make sure to Lockout Tagout before maintenance For rec ommended greasing schedule see Pulley and Idler Shafts on page 3 22 FIGURE 3 2 Top View of 990 F4 2 3 1 Hub Bearings 1 Back Frame 2 Back Section 3 Front Section Lubricate feed system hex shaft with Silicon Spray Lubricate Pulleys ...

Page 64: ... edge of the door There are 2 Ball Catch Right Hand and Left Hand assemblies on the machine Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For recommended greasing schedule see Lubrication Schedule on page 3 17 FIGURE 4 Ball Catch Bearings Rail Bearing Horizontal movement Quantity 4 Rail Bearing Vertical movement Quantity 4 ...

Page 65: ...delivers the lubricated air to valve banks and air cylinders FIGURE 3 1 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 Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator ...

Page 66: ...mony 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 th...

Page 67: ... the Carriage Heads and the Six Shooter Figure 4 below shows the locations of the replaceable parts inside the carriage heads FIGURE 4 Location of Bits in the 990 F4 Heads This machine is a powerful electro mechanical motion control system If servicing this machine fol low all safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Caution Drill Bit...

Page 68: ...ve the screws from the Top Dust Cover 3 Lift off the cover to access the assemblies Remove and Replace the Router or Pre Drill Bits Point to Point Caution Before performing this process turn off all power to the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual 1 Use a 17 mm shaft wrench and a 3 8 collet wrench to remove the bit on the pr...

Page 69: ... bit to 1 3 4 and the drill bit to 2 0 from the base of the collet nut to the tip of the bit If available use Bit Depth Gauge PN 432 C to set the depth 6 Lightly tighten and torque to correct value For torque values see Collet Torque Values on page 3 47 FIGURE 7 Setting the Bit Depths 7 Tighten the collet assembly Collet Spindle Collet Nut Verify that there is no damage or bluing on the side of th...

Page 70: ...y section of Chapter 1 of this manual 1 Inspect pre drill bits 2 To remove bits loosen chuck with chuck key Extended Chuck Key PN 12 00 100 is pictured 3 Remove damaged or worn bit 4 Before tightening the chuck assembly adjust the bit depth Set the drill bit to 1 3 8 from the base of the chuck to the tip of the bit or use tool 12 00 ZA to set length See Figure below 5 Tighten the chuck with the ch...

Page 71: ...in the safety section of Chapter 1 of this manual Adjust Six Shooter to Gain Access to Receiver Block 1 Disconnect air from Six Shooter using the air connect slide valves Slowly slide the valves back toward you listen for air to be released FIGURE 8 Disconnect Air 2 Push the Six Shooter assembly toward the machine it will move slightly Receiver Slide Location of Areas of Adjustment Air Connector D...

Page 72: ...he 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 Sli...

Page 73: ... 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 74: ... Drill Bolt Drill and the Face Plate Router Location of Assemblies on Back Section Lock Bore Motor and Drill Drills locks holes on the face of the door Bolt Drill Motor Machines lock plate on the side of the door Valve Bank Con trols Air Cylinders on back section Bolt Drill Extend and Retract Cylinder Face Plate Motor and Drill Routs face plate Ball Catch Motor and Drill Opt BC Drills ball catch o...

Page 75: ...ure 6 on page 35 4 Insert the new bit into the assembly 5 Before tightening the collet assembly adjust the bit depth Bottom out the bit and pull the bit up about 1 4 6 Lightly tighten and torque to correct value For torque values see Collet Torque Values on page 3 47 Note Make sure the arbor is not bottomed out in the back of the motor If it is the arbor will not tighten and will damage the collet...

Page 76: ...e bit on the pre drill or router assemblies See photo When loosening the collet it may tighten up crack again and continue 2 Inspect and clean collet assem bly See Figure 6 on page 35 3 Insert the new bit into the assembly 4 Before tightening the collet assembly adjust the bit depth Bottom out the bit and pull the bit up about 1 4 5 Lightly tighten and torque to correct value For torque values see...

Page 77: ...ual 2 Loosen but do not remove the four Clamping Plate retaining bolts 3 Slide out the old Chipout Block 4 Slide in the new Chipout Block 5 Tighten the Clamping Plate retaining bolts 6 Load a door into the machine and clamp it 7 At the Main Screen disable the Hinge Carriage and all functions of the Lock except the Lock Bore 8 Burn the Chipout Push the Burn Chipout Button at the Interface 9 Run a t...

Page 78: ...Chipout Block Gradually the assembly is moved toward the block burning at each step Chipout Block Spacers Chipout Block Location To lengthen the life of the blocks spacers are used to extend the block out toward the router The block can be burned in a total of three times First Installation Install new Chipout Block No Spacer Perform procedure Second Installation Add Spacer to the back of the Chip...

Page 79: ...apter 1 of the Machine Manual This procedure is accomplished by alternating between Lockout Tagout and power up 2 Locate the Router adjustable stop on the bottom of the Hinge Carriage For each router back out 6 flats of the bolt See the figure below 3 Remove the old Chipout Block Location of Router Stop Adjust when burn ing the Chipout Block Bottom View of Machine Remove the 2 Bolts and Chipout Bl...

Page 80: ...ch Hinge Carriage screw in the stop bolt by 3 flats 9 Burn the Chipout Push the Burn Chipout Button at the Interface 10 For each Hinge Carriage screw in the stop bolt all the way 11 Remove the door and the jamb 13 Run a test door to verify a clean cut 5 Before burning in the block tighten the 2 top screws to compress the top and bottom of the block together 12 Loosen the Allen bolts on the Chipout...

Page 81: ...Values 3 47 KVAL 990 F4 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 ...

Page 82: ...Collet Torque Values KVAL 990 F4 Service Manual 3 48 ...

Page 83: ...ting point for troubleshoot ing page 4 7 About the Machine Sensors Includes the voltage values of sensors during machine operation Locations of Sensors on the machine page 4 21 Troubleshooting the Air Cylinders Includes procedure to trouble shoot air cylinders such as adjusting extension and retraction speed page 4 23 Troubleshooting Electrical Problems Includes voltages in the electrical panels u...

Page 84: ...load from one fixed position to another fixed position at a constant speed and along one line axis X Y or Z A typical point to point would be a drill with a fixed depth The drill is either retracted or extended using a pneumatic cylinder Typically the drills travel is limited by physical stops Incremental Incremental motion control is used when the load is required to be moved with high accuracy t...

Page 85: ... Translates entered information so positioning system can understand Listens to the machine s other subsystems while waiting for the OK to move com mand Sends the positioning instructions to the positioning system Listens to the positioning system for position status if there is a feedback loop Tells the machine s other subsystems when the move process is completed Examples A PLC or a dedicated mo...

Page 86: ...terrupting heavy motor currents The figure below shows a block dia gram of a typical contactor circuit with typical voltages FIGURE 11 Typical Contactor Control PLC Output Fuse s Line Voltage Power Motor Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here Should...

Page 87: ... Typical Motor Control Typical Positioning System Pneumatic Circuit A control valve solenoid is used to drive cylinders to move different loads in the machine For Example extending and retracting router drill clamping a door PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Should measure Control Voltage 24 VDC here Should measure Line Voltage here...

Page 88: ...Circuit PLC Output High Pressure Air Cylinder Common Control Circuit ON Should measure 24 VDC here Control Voltage Should have High Pressure air here Extended Cylinder Retracted Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output ...

Page 89: ...fication Note See Table 4 1 on page 8 for sequence and subsystem information Verify Verify or analyze the subsystem assembly that is responsible for the issue For example How is the subsystem supposed to work What is keeping the subsystem from working Note See Analyze the Sub Systems on page 4 8 for information on verifying and analyzing subsystems Before you Adjust Sometimes simple problems can s...

Page 90: ...age 4 8 TABLE 4 1 Typical KVAL Machine Sequence Typical Machine Sequence Responsible Subsystem 1 Move Door into Position Feed System 2 Clamp the Door Door Clamp 3 Make the Cuts Cutter Positioning Cutter Power 4 Unclamp the Door Door Clamp 5 Move Door Out Feed System 6 Wait for Next Door Feed System Basic Troubleshooting Steps Determine Where The Sequence Step Where the Failure Occurs What was the ...

Page 91: ...r inputs to insure the proper sensors are activated If the controller is a PLC an activated input is lit Some touch screens have inputs status also 3 Common Position Feedback failures Photo Eye Bad element or bad cable Limit Switch Stuck or failure Wiring Broken worn insulation PLC Bad input port 4 Check the Positioning System Follow the circuit from the Controller output to the Load and check for...

Page 92: ...Block Diagram of a Common Contactor Circuit High Voltage may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician PLC Output Fuse s Line Voltage Power Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here Li...

Page 93: ...rcuit See Troubleshooting with the Status Light Panel on page 4 26 1 Open the Main Electrical Cabinet to find the Contactor Thermal Overload Assem bly 2 Press each Green Reset button on the Thermal Overload An audible click will be heard on the tripped circuit Take note of tripped circuit 3 Once the overloads are reset verify LED s are on 4 Rerun the machine and verify that motor runs without trip...

Page 94: ...ltage may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician Common Motor Drive Control PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Measure Control Voltage 24 VDC here Measure Line Voltage here Measure Line Voltage here ON Drive STF Forward RL STR Revers 2 SD COMMON OFF OFF OFF Run 30...

Page 95: ...iagram see Figure 4 3 on page 4 12 FIGURE 4 4 Sample of VFD VFD models vary in KVAL machines depending on where it is used voltage requirements and type of PLC used This is a general view on the VFD See the machine s Electrical Print for detailed information Line Voltage IN Converted Signal OUT to Motor Operation Panel Access to manual operation VFD This panel can be used for trouble shooting purp...

Page 96: ... lit To reset a VFD 1 Push lighted button to reset the indicated motor b If the button light turns off continue with production c If the button stays lit identify the motor by way of the label on the button turn off that function at the switch panel Check the corresponding output on the PLC output If the output is on it will not let the motor reset Dis connect the output wire and verify that the m...

Page 97: ...m of a Pneumatic Circuit PLC Output High Pressure Air Cylinder Common Control Circuit ON Measure 24 VDC here Control Voltage Should have High Pressure air here Cylinder Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output Schematic Drawing of Pneumatic Circuit Note Pre 2006 machines may not contain the 24 Volt relay 120 Vac is directly fed into th...

Page 98: ... the solenoid body Use this information to troubleshoot system if nec essary FIGURE 4 8 Solenoids in Manifold Air Input Cylinder Retract Cylinder Extend Electrical Wiring Box Contains inputs from PLC to Coils Solenoids Manifold Base to accept air input and output air Coil Solenoid Receives input 24V from PLC to open a port Solenoid type will vary with machine application Common controls include an...

Page 99: ...cribes the process to move a router to the extend and the retract position with a double valve Extend Process If PLC determines the conditions are right to extend the Router 1 The PLC applies the control voltage to the Control Valve which directs com pressed air to extend port of the Cylinder 2 The Cylinder and Router are extended deactivating the Retract Sensor 3 The Router fully extends activati...

Page 100: ...Cylinder and Router retract deactivating the Extend Sensor 3 When the Cylinder and Router are fully retracted the Retract Sensor is activated 4 The PLC senses the voltage from the Retract Sensor completing the process Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extend Sensor Retracted Sensor Deactivated Activated 24 Volts Extended Cylinder 24 V Applied R...

Page 101: ...ets and flipping screws in Hoppers However sometimes machine settling mechanics be broken in may be cause to slightly adjust extend and retraction speed If more than 1 2 turn on adjustment knobs are needed call in a specialist or check with KVAL customer service at 1 800 553 5825 Cylinder 0 V Router Assembly Load Position Feed Back Air In Control Valve Retract Sensor Activated Air Pressure Retract...

Page 102: ...F4 Service Manual 4 20 Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip If Installing a new flow control assembly shut down the flow control and back out 4 to 5 turns this position is a good starting point for kine adjust ...

Page 103: ...d wiring connections Sensor Locations The Figures show the sensor locations on the machine 990 F4 is displayed Auto Adjust Edge Sense Eye Before In Feed Stop Eye After In Feed Stop Eye Door In Machine Eye Before Out Feed Stop Eye After Out Feed Stop Eye Width Adjust Inside Eye Width Adjust Outside Eye X Axis Reverse Limit X Axis Home Limit X Axis For ward Limit Open Width Adjust Safety Limit Switc...

Page 104: ... get dirty Make sure they are clean If they are not clean debris may block the signal or provide a false signal Check output voltages of the sensors in the active mode The voltage should effec tively equal 0 VDC Check the output voltages of the sensors in inactive mode The voltage should effec tively equal 24 VDC ...

Page 105: ...this regulates the air flow exhausting from the cyl inder and the opposite is true for the retract motion 1 Check the air pressure to the machine 2 Check the flow controls to see that they are adjusted correctly and to the proper specifications 3 Check for any obstructions to the cylinders such as screws or a misplaced tool etc FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS 4 Check the...

Page 106: ...w cylinder c If the valve is not receiving an electrical signal for instructions It might be necessary to call in a specialist or check with KVAL customer service at 1 800 553 5825 5 If an Air Leak is coming from an exhaust port on the solenoid air bank a Check the solenoid for the manual override If the solenoid has a manual over ride you can push each of the buttons one at a time When the air le...

Page 107: ...rmine what systems are being affected If the Power Stops During Normal Operation 1 Check that the input power disconnect switch is not turned off 2 Check that all of the emergency stop buttons are in the normal position Lockout and Tagout the main power source 1 Turn the panel disconnect switch in the off position open the electrical panel door 2 Observe the disconnect switches Look for loose or b...

Page 108: ... is in proper working order The lights turn on in a sequence and will stop at the point where a fault is first detected If one or more lights are OFF follow the process below to isolate the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 4 27 STEP 2 Overload Relay Amber If light is OFF go to item B o...

Page 109: ...iring of the black and white wire going from the Control Transformer to the 120 VAC Terminal Strip 7 If there is no power between 1 and 2 check the secondary side of the trans former a Check between X1 and X2 If no power is measured it is a bad transformer b If there is power at X1 and X2 check the other side of the fuse If now power replace the fuse 2 Is the Disconnect Switch on the main electric...

Page 110: ...he Rear Access Gate and near the Tool Changer Access Gate Stop Light OFF Check for 120 VAC between 2 and 4 If there is volt age press the Start button If no voltage check the Stop button to make sure it is all the way out and not stuck in then check the contact to make sure it is closed If still no voltage check the wiring Start Light If the Start light remains unlit push in the Start button and h...

Page 111: ... no 24VDC replace the 24VDC Power Supply If there is 24VDC Reconnect the V wire to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wire from the 24VDC power supply Check for 24VDC at between any DC and DC terminal on the DC Terminal block Reinstall the 24V positive wires one by one chec...

Page 112: ...Tension Hinge Pocket Brake Out 1 Flow Control Out of Adjustment 2 Worn Out Chipout Blocks 3 Worn Out Tooling 1 Readjust as Needed 2 Replace the Chipout 3 Sharpen or Replace the tool Router Has Excessive Noise or Vibrations 1 Bent Arbor Shaft 2 Tool Out of Balance 3 Router Loose in Housing 1 Replace Arbor 2 Replace Tool 3 Tighten Router in Housing Feed System Doesn t Stop for Door to Clamp 1 Debris...

Page 113: ...s Proxim ity Sensor not Sensing 1 Look For Obstructions 2 Adjust Ferrous Proximity to within 1 31 or the reading surface Router Fails to Operate 1 Bad Fuse 2 Routers Unplugged 3 Bad Brushes 1 Replace Fuses 2 Plug In 3 Replace Brushes Routers Stuck in Pocket Position Pre Drill Only 1 Emergency Stop has Occurred 2 Power Failure Thru Beams Out of Alignment 1 Re energize Computer 2 Hit Router Out of P...

Page 114: ...Symptoms and Possible Causes KVAL 990 F4 Service Manual 4 32 ...

Page 115: ... flange block bearing maintenance schedule3 17 G gear box maintenance schedule3 17 I internet access location of connection2 3 remote connection2 3 RJ45 to intranet2 3 intranet RJ45 connection2 3 L LCD display smart power supply2 3 linear bearing maintenance schedule3 17 lockout and tagout Guidelines1 13 lockout procedure1 11 lubrication schedule bearings3 17 P pillow block bearing maintenance sch...

Page 116: ...cription4 26 use as troubleshooting key4 26 T tagout procedure1 11 tapered bearings lubrication schedule3 17 troubleshooting using status lights4 26 TwinCAT 2 software automation software2 3 U USB module2 3 W Windows CE operating system about2 3 Z zerk fittings3 18 locations3 18 zero energy start up clean up1 13 inspect1 13 ...

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Page 118: ...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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