Kval DL-2 Instruction Manual Download Page 5

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Customer Service Information

KVAL is happy to help its customer make the most of their investment, and

help solve any problems that may occur. When you call, please have the

electrical print, air print number, and the serial number of the machine ready, so

that we are able to accommodate your needs efficiently.

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

Summary of Contents for DL-2

Page 1: ...KVAL INC Instructions Manual DL 2 Door Light Cutout ...

Page 2: ...ll 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 p...

Page 3: ...o 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 ...

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Page 5: ...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 3 ...

Page 6: ...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 7: ...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 8: ...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 6 ...

Page 9: ...ployer 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 remov...

Page 10: ...afe 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 8 ...

Page 11: ...echanical 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 equipm...

Page 12: ... 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 13: ... 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 14: ...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 15: ... 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 16: ...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 17: ...ing 1 5 8 holes The template is reversible so that backsets of 2 3 8 and 2 can be machined Purchase additional alternate size inserts from KVAL Edge Detailing Machine The face bore location is on the side bore drill carriage and pivots into position when the DRILL IN air switch is PUSHED ON the CONTROL CONSOLE Once activating the DRILL IN switch PUSH the DOWN switch to lock the drill and template ...

Page 18: ...head area Loosen the collet in the spindle holding either wood or metal bits using the wrenches included with the DL 2 Use the 7 8 wrench on the spindle flats just above the pulley and the second wrench on the top hex Unscrew the draw bar by turning it counterclockwise After you have given it about three turns no more than 1 8 at a time tap the top hex with a soft faced mallet to break loose the c...

Page 19: ...ng screws below and to the front and rear of the main body Screwing the front one in will lower the front of the drill and screwing the back one will raise the drill Depth of Drilling There really is very little adjustment as far as the depth The only adjustment is by shimming the back of the cylinder out so the drill moves closer to the door edge By doing this you are able to drill deeper This is...

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Page 21: ...he shaft to identify which cut out it does Loosen the set collars and position them in the approximate position of the dimensions of your light cutout Tighten the set collars Make a test cut and adjust as necessary If you have templates for rectangular lights Place the template in the DL 2 With power off guide the carriage along the pattern At the four corners of the light pattern position a set c...

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Page 32: ...AND STAGE IT AGAINST DOOR STOP PUSH THE DOOR CLAMP BUTTON TO CLAMP THE UNIT IN PLACE CHECK TO MAKE SURE THAT THE HEAD OF THE TEMPLATE AND THE SIDE LITE ARE BOTH AGAINST THERE RESPECTIVE STOPS CUT A RECTANGULAR CUTOUT USING THE END STOPS AND THE TEMPLATE BAR SET UP ONCE THE TEMPLATE HAS BEEN MACHINED THEN UP CLAMP THE UNIT AND FEED IT OUT OF THE MACHINE THEN REMOVE THE SIDE LITE See Illustrated Dra...

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Page 35: ...e X Locks The Carriage X Locks lock the DL 2 carriage in the X or lengthwise direction Carriage Y Locks The Carriage Y Locks lock the DL 2 carriage in the Y or crosswise direction Reciprocation PUSH PULL Fabco The Reciprocation PUSH PULL Fabco on the right side of the cutter carriage is used to control the reciprocation of the cutter head Motor ON OFF The Motor ON OFF switch on the left side of th...

Page 36: ...he Push to Clamp Door button controls the clamping of the door against the locator bars clamps the door tight against the fixed fence and brings the template clamp down against the template Two Stage Cutting Push Pull Fabco optional This Push Pull valve on the end of the cylinder raises and lowers the reciprocation actuator allowing the operator to select between the top skin and the second skin o...

Page 37: ...s the location of the bolt drill OUT The drill carriage pivots away from door s edge IN The drill carriage swings IN DOWN Locks the drill carriage in position to drill Drill PLUNGE ROUTER IN This is a 3 position air switch that controls the plunge of the bolt and router After pushing the switch to the left the IN will plunge the drill into the side of the door to do the bolthole Release the switch...

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Page 39: ...type of oil see lubrication requirements WEEKLY 1 Check machine for smooth motion through a complete cycle 2 Clean linear bearings and chrome shaft then lubricate 3 Check air pressure to and on the machine 4 Adjust and lock flow controls 5 Check all air lines electrical wiring for kinks or rubbing MAY AND DECEMBER CHECK UPS 1 Wash filter and lubricator bowls with soapy water 2 Grease all bearings ...

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Page 41: ...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 42: ... 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...

Page 43: ...OR THE BITS STEEL DOOR BIT WILL ONLY CUT A FEW DOORS BEFORE BECOMING DULL SOLUTION CHECK BELT LOCATION TO MAKE SURE IT IS ON THE SLOW SPEED PULLEY CONFIGURATION IN THE CASE OF THE 3 POSITION PULLEY THE BELT SHOULD BE IN THE MIDDLE PROBLEM DOOR WILL NOT CLAMP UP SQUARE IN THE MACHINE SOLUTION MEASURE FROM FENCE TO FENCE ON BOTH IN FEED AND OUT FEED ENDS IF ONE END IS LESS THAN THE OTHER IS YOU CAN ...

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Page 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 52: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 2 NOTES ...

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Page 66: ...Notes ...

Page 67: ...Notes ...

Page 68: ...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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