Kval 994-X Operation And Service Manual Download

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Overview of the 994-X Door Hanging System

KVAL 994-X Operation/Service Manual

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Overview of the 994-X Door Hanging System

KVAL's 994-X offers a high-speed pre-hanging line with the additional flexibility of servo con-
trolled hinge routing sections. This includes high frequency spindles and programmable point to
point pre-drilling.

The 994-X is designed for both interior, exterior doors and jambs. It will accommodate 1-3/8" and
1-3/4" thick doors with a minimum width of 18" and a maximum width of 42”. Door lengths of 6'
8" or 8' 0" can both be machined. Hinge locations automatically shift between two pre-determined
factory set locations to accommodate both three hinge pockets (6’-8”) and four hinge pockets (8’).
Changeover does however require manual repositioning of the jamb clamp fixtures but can easily
be accomplished in under two minutes without the use of tools.

The door is power-fed into the machine and clamped into position. After the hinges are attached,
and machining is finished, the door and jamb automatically is off-feed as the next door enters the
machine

Hinge routing sections are completely servo controlled for pocket height, width, and depth. Each
hinge routing section is equipped with two 1-1/2 HP High Frequency spindle motors, one for rout-
ing and one for pre drilling on both the door and jamb. Servo motors allow the hinge router to
accelerate out of and decelerate into hinge corners eliminating over travel. Changeover from 3-1/
2” to 4” hinges is accomplished by selecting the desired size on the touch-screen.Our Point to
Point Pre-Drill system can be programmed to drill all common hinge patterns automatically.
Additionally, the use of servo motors allows you to machine both 1/4” and 5/8” radius corners
without changing out tooling.

Hinges may be attached manually or with the optional Six-Shooter to install 3-1/2" X 3-1/2"
hinges, or the optional Eight-Shooter for attaching 4" X 4" hinges while the door and jamb remain
clamped in position. Door-to-door productivity, including hinge mounting, is typically 35-55 sec-
onds. However, this varies depending on the operator and material flow.

The lock machining assembly will be positioned with a single servo driven ball screw. This is
controlled by the touch screen, and will allow settings for standard lock and dead bolt locations
based on the lock bore location. A third dead bolt bore may easily be added by entering the posi-
tion on the touch screen. The servo driven system will automatically position the lock boring
assembly when the door hand is changed. Lock detailing includes 2-1/8” face boring with push
button change over between 2-3/8” and 2-3/4” back sets; 1” bolt drill and face plate routing. Face
plate routing will be accomplished with a 1-1/2 hp Hi-Frequency spindle motor.

The 994-X will accommodate doors with raised molding one or both sides up to 3/4" high, and a
minimum of 4" between the raised molding and the edge of the door.

This machine is equipped with a solid state touch screen that replaces many of the mechanical
switches for the machine functions. The touch screen also includes the capability to view the sta-
tus of the various photo eyes and switches for quick diagnosis when needed, without having to
open the electrical panel or for the operator to leave his work station. The Touch Screen logic also
includes management functions such as Daily and Lifetime Totals.