TY-1500.2R说明书 Chapter - 1 (1,2)

1 Machinery Directive: 98/37/EC
2 Low Voltage Directive: 2006/95/EC

3 Electromagnetic Compatibility Directive:
2004/108/EC
1.1 Name of manufacturer or supplier
Hangzhou Tayu Machinery Co.,Ltd.
1.2 Full postal address including country of origin

Industrial Region of Xianlin, Yuhang, Hangzhou,Zhejiang, China
Description of product
Vertical Plastic Injection Molding Machine
Name, type or model, batch or serial number

Name Vertical Plastic Injection Molding Machine
Model: TY-1500.2R
Serial NO (Inspected item):
Standards used, including number, title, issue date and other relative documents
EN ISO 12100-1-2003EN ISO 12100-2-2003EN 692-2005EN 60204-1-2006EN 1050-1996
EN 954-1-1996EN 61000-6-2-2005EN 61000-6-4-2001.
Place of issue Hangzhou
Name of authorised representative Yang MaoRong
Position of authorised representative General manager
Declaration
I declare that as the authorised representative, the above information in relation to the
supply / manufacture of this product, is in conformity with the stated standards and other
related documents following the provisions of the above Directives and their amendments.
Signature of authorised representative Date:
PREFACE
CATALOGUE
PREFAC0-1
CHAPTER 1 SECURITY ASPECT 1-1
1.1 Use range of the machine1-1
1.2 ELECTRIC SAFETY EQUIPMET1-1
1.3 MACHINE SAFETY EQUIPMENT1-2
1.4 SAFETY ALARM NAMEPLATE1-3
1.5 Machine Operator General Principle
1-8
CHAPTER 2 INSTALL MACHINE
2-1
2.1 Storage condition of the machine2-1
2.2 PREPARE FOR INSTALLING MACHINE2-1
2.3 DISCHARGE AND CONVEY 2-1
2.4 INSPECT APPEARANCE 2-1
2.5 INSTALL 2-1
2.6 THE PARTS OF INSTALL MACHINE2-2
2.7 JOIN WORKING LIQUID2-2
2.8 ELECTRICAL POSITION2-3
2.9 COOLING WATER PIPELINE POSITION2-3
2.10 CLEAN WORK AFTER INSTALLATION2-5
2.11 LUBRICATE OIL2-
5
2-12INSPECTION2-5
2.13 Go out of service of the machine or treatment of maintenance waste2-6
CHAPTER 3 ATTENTION3-1
3.1 MACHINERY EQUIPMENT3-1
3.2 ELECTRIC EQUIPMENT3-2
3.3 HYDRAULIC EQUIPMENT 3-3
3.4 OTHER PROJECT3-4
CHAPTER 4 OPERATING PROCEDURE4-1
4.1 INSPECT BEFORE OPERATION 4-1
4.2 START AND STOP OIL PUMP MOTOR4-2
4.3 CLAMING MOLDOPENING MOLD AND STROKE SWITCH4-
3
4.4 INJECTION PARTS4-4
4.5 THE PARTS OF NOZZLE4-5
4.6 SLIDE PLATE4-6
4.7 THE PARTS OF EJECTOR4-6
4.8 INSTALL MOLD4-7
0-1
PREFACE
4.9 SCREW PLASTIFYING MEASURE INJECTION MATERIAL POUR
PROTECTION MEASURE
OPERATION4-8
4.10 SEMIAUTOMATIC OPERATION4-8
4.11 CLOSE AND STOP MACHINE4-9
4.12 UNLOAD MOLD4-9
CHAPTER 5 MACHINE OPERATION5-1
CHAPTER 6 MAINTENANCE AND INSPECTION6-1
6.1 DAILY INSPECTION6-
1
6.2 PERIODIC INSPECTION6-5
6.3 HEAT EXCHANGER6-9
6.4 VACUUM FILTER6-11
6.5 SCREW AND HEAT BARREL CLEAN AND INSPECT6-12
CHAPTER 7 COMMON MALFUNCTION OF THE MACHINE & EXCLUSIVE METHODS7-1
7.1 HANDLING BREAKDOWN OF MACHINE7-1
7.2 THE PROBLEMS ABOUT MOLDING7-3
CHAPTER 8 ATTACHMENT AND DRAWING8-1
Chapter 9 Special Tools and Parts Replacement9-
PREFACE
TAYU series of plastic injection molding machines are good hands for
you; it will bring performance of safety and stability.
This machine is suit for thermoplastic material, apart from this
material; strictly prohibit use this machine to product.
The noise figure of the machine is less than 80db.

The foregoing machines have already passed a series of inspections by
test-drive which they are qualified and they can be used in the kinds of
complicated environments for a long time. We can make sure safety, stability
and reliability during use.
Using machine rightly, it can make the better products for you.
You must read the instructions carefully before using the machine please.
0-1
PREFACE
The details of texts are essential for the operator and manager of
equipment. Please reading and understanding it carefully, thus you can get a
big hand about operation, maintenance and repair.
The data will be improved on the technology in near the future and the
latter data could be different from your handy data. Please deal with them
according to the fact.
Please keep the data carefully, it is a permanent file.If you sell the
machine to other customer; please transfer it together with the instruction
0-1
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CHAPTER 1 SECURITY ASPECT
In order to ensure the safety of operator, when the machine happen malfunction or cant be in
working order. The machine has prepared the security equipment in the chapter. Please inspect the
all security equipments before starting to operate the machine, and make sure them can be operate
rightly when they are required, these equipments are fitting for all TY series machines and
protection.
1.1 Use range of the machine
This machine is fit for manufacture plastic items, except for this it strictly prohibit use this
machine to produce others products.
1.2 Electric Security Equipment
1.2.1 Safety Door and Osiswitch of Safety Door
The position of safety door Osiswitch, please looking at the drawing of electrical way. And the
quantity of Osiswitch, according to the modle of machine and have or not other safety equipment.
The Osiswitch of safety door can break off the circuit of close mould, because when the safety
door open,the Osiswitch will baeak off the circuit, it can stop the motion of close mould.
1.2.1.1 Test Run of Checking
Step1: open the safety door;
Step2: make the switch become to manual. Please reference the chapter 5
Step3: make motion of closing mould;
Step4: The close mould doesnt run under normal.
Attention Under there are safety door condition around of close mould pay attention to
check the two facets of operation and nor-operation.
1.2.1.2 Periodic Checking
1Make sure the safety door can open and close flowing;
2Looking for the cause of damage safety door (Door,guideway,trolley etc.);
3Make sure the rightly matching about the Osiswatch of safety doorscrewmotivater,
etc
1.2.1.3 Pay Attention
1The safety door and Osiswatch can protect the operaterplease dont move and change
them.
2 If the safety cant rightly open and close or have some malfunction,please adjust and
repair it immediately.
1.2.2 Urgent Stop Machine Button
This button can urgent stop the machine,when you press it oil pump motor stop, and the
machine stop,put back, turn right the button.
If you dont need to urgent stop the machine, but in order to stop the oil motor under normal,
please use the choose switch. Make sure all the switches are in ther position. Press the urgent
button to stop the oil pump motor.please reference the chapter 5.
1.2.3 Safety Sensor:
The safety sensor can protect the working area of close mould,so close the mould whether
manual or semi-automaticwhen the safety sensor find the blockit will output the signal to the
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computer, the close will sotp immediately and open the mould.
Attention: because the safety sensor hold some working rangeavoid the wrong of adjusting to
make damage to human.
1.2.4Automatic Starting Button
Under the semi-automaticboth hands press the automatism starting buttonit will close the
mould, when you release your hands, the close mould will sotp immediately end the program.
When the slowly and low press switch receive the signal in the process of close mould, it will go
on to close the mould, and go in to the next motion.
When one circle of molding end, it will go on the second circle, if the computer find one of
automatic starting button is closed in this time, it will alarm, and dont start the next circle motion.
Forbid the process of producing and make the automatism starting button become short circuit, and
avoid affect the safety and producing.
1.2.5 Emergency Recover Button
In the process of close mould, if happen emergency, press the button, the mould will open
immediately, and avoid happen accident.
Attention: Nor-emergency, dont press the button, avoid damage the mould.
1.3 Machine Safety Equipment
Close Mould Safety Equipment
The structure diagram refers the machinery safety diagram in the fitting drawing of machinery.
When one of safety door is open, and start to close mould, in the process of machinery humper
move back, the safety block of machinery will move under the spring, it can ensure that even though
one electrical malfunction happen, when the mould try to starting, the safety block will forbide the
humper move ahead, thus can prevent the close mould starting.
Adjust the humper,make the ending of humper and block on the same level(please see the
machine safety fitting darwing), to the general molding plastic, at the stoping position of opening
mould and the moment stoping position of close mould, can make the humpers block automatic move,
then use the two fixed nuts fix the humper.
Attention 1: Making sure after install the mould, then adjust the machinery humper. In order to
ensure safety, when the safety opens, make sure the block can automatic move at the stop position of
open mould.
Attention 2: Dont move the humper, block and cover of protect bar.
Attention 3: Dont forget, when you stop before the machine stop open mould, the safety
equipment dont effect.
Attention 4: If you dont rightly operate, it will cause the serious danger, and make the machine
dont act and malfunction.
1.4 Safety Alarm Nameplate
In order to remind the operator pay attention to operation safety and abide the operation criterion,
there are some attention and direction affix on the machine as follow:
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A Name Plate---Keep hands away from the exclusion area when the machine is operation
The nameplate on the upper mould plate, please abide the saying, dont reach hands into the mould
of machine.
B&F Name Plate---It has electroshock danger when the machine is running, you may cut power off in condition
of maintenance.
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The nameplate on the all electrical parts which can hurt human, when service and maintenance
these parts, please dont forget to turn off the power.
C Electric Cabinet Name Plate
:
:
Name: Vertical Injection Molding Machine Power Supply: 380V/50HZ
TY-1500.2R KW
Model No Rating Power

Series No Rating Current A

Full Load Current Short-Circuit Current KA
D Machine Name Plate
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380VAC
Name Vertical Injection Molding Voltage
Machine
TY-1500
Model No Frequency 50HZ
2R 365cm3
Worktable type Theoretical Shot Volume

Series No Current A

Weight T Motor Power KW

Total Power KW Electric Heating KW
Ex-Factory Date
T Y
Tayu
Angle Machine Theoretical Shot Volume (cm3)

Single Slide S
Double Slide DS
Clamping Force Parameeter<Unit KN> Bakelite Machine B
Double Slide Bakelite Machine DSB
Two Rotary Turntable Machine 2R
Three Rotary Turntable Machine 3R
Standard Mcehine
The nameplate on anti-hot cover of material barrel, the heater of material barrels outer will melt the plastic, the
heater will be high temperature and pressure. If the operator dont pay attention, it will make the operator damage
and hurt. If you want to clear and replace the material barrel parts, please turn off the switch of power, and make
the barrel become cooling.
The nameplate on the all moving safety door, dont open the door when the machine is running.
E The nameplate on the position which dont tramp, dont tramp these area of machine.
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G Name Plate---There has high temperature in the name plate area when the machine is
working.you may turn off the power supply of the heat component and waiting for temperature
decline before maintenance the machine.
H The name plate is located above the movable safety gate, it may not open when the machine is running
1.5Machine Operator General Principle

Operator means the company who installed the machine inside their company.
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Give enough train and instruct to the machine operators, so as to make them know well about the
machine; this operating manual may used as an important tool but not the only one.
When you deal with the material such as gas, mist, vapor or dust which may harm to health,
operator may set suction equipment for install and run of this machine; the suction equipment fixed
in the die plate in the ordinary course of events.
Operator may provide proper protect tools for machine operators; especially gobesafety shoe and
glove.
Operator may follow the specified care and maintenance period and regular safety inspection.
Operator may adopt proper fire protection around the machine and provide extinguisher; train and
instruct operators and maintenance man how to use fire fighting device and rescue facilities.
Operator may stipulate responsibility and necessary intelligence to different work respectively, and
check the condition of execution of the regulation.
It may only use original spare parts or work material and spare parts approved by Hangzhou Tayu
Machinery Co., Ltd.
Operator has responsibility to comply with security requirement in technique.
It may not change the machine structure without agreement of Hangzhou Tayu Machinery Co.,
Ltd., especially to welding the supporting items and change of the safety device.
No allow altering or changing the safety device.
Only if Hangzhou Tayu Machinery Co., Ltd., has designed the interface, it will not assume any
responsibility for mutual interference between machine and peripheral equipment.
If it needs to dismantle extra equipment, all primary safety devices may reinstall and restore safe
state in technical adjustment.
Even though listed clearly in the operating manual, it may follow effective rule and norm of
enterprise health and labor security, which mainly refer to UVV/VBG and labor security legislation
in the Federal Republic of Germany.
Operating and Maintenance Man General Principle
Person who are not trained and qualified may not operate the machine, especially to the hydraulic
and electric apparatus.
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Even though listed clearly in the operating manual, it may follow effective rule and norm of
enterprise health and labor security, which mainly refer to UVV/VBG and labor security legislation
in the Federal Republic of Germany.
If need be, it also may follow safe practice established in addition in-company.
It is not allowed to operate the machine without enough training and instruct by authorized
colleague in your company include who are not know well the machine; this operating manual may
used as an important training tool but not the only one.
Attention: diseasehave medicinedrinkor other drugs may affect people competence, it can not
guarantee the reliable work in such a case.
It may have adiabatic glove and defend glasses that do maintenance and adjust work in injection
unit area.
Dont have tiescarves or earring which may draw into the machine.
It may careful and concentrate when you are working.
In addition, you may pay attention to other person nearby the machine and guarantee their safety.
Keep fluently around the machine especially operated terminal.
It may not dismantle or round the mechanical, electric apparatus and hydraulic safety equipment
which are installed in machine, such as shield, safety door and safety switch etc. for ever.
Operator may install suction device by themselves when it processing the plastic material which
may release gasvapor or dust.
Machine operators may familiar with the fire fighting facilities and fire extinguisher nearby the
work station.
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CHAPTER 2 INSTALL MACHINE

2.1 Storage condition of the machine
The machine may sotre under the normal temperauter; None moisture, none dust and enough
space, in order to guarantee safety of the operators and good working condition may prevent
machine and products from dirty.
2.2 Prepare for Installing Machine

2.2.1 Liquid (hydraulic oil) and lubricate oil
Please choose the suitable working liquid and lubricate oil from the advise consumable form,
to the liquid of quantity, please refer to the function form.
2.2.2 Electric and Water
Before supply the machine, should complete the clectical power and water supply, or else
install and mould plastic training and sue will be delay and effect.
The machine of small size and some circuitry, they may be different from the drawing
provide, thus the electrical power and water supply should contain the size of changing.
2.3 Discharge and Convey
Please read the function specification or contact us, know well the weight of machine. Because
should choose the suitable crane lift the machine, the worker shoud have profuse experience.
When lift the machine, must be careful.
2.3.1 Use the enough strong crane and carrying machine
2.3.2 If any wire rope touch the parts of machine,please put some cloth fabric or wood between the
wire rope and parts of machine, avoid damage the machine.
2.3.3 Pay attention to stability and level when the machine is lifted
2.3.4 When the whole process of discharge and convey are finished, so can move to the wood and
other pad.
2.4 Inspect Appearance
Inspect the appearance of machine.
If you find the damage of machine, please contact our sales department, or sales office. If you
are foreign customer, pelase contact our local office, agent or our factory asap.
2.5 Install
2.5.1 Please know well the dimension of shape and the position of pad ( advise use level pad),
please reference the drawing of shape dimension.
2.5.2 Install place
2471
The install place should not be1000dampness,dusty, and should be1000
extra space, and ensure the
safety of operator. And the well working condition can avoid making become dirty of machine and
1000
products. The install place should can contain the enough space for ancillary equipment and the
action of operator.
1646
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1000
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2.5.3 How Install Plastic Injection Molding Machine

The machines installation feet all use level pad directly to touch ground,then link the machines.
In the process of installation machine, use one sets of exact level equipment on the worktable of
machine, adjust the each level pad, and make sure the machines level position.
2.6 The Parts of Installation Machine
The dismantles parts and spare parts which machine was transportation,and install the all parts.
2.7 Join the Working Liquid
Viscous of woking liquid46CST/40. Please refer to the Chapter 8.
2.7.1 Via air filter, try best to join into the working liquid to the limited
of liquid meter. All prepare working is finished,will start to the
machine,inspect the oil position of oil box, if the oil position is lower than
middle of scale, please join into the working liquid again, make the liquid
meter show position is higher than the middle scale. ( the join oil mouth and
liquid meter of detal position, please looking at the machinesdrawing and
show position.)
2.7.2 About the supply quantity of working liquid, please reference the latter function
specification.
Please remember the quantity of meter include all oil crock capacity, so the quantity will make
the working liquid overflow the oil box.
Remark 1: different brand working liquid cant use mix together.
Remark 2: choose the working liquid, please reference the chapter 8, or ask our company
sales department or the supplier of working liquid.
Remark 3: The motor of oil pump dont start till three hours after join into the working
liquid, so can make the air out from the oil.
2.8 Electrical Position
Electrical position can consult Electrical Engineering CompayIts an example as follow
2.8.1 Please use one suitable exact fuse for three phase electrical source.
2.8.2 Link the electrical cable to link wire board of electrical box, electrical souce is three phase
four line380V/3phaseor three phase three line220V/3phase.
Attention: Please tell us the electrical source when you order the machine, the total power of
machine please refer to the chapter 8.
2.8.3 If the drive motors turning is contrary, please change for the two fire wire.
2.8.4 In order to avoid leak electrical case accident, link one lead ( as the below drawing) to
injection head of box base, another head link to the floor or copperplate, then cover up into earth.
Link Floor Protecting
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2.9 Cooling Water Pipeline Position

Cooling waters pressure is 210kg/cm2.
2.9.1 Pipeline and Discharge
Heat exchanger (oil cooler) and mold injection part of bases cooling water pipeline.The both,
according to regulation, both supply cooling water and via different pipeline. The cooling water
should come from the same supply water( come from the same water source), the pipeline of
position as follow:
Attention: cooling water of oil cooler should supply before the molding plastc starting
2.9.2 Discharge of Cooling Water
2.9.2.1 When molding plastic is finished, stop cooling water, and make the cooling water
discharged from the cooler.
2.9.2.2 In winter, the cooling water should go on cycle under the lower pressure. In night,if the
cooling water maybe freeze, please make the cooling water discharge from the cooler, the rest of
water should clear out use pressure air, in order to avoid the cooler and other equipment
damage.
2.9.3 Cooling Water Flow Speed
Cooling water flow speed change, it should according to the condition of molding plastic, water
temperature, air temperature,coolers dirty make the efficiency change slow and other cause. So
the below table show it is not the regulation, its only reference.
2.9.3.1 Coolers Cooling Water Flow Speedavoid working liquids temperature over 55
Output of Pump Motor Cooling Water Flow Speed
11.0 KW below 19.0 liter/minuter
15.0 KW 26.0 liter/minuter or more
2.9.3.2 Cooling Water of Injector Base Moldaccroding to the molding plastic condition
Heater Power Cooling Water Flow Speed
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1 KW 2.0 liter/minuter or more
2.10 Clean Work After Installation
2.10.1 The part of no paint have daub prevent stainless oil, they must be clean by petrol or
kerosene.(Please dont smoking or fire in the near around.)
2.10.2 The part surface with chromium, for instance: pull pole,lead pole,close mold piston pole
should clear the all dust and dirt, or else it maybe damage seal ring.
After clean work, daub the lubricate oil on all moving parts.
2.11 Lubricate Oil
2.11.1 Please use clean lubricates oil. High viscosity and no accord demand lubricate oil may
cause the lubricate action mistake.
2.11.2 For the machine with center lubricate system, please inspect the oil quantity of center
lubricate system before suppling oil.
2.11.3 The use position and kind of lubricate oil, please reference the dawing.
2.12 Inspection
At last, please inspect all fixed screw and pipeline linker, and under hydraulic pressure and
electric system fixed nut, if they are ease and loosen, please fix them.
After finishing installation from front step, it should be dual adjust, and make sure the machine
is more safety and efficient.
2.13 Go out of service of the machine or treatment of maintenance waste
(1) Waste material belongs to inrecoverable material, so when debugging the machine it may
deal with according to inrecoverable one.
(2) The cylinder sealed item which produced during maintenance is belong to rubber products, it
may deal with according to inrecoverable material; spare parts like solenoid valve hydraulic
pipe may deal with respectively and machine parts may deal with in recoverable.
(3) When machine stop operation, it may take apart; and deal with waste according to different
type.
(4) The waste hydraulic oil of the machine may deal with in inrecoverable way.
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CHAPTER 3 ATTENTION
If it consider that the design is thoughtless, want to improve it, change of the oil circuit or
electric circuit can cause accident and damage, so you may contact with the manufacturer, the
branch office of manufacturer or the agent. The manufacturer will not responsible for any accident
or damage to any improvement to the machine, especially to the parts security maintenance and
electrical and hydraulic oil or electric circuit.
When inspect the machine or do other work on machine, you must clearly remember security,
the first thing you do is cut off the hydraulic pump motor power.
3.1 Mechanical Device
3.1.1 Make sure about the security of the machine plate and operators, the machine plate should
operate by qualified worker who was trained.
3.1.2 For the sake of protect personal safety, please dont let 2 or more person operate the machine
plate in manual status at the same time.
3.1.3 When inspect the machine plate or do any work on it, before touch any moving element,
hydraulic or electric parts, you must cut off machine plate general supply, only by that it can
guarantee personal safety.
3.1.4 In order to maintenance the machine plate safe life, please dont change the component and
design at will.
3.1.5 Dont adjust the screw with red color position in machine plate, such as ejector retain limit,
slide plate left go limit etc. so as not to damage machine plate.
3.1.6 To TY vertical injection molding machine series, before install the mold and clamping mold,
you must make sure the nozzle can not high than the lower face of the upper platen, so as not to
damage the machine plate.
3.1.7 To the horizontal injection molding machine plate, such as TC series, before you install the
moving mold (rotary plate or slide platen), you must make sure the nozzle can not jut between
upper and lower platen, so as not to damage the machine plate.
3.1.8 To vertical injection molding machine plate, such as TY series, before install the moving
platen (rotary platen or slide plate) you must make sure it can not jut lower surface of the upper
platen, so as not to damage the machine plate.
3.1.9 When you install the mold or part of the operator body must go into the space of upper and
lower plate, must stop the motor operate.
3.1.10 In order to protect personal safety, this machine has done full security protection, it strictly
prohibit any part body of the person go into the space of upper and lower plate and other moving
parts of the machine plate.
3.1.11 screw rotate speed setting
In order to prevent the screw damage, after the machine started, let screw lower speed and high
torque rotating within 60rpm, time is about 1 month (1st month after starting).
3.2 Electric Equipment
3.2.1 Connect three-phase alternating-current supply
Connect three-phase alternating-current supply (L1,L2,L3) wire and median wire (N) to the wire
connecting terminal in the middle of the plate. (Vide to part of machine installation.)
3.2.2 Inspect oil pump motor rotate direction
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3.2.2.1 After the wire was connected, the machine has moved to the terminal position, it can
preoperation. Switch on the oil pump motor for a little while, you must make certain its rotate
direction should same as the oil pump rotate direction .(you may observe whether it is same as the
instruction board).
If the rotate direction of the motor and the oil pump is opposite, let the alternating-current supply
wire L1 and L2 exchange then connect to the patch board.
3.2.2.2 Use scrawl start, when start the machine. (that is switch on the power then cut off , after 1-
2 seconds, repeated the scrawl start and cut off 5 to 6 times.)
3.2.3 Stop the machine
When operation is over or a sudden power cut, please turn off the power in order to machine
security and protect electric equipment.
3.2.4 Zero Line (Vide to machine earthed parts).
3.2.4.1 Whether there is a earth wire?
3.2.4.2 Is it damaged?
3.2.5 Electric Motor Thermorelay re-adjust Dial (OL).
3.2.5.1 Set before delivery, so you should not adjust it again.
3.2.5.2 If thermorelay has changed for damage, then set the dial to the rated current of the pump
electric motor.
3.2.6 Electric Motor triangle star starter and timer which started separately by multi-electric
motor.
When the timer is working, dont adjust it as will, because it will cause trouble so as to damage
the timer.
3.2.7 Heating Barrel automatic temperature controller
It is not provide ordinary, the heating barrel is controlled by computer, you should pay attention
to it when using it, dont set more than 2 thermocouple in every phase.
3.2.8 Door of the Electric Cabinet
When operating or prepare to operate the machine, please remember at all time that the door of
the electric cabinet is close. (If there has other reason or you must inspect the machine, the first
thing you should do is shut off the power which connect to the machine).
3.3 Hydraulic Equipment
3.3.1 Hydraulic Oil
3.3.1.1 Use Hydraulic Oil that glutinosity grade within 32-68CST/40, recommend using
glutinosity grade 46CST/40 hydraulic oil.
Glutinosity
(1) If glutinosity is too high:
Friction inside adding;
Oil temperature rising too fast;
Moving parts can not operate well;
Pressure lost increase.
Power lost increase.
(2) If glutinosity is too low:
Slide surface friction is limited;
Oil leak of seal gasket increased;
TAYU MACHINERY
Operation precision declined;
Pressure declined;
Pump efficiency declined.
3.3.1.2 Pay attention to the oil level reach above the middle level.
3.3.1.3 Pay attention to hydraulic oil temperature, keep it among 15 and 55,the best suitable
temperature for operation is 40 to 50.
3.3.2 Lubricant
3.3.2.1 Use 32-68CST/40 lubricant, 1#, 3# lithium base grease, WanLingBa brand
LIEP00.
3.3.2.2 Use Manual Mode to lubricant the machine general before operate the machine, make sure
every lubricant point has been lubricant.
3.3.2.3 The lubricant of oil cup which is in movable parts of injection part should be done before
machine is started.
3.3.3 System Hydraulic Pressure
Please pay attention to the pump pressure, which should lower than the peak pressure of
hydraulic system listed in technical parameter table, if the pressure is over this sphere, it could
cause fault and a serious damage to the machine. The position of the system pressure meter is
located under the cabinet switch or in injection protective board. details please vide machine
profile drawing.
3.4 Other Project
The parts and backup parts delivery by the injection machine is design and manufacture for the
machine. So it can never use in other application. We are not responsible for any damage by any
using for other aim, because the parts is exclusively for injection molding machine.
TAYU MACHINERY
CHAPTER 4 Operating Procedure
Please obey security regulation all the way.
4.1 Inspect before Operation
4.1.1 Suitable Dress
Safety helmet
Glove
Smock or over clothes (make

sure fasten the button)
Safety boots
or shoes
4.1.2 To connect the cooling water (Vide part of cooling water in the machine installation);
4.1.3 Wired to injection molding;
4.1.4 Inspect the thermocouple and heating wire as temperature measure in the barrel, ensure it is
normal, then turn on the heating switch, adjust temperature to suit for the raw material which will
be molding. (Vide the table below):
Common Usage Plasticizing Material Name and Characteristic
Temperature Set
Hopper Screw Mold Contraction
Material
Nozzle First Second Temperature Speed Temperature percent
ABS 190-250 180-240 170-240 80-90 30-60 50-80 0.6

AS 205-240 190-235 180-230 75-85 30-60 35-50 0.1-0.6
PS 180-260 200-260 160-250 75-85 35-65 10-75 0.4
HIPS475 220-270 190-260 160-250 80-90 50-80 5-75 0.4
PP 210-300 180-260 160-240 70-80 50-99 50-80 1.0-2.5
LDPE 230-310 220-300 170-220 70-80 50-60 35-60 1.5-5.0
HDPE 230-310 220-300 170-220 70-80 50-60 35-60 2.0-5.0
PMMA 180-230 160-240 140-220 80-100 40-80 50-90 0.5
PA6 210-230 210-230 200-210 80 45-50 50-80 0.8-1.5
PA66 250-280 240-280 220-280 80 45-50 50-80 2.25
POM 190-210 175-220 160-210 80-90 40-80 50-90 2.0
PC 250-320 260-340 280-350 100-120 25-55 80-100 0.8
PVC 170-220 160-195 150-190 60-80 30 15-60 0.1-0.5
PET 280-295 270-275 265-270 130-140 25-45 35-85 5.0-15
PBT 250 245 235 130-140 40 60-70 10
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CA 180-200 170-190 150-180 50-70 85-90 40-75 0.5
SAN 190-250 180-230 170-220 75-90 90 50-80 0.2
BAKE 60-110 50-100 50-99 180
DRE+EVA 185 160 160 50-80 99 35-45 10

4.2 Start and Stop oil pump electric motor
4.2.1 Adjust selection switch according to below steps first, then you may start or stop oil pump
electric motor.
Step1: Put the operation mode into manual mode;
Step2: Put all operation switch into the middle position (to the non-touch button model);
Step3: Switch on the power;
Step4: Press the electric motor button starting it;
Step5: Press the electric start button (to non-touch button model machine) or press the stop
button, if the emergency stop button pressed, the machine will stop too.
4.2.2 Attention matter:

(1) Ensure the hydraulic oil level is above the middle level before start the machine.
(2) Open the safety door.
(3) Any hydraulic equipment (valve, filter, oil pipe etc.) need cut off, please dont start oil
pump motor.
(4) At the exact moment when the pump power is on, check the rotate direction of it.
(5) If the rotate direction is reverse, change the position of the phase position wire of the
power.
(6) When oil pump is rotate, listen carefully whether there has any abnormal noise.
4.3 Clamping mold, Opening mold and Stroke Switch
4.3.1 Clamping mold Operation
Step1: Close safety door:
Step2: See whether the indicator light of receiving terminal of safe raster is normal, use a barrier
inspect whether the reaction of safe raster is ok.
Step3: Put the machine status to manual mode;
Step4: Press auto-start button, start clamping mold action.
Caution 1: When mold is closing with a high speed, dont let the mold close discontinuously,
even when the low-pressure switch is on, the inertia always has possible make
the mold close suddenly. For this reason, when closing mold is discontinuously,
be sure select a low-speed.
Caution 2: Decide the minimum mold height according to this machine, to avoid over stroke.
4.3.2 Adjust mold operation
Step 1: See whether the indicator light of receiving terminal of safe raster is normal, use a barrier
inspect whether the reaction of safe raster is ok.
Step 2: Put the machine status to manual mode;
Step 3: Press adjust mold button, let the indicator light on;
Step 4: Press close mold button, do low-speed closing mold action (adjust mold).
4.3.3 Open mold operation
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Step 1: Put the machine status to manual mode;
Sep 2: Adjust the maximum opening stroke of the open mold;
Step 3: Start Open mold
4.3.4 Mold move position control
According to different configuration, there have two kind control way.
Switch and electric ruler.
4.3.4.1 Switch
4.3.4.1.1 Adjust the Mold Open Finish
Setting the distance of upper plate what is retreated upward subject to take out the finished
products easily and save the cycle time.
4.3.4.1.2 Adjust the Mold Close Slowly
To prevent mold damaged because of the eyewinker enter into the mold or closing mold with
high speed, so the adjustment is very important, it should subject to 2-3cm higher than lumps
position of mold close in the high pressure.
Special mold expected.
4.3.4.1.3 Adjusting mold close in the high pressure and the machine under the manual state.
Adjusting the mold and make it joint tightly, move the high pressure lump of closing mold to the
same position with the proximity switch of high pressure , but the position can not above the
proximity switch of high pressure so as to save the cycle time.
4.3.4.2 The Electronic Ruler
The close and open mold position is set by the output signal of electronic ruler. You can set it
when you enter into the setting page. (please reference to chapter 5th).
4.3.5 Adjust clamping force (the pressure switch)
Adjust the clamping force to confirm whether the mold close is finished and control the
clamping force of machine when the machine run automatically. When the closing cylinder reach a
high pressure, the value exceed the setting value of pressure switch , then the close mold action
finished. So the improper adjustment will cause can not start up injection and stop running of cycle
and alarm at the same time.
4.4 Injection Parts
4.4.1 Injection Operation (screw forward)
4.4.1.1 Put the machine into the manual state.
4.4.1.2 Press the injection key, the machine will start injection.
4.4.2 Preventing the material pour (screw retreat)
4.4.2.1 Put the machine into the manual state.
4.4.2.2 Press suck back key, the screw will retreat.
4.4.3 Measure operation (screw spinning)
4.4.3.1 Setting the measure position, the loading pressure and speed.
4.4.3.2 Press screw key, the screw start to spin and at the same time it retreat the halt position of
measurement gradually then stop spinning.
4.4.4 Injection position control
According to the different configuration, there are two kind of control way: proximity switch
and electronic ruler.
4.4.4.1 The proximity switch
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4.4.4.1.1 Adjust 2nd phase injection pressure
Adjust 2nd phase injection pressure according to the actual molding technological requirement,
when the block of 2nd phase injection pressure induced to the proximity switch, the injection
pressure changed into 2nd phase injection pressure and ejected.
4.4.4.1.2 Adjust 3rd phase injection pressure
Principle same as above, when the block of 3rd phase injection pressure induced to the proximity
switch, 2nd pressure changed into 3rd pressure and ejected.
4.4.4.1.3 Measurement adjust
The plastic capacity should be more than the actual injection capacity, or the products will cause
the instability and shrinkage; the section of measurement should keep the right stroke after
finishing ejection so as to hold pressure. The back pressure will affect the molten bulk density of
plastic in the measurement section of barrel, adjust the size rightly according to the different
characteristic of plastics.
4.4.4.1.4 Preventing the material pour adjustment

In order to avoid the molten plastic in the barrel pour into the sprue runner and caused injection
difficulty because of the blockage. After finishing loading, the machine need suck back action
during semi-automatic mode and its position adjustment was controlled by time ( except the
injection controlled by electronic ruler).
Attention: 1. In order to protect the screw, you should operate the screw in 15-30 minutes when
every point temperature reached set value in the heated barrel.
2. In order to avoid damaging the screw, it should running in below 60rpm in the
circumstance of no materials and racing.
3. Dont let your face and hands touch the tip of nozzle!
4.4.4.2 The electronic ruler
The output signal of electric ruler decide the position of injection, loading, and suck back, set
them only if you enter into the page of injection and plastic. (please reference to chapter 5th).
4.5 The parts of nozzle
4.5.1 Nozzle advance
4.5.1.1 Put the machine state into manual state
4.5.1.2 Press nozzle advance key, the nozzle start to advance
4.5.2 Nozzle retreat
4.5.2.1 Put the machine into manual state
4.5.2.2 Press nozzle retreat key, the nozzle start to retreat.
4.5.3 Nozzle advance finish position adjust
4.5.3.1 Time control mode
The carriage stop working when the setting time has been used up. (please reference to chapter
th
5 ).
4.5.3.2 Proximity switch control mode
Confirming the injection action in the semi-automatic state, the improper adjustment will cause
cant start up the injection action and hang up cycle running.
Adjust method: operating it in manual mode first, close the mold and let the nozzle advance
until it can touch the die, moved the block of nozzle advance finish into the same position with the
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proximity switch of nozzle advance finish then fixed it.
Attentions: 1. Operating the mold intermittence before it touched nozzle, that is advance first
then stop advance immediately and advance again, the flow and pressure should be lower now,
avoid damaging each other.
2. Dont clear the colophony salivate off with bare hands when nozzle is advancing. You
should stop injecting and clean it with the clipped tools; you can not operate with your hands
directly!
4.5.4 Nozzle retreat finish adjust
If the carriage was selected in the functional page, the action of mold open can not be confirmed
in the semi-automatic mode, so the improper adjustment cant start up the action of mold open and
hang up cycle running, even it can damage sprue runner and machine. It is better for the position
far from the sprue runner of the mold.
4.6 Slide plate
4.6.1 Table in
4.6.1.1 Put the machine into the manual state
4.6.1.2 Let the upper plate open to the stop position, the left and right ejector retreat to the stop
position, location advance to the stop position.
4.6.1.3 Press table in key, the slide plate start to move from right to left.
4.6.2 Table out
4.6.2.1 Put the machine into the manual state
position, location advanced to the stop position.
4.6.2.3 Press table out key, the slide board start to move from left to right.
4.6.3. Adjust the left and right limit of slide mold.
Setting the slide board left move or right move into the stop position, this is a stroke limit
switch, it has already been set before it left factory. Please dont adjust it so as to avoid damaging
the mould and machine.
4.6.4 Adjust the left and right of slide mould at slow speed
Setting the slide plate move from left or right at high speed, change into the position of low
speed, the aim of position adjustment is what slide plate can work smoothly from start to the end.
4.7 The parts of ejector
4.7.1 Ejector advance
position, location advanced to the stop position.
4.7.1.3 Press ejector advance key, ejector start to move upward.
4.7.2 Ejector retreat
4.7.2.2 Press the ejector retreat key, ejector start to move downward.
4.7.3 Adjust the ejector position
There are two control way to adjust the ejector position: time and proximity switch.
4.7.3.1 Time adjust
Setting the ejector pressure according to ejecting force of molding and restoring spring force of
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ejectors rod then the stroke of ejector advance was controlled by time.
4.7.3.2 The proximity switch
4.7.3.2.1 Ejector advance finished adjust.
Setting it initially, the stroke should be set shorter and adjust it slowly till it is right. Then fix the
inductive block at this position. You can avoid the mold damaged by this method.
4.7.3.2.2 Ejector retreat finished adjust
You should let ejector stroke retreat to the position completely, then fix the position when you
adjust it. The inductive block should be at the same position with proximity switch and its position
cant above the proximity switch. If it is a single-slide plate, double-slide plate or rotary table
machine, ejector doesnt retreat the terminal position, it will damage the machine due to ejector
collide the slide plate or the rotary table when the machine did the action about table in and out or
turn round. The position of inductive block is very low, it cant induct the proximity switch then it
cant start up the action of mold close.
Attention: In order to protect safety of person, please dont make an attempt to take out the
finished products when the machine does the action about ejector advance.
4.8 Mold installation

The mould has a high precision and expensive price, If it installed improperly, it will damage
the mould even can cause serious damage to the machine. So you should read the operation
instruction book carefully before install the mold. Confirm the size of mold according to machine
plate size and the mold height according to the minimum mold height and opening mold stroke.
4.8.1 Pre-install the mold
Please reference to drawing of the mold install in chapter 8, make sure the selected mold is fit
for machines specifications.
4.8.1.1 Adjust security equipment of clamp mold, ejector stroke and close mold limit switch etc. so
as to avoid damage the mold when adjust the mold height.
4.8.1.2 Prepare to assemble the screw bolt, connect parts and tools etc.
4.8.2 Steps of mold install
4.8.2.1 Installation method about the mold with locating ring
4.8.2.1.1 Make sure the ejector has been retreated to the terminal and the carriage has been
retreated to the terminal.
4.8.2.1.2 Letting mold open finish, mold open slow and mold close high pressure in the lowest
position. If the position of movable mold was controlled by electronic ruler, only set the value of
mold open finish is the maximum value, then opening the mold.
4.8.2.1.3 Put the mold in the below plate, press mold adjust key and the indicator light is on, then
press mold close key, start to adjust the mold and let the upper plate stop when it apart from mold a
definite distance. Readjust the position about locating ring of mold and the center hole of upper
plate, press mold close key again until the upper plate cling to the mold.
4.8.2.1.4 Shut off the motor and fix the mold with clamping bar or fix it with screw directly, then
finish molds installation.
4.8.2.1.5 Move the block of mold close high pressure upward and stop it until the light of
proximity switch is on. Screw the red plastic screw down, then fix the mold when the block of
mold close slow apart 2-3cm from mold close high pressure. (adjust the special mold according to
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the demand). Adjust the position of mold open finish block according to needed open daylight
which take out the product after opening. If the position of mold open was controlled by electronic
ruler, set the position of mold close high pressure according to the actual value on the page add
2cm. Setting the position of mold open finish and mold close slow in the same way with setting
the stroke switch of movable mold.
4.8.2.2 The install method of the mold without locating ring.
4.8.2.2.1 The method is similar to mold with locating ring 4.7.1.1.1 and 4.7.1.1.2.
4.8.2.2.2 Put the mold on the below plate, press mold adjust key, make the light of indicator on,
then press mold close key, start to do the action of mold adjust, when the mold apart 15cm from
the upper plate and loosen hand.
4.8.2.2.3 Press nozzle advance key, when the nozzle near runner of the mold loosen hand, then
observe the nozzle whether it is upright with sprue runner, adjust them and make them
anastomose. Press nozzle retreat key make the nozzle far from the sprue runner and put a thin
piece of paper in the sprue runner or paste a little inkpad in the nozzle, press nozzle advance key
again make the nozzle touch sprue runner of the mold, confirm whether it is anastomosing
according to the vestige on the paper or observe vestige in the sprue runner. If they were
anastomosing, readjust them again. Press nozzle retreat key, make the nozzle retreat a certain
distance, then press mold close key let the upper plate cling to the mold, shut off the motor,
secondly fix the mold with clamping bar or screw directly. The installation of the mold was
finished.
4.8.2.2.4 The method is similar to the locating ring installation in 4.7.1.1.5.
4.9 Screw plastifying measure, injection, material pour protective, measure operation..
4.9.1 Set measure position, loading pressure and speed;
4.9.2 Press loading key, screw spinning, it will retreat to the stop measure position gruadually and
stop spinning at the same time.
4.9.3 Injection (screw onward), press injection key, the injection start;
4.9.4 Pour protective (screw backward): press suck back key, screw start retreat, there has two kind
of control way: time and stroke.
Attention: 1. In order to protect the screw, you should start operate it about 15 to 30 minutes after
every point of the heating barrel temperature reached the pre-setting temperature.
2. In order to avoid screw damage, it should preoperation by speed below 60rpm in condition
of running idle without material;
3. Dont let your hand and face near the tip of the nozzle!
4.10 Semi-automatic Operation
4.10.1 Please check 4.9.1.1 to 4.9.1.7, before semi-automatic operation;
4.10.1.1 Inspect operator and the machine to be in line with security requirements;
4.10.1.2 Inspect whether the security equipments can work correctly.
4.10.1.3 Ensure all limit switch locating correct or electronic ruler position set correct.
4.10.1.4 Inspect each action pressure and flow rate adjust proper;
4.10.1.5 Inspect each action method (automatic cycle method) set correct;
4.10.1.6 Inspect each action time set proper;
4.10.1.7 Inspect every step according to 2 to 7 start the machine manual to be sure the heating
barrel temperature fit for the processing plastic material.
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4.10.2 Operate in semiautomatic method
4.10.2.1 Start the electric motor and heater;
4.10.2.2 Press semi-automatic key, make the indicator light on.
4.10.2.3 Press automatic start button with hands, the injection cycle begin.
Attention: Standard machine process requirement: Press automatic start button with a pair of
hands at the same time, which will start fast speed close mold, loosen hands when close mold with
low pressure and slow speed, otherwise semi automatic action will be stop working.
4.11 (After operation) Close and stop machine
When material used up or indicator light show that the quantity of needed products has been
molding completely and the condition that it must close heating and stop the machine (if it is
temporary short time stop machine, then dont cut off the heater power, shut off the motor only).
4.11.1 Cut off the heater first, then clean the remaining in heating barrel completely, in order to
avoid melted plastic remain in the barrel cause to dissolved.
4.11.2 Manually control the close mold action, let mold close but dont let the cylinder generate
high pressure, if it has been generate high pressure, press open mold key, crawl press the button
and let the high pressure off.
4.11.3 Manually control, let the nozzle and screw retreat to the stop position;
4.11.4 Turn off the electric motor, put the airbreak switch in electronic cabinet to OFF, so as to
cut off machine power.
4.12 Unload mold
Step1: Start oil pump motor;
Step2: close the mold completely;
Step3: Close and stop the oil pump motor;
Step4: Open the emergency exit, install the screw bolt in the mold so as to use next time.
Step5: Unload all mold parts;
Step6: Start the oil pump motor;
Step7: Press open mold button, close mold;
Step8: When close mold complete, close and stop the oil pump motor;
Step9: Move the mold from the machine and put it in the right place.
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CHARPTER 6 MAINTENANCE AND INSPECTION
6.1 Daily Inspection
Inspect before use machine everyday.
6.1.1 Right dressing
Safety-helmet
helh
Glove
Work clothes
Safety shoes
6.1.2 Hydraulic Oil Mass

Make sure the oil level should reached upon middle to full of the level oiler.
6.1.3 Screw bolt on the mold and every moving parts
Check whether it was loosing
6.1.4 Thermocouple (it is variation with different model of the machine)

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Insert too
shallow Pipe snap off
Screw too
loose
6.1.5 Heating Barrel Temperature Rising Time

Check it, make it clear whether the heating rising time is too short or too long, and check the
circuit of heater, make sure that it could not raise dangerous to heater circle, thermocouple,
contact.
6.1.6 Safe Device
6.1.6.1 Security Door & Stoke Switch

If the switch was fixed
correctly

6.1.6.2 Clamping Mold Safety Device
Humper Cover
Lock Screw
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Humper Baffle Plash
Moving Platen
Static Platen
6.1.6.3 Emergency Stop Button
When press this button, oil pump motor stopped.

6.1.6.4 Door Valve (annex device, but to some machine, it is standard part)
6.1.6.5 Other Annex Safety Device (safety cover, eliminate cover)
6.1.7 Various kinds of Molding Conditon
Include temperature, pressure, speed, time, times, position of action switching.
6.1.8 Cooling Water
In machines which have flow detector(annex), entrance and position of cool water,
adjustment of flow. Check oil cooler water flow, see whether it has leaked.
6.1.9 Lubrication
6.1.10 Leak and Flowrate

Pipe Joint
Valve on the
fitting surface
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Main Body of the
Valve
6.1.11 Abnormal Noise
Pump Heating
Motor Barrel Oil Motor
6.1.12 Appearance of Abnormal Phenomena In course of Operation
6.2 Periodic Inspection

6.2.1 Weekly Inspection
6.2.1.1 Check whether the screw and screw bolt has tightening which fix the stroke switch.
Loosen or
Lose
6.2.1.2 Heater Circle Surface Status
Resin Adhere Screw Bolt Circuit Lead Wire

Loosen Loosen Damaged
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6.2.1.3 Lapped Pipeline
6.2.1.4 Hydraulic Device and Function
6.2.1.5 Clean Filter Part
In 1st month, clean the filter weekly, then clean it every three weeks.
6.2.1.6 Scrub the machine and make it clean.
6.2.2 Inspection monthly
6.2.2.1 Heat exchanger (oil cooler)
When the water acidity is very high or contain plenty of salinity, clean the heater exchanger
(dismantle pipe cap). If it is urban supply water or similar water source, inspect it every 6 month.
6.2.2.2 Clean air-breather part
Air-breather part (with part)
Oil Tank
6.2.2.3 Hydraulic Oil
Dirty or contain bubble
The details vide the content about hydraulic oil in chapter 8, annex table and classification
table of the hydraulic and maintenance.
6.2.2.4 Filter Part Clean
Vide the content about the vacuum filter in this chapter.
6.2.2.5 Check fusible switch power panel
6.2.3 Inspection every 3 month
6.2.3.1 Observe whether hydraulic is dirty, if it is very dirty or oxydic, consider to change
hydraulic oil.
6.2.3.2 Loose and Bare Circuit
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Loosen
Bared Wire
6.2.3.3 Electric Cabinet

Check the nubby air filter in electric cabinet, clean it when it is necessary
Airstrainer installed in inside of the electric cabinet
6.2.3.4 Loosen Locked Nut
Die Mold
platen
Tighten Loosen
6.2.4 Inspection every 6 month

6.2.4.1 Inspection whether the heating barrel screw bolt is tightening
6.2.4.2 Inspection all of the fuses
Even if the fuse has not blown, it has need to renew regularly. Because when the power is on,
the repeated dash current can cause abrasion.
6.2.4.3 Inspection whether the screw bolt has been tightening.
Apply to tightening momental guide of screw bolt (reference value)
Screw Bolt Specification Momental
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M3 0.23
M4 0.46
M5 0.92
M6 1.6
M8 1.6
M10 7.5
M12 13.0
M16 30.6
M18 43.0
M20 61.6
M24 80.4
Momental (Kg.m)=Pipe limited length (m) force (load) (Kg)
When the load is 10Kg, 10Kg1m=kg.m
6.2.4.4 Check the damage condition of the moving part of machine, use whetstone to fix up
carefully.
6.2.4.5 Heat exchanger (oil cooler)
6.2.5 Inspection Annually
6.2.5.1 Hydraulic Oil
Observe whether it was dirty or got bad, if the condition of it is very poor, then change it.
6.2.5.2 Clean the Machine
6.2.5.3 tightening all screw bolt again
The tightening momental of screw bolt about the machine, please vide relevant content in last
page.
6.2.5.4 Insulation Test
You should let some electrical appliance installation contractor or similar company do this
work.
6.2.5.5 You should let expert in this area detect pump driving motor.
6.3 Heat Exchanger (water-cooled oil cooler)
Water-cooled cooler mainly use fresh water as cooling medium, shell side (through fresh
water) fluid and tube side fluid through heat transmitter to exchange heat, let high temperature
fluid temperature decline, To reach cooling aim.
6.3.1 Cooler Structure
Water-cooled cooler is combined with out and in water cover, pipe plate, pipe barrel, heat
transfer pipe, traverse baffle, seal gasket and horse etc.
As picture 1 show. the space which surround by surface of the heat transfer pipe and pipe barrel is
called shell side; the space of inner heat transfer pipe and the connected space of them is called
tube side. Shell side fluid and tube side fluid change heat through heat transfer pipe, which can
decline the high-temperature fluid temperature to reach cooling aim.
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Water-cooled cooler
structure
1
01-Inlet Water Cover 02-Seal Gasket 03-Fixed Tube plate 04-Seal Gasket
05-Traverse Baffle 06-Heat Transfer Tube 07-Flow Tube Plate 08-O Ring
09-Return Water Cover 10-Medial Pouring Orifice Flange 11-Seal Gasket
12-Horse 13-Pipe Barrel Component
6.3.2 Usage of the Cooler
When the cooler is using, the pressure and temperature can not over product nameplate and
product certificate posted.
Except special ordering product, the medium can only use fresh water. The requirement of fresh
water is show below:
Cooling Water Quality Standard
Item Measurement Units Cooling Water Make up Water
PH (25) US/CM 6.5 6.0-8.0
Conductivity (25) Mg/1 <800 <200
caco3 Mg/1 <200 <50
caco3 Mg/1 <100 <50
CI Mg/1 <200 <50
SO4 Mg/1 <200 <50
Fe Mg/1 <1.0 <0.3
Sio2 Mg/1 <50 <30
S Mg/1 0 0
NH4 Mg/1 <1.0 <0.2
6.3.3 Cooler Inspection, Maintenance and Clean

6.3.3.1 Cooler Inspection
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For easy to inspection to the heat exchanger, you should better unload it from the machine.
Urban supply water (or similar), inspect it every 6 month.
Industrial water and ground water or water contained plenty of salinity, inspect it monthly.
Please pay attention to the device situation, prolong or shorten the period between two
inspections if it is possible.
6.3.3.2 Cooler Maintenance
Please let off the fluid in cooler when long-time do not use it; let off the fluid in cooler after
cooler stopped working if fluid is possible to freeze.
6.3.3.3 Cooler Clean
If cooling effect declined, then the inner of every tube is possibly dirty, unload the tube cap of 2
ends, check the sign of rusty and impurity.
Clean the cooler semiannually at least. Use purchasable alkaline washing liquid to clean inner
body and surface of heat transfer pipe. Use infirm hydrochloric acid solution to wash the interlayer
which is difficult to deal with, until it was very cleaning. When there has much scale in inner of
heat transfer pipe, please select dissolved scale washing liquid to steep in, then use rinsing and
banister brush wash it clean. Especially attention dont leave the washing liquid in the cooler.
6.3.4 Common Malfunction and Countermeasure
Fault Conditions Parts Reason Analyze Solution
Seal part of the Tightening screw Tightening the
fixed and moving has not screw down screw
side of the cooler Sealing gasket or Change new
o shape ring sealing gasket
damaged
The contact sealing Repair the sealing
surface with seal surface or change
gasket was parts
damaged
Leak
Pipe flange Tightening screw
Tightening the
has not screw down
screw
Middle flange lean
Middle flange in
alignment with the
connected flange.
Spot of Outlet Screw bolt has not Tightening the
water (oil) tightening. screw bolt.
Screw bolt has not Wrap the tape in it.
wrapped tape.
Connection of two Sealing spot of the o shape ring Change new
kind fluid moving side damaged sealing gasket
The sealing surface Repair sealing
contact with the surface or change
o shape ring was parts
damaged
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Can not reach the Fluid flow not Raise fluid flow to
design temperature reached the designed value
designed flow
The side of heat Clean the heat
transfer pipe has transfer pipe.
too much dirt.
6.4 Vacuum Filter

This filter was installed in inlet of oil tank inner pump, filter and clean the hydraulic oil, you
should follow the description below when unload and change the hydraulic oil.
6.4.1 Unload
Unload the oil tank cover, drain the hydraulic oil in it, some machine need to unload side plate of
the oil tank first, then can reach filter passage.
6.4.2 Clean
Clean and change hydraulic oil every 6 month in the 1 st year, after that, inspect and clean it
annually, at the same time filter or change the hydraulic oil according to oil quality.
6.4.2.1 Use white oil, petrol or washing oil get rid of dirty of obstructed wire winding thoroughly.
Inspect surface condition then

decide processing method
6.4.2.2 Insert the compressed air from inside, blast the dirty off the wire winding.
6.4.3 Matters need to attention
(1) When the vacuum filter was unloading, dont start the hydraulic pump motor.
(2) When use compressed air blow, do not fixed the blow pump mouth too tight.
(3) If the wire winding was damaged, you must change the vacuum filter.
(4) When unload and install the filter, please keep the pump motor stop working, so as not to
damage the wire winding.
(5) When start the pump motor after vacuum filter was installed, you should start it slowly, so as
not to damage hydraulic pump.
6.5 Screw and Heat Barrel Clean and Inspect

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Unload the screw, clean and inspect it when it is necessary. Vide content of chapter 4 about
process of unload of screw and heat barrel, then you can unload it quickly and correctly.
6.5.1 Spare parts needed, except for tools:
(1) 4 to 5 block of wood (Diameter<ScrewLength<Injection Stroke);
(2) 4 to 5 block of timber (Square, 100mm300mm);
(3) 1 pliers;
(4) waste cotton
(5) 1 long pliers or bamboo (Diameter<ScrewLength>Heat Barrel Length);
(6) Brass bar and brass brush.
6.5.2 Unload Screw, then install on the timber to prevent damage.
6.5.3 Unload torpedo device in screw. (vide content of chapter 4).
6.5.4 Screw Clean and Inspect
6.5.4.1 Clean Screw
(1) Use waste cotton clean the screw body, it can get rid of most of resin form deposit;
(2) Use brass brush get rid of leftover of resin form deposit, or use a burner or similar device to
heat the resin form deposit in screw, heating for a while, then use waist cotton or brass brush
to get rid of the deposit of the screw.
(3) Use the same method to clean the torpedo form device, nonreturn ring, thrust ring and mixing
ring (mixing ring is not use in some machine) etc. (show as below). In addition, still need
use brass brush clean the screw thread and screw body of the torpedo form device in screw.
(4) Finally, when the screw cooled, use apyrous solution clean all smear.
Caution:
(1) Dont try to gall cold working material.
(2) Before install torpedo form device, add some supramoly grease lubricant or silicon oil, to
prevent contain lubricant membrane is enough, if add too much lubricant, injection
products may be polluted.
(3) When use solvent, you need a routine preventive measure, to avoid touch skin and
smoke.
6.5.4.2 Inspect Screw
(1) Check damage condition
(2) Check galled plating
(3) Observe whether the screw thread was damaged (screw body)
(4) Observe whether the non-return ring and thrust ring surface was damaged. If it has been
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damaged, it could cause plastic material refluence when injection.
Non-Return
Screw Head Ring Mixed Ring
Thrust Ring Screw
If you find plasticizing is bad the mold products appear raw meal when you manufacture the
parts, This thrust ring was recommended, it is a standard part (with 34--75mm screw).
6.4.5 Clean and inspect heating barrel
6.5.5.1 Clean the heating barrel
(1) Use a brass brush, get rid of the rezin form precipitated powder which
was adhered to the surface of the heating barrel.
(2) Use waste cotton bundle to clean inside of the barrel in end surface of
stick or long bamboo. In the course of cleaning , change the waste
cotton several times.
(3) Wash the heating barrel and nozzle, especially in two sides of the
contact surface of these parts.
(
4
Front Barrel )
Nozzle Barrel
Contact Contact
Contact Surface Contact Surface
Surface Surface
After the heating barrel temperature fell to 30-50 centigrade,

Use menstruum wet some waste cotton, adopt the method that introduced in
chapter 2. clean the barrel inside.
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(5) Use the method as below picture show, Inspect the inner face of the barrel,
Use torch Insert a piece of

Inspect lighten paper
ensure it is clean
6.5.5.2 Inspect heating barrel, observe whether the surface was scratch or damaged.
Use torch
lighten
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CHAPTER7 COMMON MALFUNCTION OF
THE MACHINE & EXCLUSIVE METHODS
7.1 Handling The Breakdown Of The Machine
Malfunction Reasons Exclusive Methods
1 The total power of input were 1 Measuring the voltage of power;
abnormal and it cant start up; 2 Replacing the fuse and find out
2 The fuse was burned out on the the reason;
computer; 3 Replacing the contacts;
3 The normally closed contacts of 4 Replacing the contactor;
emergency stop switch were 5 Press Reset button or replace it;
damaged on the panel; 6 Replacing or Repairing the
A
4 The contactor coil and contacts motor;
The pump and
were damaged on the motor; 7 Repairing shaft coupling;
motor cant be
5 The overheat protectors of motor 8 Replacing the keys.
started up.
were disengaged or damaged
6 The coil of motor was burned
out;
7 The shaft couplings of motor and
oil pump were disengaged;
8 The key of motor were damaged
on the operational panel.
B 1 The connecting lines of 1 Connecting them again or
The pump motor proportional valves were replacing the coil;
can be started up loosened or the coil was burned 2 Taking the proportional pressure
but no pressure. out; valves apart and clearing the
2 The control port of proportional impurities;
pressure valves was clogged by 3 Cleaning the oil filter and replace
impurities; the pressure oil;
3 The pressure oil is feculent, and 4 Repairing or replacing the oil
impurities swelled the surface of pump;
oil filter and hamper the pressure 5 Replacing the oil pipe;
oil enter into the pump; 6 Connecting them again or
4 The interior of pump was leaking replacing the amperemeter.
because of the long time usage
and interior was damaged by
feculent pressure oil;
5 The pipes were cracked from the
oil outlet of pump to the board of
oil circuit.
6 The connecting lines of pressure
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amperemeter were loosened or
the amperemeter was damaged.
1 The solenoid valves coil of 1 Cleaning or replacing solenoid
Mold Close was burned out or the valve of Mold Close;
valves spool was jammed; 2 Cleaning the valves spool and
2 The counter balance valves of readjusting them ;
Mold Close Slow were jammed 3 Cleaning or Replacing the pilot
or the adjustment was not right; operated solenoid valve;
3 The coil of pilot operated
solenoid valve can be burned out 4 Replacing pressure switch;
or the valves spool was jammed;
4 The pressure switch of Mold 5 Readjusting the position or
Close High Pressure was replacing the safety sensors;
C damaged;
No action of 5 The safety sensors were skew or 6 Slipping the dies to the confined
Mold Close damaged; position again or replacing
6 The slide plates have not reached proximity switch;
the terminal position or limit and
proximity switch was damaged; 7 Press the switch of Ejector
7 The Ejector Retreat hasnt Retreat manually and make it in
reached the terminal position or the place or replace the proximity
the limit and proximity switches switch;
of Ejector Retreat were damaged;
8 Location Advance hasnt arrived 8 Operating the Location Advance
the setting position or the again and let it arrive setting
proximity switch was damaged. position or replace the proximity
switch.
D 1 No Semi-automatic mode; 1
The Semi- 1) The Semi-automatic key was 1) Replacing Semi-automatic
automatic mode damaged; key;
was abnormal. 2) The automatic start button 2) Replacing Automatic Start
3) The motor cant start up; button;
4) The heater cant be started up 3) Starting up the motor again;
or it hasnt heat to the setting 4) Starting up the heater again or
temperature; wait the temperature reach
2 Opening at once after Mold setting value;
Close; 2
1) The die was abnormal or 1) Clearing the exogenous
skew; impurities in the die or
2) The proximity switch of Mold regulating the die again;
Close High Pressure has a 2) Adjusting the position or
improper position or it was replace it;
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damaged; 3) Readjusting it or replacing it;
3) The adjustment of pressure 4) Resetting the setting values;
switch was not right or it was 3 Adjusting the position of
damaged; proximity switch of Nozzle Advance
4) The time of Mold Close Low Finish or replace it;
Pressure was set inexactly; 4 Setting the time and pressure of
3 No injection after Mold Close Ejector Times or replace the limit
Finish; and proximity switch of Ejector
4 No movement of Ejector after Advance.
Mold Open Finish.
1 The adjustment was very big 1 Adjusting the values of pressure

about pressure and speed value of and speed;
Mold Close Slow; 2 Adjusting its position or replace it
E
2 The proximity switch of Mold ;
No Mold Close
Close Slow has a wrong position 3 Cleaning the counter balance
Slow Speed
or it was damaged; valve or replace the spring.
3 The counter balance valve was
jammed or the spring was broken.
1 The solenoid valve of Mold 1 Taking the spool of solenoid
Open and Close was leaked; valve apart and repair or replace
2 The spool of modular pilot it;
operated check valves was 2 Cleaning the spool of check valve
jammed; or replace it ;
F
3 The spring of prefill valve was 3 Replacing the spring;
Dont hold Mold
fractured; 4 Replacing the oil seal in the
Close High
4 The cylinder of mold is leaking; leaking place;
Pressure
5 The oil seal on the piston of 5 Replacing the oil seal;
Mold Cylinder was frayed; 6 Replacing the oil seals.
6 The oil seals of Pressurized
Cylinder and Mold Cylinder were
damaged.
G 1 The limit and proximity switch 1 Adjusting the position or replace
The injection is of Nozzle Advance wasnt it;
abnormal. confirmed or it was damaged; 2
1) Replacing the key;
2 No action of Injection 2) Waiting the temperature reach
1) The injection key was the setting value in the barrel;
damaged in a manual mode; 3) Replacing the coil or clean the
2) The temperature of barrel was solenoid valve;
too low; 4) Making the Injection Pressure
3) The coil of solenoid valve of higher or set the Injection
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injection was burned out or Time;
jammed; 5) Adjusting setting value and
4) The pressure is too low and make the temperature rise to
the time of injection wasnt setting value; if temperature
set; cant rise by adjusting the
5) The temperature of injection is setting value, please inspect
too low. whether the band heater and
contactor were burn out; if
3 The non return loop of screws they are damaged, please
head was damaged or fractured; replace them.
4 There are some exogenous
impurities in the barrel and lead 3 Replacing the non return loop of
to the nozzle was jammed. screws head;
4Clearing the barrel and nozzle.
1 The position about proximity 1 Adjusting the position or replace

switch of gauge was not right or it;
it was damaged; 2 Cleaning or replacing the
2 The solenoid valve of loading solenoid valve;
was jammed or its coil was burned 3 Inspecting whether temperature
out; control has some malfunction
H
3The temperature is too low in the (Prohibit starting the motor of
No loading or
barrel lead to overload of motor; loader at the moment or it will
loading slowly.
4The pressure or speed of loading damage the screw or transmission
are too low; agent);
5The shaft or bearing of the pump 4 Adjusting the pressure or speed
motor were damaged. value;
5 Replacing the pump motor, shaft
or bearing.
I 1 The pressure of Loading Retreat 1. Adjusting or replacing the one-way
The screw of was too high, the throttle valve of throttle valve of back pressure;
loader can rotate back pressure was damaged or the
but the plastic adjustment was not right; 2. Connecting the cooling water or
material cant 2 The cooling loop of barrel cant augment the flow of cooling
enter into the connect the water or the flow was water, then take out the coagula of
barrel. too small and lead to the materials;
temperature was too high then
prohibit the colloidal particles 3. Replacing the plastic or reduced the
enter into the screw; proportion of second materials.
3 The plastic particles are too
large, long or the proportion of
second material are too high and
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lead to the plastic particles cant
enter into the barrel.
1 The keys of Nozzle Advance and 1 Replacing the press keys;
Retreat were damaged;
2 The limit and proximity switches 2 Replacing the proximity switches
of Nozzle Advance and Retreat or adjust the position;
were damaged or their position
J
were not right; 3Replacing or cleaning the solenoid
The carriage
3 The solenoid valves of Nozzle valve;
cant move.
Advance and Retreat were
jammed or their coils were 4 Adjusting the pressure time of
burned out; Carriage Advance and Retreat.
4 The pressure was too low and the
time of carriage wasnt set.
1 The proximity switch of Mold 1 Replacing or adjusting the
Open Finish was damaged or its position;
position was not right; 2 Replacing or adjusting the
2 The left and right limit and position;
proximity switches of the slide 3 Replacing or adjusting the
plates were damaged or their position;
position were improper; 4 Replacing or adjusting the
3 The limit and proximity switches position;
K
of Location Advance were 5 Adjusting the pressure of Ejector
No Ejector
damaged or the position was Advance.
improper;
4 The limit and proximity switches
of Ejector Advance were
damaged or the position were
improper;
5 The pressure of Ejector Advance
is too low.
7.2 The Problems about Molding
The plastic molding products are produced according to standard specifications, but they will
cause the shrinking, deformation, chasm or the other unacceptable products accidentally when the
production is carrying out smoothly. So we should know the problems about the molding during the
production and find them. The materials, dies, injection machines and conditions of molding will
affect the products so this chapter will give some solution to the above problems.
You can consider four-side factors about affecting the molding problems: (1) materials (2)
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injection machines (3) design of dies (4) conditions of molding
Materials Design of dies
Rigidity
Quality of die
Die configuration
Dent resistance
Crystallinity
Obdurability
Temperature of die
Fluidity
Heat-deformation-proof
Heat safety
Chemical proofing The shape of sprue
Fixity Characteristic of Finished products

Plasticizing Injection pressure
Clamping force Temp. of barrel

Ways of plasticizing Cooling time Revolution
Speed of ejecting
Molding machines Conditions of molding
CHART ONE
7.2.1 Shrink
Shrink points there are some hollow on the surface of plastic products. It not only affects the
exterior appearance of products but also decrease the quality and strength of the products. The reason
of shrink is related to technology of molding and plastic materials.
7.2.1.1 Plastic
The different plastic materials have different washing shrinkage; please make a reference to chart
two. The common materials about shrinking easily belong to crystalline materials such as nylon and so
on. The crystalline plastic appeared fluid state and the molecule appeared irregular array. The plastic
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molecule will align the crystal slowly when it entered into the cold die configuration, then the volume
are less than the given size range, that is shrink.
CHART TWO the Washing Shrinkage of Diversified Plastic
CODE THE PLASTIC MATERIAL WASHING SHRINKAGE%

GPPS Common StyreneEbonite 0.4
HIPS Non Shattering StyreneNon 0.4
Shattering Ebonite
SAN AS 0.2
ABS PolypropyleneButadieneStyren 0.6
e
LDPE Low Density PolyethyleneLow 1.5----5
Durometre Stock
HDPE High Density PolyethyleneLow 2-----5
Durometre Stock
PP Polypropylene 1-----4.7
PPO PPO 0.6
PA6 Polyamide 6 1.0
PA66 Polyamide 66 0.8---1.5
ACEAL Polyacetal 2
COPOLYMER
CAB Acid Acetate Fiber 0.5
PET PET 2.25
PBT PBT 1.5----2.0
PC PolycarbonateBullet-proof 0.6
glue
PMMA PMMA 0.5
PVC Hard PVC 0.1----0.5
PVC Soft PVC 1-----5
PU PU PlasticUrethane 0.1----3
EVA EVA Plastic 1.0
PSF Polysulfone 0.7
7.2.1.2 The ejection technology

There are some situations of shrinkage about ejection technology such as deficient pressure, slow
speed of ejection, too small gate or too long runner etc. So you should advert about conditions of
molding and whether holding pressure are enough, avoid causing shrinkage.
7.2.1.3 The design of mould and products:
The designs of molds runner and cooling device will affect finished products greatly . As a
result of the plastics has weak heat-transfer capability and they are away from the die wall the farther,
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the thicker, then they are concreted and cooled slowly. So sufficient plastics should be filled in the die
configuration, if so, when the screw are ejecting or Hold Pressure, the plastic will not flow backwards
and decrease pressure and lead to shrink. If controlling temperature well in the barrel, they can avoid
the plastics too hot and delay the cycle assures the products have plenty cooling time.
You can improve quality of products if you can solve these problems of shrinkage. You can find
reason and solution about those problems in chart three:
CHART THREE
REASON SOLUTION
The deficient plastic entered into die. Increase the plastic material in the die
The deficient plastic quantity Loading properly and increase back pressure
The injection pressure is too low; Increasing the stroke of plastics gauge
Hold Pressure is not enough. Raising the injection pressure
The ejection time is too short. Increasing the ejection time
The ejection speed is too slow. Increasing the speed
The anisomerous gate Adjusting the size or position of dies entrance
The nozzle was jammed. Cleaning it
The temperature of hopper is too high. Decreasing the temperature
The temperature of molds is improper. Adjusting the temperature properly
The cooling time is not enough. Delaying the cooling time
The bad exhaust Increasing air vent in the place of shrinkage
The pipe is too big. Replacing the smaller pipe
No return loop of screw was fretted. Repairing it
Uneven thickness of plastic products Increasing injection pressure
7.2.2 The finished products adhered to the die.

The finished products adhered to the die, you should consider whether injection pressure or
holding pressure is too high. The higher injection pressure will cause the finished products
supersaturation and plastics be filled the other gaps then lead to the products adhered to the die.
When the temperature is too high in the hopper, it will appear these phenomena. One is higher
temperature made the plastic decompose lead to transformation, loss of original properties then
appeared the fracture; the other is difficult cooling of plastics to cooling in the die configuration and
need delay the cycle time. So you need adjust the temperature according to plastic characteristic. The
mould can also affect the products so you should improve the molds quality. Please find the reason
and solution about difficult knockout of finished products in the chart four.
CHART FOUR
REASON SOLUTION
The more material was filled. Decreasing measurement, time and speed
of ejection
The injection pressure is too high or the Reducing the injection pressure or
temperature is too high in the hopper. temperature in the hopper
The time of holding pressure is too long. Reducing the time of injection
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Fast ejection time Reducing the ejection time
The inhomogenous feeding will cause Changing the size or position of pouring
supersaturation of some parts. nozzle
The cooling time is not enough. Increasing the cooling time properly
The temperature of die is too high or too low. Adjusting the temperature of die
The die had undercut of knockout. Repairing the die and removing the
undercut
The feeding inlet of single impression mold or bar Restricting the plastic flow and let them
moulds is uneven. near to main runner possibly.
Bad design of knockout and exhaust in the hopper Providing enough vent holes
The time of Screw Advance is too long. Reducing the time of Screw Advance
The molds surface is too rough. Polishing the surface of mould
7.2.3 Die sticking of runner (Difficult knockout)

CHART FIVE
REASON SOLUTION
Too big runner Amending the die
The cooling time of runner is not enough. Prolonging the cooling time or Reducing the
temperature of pipe
The angle of knockout of runner is too Amending the die and enlarging the angle
small.
The dent of runner is not fitted with the Readjusting them
nozzle.
The inner surface of runner is rough or it Repairing the die
has undercut of knockout.
The external opening of runner was Repairing the die
damaged.
There is no lock pin in the runner. Installing the lock pin
7.2.4 The finished products appeared pore.

The finished products have some small air bladder in the process of molding. If so, they not only
affect the mechanical strength characteristic of products but also wreck the appearance. When finished
products appeared air bladder, you can inspect the following factors and find the solution.
The cooling speed of plastics is different in the mould because of the moulds salient and gage
distortion of finished products. The different cooling speed has different shrinkage degree and lastly
leads to form air bladder. You should advert to the design of moulds.
If plastics contain hydrosphere about using materials aspect, the heating plastics will be
decomposed in the process of melting and the tolerance of injection screw is too smaller then the air
will enter into the die configuration easily, at last they will form the air bladder.
CHART SIX
BREAKDOWN SOLUTION
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Drying materials and avoid changing temperature overly
The materials contain water.
before injection
The materials of ejection were Inspecting whether temperature, injection pressure and
not enough. injection time are enough.
The products fractured, the Changing design of products or position of pouring nozzle
sides or column is too thick.
The injection pressure is too Increasing injection pressure
low.
The injection time is not Increasing injection time
enough.
The pouring nozzle or runner is Enlarging the runner and entrance
too small.
The speed of ejection is too fast. Reducing the speed
The temperature of materials is Reducing the temperature of materials
too high and lead to decompose.
The cooling time is too long. Shortening the stream or increasing cooling temperature
The cooling water is torrential. Raising the short stream or cooling temperature
The back pressure is not Increasing back pressure
enough.
The temperature of mould is Adjusting temperature of mould
uneven.
The temperature is improper in Reducing the nozzle and forepart temperature as well as
the pipe. increasing posterior temperature.
7.2.5 Deformation of finished products

The plastic products appear warping because of quickly opening, too high temperature and uneven
of mould as well as asymmetric runner etc. There are two biggest possibilities: The thickness
of plastics are uneven or the round angle is not smooth enough lead to deformation of warpage.
Some flat plastic products in order to perfect appearance and gate of runner was fixed edge
of gate, but molten plastics only enter into die configuration quickly via one end when injection. So
molecule of plastics concreted the die configuration and they are all flared-out to the same direction,
that is named tropism( the internal stress is very big at the moment; these molecule will be pulled back
the original state when the plastics leave the die, if so finished products will cause deformation.)
7.2.5.1 In order to let molten plastics can fill the die configuration successfully; the design should
avoid the followings:
7.2.5.1.1 The thickness has a big difference in the same plastic products;
7.2.5.1.2 There exists an excessive acute angle;
7.2.5.1.3 The area of amble is too short then leads to a large discrepancy.
The design of die should guarantee plastics can enter into the die configuration successfully from
analyzing the gate, so the sub-runner should avoid adopting formation of quarter turn. The corner is
suitable for arched intermediate zone, so the short and thick sub-runner is optimal. It can reduce
resistance and orientation of fluid, but too big gate will increase scrap in the runner and affect
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appearance of plastic products.
Besides, in order to avoid appearing different degree of compactness lead to deformation when
filling the plastics. You should change the size and shape of the sub-runner according to injection
volume and products shape. The more difficult molding parts, the sub-runner should become thicker
and the main runner also became the bigger that is the sectional area of main runner cross is equal to
the sum of sectional area of every sub-runner.
Additionally, we should advert to two problems: one is the formation of Ejector device of Plastic
products. If Ejector device is too poor then will cause the deformation and warpage; but the quantities
of ejectors are too many, it will affect appearance of products, you need adopt method of rushing
board; the other is the design of cooling runner of die configuration, it should make the whole plastic
products shrink equably and improve quality of products.
You can make a reference to the following about the factors of the deformation:
CHART SEVEN
BREAKDOWN SOLUTION
The finished products havent been Reducing temperature of die
cooled when ejecting. Prolonging cooling time
Reducing temperature of raw materials
The products shape and thickness are Fixing it with the figurate frame after knockout
asymmetric. Changing the design of molding
The materials were filled too full. Reducing the injection pressure and increasing the
speed, time and dosage
The material was filled irregularly in the Improving the pouring nozzle
pouring nozzle.
The system of ejector is not balance. Improving the system of ejector
The temperature of die is uneven. Adjusting the temperature of die
The materials of pouring parts are too Increasing or reducing injection time
loosened or too tight.
7.2.6 The crazing and air bladder

The formation of crazing due to quick start of injection and the forepart air cant discharge by
colloidal particle in the die configuration then mix the raw material. At last these will cause the gloss
and color of products is uneven, that is named crazing. It not only affects the appearance of products
but also reduce mechanical strength. So we had better avoid these flaws and find the causation then
improve the quality.
The formation of crazing because of fuse-element exist the air, the following we will discuss the
main source of air:
7.2.6.1 The plastics contained water or oil;
The plastics will suck the air or oil in the air during manufacturing; filling some wrong
proportional ingredients when mixing, then these volatile substances will be affected by heat and
cause gas when doing action of Plastic.
7.2.6.2 The raw materials will be affected by heat and cause decomposing:
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If temperature of hopper back pressure and injection speed were adjusted too high, or the
molding cycle were too long, then the plastics what easily to be affected by the heat such as PVCPC
and so on, they are easy to be affected by high temperature and decomposed then brought the gas.
7.2.6.3 Air:
The plastic particles and particles all contained air, if temperature of screw and hopper were
adjusted very high near the hopper, the plastic particles surface were melted and stick together before
they have not been constricted yet, if so, the air cant discharge completely among the plastics.
So drying the plastics and adopting proper temperature and speed of Plastic as well as matching
proper back pressure then you can gain optimal plastic products. Besides, the design of mould is very
important. The gas has little opportunity enter into the die configuration when the runner is very big
and sprue is very small.
About injection molding technology, one method is add pressure unit in the configuration of
mold and an inlet of compressed air avoid causing the crazing. After closing the mold, the compressed
air entered into the die and made air pressure increase in the die. When molten plastics entered into
this die with high pressure, the air vent of mold started to discharge and Hold Pressure and increased
air pressure in the die configuration avoid causing the crazing. For example: We handled with the
moisture contents 0.1% of ABS by a normal way, it will cause crazing; you can handle the ABS of
high water content by increasing air pressure in the die configuration gradually, it will not cause the
crazing.
CHART EIGHT
BREAKDOWN SOLUTION
The temperature is too high in the hopper. Reducing temperature
The injection speed is too fast. Adjusting injection speed
The materials contain water. Drying the materials thoroughly
The temperature of die is too low. Increasing temperature of die
The gate is too small. Readjusting the diameter of hole or temperature.
There is some air in the hopper. Reducing the posterior temperature of hopper and
increasing the pressure
The thicknesses of raw materials Using even particles of raw materials
particles are uneven.
The other accretions of raw materials Mixing them equably
were mixed nonuniformly.
Dye Replacing the materials what hard to be affected by
the heat
7.2.7 The burr

The burr is common problem of Injection. The pressure of plastics is too high in the die
configuration then the partial forces is greater than the clamping force, open the mould compulsively
then make the plastics be extruded and caused the burr in the surface of products. There are many
problems about causing the burr such as the problem of plastics, the injection machine was damaged
or the other reasons, so it is difficult to find the solution. The high or low viscosity will cause the burr,
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if the viscosity is too low and the fluid will be too high and easy to enter into small clearance of
closing face and increase die parting force until appearing the burr.
Generally speaking, the plastic temperature has a big effect to viscosity, the pressure and rate of
cutting can also affect viscosity. If increasing the temperature and the viscosity will decrease; but if
decreasing the temperature and the viscosity will increase.
The other problems about drying state of plastic and inspect whether there are some impurities.
Some plastics such as nylon and ABS, they can also affect the plastic characteristics, as to
polycarbonate, although it doesnt have bibulous characteristic but it is sensitive to water of surface.
So you need dry the plastics before Injection, then you can control the performance, if the impurities
were mixed with the plastics or different type of plastics, or it is more difficult to predict the variation
of plastic performance surely.
The plastic pressure of die configuration will change according to filling face of die
configuration. The forepart pressure of fused mass is equal to zero before die configuration wasnt
filled fully, the pressure of sprue gate is higher than the other positions pressure in the die
configuration, but when the die opening was filled fully, the pressure loss of plastics flow will vanish,
the whole pressure of die configuration will become the same static pressure, the force what opening
the mold compulsively will increase and cause the burr. In order to avoid these circumstances,
injection pressure should be adjusted to lower holding pressure at once when the die configuration was
fully filled. Except adjusting the pressure control system correctly, another subsidiary method is
decrease injection speed. The forepart plastics of fused mass have plentiful cooling time and solidify
of part so they can avoid causing the burr. The production will reduce due to slow injection speed, the
best adjustment of injection speed should match the clamping force, or it also produced the burr.
If problems about mechanical structures of injection machine, it is more difficult to find the
causation. For example the parallelism has some deviations between the plates or the uneven force
were distributed in tie bar of mold, these problems can caused uneven clamping force between
working dies, and the plastic products appeared the burr in the weak position of clamping force. The
other aspect: if the screw or hopper was frayed, the fused mass will slip and backflow between the
external diameters of thread and hopper, so switching point of pressures position is not correct and
caused the burr.
Except the above factors, if working dies brought some problems and they also caused the burr.
For example, using working die a long time and some parts were frayed and produce the burr. Evenly
a small flaw such as the air vent was jammed also can increase the pressure in the die configuration
and high pressure will cause the burr. If the design of shoot are not equal then the plastics flow are
non asymmetrical in the multi-die-configuration, it will cause the individual die configurations
pressure is not enough but the others will appear the burr.
CHART NINE
PROBLEMS BASIC FACTORS EXAMINED ITEM &SOLUTION
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The temperature is too high. Inspecting the dryer the plastic storage and
transportation
Suffering the pollution Inspecting plastics and any impurities and find the
plastics
source of pollution.
Inspecting setting conditions of operation of
The wrong operation
injection machine according to the data of supplier
The clamping force is too Inspecting pressure value and adjust it.
low.
The injection pressure is too Inspecting setting value and adjust it.
high.
The hold pressure is too Inspecting setting value and adjust it.
high.
The injection pressure Inspecting position of converted pressure and
converted lately. readjusting the position
Injection The injection speed is too Inspecting & adjusting the flow control valve
machine fast.
The temperature is too high. Inspecting the heaters system and revolution of
screw
The temperature is too low. Inspecting the heater, screw and revolution
The slide boards are Readjusting them
unparallel.
The rigidity of plate is not Inspecting the clamping force and replace the plate
enough.
The screw was frayed. Inspecting and replacing it
The air vent was jammed. Inspecting and cleaning it
The working die was frayed. Inspecting using time and clamping force, repair or
replace the die
The working
The size of runner and shoot Inspecting whether the using size is fit or the
die
are improper. position is correct.
The line of partial die is not Inspecting whether the relative position is swept,
matched. readjust the position
The viscosity is too high. Inspecting the plastic viscosity and operational
plastics
conditions of injection machine
Injection The injection pressure is too Decreasing pressure.
machine high.
The injection speed is too Adjusting flow control or increasing temperature
fast.
The injection speed is too Increasing speed
slowly.
The clamping force is too Inspecting clamping force and calculating the
low. correct value of clamping force
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The temperature of working Inspecting heater system and repairing it
die is too low.
The check valve was frayed. Inspecting, repairing or replacing the check valve
The screw or hopper was Inspecting setting conditions of operation of
Injection frayed. injection machine, repairing or replacing it.
machine The clamping force is not Inspecting the force of tie bar
balance.
The plates are unparallel. Inspecting and adjusting the plates
The shoot is not balance. Inspecting the design and revising it
The working die deviated Inspecting the thickness of plastic products and
The working
relatively. adjust it
die
The working die was heated Inspecting system of heater and repair it
unevenly.
7.2.8 The materials were insufficient the hopper.
The hopper were not filled fully by materials, that is the molten materials didnt fill the every
clearance because of the improper setting of molding condition, the design of die, the thick thickness
of finished products. You can increase temperature of materials, the dies temperature and increase
injection pressure, injection speed and fluid of materials to solve forming conditions. About the dies
problem you can increase the runner or size of shoot, inspect the position, size and number of gate etc
and make the molten materials flow easily. In order to discharge the gas successfully in the clearance,
you can add some air holes.
CHART TEN
BREAKDOWN SOLUTION
The injection pressure is not enough. Increasing injection pressure
The temperature is too low in the hopper. Increasing temperature of hopper
The speed of ejection is too fast. Decreasing speed of ejection
The funnel was jammed. Cleaning the funnel
The position of gate is not proper. Adjusting the gate
The runner is too small. Enlarging the runner
The temperature of die is too low. Adjusting the temperature of die
The gas cant be discharged successfully Adding air vents in the right position
in the space.
The lubricant is insufficient. Increasing the lubricant
The plastic quantity is not enough. Increasing stroke of gauge
The injection time is too short. Increasing injection time
The nozzle was jammed. Cleaning the nozzle
The runner or gate is too small. Enlarging the runner or gate
The non return ring of screw was Repairing or replacing it
damaged.
The material was not even. Adjusting the position of pouring gate or using right
back pressure
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The temperature of die is not even. Readjusting the pipe of die
7.2.9 The conjugation line
The conjugation line is plastic materials formed the line in two runners or more. The reason
about conjugation line as follows:
7.2.9.1 The shape of finished products leads to the way of materials fluid;
7.2.9.2 The fluid of molten material is too bad;
7.2.9.3 There is some air or volatile substance in the junction of molten materials.
The conjugation line is the forepart junction and temperature is too low in this part because of
the materials were not melted fully in the junction. The windows and holes of finished products
appeared junction easily and appear the conjugation line. But if fluid of materials is better and you
cant see conjugation line. At the same time increasing temperature of materials and dies can move
the conjugation line to the other position, adding air vent in the junction, discharge the gas and
volatile substance quickly or adding the pouring pond near the junction, at last eliminating
conjugation line.
The conjugation line affects not only the appearance of products but also the strength of finished
products.
CHART ELEVEN
BREAKDOWN SOLUTION
The injection pressure is not enough.Increasing injection pressure
The injection speed is too slow. Increasing injection speed
The gate and runner are too small. Adjusting size of die and changing the position of gate
The position of gate is not right. Adjusting size of die and changing the position of gate
Increasing temperature of materials
The molten materials were bad. Increasing back pressure
Increasing revolution of screw
The air wasnt discharged in the die Adding air vents
configuration. Inspecting whether original air vents are jammed
The material is impure. Inspecting raw materials
The oil of knockout is too much. Using a little oil of knockout
7.2.10 The gloss of products surface is bad.

The products surface lost original gloss and form ivory film or dim state etc. these are all the
bad gloss of surface.
The gloss of products surface is bad because of dies surface. When the surface of die is bad
then the surface of finished products are surely bad. But if the surface of die has a good state, increase
the temperature of materials and die, these can improve the gloss of surface. Using the much mold
release agent can caused bad gloss; the impurities mixed the materials also caused bad gloss
CHART TWELVE
BREAKDOWN SOLUTION
The injection speed is too slow. Increasing injection speed
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The surface of forming space contains water Clearing them
or other impurities.
The surface was polished badly. Polishing the die
The gate and runner are too small. Adjusting size of dies entrance
The nozzle was jammed. Cleaning it
The different materials mixed raw materials.
Containing volatile substance
Hydroscopic property
The dosage of raw materials was Increasing injection pressure, speed, time and
insufficient. quantity
7.2.11 The black crazing
The black finished products will appear black crazing because of bad thermal stability of materials.
In order to avoid causing black crazing, you can decrease the temperature in the barrel and reducing
injection speed. If screw had some scars, then these partial materials will overheat and appear thermal
decomposition. The non return ring will cause thermal decomposition due to the retention of plastics.
So you should advert materials with high viscosity or easily decomposing materials, they can cause
black crazing easily.
CHART THIRTEEN
BREAKDOWN SOLUTION
The temperature of raw materials was too Reducing temperature in the hopper
high and easy to decompose.
The revolution of screw is too fast. Decreasing the revolution of screw
The screw and hopper have a deviation and Inspecting the machine
cause the abnormally frictional heating.
The nozzle is too small or temperature is too Readjusting the nozzle or temperature
high.
The machine or hopper is too big. Replacing the hopper or machine
There are some black materials in the barrel.
The different materials mixed together.
7.2.12 The flow liner
The flow line is the track what molten materials flow as gate center then appear the stripe.
The flow line because of fast cooling that the plastics flowed the forming space initially, and the
anterior materials and the posterior materials formed boundary line. In order to avoid flow mark, you
can improve fluid of plastics, increase the plastic temperature and adjust injection speed.
The cool plastics stayed forepart of nozzle of machine, if they entered into the forming space
directly then cause flow mark. So keep enough retentive space in the junction and it can avoid causing
flow mark effectively as well as enlarge size of gate can also avoid flow line.
CHART FOURTEEN
BREAKDOWN SOLUTION
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The time of Hold Pressure is too short. Increasing time of Hold Pressure
The temperature is too low near the gate. Increasing temperature
The size or position of gate is not right. Enlarging gate or changing the position
Increasing temperature of raw materials
The molten raw materials are bad. Increasing back pressure
raising revolution of screw
The thickness of products fracture deviated too Changing the design of finished products
much.
The injection pressure is too high or too low. Adjusting injection pressure rightly
The injection speed is too fast or too slow. Adjusting injection speed rightly
The raw materials are impure or they were Checking the raw materials
mixed different materials.
7.2.13 The finished products fractured when opening the mould or ejecting.
The fractured surface of products appeared crazing. When finished products had some acute
angles, this part is difficult to see thin crackle. The crackle is the fatal problem of finished products.
The main reasons please make a reference to the following:
7.2.13.1 The finished products leave the die difficultly;
7.2.13.2 The materials were filled too much;
7.2.13.3 The temperature of die is too low;
7.2.13.4 The configuration of finished products has some defects.
The forming space should have enough angle of knockout; inspect the size, position, forming of
knockout pin as well as the every part has even knockout resistance when finished products left the
die.
Decreasing injection pressure, dont fill too much and these can avoid causing the crackle.
The gate is easy to stay larger internal stress and brittle easily especially direct gate parts. The
internal stress will make the finished products fracture easily such as shape of cup or bowl, this shapes
of products appear the crackles easily.
CHART FIFTEEN
BREAKDOWN SOLUTION
The injection pressure is too high or the Decreasing injection pressure, time, speed and
materials were filled too much. plastic quantity
The temperature is too low in the barrel. Increasing temperature in the barrel
The knockout angle is not right.
The mode of ejector is not right. Inspecting the die
The gate is too small.
The partial knockout angle is not right. Inspecting and repairing the die
Existing the knockout chamfer angle Inspecting and repairing the die
The finished products cant leave the die Inspecting and repairing the die
evenly.
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the die appeared vacuum phenomenon Opening or packing out slowly, installing the inlet
when products left the die. device
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CHAPTER 8 ATTACHMENT AND DRAWING
8.8.1 Hydraulic Oil

The hydraulic pressure oil used in hydraulic equipment of this machine, not only used as a
dynamic transfer medium, but can lubricating metal surface.
Because the hydraulic equipment became diversity gradually, and reached higher performance,
so its using condition became more and more rigor too.
8.8.1.1 The performance hydraulic pressure oil required
Generally speaking, hydraulic pressure oil needs to satisfy the performance below:
(1) Keep flow freely under the condition of using.
(2) Forming proper seal in movable parts.
(3) Almost have no physical or chemical reaction.
(4) Rust prevention and corrosive prevention.
(5) Endure proper load, reduce wear of the movable parts.
(6) Separate moisture, dirt and other impurity quickly in still mode, so as to remove them from
the hydraulic system.
(7) Fit for seal when it was using.
(8) Fire resistant.
(9) Not easy to spume.
8.8.1.2 Hydraulic pressure oil type
General purpose hydraulic pressure oil type, for example classified by constituent, show as
table 1 list below:
Table11 Hydraulic pressure oil type
General type(turbine
R&O)
Wear resistant Low temperature oil
Mineral Oil hydraulic oil Wide-temperature
High viscosity energy hydraulic oil
Saving hydraulic oil
Oil-in-water type
Hydraulic emulsified liquid
Watery hydraulic emulsified liquid
Oil Water-in-oil type
oil(inflaming emulsified liquid
retarding
Waterethylene glycol type
hydraulic fluid)
HWBF
nitric acid ester (inflaming retarding

hydraulic fluid)
Compound fluid
fatty acid (waterproof)
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8.8.1.2.1 Mineral Type Hydraulic Oil
Mineral type hydraulic oil is the most common use oil at present, as most lubrication oil,
according to the difference of boiling point. it can get different viscocity crude oil. Based on this
reason, the application range of this type oil is quite wide. It can fit for different usage when add
proper additive in this type of crude oil.
(1) Common usage hydraulic oil
This type hydraulic oil mainly contains antioxidative and rust prevention additives, they
are stable to oxidize and heat, mainly used in low hydraulic pressure hydraulic equipments.
They can also use as additive, turbine, electromotor turbine, common use industrial machine
bearings lubrication oil, gear lubrication oil, and used as hydraulic oil in many factories who
use multi type oil and require the consistency of the oil type so as to control lubricating.
(2) Wear proof hydraulic oil
The additive which named extreme pressure liquor and wear resistant liquor mixed with
oil, so as to use in high pressure hydraulic equipments such as vane pump.
In comparison with R&O type hydraulic oil, the old type wear resistant hydraulic oil
seems to lack stability, but now it has been solved, new type of wear resistant oil (also used as
R&O0 type hydraulic oil) is in service now.
(3) Wide temperature hydraulic oil
When hydraulic oil is used in cold region, or cooling equipments, it using not only
wearproof and oxidation resistance additive, but additive, so as to reduce flow point, through
this method it can get correct flow in cold condition.
The oil viscosity variation must be minimal when used in require fast response and very
high precision numerical control machine and other equipments.
In order to do the business, use additive to add viscosity factor, by that, when temperature
verified, even though use high viscosity factor oil, the viscosity changed almost nothing.
(4) Energy saving oil
This kind of hydraulic oil in this type oil is deeply refined, high viscosity crude oil, it
added basic additive, limit pressure wearproof liquor and viscosity additive, it can form
thickened oil, it can save energy and other resources.
8.8.1.2.2 Inflaming retarding hydraulic oil
Inflaming retarding hydraulic oil can roughly divided into two types, one is watery, the other
type is compound oil; the oil which contains water include oil-in-water type and water-in-oil type
emulsified liquid, waterethylene glycol, and HWBF. The compound fluids include
phosphate and fatty acid type (fireproof) etc. they were used as condition which exist
dangerous, such as: continuous forging of steel, rolling and smithing equipments, open
and close stove kiln entrance device. But generally speaking, their lubricating quality,
stability and sealability etc. can still not compare with mineral oil. So before use it
please consulted the manufacturer.
Now the main kind of waterethylene glycol hydraulic fluid is base on ethylene glycol,
water soluble polymer, and mix with various kinds of additives. It may be consider gas
containing antirust is one of its characteristic. The oil contains this kind of additive can
prevent water in fluid rust the empty part of the container.
Waterthe main kind of ethylene glycol is ethanol type hydraulic fluid. It has been
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used in high pressure vane pump; its lubricating performance has been increased.
Compared with mineral hydraulic oil, its burning resistance, low temperature
performance and viscosity-temperature characteristic are pretty good in the mass. But
to avoid water evaporation, it need keep the fluid temperature under 5, some type
of this product can rusty zinc and aluminum. So you must be careful. Especially
when you change the substitute mineral oil, because it mixed with mineral oil may
form emulsified mixture or plastocene.
In the old days, the injection molding machine mainly using mineral hydraulic oil,
but due to existence of water and explosion dangerous, in recent year the inflaming
retarding hydraulic fluid has been used gradually. Among all kinds of the inflaming
retarding hydraulic fluid, water ethylene glycol hydraulic fluid is recommended by the
legal profession who advocate fireproofing. In addition, because this kind of fluid is fit
for use and easy to deal with, also used gradually.
8.8.2 Select hydraulic oil
8.8.2.1 Select type
The standard raised in table 2 is the norm that you select the hydraulic oil, the usage
of the hydraulic equipment and environment will decide whether you should select
mineral oil or non combustible fluid. Other factor you must consider include hydraulic
pump and other device type, the usage pressure, temperature the fluid lubricating
quality economical efficiency and applicability with the seal sealing element material
and etc.
Item Comment
The requirement of fire resistance Mineral oil, non combustible fluid (or oil)
Pump type Viscosity applicability
Temperature range Low and high temperature or high viscosity oil
Metal or other mixture during

Consider of economical efficiency
using and leak external
Limit to usable pressure Common usage or wearproof oil
Risk of water mixture Common type and emulsification-proof type
Check the considerable lubricate Consider oil type and brand

Consider oil(fluid) operating life and high quality
Economical efficiency
products
8.8.2.2 Select viscosity
Because hydraulic oil is the transport power medium in hydraulic equipment, abnormal
operation and error of the hydraulic oil which listed in table 3 will help to distinguish
unsuitable viscosity hydraulic oil. Base on this reason, you must select proper viscosity,
to fit hydraulic equipment structure, and oil operating temperature and transfer
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pressure and so on, so as to get the highest efficiency and performance.
Table 3 the error caused by incorrect selection of viscosity
When viscosity is overtop When viscosity is too low
Increase internal friction(around pump Increase in-external leakiness

vane)
Increase oil flow in jaw opening and Increase pump slip(may cause pump
valve efficiency decline, oil temperature raise)
Temperature rise Increase slipped parts abrasion
Operating no more smooth Decline hydraulic system pressure
Increase hydraulic system pressure loss Reduce working precision
Increase electrical power consume
8.8.2.3 Lubricating performance

One function of hydraulic oil is used as lubricant, before the more high pressure and more
fast speed hydraulic developed successfully, this is very important. In many situations, the
lubricating performance of hydraulic oil can be judged according to the pump abrasion, the
reason is: nowadays, trend of equipment pressure raise has effect in the pump
directly, the increased touch pressure act on pump smooth surface, let temperature
raise, and deal with factor of device structure.
8.8.2.4 Other quality
When you select the hydraulic oil, if viscosity and lubricating performance can fit for the oil
using situation, perhaps there has no problem in common, but in order to use it long term and
reliable, and prolong the equipment operating life, you need to consider the
characteristic and quality described below:
(1) Oxidize stability
Oxidize stability of the hydraulic oil can influence oil operating life, compact hydraulic
device which require smaller tank and operating in high pressure and speed can cause oil
temperature a big rise, high oil may cause oil oxidize and go bad; the result of oxidize and go bad
is accelerate plastocene formation, thus it can cause filter, valve and hydraulic circuit
and other parts function, hydraulic device rusty and abrasion also increase whereupon.
The hydraulic oil degree of oxidize stability is decided by turbine oil oxidize
stability test, the common method is not estimate the oil operating life simply
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according to total oxidize value only, also you may look the plastocene quantity during
the setting period, this is because plastocene formation trend is considered as an
important factor.
(2) Shear stability
High viscosity hydraulic oil usually contains HMW viscosity add additive or decline flow
point additive, the pump, valve and other parts shearing action in hydraulic circuit can
raise decline of the viscosity sometimes. So in order to maintain the viscosity in a
proper range, you need select the hydraulic oil which has good shearing action and
stability.
(3) Inflaming retarding
Incombustibility degree is mainly depend on constituent of the hydraulic oil or
fluid, table 4 listed the test result example of inflaming retarding which buy in the
market.
(4) Influence to the sealing material
According to hydraulic oil type, the sealing element and stuffing maybe expansion
harden or dissolve, so as to cause hydraulic oil leak. So it is very important to consider the oil
stability.
We have pointed out the main characteristic and performance, when selected hydraulic oil,
other characteristic include: rust prevention, water resolve stability and emulsifying property
resistant etc.
When select oil type, you need to consider all these characteristics.
Table 4 Hydraulic fluid inflaming retarding test example
Viscos Viscos Flash
Incombustibility estimate test
ity ity point
High
Self- Heat
Type Initial coeffic
Burnin
burnin-g manifold
pressure Pipe
point ient g point injection elimin
point method
method ator
37.8
Burn
Miner
35.7 109 224 245 340 violent Fire 3
al oil
after firing
A little
Phosp fire near
48.5 8 236 368 500 Not fire 80
hate the fire
brand
Water
46.3 205 400 Rising Not fire 66
glycol
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Oil- Burning
in- only
water 107 140 Rising near the 55
emuls fire
ion brand
8.8.3 Hydraulic oil control and maintain
No matter how well hydraulic oil is, if you dont maintain it correctly, it may cause damage. So
we should draw up some process, so as to maintain the oil itself. Maintain machine operation and
hydraulic equipment, please attention hydraulic oil maintenance particularly.
8.8.3.1 Hydraulic oil maintenance item
In common, it can divide the item into three types roughly:
(1) Impurity: judged by viscosity, total acid value or color.
(2) Exotic pollution: judged by weight or use numeration method.
(3) External appearance: judged main by color.
Among these, the last kind of method is simplest, but not always correct, it may cause change
oil and waist money premature.
The items listed below will have more utility value.
(1) variation of the viscosity
Viscosity is an important item in maintenance, because the variations of viscosity affect
hydraulic device performance directly, it also affects their operating life.
The Oxidize and metamorphism caused by heat will increase the viscosity, and reduce of the
viscosity is because the using of additive for raise viscosity value index or reduce flow point,
such as high molecular weight material shearing, this is the special problem for high
viscosity index hydraulic oil. Obviously the reason that cause the sudden variation of
viscosity is using an improper type of oil when complementary supply.
(2) Total acid value variation

Total acid value variation will base on crude oil to decide whether use additive, and variation
according to additive type. But generally speaking, if additive exist, total acid value will reduce
with elapse of the time, and with oxidize aggravated cause metamorphism; the total acid value
will increase. Although the variations of total acid value will variation with oil using condition,
youd better test the total acid value regularly.
(3) Water in the oil

When using mineral hydraulic oil, you must deserve extra attention, because the interfusion
of water will lead to emulsification, it is harm to lubricating, cause rust and other problem and
shorten hydraulic equipment and oil operating life.
Under the serious circumstances, water exist can detect by naked eye.
(4) Color
Hydraulic oil colors will variation with oil viscosity and the additive type and volume in the
water. It needs to compare with the new oil, but generally speaking, when oxidize or heat
aggravate cause deteriorate, its color turn into dark, when checking under the working situation,
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this variation can act as a simply guide.
(5) Pollution degree
When oil contains impurity, it is always harm to the hydraulic device performance and
reliability, so avoid pollution is a very important part in maintenance. Usually the two kinds of
method which used to estimate pollution degree are: weight method and statistics method.
a) In term of weight method: under common conditions hydraulic equipment pollution material
volume can not above 10mg/100ml, and not above 5mg/100ml in numerical control device.
b) In term of statistics method: when using service for the convenience of the customers valve in
hydraulic equipment, the ideal oil maintenance is keep pollution degree in NAS classification
7 grade or even higher. These NAS classification or grade figure listed in table 5 below. Table
6 list the impurity influences the hydraulic circuit.
Table 5 NAS pollution standard (per 100ml quantity)
Specification Grade
classified(micron
00 0 1 2 3 4 5
)
5-15 125 250 500 1000 2000 4000 8000
15-25 22 44 89 178 356 712 1425
25-50 4 8 16 32 63 126 253
50-100 1 2 3 6 11 22 45
100 0 0 1 1 2 4 8
6 7 8 9 10 11 12
5-15 16000 32000 64000 128000 256000 512000 1024000
15-25 2850 5700 14000 22800 45600 91200 182400
25-50 506 1012 2025 4050 8100 16200 32400
50-100 90 180 360 720 1440 2880 5760
100 16 32 64 128 256 512 1024
Table 6 Influence of all kinds of pollution material to the hydraulic system
Pollution
Possible error type Reason and attention point
material type
Hydraulic oil resolve, high
Oxidize
Cause metal rusty temperature or water mix in will
product
cause error
Oil resolve, high temperature,
plastocene Obstruct function
overfall can lead to this problem
Form emulsified
water Condensation or cooler leak
mixture
Air dissolubility to inhibit with foam killer
Pressure decline rapidly, stuffing
Air infusibility
fault
Extra oil Will mix but
besides sometimes it will be Tank design improperly
hydraulic oil react
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Happen water pollution, a little bit
usable rust prevent control happen
Metal granulum Insoluble, make
in pipe and tank, do not washing
dirt catalysis
correctly before installation or
after that
Insoluble, influence Paint non-volatile, or old tank
Dope gobbet
function internal dope dropped off
Granulum
Abrasion device
caused by fine particle float in the air
Obstruct function
friction
Plastic fine Damaged sealing elements, check
Obstruct function
particle them
Abrasion, damaged, Damaged sealing elements, check
Sand
obstructed function them
Improper washing hydraulic trough
after unload it, avoid use the
Filament, fiber Obstruct function material which can possibly let the
filament get into the oil when using
stuffing
8.8.3.2 Control reference value
Because the hydraulic oil control and maintenance reference value changed with oil type,
whether use additive, how much does it add, using condition of the hydraulic equipment and
requirement of precision etc. so it is not easy to establish a set of fixed value. But for the sake of
reference, table 7 lists the reference value of the hydraulic oil control and maintenance for
industrial machine using.
The oil need to change regularly, the reason is the dirty, not oil deteriorates itself. In many
conditions, once the dirty was get rid of, the oil can use again.
Table 7 Industrial machine hydraulic oil control reference value example
Tested Item Reference Value
Viscosity variation 10%
Total acid value add 0.4mg potassium hydroxide/g
Water 0.1% or dirty
Insolubility component (benzene)` 0.05%
Color Great change
Pollution degree 7mg/100ml
8.8.3.3 Control about the operation
Here, we will discuss the items about operating, hydraulic equipment and daily maintenance
and check measure. In order to prevent machine go wrong, you must fulfill these maintenance and
check.
(1) Oil volume
Please guarantee the lowest oil level is not lower than the middle oil level, if the oil
level is too low, it can difficult to separate the granulum, water and bubble etc, so as to
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accelerate deteriorate. When you check it at fixed periods, please record oil volume in the
tank, and reference measuring control diagram.
(2) Oil temperature
When the oil temperature is too low, please racing the machine before start product, so
as to heating it properly. When the machine in regular operating, please adjust the cooler too,
so as to guarantee oil temperature not higher than 5.
When oil is overheating, oil lubrication can not covering like normal time any more, so
the sealing material will damaged, pump efficiency will have harmful influence.
(3) Oil pressure
Please guarantee the pressure reading ordinary. If the pressure is abnormal, if will cause
filter clogging up, air can be suck into the oil, you need to check pump and pressure gauge.
(4) Check the filter
Please attention the variation of the filter pressure, and clean it regularly. if there have
much impurity, please check them and try to find out how were they enter into it.
(5) Noise of the pump
The reason cause abnormal noise includes filter clog, air sucked into the oil, oil
viscosity is over high or impurity enter into the pump etc.
(6) Check the leak
Check the connection, flange and soft pipe, whether it has leak caused by deteriorate of
the sealing elements.
8.8.3.4 Hydraulic equipment maintenance
You must check and change the hydraulic oil and washing work carefully and completely.
8.8.3.4.1 Loading tank and replenishing the oil supplement
(1) Please load the oil through the air filter. Unload the cover and cap when loading the oil;
but please dont put them in workshop floor; dust, filament may stick into the internal
of the tank.
(2) Because the inner diameter of the stuffing is around 50mm, so the 1.5inch pipe in oil feed
pump is very easy to insert, so as to replenish the oil. There has a 100 screen mesh
filter in air filter, if it was blocked, the oil will flow out in the opposite direction from
the filter, and spill in the ground. When you use the oil feed pump, please attention this
point. If you dont use the filter, please guarantee the oil is not pollution by foreign
object when unload the tank cover and load the oil.
(3)When you load the oil to large machine and dont use filter for the first time, please use
at least 100 screen mesh filter, and please guarantee all equipments used in loading oil
clean completely. We suggest when you load the tank use small device.
(4)Youd better advise the oil provider and get their help not only when you load the
machine tank but when you use new oil to replenish the supplement. Because these
companies are very glad to help you.
(5)After change the pressure oil, please let them keep stillness for 3 to 5 hours, so as to
let air bubble disappear, floater precipitate.
8.8.3.4.2 Oil performance regularly test
If oil pollution or got bad, the machine operating life will be shorten and went wrong
possibly. So its very important to test it regularly, so as to check variation of the oil performance.
TAYU MACHINERY
Properly speaking, this type of test should do in the oil products company laboratory, but user has
possible to check it with eyes. Please sampling from the hydraulic oil tank immediately when the
machine stopped, because the oil is mixed fully at that time.
(1) Test clients can do
a) External appearance test
Put new oil sample and the sample in use into each test tube, Compare with their
color, clarity, exist flotage and water precipitate in test tube bottom etc.
b) Stillicide test
Adapt the same method as a), through compared with the new oil, you can find out
the oil situation. Drip a drop of oil in filter paper, and study it 2 to 3 hours later. If the oil
is dirty, or deteriorate obviously, then it will easy to watch the dirty.
(2) Oil products company qualitative and quantitative tests
If the above mentioned 2 kinds of test show the oil is abnormal, it need to
a farther test in provider laboratory.
Experienced oil products company technician can assure immediately
according to the above mentioned tests whether it need change or take back
the sample to their laboratory, and test it thoroughly so as to get final result.
(3) Periodic test cycle
To set one day to do external appearance or Stillicide test monthly.
If the oil products company do the qualitative and quantitative tests in one
moth, two moth and three month after change new oil, then do the above
mentioned test quarterly. When buying new oil, suggest client sign a special
contract about oil examine with oil provider.
(4) Hydraulic oil using limitation
In order to confirm hydraulic oil using limitation, when you are using
hydraulic equipment, please judge it according to the items listed below:
Oil deteriorates itself: Oil Products Company will decide whether
deteriorate has run to the condition that the oil must be changed according to
the above mentioned qualitative and quantitative tests.
Pollution degree: by now, we need to raise opinion about oil pollution
degree to Oil Products Company. You must keep oil pollution degree within the
limitation lists below of the hydraulic equipment. the oil maintenance is
especially important within 1st to 3rd month after the oil was bought, it can say
without exaggeration, during this period, it can decide the operating life of the hydraulic
equipment. See the table below:
Weight method, particle
Measuring method Statistical method
weight/100ml
Oil pollution permission
7ml NAS 11 grade
degree
Note: Because of adapt statistical method, so it can only statistic the particle of 5mm or
bigger than that, so this figure is FYI only.
8.8.4.4.3 Washing
TAYU MACHINERY
(1) Aim and steps
Firstly, wash the metal particle, sand and dust that possibly enter into the tank and pipe
when the machine is manufacture, assemble or install. The second reason is the equipment
needs clean after hydraulic equipment was operated for some time. We consider that youd
better ask oil products company expert, use their equipment to wash in your factory.
(2) Washing when changing the oil
No matter the hydraulic oil is good, after it used for some time, the particle in wear
abrasion hydraulic pump and other movable parts, and oil deteriorate can cause generate
plastocene and dirty. So it is necessary to change the oil, as mentioned before, even though
hydraulic oil was used correctly, it is consider that its operating life is about 2 to 3 years,
once it became deteriorate, the oil will be unusable soon. Under this condition, you should
not only change the oil, but washing the equipment.
Firstly, discharge the oil completely, then after using sponge clean the tank, use the oil
which has the same viscosity as hydraulic oil to wash , now use one washing equipment
washing it in low pressure. Through 4 to 8 hour wash, it is possibly to get rid of all wear
abrasion equipment metal particle, and every kind of plastocene and dirty. Of cause, after
washing, you should discharge the washing oil completely as far as possible, and clean the
inside of the tank carefully.
(4) Washing when the old oil was polluted extremely by water or chemicals etc.
According to the above description, client should consult oil Products Company
washing expert and our company serviceman, so as to select correct type of oil, and
decide how to start washing equipments.
8.8.3.4.4 Maintenance and caresummary
(1) Select correct type of oil.
(2) Inspect oil condition, through periodic test.
(3) Keep the oil temperature within a proper range that is 4.(Control cooling water volume
and temperature correctly).
(4) When change new oil, wash equipment as requested.
8.8.4. Lubricating oil and grease
8.8.4.1 Select lubricating oil
Except hydraulic oil, the using lubricating oil includes tooth oil and grease lubricant in slide
surface. When select this kind of oil, please reference the recommended oil type and viscosity file.
It is important to limit the using oil type as least as possible.
Herein, please use it according to recommendation in chapter3.
8.8.4.2 Maintenance of the lubricating oil
The hydraulic oil can buy at any time, and can change it quickly, but the lubricating oil is not
the same as it, it should store in a long term, you should take good care of care and storing of the
hydraulic oil.
(1) You must store the tank in wood floor.
(2) Seal the tank well, if possibly, use waterproof paper or other applicable lid, cover the
tin or tank.
(3) Be assure oil container avoid direct sunlight.
(4) Be assuring oil storage place temperature is not above 4.
TAYU MACHINERY
(5) After some given period, the grease which use in bearing or movable surface is no
longer an available lubricant, it was polluted by water, vapor, and dust in air and
deteriorate. Please dont forget to lubricant every part according to recommended
frequency; if grease became black, hard, please clean it, and lubricant those parts. If it
was very dirty, please use kerosene or similar materials to wash.
TAYU MACHINERY
Chapter 9 Special Tools and Parts Replacement
9.1 Special Tool List
SN. Name Specification

1 Slotted Screwdriver 3inch
2 Phillips Screwdriver 3inch
3 inner hexagon spanner 3mm-14mm
4 Open Spanner 17-19
22-24
5 Coeswrench 300X36
6 Knocker Wrench Caliber 41-46
9.2 Spare parts which need to be replacement ordinary list
SN. Name Specification Quantity Weight

115x115Lx1650W 6 300g/Piece
1 Heater
60x50Lx500W 1 120g/Piece
VE-11M8 4M-K 2 15g/Piece
2 Thermosetcouple
VE-11M8 1M-K 2 10g/Piece
3 Nozzle 1 400g/Piece
4 Screw Head 46 1 350g/Piece
5 Anti-O-Ring 1 100g/Piece
6 Anti-Leak-Ring 1 50g/Piece
TAYU MACHINERY
To vast user of Tayu Injection Molding Machine
In order to thank better to vast customers support, from now on, we make Five-star Service
promise, and carry out as below:
1Do 24-hours telephone counselling service, provide star-grade service.
2 Set up Customer Complaint Dedicated Line, provide a channel for customers to
reflect advice and complaint. In order to guarantee your benefit, you can complaint through the
dedicated line when you run into machine quality or our after-service mans service quality issues.
3Estabish marketing engineering division to upgrade service quality, done turn-key job
well, and take advice of our products in every way, know customer requirement as the
basis of improve our service and product quality continuously in the future.
4 Increase branch office spare parts reserve, so as to provide original spare and
accessory parts to customers in faster speed and more favourable price.
5 To arrange training plan according to customers requirement, guide their workers
operate Tayu brand injection molding machine smoothly and provide basic machine
maintenance knowledge.
If you have any inquiry about our machine, welcome to dial the hotline below:
24-hours service hotline:0086- 571-88687297
Customer complaint line: 0086-571-88686887 (nightfax)
Hangzhou Tayu Machinery Co., Ltd.
Add: Xianlin Industrial City, Yuhang District, Hangzhou, China
Post Code: 311122
E-mail:hztayu@yahoo.com.cn
Website: www.tayu.cn

TY-1500.2R说明书 Chapter - 1 (1,2)

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TY-1500.2R说明书 Chapter - 1 (1,2)

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1 Machinery Directive: 98/37/EC

2 Low Voltage Directive: 2006/95/EC

1.2 Full postal address including country of origin

Name, type or model, batch or serial number

Place of issue Hangzhou

Name of authorised representative Yang MaoRong

Position of authorised representative General manager

material; strictly prohibit use this machine to product.

The noise figure of the machine is less than 80db.

C Electric Cabinet Name Plate

D Machine Name Plate

Angle Machine Theoretical Shot Volume (cm3)

1.5Machine Operator General Principle

No allow altering or changing the safety device.

Operating and Maintenance Man General Principle

It may careful and concentrate when you are working.

Keep fluently around the machine especially operated terminal.

CHAPTER 2 INSTALL MACHINE

2.2 Prepare for Installing Machine

2.5.3 How Install Plastic Injection Molding Machine

Link Floor Protecting

2.9 Cooling Water Pipeline Position

Smock or over clothes (make

ABS 190-250 180-240 170-240 80-90 30-60 50-80 0.6

DRE+EVA 185 160 160 50-80 99 35-45 10

4.2.2 Attention matter:

4.4.4.1.4 Preventing the material pour adjustment

4.8 Mold installation

6.1.2 Hydraulic Oil Mass

6.1.4 Thermocouple (it is variation with different model of the machine)

6.1.5 Heating Barrel Temperature Rising Time

6.1.6.2 Clamping Mold Safety Device

Humper Baffle Plash

6.1.6.3 Emergency Stop Button

When press this button, oil pump motor stopped.

6.1.10 Leak and Flowrate

6.1.11 Abnormal Noise

6.1.12 Appearance of Abnormal Phenomena In course of Operation

6.2 Periodic Inspection

6.2.1.2 Heater Circle Surface Status

Resin Adhere Screw Bolt Circuit Lead Wire

6.2.2.3 Hydraulic Oil

Dirty or contain bubble

6.2.3.3 Electric Cabinet

Airstrainer installed in inside of the electric cabinet

6.2.3.4 Loosen Locked Nut

6.2.4 Inspection every 6 month

6.3.3 Cooler Inspection, Maintenance and Clean

6.4 Vacuum Filter

Inspect surface condition then

6.5 Screw and Heat Barrel Clean and Inspect

Thrust Ring Screw

After the heating barrel temperature fell to 30-50 centigrade,

Use torch Insert a piece of

1 The adjustment was very big 1 Adjusting the values of pressure

1 The position about proximity 1 Adjusting the position or replace

7.2 The Problems about Molding

Materials Design of dies

Fixity Characteristic of Finished products

Clamping force Temp. of barrel

Molding machines Conditions of molding

CHART TWO the Washing Shrinkage of Diversified Plastic