TRAVERSE AUTOMATIC UNLOADER

CY-600GII
OPERATION MANUAL CYS-600GII
CY-800GII
CYS-800GII

GⅡ
INTRODUCTION
Thank you for purchase of the Star Traverse Automatic Unloader. When linked to a molding machine,
the unloader will automatically remove products from the mold and transport them to a conveyor belt to
other designated location. This manual describes the unloader's functions and presents important
information about operating methods and precautions. Please read through this manual carefully so that
you will be able to use the unloader safely and effectively. Keep this manual in a place of easy access.

* This manual describes the standard model. For optional specifications, refer to corresponding separate
manuals.
Contents
MACHINE SECTION

1. FOR SAFE OPERATION ................................................................... 1

1-1. Manual Organization ............................................................................................... 1
1-2. Safety-Precaution Indications .................................................................................. 1
1-3. Safety Precautions ................................................................................................... 2
1-4. Locations of Warning Labels................................................................................. 10
1-5. Mechanical Specifications ......................................................................................11

2. NAMES OF THE PARTS AND THEIR FUNCTIONS........................ 12

2-1. Configuration Diagram .......................................................................................... 12
2-2. Motion Patterns...................................................................................................... 12
2-3. Product-Side Vertical/Crosswise Unit ................................................................... 13
2-4. Runner-Side Vertical/Crosswise Unit (CYS model).............................................. 15
2-5. Traverse Rail Unit.................................................................................................. 17
2-6. Valve Unit .............................................................................................................. 19
2-7. Locations of Limit Switches.................................................................................. 22

3. AUTOMATIC UNLOADER SETTINGS ............................................ 24

3-1. Before Making Settings ......................................................................................... 24
3-2. Setting Procedure................................................................................................... 28

4. MAINTENANCE AND INSPECTION ............................................... 39

5. PARTS LIST .................................................................................... 43

6. EXPENDABLE PARTS LIST............................................................ 44

7. AIR CIRCUIT DIAGRAM ................................................................. 46

8. GENERAL DRAWING ..................................................................... 48

1. FOR SAFE OPERATION
1-1. Manual Organization
This manual includes important safety precautions relating precautions relating to unloader functions,
settings, maintenance, and operation. Please observe these precautions so as to ensure safe operation at
the unloader.
Note that this manual is part of a three-volume set, and must be read in conjunction with the controller
"Operation section" and "Technical section". Please read through all of these manuals carefully before
beginning use of the unloader.

1-2. Safety-Precaution Indications

z Symbol of danger levels
Cautions are classified depending into the following three levels on risks or damage that may arise
from improper operation.

Indicates that misapplication of the machine will

DANGER lead to death or critical injury.

Indicates that misapplication of the machine might

WARNING lead to death or critical injury.

Indicates that misapplication of the machine may

CAUTION lead to bodily injury or property damage.

z Point

Important points for operation procedures are displayed with mark in this manual.

-1-
1-3. Safety Precautions

DANGER
z Do not enter the operation range.

Do not enter the operation range of the machine. You may be caught or lodged in the
machine resulting in injury.

z Do not maintain the machine during operation.

Do not maintain the machine while it is in operation. Shut down the air supply and turn off the
power switch on the operation panel and the power circuit breaker before maintenance.

WARNING
z Clothing must be proper for working.

Wear proper clothes for working. To avoid injury from trapping, do not wear too large
clothes or costume jewelry/accessories.

z Do not modify the machine.

Do not modify the machine. STAR assumes no responsibility for accidents or failures
caused by modifications to the machine by users.

z Ground the machine.

To avoid electric shock, ground the machine in accordance with the relevant regulation
in your country. When a routine inspection is made or the conveyor is relocated, check
that the machine is grounded appropriately.

z Use a non-fuse circuit breaker.

To prevent fire resulting from overcurrent, use a non-fuse circuit breaker for wiring to
the power source.

z Do not open the electric box.

A high voltage is applied in the electric box. Opening it may result in electric shock or injury.

-2-
z Do not touch the machine during operation.

To prevent trapping accidents, do not insert your hand in the machine while it is running.

z Shut down operation during periods of frequent power outage.

The machinery should be shut down during times when power supply is frequently
going off due to thunderstorm or other such external event. Operating with an irregular
power supply may lead to equipment damage.

CAUTION
z Determine the supervisor for performing operation.

Determine the supervisor when teaming up with two or more operators for making
machine adjustments, etc.

z Pneumatic source

To protect pneumatic components from damage, supply dry air using a dryer. After-
coolers and air dryers are available from STAR. Contact your local distributor when
necessary.

z Read this instruction manual thoroughly.

Read and follow the operational procedures and precautionary remarks provided in this
manual.

z Provide an enough maintenance room around the machine.

Provide a 1-m-wide or larger maintenance room around the machine for safe operation.
Keep obstacles clear of the room.

z Tidy up the area around the machine.

Tidy up the area around the machine, and keep the area well illuminated.

-3-
z Perform maintenance daily.

Perform maintenance daily and check that the machine is in normal conditions. Contact
your local distributor in the event of failure.

z Stop operation in the event of failure or abnormality.

If an abnormality or failure is found during operation, stop the machine and follow the
directions from your local distributor.

z When running the machinery...

Never touch keys or switches with wet or dirty hands.

z Do not use the machine under the following environment.

• Place where ambient temperature is 0℃ and less or 40℃ and more.

• Place where the machine is exposed to dust, chemicals or steam.
• Place where it is highly humid and condensation occurs.
• Place where strong electric field or magnetic field occurs.
• Place where it is poorly ventilated.
• Place where heavy vibration occurs.

z Post clear indication of ongoing maintenance and repair work.

When carrying out inspection, repair, adjustment, cleaning, or lubrication work within the
unloader's movement range, be sure to lock the POWER switch. Post an appropriate sign on the
operation Panel to ensure that no one switches on the machinery while work is in progress.

z Use secure scaffolding.

Some inspection, repair, adjustment, cleaning, and lubrication work must be carried out while
standing on a platform or scaffold. Be sure that the stand is securely set up, and wear a safety belt.

z Stop all linked devices when working on the unloader.

Before carrying out inspection, repair, adjustment, cleaning, or lubrication work within
the unloader's movement range, you must shut down not only the unloader itself but also
all devices that are linked to it (such as the molding machine and conveyor).

-4-
„ Types of warning labels
z Do not enter within the movable range.
Warning label for downward movement
Warning label for horizontal movement
Warning label for travelling movement
-5-
The unloader has a movable range at high
speed.
Do not enter the movable range during
automatic operation.
Be sure to turn OFF the power and the air
pressure before all or part of your body enters
in this range for maintenance or any other
reason in manual operation mode.
z Warning label for high voltage
Be sure to turn off the circuit breaker in the
control box during maintenance.
In particular, disconnect the cable to the
molding machine before performing
maintenance on the control box, and turn off
the primary power of the plant.

This label can be found at the locations

(terminal block, etc.) where special attention
is required in the range of high voltage
warning.

-6-
z Precautions for travel adjustment
Refer to the operation manual for travel
adjustment of movable parts. Make
adjustments in a safe way.
Even if the power and the air pressure are
turned off, some pressure may remain in the air
cylinder. The cylinder may move abruptly. Be
sure to wear protective equipment for
adjustment. Avoid adjustment within the
movable range.

z Warning for high temperature on the motor

Temperature of the motor is high during
operation. Do not gain access to the motor
during operation.
Wait until the temperature becomes low after
the power is turned off before touching the
motor for maintenance.

-7-
z Warning for being caught
Do not inadvertently touch the parts such as
motor, spindle, gear, pulley or belt, that may
catch, within the movable range for
maintenance or any other reason.
Turn off the power and the air pressure before
accessing the machine.

z Warning for contact with blade

Do not inadvertently touch the blade of
nippers for maintenance or any other reason.
Turn off the power and the air pressure before
gaining access to the machine.

-8-
List of hexagon wrench size and min. tightening torque

Hexagon Min. Tightening Tightening Point of

Bolt Dim. C Length
wrench torque Nm force F as a application of
size (mm) L1 x L2 (mm)
size (kgf•cm) guide (kgf) force L3 (mm)

M4 3 3.0 20 x 125 3.0 (30) 6.0 50

M5 4 4.0 25 x 150 6.2 (63) 6.3 100
M6 5 5.0 28 x 165 9.9 (101) 10.1 100
M8 6 6.0 32 x 180 22.0 (224) 14.9 150
M10 8 8.0 36 x 200 48.0 (490) 16.3 300
M12 10 10.0 40 x 225 86.0 (878) 14.6 600
M14 12 12.0 50 x 125 114.0 (1163) 19.3 600
M16 14 14.0 50 x 140 142.0 (1449) 24.2 600
M20 17 17.0 60 x 180 276.0 (2816) 21.7 1300
M24 19 19.0 80 x 180 495.0 (5051) 38.8 1300

<Caution>
z Tighten bolts at least with the standard torque specified above.
z After tightening a bolt, be sure to check that it is secured on the tightening surface.
Shallow tightening tap or clogged chips inside the tap may prevent a bolt from being
tightened even when it's been tightened with the specified torque.
z Use values of the tightening force F and the point of application of force L3 as
guides.
z Check bolts for looseness every month.

-9-
1-4. Locations of Warning Labels
The following diagram shows the location and content of caution plates affixed to the unloader.

z Example of caution plates disposition

- 10 -
1-5. Mechanical Specifications
Model CY-600GII CYS-600GII CY-800GII CYS-800GII

Power supply Single phase 200VAC ±10% 50/60Hz

Required power 0.9 kVA

0.49MPa [5 kgf/cm2]
Normal air pressure
(No water content or dust allowed in air)

Maximum permissible air pressure 0.69 MPa [7 kgf/cm2]

Product-side Air cylinder

Vertical Air cylinder
Runner-side

Product-side Air cylinder

Driving
Crosswise Air cylinder
method
Runner-side

Traverse AC servo motor

Posture Air cylinder

Product-side 600 800

Vertical
(mm)
Runner-side 650 850

Product-side 150
Crosswise
Stroke (mm)
Runner-side 100 100

Traverse (mm) 1400 1200 (1600) <1000>

Posture Fixed at 90°

Maxi. Load weight (kg)

Cylinder 3kg
*(including weight of chuck)
output
(at 0.49MPa)
Posture torque (Nm) 4.45 N ∙ m [45.4 kgf-cm]

Air consumption (N /cycle) 15.4 19.8 18.9 24.5

* Values in [ ] represent the conventional units.
* These specifications are subject to change without prior notice.
* shows 1200mm traverse stroke specification.
* ( ) shows 1600mm traverse stroke specification.
*< > shows 1000mm traverse stroke specification.

- 11 -
2. NAMES OF THE PARTS AND THEIR FUNCTIONS
2-1. Configuration Diagram

Runner-side vertical unit

Product-side vertical unit

Valve unit

Traverse rail unit

Crosswise unit

2-2. Motion Patterns

zProduct side vertical unit zRunner side vertical unit (CYS)

- 12 -
2-3. Product-Side Vertical/Crosswise Unit

⃝
1 Vertical stroke adjustment stopper

This stopper sets the vertical stroke by adjusting the position.

⃝ Ascent end shock absorber
2

This absorber absorbs shock at the end of ascending.

⃝ Vertical cylinder
3

This cylinder moves the vertical arm up and down.

⃝ Vertical LM guide
4

This guide supports vertical movement of the arm.

⃝ Absorber bracket
5

This bracket sets crosswise standby position and crosswise stroke by adjusting the position.
⃝ Shock absorber for advance end
6

This absorber absorbs shock at the end of advancement.

⃝ Shock absorber for descent end
7

This absorber absorbs shock at the end of descending.

⃝ Return end automatic switch (LS-6)
8

This switch is used to confirm that vertical arm completes returning.

⃝ Crosswise cylinder
9

This cylinder is used to advance and return the vertical arm.

- 13 -
 ①

⑪ ⑩

⑧
③ ⑦

④
⑥

② ⑨

⃝
1 Crosswise LM guide ⃝
8 Ascent end proximity switch (LS-3)

This guide holds crosswise straightness.
⃝
2 Chuck mounting plate (link bracket)
The chuck plate is mounted here.
This switch is used to confirm that the vertical arm
completed ascending.
⃝
9 Connection terminal for wiring of product-in-

chuck confirmation limit switch

When the product confirmation limit switch is used
inside the chuck, the switch is connected to this
plug.

POINT
This connector can be connected only to the
⃝
3 Posture action speed controller
machine-type limit switch.
This controller controls the posture action speed.
⃝
4 Posture cylinder
⃝
10 Release prevention vertical lock cylinder
This cylinder turns the posture section 90° in
The release prevention cylinder activates and
reverse.
⃝
5 Posture return speed controller
prevents the posture section from being released
when the air pressure is reduced with the pressure
This controller controls the posture return speed. relief cock, etc.
⃝
6 Ascent end proximity switch dog (for LS-3)
⃝
11 Posture action end auto-switch (LS-9)
This dog is used to activate the ascent end This switch is used to confirm that the posture side
proximity switch completed action.
⃝
7 Posture return limit automatic switch (LS-8)

This switch is used to confirm the posture

completed returning.

- 14 -
2-4. Runner-Side Vertical/Crosswise Unit (CYS model)
② ③ ④

⑤ ⑥

⃝
1 Vertical stroke adjustment stopper plate

This plate sets the descending stroke by adjusting the position.

⃝
2 Runner advancement speed controller

This controller controls runner advancement speed.

⃝
3 Crosswise cylinder

This cylinder advances or returns the vertical arm.

⃝
4 Runner return speed controller

This controller controls runner return speed.

⃝
5 Advance end shock absorber

This absorber absorbs shock at the end of advancement.

⃝
6 Crosswise stroke adjustment stopper bolt

This bolt sets crosswise stroke by adjusting the position.

- 15 -
 ②

④
⑦

⃝
1 Crosswise LM guide ⑥

This guide supports the crosswise movement of the vertical unit.

⃝
2 Descent end shock absorber

This absorber absorbs shock at the end of descending.

⃝
3 Ascent end proximity switch (LS-3S)

This switch confirms that the runner chuck completed ascending.

⃝
4 Releaser prevention vertical lock cylinder

The release prevention cylinder activates and prevents the runner chuck section from being
released when the air pressure is reduced with the pressure relief cock, etc.
⃝
5 Runner confirmation sensor in the chuck (LS-4S)

This sensor confirms that the runner is securely chucked.

⃝
6 Runner chuck

This unit chucks the runner and unload it.

⃝
7 Ascent end shock absorber

This absorber absorbs shock at the end of ascending.

- 16 -
2-5. Traverse Rail Unit

② ① ④ ⑤ ⑧ ⑨ ⑥ ⑦

⃝
1 Pressure reducing valve with filter ⃝
6 Traverse home position proximity switch

(Refer to the corresponding operation manual.) (LS-1)

⃝
2 Residual pressure releasing cock
This cock reduces the air pressure of the
pressure reducing valve with filer to 0 Mpa and
thoroughly discharge air remaining in each
cylinder.
POINT
This switch is activated when the traverse
home position is detected.
⃝
7 Traverse home position proximity switch
dog (for LS-1)
This dog turns on the traverse home position
proximity switch.
⃝
8 Extract-side area proximity switch (LS-10)

Be sure to keep this residual pressure This switch is activated when the carriage unit is
releasing cock closed when using the positioned in the area where products can be
unloader. extracted.
⃝
9 Extract-side area proximity switch dog

⃝
3 AC servo motor
(for LS-10)
This dog turns on the extract-side area proximity
⃝
4 Release-side area proximity switch (LS-12)
switch (LS-10).
This switch is activated when the carriage unit is
not positioned above the molding machine.
⃝
5 Traverse over run proximity switch (LS-2)

This switch is activated when the traverse over

run position is detected.

- 17 -
 ① ②

③ ⑤ ⑥

⃝
1 Toothed belt for traverse (iron rubber AT belt)

⃝
2 Transverse LM guide

This guide supports movement of the carriage unit.

⃝
3 Release-side traverse end stopper

This stopper adjusts the release-side traverse position.

* This stopper is also used for possible runaway of the machine.
⃝
4 Link-less cable chain

This chain guides and protects the wire and pipe.

⃝
5 Traverse over run proximity switch dog (for LS-2)

This dog turns on the traverse over run proximity switch.

⃝
6 Release-side area proximity switch dog (for LS-12)

This switch dog turns on the release-side area proximity switch.

- 18 -
2-6. Valve Unit

CAUTION
• Never attempt to adjust the air cylinder while automatic operation
is in progress, as this can be dangerous. Switch operation to
MANUAL mode before making the adjustment.

• Do not set the air cylinder speed too high, as this may result in
equipment damage. Begin adjustment at slow speed, and
increase the speed gradually to the appropriate level.

• When possible, avoid using the manual operation button on the

solenoid valve. Instead, execute operation from the control box.
If you cannot avoid using the switch on the valve, proceed with
care. Note that wiring and piping may move in unison with the air
cylinder: be careful to avoid entanglement.

• Note that the solenoid valve may become hot during operation,
and may remain hot for some time after power is shut off. Don't
touch the solenoid until you are sure it has cooled off.

POINT

Be sure to set the controller POWER switch to OFF before using the manual operation
button on the solenoid.
Note that forward and return operation may not be available.

- 19 -
 ③ ② ①

⑬ ⑥

⑪
⑮
⑩

⑨
⑯
⑧
⑰ ⑭
⑦

- 20 -
⃝
1 Unload-side descending high speed control

⃝
2 Produce-side descending speed control

⃝
3 Runner-side descending speed control

⃝
4 Product-side ascending speed control

⃝
5 Runner-side ascending speed control

⃝
6 Manual operation button for the product side high speed descent

If pressed concurrently with 16, the product side vertical arm descends with high speed.
⃝
7 Posture action manual operation button

Pressing this button starts the posture of the product chuck section.
⃝
8 Produce-side advancement manual operation button

Pressing this button advances the product-side vertical arm and releasing the button returns the
arm.
⃝
9 Runner-side advancement manual operation button

Pressing this button advances the runner-side vertical arm and releasing the button returns the arm.
⃝
10 Runner-side chuck opening manual operation button

Pressing this button opens the runner chuck and releasing the button closes the chuck.
⃝
11 Product-side chuck opening manual operation button

Pressing this button opens the produce-side chuck and releasing the button closes the chuck.
⃝
12 Sprue chuck opening manual operation button

Pressing this button opens the sprue chuck and releasing the button closes the chuck.
⃝
13 Absorption manual operation button

Pressing the button when the power is off releases absorption and releasing the button starts
absorption.
⃝
14 Vacuum generator

(Refer to the corresponding operation manual.)

⃝
15 Runner-side descending manual operation button

Pressing this button moves down the runner side vertical arm and releasing the button moves up
the arm.
⃝
16 Product-side descending manual operation button

Pressing this button moves down the product side vertical arm and releasing the button moves up
the arm.
⃝
17 Posture return manual operation button

Pressing this button returns the posture of the product chuck section.

- 21 -
2-7. Locations of Limit Switches

③
⑥ ④ ⑤

No. Symbol Name Remarks

◯
1 LS-6 Product-side return end auto switch
◯
2 LS-3 Product-side ascent end proximity switch
◯
3 LS-8 Posture return end auto switch
◯
4 LS-4S Runner confirmation sensor in chuck CYS model
◯
5 LS-3S Runner-side ascent end proximity switch CYS model
◯
6 LS-9 Posture action end auto switch

- 22 -
 ① ② ③ ④

No. Symbol Name Remarks

⃝
1 LS-12 Release-side area proximity switch
⃝
2 LS-2 Traverse over run proximity switch
⃝
3 LS-10 Extract-side area proximity switch
⃝
4 LS-1 Traverse home position proximity switch

- 23 -
3. AUTOMATIC UNLOADER SETTINGS

POINT

For full information about how to set the unloader, refer also to <Operation section>.

3-1. Before Making Settings

CAUTION
Before making settings of the unloader or manually checking its
operation, lower the speed of each cylinder with the speed controller.

„ Wiring
Connect the molding machine to the control box of the unloader, and use the control box to verify the
signals between the molding machine and unloader.

1. Connecting the molding machine to the unloader

WARNING
• If you are going to operate the molding machine independently
(unlinked), you should first move the carriage unit to the release
side (outside of the molding machine).
• If jumper is plugged into the relay metal connector box, the
molding machine will remain able to execute mold open/close
even while the unloader's vertical arm is in lowered position within
the mold. This can result in damage to the mold and/or the arm.

Relay junction metal connector box

Connect the unloader's metal plugs to the junction metal
Power connector box installed on the molding machine.
metal connector
* When running only the molding machine, disconnect
the interlock metal plug and connect the jumper plug
in its place.

Interlock
metal connector

Jumper plug

- 24 -
2. Checking the signals in the control box
Turn on the power switch on the pendant unit. The
power lamp lights up on the pendant unit.
The following screen appears on the LCD and initial
check starts.

When initial check has been completed normally, the initial screen is displayed.

Bring up the I/O display screen using the key.

When the input signals from the molding machine indicated on the screen are under normal
conditions, wiring is completed.
ON ........... In reverse video
OFF ......... In normal video (characters in black)

♦ I/O signals from molding machine

Symbol Name Symbol Name

MD Safety door closed ME Ejector advance-end
MO Mold opening completed MN Molding defect
MC Mold closing completed MA Automatic

- 25 -
„ Piping
Connect the primary-side air hose you have prepared to
the <IN> of the filter regulator.

Primary-
side hose

Release z Setting the air pressure

Air pressure Lower c Filter regulator
adjustment Higher
knob Pull the air pressure adjustment knob and turn it to
Fix
adjust the air pressure. After adjustment has been
completed, push the knob securely.
Set the air pressure to 0.49Mpa [5kgf/cm2]

z Releasing air in the cylinder

Interrupt air with the air adjustment knob when
releasing air by adjusting crosswise stroke and open the
residual pressure releasing cock to completely release
residual air in the cylinder.

Residual
pressure
POINT
releasing
cock Be sure to keep the residual pressure releasing cock
completely closed when operating the unloader.

z To use the vacuum generation device

When the vacuum generation device is used to extract
a product with the suction pad, provide the vacuum
generation device with air by opening the suction
Suction
ON/OFF cock ON/OFF cock. When the device is not used, close the
cock tightly.

- 26 -
„ Unloading and Release Positions

z Unloading position
When operating the unloader for the first time after
installing it, be sure to input a point (value) within the
extract side area so that the center of the unloader
2025 carriage unit comes at the center of the mold.

POINT

If the runner chuck cannot be aligned because of the

runner shape, loosen the bolt on the vertical arm and
adjust the position of the runner chuck. (CYS model)

Release-side area Release-side end

z Release position
proximity switch proximity switch
Adjust the releasing position of the unloader with the
Do not hit. Carriage unit release-side end proximity switch dog, the release-side
area proximity switch dog and the release-side travel end
stopper.

POINT

Release-side • Adjust the release-side travel end stopper to the

travel end
adjustment position detected by the release-side end proximity
stopper
Release-side switch.
Release-side area proximity
end proximity switch dog
switch dog • Be sure to conduct <PS operation> when adjusting the
unload and release-side travel end stopper and the
position of the proximity switch dog.

- 27 -
3-2. Setting Procedure

1. Product Chuck Replacement

Move the vertical unit to the position where the chuck can be mounted by manual operation
<MANU>.

* When the manual mode is not set, press the key.

c Press OPERAT key and key of travelling and

stop the carriage unit at the release-side descend

position.
d To descend the vertical arm, press the OPERAT key

and the key of the arm.

Release-side end
proximity switch dog

POINT

• When descending, turn on the release side descent mode (MD2) in advance.
• When replacing the product chuck in a state of posture returned, turn off the release-side
posture mode (MDSS).
After chuck plate replacement, turn on the release-side posture mode (MDSS) at the arm
ascent end and adjust the speeds of posture action and return (refer to "2-3").

e Mount the chuck, and perform piping and wiring.

f Return the unloader to the home position as follows.

Press OPERAT key and key concurrently and return the unloader to the home position.

- 28 -
2. Product-Side Crosswise Standby Position Setting

c Interrupt supply of power and air to the unloader.

d Loosen the bolt of the absorber bracket with the

hexagonal wrench.

e Manually move the vertical unit to the position where the

product is chucked and decide the advance position.

1021

f Fully press the shock absorber for advancement against

the vertical unit and fix it by tightening the fixation bolts
1022 of the absorber bracket with the hexagonal wrench.

g Supply air after completion of adjustment.

- 29 -
3. Product-Side Crosswise Stroke

c Interrupt supply of power and air to the unloader.

1023 d Loosen the fixation bolt of the rod clamp with the
hexagonal wrench.

e Completely pull out the cylinder rod.

POINT
1024
Adjust the stroke after completely pulling out the
cylinder rod of the crosswise cylinder because the
setting position may be misaligned when supplying
air.

f Move the vertical unit to the position where the

product can be removed from the mold.

1025

g Tighten the fixation bolt of the rod clamp with the

hexagonal wrench.
h Supply power and air after adjustment is completed.
1026

- 30 -
4. Product-Side Vertical Stroke Setting
c Measure a distance A from the center of the nozzle of the
chuck plate to the center of the nozzle of the molding
machine.
Please note that the center position of the chuck
1027 plate may not match with height of the center of
A
the nozzle of the molding machine due to structure
of the chuck plate.

d Adjust the distance so that the distance from the lower

side of product-side vertical stopper when completely
1028 ascended to the head section of the descent end shock
absorber fully pressed back will be the same as "distance
A" mentioned in ⃝
1 .

CAUTION
• Never adjust the stroke when the vertical arm is lowered. It is
very dangerous because the stopper is loaded.
• Adjust the stroke when the vertical arm is at the ascent end. The vertical
arm may descend and it is very dangerous if it is not at the ascent end.

e Loosen the fixation bolt of the vertical stopper with the

hexagonal wrench and adjust it.

CAUTION
Be sure to additionally tighten the fixation bolt
after adjustment.

- 31 -
5. Runner-Side Crosswise Standby Position Setting (CYS model)

c Interrupt supply of power and air to the unloader.

d Loosen the fixation bolt of the rod clamp at the
1030
runner side with the hexagonal wrench.

e Completely pull out the cylinder rod.

POINT

1031 Adjust the stroke after completely puling out the cylinder
rod of the crosswise cylinder because the setting position
may be misaligned when supplying air.

f Manually move the vertical unit to the position where

the product can be removed from the mold and decide
the return position.

1032

g Tighten the fixation bolt of the rod clamp with the

hexagonal wrench.
h Supply power and air after adjustment is completed.

1033

- 32 -
6. Runner-Side Crosswise Stroke Setting (CYS model)

c Interrupt supply of power and air to the unloader.

d Loosen the stopper for adjustment of runner-side
crosswise stroke with the spanner.
1034

e Manually move the vertical unit to the position where

the runner can be chucked and decide the crosswise
stroke.
1035

f Completely push back the shock absorber with the

stopper and tighten it with a bolt.

1036
CAUTION
Be sure to additionally tighten the
stopper bolt after adjustment.

g Supply power and air after adjustment is completed.

- 33 -
7. Runner-Side Vertical Stroke Setting (CYS model)

CAUTION
Never adjust the stroke when the vertical arm is lowered. It is very
dangerous because the stopper is loaded.

c Measure a distance A from the chuck position of the

runner chuck to the center of the nozzle.

1037 POINT
The runner may be caught at the position other than
center of the nozzle of the molding machine
according to the shape of the runner.

d Adjust the distance so that the distance from the

lower side of product-side vertical stopper when
completely ascended to the head section of the
1038 descent end shock absorber fully pressed back will be
the same as "distance A" mentioned in c.

e Loosen the bolt of the stopper plate with the

hexagonal wrench to adjust it.

1039

CAUTION
Be sure to additionally tighten the bolt after adjustment.

- 34 -
8. Selection and Checking of Product Confirmation Limit Switch
Check the product manually and verify that this is shown on the control box's I/O display screen.
c For product-side vertical unit
The confirmation limit switch depends on the product extracting method, so select the
corresponding mode first.

POINT

For detail on how to set these modes, see the operation manual for the controller.

a. Single-cavity product confirmation limit switch (LS-4, option)

Adjust this switch with the product runner chucked to
the position which can be detected when the product-
side vertical arm ascends with the mounting hardware.
* Turn on the MD4 product confirmation mode.

2057

b. Chuck-internal product confirmation switches (LS-4T)

These switches are located within the chuck plate (one switch for each product). Execute
chucking and confirm that all limit switches can produce correct detection. Adjust as necessary.
* Turn on the MD4T chuck confirmation mode.

- 35 -
c. Suction-confirmation sensor (LS-4V)

This sensor is contained in the vacuum generator.

Confirm that the sensor turns on when all suction pads
suck a product and that the sensor turns off when any
1041 suction pad releases a product.
* Turn on the MDCV suction confirmation mode.

d Runner-Side Vertical Unit (CYS model)

It is contained in the sensor (LS-4S) chuck in the
chuck.
Confirm it when the runner is being chucked.

POINT

It is necessary to turn on the MDS runner extract

mode.

- 36 -
 z Setting the detection area
Observe the lamp to find the position at which
detection is made with the runner chucked.

1043 a. Loosen the set screws.

b. Slide the runner confirmation auto switch up on
down depending on the thickness of the runner.
When the runner is thick: Slide the switch up.
When the runner is shin: Slide the switch down.

POINT

Make sure that the sensor is OFF when there is no

2065 runner (chuck is open or completely closed).

- 37 -
 9. Position while Travelling Setting

c Press OPERAT key and key or key for

travelling to move the carriage unit to the position to

set.

1044 POINT

Set it to the position where the runner does not go into

the safety door of the molding machine when the
runner is open.

Release-side area proximity switch d Set the release-side area proximity switch dog with
the release-side area proximity switch (LS-12).

POINT

Adjust it to the position where the ON lamp of the

ON lamp proximity switch comes on.

Release-side area
proximity switch dog

Set the mode and the timer referring to the operation section of the manual after the above
mechanical setting is completed.

CAUTION
• Be sure to additionally tighten each bolt adjusted when setting before starting
the automatic operation.
• Check to see that the tools used for mechanical adjustment are not left on the
unloader or inspection table again before starting manual or automatic
operation after adjusting the machine. If something drops, workers may be
injured or machines may be damaged.

POINT

The next preparation time can be reduced by recording the set dimension for each mold.

- 38 -
4. MAINTENANCE AND INSPECTION
To prolong the service life of the unloader and to prevent accidents, inspect the unloader regularly (once
a month).

z Tightening loose nuts and bolts

The loader and molding machine are exposed to storing impact for a long period of time. Therefore,
exercise added care to avoid loose nuts and bolts, which may cause breakage of the loader and mold of
the molding machine.
• Looseness of mounting bolts of each limit switch for ascending, travelling, advancement and
confirmation of the products
• Looseness of the lock bolts of stopper for vertical stroke adjustment and the absorber bracket
• Looseness of ascent and descent end shock absorber fixing nut and advance end shock absorber fixing
nut
• Looseness of the terminal in the terminal box which is a relay between the carriage unit and the
control box (It may cause a malfunction.)

z Lubricating parts subject to friction

Apply grease periodically according to the lubrication diagram.

z Cleaning LM guide and traverse rail surfaces

Scratches, grease and dirt on the surface of the vertical and crosswise LM guides and the traverse LM
guide on the traverse rail top may impede smooth operation, so clean them off periodically.

z Replacing damaged air tubes

Bent or damaged air tubes interfere with the proper flow of air. If there is air leak from any joint or air
tube, replace et immediately.

z Confirmation of Pressure-reducing Valve with Filter

Confirm the adjustment method and precautions for pressure reducing valve with the operation manual
for filter and regulator (AW series) described later.

z Confirmation of Vacuum Generator

Confirm the adjustment method and precautions for the vacuum generator with the corresponding
operation manual.

z Checking expendable parts and sub expendable parts

Check and replace expendable parts in accordance with the expendable parts list.

- 39 -
„ Maintenance and Inspection Table

Inspection
Work No.

Half-yearly
Every three

Every two
Monthly

Yearly Inspection point Method Item Action

months

years
Daily

Pressure
1 { Air pressure Visual
gauge(0.49MPa)

Wrench, Damage, Re-

2 { Bolt, nut
spanner looseness tighten.
3 { Timing belt Damage, tension Adjust.
LM guide Supply oil
4 { Visual Damage, dirt
(grease) and clean.
Clean or
5 { Pipes, wires Visual Damage
replace.
Replace
6 { Air cylinder Air leakage
packing.
Clean or
Element Dirt, blocking,
7 { Visual replace
(filter, regulator) drain
element.
Clean or
8 { Silencer Visual Dirt, blocking
replace.
Vacuum filter Suction Check suction Clean or
9 {
(suction unit) pressure pressure. replace.
General Consult
10 { By Star
diagnosis** with Star.

* If you gave any questions regarding inspection methods, items and actions, contact the technical
service staff at our sales office.
** General diagnosis will be provided at your company's expense. Please consult the sales staff at our
sales office.

- 40 -
„ Lubrication diagram

② ①

② ①

No. Location No. of points Interval Model

c Crosswise LM guide for product 4
d Vertical LM guide for product 2 Greasing every
e Crosswise LM guide for runner 2 3 months CYS
f Traverse LM guide 4

- 41 -
„ Oiling

z LM guide
1. Feed grease by the grease pump from the grease
nipple.

2. Supply grease until the casing just overflows.

3. Wipe the excessive grease using a cloth, etc.

1047

„ Grease
* Supply grease from the grease nipple periodically (refer to "Lubrication Diagram").
* Use lithium grease #0.

- 42 -
5. PARTS LIST

Part Name Type Purpose Manufacturer Qty Code No.

Traverse home position
Extract-side area
TL-Q5MC1-C 4
Release-side area Star Seiki 196257
Proximity switch with connector Product side ascent end
(5)
with connector (Runner side ascent end)
TL-Q5MC2-C
Traverse over run Star Seiki 1 193838
with connector
Posture action end
D-C73 SMC 2 030140
Posture return end
Auto switch (Runner confirmation)
D-97-90 SMC (1) 030119
(Sensor in chuck)
D-C73 Product side return end SMC 1 030140
Posture action
AS2201F-01-04S SMC 2 001873
Posture return
Speed controller Product side advance
Product side return 2
AS2201F-01-06S SMC 001878
(Runner side advance) (4)
(Runner side return)
Filter regulator AW30-03BDE Air adjustment SMC 1
Vacuum generator ZM101M-A5G-E15
Suction SMC 1
unit -X247
Check valve AKB02A-02S SMC 1 001876
Residual pressure
IN-289-731 Release of residual pressure SMC 1 080169
exhaust valve
AC servo motor MSMA042A1E Traverse Matsushita 1
Gear with motor VRKF-S9C-400 Traverse SHIMPO 1

- 43 -
6. EXPENDABLE PARTS LIST
z Product-side vertical unit
Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
1 Vertical cylinder
1 Packing set ARDB32- 610- R3118 TANHAY 3000 km
SET (600GII)
1 Vertical cylinder
2 Packing set ARDB32 –810-R3118 TANHAY 3000 km
SET (800GII)
ARDBA32-150-C73KS- 1
3 Packing set TANHAY 3000 km Crosswise cylinder
R3110 SET
1
4 Packing set ARDB32-65-C73KS-R3112 TANHAY 3000 km Posture cylinder
SET
1 Drop prevention
5 Packing set ACQ2B25-10T-R3123 TANHAY 3000 km
SET cylinder
6 120484 DU bush DUB0808 DAIDO 2 1 year Posture
7 220031 DU thrust washer DUT06 DAIDO 2 1 year Posture
2 million
8 Shock absorbor KBM10-50-11-SCMK2 KYB 1 Ascent end
times
2 million
9 100858 Shock absorbor KBM10-50-12C KYB 1 Descent end
times
2 million
10 100854 Shock absorbor KBMT12-20-7 KYB 1 Advance end
times

z Runner-side vertical unit

Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
1 Vertical cylinder
1 Packing set ARDB25-660-R3117 TANHAY 3000 km
SET (600GII)
1 Vertical cylinder
2 Packing set ARDB25-860-R3117 TANHAY 3000 km
SET (800GII)
1
3 Packing set ARDBA32-100-R3115 TANHAY 3000 km Crosswise cylinder
SET
1 Drop prevention
4 Packing set ACQ2B25-10T-R3123 TANHAY 3000 km
SET cylinder
2 million
5 Shock absorbor KBMT12-20-8 KYB 1 Ascent end
times
2 million
6 100858 Shock absorbor KBM10-50-12C KYB 1 Descent end
times
2 million
7 100854 Shock absorbor KBMT12-20-7 KYB 1 Advance end
times

- 44 -
z Valve unit
Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
Product side
crosswise
Runner side
20 million
1 182837 Solenoid valve SY3140-5MO SMC 5 crosswise
times
Runner chuck
Product chuck
Sprue chuck
20million Runner side
2 182841 Solenoid valve SY7120-5MO-02 SMC 1
times vertical
20 million Posture action
3 182838 Solenoid valve SY3240-5MO SMC 1
times return
20million Product side
4 182836 Solenoid valve SY9120-5MO-03 SMC 1
times vertical
20million Product side
5 210675 Solenoid valve VP542R-5G-03A SMC 1
times descent low speed
6 001877 Silencer AN110-01 SMC 2 1 year Manifold
7 Suction filter ZM-SF SMC 1 1 year Vacuum generator
8 Silencer Ass’y ZM-SA SMC 1 1 year Vacuum generator
9 Filter element AF30P-060S SMC 1 1 year Filter regulator

z Traverse rail unit

Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
1 Timing belt 025-AT10-0416E-L NOK 1 2 years 1400TR
2 Timing belt 025-AT10-0456E-L NOK 1 2 years 1600TR
3 Timing belt 025-AT10-0376E-L NOK 1 2 years 1200TR
* Classification of expendable parts
Parts which are replaced within 1 year .......................Expendable parts
Parts which are replaced between 1 and 2 years.........Sub expendable parts
* The above replacement intervals are decided based on the documents presented by the manufacturer.
The replacement intervals may vary depending on frequency of use of the unloader and operating
environment.
(The replacement intervals are given as a guide only, and do not refer to a guarantee period.)
* Parts used in the unloader are subject to change without prior notice.

- 45 -
7. AIR CIRCUIT DIAGRAM

19 Taper plug with hexagon hole 1/8-8 10

18 Speed controller AS2201F-01-06S SMC 2
17 Speed controller AS2201F-01-04S SMC 2
16 Ace ball 1/4 2
15 Check valve AKB02A-02S SMC 1
14 Vacuum pressure GZ46-K-01 SMC 1
13 Vacuum generation unit ZM101M-A5G-E15-X247 SMC 1
12 Valve for removing residual air pressure IN-289-731 SMC 1
11 Silencer AN110-01 SMC 2
10 Valve with silencer ASN2-04 SMC 3
9 Blanking plate ass'y SY3000-26-9A SMC 3
8 Solenoid valve SY3140-5MO SMC 3
7 Solenoid valve SY3240-5MO SMC 1
6 Manifold SS5Y3-42-07-01 SMC 1
5 Blanking plate ass'y SY7000-26-22A SMC 1
4 Three-port solenoid valve VP542R-5G-03A SMC 1
3-2 Gasket (bis) SY9000-11-3A SMC 1
3-1 Solenoid valve SY9120-5MO-03 SMC 1
2 Manifold 302384-101-0 STARTECHNO 1
1 Filter regulator AW30-03BDE SMC 1
No. Name Type Manufacturer Qty Remarks

This diagram shows a type without S side vertical unit.

CY-600GII
CY-800GII

- 46 -
 20 Taper plug with hexagon hole 1/8-8 7
19 Union Y KQ2U06-00 SMC 1
18 Speed controller AS2201F-01-06S SMC 4
17 Speed controller AS2201F-01-04S SMC 2
16 Ace ball 1/4 2
15 Check valve AKB02A-02S SMC 1
14 Vacuum pressure GZ46-K-01 SMC 1
13 Vacuum generation unit ZM101M-A5G-E15-X247 SMC 1
12 Valve for removing residual air pressure IN-289-731 (6*6) SMC 1
11 Silencer AN110-01 SMC 2
10 Valve with silencer ASN2-04 SMC 5
9 Blanking plate ass'y SY3000-26-9A SMC 1
8 Solenoid valve SY3140-5MO SMC 5
7 Solenoid valve SY3240-5MO SMC 1
6 Manifold SS5Y3-42-07-01 SMC 1
5-3 Screw M4*31 (For SY7000) SMC 2
5-2 Gasket SY7000-11-9 SMC 1
5-1 Solenoid valve SY7120-5MO-02 SMC 1
4 Three-port solenoid valve VP542R-5G-03A SMC 1
3-2 Gasket (bis) SY9000-11-3A SMC 1
3-1 Solenoid valve SY9120-5MO-03 SMC 1
2 Manifold 302384-101-0 STARTECHNO 1
1 Filter regulator AW30-03BDE SMC 1
No. Name Type Manufacturer Qty Remarks
This diagram shows a type with S side vertical unit.

CYS-600GII
CYS-800GII

- 47 -
8. GENERAL DRAWING

Dimension within ( ) indicates dimension for 600st.

Dimension within < > indicates dimension for 1000TR.
Dimension within { } indicates dimension for 1200TR.
Dimension within [ ] indicates dimension for 1600TR.
1400TR regular operation

CY-600GII
CY-800GII

- 48 -
 Dimension within ( ) indicates dimension for 600st.
Dimension within < > indicates dimension for 1000TR.
Dimension within { } indicates dimension for 1200TR.
Dimension within [ ] indicates dimension for 1600TR.
1400TR regular operation

CYS-600GII
CYS-800GII

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