MAINTENANCE

MANUAL
HT TOGGLE CLAMP
INJECTION MOLDING MACHINE
WITH
ALLEN BRADLEY PRO-SET 700®
SERIES CONTROL SYSTEM

MACHINE SERIAL NUMBER

PUBLICATION NUMBER MHTM(AB)-1/01

COVERED BY ONE OR MORE OF THE FOLLOWING

UNITED STATES PATENTS OR OTHER PATENTS PENDING
3,319,299 - 3,319,298 - 3,647,309 - 3,752,363
4,372,910 - 4,470,796

Van Dorn Demag Corporation

P.O. Box 368021
Strongsville, Ohio 44136-9721
Telephone: (440) 876-8960
 MANUAL TABLE OF CONTENTS

PARAGRAPH SUBJECT PAGE

PREFACE
MOLDER ACTION NETWORK .............................................................................. P1
PARTS ORDERING .............................................................................................. P2
MODEL AND SERIAL NUMBER DESCRIPTION ................................................... P2
LOCATING THE PART NUMBERS ....................................................................... P2
SHIPPING METHODS .......................................................................................... P2
RECOMMENDED SPARE PARTS ....................................................................... P3
STANDARD TORQUE INFORMATION .................................................................. P3

SECTION 1 INSTALLATION
1.1 GENERAL ........................................................................................................... 1-1
1.2 SITE PLANNING .................................................................................................. 1-1
1.3 RECEIPT OF EQUIPMENT .................................................................................. 1-2
1.4 UNLOADING AND MOVING ................................................................................. 1-2
1.5 MACHINE LEVELING .......................................................................................... 1-5
1.6 SERVICE REQUIREMENTS ................................................................................ 1-7
1.7 HYDRAULIC OIL AND LUBRICATION REQUIREMENTS ..................................... 1-10
1.8 PRINTER INSTALLATION .................................................................................... 1-13
1.9 PRE-OPERATIONAL CHECKOUT .......................................................................1-13

SECTION 2 SAFETY FEATURES

2.1 GENERAL ........................................................................................................... 2-1
2.2 OPERATION OF PROTECTIVE DEVICES ........................................................... 2-3
2.3 OPERATOR'S STATION EMERGENCY STOP .................................................... 2-5
2.4 SAFETY CHECK LIST ......................................................................................... 2-6
2.5 GATE LIMIT SWITCH ADJUSTMENT ................................................................... 2-8
2.6 CONTROL ENCLOSURE-POWER DISCONNECT ............................................... 2-9
2.7 MACHINE GROUNDING ......................................................................................2-10
2.8 METAL SHIELD (HEATER BANDS) ..................................................................... 2-10
2.9 MATERIAL FUMES ............................................................................................. 2-10
2.10 INJECTION FEED THROAT ................................................................................. 2-10
2.11 RECOMMENDED STANDARDS ..........................................................................2-11
2.12 ALTERATIONS/ADDITIONS TO MACHINE ...........................................................2-11
2.13 HIGH SPEED ACCUMULATOR INJECTION OPTION ........................................... 2-13
2.14 GENERAL SAFETY PRECAUTIONS ................................................................... 2-13

SECTION 3 PREVENTATIVE MAINTENANCE

3.1 DAILY PREVENTATIVE MAINTENANCE PROCEDURES ................................... 3-1
3.2 WEEKLY PREVENTATIVE MAINTENANCE PROCEDURES .............................. 3-10
3.3 MONTHLY PREVENTATIVE MAINTENANCE PROCEDURES .............................3-13
3.4 QUARTERLY PREVENTATIVE MAINTENANCE PROCEDURES ........................ 3-16
3.5 SEMI-ANNUAL PREVENTATIVE MAINTENANCE PROCEDURES ...................... 3-19
3.6 ANNUAL PREVENTATIVE MAINTENANCE PROCEDURES ............................... 3-19

SECTION 4 CLAMP MAINTENANCE

4.1 GENERAL ........................................................................................................... 4-1
4.2 TIE RODS AND SINGLE POINT ADJUSTING NUTS ............................................ 4-1
4.3 TIE BAR PRELOADING PROCEDURE ................................................................ 4-2
4.4 BUSHING AND LINK PINS .................................................................................. 4-3
4.5 HYDRAULIC EJECTION AND MECHANICAL KNOCKOUT PLATES .................... 4-5
4.6 MACHINE LEVELING .......................................................................................... 4-5
4.7 PLATEN SHOE ADJUSTMENT PROCEDURE ..................................................... 4-6

MHT-1047 Page i MHTM(AB)-1/01

 4.8 CLAMP SINGLE POINT ADJUSTMENT PROCEDURE ........................................ 4--7
4.9 TOGGLE LINKAGE BREAKPOINT ADJUSTMENT ...............................................4-11

SECTION 5 INJECTION UNIT MAINTENANCE

5.1 GENERAL ........................................................................................................... 5-1
5.2 IN-LINE INJECTION UNIT ..................................................................................... 5-1
5.3 BARREL REPLACEMANT - IN-LINE. ................................................................... 5-10
5.4 ROTATING RAM INJECTION UNIT .......................................................................5-12
5.5 OPTIONAL TWIN CYLINDER INJECTION (NEWBURY STYLE)...........................5-25
5.6 HEATER BAND AND WIRE TERMINAL ASSEMBLY.........................................5-29
5.7 TEMPERATURE CALIBRATION PROCEDURE ................................................... 5-30
5.8 SCREW MOTOR INFORMATION ......................................................................... 5-32

SECTION 6 HYDRAULIC SYSTEM MAINTENANCE

6.1 GENERAL ........................................................................................................... 6-1
6.2 HYDRAULIC OIL .................................................................................................. 6-1
6.3 OIL RESERVOIR ................................................................................................. 6-4
6.4 HYDRAULIC OIL TEMPERATURE CONTROL ...................................................... 6-5
6.5 HYDRAULIC OIL FILTER ..................................................................................... 6-7
6.6 HYDRAULIC PUMPS ........................................................................................... 6-7
6.7 HYDRAULIC CYLINDERS .................................................................................... 6-9
6.8 HYDRAULIC MOTORS ........................................................................................ 6-10
6.9 MANIFOLDS ........................................................................................................6-10
6.10 VALVE DESCRIPTIONS ......................................................................................6-32

SECTION 7 ELECTRICAL MAINTENANCE

7.1 MACHINE ELECTRICAL SYSTEM ....................................................................... 7-1
7.2 SAFETY PRECAUTIONS ..................................................................................... 7-1
7.3 WIRING SYSTEM ................................................................................................ 7-2
7.4 PUMP MOTOR .................................................................................................... 7-2
7.5 BARREL AND NOZZLE TEMPERATURE CONTROL ........................................... 7-4
7.6 VALVE SOLENOID IDENTIFICATION .................................................................. 7-6
7.7 SENSING DEVICES CHART ................................................................................ 7-8
7.8 LINEAR POSITIONING DEVICES ........................................................................ 7-9
7.9 PRO-SET 700® SERIES SYSTEM STRUCTURE ................................................ 7-10
7.10 CONTROLLER INSTALLATION ............................................................................ 7-15
7.11 CONTROLLER MAINTENANCE ........................................................................... 7-17

SECTION 8 TROUBLESHOOTING
8.1 MACHINE TROUBLESHOOTING ......................................................................... 8-1
8.2 SEQUENCE DIAGRAM ....................................................................................... 8-3
8.3 MACHINE TROUBLESHOOTING GUIDE ............................................................. 8-4
8.4 MACHINE ERROR AND OPERATION MESSAGES ............................................ 8-8

SECTION 9 MACHINE SET-UP PROCEDURE

9.1 GENERAL INFORMATION ................................................................................... 9-1
9.2 GENERAL NOTES..........................................................................................9-2
9.3 PRELIMINARY PROCEDURES ........................................................................... 9-2
9.4 MACHINE SETUP PROCEDURE ......................................................................... 9-2
9.5 VALVE SETUP PROCEDURE .............................................................................9-14
9.6 INITIAL SETPOINT VALUES ................................................................................9-15
9.7 CALIBRATION FOR PROPORTIONAL VALVES ..................................................9-22
9-8 SAVING CALIBRATION VALUES ........................................................................ 9-24

MHT-1047 Page ii MHTM(AB)-1/01

 NOTE

This manual has been written as a companion to the Toggle Clamp Injection Molding Machine Operation Manual. This
Maintenance Manual has been designed specifically for maintenance personnel and does not include operation and
set-up information. Refer to the companion Operation Manual, supplied with the machine, for information pertaining to
the machine operation and set-up.

This manual has been provided to aid in the proper installation and operation of the Van Dorn Injection Molding Ma-
chine. This publication is not to be copied reproduced, disclosed or used for any purpose other than the purpose for
which is was provided. Van Dorn Demag reserves the right to alter any specifications and/or information contained in
this manual, without prior customer notification.
 PREFACE TO MAINTENANCE MANUAL

This manual has been written as a companion to the HT Toggle Clamp Machine with Allen Bradley Pro-Set 700®
Series Control System Operator Manual. This Maintenance Manual has been designed specifically for maintenance
personnel and includes maintenance and troubleshooting information. Refer to the Operator Manual, supplied with the
machine, for information pertaining to machine set-up and operation. This manual is organized into sections to provide
needed information with a minimum amount of search. A Table of Contents precedes each section and gives an outline
of the subjects covered within that section.

Our toggle clamp machines are built in several sizes and with a number of variations and optional features to meet
specific requirements with improvements being made constantly. For these reasons, your machine may not be
exactly like those illustrated, but the differences are minor and instructions are written to cover these variations. If you
should need further information or assistance relating to your machine, contact us by telephone, telex. or at the
address listed below.

VAN DORN DEMAG CORPORATION

Molder Action Network
8220 Mohawk Drive
Strongsville, Ohio 44136-1794

Telephone: 1-866-491-1045
Fax: (440) 512-4184
Internet http:\\vandorndemag.co

MOLDER ACTION NETWORK

Our customer focus service center will provide you with all your training,service, parts and processing needs:

1. Customer Training School

Van Dorn Demag holds training seminars on a regularly scheduled basis at our Strongsville, Ohio
facility. The course is designed to give operation and maintenance personnel detailed instruction on:
Machine Operation, Hydraulic Circuit Troubleshooting, Electrical Circuit Troubleshooting, and other technical
information pertaining to our injection molding machines.

2. Field Service

If you ever have need for service assistance, contact the Van Dorn Demag Service Department at the
number listed above. Our technical phone support system will direct you to the appropriate department.
Please have the following information available when contacting us for service:
• A description of the machine problem.
• Drawing or schematic number.
• Complete model and serial number of the machine.
Ask our Field Service department about preventative maintenance plans. Van Dorn Demag offers a
complete 50 Point Plus Manchine Health Checkup. PM programs can also be customized to match your
needs.

3. Process Solution Lab

Here in our state-of-the-art lab facility, we can optimize your process applications. We can actually "test
drive" your mold on our machines. Our process specialists can optimize your machine set-up and
reduce cycle times. In addition, we also offer on-site assistance.

TM-1047-Preface Page P-1 MHTM(AB)-1/01

 4. Parts and Retrofits

When a component part is needed for your Van Dorn Injection Molding Machine (either a spare for the shelf or
an emergency repair part), it is important that certain information be given to the parts department before they
can process your order. To aid in parts handling, be sure to provide the following information:

1. Your name (person placing the order).

2. Company name, address, and zip code (both shipping and billing address if different).
3. Phone or Fax.
4. Complete Model and Serial Number of the machine(s).
5. Purchase order number.
6. Part number(s) (Van Dorn Demag and/or manufacturer’s) or the best possible description of the compo-
nent you require.
7. If available, the serial number of the component that is being returned for repair or replacement.
8. Urgency of the order.
9. Desired method of shipment.

MODEL AND SERIAL NUMBERING DESCRIPTION

Van Dorn injection molding machines are identified by the clamp tonnage, type of screw, and type and capac-
ity of the injection unit, for example:

500 HT 48F 101

Clamp Hydraulic Injection Machine

Tonnage Toggle Unit Manufacturing
Maximum Global Capacity - Number
Grams of Designation
G.P. Polystyrene

LOCATING THE PART NUMBERS

Schematics of the hydraulic and electrical control systems and various assembly drawings are provided with
the manual. Most of the parts which will be needed during the life of the machine can be found on these
drawings (and schematics) which list a descriptive name and a Van Dorn Demag Part Number. If the part
number is obtained from the drawings and used when ordering parts, Van Dorn Demag’s service will be faster
and chances of error will be greatly reduced. Some part numbers cannot be found on these drawings and a
description of the part should then be used. Typical instances are:

1. Electrical Components - Please provide the manufacturer’s name and model number which is usually
marked on the component. If this cannot be found, the functional description along with any name tag
designation, will normally suffice.
2. Hydraulic Components - Tubing, hosing, fittings, restrictors, and other miscellaneous components should be
identified by length, diameter, fitting type, and location or connecting points.
For Example: Hose - 48 inches O. A. L. (overall length) X 2 inches I. D. (inside diameter) - Female swivel at
each end - Connection Points: Port #53 of Injection Manifold to H. V. Pump.
3. Commercial components which are built into the machine (motors, cylinders, instruments, gauges, etc.)
carry Van Dorn Demag Part Numbers and are available as complete units. Limited life portions of these
commercial components, such as seal kits, are also stocked. Other parts within these commercial units are
obtainable directly from the manufacturer. Assembly drawings of some of these commercial components
can be found at the end of the Hydraulic and Electrical Sections of this manual. We will be glad to assist
you if any problem should arise.

MT-1047-Preface Page P-2 MHTM(AB)-1/01

 SHIPPING METHODS

The methods of transportation available for shipping are:

1. Air Freight (ie. same day delivery, next day, ect.)
2. Motor Freight
3. United Parcel Service
4. Parcel Post
5. Please Note: On Warranty shippment's, Van Dorn Demag will pay ground freight to and from your facility,
however the cost of any additional shipping charges will be paid by the customer.
RECOMMENDED SPARE PARTS

A complete spare parts package is offered for your machine that includes the most commonly replaced compo-
nents. If a breakdown should occur, having the part on hand can significantly reduce undesirable downtime. These
spare parts packages and/or lists are handled through the Van Dorn Demag parts department.

STANDARD TORQUE INFORMATION

The following are general guidelines for the proper pre-loading of fasteners. If special torque ratings are required,
they will be listed on the machine prints. If torque values are not listed, refer to the following general guidelines.

1. All torque values will assume that the thread and bearing surfaces are coated with a water based carnuba
wax. Note that copper based lubricants such as Felpro are useful in preventing high temperature seizing, but
is not a good lubricant.

2. This information pertains to fasteners that have a Proof Load Stress of 90,000 psi, a Hardness of Rc36 Max.,
and the following specifications:

Hex Head Cap Screws SAE J429-Gr.5 (Metric-DIN 931 or 933 Class 8.8)
Socket Head Cap Screws ASTM A574 (Metric - DIN 912 Class 12.9)
Nuts SAE J995-Gr.8 (Metric - DIN 934 Class 8)

Note: These general torque recommendations do not apply to stainless and non-ferrous fasteners or joint
components.

3. The following torque values should be used for non-critical, general fastening and assembly applications where
stresses felt by the fasteners do not exceed 14,000 psi.

Socket Head and Hex Head Cap Screws, Hex Head

SAE Grade 8, Preloaded to 25% of yield Cap Screws
Bolt Size Stress Tensil SAE Grade 5,
UNC Area Preload Preload Torque % of yield
psi (Ft/Lbs) (N-m) (kg-m)
10-24 0.0175 40500 2.2 3.0 0.30 44.0
1/4-20 0.0318 40500 5.4 7.3 0.74 44.0
5/16-18 0.0524 40500 11.0 15.0 1.53 44.0
3/8-16 0.0775 40500 19.6 26.6 2.71 44.0
7/16-14 0.1063 40500 31.4 42.5 4.33 44.0
1/2-13 0.1419 40500 48 65 6.6 44.0
5/8-11 0.226 38250 90 122 12.4 41.6
3/4-10 0.334 38250 160 217 22.1 41.6
7/8-9 0.462 38250 258 349 35.6 41.6
1-8 0.606 38250 386 524 53.4 41.6
1 1/8-7 0.763 38250 547 742 75.6 47.2
1 1/4-7 0.969 38250 772 1047 107 47.2
1 1/2-6 1.405 38250 1344 1822 186 47.2
1 3/4-8 2.082 38250 2323 3149 321 47.2

MT-1047-Preface Page P-3 MHTM(AB)-1/01

 Socket Head and Hex Head Cap Screws, Hex Head
DIN 912, Class 12.9, Preloaded to 25% of yield Cap Screws
Bolt Size Stress Tensil SAE Grade 5,
Metric Area Preload Preload Torque % of yield
(mm2) (Mps) (N-m) (kg-m) (ft-lb)
M4 8.8 275 1.9 0.19 1.4 43.0
M5 14.2 275 3.9 0.40 2.9 43.0
M6 20.1 275 6.6 0.67 4.9 43.0
M8 36.6 275 16.1 1.64 11.9 43.0
M10 58.0 275 32 3.26 24 43.0
M12 84.3 275 56 5.7 41 43.0
M14 115 275 89 9.1 65 43.0
M16 157 275 138 14.1 102 43.0
(M18) 192 275 190 19.4 140 41.7
M20 245 275 270 27.5 199 41.7
M24 353 275 466 47.5 344 41.7
M30 561 275 926 94.4 683 41.7
M36 817 275 1618 165 1193 41.7
M42 1120 275 2587 264 1908 41.7
M48 1470 275 3881 396 2862 41.7

4. The following are Critical Case Preload Torque Values. Note that preloads based on bolts made of steel
per ASTM A 574 having minimum yield strength of 162,000 psi up to 0.50inch diameter and 153,000 psi
for 0.625 inch diameter and greater.

Socket Head and Hex Head Cap Screws,

Preloaded to 40% of yield
Bolt Size Stress Tensil
UNC Area Preload Preload Torque
(in2) (psi) (lb-ft) (N-m) (kg-m)
10-24 0.0175 64800 3.6 4.9 0.50
1/4-20 0.0318 64800 8.6 11.6 1.18
5/16-18 0.0524 64800 17.7 23.9 2.44
3/8-16 0.0775 64800 31.4 42.6 4.34
7/16-14 0.1063 64800 50.2 68.0 6.93
1/2-13 0.1419 64800 77 104 10.6
5/8-11 0.226 61200 144 195 19.9
3/4-10 0.334 61200 256 346 35.3
7/8-9 0.462 61200 412 559 57
1-8 0.606 61200 618 838 85
1 1/8-7 0.763 61200 876 1187 121
1 1/4-7 0.969 61200 1235 1675 171
1 1/2-6 1.405 61200 2150 2915 297
1 3/4-8 2.082 61200 3716 5039 514

MT-1047-Preface Page P-4 MHTM(AB)-1/01

 Socket Head and Hex Head Cap Screws,
Preloaded to 40% of yield
Bolt Size Stressed Tensil
Metric Area Preload Preload Torque
(mm2) (Mps) (N-m) (kg-m) (ft-lb)
M4 8.8 440 3.1 0.32 2.3
M5 14.2 440 6.2 0.63 4.6
M6 20.1 440 10.6 1.08 7.8
M8 36.6 440 25.8 2.63 19.0
M10 58.0 440 51 5.2 38
M12 84.3 440 89 9.1 66
M14 115 440 142 14.5 104
M16 157 440 221 22.5 163
(M18) 192 440 304 31 224
M20 245 440 431 44 318
M24 353 440 746 76 550
M30 561 440 1481 151 1092
M36 817 440 2588 264 1909
M42 1120 440 4140 422 3053
M48 1470 440 6209 633 4580

5. The following torque values should be used for hydraulic valve mounting and SAE Flange mounting.

Hex Head Socket Head

Screw Cap Screw Gr.8 Cap Screw
Size 19,000 psi 24,000 psi
Max. Stress Max. Stress

10-24 1.6 to 1.7 2.0 to 2.1

1/4-20 4.0 to 4.24 4.7 to 5.0
5/16-18 8.5 to 8.9 10.0 to 10.5
3/8-16 15 to 16 17.8 to 18.8
7/16-14 20 to 25 28.6 to 30.0
1/2-13 37 to 40 52 to 56*
5/8-11 75 to 83 117 to 127*
3/4-10 134 to 141 158 to 166
7/8-9 219 to 233 158 to 274
1-8 332 to 346 390 to 407
1 1/8-7 450 to 470 532 to 557
1 1/4-7 640 to 685 757 to 807
1 1/2-6 1130 to 1185 1330 to 1400

* The values for 1/2-13 and 5/8-11 SHCS will produce a tensile stress higher than 24,000 psi in order to
provide adequate torque for SAE Flange applications.

6. Torque values for mounting electrical components must follow the recommendations of the component
manufacturer.

7. For American Standard and A.P.I. Line Pipe Threads there is not a Torque Specification. The following
chart list the "Required Engagement" Specifications. Note the pipe diameter, referance the "Required
Engagement" specification below, measure the distance for the size pipe to be tightened and make a mark
on the threads with a grease pencil. Tighten the pipe fitting until this point is reached, this will insure a
proper seal.

Dimensions in Inches
Pipe Diameter 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2
Required Engagement 1/4 3/8 3/8 1/2 9/16 11/16 11/16 11/16 3/4 15/16 1 1-1/16

MT-1047-Preface Page P-5 MHTM(AB)-1/01

 SECTION 1

INSTALLATION

1.1 INSTALLATION

Ample operating space and a solid foundation are required for setting up the machine. Insure that the floor
has adequate strength and the ceiling is high enough to facilitate installation and removal of components.

Attention should be given for safe operation by providing for sufficient head room, unrestricted accessibility on
all sides and adequate lighting.

1.2 SITE PLANNING

Careful consideration should be given to the following suggestions to ensure a safe and efficient manufacturing
facility.

1.2.1. MACHINE SPACE REQUIREMENTS (per installation drawings)

1.2.1.1. Overall floor area.

1.2.1.2. Overall height, from floor to top of hopper (include additional space requirement for vibration mounts).

1.2.1.3. Sufficient room for removal of clamp tie rods, injection unit screw and motor(s).

1.2.1.4. Space for electrical control cabinet (If required with optional controller).

1.2.2. AUXILIARY EQUIPMENT SPACE REQUIREMENTS

Provide sufficient space for chillers, conveyors, weighing equipment, dryers, etc. If possible, allow space for
additional equipment which may be needed at a later date. Note that the hopper assembly is furnished as an
option only. Refer to the Table on Page 1-14 for the feed throat dimensions prior to mounting feed equipment.

1.2.3. FOUNDATION

The depth of the foundation needed to support the machine will vary with local soil conditions. A solid, rein-
forced concrete base that will support the specified weight is necessary.

We recommend a Civil Engineer be consulted prior to machine placement.

1.2.3.1. Machine dimensions determine the required floor space.

1.2.3.2. Machine weight: Refer to approximate weight listed on the Specification Chart in Section 1 of the
companion Operator Manual or to the bill-of-lading for actual weight.

NOTE

THESE WEIGHTS ARE WITHOUT OIL IN THE RESERVOIR. MAKE AN ALLOWANCE FOR THE ADDITIONAL
WEIGHT AFTER THE RESERVOIR IS FILLED.

Hydraulic fluid weights approximately 7.4 pounds per gallon. As an example, the 250 gallon reservoir on a
500 ton machine would add approximately 1850 pounds to the weight of the machine.

1.2.3.3. The foundation should be prepared far enough in advance to allow sufficient time for the concrete to cure
properly.

MHT-1047 Page 1-1 MHTM(AB)-1/01

INSTALLATION MAINTENANCE MANUAL
1.3 RECEIPT OF EQUIPMENT

1.3.1. INITIAL INSPECTION

Visually inspect the machine for any indication of damage that could have occurred during transit.

1.3.2. MISCELLANEOUS PARTS BOX

A box containing components such as optional hopper, cover, miscellaneous tools and spare parts is shipped
with the machine. An additional box containing optional equipment, e.g. core pull limit switch leads, vibration
mounts, etc., may also accompany your machine.

1.3.4. LOST OR DAMAGED GOODS

The signed Bill-of-Lading or Express Receipt is an acknowledgment by the transportation company of the
receipt in GOOD CONDITION of the shipment covered by our invoice.

Van Dorn Demag’s responsibility for the shipment ceases when the transportation company signs for it.

If any of the goods called for in the Bill-of-Lading or Express Receipt are short or damaged, do not accept
them until the freight or express agent makes a damage notation on your freight bill or express receipt.

You should thoroughly inspect this shipment as soon as received. If any concealed loss or damage is discov-
ered, NOTIFY YOUR FREIGHT OR EXPRESS AGENT AT ONCE and request him to make an inspection.
This is absolutely necessary. Unless you do this, the transportation companies will not entertain any claim of
loss or damage. If the agent will not make an inspection, then you should make an affidavit that you notified
him on a certain date and he failed to do so. This with other papers will properly support your claim. We are
willing to assist you in every possible manner in collecting claims for loss or damage, but this willingness on
our part does not make us responsible for collection of claims or replacement of the material.

1.4 UNLOADING AND MOVING

1.4.1. GENERAL

Riggers and/or experienced heavy machinery handlers should be on hand to unload, move and set the machine
in place.

1.4.1.1. Leave all blocking and strapping in place until the machine is unloaded and set.

1.4.1.2. Exercise care to prevent damaging the tie rods, injection unit components, or other machined areas.

1.4.1.3. It is not necessary to remove the antirust protection.

1.4.1.4. Move the machine with deliberate caution in accordance with the following methods.

1.4.2. LIFTING

CAUTION

ALL HOLES AND EYEBOLTS, EXCEPT WHERE SPECIFIED ARE EITHER FOR LIFTING INDIVIDUAL
COMPONENTS OR MANUFACTURING PURPOSES. DO NOT LIFT THE MACHINE AT POINTS
OTHER THAN THOSE SPECIFIED.

Have available lifting equipment of suitable capacity to carry the weight of the unit, e.g. crane slings,
chains, etc. Refer to the shipping papers for gross weight.

MHT-1047 Page 1-2 MHTM(AB)-1/01

 MAINTENANCE MANUAL INSTALLATION
For Winch or other Tow Device,
For Winch or other Tow
install Nylon Straps (no chains) at
Device, install steel cable at
front and rear of injection unit
clamp end as illustrated.
guide rail support spacers as
VAN DORN illustrated.

Remove shipping
bracket prior to leveling
and operating the
machine.

Place two jacks on the front and two jacks on the rear of the machine in the
areas shown. Raise the machine and place solid steel cylinders, machinery
mover dollys, or other such devices, under the base of the machine.

Figure 1-1. ROLLER AND JACK PLACEMENT

Nylon slings are preferred for lifting at tie rod points. However, if wire rope (cable) is used, protect the tie
rods from damage by wrapping at the lift points with heavy canvas or burlap before lifting. NEVER USE
CHAIN ON THE TIE RODS.

DANGER

INSPECT ALL CHAINS, SLINGS, CABLES, CRANES AND OTHER HOISTING EQUIPMENT BEFORE PROCEEDING.

For lifting purposes (as illustrated in Figures 1-3 and 1-4) we recommend the use of a suitably sized pivot/
swivel type safety hoist ring (M30 or M36), as depicted in Figure 1-2. We DO NOT recommend the use of a conven-
tional eyebolt for this purpose.

1.4.2.1. Spreader Bar

The preferred method to prevent damage to the machine or its components is to utilize a spreader bar,
refer to Figure 1-3.

1.4.2.1.1. Install a suitably sized pivot/swivel type safety hoist ring (shown in Figure 1-2) in the holes
provided in the lifting weldment. Tighten to full torque rating (minimum grip length should be at
least 1.5 times the nominal diameter).

1.4.2.1.2. Insert the chain hook from the spreader bar through the safety hoist ring eye.

1.4.2.1.3. Place a strap around the upper tie rods as close to the Stationary Platen as possible, as
depicted in Figure 1-3.

1.4.2.1.4. Raise the load carefully to check for balance. If the load is not balanced, shorten or lengthen
the chain as required. Check by lifting.

1.4.2.1.5. After the load is safely balanced, move the machine to its permanent site, keeping it low to the
floor. Try to avoid lifting over other equipment.

MHT-1047 Page 1-3 MHTM(AB)-1/01

INSTALLATION MAINTENANCE MANUAL
1.4.2.2. Slings and Chains Conventional Safety Hoist
Eye Bolt Ring
If a spreader bar is not available, as an
alternate method, slings and chains may be
used. Refer to Figure 1-4 for proper
placement.

1.4.2.1. Install a suitably sized pivot/swivel

type safety ring (M30 or M36)
shown on Figure 1-2 in the holes
provided in the lifting weldment.
Tighten to full torque rating.

1.4.2.2. Place a sling or wire rope around

the upper tie rod, as close to the
stationary platen as possible. Figure 1-2. RECOMMENDED SAFETY HOIST RING

1.4.2.3. Insert the chain hook through the

eye of the safety hoist ring and install the ring end of the chain over the crane hook. Place the
slings or cables attached to the tie rods over the crane hook.

1.4.2.4. Raise the load carefully to check for balance. If the load is not balanced, shorten or lengthen the
chain as required. Check by lifting.

1.4.2.5. After the load is safely balanced, move the machine to its permanent site, keeping it low to the
floor. Try to avoid lifting over other equipment.

1.4.3. MOVING WITH ROLLERS (Refer to Figure 1-1 for procedure.)

The machine may be lifted by placing jacks in the designated areas at the clamp and injection ends of the
machine, and inserting rollers under the machine for ease of moving. If you move the machine on rollers, be
certain that a sufficient number of rollers are used to adequately support the machine, taking every precaution
to prevent it from running off the rollers and/or tipping. We recommend that two (2) winches be used, one to
advance the machine and the other to brake and control movement. Again refer to the figure and place nylon
straps and cables in the designated areas. A heavy duty lift truck may also be used for this movement if
winches are not feasible to your operation.

Place Straps next to

Stationary Platen

Figure 1-3. STRAP AND SPREADER BAR PLACEMENT

MHT-1047 Page 1-4 MHTM(AB)-1/01
 MAINTENANCE MANUAL INSTALLATION

Place Straps next to

Stationary Platen

Figure 1-4. SLING AND CHAIN PLACEMENT

1.5 MACHINE LEVELING

1.5.1. GENERAL.

It is extremely important that the machine be leveled prior to start-up, checked again after the first few days
and every six months thereafter. A level base is required to allow the machine to operate properly.

Exercising care in leveling will assure proper alignment and eliminate twisting the machine base and linkage
areas. Prior to final placement and leveling of the machine, it is recommended that vibration mounts be
installed. The mounts significantly reduce shock feedback and frame stresses to bearings, gibs, tie rods,
hydraulic system components, and other machine areas. An additional benefit of their usage is that they can
reduce the time spent on leveling. (Refer to the installation drawing and install the vibration mounts in accor-
dance with the recommended locations.)

1.5.2. LEVELING: Functional Requirements

1.5.2.1. Use a precision machinist's level. Level the machine to within 0.003 inches or less per foot in
accordance with the following procedure.

1.5.2.1.1. Refer to the installation drawing and install the vibration mounts in the recommended locations.

1.5.2.1.2. If the machine is furnished with vibration mounting pads, level the machine by adjusting of the
height of the pads. Note that shims can be used to help adjust the space between the pads
and the base. After the machine is level, insure that the mounts are locked in place.

1.5.2.1.3. On machines that are not furnished with vibration mounting pads, the method of leveling is up to
the customer's discretion. Regardless of the method used, the machine level should remain in
tolerance for the useful life of the machine.

1.5.2.1.4. Transverse measurements should be made with the aid of a calibrated precision bridge, when
ever possible. For setup where a bridge is not available, a fluorescent light tube is an accept
able alternate or, on machines so equipped, machined leveling pads at the injection and clamp
ends may be used.

1.5.2.1.5. Without a mold installed, use the manual die height adjustment to set the mold height approxi
mately two inches greater than minimum setting. Use the manual mold close to extend the
linkage so that the clamp is fully closed.

MHT-1047 Page 1-5 MHTM(AB)-1/01

 INSTALLATION MAINTENANCE MANUAL

1.5.2.1.6. Level the machine to within tolerance. Note that for best results, recheck the level after install-
ing a mold.

NOTES

THE LEVEL CONDITION IN THE CLAMP AREA SHOULD NEVER BE COMPROMISED IN ORDER TO ACHIEVE
LEVEL CONDITION AT THE INJECTION UNIT END.

CHECK THE SURFACE OF THE MACHINE FOR DIRT OR IMPERFECTIONS IN THE SURFACE BEFORE PLAC-
ING THE LEVEL ON THE MACHINE.

1.5.2.2. Locations for Measurement (Reference Figure 1-5.)

1.5.2.2.1. Clamp assembly:

1.5.2.2.1.1. Longitudinally on top of wear strips between movable platen and linkage housing, as
close as possible to the movable platen.

1.5.2.2.1.2. Transversely on top of wear strips as close as possible to the stationary platen.

1.5.2.2.1.3. On top of wear strips behind the linkage housing, longitudinally and transversely.

1.5.2.2.1.4. Transverse leveling may be done on top of the tie bars adjacent to the stationary platen
and linkage housing, or on the machine leveling pads, on the platen ways.

1.5.2.2.2. On top of injection unit ways, longitudinally and transversely.

1.5.2.3. After performing the Machine Leveling Procedure, refer to Paragraph 4.6 in the Clamp Maintenance
Section of this manual and check the Platen Supports.

1.5.2.4. After performing the Machine Leveling and Platen Support Adjustment Procedures, refer to Paragraph
4.7 in the Clamp Maintenance Section of this manual and check the Clamp Single Point Adjustment.

Platen Wear Strips Movable Platen Leveling Pad Injection Unit Ways

Leveling Pad Linkage Housing Stationary Platen

= Leveling Locations

Figure 1-5. LEVELING LOCATIONS

MHT-1047 Page 1-6 MHTM(AB)-1/01

MAINTENANCE MANUAL INSTALLATION
1.6 SERVICE REQUIREMENTS

1.6.1. POWER

The main disconnect switch (supplied by the customer) and all related wiring and electrical equipment must be
installed in accordance with the regulations of the National Electrical Code and all Local Codes.

Check the electrical data tag located inside the main control cabinet and refer to the Machine Current Usage
Chart located in Table 1-1, for aid in selection of the correct wire size and disconnect devices.

Since a certain amount of vibration is typical of all injection molding machines, DO NOT USE RIGID CONDUIT
ON CONNECTIONS TO MACHINE.

Model Motor Heater Cont. Max Max Circuit Breaker Size

F.L.A. Amps Trans. Current Current 230V 230V 460V 460V
@230V @230V FLA Draw Draw Main Heat Main Heat
@230V @230V @460V

85RS 3F 39.4 16 4.4 103.1 51.6 125 — 50 —

85RS 5F & 6F 39.4 21 4.4 108.1 54.1 125 — 50 —

120RS 6F 52 21 4.4 134.6 67.3 125 — 70 —

120RS 8F 52 29 4.4 142.6 71.3 125 — 70 —

170RS 8F 73 29 4.4 186.7 93.4 200 — 100 —

170RS 14F 73 41 4.4 198.7 99.4 200 — 100 —
170RS 20F 73 49 4.4 206.7 103.4 200 — 100 —

230RS 14F 97 41 4.4 235.4 117.7 225 50 125 50

230RS 20F 97 49 4.4 243.4 121.7 225 70 125 50
230RS 30F 97 54 4.4 248.4 124.2 225 70 125 50

300RS 14F 116 41 4.4 277.4 138.7 225 50 125 50

300RS 20F 116 49 4.4 285.4 142.7 225 70 125 50
300RS 30F 116 54 4.4 290.4 145.2 225 70 125 50

400RS 30F 135 54 4.4 314.9 157.5 300 70 150 50

400RS 48F 135 77 4.4 337.9 169.0 300 100 150 50
400RS 60F 135 74 4.4 334.9 167.5 300 100 150 50

500RS 30F 168 54 4.4 434.2 217.1 350 70 175 50

500RS 48F 168 77 4.4 431.2 215.6 350 100 175 50
500RS 60F 168 74 4.4 451.2 225.6 350 100 175 50

650RS 60F 232 74 4.4 565.6 282.8 500 100 200 50

650RS 80F 232 194 4.4 585.6 292.8 500 125 200 100
650RS 125F 232 136 4.4 627.6 313.8 500 175 200 100

NOTE: THESE FIGURES HAVE BEEN CALCULATED AND SHOULD BE USED AS REFERENCE ONLY. THESE FIGURES ARE SUBJECT TO
CHANGE WITHOUT PRIOR NOTICE OR WRITTEN VERIFICATION.

Table 1-1. MACHINE CURRENT USAGE

MHT-1047 Page 1-7 MHTM(AB)-1/01

INSTALLATION MAINTENANCE MANUAL

The machine has a central grounding terminal inside of the control panel. Make certain that there is no paint,
grease, dirt, etc., between wire lugs and terminal points.

1.6.2. ELECTRICAL NOISE CONSIDERATIONS

Though all microprocessor control systems contain filters for noise rejection; ground connections, shield
connections, wire runs, circuit interrupting devices, etc., can create electrical noise problems.

Alterations, additions or attachments to the machine should not be made until approved by Van Dorn Demag.
Refer to Section 2, Safety Features.

1.6.3. EARTH GROUNDING REQUIREMENTS

To ensure a good low impedance earth ground, for proper machine operation, each machine must have a
separate ground rod as detailed in the procedure below. Power grounds, building frames, pipes and conduits
do not provide reliable, low impedance earth grounding. Note that all grounding and ground rods must comply
with all national and local Electrical Codes.

1.6.3.1. Ground Rod Specifications

• Material — Copper with a minimum diameter of 12.7mm (1/2 inch) or galvanized iron or steel with a
minimum diameter of 15.9mm (5/8 inch).
• Length — Minimum of 2.5 meter (8 foot) length of rod into the soil. This does not include the length
necessary to clear any type of flooring.
• Impedance (5 ohms or less)— The recommended method of measuring impedance is to measure 60
Hz impedance between the system ground rod and a second ground rod which is located a distance of
6.1 meters (20 feet) from the system ground rod. Refer to Figure 1-7.

1.6.3.2. Ground Cable Specifications

Note, always use braid or welding cable to effectively reduce high frequency ground noise. Listed below
are the recommended wire gauges for various ground runs. Note that runs greater than 23 meters (75
feet) are not recommended. The system ground wires and cables must be separated from power wiring.

▲
! DANGER
High Voltage.
Before servicing turn off, lock out/
tag out main power disconnect.
Do not modify electric or hydraulic
circuits unless authorized by
manufacturer.
Earth ground machine and electrical
cabinet before turning on power.
Failure to comply can cause shock,
burns or death.

Figure 1-6. TYPICAL EQUIPMENT HIGH VOLTAGE/GROUNDING SIGN

MHT-1047 Page 1-8 MHTM(AB)-1/01

MAINTENANCE MANUAL INSTALLATION
#6 Gauge for runs of less than 6 meters (20 feet)
#4 Gauge for runs of 6 to 9 meters (20 to 30 feet) 1:1
Isolation
#2 Gauge for runs of 9 to 23 meters (30 to 75)
feet 2 Amp 100 Watt
120 Fuse Light Bulb
VAC
1.6.3.3. Ground Rod Location and Connections A
Transformer
The ground rod should be located no farther than 150 Watt Min. V
61cm (2 feet) from the machine. Locate the rod
in such a manner as to minimize runs to the Test 25 Feet Minimum System
Ground Ground
various system components. When connecting Rod Rod
the ground cable to both the ground rod and the Earth
ground stud or bus bar insure that all surfaces V = Volts measured as potential between two ground rods
are free of dirt, paint, or other substances before I = Amperes as read at meter
making any connection. Also use a toothed V
locking or star washer between terminals to = <5 ohms
I
ensure a positive connection.

1.6.3.4. Power Cabinet Ground Bar or Bus Bar Figure 1-7. GROUND ROD IMPEDANCE

Connect separate ground cables from the

various system component grounds (motor
frame, control transformers, machine frame, heater box and controller grounds) to the power cabinet ground
stud or bus bar. The ground stud or bus bar should be connected directly to the ground rod using a dedi-
cated cable. If the electronic control is located in a separate cabinet insure that the cabinet ground stud is
connected directly to the power cabinet ground stud or bus bar.

1.6.3.5. Ground Noise Measurement

With power applied, AC voltages between various grounds within the control cabinet or around the ma-
chine should not exceed 100 millivolts (20 to 50 millivolts is ideal).

1.6.3.6. Ground Rod Impedance

The ground rod impedance between two rods 6 meters (20 feet) apart should be less than 5 ohms. Refer
to Figure 1-7 for the proper method to measure the impedance.

1.6.4. WATER

1.6.4.1. Hydraulic Oil Cooling

The heat exchanger on the machine requires a water feed line and drain connections. Refer to the ma-
chine installation drawing for the correct size and connector locations. Also refer to Table 1-2 for the
Hydraulic Oil Cooling Water requirement chart.

CAUTION

OPERATING OIL TEMPERATURE SHOULD NOT EXCEED 54°C (130°F). ELEVATED TEMPERATURE AFFECTS
PERFORMANCE AND THE LIFE OF THE COMPONENTS.

1.6.4.2. Injection Unit Cooling

Water feed and drain lines are also required at the throat area of the injection unit. These connections are
located on the rear side of the injection unit directly below the material feed throat opening. The recom-
mended line size for all injection units is 1/4 inch N.P.T. minimum (USE FLEXIBLE LINES ONLY).

MHT-1047 Page 1-9 MHTM(AB)-1/01

 INSTALLATION MAINTENANCE MANUAL
Source Water Information Note

Your injection molding machine requires a good source of water for cooling the hydraulic system and the injec-
tion unit feed throat area. Depending on the source of water, treatment may be required to stabilize, remove,
and/or reduce impurities. The impurities from untreated water could cause problems in the heat exchanger and/
or feed throat by either leaving deposits which could build-up, reducing water flow and thus reducing heat
transfer, or by producing corrosion which could eat through the tubing in the heat exchanger allowing the water
to mix with the hydraulic oil.

Impurities in the water depend largely on the source. Water sources as classified as either ground water (wells
and springs) or surface water (rivers and lakes). Ground water is generally free from suspended matter but picks
up impurities as it seeps through rock strata. Surface water generally contains organic matter such as leaf mold
and insoluble matter such as sand and silt. Other variables such as rainfall, water flow rate, etc. can change the
characteristics of the water.

If all water carried the same impurities there would be only one type of treatment. For industry, water impurities
can be classified into the following main groups: 1) dissolved mineral and organic matter, 2) dissolved gasses
such as oxygen and carbon monoxide, 3) turbidity (suspended matter), 4) color, 5) taste and odor, 6) microor-
ganisms. There are specific treatments for each of these classifications, therefore we strongly recommend that
you seek the advice of a water consultant. His selection of treatment must take into account the machine re-
quirements as well as an analysis of the water source.

Taking the necessary actions to monitor and control water quality will help to protect your investment and avoid
early failures which may not be covered under your machine's warranty.

LPM (GPM) @ LPM (GPM) @

Model 28.4°C (85°F) 21.1°C (70°F)
85 19 (5) 15 (4)
120 27 (7) 23 (6)
170 30 (8) 27 (7)
230 45 (12) 34 (9)
300 61 (16) 45 (12)
400 80 (21) 64 (17)
500 80 (21) 64 (17)
650 91 (24) 76 (20)

Table 1-2. WATER (HYDRAULIC OIL COOLING)

1.7 HYDRAULIC OIL AND LUBRICATION REQUIREMENTS

1.7.1. GENERAL

Oil in a Hydraulic System performs the dual functions of lubrication and power transmission. Proper servicing of
the Hydraulic System will assure satisfactory life and operation of its components.

Typically oil provided to customers falls in the NAS Class 12 or ISO 21/18 range. This class of oil must not be
used in your injection molding machine as it has the potential to cause premature wear of hydraulic compo-
nents. Note that if the oil is certified NAS Class 7 or ISO 16/13 the machine can be filled without additional
filtering. Refer to the following procedure for the recommended filtering procedure. Certified clean oil can be
purchased from the Van Dorn Demag Parts Department.

1.7.2. FILTERING

When filling your machine from a 55 gallon drum or 200 gallon tote, the methods are basically the same.
Regardless of the method, the oil must be filtered to at least an NAS Class 7/ISO 16/13 cleanliness level with
one pass through filter. Refer to Paragraph 1.7.3, Cleanliness.When filtering the oil use a portable non-bypass
filter with a three micron filter element.

MHT-1047 Page 1-10 MHTM(AB)-1/01

MAINTENANCE MANUAL INSTALLATION
The recommended GPM's of the system should equal 10, +2 GPM. When filtering the oil using a 5 to 10
micron filter element, circulate the oil in the container so that the oil passes through the filter a minimum of six
times. At 10 GPM, approximately 33 minutes is required to circulate the oil in a 55 gallon drum and approxi-
mately 2 hours is required to circulate the oil in a 200 gallon Tote.

1.7.3. CLEANLINESS

Visually inspect the hydraulic reservoir prior to filling to assure the tank is clean and free of contaminants, e.g.,
moisture, paint or metal chips, lint, rust, scale, etc.

Oil must be filtered to NAS class 7 (ISO 16/13) cleanliness level (particle counts in 100ml samples), prior to
being pumped into the machine.

Size Range Particle

Microns Count
5-15 32,000
15-25 5,700
25-50 1,012
50-100 180
over 100 32

Always use clean transferring equipment and filter the oil (3 microns) when filling the reservoir. It is appropriate
to assume that even new oil is not clean.

Fill the tank after removing the breather/filler cap plug located on the upper tank inspection cover plate. This
cover plate can be accessed by removing the cover plate located on the machine base just below the purge
guard. Fill the tank to the upper level of the sight glass which is located below the operator’s control panel.

1.7.4. HYDRAULIC OIL SPECIFICATIONS

We recommend AW46 Anti-Wear type Hydraulic Oil with a viscosity of 215/240 SUS @ 38°C (100°F) or its
equivalent in grade and quality such as Mobil DTE 25. Refer to the machine specification chart and/or installa-
tion drawing for hydraulic reservoir capacity. Refer to Table 1-3 for permissible oil grades.

The system filter should be changed initially after the first week of operation, then checked and changed when
required at subsequent intervals.

In-Line Piston
Oil Type Viscosity Pump Start-Up Operating Max.
or Equivalent SUS @ 38°C (100°F) Min. Temp. Temp. Range Temp.**

AW 32 150/165 5.6°C (42°F) 35.6°C (96°F)-44.4°C (112°F) 54°C (130°F)

AW 46* 215/240 12.2°C (54°F) 43°C (110°F)-54°C (130°F) 54°C (130°F)
AW 68 315/360 18.9°C (66°F) 51.1°C (124°F)-54°C (130°F) 54°C (130°F)

* Recommended Grade
** Do NOT operate pumps at oil temperature above 54°C (130°F). Note that an alarm will
be issued if this setpoint is exceeded.

Table 1-3. PERMISSIBLE OIL GRADES/OPERATING TEMPERATURE

1.7.5. LUBRICATION
WARNING

REFER TO THE LUBRICATION CHART IN THIS MANUAL OR THE LUBRICATION TAG LOCATED ON THE MACHINE
BASE-OPERATOR SIDE, FOR ALL LUBRICATION SPECIFICATIONS. REFER TO FIGURE 1-7.
MHT-1047 Page 1-11 MHTM(AB)-1/01
INSTALLATION MAINTENANCE MANUAL

LUBRICATION
WE RECOMMEND THE FOLLOWING LUBRICANTS OR THEIR EQUIVALENT IN GRADE AND QUALITY.

LUBRICATION POINT TYPE LUBRICANT LUBRICATION SERVICE

HYDRAULIC SYSTEM AW46 FILL TO NEAR HIGH LEVEL ON

RESERVOIR ANTIWEAR TYPE HYDRAULIC OIL SIGHT GLASS WITH 3 MICRON
VISCOSITY 215-240 SUS AT 100°F. FILTERED OIL. MAINTAIN
TEMPERATURE BETWEEN 110° AND 130° F.

SCREW DRIVE UNITS FROM HYDRAULIC SYSTEM NONE REQUIRED

WITH CHAR LYNN
BEARINGLESS MOTORS

SCREW DRIVE UNITS WITH MOBILGEAR NO. 460 FILL BEARING CAVITY TO MID-
WITH RADIAL PISTON MOTORS POINT ON SIGHT GLASS

INJECTION UNIT SCREWS, FEL-PRO C670 MOLY PASTE PACK WITH LUBRICANT
SPLINES, SHAFTS, & KEYS LUBRICANT WHEN INSTALLING

ELECTRIC MOTOR & COUPLING LUBRIPLATE 1241 EVERY 6 MONTHS

CROSSHEAD GUIDE RODS, TIE MOBILGREASE CM-L* SEE CHART, EVERY 100,000 CYCLES
RODS, PLATEN SUPPORTS OR EVERY MONTH

TOGGLE LINKS, ADJUSTING MOBILGREASE CM-L* SEE CHART, EVERY 500,000 CYCLES
NUTS, RING GEAR OR EVERY 3 MONTHS

* An equivalent high quality soap based grease with a minimum of 3% moly can also be used.

Adjusting Nuts Toggle Linkage

8 Places 16 Places

Ring
Gear

Crosshead Tie Bars

Guide Rods 4 Places Platen Supports
2 Places 2 Places

CAUTION, DO NOT SOAK OR WIPE THE FOLLOWING WITH SOLVENT:

LINK BUSHINGS EJECT PLATE BUSHINGS

TIE ROD BUSHINGS INJECTION CARRIAGE BUSHINGS
MOVABLE PLATEN SHOES.

Figure 1-8. LUBRICATION SIGN

MHT-1047 Page 1-12 MHTM(AB)-1/01
 MAINTENANCE MANUAL INSTALLATION
The HT Toggle Machines are furnished with an eight point manual lubrication system which supplies grease to the
platen supports, the tie rod bushings and the Crosshead Bushings. The manual grease pump gun is located above the clamp
manifold on the nonoperator side of the machine.

1.8 PRINTER INSTALLATION REQUIREMENTS

The Pro-Set 700® Control system is compatible with all standard Epson FX and LQ compatible printers. The printer ports
on the control system are compatible to the Comm 1 and LPT 1 ports on a standard IBM. To connect the printer, use an IBM
PC compatible cable.

After connecting the printer hardware, the following variables should be entered on the OP Setup Screen:

Print Page: When this feature is selected off, the page break entry will be ignored. If this feature is active, the
controller will fill the paper with printed screens, then insert a page break that is determined by the
entry for the number of lines/page.
Lines/Page: Designates the number of lines that will print prior to a page break.
Print Time/Out: This entry is a time delay in milliseconds for the controller to receive a response from the printer, prior
to issuing a fault.

1.9 PREOPERATIONAL CHECKOUT

Prior to start-up, perform the following preparatory services and checkouts.

DANGER

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO TRAIN AND INSTRUCT HIS PERSONNEL IN THE SAFE
METHOD OF MACHINE OPERATION AS WELL AS THE PURPOSE AND PROPER USE OF ALL THE SAFETY
DEVICES. MAKE CERTAIN ALL PERSONNEL HAVE READ, ARE AWARE OF, AND UNDERSTAND ALL SAFETY
PRECAUTIONS IN THIS MANUAL AS OUTLINED IN SECTION 2.

1.9.1. Service the entire machine in accordance with the instructions on the Lubrication Tag, located on the
machine base. Refer to Figure 1-8.

1.9.2. Open the cooling water supply valves and make certain water is circulating through the heat exchanger and
the feed throat.

1.9.3. Remove the hold-down bolts/brackets from the bottom of the link plate. These tie-downs were installed prior
to shipment and must be removed to permit mold height adjustment. These bolts are accessible through the
two access holes in the linkage drip pan, just below the rear link plate.

1.9.4. Verify that all guards are in place.

1.9.5. Visually check the hydraulic oil reservoir to verify that the temperature is at least 12.2°C (54°F) (when AW
46 or equivalent is used). Refer to Table 1-3 for permissible oil grades and operating temperatures.

1.9.6. Place the Control Selector Switch, located on the operator’s control panel, to the on position.

CAUTION

WARN ALL PERSONNEL IN THE VICINITY OF THIS EQUIPMENT THAT YOU WILL BE OPERATING THE MACHINE.

WARNING

BEFORE STARTING MOTOR, MAKE CERTAIN THE SUCTION LINE SHUT-OFF VALVE LOCATED BETWEEN THE
PUMP AND THE RESERVOIR IS IN THE OPEN POSITION.

MHT-1047 Page 1-13 MHTM(AB)-1/01

MHT-1047

INSTALLATION
FEED THROAT AND HOPPER MOUNTING DIMENSIONS FOR NON-VAN DORN HOPPERS
HOPPER C
INJ. SCREW HOUSING CAPACITY
1/2 C
UNIT DIA. PART # A B C T LBS. GPPS
3F 30mm 333004 3.13 1.94 5.00 3/8-16 UNC 40
5F 35mm 333005 3.13 1.94 5.00 3/8-16 UNC 40
6F 38mm 333005 3.13 1.94 5.00 3/8-16 UNC 40
8F 40mm 333006 3.13 1.94 5.00 3/8-16 UNC 85
14F 50mm 331705 3.13 2.94 5.00 3/8-16 UNC 145
A
20F 57mm 331705 3.13 2.94 5.00 3/8-16 UNC 145 1/2 A
30F 65mm 333156 3.13 2.94 5.00 3/8-16 UNC 145
48F 75mm 333157 3.13 2.94 5.00 3/8-16 UNC 145
60F 80mm 306722 3.13 3.50 5.00 3/8-16 UNC 225
80F 90mm 307009 6.50 3.88 6.50 1/2-13 UNC 225
125F 105mm 307019 6.50 3.88 6.50 1/2-13 UNC 225
165F 115mm 307151 6.50 4.50 6.50 1/2-13 UNC 400 T
Page 1-14

260F 135mm 307283 6.50 4.50 6.50 1/2-13 UNC 400

B
400F 155mm 86685 6.50 4.50 6.50 1/2-13 UNC 400
600F 180mm 318522 8.50 5.50 8.50 3/4-10 UNC

HTG INJ.
UNIT
30mm 79.5 50.0 127.0 M10 20kg, 35l, 45lb
270 35mm 79.5 50.0 127.0 M10 20kg, 35l, 45lb

MAINTENANCE MANUAL
360 40mm 79.5 50.0 127.0 M10 40kg, 70l, 90lb
500 45mm 79.5 65.0 127.0 M10 40kg, 70l, 90lb
720 50mm 79.5 65.0 127.0 M10 65kg, 110l, 145lb
1220 60mm 79.5 65.0 127.0 M10 65kg, 110l, 145lb
1920 70mm 79.5 75.0 127.0 M10 65kg, 110l, 145lb
MHTM(AB)-1/01

2800 80mm 165.1 90.0 165.1 M12 100kg, 170l, 225lb

4300 95mm 165.1 90.0 165.1 M12 100kg, 170l, 225lb
6800 110mm 165.1 90.0 165.1 M12 100kg, 170l, 225lb
130mm 165.1 90.0 165.1 M12 100kg, 170l, 225lb
MAINTENANCE MANUAL INSTALLATION .
1.9.7. Check pump drive motor rotation as follows:

1.9.7.1. Place the main electrical disconnect switch(es) in the on position.

1.9.7.2. Jog the main drive motor with the Pump Motor Start and Emergency Stop pushbuttons and observe the
direction the coupling or shaft is rotating. It should be rotating in the direction indicated by the arrow on
the hydraulic pump.
NOTE

A CAVITATION NOISE MAY BE HEARD WHICH SHOULD SUBSIDE IN A FEW SECONDS. IF THE NOISE DOES NOT
STOP, JOG THE PUMP MOTOR SEVERAL TIMES WITH THE “START-STOP” BUTTONS. IF THE NOISE STILL
CONTINUES, CONTACT YOUR VAN DORN DEMAG SERVICE REPRESENTATIVE.

1.9.7.3. If the motor is running in the wrong direction, DISCONNECT THE MAIN POWER SOURCE to the
control panel and reverse any two of the three incoming leads to the main disconnect.
1.9.7.4. Repeat Steps 1 and 2 to verify correct rotation.

WARNING

DO NOT ATTEMPT TO ROTATE THE FEED SCREW UNTIL THE BARREL IS HEATED TO PROPER TEMPERATURE.
SOME MATERIAL PROBABLY REMAINS IN THE BARREL FROM THE MACHINE INSPECTION TESTS.

1.9.8. Turn the machine pump motor off. Lock the main disconnect switch in the off position and tag.

1.9.9. If a Van Dorn Demag Service Engineer has been scheduled to perform the installation, it is preferable, but
not necessary, to install a mold prior to his arrival. However, if the mold is not installed, make certain the
lifting equipment, mold, related piping and hardware are on hand. Refer to Section 4 in the Operator's
Manual for the recommended procedure.

DANGER

BEFORE ATTEMPTING TO INSTALL A MOLD OR OPERATE THE MACHINE, ALL PERSONNEL SHOULD BE
THOROUGHLY FAMILIAR WITH THIS MANUAL IN GENERAL AND THE SAFETY FEATURES OF THE MACHINE AND
ALL REFERENCES TO SAFE OPERATING PRACTICES OUTLINED IN THE MANUAL, (SECTION 2 - SAFETY
FEATURES).

1.9.10. If necessary, refer to the information in Section 3 and access the Password Screen shown in Figure 1-10
(Manufacturing Level Access) and assign the appropriate codes and levels to personnel that will be operat
ing and servicing the machine. Because the access codes will allow personnel to alter mold setups as well
as the machine's factory setups, personnel should be assigned an access based on their ability to operate,
setup, and maintain the machine.To assign an access code (ID), press the softkey below the Add Record
prompt. A window will appear over the screen that allows for entry of a name and personal ID Code as well
as assigning the access level for designated personnel. To remove personnel from the access listing, use
the cursor to highlight the entry, then press the softkey below the prompt Delete Record. Note that if the
Add Record key is pressed while the cursor is highlighting an entry, the selected entry will appear in the
window. Note that by changing the information in the window, the original name and access will not be
altered. Prior to adding or deleting an entry, the abort change key can be pressed to stop the change.

1.9.11. Before placing the machine in operation, refer to Section 4 in this manual, Clamp Maintenance, and check
the Clamp Single Point Adjustment and the Toggle Linkage Breakpoint Adjustment.

MHT-1047 Page 1-15 MHTM(AB)-1/01

INSTALLATION MAINTENANCE MANUAL

Accounts
Logon Name Level Last Time On
Selectd 1 1 11/17/98 14:19:46
Account 2 2
20 20
3 3
Sort
By
Time

Sort
By
Time

Change View
Logon Logoff Pass- Downld
word Log

Machine ID: Van Dorn

HW1:31 Name: 1 Level: 1 Nov 17 2:20:11 pm

Figure 1-10. TYPICAL ACCESS CODE SCREEN

MHT-1047 Page 1-16 MHTM(AB)-1/01

 SECTION 2

SAFETY FEATURES

2.1 GENERAL

A variety of safety features have been built into your Van Dorn Plastic Injection Molding Machine (Ref: ANSI
B151.1 and as superseded by the guideline to minimize hazards of unguarded mold area motions, developed by the
Standards Development Sub-Committee of the Injection Section, Machinery Division, The Society of the Plastic
Industry. Inc.) The Standard Guideline adopted supersedes that of ANSI B151.1 [5.2.1 and 6.2.1] that the clamp
“stop or open” and requires instead that the clamp “stop” (when the operator gate is opened a maximum distance of
one inch.)

It is the responsibility of the user to create safe operating conditions on and around the machine. The purpose
of this section is to assist in accomplishing this by:

2.1.1. Making Operating and Maintenance personnel familiar with the potential hazards that exist, and the
precautions required to safely operate and maintain the machine.
2.1.2. Providing information to assist management in developing an accident prevention program.

Safety devices such as those illustrated below are mechanical. It is possible to bypass or remove them. It
may be necessary, occasionally, to remove a protective device to perform setup and maintenance work on a ma-
chine.
WARNING

UNDER NO CIRCUMSTANCES SHOULD THE MACHINE BE OPERATED WITHOUT ALL PROTECTIVE DE-
VICES IN PLACE AND FUNCTIONING PROPERLY.

Protective features are built into the machine to protect personnel. The user must insure that each protec-
tive device is in good working order before the machine is placed in operation.

WARNING

SAFETY SIGNS ARE FASTENED TO YOUR MACHINE AT STRATEGIC LOCATIONS. UNDER NO CIRCUM-
STANCES SHOULD THEY BE REMOVED.

2.1.3. Safety Signs

Safety signs must be kept clean and legible. Operating and maintenance personnel must understand
each safety instruction before he or she is permitted to work on the machine. Check your machine
installation drawing for tag locations on the machine. Replace them if they become lost or illegible.

2.1.4. Hazardous Materials

Refer to the Occupational Safety and Health Administration guidelines (OSHA) for the proper use and
disposal of hazardous materials. Disposal of any Hazardous Materials must be in compliance with all
State, Federal, and Local regulations (EPA). When returning components to Van Dorn Demag, they
must be drained free of oil or other contents prior to shipment. It will also be necessary to provide a
Material Safety Data Sheets (MSDS) and verification that components have not been exposed to
Polychlorinated Biphenyl (PCBs) or any other hazardous toxins.

To minimize hazardous materials activity, arrangements have been made with Mercury Displacement
Industries Inc. (MDI) to return faulty or failed mercury contactors to their facility for proper disposal or
reclamation. To return a faulty or failed contactor, label the component 'For Disposal' then box and ship
to MDI via UPS at the following address:

HO&M-1047 Page 2-1 O/MHTM(AB)-1/01

SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

2.1.5. Guards

Your Van Dorn machine is enclosed with protective guards as depicted in Figure 2-1.

2.1.5.1. The front fixed and rear fixed guards on a hydraulic clamp machine cover the clamp and ejector
mechanism and are electrically interlocked.

2.1.5.2. The rear guard covers the mold area at the back of the machine and is electrically interlocked.

2.1.5.3. A metal purge shield covers the nozzle and the area between the nozzle and the cutout side of
the stationary platen. A window on the operator’s side of the shield door allows monitoring of the
purging area. When the shield door is closed, a limit switch is actuated which allows injection
unit functions to occur. When the shield door is out of position and the limit switch is not actu
ated, injection, screw rotation, and pullback will not occur. If the machine is operating in the Semi
or Auto Mode, the machine cycle will be interrupted.

2.1.5.4. A metal shield covers the injection barrel and nozzle adapter, providing protection against contact
with the high voltage at the heater bands and also the high temperature surfaces. Band terminals
are individually covered with ceramic caps.

2.1.5.5. The miscellaneous guards shown, include those over the moving platen stop bar cover, injection
unit guards and pump motor coupling guard. These are designed to prevent inadvertent contact
with moving elements.

2.1.6. Front Operator Gate

The front operator gate covers the mold area at the front of the machine. This gate is interlocked
electrically, hydraulically and mechanically.

When the front operator gate is opened more than one-half inch, all motion will cease. See Paragraph
2.2 in this section of the manual for the ‘exception’, when optional Core and Ejector Motion/No Motion
Key Lock Switch is installed.

Rear Fixed Purge

Guard Rear Guard Shield
Injection
Unit Covers

Front Fixed Front Gate Heater

Guard Platen Stop Band
Bar Cover Shield

Figure 2-1. GUARD AREAS

HO&M-1047 Page 2-2 O/MHTM(AB)-1/01
OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES

▲
! DANGER
High speed moving parts.
Do not operate with gate/
guards removed or open.
DO NOT REACH AROUND,
UNDER, OVER OR THROUGH
GATE/GUARDS
while machine is operating.
Can cause crushing injury or
death.
© NUTRON 1992

Figure 2-2. HIGH SPEED MOVING PARTS SIGN

2.2 OPERATION OF PROTECTIVE DEVICES

2.2.1. FIXED (CLAMP/EJECTOR MECHANISM) GUARDS AND REAR (MOLD AREA) GUARD.

If any one of these guards is not closed properly, an electrical signal cannot be initiated to start the
electric motor(s). If any one of these fixed guards is opened while the mechanism is operating, the
motor(s) will stop.

2.2.1.1. Rear Fixed Guard (1LS & 1ALS)

2.2.1.2. Front Fixed Guard (61LS)

NOTE

ALL FIXED GUARDS ON HYDRAULIC CLAMP MACHINES, FRONT AND REAR, ARE SECURED.

2.2.2. FRONT OPERATOR GATE

2.2.2.1. Electrical Interlock

2.2.2.1.1. MANUAL OPERATION

2.2.2.2.1.1.1. There will be no clamp, ejector, or core motion with the operator gate open greater
than one-half inch.

2.2.2.2.1.1.2. There will be no injection or screw rotation with the operator gate open greater than
one-half inch.

2.2.2.1.2. SEMI or FULL AUTO (Without Special Core and Eject Motion/No Motion Switch option)

2.2.2.1.2.1. There will be no clamp, ejector or core motion with the safety gate open greater
than one-half inch. If the gate is opened while clamp, ejectors, or cores are in
motion, movement will stop, and the cycle will be interrupted.

The cycle at the above mentioned times can be reinitiated simply by closing the safety
gate. The motions and cycle will automatically resume. (It should be noted that with the
clamp closing or ejector forward motions, certain positions may be reached where available
pressure [operator set] was sufficient to start the motion initially, but not enough to start it
in the new position after having stopped. In these instances, it will be necessary to select
the manual mode, and return each function to its cycle start position.
HO&M-1047 Page 2-3 O/MHTM(AB)-1/01
SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

▲
! CAUTION
Crushing injury.
High speed moving parts.
When operator gate is open and key
switch "Core and Ejector Motion" is
turned to motion, do not reach into
unguarded mold area where pinch
points are created.
Consult supervisor for instructions.
Failure to follow safety procedures
can cause injury.

Figure 2-3. SPECIAL EXCEPTION MOTION SIGN

2.2.2.1.2.2. There will be no injection or screw rotation with the operator gate open greater than
one-half inch. If the gate is opened while injecting, during screw rotate or pullback,
these motions will stop and the cycle will end. It will be necessary to select the
manual mode of operation, return the clamp to full open, return the screw to its
retracted position, etc., to prepare for the next cycle.

2.2.2.1.3. CORE AND EJECTOR MOTION/NO MOTION SWITCH OPTION

The machine sequence will follow the SPI recommended Guideline to minimize hazards of
unguarded molds, unguarded ejectors, and unguarded cores, by preventing their movement
when the operator’s gate is open.

A switch labeled ‘Core and Ejector Motion’ with positions ‘No Motion’ and ‘Motion’ is available as an option.
This switch, which is mounted on the Operator Control Panel, is of the key-lock type. The ‘Special Excep-
tion to the SPI Recommended Guideline allows the user to operate the machine in the ‘Motion’ mode. This
special motion switch position is only to be used after mold guards have been installed over the pinch points
created by the cores and ejectors, in the mold area, as the clamp/mold opens. Due to the variety of mold
designs, it is not Van Dorn Demag’s responsibility to insure that these pinch points are guarded, but the
responsibility of the mold designer, the mold maker and the owner or user.

2.2.2.1.3.1. No Motion Position (Key switch to Off)

The ‘No Motion’ position, or normal position, does not allow clamp, ejector, or core motion while
the front operator safety gate is open. Therefore, in Semi or Auto Operation, with the safety gate
open during the clamp open sequence, the mold will not continue to open, the ejectors will not
operate, and the cores will not operate. Closing the front gate will allow the machine to continue
the cycle, with the conditions noted in paragraph B1b(1).

2.2.2.1.3.2. Motion Position (Key switch to On)

If the machine is in the Semi Mode with the front gate open, and the sequence has advanced to
Mold Open, the clamp will continue to open, the cores will pull (if selected) and the ejector (if
selected) will move forward to the ejector full forward position. If the gate remains open, the
clamp will not close, the ejectors will not retract, and the cores will not set until the front gate is
closed for the next cycle. The switch has no function in the Auto Mode of operation.

It is the responsibility of the operator to determine when the ‘Special Exception’ motion is not
required and return the switch to the ‘No Motion’ position.
HO&M-1047 Page 2-4 O/MHTM(AB)-1/01
OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES
2.2.2.2. Front Gate Mechanical Safety Interlock (See Figure 2-4)

The mechanical stop bar is designed for emergency use and not for routine cycle break. The stop
bar sees impact when it performs its job which, after a period of time, may produce wear on the
stop bar components.

This machine has a ratchet type full time safety stop bars that do not require adjustment unless the
ejector box or spacer(s) are removed. When the operator gate is open, the stop plate drops down to
the bar and rides along it as the moving platen opens. A series of machine segments along the full
length of the bar have a vertical surface on their left side and an angled surface on their right side.
As the bar, attached to the moving platen, moves from right to left during mold opening, the stop
plate, resting on the bar, falls off a vertical surface into a segment, rides up the angled surface, and
drops into the next segment, etc. In the closing direction, the stop plate rides the angled surface
down into the cutout and engages the vertical surface, stopping the moving platen. The length of the
bar is such that at maximum daylight dimension (clamp at full open stroke) the stop plate does not
drop in front of the bar, but rests on top of the bar to stop the platen at the first vertical cutout
surface.

Check movement of the stop plate daily by lifting, and allowing it to drop back into the smallest
diameter of the bar. Insure that the bar is fastened solidly to the platen. Visually inspect the follow-
ing stop bar component areas at the beginning of each shift.

2.2.2.2.1. The stop plate should move freely with flat surfaces on both sides and no binding at the
pivot pin or against the platen face.
2.2.2.2.2. There should be square corners on all stop bar shoulders with no visible rounding or
coining.
2.2.2.2.3. The bar should be straight and centered in the mounting hole through the platen.

The stop bar is fastened to the movable platen, using split keys which fit in a groove in the stop bar.
The larger than bar diameter keys, fit in a counterbore in the platen, and a locking screw is threaded
down from the top of the platen into another groove in the bar, securing the bar to the platen. Refer
to the illustration. An alternate set of grooves in the bar, locate the bar when the clamp spacers
and/or ejector box is removed.

Movable Stationary
Platen Platen
Alternate Split Ring
Circular Key Locating Tie Bar
Groove Split Circular
Keys

Platen Stop
Alternate Bar Platen Stop
Locking Screw Locking Plate Cam/Platen
Locating Screw Stop Plate
Groove Drop Bar Cover

Figure 2-4. OPERATOR GATE - MECHANICAL INTERLOCK

HO&M-1047 Page 2-5 O/MHTM(AB)-1/01
SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

WARNING

ADJUSTMENT OF THE PLATEN STOP BAR IS ONLY NECESSARY WHEN THE EJECTOR BOX AND/OR THE
SPACER (OPTIONAL) ARE REMOVED TO ACQUIRE MAXIMUM DAYLIGHT OR WHEN REINSTALLED FOR
MINIMUM MOLD HEIGHT.

Perform the following procedure to adjust the platen stop bar. Note, reverse this procedure when the
ejector box and optional spacer are reinstalled.

2.2.2.2.3.1. With a mold installed, use the Manual Mold Close pushbutton to fully close the mold.
2.2.2.2.3.2. Turn the power disconnects to the off position, lock out, and tag.
2.2.2.2.3.3. Remove the locking screw from the movable platen.
2.2.2.2.3.4. Close the operator gate to lift the platen stop plate upward.
2.2.2.2.3.5. Push the stop bar towards the stationary platen (the split keys will drop out).
2.2.2.2.3.6. Insert the split circular keys into the alternate key locating groove.
2.2.2.2.3.7. Push the stop bar towards the movable platen until the split circular keys are seated in
the movable platen.
2.2.2.2.3.8. Insert the locking screw into the movable platen and tighten until fully seated in the
stop bar groove.
2.2.2.2.3.9. Check all interlocks as described on the Operator Gate Caution Tag.

2.2.2.3. Front Operator Gate Hydraulic Interlock Valve

When the front gate is opened, the hydraulic interlock valve shifts to prevent the Mold Close Valve
from operating, thus inhibiting the clamp from closing. The pilot stage is interrupted electrically
while the main stage is interrupted hydraulically.

As the front gate is closed, a cam on the gate shifts the hydraulic interlock valve to allow the Clamp
Close valve to operate. This allows oil to flow into the clamp close circuit.

2.2.2.4. Power Assisted Operator Gate (option)

The Power Assisted Front Gate is equipped with a sensor strip that stops gate movement when an
obstruction is sensed.

2.3 OPERATOR’S STATION EMERGENCY STOP

These machines are equipped with one or more red Emergency Stop Buttons. One button will always be located
on the operator control panel face (control station) in a position readily accessible to the operator. Additional
pushbuttons may also be strategically located on the machine. Pressing any red Emergency Stop button stops the
machine's pump motor(s) and all machine functions.

DANGER

POWER TO THE HEATING BANDS WILL REMAIN ‘ON’. THEY ARE CONTROLLED SEPARATELY.

2.4 SAFETY CHECK LIST

2.4.1. GENERAL

DANGER

DO NOT OPERATE THIS MACHINE UNLESS ALL INTERLOCKS AND/OR DEVICES FUNCTION PROPERLY AS
DESCRIBED IN THIS SECTION OF THE MANUAL. AT THE START OF EACH SHIFT AND AFTER EACH MOLD
CHANGE, CHECK THE OPERATION OF THE FRONT GATE LIMIT SWITCH, HYDRAULIC INTERLOCK VALVE,
PLATEN STOP BAR AND STOP PLATE, REAR GUARD, REAR FIXED GUARD AND FRONT FIXED GUARD.
HO&M-1047 Page 2-6 O/MHTM(AB)-1/01
OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES

It is the responsibility of the employer to establish a program of periodic and regular inspections of this
machine to insure that protective devices are in proper operating condition and are adjusted properly.

It is recommended that all shift change and mold change inspections be documented by keeping a log
showing the time and date of the inspection and the signature of the inspector.

Good preventive maintenance is an asset to having a safe machine. All maintenance records should be
kept safely in permanent storage, in particular, all records of maintenance work performed on protective
devices.

2.4.2. CHECK LIST: Check at the start of each shift and after each mold change.

2.4.2.1. Visual Checkout

Make a general visual inspection of the machine to verify that no components have been removed
for maintenance or servicing during the previous shift. Be certain that all guards are secure and
properly installed and in accordance with all applicable federal and local requirements. Check that
the machine and machine area are clear of rags, tools, spare parts, raw material, scrap, etc., that
could interfere with safe operation. Verify that the floor is dry and free of oil, grease and water.

2.4.2.2. Operational Check-Out Pump Motors Off

2.4.2.2.1. Assure free movement of the platen stop plate by lifting and observing its return to block
the motion of the platen stop bar. The bar must be readjusted whenever the ejector box is
removed or reinstalled.

2.4.2.2.2. Check that the platen safety stop bar is securely fastened to the moving platen. If any
horizontal motion is detected, refer to Figure 2-3 and insure that the stop bar is adjusted
properly.

2.4.2.3. Operational Check-Out With Pump Motors Running

2.4.2.3.1. EMERGENCY STOP PUSHBUTTON — Press the Red Emergency Pushbutton located on
the operator’s station and verify that the pump motor stops. If additional Emergency Stop
pushbuttons have been furnished, repeat the same procedure to check their operation.
Note that the pushbuttons must be pulled out to restart the motors.

2.4.2.3.2. FIXED GUARDS — Clamp mechanism. Release the catch that secures the front fixed
guard and verify that the pump motor(s) stop when the guard is opened.

Remove the pin securing the two rear guards together and verify that the pump motor(s) stop.
See the rear gate ‘DANGER’ tag (Figure 2-2) and the front gate ‘CAUTION’ tag (Figure 2-5) .

2.4.2.3.3. OPERATOR GATE — Verify that the mechanical, hydraulic, and electrical interlocks are
working properly as described below (also see Figure 2-5).

2.4.2.3.3.1. Select the Manual, Setup Mode of operation.

2.4.2.3.3.2. Start the electric motors and open the operator gate four inches.

2.4.2.3.3.3. Press the Clamp Close pushbutton; the clamp must not move.

2.4.2.3.3.4. Actuate the gate limit switch 5LS while pressing the Clamp Close pushbutton; the
clamp must not move.

HO&M-1047 Page 2-7 O/MHTM(AB)-1/01

SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

▲
! CAUTION
ety
Saf High speed moving parts.
Do not operate machine unless you are trained, read
ns
Operatio and understand the Maintenance/Operator

nance
manual(s).
Mainte At start of each shift and after each mold change,
check the operation of:
1) Operator gate limit switch(s).
2) Operator gate hydraulic valve.
3) Mechanical platen stop mechanism.
4) Power gate leading edge switch(s) if equipped.
Do not operate machine unless interlocks/safety
devices are in place and functioning properly.
Failure to follow instructions could result in injury.
© NUTRON 1992

Figure 2-5. PROTECTIVE DEVICES CHECKOUT PROCEDURE

2.4.2.3.3.5. With the gate open one-half inch, press the Clamp Close pushbutton; the clamp
must not move.

2.4.2.3.3.6. With the front gate closed press the Clamp Close pushbutton; the clamp should
close.

2.4.2.3.4. PURGE SHIELD (GUARD) AND INJECTION FORWARD INTERRUPTION — with pump
motor(s) running and the barrel at the proper temperature, proceed as follows:

2.4.2.3.4.1. Select the Manual Mode of operation.

2.4.2.3.4.2. Retract the injection unit.

2.4.2.3.4.3. Close the front operator gate.

2.4.2.3.4.4. Jog the injection screw forward by pressing the Man. Inject Fwd. pushbutton until
the unit is at the Zero position on the injection position scale.

2.4.2.3.4.5. Open the purge shield door to deactivate the limit switch. Monitor the injection
pressure while pressing the Man. Inject Fwd. pushbutton. Verify that the pressure
drops to zero.

2.4.2.3.4.6. Move the purge shield back into position to activate the purge shield limit switch.

2.4.2.3.4.7. Open the operator gate while simultaneously pressing the Man. Inject Fwd. switch.
Insure that the injection pressure registers zero on the Diagnostics Screen.

2.5 CONTROL OR POWER ENCLOSURE-POWER DISCONNECT

This enclosure is equipped with two circuit breakers, one controls the motor (1 CB) and power to the controller,
and the other controls the barrel heating circuit (2 CB), each operating independently. (See Figure 2-6)

HO&M-1047 Page 2-8 O/MHTM(AB)-1/01

OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES

▲
! DANGER
High Voltage.
Before servicing turn off, lock out/
tag out main power disconnect.
Do not modify electric or hydraulic
circuits unless authorized by
manufacturer.
Earth ground machine and electrical
cabinet before turning on power.
Failure to comply can cause shock,
burns or death.

Figure 2-6. HIGH VOLTAGE/GROUNDING SIGN

DANGER

ALTHOUGH THE POWER OUTPUT FROM THE CIRCUIT BREAKER IS INTERRUPTED WHEN THE CIRCUIT
BREAKER IS IN THE “OFF” POSITION, THE CIRCUIT BREAKER IS STILL CONNECTED TO THE PLANT
POWER SUPPLY. THEREFORE, SAFETY PRECAUTIONS SHOULD BE TAKEN WHEN WORKING INSIDE
THE PANEL. THE MAIN POWER DISCONNECT (SUPPLIED BY THE CUSTOMER) MUST BE TURNED TO OFF
AND LOCKED OUT. CHECK TO INSURE THAT POWER IS NOT PRESENT WHEN SERVICING THE
MACHINE’S ELECTRICAL SYSTEM.

2.6 MACHINE GROUNDING REQUIREMENTS (See Figure 2-6)

Observe proper grounding procedures as outlined in the Installation Section of this manual. The grounding
conductor wire size should be based on the recommendations of the National Electrical Code and local wiring
codes. The machine must be adequately grounded with wire size sufficient to carry maximum current on a short
term basis.

Use a good earth ground, not water pipes, etc., and check ground connections on a regularly scheduled basis.
Add a ground check procedure to your preventive maintenance list.

2.7 METAL SHIELD (HEATER BANDS) (See Figure 2-7)

This sheet metal guard covers the barrel and heater bands. It must be in position when power is on and/or the
machine is in operation.

2.7.1. Heater band terminal ceramic insulator caps should be maintained in good condition. If contact is
made with any bare terminal while the power is on, electrical shock may result.

2.7.2. Severe burns may also result if contact is made with hot metal surfaces or heater bands.

2.7.3. Never stand on this shield. It is not designed to bear weight.

2.8 MATERIAL FUMES (See Figure 2-8)

Follow the instructions listed on the Warning sign. Consult your material supplier concerning the necessity of
filters, masks, and ventilation.

2.9 INJECTION UNIT FEED THROAT (Figure 2-9)

Insure that all electrical power to the machine has been disconnected when clearing obstructions in the feed
throat area.
HO&M-1047 Page 2-9 O/MHTM(AB)-1/01
SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

▲
! DANGER
High voltage.
Hot surface.
Turn off and lock out main
power disconnect, allow to
cool before servicing.
Can cause shock, severe
burns or death.

© NUTRON 1992

Figure 2-7. BARREL COVER HIGH VOLTAGE/HIGH HEAT

▲
! CAUTION
Vapors and fumes.
Consult Material Safety Data
Sheets (MSDS) for handling
information. Adhere to safety
requirements.
Protective gear may be required
for some materials.
Exposure to certain raw materials
may cause injury.

Figure 2-8. MATERIAL FUMES SIGN

▲
! WARNING
Rotating screw.
Do not operate with
hopper removed or put hands or
feet into
opening.
Serious bodily injury can occur.

© NUTRON 1992

Figure 2-9. ROTATING PARTS SIGN

HO&M-1047 Page 2-10 O/MHTM(AB)-1/01

OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES

Check the actual barrel zone temperatures to insure that an over-temperature problem does not exist before
attempting to swing the hopper away from the feed throat opening. Use extreme caution when clearing partially plasti-
cized or previously plasticized material now solidified, as pressure can be trapped in the barrel under certain circum-
stances. Always wear appropriate safety equipment including safety glasses.

Use only soft metal, wood, or other similar non-marring tools for loosening the obstruction. Use a vacuum cleaner
on loose or loosened material. Never place your hand in the feed opening.

2.10 OSHA STANDARDS

2.10.1. COLOR CODE

All moving and associated stationary machine parts presenting a possible hazard are painted 'Yellow'. Emer-
gency Stop Buttons are always colored Red.

2.10.2. OSHA LOCKOUT/TAGOUT REGULATIONS

The following are highlights of OSHA's Lockout/Tagout Standard. It is recommended that all employers read
Part 1910 of the Occupational Safety and Health Standards in its entirety.

2.10.2.1. Employers must:

2.10.2.1.1. Develop and implement a written energy control program.

2.10.2.1.2. Insure that new equipment or overhauled equipment can accommodate locks.
2.10.2.1.3. Use locks when equipment can be locked out or employ additional means to ensure safety when
tags, rather than locks, are used by using an effective tagout program.
2.10.2.1.4. Identify and implement specific procedures (generally in writing) for the control of hazardous energy,
including preparation for shutdown, shutdown, equipment isolation lockout/tagout application,
release of stored energy and verification of isolation.
2.10.2.1.5. Institute procedures for release of lockout/tagout, including machine inspection, notification and safe
positioning of employees and removal of the lockout/tagout device.
2.10.2.1.6. Obtain standardized locks and tags that indicate the identity of the employee using them and which
are of sufficient quality and durability to ensure their effectiveness.
2.10.2.1.7. Conduct inspection of energy control procedures at least annually.
2.10.2.1.8. Train employees in the specific energy-control procedures, with training reminders as part of the
annual inspections of the control procedures.
2.10.2.1.9. Adopt procedures to ensure safety when equipment must be tested during servicing, when outside
contractors are working at the site, when a multiple lockout is needed for a crew servicing equip-
ment and when shifts or personnel change.

2.10.2.2. Excluded from coverage are:

2.10.2.2.1. Normal production operations, including repetitive, routine and minor tool changes and adjustments
and other minor servicing activities that are integral to the production process. These would be
covered under OSHA's machine guarding standards.
2.10.2.2.2. Work on cord and plug connected electric equipment when it is unplugged, and the employee
working on the equipment has complete control over the plug.
2.10.2.2.3. Hot tap operations involving gas, steam, water or petroleum products when the employer shows that
continuity of service is essential, shutdown is impractical and documented procedures are followed
to provide proven, effective protection for employees.

2.11 ALTERATIONS/ADDITIONS TO MACHINE

Alterations, additions, or attachments to any part of the machine require prior written approval from Van Dorn
Demag Corporation. Write to the Machine Modification Specialist stating the desired changes or alterations. Provide
drawings, prints, schematics, photos, etc. regarding the changes. Van Dorn Demag will approve acceptable changes
HO&M-1047 Page 2-11 O/MHTM(AB)-1/01
SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL
not affecting safety or machine integrity. Whether changes being made are major or simple in nature, approval re-
ceived from Van Dorn Demag is required regarding the change, and not the workmanship involved in the change.

All changes should be documented at the machine and in the machine manual, to insure that anyone attempting
to work on the machine at a future date, will be aware of these changes.

Van Dorn Demag cannot be held responsible for workmanship or maintenance methods or practices that endan-
ger personnel or lead to machine performance or reaction not consistent with its original performance. This includes
workmanship and methods necessitated by wear or use, whether or not such wear is considered normal.

The following are some general guidelines for consideration when altering or adding equipment to an existing
system.

2.11.1. When installing wiring, identify and tag each wire to correspond to the documentation. This will insure
that the changes are properly made and the circuits can be traced and checked in the future, for example
during troubleshooting. Neatly dress all wires, paying particular attention to pinch point areas, to avoid the
possibility of a short circuit or open lead.

2.11.2. Following any alteration to the heating circuits, controllers or thermocouples, the system must be
thoroughly checked to insure that the elements of each zone (controller, contactor, heating bands,
thermocouple) are isolated from all other zones and that each zone is properly controlled.

2.11.3. When adding attachments to the system, attach the proper ‘KEEP OFF’, ‘DANGER’, or ‘CAUTION’ signs
to all applicable areas.

2.12 HIGH SPEED OR ACCUMULATOR INJECTION OPTION

If your machine is equipped with a High Speed or High Speed with Accumulator Option, the following safety
features are incorporated:

2.12.1. MANUAL OPERATION - only normal injection will occur.

2.12.2. AUTOMATIC OR SEMI-AUTOMATIC AND H.S. WITH ACCUMULATOR SELECTED. - The injection
unit must be fully forward (nozzle seated in sprue bushing), actuating the injection Carriage Forward
Limit Switch (22LS), before injection will occur.

2.12.3. ACCUMULATOR - bleeds off in manual operation and when pump motor is stopped.

2.13 GENERAL SAFETY PRECAUTIONS

2.13.1. HAND FILLING OF HOPPER - When hand filling the hopper, an OSHA approved safety ladder with
safety tread steps and hand rails should be used. Do NOT stand on the machine. Remove hopper
loaders from hopper for servicing. Do NOT attempt any work on any device attached to, or resting on,
the hopper unless it is properly supported from the ceiling.

2.13.2. MATERIAL

2.13.2.1. All plastic molding requires heat to initially melt or condition the material. The temperature of the
material and surrounding metal is sufficient to cause severe burns. There is a possibility of hot
material splattering either from the mold or from the nozzle. Proper protective clothing, including
gloves and face protection, should always be worn by anyone working on or near an operating
machine or one on which the heaters have been turned On.

2.13.2.2. If it is necessary to remove the nozzle adapter, such as when changing or cleaning screws,
replacing check ring or ball check parts, observe the same cautions regarding protective clothing
and procedures that were listed for working in, on, or around the material, nozzle, and feed throat.

HO&M-1047 Page 2-12 O/MHTM(AB)-1/01

OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES
2.13.2.3. Materials used for injection molding must be handled, stored and processed according to the
manufacturer’s recommendations. Do NOT allow processing temperatures to exceed the
recommended values. Technical data sheets for plastic molding compounds are available on
request from all material manufacturers. Failure to follow recommended processing procedures
can result in serious bodily injury and/or damage to equipment. Material residence time in the
barrel should also be carefully monitored. Overheated materials can explode with serious
results.

2.13.2.4. Appropriate exhaust ventilation should be used to remove smoke, vapor, or dust that can be
generated while processing certain materials. Consult your material manufacturer for ventilation
requirements.

2.13.3. SAFETY SIGNS

Familiarize yourself with all the signs described in this section of the manual. Know the safety sign
locations and thoroughly understand their meanings, before operating the machine. Replace all missing
and illegible signs.

2.13.4. SAFE PURGING PRACTICES

2.13.4.1. Wear long sleeves to provide protection from burns.

2.13.4.2. Wear approved gloves that overlap the sleeves.

2.13.4.3. Wear approved face protection.

2.13.4.4. Move injection unit forward, if necessary, so that nozzle is under the purge shield. Do not purge
into the mold.

2.13.4.5. The nozzle heat must be up to proper temperature to prevent freeze-off.

2.13.4.6. Turn the Cut-Off (Boost) Timer to zero seconds.

2.13.4.7. Use low injection pressure.

2.13.4.8. Use slow injection speed.

DANGER

NEVER ATTEMPT TO CLEAR A CLOGGED NOZZLE BY INJECTING MATERIAL.

▲
! WARNING
High pressure
molten material.
Stand clear and wear protec-
tive gear when purging and/or
servicing injection system.
Can cause severe burns.

© NUTRON 1992

Figure 2-10. HOT, PRESSURIZED MATERIAL WARNING SIGN

HO&M-1047 Page 2-13 O/MHTM(AB)-1/01
SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

2.13.4.9. If the nozzle is plugged, perform the following procedure.

2.13.4.9.1. Using the manual Inject Retract switch, pull the screw back to decompress the melt.

2.13.4.9.2. Stop the pump motor(s).

2.13.4.9.3. Turn the heaters off, and allow approximately three hours for the temperature of the
nozzle to reach ambient. The internal pressures of some materials may remain hazard-
ous, check with your material's manufacturer for the characteristics of the plastic being
used.

2.13.4.9.4. Wear approved gloves and upper body and face protection. Clear the area of all person
nel. Stand behind the end of the barrel and slowly unscrew the nozzle. Handle with care,
and clean or replace as required.

2.13.5. PRECAUTIONS AROUND ELECTRICAL CIRCUITRY

2.13.5.1. Keep electrical enclosure covers and doors closed.

2.13.5.2. Never place obstructions near the electrical control cabinet doors that could prevent ready
access.

2.13.5.3. Heed the High Voltage sign.

2.13.5.4. When performing electrical maintenance on the machine:

2.13.5.5. Remove rings, bracelets, watch bands, etc. before opening any electrical enclosure.
ACCIDENTAL CONTACT WITH LIVE CIRCUITS CAN BE DEADLY!

2.13.5.6. When power disconnects are physically turned off and work must be performed on electri-
cal devices and connections; NEVER ASSUME THAT THE POWER IS OFF. These are
mechanical devices and subject to failure. Check for voltage on the load side of the
disconnect device with a good voltage testing instrument.

DANGER

LOCK OUT DISCONNECT HANDLE(S) WITH PADLOCK(S)

2.13.6. FLOOR AREA AND MACHINE

2.13.6.1. Keep the area around the machine clear of scrap or raw materials and well illuminated. Ample
room for cleaning and material handling should be provided.

2.13.6.2. Make sure the floor is dry. Oil, water and other liquids should be covered with a noncombus-
tible absorbent material, swept up immediately and placed in a covered metal container.

2.13.6.3. Never use compressed air to blow foreign matter (pellets, dust, etc.) off the machine, clothing or
floor. Dirt or other matter projected by the air can penetrate the skin or enter an eye causing
severe injury. A vacuum cleaner is preferred for cleaning up plastic pellets, etc.

2.13.6.4. Make certain there is sufficient clearance between machines so that movement of one operator
does not interfere with the work of another. Also, that ancillary equipment does not interfere
with other operators.

HO&M-1047 Page 2-14 O/MHTM(AB)-1/01

OPERATOR AND MAINTENANCE MANUAL SAFETY FEATURES

2.13.7. ADDITIONAL SAFETY PRECAUTIONS

2.13.7.1. Do not wear loose clothing, ties, jewelry, etc., which can become entangled in mechanical
devices.

2.13.7.2. Wear safety glasses at all times.

2.13.7.3. Do not attempt to bypass or reach around any guard while the machine pump motor(s) are
running. (See Figure 2-11.)

2.13.7.4. Remove parts from the mold only after it has opened fully and stopped, and the platen stop bar
drop plate is in position.

2.13.7.5. When mounting a mold, never remove the support until the mold has been securely fastened to
both platens.

2.13.7.6. When investigating a machine that has stopped cycling, use extreme caution. If overheating of
the material occurs, there is a possibility that this molten plastic may splatter when the mold
opens. Therefore, remember to KEEP THE OPERATOR GATE CLOSED, select a slow clamp
open speed, and open the mold slowly in Manual operation. Then slowly retract the injection
unit (Purge Shield Door in place), NOW open the Operator Gate and determine the cause of the
problem.

2.13.7.7. Follow the operating, purging, and shutdown instructions outlined in Section 4 of this manual.

2.13.7.8. Permit only trained operators and qualified maintenance personnel to work on injection molding
machines.

2.13.7.9. Do not attempt to adjust, repair, or perform maintenance on a machine while it is operating.

2.13.7.10. Do not begin operation, without first walking completely around the machine to insure that all
personnel are standing clear.

2.13.7.11. If more than one person is working on the machine at a time, before applying power to the
machine, all personnel must be in full view of the operator.

2.13.7.12. Do not call out instructions to co-workers to manually operate devices while trying to monitor
results or make adjustments.

▲
! DANGER
High speed moving parts.
Do not operate with gate/
guards removed or open.
DO NOT REACH AROUND,
UNDER, OVER OR THROUGH
GATE/GUARDS
while machine is operating.
Can cause crushing injury or
death.
© NUTRON 1992

Figure 2-11. HIGH SPEED MOVING PARTS SIGN

HO&M-1047 Page 2-15 O/MHTM(AB)-1/01

SAFETY FEATURES OPERATOR AND MAINTENANCE MANUAL

2.13.7.13. Do NOT attempt to stop an oil leak on a high pressure hose by placing your finger or hand
over the hole. Oil, at high pressure could be injected under the skin causing severe injury.

2.13.7.14. To ensure safe operation, maintain all machine gauges, controls, and instruments in good
working condition. Repair or replace any defective gauges, lamps, etc., as required.

SUMMARY

Protective devices are there for your safety. You will find that your machine is equipped with safety devices
and guards which conform with industry standards. Do NOT defeat their purpose by disregarding, bypassing, or
removing them.

HO&M-1047 Page 2-16 O/MHTM(AB)-1/01

 SECTION 3

PREVENTIVE MAINTENANCE
This section of the manual has been written as a companion to the Preventive Maintenance Chart located on
Pages 3-3 and 3-4. The chart contains the same numbering scheme as the steps in this section. For example, on the
chart under Daily Preventive Maintenance, Step 1, is Make a Visual Inspection of the Machine and Machine Area; the
actual procedure is detailed in Step 1 below.

3.1 DAILY PREVENTIVE MAINTENANCE PROCEDURES

It is recommended that the operator refer to the Safety Features Section of this manual before performing any
maintenance. If necessary refer to the specific sections of this manual for additional information on various compo-
nents.
DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT CAN PRODUCE SEVERE PERHAPS FATAL ELECTRICAL
SHOCK. UNLESS OTHERWISE STATED, ALL MAINTENANCE PROCEDURES SHOULD BE PERFORMED WITH
THE MAIN DISCONNECTS TURNED OFF, LOCKED OUT, AND TAGGED. REMOVE ALL WATCHES RINGS AND
OTHER JEWELRY BEFORE OPENING ANY ELECTRICAL ENCLOSURES. UNDER NO CIRCUMSTANCES
SHOULD THE MACHINE BE OPERATED WITHOUT ALL PROTECTIVE DEVICES IN PLACE AND FUNCTIONING
PROPERLY.

3.1.1. MAKE A VISUAL INSPECTION OF THE MACHINE AND MACHINE AREA

3.1.1.1. Insure that the machine and machine area are clear of all rags, tools, spare parts, raw material, scrap,
etc., that could interfere with safe operation.

3.1.1.2. Insure that the floor is dry. Oil, water, and other liquids should be covered with noncombustible absorb
ent material, swept up immediately, and placed in the proper container.

3.1.1.3. Insure that no components have been removed for maintenance during the previous shift.

3.1.2. CHECK FOR MISSING OR ILLEGIBLE SAFETY SIGNS

WARNING

SAFETY SIGNS ARE FASTENED TO YOUR MACHINE AT STRATEGIC LOCATIONS. UNDER NO CIRCUM-
STANCES SHOULD THEY BE REMOVED.

Stationary Injection Unit Covers (Pre-

Platen Guard vents contact with screw drive
Rear Guards Heater Band housing, front and rear.)
Guard
Mold Height
Adjustment
Guard

Purge Pump Motor Coupling Guard

Front Fixed Front Operator Guard
Guard (Prevents contact with pump
Gate
to motor coupling.)

Figure 3-1. TYPICAL GUARD AREAS

MHT-1047 Page 3-1 MHTM(AB)-1/01

 ▲
PREVENTIVE MAINTENANCE MAINTENANCE MANUAL

! CAUTION
ety
Saf High speed moving parts.
ns Do not operate machine unless you are trained, read
Operatio e
and understand the Maintenance/Operator

enanc
manual(s).
Maint At start of each shift and after each mold change,
check the operation of:
1) Operator gate limit switch(s).
2) Operator gate hydraulic valve.
3) Mechanical platen stop mechanism.
4) Power gate leading edge switch(s) if equipped.
Do not operate machine unless interlocks/safety
devices are in place and functioning properly.
Failure to follow instructions could result in injury.
© NUTRON 1992

Figure 3-2 PROTECTIVE DEVICES CHECKOUT PROCEDURE—OPERATOR GATE SIGN

Safety signs must be kept clean and legible. Operating and maintenance personnel must understand each
safety instruction before he or she is permitted to work on the machine. Check your machine installation
drawing for tag locations on the machine. Replace them if they become lost or illegible.

3.1.3. CHECK FRONT OPERATOR GATE

3.1.1. Insure that there is no clamp, ejector, or core motion; no injection or screw rotation; or no movement of
the mold (die) height adjust mechanism with the operator gate open greater than 12.7mm (1/2 inch).

3.1.2. During Semi or Auto operation (special Core/Ejector Motion Switch set to No Motion), insure that if the
gate is opened while the clamp, ejectors, or cores are in motion, movement will stop, and the cycle will
be interrupted.

3.1.3. During Semi or Auto operation, insure that if the gate is opened while injecting, during screw rotate or
pullback, these motions will stop and the cycle will end.

3.1.4. CHECK FRONT FIXED AND REAR FIXED GUARDS AND REAR (MOLD AREA) GUARD INTERLOCKS

If any one of the guards is not closed properly, an electrical signal cannot be initiated to start the electric
motor(s). If any one of these fixed guards is opened while the machine is operating, the motor(s) will stop.

3.1.4.1. Release the catch that secures the front fixed guard and verify that the pump motor(s) stop when the
guard is opened.

3.1.4.2. Remove the pin securing the two rear guards together and verify that the pump motor(s) stop.

3.1.5. CHECK MOLD HEIGHT ADJUSTMENT AREA GUARDS

Insure that the guard over the Mold Height Mechanism is secured.

3.1.6. CHECK STATIONARY PLATEN GUARD

Insure that the guard over the stationary platen is secure.

3.1.7. CHECK PURGE SHIELD (GUARD) AND ELECTRICAL INTERLOCK

With pump motor(s) running and the barrel at the proper temperature, insure that all injection and screw
functions are inhibited with the purge guard open.

MHT-1047 Page 3-2 MHTM(AB)-1/01

MHT-1047

MAINTENANCE MANUAL
Machine Model and Serial Number: ______________________________________________ Technician: ______________________________ .
DAILY/WEEKLY/MONTHLY MAINTENANCE RECORD
Month (Circle One): January February March April May June July August September October November December
Year: ___________
Initial and Date after checking items.
Daily M T W T F S/S M T W T F S/S M T W T F S/S M T W T F S/S
1. Make a visual inspection of the machine and area.
2. Check for missing or illegible safety signs
3. Check front operator gate interlocks
4. Check front and rear fixed guards and rear guard interlocks
5. Check Mold Height Adjustment Area Guards
6. Check stationary platen guard
7. Check purge shield (guard) and electrical interlock
8. Check heater band shield
9. Check injection unit guards
10. Check pump motor coupling guard(s)
11. Check platen stop bar cover and stop bar operation
12. Check mold guards when applicable
13. Check operator's station emergency stop
14. Check core and ejector motion/no motion(option) switch operation
Page 3-3

15. Check for proper hydraulic oil level(fill with filtered oil only)
16. Check alarm messages screens
17. Check for water leaks
18. Check hydraulic oil filter for by-pass indication.
19. Check clamp and injection unit lubrication
20. Check oil temperature (between 110°F and 130°F)
21. Check clamp and injection unit tie rods and ways.

PREVENTIVE MAINTENANCE
22. Check for hydraulic oil leaks.
23. Check for abnormal noises and smooth machine operation
Weekly
1. Clean fans and fan filters.
2. Clean all tie rods and guide rods.
3. Check cleanliness of machine and work area
4. Check clamp low pressure close mold protection circuitry
5. Lubricate crosshead guide rods, tie bars, platen supports
MHTM(AB)-1/01

Monthly
1. Check heater band straps and connections for tightness.
2. Check heater band and thermocouple operation.
3. Check limit switches and sensors.
4. Clean membrane switches on controller.
5. Check and clean water valve 'Y' strainer
 PREVENTIVE MAINTENANCE
MHT-1047
Machine Model and Serial Number: ______________________________________________ Technician: ______________________________ .

QUARTERLY/SEMI-ANNUAL/ANNUAL MAINTENANCE RECORD

Initial and Date after checking items.
1st 2nd 3rd 4th
Notes:
Quarterly Quarter Quarter Quarter Quarter
1. Clean the pump inlet strainer.
2. Replace canister style filter/breather
3. Check movable platen shoe adjustment
4. Inspect hydraulic system oil (Chem lab analysis)
5. Check operation of the oil filter bypass alarm
6. Lubricate toggle links, adjusting nuts, ring gear
7. Inspect heat exchanger
8. Check condition of operator gate and guards
9. Check accuracy of hydraulic gauges
10. Check accuracy of pressure transducers
11. Check plasticating screw-to-screw drive retainer bolts
12. Check for worn hydraulic and lubrication hoses.
13. Check main disconnect
Page 3-4

14. Clean oil reservoir tank magnets

Semi-Annually
1. Lubricate electric pump motors and motor-to-pump
couplings.
2. Inspect electric motors and couplings.

Annually
1. Inspect all electrical connections and components.
2. Check for any loose screws or nuts.
3. Check high pressure settings on all relief valves.

MAINTENANCE MANUAL
4. Change oil in the injection unit housing
5. Level machine to within 0.003 in/ft
6. Check nozzle for leakage around sprue bushing
7. Clean and regrease mold height mechanism
8. Check clamp single point adjustment
9. Check barrel, screw, and screw tip
MHTM(AB)-1/01

10. Change fan filter

11. Check platen support wear
12. Replace controller battery
13. Clean entire machine
MAINTENANCE MANUAL PREVENTIVE MAINTENANCE
3.1.8. CHECK HEATER BAND SHIELD

Insure that the heater band shield is secure.

3.1.9. CHECK INJECTION UNIT GUARDS

Insure that the Injection Unit Guards are secure.

3.1.10. CHECK PUMP MOTOR COUPLING GUARD

Insure that the pump-to-motor coupling guard is secure.

3.1.11. CHECK THE PLATEN STOP BAR COVER AND STOP BAR OPERATION

Insure that the stop bar cover is secured. The mechanical interlock devices being supplied on currently
manufactured machines are designed to provide an additional safety interlock to prevent the clamp from
closing if the front gate is opened more than 12.7mm (1/2 inch). This device is a full ratchet style platen stop
bar that requires no adjustment. Refer to Figure 3-3.

3.1.11.1. Check that the latch is free moving with flat surfaces on both sides and without any binding at
the pivot pin or against the platen face.

3.1.11.2. Assure free movement of the platen stop plate by lifting and observing its return to block the motion of
the platen stop bar.

3.1.11.3. Check that the platen safety stop bar is square without any visible rounding or coining. The bar must be
straight and centered with the holes in the platen and securely fastened to the moving platen. If any
horizontal motion is detected, refer to the Safety Features Section of this manual, and insure that the
stop bar is secured and the limit switch is adjusted properly.

Stationary Platen at
Minimum Daylight
Position

Drop Bar
Stationary Safety
Movable Platen Cover
Platen Stop
Plate
Limit Front
Switch Gate
Stationary
Platen

Stop
Plate

Tie Bar

Figure 3-3. OPERATOR GATE - MECHANICAL INTERLOCK

MHT-1047 Page 3-5 MHTM(AB)-1/01

PREVENTIVE MAINTENANCE MAINTENANCE MANUAL
3.1.12. CHECK MOLD GUARDS (Motion/No Motion Option)

Insure that appropriate guards are installed over the pinch points created by the cores and ejectors, in the
mold area, are secured. These end-user supplied guards are required when the 'Special Exception' Motion/No
Motion Switch is supplied.

3.1.13. CHECK OPERATOR’S STATION EMERGENCY STOP

The Emergency Stop Button is located on the operator control panel face (control station) in a position which is
readily accessible to the operator. Pressing the red emergency stop button stops the machine motor(s) and all
functions associated with it.

DANGER

PRESSING THE STOP BUTTON WILL NOT REMOVE POWER TO THE HEATING BANDS. THEY ARE CON-
TROLLED SEPARATELY.

3.1.14. CHECK THE OPTIONAL CORE AND EJECTOR MOTION/NO MOTION SWITCH OPERATION

With the Motion Key Off and the No Motion control selected, no clamp movement should occur when the front
operator gate is open.

To enable the Motion Function, perform the following steps:

3.1.14.1. With the front gate open and all other cycle conditions met, select the Semi Mode of operation.
3.1.14.2. Turn the Motion Key to On, then Off, then back to On.
3.1.14.3. Close the front gate.

Once the Motion Function has been enabled, the following sequence should occur. When the machine is in the
Semi Mode with the front gate open, the clamp will continue to open, the cores will pull (if selected) and the
ejector (if selected) will move forward to the eject or full forward position. If the gate remains open, the clamp
should not close, the ejectors should not retract, and the cores should not set until the operator safety gate is
closed for the next cycle.

DANGER

THE MOLD AREA MUST BE GUARDED PROPERLY AS OUTLINED IN THE SAFETY SECTION OF THE
OPERATOR'S MANUAL, AS REQUIRED WHEN THE 'SPECIAL EXCEPTION' MOTION/NO MOTION FEATURE IS
ACTIVATED. ALSO REFER TO PROCEDURE 3.1.14 ABOVE.

3.1.15. CHECK FOR PROPER HYDRAULIC OIL LEVEL

The oil level, as indicated on the Hydraulic Oil Sight Gauge, should be maintained at the high mark. Do NOT
start the machine if the oil level is below the low mark on the gauge. Note that the machine also uses a Low Oil
Level detector switch, which when activated will display an alarm fault message on the control screen. Check
the oil level detector when the oil level is low. If oil needs to be added, insure that the oil and transferring
equipment is clean (filter to 3microns). Follow NAS Class 7 guidelines for cleanliness. Also see Pages 1-10
and 1-11 in Section 1 of this manual.
NOTE

USE AW46 OR EQUIVALENT, ANTI-WEAR TYPE HYDRAULIC OIL — VISCOSITY 215 to 240 SUS AT 100°F (38°C).

3.1.16. CHECK ALARM MESSAGES SCREEN

Check the Alarm and Alarm History Screens for any indication of a malfunction, especially a malfunction which
has been reset, but not corrected. Refer to Section 3 in the Operator Manual for additional information on the
Alarm Screens.

MHT-1047 Page 3-6 MHTM(AB)-1/01

MAINTENANCE MANUAL PREVENTIVE MAINTENANCE

OIL LEVEL GAUGE

Figure 3-4. OIL LEVEL GAUGE
3.1.17. CHECK FOR WATER LEAKS

Insure that the main water supply valve has been opened, then check for leakage in the following areas:

3.1.17.1. Check oil heat exchanger unit end caps and water inlet and outlet connections.

3.1.17.2. Injection unit feed throat cooling area housing and water inlet and outlet connections.

3.1.17.3. With the rear guard and front gate opened (motor stopped) check all water connections to the water
manifolds and mold.

3.1.18. CHECK HYDRAULIC OIL FILTER FOR BYPASS INDICATION

Regular maintenance of the filter elements is the key to clean fluid and long component life. Filters do not
function when the elements are clogged with dirt to the point of bypass. Check to insure that the filter is not in
Bypass. Replace with the correct filter element as listed in the hydraulic parts list. Follow the procedure outlined
in the Hydraulic Maintenance Section of this Manual.

3.1.19. CHECK INJECTION AND CLAMP UNIT LUBRICATION

The lubrication requirements of your machine are listed on the lubrication sign affixed to your machine. Refer
to the actual sign or the illustration in Figure 3-7. For machines with Automatic Lubrication System, set Lube
Count to a value accordingly for proper lubrication at all points. Insure that the lubricator is filled to the proper
level with MOBILGREASE CM-L or equivalent grease.

3.1.20. CHECK THE OIL TEMPERATURE

When the machine is operating the Oil Temperature should maintain a reading of approximately 110°F (43°C),
as displayed on the Temperature Screen. (A range of 110°F [43°C] to 130°F [54°C] is selectable with a Setup
Level access.) The High Oil Temperature Alarm setting has been factory set so that an alarm is issued when the
temperature of the oil reaches 130° (54°C).

3.1.21. CHECK CLAMP AND INJECTION UNIT TIE RODS AND WAYS

After the machine has been cycling for a short period of time (as instructed by your supervisor), stop the pump
motor, turn the power disconnects off, lock out, and tag, then check the following areas for scoring and high
heat. Also check the tie rods for nicks and scratches. Use a stone to remove any imperfections which may
damage the platen bushings.

3.1.21.1. Tie rods in mold area, with the mold in the full open position.
MHT-1047 Page 3-7 MHTM(AB)-1/01
PREVENTIVE MAINTENANCE MAINTENANCE MANUAL

3.1.21.2. The way on the mold area base.

3.1.21.3. The ejector guide rods and cylinder piston rod.

3.1.21.4. Check Injection Unit carriage positioning cylinder.

3.1.21.5. Check injection unit carriage guide rods.

3.1.22. CHECK FOR HYDRAULIC OIL LEAKS

While the pump motor and power disconnects are off, locked out, and tagged make a visual inspection of the
work area around the machine for pools of hydraulic oil. Also check for leaks at all hose and tubing fittings,
valves, manifolds, motors and oil cylinder piston rods.

3.1.23. CHECK FOR ABNORMAL NOISES AND SMOOTH MACHINE OPERATION

In general, check the machine while it is operating and check the following areas. Note, it is recommended that
the machine be monitored while operating properly so that any changes in sound or action will be noticeable.

Screw Drive
Motor

Oil
Injection 'Y' Heat
Filter Clamp/Eject
Manifold Strainer Exchanger Manifold

NOTE: The 650 Ton HT Machine is supplied with two oil filters.

Figure 3-5. OIL FILTER LOCATION

3.1.23.1. Clamp Mechanism: Listen for sounds which may indicate a lack of lubrication or damage to bushings
in the toggle linkage area, ejector assembly, or movable platen area. Also monitor the following areas
during operation; even stroke of ejector/core pull functions, clamp stroke and optional robot unit
operation.

3.1.23.2. Check the injection carriage for smooth operation.

3.1.23.3. Check for unusual noise during screw rotate, such as a squeaking noise in the screw/barrel chamber
or noise at the hydraulic motor.

3.1.23.4. Check to insure that a cushion can be maintained during the Injection Pack/Hold Stage (being unable
to do so would indicate a non-return valve or barrel wear problem).

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE

LUBRICATION
WE RECOMMEND THE FOLLOWING LUBRICANTS OR THEIR EQUIVALENT IN GRADE AND QUALITY.

LUBRICATION POINT TYPE LUBRICANT LUBRICATION SERVICE

HYDRAULIC SYSTEM AW46 FILL TO NEAR HIGH LEVEL ON

RESERVOIR ANTIWEAR TYPE HYDRAULIC OIL SIGHT GLASS WITH 3 MICRON
VISCOSITY 215-240 SUS AT 100°F. FILTERED OIL. MAINTAIN
TEMPERATURE BETWEEN 110° AND 130° F.

SCREW DRIVE UNITS FROM HYDRAULIC SYSTEM NONE REQUIRED

WITH CHAR LYNN
BEARINGLESS MOTORS

SCREW DRIVE UNITS WITH MOBILGEAR NO. 460 FILL BEARING CAVITY TO MID-
WITH RADIAL PISTON MOTORS POINT ON SIGHT GLASS

INJECTION UNIT SCREWS, FEL-PRO C670 MOLY PASTE PACK WITH LUBRICANT
SPLINES, SHAFTS, & KEYS LUBRICANT WHEN INSTALLING

ELECTRIC MOTOR & COUPLING LUBRIPLATE 1241 EVERY 6 MONTHS

CROSSHEAD GUIDE RODS, TIE MOBILGREASE CM-L* SEE CHART, EVERY 100,000 CYCLES
RODS, PLATEN SUPPORTS OR EVERY MONTH

TOGGLE LINKS, ADJUSTING MOBILGREASE CM-L* SEE CHART, EVERY 500,000 CYCLES
NUTS, RING GEAR OR EVERY 3 MONTHS

* An equivalent high quality soap based grease with a minimum of 3% moly can also be used.

Adjusting Nuts Toggle Linkage

8 Places 16 Places

Ring
Gear

Crosshead Tie Bars

Guide Rods 4 Places Platen Supports
2 Places 2 Places

CAUTION, DO NOT SOAK OR WIPE THE FOLLOWING WITH SOLVENT:

LINK BUSHINGS EJECT PLATE BUSHINGS

TIE ROD BUSHINGS INJECTION CARRIAGE BUSHINGS
MOVEABLE PLATEN SHOES.

Figure 3-6. LUBRICATION

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PREVENTIVE MAINTENANCE MAINTENANCE MANUAL

3.1.23.5. Check for hydraulic pump/electric motor noise which may be caused from; pump cavitation (starving
pump), aeration (picking up air), motor coupling misalignment, worn motor bearings, etc.

3.1.23.6. Monitor all hydraulic hoses and tubings; looking for any indication of hydraulic shock.

3.1.23.7. Listen for any unusual noise at the hydraulic valve manifolds.

3.2 WEEKLY PREVENTIVE MAINTENANCE PROCEDURES

The following procedures should be performed on a weekly bases.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT CAN PRODUCE SEVERE, PERHAPS FATAL ELECTRICAL
SHOCK. UNLESS OTHERWISE STATED, ALL MAINTENANCE PROCEDURES SHOULD BE PERFORMED WITH
THE MAIN DISCONNECTS TURNED OFF, LOCKED OUT, AND TAGGED. REMOVE ALL RINGS WATCHES, ETC.
BEFORE OPENING ANY ELECTRICAL ENCLOSURE.

3.2.1. CLEAN FANS AND FAN FILTERS

Always use a vacuum cleaner when cleaning the fans and filters on the control cabinet. Using compressed air
could force particles into the air causing personal injury or into the module causing damage to the machine.
Fans are installed to provide adequate air flow and reduce operating temperature within the cabinet. Filters are
used to minimize the accumulation of dust, dirt and other particles which could prevent adequate heat dissipa-
tion. Clean the filters by washing in solvent and blowing dry in the reverse direction to normal air flow. After
cleaning, check fan operation.

3.2.2. CLEAN CLAMP, EJECTOR AND INJECTION GUIDE OR TIE RODS AND WAYS

CAUTION

DO NOT SOAK OR WIPE THE FOLLOWING WITH SOLVENT: LINK BUSHINGS, TIE ROD BUSHINGS,
MOVABLE PLATEN SHOES, AND INJECTION CARRIAGE BUSHINGS.

Referring to the drawings supplied with the machine, or the illustration on the following page, clean the follow-
ing areas with a soft rag. (Also check the tie rods for nicks and scratches. Use a stone to remove any imper-
fections which may damage the platen bushings.)

3.2.2.1. Clamp tie rods

3.2.2.2. Clamp shoe support ways

3.2.2.3. Ejector guide rods

3.2.2.4. Injection Carriage guide rods

3.2.3. CHECK CLEANLINESS OF ENTIRE MACHINE AND WORK AREA

Insure that the area around the machine is clear of scrap and raw materials. Insure that the floor is dry. Oil,
water, and other liquids should be covered with noncombustible absorbent material, swept up immediately and
placed in the proper container. Never use compressed air to blow foreign matter (pellets, dust, etc.) off the
machine, clothing, or floor. Dirt or other matter projected through the air could penetrate the skin or enter an
eye causing severe injury. A vacuum cleaner is the recommended way to clean up any dry foreign matter.

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE
3.2.4. CHECK CLAMP LOW PRESSURE CLOSE MOLD PROTECTION CIRCUIT FUNCTION

After the machine and mold have warmed to operating temperature, check the clamp low pressure mold protec-
tion circuit as described in the following steps. Note that adjustments to Low Pressure Speed, Pressure and
Position must be made prior to performing these steps.

3.2.4.1. Apply a thin film of grease to a piece of paper or card stock that is 0.010 inch (0.254mm) thick, and
insert on the mold half when the clamp has stopped and the front gate is open.

3.2.4.2. While operating in the Semi-Mode the clamp should close, but not lock up. Also check the low pres
sure close light and bell at this time. After the low pressure timer has timed out, the red light should
illuminate, the bell should sound, and an alarm fault message should appear on the screen.

LOCATION OF FANS, FILTER, AND

VENTILATION SLOTS

Figure 3-7 FAN AND FILTER LOCATIONS

3.2.5. LUBRICATE CROSSHEAD GUIDE RODS, TIE BARS, AND PLATEN SUPPORTS

Refer to the Lubrication Sign illustrated in Figure 3-6 to locate the grease fittings associated with the guide rods,
tie bars, and supports. Note that HT Model Machines are furnished with an eight point manual lubrication
system for the reciprocating bushings. Also note that the lubrication interval may be less than every month if
the machine exceeds 100,000 cycles.

3.3 MONTHLY PREVENTIVE MAINTENANCE PROCEDURES

The following procedures should be performed on a monthly schedule.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT CAN PRODUCE SEVERE, PERHAPS FATAL ELECTRICAL
SHOCK. UNLESS OTHERWISE STATED, ALL MAINTENANCE PROCEDURES SHOULD BE PERFORMED WITH
THE MAIN DISCONNECTS TURNED OFF, LOCKED OUT, AND TAGGED. REMOVE ALL RINGS, WATCHES,
ETC. BEFORE OPENING ANY ELECTRICAL ENCLOSURE.

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PREVENTIVE MAINTENANCE MAINTENANCE MANUAL
3.3.1. CHECK HEATER BAND STRAPS AND CONNECTIONS (For Tightness and Cleanliness)

DANGER

TURN ALL POWER TO THE MACHINE OFF. STRAP SCREWS SHOULD BE TIGHTENED WHILE THEY ARE
STILL HOT. WEAR PROPER PROTECTIVE CLOTHING TO AVOID INJURY DUE TO BURNS.

CAUTION

TO AVOID DAMAGE TO THE HEATER BANDS, DO NOT ALLOW THE HEATER BAND TERMINAL POST TO
ROTATE WHILE TIGHTENING THE HEXAGON NUTS.

Check all the nuts and screws securing the heater bands to the barrel. Also check the electrical connectors
which supply power to the bands. For longer heater band life, the bands should remain tight against the barrel.
An air gap between the bands and the barrel could cause poor heat transfer, wasted energy, and shorter
heater band life. Maintaining the bands free of dirt, oil, plastic material, etc. can also prolong heater band life.
Deposits which are allowed to build up around the terminals could eventually short the bands.

TIE RODS
Ejector
Figure 3-8. CLAMP TIE RODS Guide
Rods

Figure 3-9. EJECTOR GUIDE RODS

Injection Carriage
Guide Rods
Z

Figure 3-10. INJECTION CARRIAGE TIE ROD LOCATIONS

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE

3.3.2. CHECK HEATER BAND AND THERMOCOUPLE OPERATION

Perform the following checks for heater band operation.

3.3.2.1. With the power disconnects off, locked out, and tagged, check for grounded bands.

3.3.2.2. With the power disconnects off, locked out, and tagged, insure that the thermocouples are fully seated
in the barrel well.

3.3.2.3.. With the power disconnects off, locked out, and tagged, check the thermocouples and heater bands for
cleanliness and clean if required.

3.3.2.4. With the power on, check the current through each zone. Record the value for comparison during the
next month's Preventive Maintenance Check.

3.3.2.5. With power on, insure that each thermocouple is monitoring its respective zone.

3.3.3. CHECK LIMIT SWITCHES AND SENSORS

Visually inspect the various machine limit switches for actuator arm wear and secure mounting. The mechani-
cal operation of the switches should be smooth. The switches should be adjusted so that actuation occurs with
the associated function. Also check to insure that all transducers and position sensors are securely fastened
and that their cables are not frayed, pinched, etc.

3.3.4. CLEAN MEMBRANE SWITCHES ON CONTROLLER

Use a clean soft rag and a mild detergent to clean the membrane switches on the Operator Station. Do NOT
use a cleaning solvent.

3.3.5. CLEAN WATER STRAINER

The water strainer must be inspected and cleaned on a periodic basis. These inspection intervals will depend
on the water supply conditions. Begin inspection of the strainer on a weekly basis, then increase or decrease
as conditions warrant. The strainer can be cleaned by removing it from the valve and washing with soap and a
soft bristled brush.

3.3.6. CHECK INJECTION UNIT SWIVEL MONITOR (LS126)

With the pumps running and the barrel at operating temperature, swivel the injection unit away from the purge
area. Verify the manual injection function is operable only at a reduced rate. There also should be an alarm
message on the screen. There should be no operation in Auto or Semi - Auto Modes.

3.4 QUARTERLY MAINTENANCE PROCEDURES

The following section of this manual is designed to elaborate on the various procedures outlined under the
Quarterly listing in the Yearly Machine Maintenance Record. It is the responsibility of the employer to establish a
program of periodic and regular inspections of this machine to insure that protective devices are in good operating
condition and are properly adjusted. Good preventive maintenance is an asset to having a safe machine. All mainte-
nance records should be kept safely in permanent storage, in particular, all records of maintenance work performed on
protective devices.

DANGER

THIS MACHINE OPERATES FROM VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE PERHAPS FATAL
ELECTRICAL SHOCK. UNLESS OTHERWISE STATED, INSURE THAT THE MAIN POWER DISCONNECTS ARE
TURNED OFF, LOCKED OUT, AND TAGGED, PRIOR TO PERFORMING ANY MAINTENANCE PROCEDURES. ALSO

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 PREVENTIVE MAINTENANCE MAINTENANCE MANUAL
Barrel
Cover Heater Band
Nozzle Heater Thermocouples
Band

Heater Bands

Figure 3-11. HEATER BAND LOCATION

REMOVE ANY RINGS, WATCHES, ETC. BEFORE OPENING ANY ELECTRICAL ENCLOSURES.

3.4.1. CLEAN THE PUMP AND INLET STRAINER

All machine models are equipped with pump inlet line strainers that use 60 mesh wire screen to trap dirt or
foreign objects of 0.01 inch (0.254mm) or larger (Figure 3-13.). These strainers are installed to protect the
pumps from large contaminants and must be cleaned quarterly. They are located on each pump inlet line, inside
the oil reservoir.

3.4.2. REPLACE CANISTER STYLE FILTER/BREATHER

The spin-on canister type filter/breather should be replaced after every 500 hours of operation. The canister is
located on the non-operator side of the machine, mounted to the side of the oil reservoir.
Inject Position
Sensor
Alarm Injection Injection Unit
Front Gate Light/Bell Carriage Limit Swivel Monitor
Clamp Position Drop Bar Limit Switch Switch (126LS)
Operator
Potentiometer Monitor (5LS) (22LS)
Control
(106LS) Screw
Panel
Speed
Tachometer

Control/
Power
Cabinet

Front Guard
Limit Switch Front Gate Oil Level
Machine I.D. Purge Guard Limit Main Circuit
(61LS) Hydraulic Safety Gauge Electric Motor/
Date/Name Plate Switch (99LS) Breaker
Dump Valve/ Pump Assembly
Monitor (Behind guard)
(120LS)

Figure 3-12A. SWITCH AND SENSOR LOCATIONS

(Front Machine View)
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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE
Redundant Rear
Guard Limit Switch Ejector Position
(1ALS) Potentiometer
Feed Throat Clamp
Water Valves Cylinder

Mold Height
Limit Switch
Oil Filter Oil Cooling Core Pull Rear Guard (3LS)
Injection Manifold
Bypass Switch Water Valve Receptacle Limit Switch Clamp/Eject
with Inject Pressure Manifold
(1OF) (WV) (14LS/15LS) (1LS)
Transducer
Figure 3-1B. SWITCH AND SENSOR LOCATIONS (Rear Machine View)
The following table lists the typical electrical sensing devices. For a complete listing, refer to the Control Dia-
gram supplied with the machine.

Switch or Sensing Device Location Name/Function

Function Type
1LS Limit Switch Rear Guard Rear Guard Closed
1ALS Limit Switch Rear Guard Redundant Rear Guard
3LS Limit Switch Clamp Link Plate-Rear Side Mold Height Adjust/Overtravel
5LS Limit Switch Front Operator Gate Front Gate
1OF Micro-Switch Oil Filter—Non-Oper. Side Oil Filter Bypass
1FS Micro-Switch Oil Reservoir—Top Side Oil Level
14LS/15LS* Limit Switch Receptacle Box—Rear Side Core Is Out/In
22LS Limit Switch Injection Unit—Oper. Side Injection Carriage Fwd/Ret
61LS Limit Switch Clamp End—Oper. Side Front Guard Closed
99LS Limit Switch Purge Guard Purge Guard Closed
106LS Limit Switch Stop Bar Safety Flag Up
120LS Limit Switch Below Front Operator Gate Dump Valve - Hydraulic Safety
126LS Limit Switch Below Injection Unit Injection Unit Swivel (Out of Position)
Door Inter- Micro-Switch Control Cabinet Door Interlock*
lock Switch
Clamp Linear Position Link Plate—Top Side Clamp Position Sensor
Position Sensor
Eject Linear Position Ejector Box/Movable Platen— Ejector Position Sensor
Position Sensor Oper. Side
Screw Linear Position Injection Unit—Oper. Side Screw Position Sensor
Position Sensor
Screw Speed Proximity Switch Inject Unit—Near Hyd. Motor Screw Speed Sensor
Tachometer or Transducer (Top Side)
Barrel/Nozzle Thermocouple Barrel/Nozzle—Rear Side Barrel/Nozzle Zones Temp. Control
Temp. TC (Type J)
Oil Temp Thermocouple Oil Reservoir Oil Temperature Control
(Type J)
Cabinet Thermocouple Inside Control Cabinet Control Cabinet Temperature Sensor
Temperature (Type J)
* Used on larger machines equipped with separate auxiliary power control panel.

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PREVENTIVE MAINTENANCE MAINTENANCE MANUAL
WATER
VALVE

STRAINER
OIL COOLING
HEAT EXCHANGER

Figure 3-13. STRAINER LOCATION

3.4.3. CHECK MOVABLE PLATEN SUPPORT ADJUSTMENT

The Toggle Clamp Machines are equipped with greaseless moveable platen supports (Figure 3-15). Check to
insure that they are properly adjusted. Refer to the Clamp Maintenance Section of this manual for the recom-
mended adjustment procedure.

3.4.4. INSPECT THE HYDRAULIC SYSTEM OIL (CHEM LAB ANALYSIS)

Most fluid suppliers can analyze samples taken from the oil reservoir and check for contaminates (water,
undesirable chemicals, metals, etc.) and can also recommend additives to replace those lost through heat and
time. By replenishing the oil, several years of service can be obtained without a total oil reservoir drain and refill.

3.4.5. CHECK OPERATION OF THE OIL FILTER BYPASS ALARM

Stop the pump motor, remove the hydraulic access cover and disconnect the electrical switch (1OF) from the
filter. The alarm should activate and a fault code number for Oil Filter In Bypass should be displayed.

3.4.6. LUBRICATE TOGGLE LINKS, ADJUSTING NUTS, AND RING GEAR

Refer to the mechanical drawings supplied with your machine to locate the grease fittings on the mold height
adjust mechanism. Lubricate with Mobilgrease CM-L or equivalent in grade and quality as listed on the lubrica-
tion tag affixed to your machine.

3.4.7. INSPECT HEAT EXCHANGER

To minimize the build-up of scale deposits inside the heat exchanger, some form of water treatment may be
desired. Good maintenance requires an occasional removal of deposits which could cause reduced heat transfer.

CANISTER TYPE FILTER/

BREATHER
(On Tank Non-operator Side)

PUMP INLET STRAINERS

( INSIDE TANK )

Figure 3-14. PUMP INLET STRAINER AND CANISTER FILTER LOCATIONS

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE
If the heat exchangers will not be in service for a short period of time, the water should be circulated through the
heat exchanger on a daily basis or the heat exchanger should be drained and blown dry with air. If the machine
will remain idle while being exposed to freezing temperatures, completely drain the heat exchanger and blow dry
with air.

Although a heat exchanger requires very little attention, it should be inspected periodically to ensure continued
satisfactory performance, as outlined in the following steps.

3.4.7.1. Match mark the bonnets to the housings on both sides.

3.4.7.2. Remove the bonnets. Inspect all tubes carefully for possible erosion, corrosion, and foreign materials.

3.4.7.3. Inspect all anodes to insure that they are neither excessively corroded nor insulated with scale. Scrape
away any build-up.

3.4.7.4. Inspect and clean filters/strainer on inlet to prevent foreign matter from entering the exchanger.

3.4.7.5. Assemble, insuring that the bonnets and housings are matched, per the marks made in Step 3.4.7.1.
NOTE: It is recommended that both gaskets be replaced.

3.4.8. CHECK CONDITION OF FRONT OPERATOR GATE AND OTHER GUARDS

In general check the front operator gate and other movable guards (clamp front and rear fixed guards and
purge guard) for worn rollers, tracks, window visibility, cam tightness, etc.

3.4.9. CHECK ACCURACY OF ALL HYDRAULIC PRESSURE GAUGES

Optional Injection/Back Pressure Gauge, located on the screw drive housing.

3.4.10. CHECK ACCURACY OF ALL PRESSURE TRANSDUCERS

Compare actual pressure with gauge reading. Calibrate and/or repair as required.

Platen Support
Location

Figure 3-15. TYPICAL PLATEN SUPPORT LOCATION (Side view of Toggle Assembly)

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PREVENTIVE MAINTENANCE MAINTENANCE MANUAL

3.4.11. CHECK PLASTICATING SCREW-TO-SCREW DRIVE RETAINER BOLTS FOR TIGHTNESS

With power to the machine turned off, locked out, and tagged, check that all retainer bolts are tight. Replace
any guards that may have required removal during this check.

3.4.12. CHECK FOR WORN HYDRAULIC AND LUBRICATION HOSES

Visually inspect all the hydraulic and lubrication hoses and tubings for signs of cracking, rubbing, excessive
heat, weak spots, and splitting, as well as any signs of leakage around connectors and fittings.

3.4.13. CHECK MAIN DISCONNECT

Operate the main disconnect device to ensure proper operation. Use a multimeter to verify that power is not
present on the load side of the disconnect device when it is switched to the off position.

3.4.14. CLEAN OIL RESERVOIR TANK MAGNETS

Magnets, immersed in the oil reservoir, are used to trap ferrous metallic particles. They should be removed and
cleaned at least quarterly.

3.5 SEMI-ANNUAL MAINTENANCE PROCEDURES

DANGER

THIS MACHINE OPERATES FROM VOLTAGES WHICH ARE CAPABLE OF PRODUCING SEVERE PERHAPS
FATAL ELECTRICAL SHOCK. UNLESS OTHERWISE STATED DO NOT PERFORM ANY MAINTENANCE PROCE-
DURES WITHOUT FIRST TURNING THE MAIN POWER DISCONNECTS OFF AND LOCKING THEM OUT. ALSO
REMOVE ALL WATCHES, RINGS, AND OTHER JEWELRY PRIOR TO OPENING ANY ELECTRICAL ENCLOSURES.

3.5.1. LUBRICATE ELECTRIC PUMP MOTORS AND MOTOR-TO-PUMP COUPLINGS

With the motor stopped and still warm, lubricate the motors and couplings with proper lubrication. Note that if
the motor is not manufactured by Reliance Electric, refer to the manufacturer's recommendations.

If the motor is supplied with grease fittings, lubricate the motor(s) at 6 month intervals with Mobilgrease CM-
L or equivalent. With the motor warm and stopped, use the following method:

Remove the upper pipe plug and insert a lubrication fitting in its place. Then, if furnished, remove the
bottom grease drain plug for grease relief. Be sure the lube fittings are clean and free of dirt. Using a low
pressure hand operated grease gun, pump clean recommended grease until new grease appears at the
relief hole. After lubricating, allow the motor to run for two hours before replacing the drain plug.

WARNING

MIXING LUBRICANTS IS NOT RECOMMENDED DUE TO POSSIBLE INCOMPATIBILITY. IF IT IS DESIRED TO

CHANGE LUBRICANTS, FOLLOW THE INSTRUCTIONS FOR LUBRICATION AND REPEAT LUBRICATION A SEC-
OND TIME AFTER 100 HOURS OF SERVICE. CARE MUST BE TAKEN TO LOOK FOR SIGNS OF LUBRICANT
INCOMPATIBILITY, SUCH AS EXTREME SOUPINESS VISIBLE FROM THE GREASE RELIEF AREA.

Lubricate Pump-To-Motor Coupling. Remove both pipe plugs, insert a grease fitting in one hole, then using
a grease gun force grease (Lubriplate 1241 or equivalent) until clean grease flows from the opposite hole.
Remove grease fitting and reinstall pipe plugs.

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE

3.5.2. INSPECT ELECTRIC MOTORS AND COUPLINGS

Inspect motors and couplings at regular intervals, to insure that all mounting hardware is secure. Also clean the
motor and insure that the ventilation openings are clear.

3.6 ANNUAL MAINTENANCE PROCEDURES

The following section of this manual is designed to elaborate on the various procedures outlined under the
Annual listing in the Yearly Machine Maintenance Record.

DANGER

THIS MACHINE OPERATES FROM VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE PERHAPS
FATAL ELECTRICAL SHOCK. BEFORE PERFORMING ANY MAINTENANCE PROCEDURES, INSURE THAT THE
MAIN POWER DISCONNECTS ARE TURNED OFF, LOCKED OUT, AND TAGGED. ALSO REMOVE ANY
WATCHES, RINGS, OR OTHER JEWELRY PRIOR TO OPENING ANY CABINETS.

3.6.1. INSPECT ALL ELECTRICAL CONNECTIONS AND COMPONENTS.

CAUTION

THE CONTROLLER IS SENSITIVE TO STATIC ELECTRICITY, THEREFORE, TO AVOID THE POSSIBILITY OF

DAMAGE TO THE CONTROLLER, WEAR A STATIC STRAP WHEN WORKING INSIDE THE CABINET.

Referring to the Electrical Wiring Diagram supplied with the machine, check the following:

3.6.1.1. Secure all wiring connections at the terminal blocks inside the control cabinet.

3.6.1.2. Insure that all the modules are securely installed on their connectors.

3.6.1.3. Check all wiring connections to and/or from; transducers, solenoid valves, linear positioning devices,
limit switches, thermocouples, oil heater elements, potentiometers, pulse generator, electric motors,
etc.

3.6.1.4. Check all ground connections for good contact.

3.6.1.5. Check operation of the AC Contactors.

3.6.1.6. Verify that all fuses are in accordance with the Electrical Schematic.

3.6.2. CHECK FOR ANY LOOSE SCREWS OR NUTS

Visually inspect the machine for any loose screws, nuts or bolts. Pay particular attention to areas of the ma-
chine that support or retain moving parts.

3.6.3. CHECK HIGH PRESSURE SETTINGS ON ALL RELIEF VALVES

Refer to the Hydraulic Circuit Diagram, supplied with the machine, for the correct pressure settings.

3.6.4. CHANGE OIL IN THE INJECTION UNIT HOUSING (Sealed Injection Unit Reservoirs - In Line Units))

Drain the oil in the Injection Unit Housing and replace with "Mobilegear SHC 460", or equivalent, Hydraulic Oil.
While draining the oil, inspect the oil for particles of metal that could indicate abnormal component wear.

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PREVENTIVE MAINTENANCE MAINTENANCE MANUAL

VAN DORN

ELECTRIC MOTOR AND PUMP-TO-

MOTOR COUPLING LOCATION.

Figure 3-16. ELECTRIC MOTOR LOCATION

THE OIL LEVEL FLOAT SWITCH AND THE OIL

SUBMERSIBLE TANK MAGNET ARE ACCESSIBLE
AFTER REMOVING THE TOP COVER.

VAN DORN

Figure 3-17. OIL RESERVOIR LOCATION

3.6.4.1. ROTATING RAM INJECTION UNITS

The Rotating Ram Injection units are lubricated by the system oil, there is no seperate reservoir.

3.6.5. LEVEL MACHINE TO WITHIN 0.003 IN/FT (0.76mm/30.5cm)

Follow the procedure for machine leveling as detailed in the Installation Section of this manual.

3.6.6. CHECK FOR NOZZLE TO SPRUE BUSHING LEAKAGE

After leveling the machine check to ensure a proper seal between the nozzle and the sprue bushing. This is
accomplished by checking the area, after injecting plastic material into the mold. Refer to the Nozzle Alignment
Procedure outlined in the Injection Maintenance Section of this manual.

3.6.7. CLEAN AND GREASE THE MOLD HEIGHT MECHANISM

Clean grease etc. from the tie rod threads, ring gear and tie rod gear nuts and pack with clean Mobilgrease CM-
L. Also inspect all components for abnormal wear, tightness of screws, bolts, etc.

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MAINTENANCE MANUAL PREVENTIVE MAINTENANCE

3.6.8. CHECK CLAMP SINGLE POINT ADJUSTMENT

Following the Clamp Single Point Adjustment Procedure outlined in the Clamp Maintenance Section of this
manual, check the adjustment.

3.6.9. CHECK BARREL, SCREW, AND SCREW TIP

Refer to Section 5—Injection Unit Maintenance, in this manual for the recommended procedure for screw
removal. Disassemble the screw and barrel and check for signs of wear or scoring.

3.6.10. CHANGE FAN FILTER

Replace the fan filter located in the front door of the control panel.

3.6.11. CHECK PLATEN SUPPORT WEAR

The Platen Support and the Bushings should share the weight of the movable platen. The supports should be
adjusted so that the bushings just ride on the tie rods. If the supports can no longer be adjusted so that contact
is maintained between the top of the bushings and top of the tie rods, the supports, and most probably the
bushings, will need to be replaced. (Refer to the Clamp Maintenance Section of this manual for the Platen
Support Adjustment Procedure.) Note that brass pick-up and mold leader pin misalignment are some of the first
signs of bushing and platen shoe wear.

3.6.12. REPLACE BATTERY

Refer to the Electrical Maintenance Section of this manual for the procedure on battery replacement and replace
the battery on a yearly basis. Note the replacement date on the preventive maintenance sheet.

3.6.13. CLEAN THE ENTIRE MACHINE

Clean the entire machine, keeping in mind not to use any solvents on the greaseless bushings and platen
shoes.

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 SECTION 4

CLAMP MAINTENANCE
4.1 GENERAL

The clamp design is based on sound engineering practices to give long profitable service. It has been checked
to ensure equal clamping force on a parallel mold. The user must establish a good clamp maintenance program and be
aware, that after long use, repair or replacement of some parts will be required. Refer to the Clamp Unit Description in
Section 1 of the companion Operator Manual for a functional description of the assembly.

Refer to your machine’s assembly drawings before beginning disassembly or when ordering parts. Also refer to
the Safety Section of this manual for information on setting the Operator Gate Dump Valve and Drop Bar Limit Switches.

4.2 TIE RODS AND SINGLE POINT ADJUSTING NUTS

4.2.1. DESCRIPTION

The only maintenance required on the tie rods is to keep them free of dirt and other contaminates. They should
be cleaned with a soft rag (including the threads) whenever there is a mold change. This will prevent moving the
platen or nuts over areas that have not been used for a long time and therefore may have a buildup of dirt.

4.2.2. REPLACEMENT

WARNING

THE TIE RODS MUST HAVE THE PROPER PRELOAD BEFORE OPERATING THE MACHINE. REFER TO
THE PROCEDURE IN THIS MANUAL AND THE CLAMP ASSEMBLY DRAWING SUPPLIED WITH YOUR
MACHINE FOR THE CORRECT PROCEDURE.

The tie rods are both keyed and locked to the stationary platen. Refer to the Linkage Assembly drawings. If tie
rod removal is required for any reason, perform the following steps:

4.2.2.1. If required, remove the mold and other peripheral devices.

4.2.2.2. Turn main power off, lock out, and tag the power disconnects.

4.2.2.3. Remove the link plate guards, covering the clamp cylinder/mold height drive assembly.

4.2.2.4. Remove the adjusting nut retainers screws. (This may necessitate removal of some adjusting nut
grease fittings.)

4.2.2.5. Remove the set screws from the nut on the stationary platen end of the clamp and carefully remove the
nut.

4.2.2.6. Tap tie rod toward the link end of the clamp with a piece of wood or a brass hammer. (After the first
inch of tie rod travel, the split ring and dowel pin located on the mold side of the stationary platen should
be visible.)

4.2.2.7. Remove the split ring and dowel pin.

4.2.2.8. Have a lift of sufficient capacity available before attempting to remove the tie rod. Place straps from the
lifting device around the tie rod so that balance is maintained while pushing the tie rod out through the
link housing. Do Not allow the tie rod to be suspended from a single platen. Also use care when pulling
the threaded end of the tie rod through the seals in the moving platen. Use shim stock and tape to
cover the threads and start it through the seals slowly.

4.2.2.9. Assemble in the reverse order being extremely careful with the oil seals in the movable platen.

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CLAMP MAINTENANCE MAINTENANCE MANUAL
Cover/Wear Plate
Spacer
Retainer
123
Screws 123
123
1234567890123456789
1234567890123456789 123
1234567890123456789
1234567890123456789 123
123
1234567890123456789
1234567890123456789 123 Tie Rod
1234567890123456789 123
123
Adjusting Nut

Ring Gear Rear Link

Link Bushing
Link Plate

Toggle Link
Pin
12
12
12
1234567890123456789 12 SPIROL Roll
1234567890123456789 12
1234567890123456789
1234567890123456789 12 Pin
1234567890123456789 12
1234567890123456789
1234567890123456789 12
12
12 Tapped
Hole

Figure 4-1. CLAMP TOGGLE LINK PIN/BUSHING REMOVAL

4.2.2.10. Check the Movable Platen Support Assembly and adjust if necessary. (Refer to Paragraph 4.6, Platen
Support Adjustment Procedure.)

4.2.2.11. Check Single Point Settings and adjust if necessary. (Refer to Paragraph 4.6, Single Point Adjustment
Procedure.)

CAUTION

IF A TIE ROD HAS BEEN BROKEN, ULTRASOUND TESTING INDICATES THAT STRESS FACTURES MAY
APPEAR ON THE REMAINING TIE RODS. IT IS THEREFORE RECOMMENDED THAT IF ONE TIE BAR
REQUIRES REPLACEMENT, THAT THE REMAINING TIE RODS ALSO BE REPLACED AT THE SAME TIME.

4.3 TIE BAR PRELOADING PROCEDURE (Refer to Figure 4-1.)

The tie rods must have the proper preload before placing the machine in operation. After replacing the tie rods
perform the following procedure. Note that the machine must be level before performing this procedure.

4.3.1. Remove the mold and all peripheral devices that may interfere with work performed on and around the tie rods.

4.3.2. Turn power disconnects off, lock out, and tag.

4.3.3. Remove the tie rod set screws from the nuts that are on the stationary platen end of the rod.

4.3.4. Using the appropriate tie rod wrench and a #10 sledge hammer, loosen all four tie rod nuts.

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MAINTENANCE MANUAL CLAMP MAINTENANCE
4.3.5. Using the same wrench and sledge hammer, tighten the tie rod nuts enough to partially preload the tie rods.

4.3.6. Loosen all four tie rod nuts.

4.3.7. Tighten all four nuts hand tight.

4.3.8. Using a center punch, permanently mark the position of the tie rod nut to the stationary platen to represent a
starting point.

4.3.9. Referring to the following table, use a divider to measure the angle or distance that is listed for the Nut Rota
tion. Punch mark the stationary platen (as close to the nut as possible) to this 'Going To' position (clockwise).
See Table 4-1.
Angle

Machine Tie Rod Nom. Thread Nut Rotation

Size Diameter Pitch Angle Length
85 2.375 8 12.69 0.39
120 2.750 8 14.12 0.51
170 3.250 8 15.73 0.67
230 3.750 6 12.79 0.63
300 4.250 6 14.00 0.78
400 5.00 4 15.04 0.98 Length
500 5.500 4 15.93 1.14
650 6.250 4 18.25 1.49
400G 5.000 4 9.86 0.64
500G 5.500 4 10.91 0.78
650G 6.250 4 12.18 0.99

This chart is effective for Machines built after 9/97.

4.3.10. Alternately tighten the nuts, in two stages, so that the mark on the nut aligns with the mark made in Step 9
on the stationary platen.

4.3.11. Tighten the set screws on the tie rod nuts.

4.3.12. Refer to the Platen Support Adjustment procedure in this section and check the platen support adjustment.

4.3.13. Perform the Clamp Single Point Adjustment Procedure described in this section of the manual.

4.4 BUSHINGS AND LINK PINS (Refer to Figure 4-1.)

4.4.1. DESCRIPTION

The toggle mechanism is equipped with replaceable toggle pins and press fit type bushings. With proper
maintenance, periodic lubrication, and periodic inspection of the toggle mechanism for loose linkage screws,
misadjusted movable platen supports, etc., wear on linkage parts can be kept to a minimum. Refer to the
Lubrication Tag attached to the machine or the Lubrication Tag Illustration located in the Preventive Maintenance
Section of this manual.

4.4.2. REPLACEMENT

All toggle pins have tapped holes in each end, so that a threaded rod or bolt can be used to help remove the
pins. If it becomes necessary to change a toggle link bushing or pin, it may be necessary to first remove the tie
rod (refer to the Tie Rod and Single Point Adjusting Nut replacement in this section), if tie rod removal is not
necessary continue with the following steps:

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CLAMP MAINTENANCE MAINTENANCE MANUAL
4.4.2.1. Refer to your linkage assembly drawing.

4.4.2.2. Using safe maintenance practices, remove the mold from the machine.

4.4.2.3. Disconnect any cables or lines which may interfere with the bushing or link pin removal.

4.4.2.4. With the machine in the Manual and Set-Up mode, use the control panel pushbutton to close the
clamp.

4.4.2.5. Turn main power disconnects off, lock out, and tag.

DANGER

WHEN TOGGLE PINS ARE REMOVED, SOME LINKAGE ASSEMBLIES MAY SWING FREE, AND CAUSE VARIOUS
PINCH POINTS. TO ENSURE PERSONAL SAFETY, ALWAYS SUPPORT THE ASSOCIATED LINKAGE ASSEM-
BLIES BEFORE REMOVING THE PIN(S).

4.4.2.6. If necessary support the linkage with overhead support or blocking. Depending on which toggle pin
requires removal, it may be necessary to support various linkage assemblies before proceeding.

4.4.2.7. Refer to Figure 4-1. Use a pin punch of sufficient diameter and a hammer to drive the Spirol® roll pin into
the toggle link pin on both sides of the machine.

4.4.2.8. Use the tapped hole in the toggle pin to pull the pin out of the links, or use wood or brass to knock out
the toggle pins. (Be sure to work in a direction that has enough clearance to remove the pin.)

NOTE

SPACERS ARE LOCATED WITHIN THE LINKAGE ASSEMBLY. INSURE THAT ANY SPACERS RE-
MOVED TO PERFORM THIS PROCEDURE ARE REINSTALLED IN THE SAME LOCATIONS DURING
REASSEMBLY.

4.4.2.9. Remove links as required.

4.4.2.10. Use a press to remove the bushings from the link. Support the metal close to the bushing to prevent
part distortion.

4.4.2.11. Examine all parts for scoring and cracks. Check toggle pins for wear. If damaged, repair or replace as
needed.

4.4.2.12. Use a pin punch to drive the Spirol® roll pin out of the link pin. Replace or dress the spiral roll pin as
required.

4.4.2.13. Refer to the Assembly Notes below and assemble in the reverse order.

4.4.2.13.1. For shrinkage of bushings, several methods are possible. One method is to place the
bushing(s) in a freezer for at least 24 hours. Another method is to place the bushing in a liquid
Nitrogen bath for at least five minutes. A third method is to place the bushing(s) in a glass
container surrounded by ‘Dry Ice’ for at least three to four hours.

NOTE

THE LUBRICATION GROOVE INSIDE THE BUSHING MUST BE POSITIONED SO THAT THE LOAD
BEARING SURFACE IS NOT COMPROMISED. REFER TO THE LINKAGE ASSEMBLY DRAWING FOR
DETAILS.

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MAINTENANCE MANUAL CLAMP MAINTENANCE
4.4.2.13.2. Do NOT clean bushings with solvent. Solvent removes the oil stored in the graphite plugs.

4.4.2.13.3. Apply a thin layer of Mobilgrease CM-L grease (without lead), to the inside bearing surface
before inserting the linkage pins.

4.4.2.13.3. Make sure that any spacers removed during this procedure are replaced in the same locations.

4.4.2.14. Refer to Paragraph 4.8 and check the Linkage Breakpoint Adjustment.

4.5 HYDRAULIC EJECTION AND MECHANICAL KNOCKOUT PLATES

There are no special maintenance requirements other than assuring proper lubrication, bushing replacement or
ejector cylinder replacement.

Refer to the linkage assembly drawing for replacement of these components.

NOTE

USE LOCTITE® 242-31 ADHESIVE ON ALL SOCKET HEAD CAP SCREWS ON THE EJECTOR CYLINDER ROD
AND GUIDE POSTS.

4.6 MACHINE LEVELING

4.6.1. GENERAL.

It is extremely important that the machine be leveled prior to start-up, checked again after the first few days and
every six months thereafter. A level base is required to allow the machine to operate properly.

Exercising care in leveling will assure proper alignment and eliminate twisting the machine base and linkage
areas. Prior to final placement and leveling of the machine, it is recommended that vibration mounts be in-
stalled. The mounts significantly reduce shock feedback and frame stresses to bearings, gibs, tie rods, hydrau-
lic system components, and other machine areas. An additional benefit of their usage is that they can reduce
the time spent on leveling. (Refer to the installation drawing and install the vibration mounts in accordance with
the recommended locations.)

4.6.2. LEVELING: Functional Requirements

4.6.2.1. Use a precision machinist's level. Level the machine to within 0.003 inches or less per foot in
accordance with the following procedure.

Platen Wear Strips Movable Platen Leveling Pad Injection Unit Ways

Leveling Pad Linkage Housing Stationary Platen

= Leveling Locations

Figure 4-2. MACHINE LEVEL PLACEMENT

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CLAMP MAINTENANCE MAINTENANCE MANUAL

4.6.2.1.1. Refer to the installation drawing and install the vibration mounts in the recommended locations.

4.6.2.1.2. If the machine is furnished with vibration mounting pads, level the machine by adjusting of the
height of the pads. Note that shims can be used to help adjust the space between the pads
and the base. After the machine is level, insure that the mounts are locked in place.

4.6.2.1.3. On machines that are not furnished with vibration mounting pads, the method of leveling is up to
the customer's discretion. Regardless of the method used, the machine level should remain in
tolerance for the useful life of the machine.

4.6.2.1.4. Transverse measurements should be made with the aid of a calibrated precision bridge, when
ever possible. For setup where a bridge is not available, a fluorescent light tube is an accept
able alternate or, on machines so equipped, machined leveling pads at the injection and clamp
ends may be used.

4.6.2.1.5. Without a mold installed, use the manual die height adjustment to set the mold height approxi
mately two inches greater than minimum setting. Use the manual mold close to extend the
linkage so that the clamp is fully closed.

4.6.2.1.6. Level the machine to within tolerance. Note that for best results, recheck the level after installing
a mold.

NOTES

THE LEVEL CONDITION IN THE CLAMP AREA SHOULD NEVER BE COMPROMISED IN ORDER TO ACHIEVE
LEVEL CONDITION AT THE INJECTION UNIT END.

CHECK THE SURFACE OF THE MACHINE FOR DIRT OR IMPERFECTIONS IN THE SURFACE BEFORE PLACING
THE LEVEL ON THE MACHINE.

4.6.2.2. Locations for Measurement (Reference Figure 4-2.)

4.6.2.2.1. Clamp assembly:

4.6.2.2.1.1. Longitudinally on top of wear strips between movable platen and linkage housing, as
close as possible to the movable platen.
4.6.2.2.1.2. Transversely on top of wear strips as close as possible to the stationary platen.
4.6.2.2.1.3. On top of wear strips behind the linkage housing, longitudinally and transversely.
4.6.2.2.1.4. Transverse leveling may be done on top of the tie bars adjacent to the stationary platen
and linkage housing, or on the machined leveling pads, if present.

4.6.2.2.2. On top of injection unit ways, longitudinally and transversely.

4.7 PLATEN SUPPORT ADJUSTMENT PROCEDURE

The base must be level (Paragraph 4.5) within tolerances, prior to adjusting the Supports.

4.7.1. Without a mold on the movable platen, fully extend the linkage to place the movable platen at minimum
die height.

4.7.2. Turn the support adjustering nuts until they are finger tight.

4.7.3. Use a wrench to turn an additional 1/8 turn. Do not over tighten.

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MAINTENANCE MANUAL CLAMP MAINTENANCE

Platen Support
TURN BOTH SUPPORT ADJUST-
ERS EVENLY TO INCREASE OR Location
DECREASE THE SUPPORT

Figure 4-3. MOVABLE PLATEN SUPPORT ASSEMBLY

4.7.4. Repeat Steps 4.7.2 and 4.7.3 on the opposite side of the machine.

4.8 CLAMP SINGLE POINT ADJUSTMENT PROCEDURE

4.8.1. DESCRIPTION

Each tie rod is equipped with an adjusting nut which rides on the link plate. All HT machine models utilize a ring
gear to mesh with and turn all four of the adjusting nuts simultaneously. It is important that equal stretch be
placed on the four tie rods when the clamp is fully locked. If this is not accomplished, mold flashing may result.
If mold flashing or non parallel movement of the link plate is observed, it may be an indication that the single
point is out of adjustment. The 300 through 650 Ton HT machines require a strain gauge kit to perform the single
point adjustment. Contact your Van Dorn Demag representative for adjusting the larger machine sizes. Use the
following procedure to check and adjust the single point settings on the 85 through 230 Ton machines.

Machine Minumum Rectangular Test Block

Size Horizontal Vertical Thickness
Tons in mm in mm in mm
85 10.7 271 9.1 230 6.0 152
120 11.3 288 11.3 288 8.0 203
170 13.3 339 13.3 339 8.0 203
230 14.7 373 14.7 373 9.0 229
300 16.7 423 16.7 423 10.0 254
400 18.7 474 18.7 474 10.0 254
500 21.7 550 21.7 550 12.0 305
650 24.0 610 24.0 610 14.0 356

Table 4-1. TEST BLOCK DIMENSIONS

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CLAMP MAINTENANCE MAINTENANCE MANUAL

To avoid the possibility of the

Ring Gear falling off the
machine, when performing the
Single Point Adjustment
Procedure: Figure 4-4. CLAMP SINGLE POINT
Do NOT remove the Die Height ADJUSTMENT - MOLD HEIGHT
Motor or Mounting Plate. This MECHANISM
could occur if the four adjusting
nur retainers are also removed.

Retainer Screw 12345 TIE BAR STRETCH READINGS

12345
12345678901 12345
12345
Link Plate
12345678901 12345
12345
12345678901 12345
12345 Adjusting
1 2
12345678901 12345
12345
12345678901 12345
12345
12345
Nut
12345
12345
Tie Rod 1234
1234
1234
1234
1234
1234 Spacer
1234
1234
1234
1234
1234
1234
1234
1234
1234
1234
1234 4 3
1234
1234
1234
1234
1234
1234
1234
1234
Ring Gear 1234
1234
1234
12345
Cover Wear Plate 12345
12345678901 12345
12345
12345678901 12345
12345
12345678901 12345
12345
12345678901 12345
12345
12345678901 12345
12345
12345 Readings should be within 0.001 to 0.003 of
12345
12345
12345 each other.

Bolt or Clamp Support Angles

to Machine Base Figure 4-6. CLAMP SINGLE POINT ADJUSTMENT
READINGS
Figure 4-5. CLAMP END SUPPORT ANGLE PLACEMENT

MHT-1047 Page 4-8 MHTM(AB)-1/01

MAINTENANCE MANUAL CLAMP MAINTENANCE

_
_
1234512345
1234512345 _
_1234
1234
12345
1234512345
12345
1234512345 _
_
1234
1234
1234
___ _
_
1) Place Control in

_
_
Manual/Run
2) Slowly jog mold

_
_
open until gears no

_
longer mesh

_
3) Rotate Adjusting

_
Remove Retainer Nut (1 tooth = 0.001

_
Screws and Spacers to 0.003 inches

_
(4 Locations) difference in rod

_
_
stretch)

_
4) Realign Gear Teeth

Figure 4-7. CLAMP SINGLE POINT _

_
before reengaging

ADJUSTMENT 123412345
123412345 _
_1234
1234
123412345
123412345
123412345 _
_
1234
1234
_1234

Lock-up Tie Rod Variation

Machine Pressure Stretch in Stretch
Size psi 1 inches 2 between 1. Lock-up pressure can be varied +50 psi to achieve
Tie Rods 3 proper tie rod stretch.
55 1340 0.012-0.014 0.002 2. Tie rod stretch is based on the following mold
block thickness:
85 2075 0.014-0.018 0.002
• 8.125 inches on 55, 85, 120, and 170 Ton
120 1700 0.017-0.021 0.002 • 10.250 inches on 230 and 300 Ton
170 1550 0.020-0.024 0.002 • 12.375 inches on 400 Ton
230 2200 0.024-0.028 0.002 3. Stretch on all four tie rods must be within this
300 1550 0.030-0.034 0.002 tolerance range.
400 2200 0.031-0.035 0.003 NOTE: Strain gauges are required to check the tie
500 1750 0.037-0.041 0.003 rod stretch on 300 through 650 Ton machines.
650 1600 0.041-0.045 0.003

Table 4-2. CLAMP STRETCH SPECIFICATIONS FOR SINGLE POINTING

MHT-1047 Page 4-9 MHTM(AB)-1/01

CLAMP MAINTENANCE MAINTENANCE MANUAL

NOTE

TO INSURE ACCURATE MEASUREMENTS ON ALL HT MODEL MACHINES, IT IS RECOMMENDED THAT

STRAIN GAUGES OR AN ULTRASONIC MEASURING DEVICE BE USED TO PERFORM THE SINGLE POINT
ADJUSTMENT PROCEDURE. IF NEITHER OF THESE DEVICES ARE AVAILABLE DIAL INDICATORS MAY BE
USED ON 85 TO 230 TON MODELS ONLY, AS DESCRIBED BELOW.

4.8.2. CHECKING AND ADJUSTING

4.8.2.1. Install a test block or mold that is parallel and has the minimum dimensions listed in Table 4-1. Adjust for
full lockup.

4.8.2.2. Level the machine as described in Paragraph 4.5, located in this section of the manual.

4.8.2.3. Check for adequate lubrication at all points on the clamp assembly.

4.8.2.4. Check stationary platen tie rod nuts for tightness by using the following procedure: lock clamp under full
tonnage; with a hammer and a small brass rod, try to rotate the split ring in the face of the stationary
platen.

4.8.2.5. If the split ring can be moved by tapping, open the clamp to remove the load on the tie bars and tighten
the nut until the split ring cannot be moved. Loosen the set screws that secure the stationary platen tie
rod nuts to the tie rod. Using a wrench, secure the nuts by driving in a clockwise direction with at least a
five pound sledge. Secure the set screws.

CAUTION

FAILURE TO PRELOAD THE TIE BARS THE PROPER AMOUNT, BY TIGHTENEING THE STATIONARY
PLATEN TIE ROD NUT, COULD RESULT IN TIE ROD FAILURE. REFER TO THE LINKAGE ASSEMBLY
DRAWING FOR THE PROPER PROCEDURE.

4.8.2.6. Check the alignment of the clamp assembly on the base. With the link plate properly aligned with the
base rails, and the clamp at full stroke, tighten the screws that hold the stationary platen to the base.
These screws must be securely tightened to prevent any movement of the platen during machine opera
tion.

4.8.2.7. Check and adjust the platen supports, if required. Refer to the Platen Support Adjustment Procedure.

4.8.2.8. Remove the link plate guards, covering the clamp cylinder/mold height drive assembly, Figure 4-4.

4.8.2.9. Referring to Figure 4-5, install two suitable lengths of angle iron, and securely bolt or clamp to the ma
chine base to prevent any rocking action or vibration. The angles should be long enough to reach from the
duct to the top tie rods and rigid enough to support the test indicators against the tie rods.

NOTE

DO NOT USE THE LINKAGE GUARD FRAME AT THE REAR OF THE MACHINE IN PLACE OF THE INDE-
PENDENT ANGLE IRONS AS STATED ABOVE. USING THE LINKAGE GUARD FRAME FOR DIAL INDICA-
TOR MOUNTS WILL ADVERSELY AFFECT THE ACTUAL READINGS.

4.8.2.10. Install four dial indicators on the angle iron in such a position that the tip of the plunger is on the flat
surface of the tie rod as close to the center as possible. The plunger must be perpendicular to the end of
the tie rod as shown in Figures 4-5 and 4-6. With the clamp open set all the indicators to zero.

4.8.2.11. From the Operator Station insure that the following parameters are set:
4.8.2.11.1. The Mold Safe (Lock-Up) Pressure set to maximum.
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MAINTENANCE MANUAL CLAMP MAINTENANCE
4.8.2.11.2. The control mode set to Run.
4.8.2.11.3. The clamp positions set for proper low pressure to mold safe transition.
4.8.2.11.4. Adjust the mold height to obtain maximum lockup force.

4.8.2.12. Close the clamp in the Run mode to achieve maximum clamp lockup force. Examine all four tie rods
and record the tie bar stretch readings for each of the dial indicators. (See Figure 4-6.)

4.8.2.13. Compare the actual readings to the specification values listed in Table 4-2.

DANGER

WHEN PERFORMING THE FOLLOWING STEPS, DO NOT REMOVE THE DIE HEIGHT MOTOR OR THE MOTOR
MOUNTING PLATE, AFTER THE FOUR SETS OF ADJUSTING NUT RETAINER COVER AND SCREWS HAVE
BEEN REMOVED. ONCE THESE COMPONENTS ARE REMOVED, THE POSSIBILITY EXISTS FOR THE RING
GEAR TO BECOME DETACHED FROM THE MACHINE, WHICH MAY RESULT IN PERSONAL INJURY AND/OR
DAMAGE TO THE MACHINE.

4.8.2.14. If adjustment is necessary, make sure the mold faces are touching and not locked up against the mold,
then match, mark and remove the four adjusting nut retainer cover wear plates, being careful to keep the
individual spacers with the original cover.

4.8.2.15. Disengage the ring gear and the adjusting nuts. This can be accomplished by disengaging the teeth on
the adjusting nuts and the ring gear as follows:

4.8.2.15.1. Place the machine in the Run Mode.

4.8.2.15.2. Use the Manual Mold Open switch to jog the machine until the ring gear just clears the teeth on
the adjusting nuts. Refer to Figure 4-8. (If necessary strap the movable and stationary platens
together.) The adjusting nuts can now be moved clockwise to increase stretch and counter
clockwise to decrease stretch.
NOTE

IT IS BETTER TO ADJUST THE NUT(S) WITH THE LEAST STRETCH TO A HIGHER READING. HOWEVER, IF
THREE TIE RODS READ LOW AND ONE READS HIGH, ADJUST THE HIGH READING. TURNING THE ADJUSTING
NUT ONE TOOTH WILL CHANGE THE INDICATOR READINGS APPROXIMATELY 0.001 to 0.003 INCH.

4.8.2.15.3. After adjustment, visually check and make certain the teeth on the adjusting nuts are aligned to
properly mesh with the teeth on the ring gear by jogging the mold closed (in Set-Up Mode), to
reengage the gears. (Do NOT Lock up at this time.)
4.8.2.15.4. Reset all dial indicators to zero (0).
4.8.2.15.5. Place the controls in Manual and use the Mold Close switch to lock up the mold.
Examine and record the readings. (See Figure 4-6.)
4.8.2.15.6. If readjustment is necessary, repeat Steps 4.8.2.15.1 through .5 described above.

4.8.2.16. When the proper adjustment has been obtained, reinstall and secure the adjusting nut retainer covers.

4.8.2.17. Again check the single point stretch readings to insure that the readings have remained within toler
ance. If the readings have shifted out of tolerance repeat the above procedure.

4.9 TOGGLE LINKAGE BREAKPOINT ADJUSTMENT

The Breakpoint Adjustment should be checked if any linkage components have been replaced or if the clamp
cylinder has been replaced or reworked. Perform the following procedure to check the adjustment. Note that this proce-
dure requires the use of metric sized wrenches.

4.9.1. Fully extend the linkage.

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CLAMP MAINTENANCE MAINTENANCE MANUAL
4.9.2. Place a straight edge across the top of the outer pins located on the upper linkage assembly (either
side of the machine).

4.9.3. Measure the distance between the bottom of the straight edge and the top of the center link pin. Make
a note of this reading.

4.9.4. Hold the straight edge on the bottom of the outer pins located on the lower linkage assembly.

4.9.5. Measure the distance between the bottom of the center pin and the top of the straight edge. Make a
note of this reading.

4.9.6. Average the reading taken in Step 4.9.3 with the reading taken in Step 4.9.5. Compare this value to the
tolerance level listed on the Linkage Assembly Drawing.

4.9.7. If the value is within specification, the procedure is complete. If the value is not within specification,
continue with the following adjustments.

4.9.8. Install a new spacer in the gap between the crosshead and the clamp cylinder rod. Note that a spacer
change of approximately 0.010 will result in approximately 0.001 breakpoint distance change.

4.9.9. Repeat the above procedure to check the breakpoint distance, and if necessary alter the size of the
spacer until the distance falls within the tolerance limits listed on the Linkage Assembly Drawing.

MHT-1047 Page 4-12 MHTM(AB)-1/01

 SECTION 5

INJECTION UNIT MAINTENANCE

5.1 GENERAL

The plasticating unit of your machine has been designed for ease of maintenance and troubleshooting. Described in this
section of the manual are specific procedures for screw removal, injection cylinder removal, screw motor removal, drive housing
repairs and other maintenance procedures.

5.2 SCREW REMOVAL AND REPLACEMENT PROCEDURE - IN LINE INJECTION UNITS

All screw injection machines require periodic screw removal, either for cleaning, repair, or for changing to a special purpose
screw. Your machine is equipped with a pivoting housing which aids in screw removal. Refer to Figure 5-1.

The screw is one of the most important (yet potentially dangerous) machine components and therefore, care and extreme
caution should be taken whenever working in this area. Perform the following procedure when it is necessary to remove the
screw from the barrel.

5.2.1. If possible, fill the barrel and screw with either polystyrene or polyethylene, then completely purge the system.
(Refer to Section 2 for the safe purging procedure).

5.2.2. Use the positioning cylinder to move the injection unit to its fully retracted position, away from the stationary
platen.

5.2.3. The screw is coupled to the screw drive shaft by straight sided splines or a key and secured by a split ring
and cap screws. Refer to Figure 5-2A or 5-3A.

The screw split ring and cap screw connection can be reached through the opening at the extreme forward point
of the drive housing assembly (after removing the guard covers) on the injection housing.

5.2.4. Press the Manual Inject Retract pushbutton to obtain wrench clearance.

DANGER

WHILE THE MACHINE IS OPERATING, DO NOT REACH INTO HOUSING FOR ANY REASON. TURN POWER OFF,
LOCK OUT DISCONNECTS, AND TAG BEFORE PERFORMING ANY MAINTENANCE.

5.2.5. Remove the cap screws and split ring.

5.2.6. Restart the pump motor. Move the screw to its fully forward position by pressing the Manual Inject Forward
pushbutton.

5.2.7. Using the Manual Inject Retract pushbutton, separate the screw drive shaft from the screw. Normally it is
not necessary to support the screw at this time.

The screw shaft spline should now be visible and separated from the drive shaft.

5.2.8. Turn all machine power disconnects off, lock out, and tag.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE, PERHAPS FATAL,
ELECTRICAL SHOCK. BEFORE PROCEEDING, INSURE THAT ALL POWER HAS BEEN DISCONNECTED FROM
THE MACHINE, LOCKED OUT, AND TAGGED.

MHT-1047 Page 5-1 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

Material
Hopper Barrel Lock Screw Injection
and Hex Jam Nut Cylinder

Injection Screw Drive

Linear Motor
Barrel Positioning Housing
Retainer Transducer
Nozzle Split Ring
Nozzle Adapter

Barrel

Screw

Injection Unit Hold Injection Unit Air Floatation

Down Screws Injection Unit Sled Fitting (On 30F and larger units
Assembly only. Remove plug, insert a
connector for 1/4" air line rated
for approximately 100psi.)

Screw
Speed
Sensor Hopper Swing Heater Barrel Zone
Away Mechanism Band Thermocouples
Cover Nozzle Heater
Band
Heater Power and
Thermocouple
Connection Box

Heater Bands Nozzle

Thermocouple
Oil Level
Sight
Glass
Water Pivot Pin
Valves Power Pivot
and
Cylinder Location
Screw

NOTE: The oil level sight glass is supplied on 20 oz. and larger units only.
Smaller units are lubricated via hydraulic motor case drain oil.

Figure 5-1. INJECTION UNIT ASSEMBLY

MHT-1047 Page 5-2 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
INJECTION PISTON CYLINDER
BARREL
BARREL CYLINDER MOTOR ADAPTER
LOCK SCREW ASSEMBLY TUBE PLATE
HEAD
SPLIT
RING

DRIVE
SHAFT

SPLIT RING
CAP SCREWS

MOTOR
ADAPTER
D-1042-2
PLATE

Roller
Bearing
Stub
Axle
Stub Axle
Shims (Bearing
Cap Screw
Preload)

O-Ring

Ball Bearing
Split
Ring Drive Shaft
Cap Splines
Screws Thrust Thrust
Bearing Bearing
Support

Front Oil
Seal

Retaining
Cap Screws
Bearing
Retainer

Figure 5-2-A. CROSSECTIONAL VIEW (3F to 48F Units)

MHT-1047 Page 5-3 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
INJECTION PISTON CYLINDER
BARREL
BARREL CYLINDER MOTOR ADAPTER
LOCK SCREW ASSEMBLY TUBE HEAD
PLATE
SPLIT
RING

DRIVE
SHAFT

SPLIT RING
CAP SCREWS

MOTOR
ADAPTER
D-1042-2
PLATE

O-Rings

Rod Seal Front Piston

Bushing
Rod Bearing Ring

Front Gland Front Bushing

Ring with Wiper Retainer

Figure 5-2-B. CROSSECTIONAL VIEW (3F to 48F Units)

MHT-1047 Page 5-4 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
BARREL INJECTION PISTON CYLINDER MOTOR ADAPTER
CYLINDER
BARREL LOCK SCREW ASSEMBLY PLATE
SPLIT TUBE HEAD
RING

DRIVE
SHAFT

SPLIT RING
CAP SCREWS

D-1042-2

O-Rings

Rod Bearing

Ball
Bearing
Rear
Bushing Rod Seal

Rear Bushing
Retainer

Figure 5-2-C. CROSSECTIONAL VIEW (3F to 48F Units)

MHT-1047 Page 5-5 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

D-1054

Track

Bearing Retainer

Shim (Bearing
Preload)

Barrel

Screw
Split Ring Oil Seal Drive Shaft

Front Ram

O-Ring Cone & Cup

Hub

Cam
Follower

Figure 5-3-A. CROSSECTIONAL VIEW (60F and Larger Units)

MHT-1047 Page 5-6 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

Front
Bushing Front
Retainer Bushing
Piston
Injection Ring
Housing

Rod Scraper & O-Ring

Scraper Retainer

Front Spring
Ram

Bearing Drive Shaft

Support

Rear
Ram

Seal
Thrust Bearing

Cylinder
Body

O-Rings
Front Cylinder
Head

Figure 5-3-B. CROSSECTIONAL VIEW (60F and Larger Units)

MHT-1047 Page 5-7 MHTM(AB)-1/01
INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

Motor Adapter
Plate
Sight
Glass
Bearing
Retainer
Rubber
Boot

Roller
Bearing
Rear
Ram

Rear Gear Tachometer (Pulse

Bushing Generator Pick Up)

O-Ring & O-Ring

Backup
Ring Seal
Hydraulic Motor

Tie Rod

O-Ring Rear Cylinder

Head

Figure 5-3-C. CROSSECTIONAL VIEW (60F and Larger Units)

MHT-1047 Page 5-8 MHTM(AB)-1/01

 MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
5.2.9. The injection unit can be pivoted approximately 20° by completing the following steps. (Refer to Figure 5-
1).

5.2.9.1. Before removing the hold down screws, located at the front of the injection housing, on the bottom of the
carriage (sled), check the injection unit pivot screw (accessible from the bottom of the carriage) to insure
that it is in place and secured. Attempting to pivot the injection unit without the pivot screw in place may
cause the unit to fall off the carriage.

5.2.9.2. Remove the injection housing/carriage hold down screws.

NOTE

ON 60F AND LARGER UNITS, REMOVE THE 1/4" N.P.T. PIPE PLUG AND INSERT A MALE AIR FITTING. CONNECT
AN AIR SUPPLY TO PERMIT FLOTATION OF THE INJECTION UNIT FOR EASE OF PIVOTING.

5.2.9.3. Manually push the screw motor away from the operator’s side of the machine until the unit pivots to
the desired clearance.

5.2.10. Wear heat resistant gloves, then remove the nozzle heater band and the nozzle adapter heater band. On
larger units it may be necessary to use an overhead crane to support the weight of the adaptor.

5.2.11. Remove the nozzle adapter and any residual material. Keep both the barrel and adapter seat areas
clean. Keep the seat area clean on both the adapter and the barrel. On larger size injection units, use a
heat resistant sling and an overhead crane to support the weight of the assembly.

NOTE

THE NOZZLE ADAPTER IS PILOTED AND MAY HAVE SOME PLASTIC BEHIND IT. IF IT IS STUCK, A FIRM RAP WITH
A PIECE OF WOOD OR A BRASS BAR SHOULD BREAK IT LOOSE FROM THE BARREL. IT MAY THEN BE NECESSARY
TO TAP THE ADAPTER BACK AND FORTH UNTIL IT CAN BE REMOVED FROM THE PILOT DIMENSION.

REFER TO THE SAFETY SECTION (SECTION 2) OF THIS MANUAL FOR SAFE ADAPTER/NOZZLE REMOVAL.

5.2.12. After the nozzle adapter has been removed, the screw can then be removed from the barrel by perform-
ing the following procedure:

5.2.12.1. Wrap a heat resistant sling, of sufficient load capacity, around the screw tip and pull the screw out
from the barrel.

5.2.12.2. Remove the non-return valve from the screw and clean all components immediately after removal. A
brass bar and brass brush can be used to clean both the screw and barrel.

5.2.12.3. All front end parts can now be checked for wear according to the tolerances listed in Table 5-1.

5.2.13. Coat the threads of the screws, the adapter bolts, and the nozzle with a high temperature anti-seize
lubricant such as Chesterton #6423 or Bostic Never Seez. Apply a coat of FEL PRO C670 Molylubricant
to male and female splines before inserting the screw into the barrel. Assemble the screw and barrel in
the reverse order.

NOTE

WHEN REPLACING NOZZLE ADAPTERS, MAKE CERTAIN THAT MATING SURFACES ARE CLEAN AND FREE OF
PLASTIC, NICKS AND SCRATCHES.

REFER TO FIGURE 5-4 OR YOUR MACHINE’S INJECTION UNIT ASSEMBLY DRAWINGS FOR THE REQUIRED
SCREW TORQUE VALUES. BOLTS SHOULD BE TIGHTENED GRADUALLY, IN AN ALTERNATING PATTERN,

MHT-1047 Page 5-9 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
SIZE BARREL SCREW CHECK RING
0.5F (18mm) 0.7085/0.7095 0.7055/0.7045 0.707/0.706
1.7F (25.4mm) 1.001/1.002 0.996/0.995 0.999/0.998
2.3F (31.75mm) 1.251/1.252 1.246/1.245 1.249/1.248
3F (30mm) 1.1810/1.1820 1.1732/1.1712 1.1803/1.1795
5F (35mm) 1.3779/1.3794 1.3700/1.3680 1.3767/1.3757
6F (38mm) 1.4960/1.4975 1.4880/1.4860 1.4950/1.4940
8F (40mm) 1.5750/1.5760 1.5669/1.5649 1.5738/1.5728
14F (50mm) 1.969/1.970 1.961/1.959 1.9675/1.9665
20F (57mm) 2.244/2.246 2.236/2.234 2.2428/2.2416
30F (65mm) 2.559/2.549 2.551/2.549 2.5580/2.5570
35F (69mm) 2.716/2.718 2.709/2.707 2.7153/2,7141
48F (75mm) 2.953/2.955 2.944/2.942 2.9510/2.9500
60F (80mm) 3.149/3.151 3.142/3.140 3.1484/3,1472
80F (90mm) 3.543/3.545 3.531/3.529 3.541/3.539
125F (105mm) 4.134/4.136 4.120/4.118 4.1274/4.1264
165F (115mm) 4.5275/4.5296 4.5157/4.5138 4.5212/4.5202
260F (135mm) 5.3150/5.3175 5.3031/5.3012 5.3072/5.3062
400F (155mm) 6.102/6.104 6.088/6.086 6.0947/6.0937
Table 5-1. STANDARD FRONT END PART DIAMETERS
THROUGH SEVERAL STAGES OF INCREASING TORQUE.

5.2.14. Pivot the unit to its original position. Check the nozzle to mold sprue bushing alignment before fully
seating the nozzle.

5.2.15. Tighten the hold down bolts on the bottom of the injection unit carriage, while maintaining the nozzle to
sprue bushing alignment.

5.3 BARREL REMOVAL AND REPLACEMENT PROCEDURE IN LINE INJECTION UNITS

5.3.1. Refer to the machine’s injection unit assembly drawings and Figures 5-1 through 5-3C.

5.3.2. Fill, then purge the screw, using either polystyrene or polyethylene. (Refer to the safe purging practices
in Section 2.)

5.3.3. Remove the screw using the Screw Removal and Replacement Procedure in this section of the manual.

5.3.4. Turn all power disconnect(s) off, lock out, and tag. Disconnect all heater wires connected at the heater
power connection box. Remove the thermocouples at the barrel connectors.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE, PERHAPS FATAL,
ELECTRICAL SHOCK. BEFORE PROCEEDING, INSURE THAT ALL POWER HAS BEEN DISCONNECTED FROM
THE MACHINE, LOCKED OUT, AND TAGGED.

5.3.5. Remove the barrel cover (shield).

5.3.6. Remove the barrel retainer split ring cap screws and split rings.

5.3.7. Refer to the top section of Figure 5-1. Back off and remove the barrel lock screw and hex jam nut
(located next to the hopper assembly), then remove the slug from the hole.

5.3.8. Install an eyebolt in the barrel lifting hole. This is generally located under the heater bands and between
the two rear barrel cover studs.

MHT-1047 Page 5-10 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
PROCEDURE FOR APPLICATION OF BOLT TORQUE ON FLANGED JOINTS
NOZZLE ADAPTER BOLTS
INJECTION UNIT TORQUE BOLT
STEP 1 ALIGN COMPONENT PARTS AND CLAMP TOGETHER MODEL SIZE FT. LBS THREAD SIZE
WITH HOLD DOWN.
0.5F (18mm) N/A N/A
STEP 2 LUBRICATE STUD (OR BOLT) THREADS IN AREA OF NUT 1.7F (25.4mm) 20 3/8 - 16 x 1.75
(OR FORGED RING) ENGAGEMENT, ALSO LUBRICATE 2.3F (31.75mm) 48 1/2 - 13 x 1.75
FACE OF NUTS (OR BOLT HEAD) USING A SUITABLE 3F (30mm) 16 3/8 -16 x 2.75
5F (35mm) 22 7/16 -14 x 3.00
LUBRICANT.
6F (38mm) 25 7/16-14 x 2.50
8F (40mm) 25 3/8 - 16 x 1.50
STEP 3 INSTALL ALL BOLTS AND NUTS FINGER TIGHT. 8.5F (40mm) HP 66 M12-1.75 x 55.00
10.7F (45mm) 66 M12-1.75 x 55.00
STEP 4 NUMBER BOLTS SO THAT TORQUING REQUIREMENTS 11.9F (45mm) HP 66 M12-1.75 x 55.00
CAN BE FOLLOWED. 14F (50mm) 65 5/8 - 11 x 2.50
14.7F (50mm) 66 M12-1.75 x 50.00
STEP 5 APPLY TORQUE IN 20% (1/5) STEPS OF REQUIRED 17.6F (50mm) HP 163 M16-2.00 x 70.00
20F (57mm) 85 5/8 - 11 x 2.50
TORQUE, LOADING ALL BOLTS AT EACH STEP BEFORE
25.4F (60mm) 163 M16-2.00 x 70.00
PROCEEDING TO NEXT STEP. 29.6F (60mm) HP 163 M16-2.00 x 90.00
30F (65mm) 100 5/8 - 11 x 2.50
STEP 6 TIGHTEN BOLTS IN SEQUENTIAL ORDER (1-2, 3-4, 5-6, 35F (69mm) 145 3/4 - 10 x 3.00
ETC.) AT EACH STEP UNTIL FINAL TORQUE IS REACHED. 40.3F (70mm) 163 M16-2.00 x 90.00
45.4F (70mm) HP 318 M20-2.50 x 100.00
STEP 7 USE ROTATIONAL TIGHTENING UNTIL ALL BOLTS ARE 48F (75mm) 145 3/4 - 10 x 3.00
STABLE AT FINAL TORQUE LEVEL. (TWO COMPLETE 59.2F (80mm) 318 M20-2.50 x 100.00
60F (80mm) 200 3/4 - 10 x 3.25
TIMES AROUND IS USUALLY REQUIRED.)
3.5F (80mm) HP 318 M20-2.50 x 90.00
80F (90mm) 300 1 - 8 x 4.00
STEP 8 ON NOZZLE ADAPTERS, REPEAT STEP 7 WHEN THE 89.6F (95mm) 318 M20-2.50 x 110.00
BARREL IS AT OPERATING TEMPERATURE. 103.7F (95mm) HP 550 M20-3.00 x 140.00
125F (105mm) 500 1 1/4 - 7 x 4.50
139.1F (110mm) 550 M20-3.00 x 140.00
1 165F (115mm) 900 1/2 - 6 x 6.00
14 5 260F (135mm) 1100 1 1/2 - 6 x 6.00
8 O O O 9 400F (155mm) 1760 1 3/4 - 8 x6.00
O O 1
12 3 12 5
O O
O O O
1

4 O O 8
O O 9 8 O 5
11
O O O O
10 O O O 7 O O
4 3 4 O O 9
6 13 O O
2 10 7 O O
O O O 10 3
14 BOLT PATTERN 6 11 O O
2 6 O 7
SEQUENTIAL ORDER 12 BOLT PATTERN 2
1-2
3-4 SEQUENTIAL ORDER 10 BOLT PATTERN
5-6 1-2
7-8 3-4 SEQUENTIAL ORDER
9-10 5-6 1-2
11-12 7-8 3-4
13-14 9-10 5-6
11-12 7-8
ROTATIONAL ORDER 9-10
1 2 ROTATIONAL ORDER
5 6 1 2 ROTATIONAL ORDER
9 10 5 6 1 2
3 4 9 10 5 6
11 12 3 4 9 10
7 8 7 8 3 4
13 14 11 12 7 8
Figure 5-4. BOLT TORQUE PROCEDURE AND NOZZLE ADAPTER BOLT TORQUE VALUE CHART
MHT-1047 Page 5-11 MHTM(AB)-1/01
INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

The barrel and screw can be removed as one complete unit, however, the balanced lifting point will
change. Due to this shift in balance, the drilled and tapped hole in the barrel cannot be used alone.
Place a sling around the feed end of the barrel, as well as one connected to the eyebolt, before com-
pletely removing it from the housing.

5.3.9. While supporting the barrel with the lifting device, insert a sling or chain hook through the eyebolt and
pull the barrel outward. Allow sufficient slack in the lifting sling (it is important not to let the barrel bind
up in the housing). If the barrel cannot be easily removed from the housing, place a hydraulic jack
between the end of the barrel and the screw drive housing. Install blocking as required. As the barrel
begins to move, rebalance the load (to prevent binding).

5.3.10. Perform the following steps to assemble the barrel.

5.3.10.1. Referring to the Screw Replacement Procedure, clean the barrel and screw. Coat the feed end of
the barrel with a high temperature lubricant such as Chesterton #6423 or Bostic Never Seez.
(Carefully stone out any high spots on the surface.)

5.3.10.2. Reinsert the barrel into the housing. The barrel will slide in by hand provided that the weight of the
barrel is properly supported and it is not allowed to bind against the housing surface.

5.3.10.3. Refer to the injection unit assembly drawings and install the barrel retaining split rings. Torque the
screws to the values shown on the drawing.

5.3.10.4. Reinstall the screw as described in the Screw Removal and Replacement Procedure.

5.3.10.5. Start the machine pump motor(s) and slowly retract the injection cylinder piston. If the screw
retainers have not been installed as yet, force the screw back into the drive shaft as the piston is
moved every inch or two. Remember to shut the pump down after each movement.

5.3.10.6. Turn the power disconnects off, lock out, and tag.

5.3.10.7. Check for clearance between the barrel ID and the screw OD (check at the sealing area behind the
flights of the screw). If there is uneven clearance at either the top or bottom, use the barrel lock-
screw to adjust for sufficient clearance (no rubbing). Remember to reinsert the slug under the screw.

5.3.10.8. Tighten the jam nut on the barrel lock screw.

5.3.10.9. Reinstall the nozzle adapter, heater bands, barrel cover, thermocouples, and other components.
Reconnect the power wires at the heater power connection box. Secure all the screws according to
the specifications listed on the assembly drawing.

5.4 ROTATING RAM INJECTION UNIT

This manual is for the use of employer authorized maintenance personnel only. The information in this manual assumes
that personnel posses the skills necessary for servicing and maintaining injection molding machines. When performing
maintenance on the injection unit refer to the assembly drawings shipped with the machine for detailed information.

Described in this section of the manual are specific procedures for screw and barrel removal, motor information, and other
service procedures. If maintenance procedures are required that are not covered in this section of the manual (for example
injection cylinder removal, drive housing repairs, bearing/O-ring replacement, etc.), contact your Van Dorn Demag Service
Representative.

MHT-1047 Page 5-12 MHTM(AB)-1/01

 MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

SIZE / INJECT. UNIT BARREL SCREW CHECK RING

8.5F (40mm / 500) 40.00 / 40.03 39.88 / 39.82 39.954 / 39.980

10.7F (45mm / 500) 45.00 / 45.03 44.87 / 44.81 44.958 / 44.983
11.9F (45mm / 720) 45.00 / 45.03 44.87 / 44.81 44.958 / 44.983
14.7F (50mm / 720) 50.00 / 50.03 49.87 / 49.81 49.936 / 49.983
17.6F (50mm / 1220) 50.00 / 50.03 49.87 / 49.81 49.936 / 49.983
25.4F (60mm / 1220) 60.00 / 60.03 59.86 / 59.79 59.944 / 59.969
29.6F (60mm / 1920) 60.00 / 60.03 59.86 / 59.79 59.944 / 59.969
40.3F (70mm / 1920) 70.00 / 70.03 69.85 / 69.78 69.952 / 69.977
45.4F (70mm / 2800) 70.00 / 70.03 69.85 / 69.78 69.952 / 69.977
59.2F (80mm / 2800) 80.00 / 80.03 79.85 / 79.78 79.934 / 79.956
63.5F (80mm / 4300) 80.00 / 80.03 79.85 / 79.78 79.934 / 79.956
89.6F (95mm / 4300) 95.00 / 95.04 94.83 / 94.74 94.920 / 94.945
103.7F (95mm / 4300) 95.00 / 95.04 94.83 / 94.74 94.920 / 94.945
139.1F (110mm / 4300) 110.00 / 110.05 109.82 / 109.73 109.906 / 109.931

Table 5-2. ROTATING RAM FRONT END PARTS DIAMETERS

5.4.1. SCREW AND BARREL REMOVAL AND REPLACEMENT PROCEDURE

All screw injection machines require periodic screw removal either for cleaning, repair, or for changing to a special
purpose screw. Refer to Figure 5-9 thru 5-12.
The screw is one of the most important (yet potentially dangerous) machine components and therefore, care and
extreme caution should be taken whenever working in this area. Perform the following procedure when it is necessary
to remove the screw from the barrel.
ATTENTION

WHILE THE MACHINE IS OPERATING, DO NOT REACH INTO HOUSING FOR ANY REASON. FIRST INSURE
THAT POWER IS OFF AND DISCONNECTS ARE LOCKED OUT AND TAGGED.

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE PERHAPS FATAL
ELECTRICAL SHOCK. BEFORE PERFORMING ANY MAINTENANCE PROCEDURES, INSURE THAT ALL POWER
HAS BEEN DISCONNECTED FROM THE MACHINE.

5.4.1.1. If possible, fill the barrel and screw with either a polystyrene or polyethylene, then completely purge the
system, leaving the screw in the forward position. (Refer to Section 4 in the Setup Manual; Injection Unit Start-
Up Procedure).

5.4.1.2. Use the manual pushbuttons to move the injection unit to its fully retracted position, away from the stationary
platen.

5.4.1.3. Switch off, lock out and tag the power connections, including those to the heater bands. Allow sufficient time
for the barrel to cool to ambient temperature. Disconnect the Heater Band and thermocouple connectors.
Turn the water supply to the feed throat opening off and disconnect the hoses.

5.4.1.4. Release the material hopper bracket, on the nonoperator side of the machine, and push the assembly as
far as possible to the right (towards the screw motor).

5.4.1.5. Turn the drive shaft until the Screw Coupling Retaining Bolt, shown in Figure 5-7, is accessible.

5.4.1.6. Loosen the bolt and turn the screw locator cap nut off the coupling.

5.4.1.7. In Manual Mode carefully move the injection cylinder away from the screw shaft.

MHT-1047 Page 5-13 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
5.4.1.8. Swing the injection unit so that the nozzle clears the stationary platen. Attach a lifting device of adequate
capacity to the lifting eye bolts located on top of the barrel.

5.4.1.9. Loosen the Barrel Nut Retaining Safety Screw.

5.4.1.10. Using a spanner wrench, unscrew the Barrel Retaining Nut from the centering device.

5.4.1.11. Carefully lift the barrel out of the Coolant Jacket and the injection housing.

5.4.1.12. Carefully set the barrel on a clean work surface.

Note that if the barrel and screw are to be replaced with a different sized unit, the Coolant Jacket and the Barrel
Retaining Nut may also require replacement.

5.4.1.13. To remove the screw after the barrel has been removed, perform the following steps.

5.4.1.13.1. Carefully pull the screw out from the drive end of the barrel.

Note that if the screw cannot be pulled from the barrel, reconnect the heater bands and soften the
residual material. Follow all cautions and warnings related to heated barrels and materials.

5.4.1.13.2. If necessary, clean the Screw, Nozzle and Barrel.

5.4.1.13.3. To install the screw, carefully slide the screw inside the barrel from the drive shaft end.

5.4.1.14. If replacing the barrel, insure that the OD of the barrel fits into the coolant jacket flange. If the barrel
does not fit in the coolant jacket, the jacket will require replacement as outlined in the following steps.

5.4.1.14.1. Support the coolant jacket using a sling and overhead crane.

5.4.1.14.2. Remove the Jacket Retaining Bolts and place the jacket to one side.

5.4.1.14.3. Lift and align the replacement Jacket to the bolt pattern in the injection housing. Tighten the
retaining bolts in an alternating pattern, referring to the assembly drawing supplied with your
machine, for the recommended torque values.

5.4.1.15. Using lifting gear of adequate capacity, lift and guide the barrel through the coolant jacket and into the
injection housing.

5.4.1.16. Screw the Barrel Retaining Nut onto the centering device. Tighten the Barrel Nut Retaining Safety
Screw.

5.4.1.17. Disconnect and remove the Feed

liftingThroat
device from the barrel.
Screw Opening
Tip

Check Rear
Ring Seat
Nozzle Coolant Jacket
Adaptor
Figure 5-9. SCREW AND BARREL ASSEMBLY, ONE PIECE COOLING JACKET
MHT-1047 Page 5-14 MHTM(AB)-1/01
MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
Lifting Eyebolts

Feed Throat
Screw Opening
Tip

Nozzle
Check Rear Coolant
Jacket Jacket Barrel
Nozzle Ring Seat
Retaining Nut
Adaptor
Bolts
Figure 5-10. SCREW AND BARREL ASSEMBLY

Linear Ball
Bearing
Screw Positioning
Potentiometer

Screw
Coupling
Nut

Proximity
Switch

Figure 5-11. INJECTION UNIT ASSEMBLY, MOTOR END

Screw
Screw Coupling Coupling
Retaining Bolt(s) Nut

Barrel
Nut

Injection
Screw
Piston
Shaft

Screw
Split Screw
Collar Coupling/
Drive Key

Figure 5-12. SCREW COUPLING ASSEMBLY

MHT-1047 Page 5-15 MHTM(AB)-1/01
INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

C C B B
E

Figure 5-13. INJECTION UNIT ASSEMBLY, EXPLODED VIEW

MHT-1047 Page 5-16 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

Figure 5-13-A. SIDE VIEW OF

CUT OUT FROM B TO B, AS
ILLUSTRATED

Figure 5-13-B. SIDE VIEW

OF CUT OUT FROM C TO
C, AS ILLUSTRATED

Figure 5-13-C SIDE VIEW

OF CUT OUT FROM D TO
D, AS ILLUSTRATED

Figure 5-13-D SIDE VIEW

OF CUT OUT FROM E TO
E, AS ILLUSTRATED

MHT-1047 Page 5-17 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
5.4.1.18. Carefully guide the screw shaft into the Coupling Flange.

5.4.1.19. Secure the plasticating screw by tightening the Locator Cap Nut onto the Screw Coupling with the
following procedure.

5.4.1.19.1. Using the supplied assembly bars turn the Locator Cap Nut onto the Screw Coupling until there
are no threads showing.
5.4.1.19.2. Set the speed to 50 percent of the units maximum speed and rotate the screw for 20 seconds.
5.4.1.19.3. This should be performed with material in the barrel for proper alignment and lubrication.
5.4.1.19.4. Repeat steps 5.4.2.10. and 5.4.2.11. until the retaining nut is securely fastened.
5.4.1.19.5. Apply "BLUE" loctite No. 242-31 to the retaining bolt(s) and tighten to the specified torque
requirement as listed in Table 5-3.
5.4.1.19.6. If the unit is equipped with two locking screws alternate between them until they both are at
the proper torque requirement.

5.4.1.20. Swivel the injection unit back into position. Connect the feed throat water hoses and the central plug for
the heater band and thermocouple leads.

5.4.1.21. Slide the hopper over the barrel and secure the assembly by tightening the hopper plate.

5.4.2. SCREW REMOVAL AND INSTALLATION

If the screw must be removed while the barrel is still installed on the injection unit, refer to the Safety Section of
this manual and follow all safety procedures associated with the injection unit and the materials being pro-
cessed.

5.4.2.1. Swing the hopper into the locking position. Refer to the Safety Section in this manual and purge all
residual material.

5.4.2.2. In the Manual/Setup Mode, fully retract the injection unit.

5.4.2.3. Loosen the Screw Coupling Retaining Bolt. Refer to Figure 5-12.

5.4.2.4. Turn the Locator Cap Nut off the screw coupling. Manually retract the screw drive.

5.4.2.5. Swivel the Injection unit so that the nozzle is out and away from the stationary platen.

5.4.2.6. Remove the nozzle and the nozzle adapter from the end of the barrel.

NOTE

THE NOZZLE ADAPTER IS PILOTED AND MAY HAVE SOME PLASTIC BEHIND IT. IF IT IS STUCK, A FIRM RAP
WITH A PIECE OF WOOD OR A BRASS BAR SHOULD BREAK IT LOOSE FROM THE BARREL. IT MAY THEN
BE NECESSARY TO TAP THE ADAPTER BACK AND FORTH UNTIL IT CAN BE REMOVED FROM THE PILOT
DIMENSION.

REFER TO THE SAFETY SECTION OF THIS MANUAL FOR SAFE ADAPTER/NOZZLE REMOVAL.

5.4.2.7. Carefully pull the screw out of the barrel. Note, if necessary use a lifting device to help remove the
screw.

5.4.2.8. Perform any necessary maintenance, and check the screw for wear. Coat the threads of the screws,
the adapter bolts, and the nozzle with a high temperature anti-seize lubricant such as ‘FEL-PRO
C5A’. Apply a coat of FEL PRO C670 Molylubricant or equivalent to male and female splines before
inserting the screw into the barrel.

5.4.2.9. To install a screw, carefully slide the screw inside the barrel. Place the Nozzle Adapter over the end
MHT-1047 Page 5-18 MHTM(AB)-1/01
 MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
of the barrel and referring to the assembly drawing supplied with your machine torque the retaining
bolts to the listed values.
NOTE

WHEN REPLACING NOZZLE ADAPTERS, MAKE CERTAIN THAT MATING SURFACES ARE CLEAN AND FREE OF
PLASTIC, NICKS AND SCRATCHES.

REFER TO YOUR MACHINE’S INJECTION UNIT ASSEMBLY DRAWINGS FOR THE REQUIRED SCREW TORQUE
VALUES. BOLTS SHOULD BE TIGHTENED GRADUALLY, IN AN ALTERNATING PATTERN, THROUGH SEVERAL
STAGES OF INCREASING TORQUE.

5.4.2.10. Using the supplied assembly bars turn the Locator Cap Nut onto the Screw Coupling until there are
no threads showing.

5.4.2.11. Set the speed to 50 percent of the units maximum speed and rotate the screw for 20 seconds.

5.4.2.10.1. This should be performed with material in the barrel for proper alignment and lubrication.
5.4.2.10.2. Repeat steps 5.4.2.10. and 5.4.2.11. until the retaining nut is securely fastened.
5.4.2.10.3. Apply "BLUE" loctite No. 242-31 to the retaining bolt(s) and tighten to the specified torque
requirement as listed in Table 5-3.
5.4.2.10.4. If the unit is equipped with two locking screws alternate between them until they bothe are at
the proper torque requirement.

5.4.2.11. Pivot the unit to its original position.

5.4.2.12. In Manual and Set up Modes move the screw drive forward to the screw shaft.

5.4.2.13. Check the nozzle to mold sprue bushing alignment before fully seating the nozzle.

5.4.2.14. Tighten the hold down bolts on the bottom of the injection unit carriage, while maintaining the nozzle
to sprue bushing alignment.

5.4.3. ROTATING RAM INJECTION UNIT - SCREW ALIGNMENT PROCEDURE

ATTENTION

WHILE THE MACHINE IS OPERATING, DO NOT REACH INTO HOUSING FOR ANY REASON. FIRST INSURE
THAT POWER IS OFF AND DISCONNECTS ARE LOCKED OUT AND TAGGED.

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE PERHAPS FATAL
ELECTRICAL SHOCK. BEFORE PERFORMING ANY MAINTENANCE PROCEDURES, INSURE THAT ALL POWER
HAS BEEN DISCONNECTED FROM THE MACHINE.

5.4.3.1. Fill the screw with either polystyrene or polyethylene. Insure the barrel is at the proper operating
temperature for the material being processed, typically 450°. Swing the hopper into the locking
position. Refer to the Safety Section in this manual and purge all residual material.

5.4.3.2. In the Manual Mode, retract the injection piston to 25% of its total stroke.

5.4.3.3. Rotate the screw at the lowest RPM, until the screw coupling bolt(s) become visible.

5.4.3.4. Loosen the screw coupling retaining bolt(s). Refer to Figure 5-12.

5.4.3.5. Turn the screw adaptor nut off the screw coupling using the supplied assembly bars. Slide the screw

MHT-1047 Page 5-19 MHTM(AB)-1/01

 INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
adaptor nut back and rest it on the injection piston as shown in Figure 5-14. Manually retract the
screw drive/injection piston to allow free and easy access to the key shown in Figure 5-15.

5.4.3.6. Remove the bolts securing the screw drive coupling key to the injection piston. Inspect the screw
drive coupling key for any burrs or nicks on the surfaces. Repair or replace if necessary.

5.4.3.7. Apply a high temperature anti-seize lubricant such as "FEL-PRO C5A" to the key and the bolts
before reinstalling it to the injection piston.

5.4.3.7.1. To ease assembly, the slot in the injection piston should be horizontal. Visually
insure that the key is centered on the injection piston prior to tightening the bolts.
5.4.3.7.2. The screw coupling must be flush with the end of the screw shaft and seated against
the split collar.

5.4.3.8. If necessary, carefully rotate the screw by hand or the injection piston/screw drive, so that the screw
coupling/drive key is PERFECTLY aligned with the screw coupling (Figure 5-16).

5.4.3.9. Use a block of wood such as a 2 X 4, to pry the screw backwards until the key engages the
coupling. Slide the screw adaptor nut onto the screw coupling.

5.4.3.10. Secure the plasticating screw by tightening the screw adaptor nut onto the screw coupling with the
following procedure.

5.4.3.10.1. Using the supplied assembly bars tighten the nut until it is fully seated and there are NO
THREADS VISIBLE ON THE SCREW COUPLING (Figure 5-17).
5.4.3.10.2. Set the screw speed to 50 percent of the units maximum speed, rotate the screw for 20
seconds.

5.4.3.10.2.1. This should be performed with material in the barrel for proper alignment and
lubrication.

5.4.3.10.3. Repeat steps 5.4.3.10.1. and 5.4.3.10.2. until the retaining nut is securely fastened.
5.4.3.10.4. Apply "BLUE" Loctite No. 242-31 to the locking screw(s) then, tighten to the specified torque
requirement as listed in Table 5-3.

5.4.3.10.4.1. If the unit is equipped with two locking screws alternate between them until they both
Screw
Adaptor Screw
Screw Nut Drive
Coupling Coupling
Key

Remove
Bolts

Must be aligned by hand

DO NOT USE THE MACHINE
HYDRAULICS TO ENGAGE THE KEY AND COUPLING
Figure 5-14. SCREW COUPLING DISASSEMBLY Figure 5-15. SCREW COUPLING KEY REMOVAL

MHT-1047 Page 5-20 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

INJECTION UNIT SIZE LOCKING SCREW THREAD TORQUE

500,720,1220,1920 M6 X 35 2.38 Ft-Lbs (10.6 N-m)

2800,4300,6800 M8 X 40 5.80 Ft-Lbs (25.8 N-m)

Table 5-3. RECOMMENDED TORQUE VALUES FOR SCREW LOCKING NUTS

are at the proper torque requirement.

5.4.3.11. Observe the screw and injection piston at start-up, a dial indicator can be used to check run-out.
The drive end of the screw is the best location to place a dial indicator. The screw run-out should
not exceed .005 inches (.13mm), or slightly higher on 4300 and 6800 series injection units.

5.4.3.12. If the run-out observed is excessive, loosen the nut slightly, re-torque the lock down screw(s),
rotate the injection unit to recheck.

NOTE:

INSURE ALL HEATER ZONES ARE AT THE PROPER TEMPERATURE'S - A REAR ZONE THAT IS TOO
COLD CAN CAUSE DEFLECTION OF THE SCREW AND FORCE IT AGAINST THE BARREL WALL.

WARNING

Screw Coupling & Screw Adaptor Nut must

Screw be flush, NO THEADS SHOWING
Coupling Adaptor
Nut
Screw Split
Collar

Screw
Shaft Assembly
Rods

Screw
Coupling
Drive Key

Figure 5-16. SCREW COUPLING / ADAPTOR RE-ASSEMBLY Figure 5-17. FINIAL ASSEMBLY

MHT-1047 Page 5-21 MHTM(AB)-1/01

 INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL
ALWAYS WEAR PROTECTIVE CLOTHING WHEN WORKING ON THE SCREW/BARREL. REFER TO THE SAFETY
SECTION OF THIS MANUAL FOR THE PROPER ATTIRE AND PROCEDURE FOR PURGING AND WORKING ON THE
INJECTION UNIT.

5.4.4. MAINTENANCE AND CLEANING PROCEDURE

Periodic cleaning of the screw and barrel is not recommended. When changing materials or colors, refer to the
Operation Section (4) of the Operation Manual for the correct procedure. Depending on the type of contamina-
tion, either a partial or total cleaning may be required.

5.4.4.1. Partial Cleaning Procedure

In most cases, inspection and cleaning of the screw tip, bore, and sealing faces are sufficient to eliminate
contamination. Refer to Paragraph 5.2.1. when performing the following procedure.

5.4.4.2. Remove the nozzle adapter and any residual material.

NOTE

THE NOZZLE ADAPTER IS PILOTED AND MAY HAVE SOME PLASTIC BEHIND IT. IF IT IS STUCK, A FIRM RAP WITH
A PIECE OF WOOD OR A BRASS BAR SHOULD BREAK IT LOOSE FROM THE BARREL. IT MAY THEN BE NECESSARY
TO TAP THE ADAPTER BACK AND FORTH UNTIL IT CAN BE REMOVED FROM THE PILOT DIMENSION.
REFER TO THE SAFETY SECTION OF THIS MANUAL FOR SAFE ADAPTER/NOZZLE REMOVAL.

5.4.4.3. After the nozzle adapter has been removed, the screw can then be removed from the barrel by
performing the following procedure:

5.4.4.3.1. Wrap a heat resistant sling, of sufficient load capacity, around the screw tip and pull the screw
out from the barrel.

5.4.4.3.2. Remove the non-return valve from the screw and clean all components immediately after
removal. A brass bar and brass brush can be used to clean both the screw and barrel.

5.4.4.3.3. All front end parts can now be checked for wear.

5.4.4.4. Coat the threads of the screws, the adapter bolts, and the nozzle with a high temperature anti-seize
lubricant such as ‘FEL-PRO C5A’. Apply a coat of FEL PRO C670 Molylubricant (DIN 51825KP1M-30) to
male and female splines before inserting the screw into the cylinder. Assemble the screw and cylinder
in the reverse order.

NOTE

WHEN REPLACING NOZZLE ADAPTERS, MAKE CERTAIN THAT MATING SURFACES ARE CLEAN AND FREE OF
PLASTIC, NICKS AND SCRATCHES. REFER TO YOUR MACHINE’S INJECTION UNIT ASSEMBLY DRAWINGS FOR
THE REQUIRED SCREW TORQUE VALUES. BOLTS SHOULD BE TIGHTENED GRADUALLY, IN AN ALTERNATING
PATTERN, THROUGH SEVERAL STAGES OF INCREASING TORQUE.

5.4.4.5. Pivot the unit to its original position. Check the nozzle to mold sprue bushing alignment before fully
seating the nozzle.

5.4.4.6. Tighten the hold down bolts on the bottom of the injection unit carriage, while maintaining the nozzle to
sprue bushing alignment.

5.5 TWIN CYLINDER (NEWBURY STYLE) INJECTION UNIT

MHT-1047 Page 5-22 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

Thermocouples

Nozzle
Heater Bands

Barrel Locating Bolt Locking Set Screw

Spanner Nut Screw Retainer Pin Pivot Bolt

Linear Positioning Transducer

Hold Down Bolts

Figure 5-18. Newbury Style Injection Assembly

MHT-1047 Page 5-23 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

1. Thrust Housing S/A 7. Cone 13. Key

2. Screw Coupling 8. Cup 14. Pressure Relief Vent
3. Retainer Plate 9. Locknut
4. Retainer Plate Gasket 10. Oil Seal
5. Cup 11. Coupling Pin
6. Cone 12. Snap Ring

14
9
3 4

7 8
11 5 6

12

13

2
10

Figure 5-19 Newbury Style Thrust Housing

MHT-1047 Page 5-24 MHTM(AB)-1/01

 MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

▲
! WARNING
High pressure
molten material.
Stand clear and wear
protective gear when
purging and/or servicing
injection system.
© NUTRON 1992 Can cause severe burns.

Figure 5-20. High Pressure Molten Material Warning

The plasticizing unit of your machine has been designed for ease of maintenance and troubleshooting. Described in this
section of the manual are specific procedures for screw removal, injection cylinder removal, screw motor removal, drive
housing repairs, and other maintenance procedures.

5.5.1. PIVOTING THE SCREW/BARREL ASSEMBLY

All screw injection machines require periodic screw removal either for cleaning, repair, or for changing to a special purpose
screw. Your machine is equipped with a pivoting table which aids in screw removal. Refer to Figure 5-18. The injection unit
assembly can be pivoted approximately 30 degrees off centerline.

CAUTION

USE CAUTION WHEN PIVOTING THE INJECTION UNIT TO AVOID STRAIN ON THE LUBRICATION
LINES, COOLING WATER SUPPLY LINES, ELECTRIC CABLES, AND HYDRAULIC HOSES.

To pivot the injection unit, perform the following steps.

5.5.1.1. Locate the pivot and hold-down bolts on the carriage subplate. Note that the two hold-down bolts are located
at the screw/barrel end of the unit, and the pivot bolt is located at the motor end of the unit.

5.5.1.2. Remove the two hold-down bolts. Do NOT remove the pivot bolt.

5.5.1.3. Carefully pivot the injection unit, avoiding strain on the lubrication lines, cooling lines, hydraulic lines, and
electric cables.

5.5.2. SCREW REMOVAL AND REPLACEMENT PROCEDURE

The screw is one of the most important (yet potentially dangerous) machine components and therefore, care and
extreme caution should be taken whenever working in this area. Perform the following procedure when it is necessary to
remove the screw from the barrel.

5.5.2.1. If possible, fill the barrel and screw with either polystyrene or polyethylene, then completely purge the
system. (Refer to Section 4 in the Operation Manual, Injection Unit Start-Up Procedure).

5.5.2.2. Use the positioning (carriage) cylinder to move the injection unit to its fully retracted position, away from the
clamp assembly.

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INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

▲
! DANGER
High voltage.
Hot surface.
Turn off and lock out main
power disconnect, allow to
cool before servicing.
Can cause shock, severe
burns or death.

© NUTRON 1992

Figure 5-21. High Voltage Warning

5.5.2.3. Press the Screw Forward pushbutton on the control panel to move the screw to the forward position.

5.5.2.4. The screw is attached to the coupling by the Screw Retainer pin. The Screw Retainer pin can be reached
through the opening in the drive housing assembly (after removing the guard covers) between the injection
feed housing and the drive housing. Remove the Screw Retainer pin.

5.5.2.5 When re-installing the Screw to Coupling, insure that the Screw Retainer Pin is installed in the correct hole.

DANGER

WHILE THE MACHINE IS OPERATING, DO NOT REACH INTO HOUSING FOR ANY REASON. FIRST INSURE THAT
POWER IS OFF AND DISCONNECTS ARE LOCKED OUT AND TAGGED.

5.5.2.5. Start the pump motor. Move the screw to its fully forward position by pressing the Screw Forward pushbutton.

5.5.2.6. Using the Screw Retract pushbutton, separate the screw drive shaft from the screw. Normally it is not
necessary to support the screw at this time.

The screw shaft should now be visible and separated from the drive unit.

5.5.2.7. Turn all machine power disconnects off, lock out, and tag.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE, PERHAPS FATAL,
ELECTRICAL SHOCK. BEFORE PROCEEDING, INSURE THAT ALL POWER HAS BEEN DISCONNECTED FROM THE
MACHINE, LOCKED OUT, AND TAGGED.

5.5.2.8. The injection unit can be pivoted approximately 30° by completing the steps detailed in Paragraph 5.2.

5.5.2.9. Wear heat resistant gloves. Remove the nozzle thermocouple and heater band first, then remove the
first barrel heater band. Remove the nozzle adapter retaining screws and remove the nozzle and
adapter from the front of the barrel.

5.5.2.10. Remove any residual material.

MHT-1047 Page 5-26 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

NOTE

THE NOZZLE ADAPTER IS PILOTED AND MAY HAVE SOME PLASTIC BEHIND IT. IF IT IS STUCK, A FIRM
RAP WITH A PIECE OF WOOD OR BRASS BAR SHOULD BREAK IT LOOSE FROM THE BARREL. IT MAY
THEN BE NECESSARY TO TAP THE ADAPTER BACK AND FORTH UNTIL IT CAN BE REMOVED FROM THE
PILOT.

REFER TO THE SAFETY SECTION (SECTION 2) OF THIS MANUAL FOR SAFE ADAPTER/NOZZLE REMOVAL.

5.5.2.11. After the nozzle adapter has been removed, the screw can then be removed from the barrel by perform
ing the following procedure:

5.5.2.11.1. Wrap a heat resistant sling of sufficient load capacity around the screw tip, and pull the screw
out from the barrel.

5.5.2.11.2. Remove the non-return valve from the screw, remembering that the non-return valve is a left-
handed thread, and clean all components immediately after removal. A brass bar and brass
brush can be used to clean both the screw and the barrel.

5.5.2.11.3. All front end parts can now be checked for wear.

5.5.2.12. Coat the threads of the screws, the adapter bolts, and the nozzle with a high-temperature anti-seize
lubricant such as ‘FEL-PRO C5A'. Assemble the screw and barrel in reverse order. Apply a coat of FEL
PRO C670 Molylubricant to the end of the screw and screw coupling after inserting the screw into the
barrel.

NOTE

WHEN REPLACING NOZZLE ADAPTERS, MAKE CERTAIN THAT MATING SURFACES ARE CLEAN AND
FREE OF PLASTIC, NICKS, AND SCRATCHES.

REFER TO YOUR MACHINE’S INJECTION UNIT ASSEMBLY DRAWINGS FOR THE REQUIRED SCREW
TORQUE VALUES. BOLTS SHOULD BE TIGHTENED GRADUALLY, IN AN ALTERNATING PATTERN,
THROUGH SEVERAL STAGES OF INCREASING TORQUE.

▲
! WARNING
Rotating screw.
Do not operate with
hopper removed or put
hands or feet into
opening.
Serious bodily injury can
© NUTRON 1992 occur.

Figure 5-22. Rotating Screw Warning

MHT-1047 Page 5-27 MHTM(AB)-1/01

MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE
5.5.2.13. Pivot the unit to its original position. Check the nozzle to mold sprue bushing alignment before fully
seating the nozzle. Make sure there are no nicks or scratches on the mating surfaces.

5.5.2.14. Tighten the hold down bolts on the injection unit subplate while maintaining the nozzle to sprue bushing
alignment.

5.5.3. BARREL REMOVAL AND REPLACEMENT PROCEDURE

5.5.3.1. Refer to the machine’s injection unit assembly drawings.

5.5.3.2. Fill, then purge the screw, using either polystyrene, polyethylene, or a manufacturer approved material.
(Refer to Injection Unit Start-Up in Section 4 of the Operation Manual.)

5.5.3.3. You can either remove the screw now or remove it with the barrel in Step 5.4.8. To remove the screw
now, use the Screw Removal and Replacement Procedure, Section 5-3.

5.5.3.4. Turn all power disconnect(s) off, lock out, and tag. Disconnect all heater wires connected at the heater
power connection box. Remove the barrel heater shield, then the thermocouples at the barrel connec
tors.

DANGER

THIS MACHINE OPERATES ON VOLTAGES THAT ARE CAPABLE OF PRODUCING SEVERE, PERHAPS
FATAL, ELECTRICAL SHOCK. BEFORE PROCEEDING, INSURE THAT ALL POWER HAS BEEN DISCON-
NECTED FROM THE MACHINE.

5.5.3.5. Remove the barrel cover (shield).

5.5.3.6. Remove the barrel locating bolt on the side of the feed housing and loosen the locking set screw on the
spanner nut. Then remove the spanner nut.

5.5.3.7. Using an over head lifting device, place a sling over the barrel to support the weight of the barrel and
screw.

5.5.3.8. The barrel and screw can be removed as one complete unit, however, the balanced lifting point will
change. Due to this shift in balance, the drilled and tapped hole in the barrel cannot be used. Place a
sling around the feed end of the barrel as well as on the nozzle end of the barrel, before completely
removing it from the housing.

5.5.3.9. With the barrel being supported by a sling and lifting device, pull the barrel outward. Allow for
adjustment in the lifting sling (it is important not to let the barrel bind up in the housing). If the barrel
cannot be easily removed from the housing, place a hydraulic jack between the end of the barrel and the
screw drive housing. Install blocking as required. As the barrel begins to move, balance the load (to
prevent binding).

5.5.3.10. Perform the following steps to assemble the barrel.

5.5.3.10.1. Referring to the Screw Replacement procedure, clean the barrel and screw. Coat the feed end
of the barrel with a high-temperature lubricant such as FEL-PRO C-5A or equivalent. (Carefully
stone out any high spots on the surface.)

5.5.3.10.2. Reinsert the barrel into the housing. The barrel will slide in by hand provided that the weight of the
barrel is properly balanced and it is not allowed to bind against the housing surface.

MHT-1047 Page 5-28 MHTM(AB)-1/01

INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

NOTE

Make sure that the feed hole is in the upright position (12:00 o'clock). Refer to the front end parts
assembly drawing supplied with the machine.

5.5.3.10.3. Refer to the injection unit assembly drawings when reinstalling the barrel. Make sure that the
barrel locator on the barrel lines up with the locator hole before reinstalling the locator screw.
Install the spanner nut and torque the spanner nut and set screw to the values shown on the
drawing.

5.5.3.10.4. Reinstall the screw as described in the Screw Removal and Replacement procedure.

5.5.3.10.5. Start the machine pump motor(s) and slowly retract the injection cylinder pistons and thrust
housing. If the screw retainer pin has not been installed as yet, insert the screw back into the
screw shaft coupling and insert the retainer pin. Remember to shut the pump down after each
movement.

5.5.3.10.6. Turn the power disconnect(s) off, lock out, and tag.

5.5.3.10.7. Install and torque to spec: the nozzle adapter, heater bands, barrel cover, thermocouples, and
other components. Connect the power wires at the heater power connection box. Secure all the
screws according to the specifications listed on the assembly drawing.

5.6 HEATER BAND AND WIRE TERMINAL ASSEMBLY

The following procedures should be performed when replacing one or more heater band assemblies. Refer to the
appropriate procedure for either Mica Insulated or Mineral Insulated assemblies.

5.6.1. MICA INSULATED

5.6.1.1. Clean the barrel surface with a cosmoline type remover to ensure a clean, grit and oil free surface.

5.6.1.2. Slide the heater band over the end of the barrel and into position. Caution, prying a heater band that was
not designed to be spread, may cause damage to the heating element.

5.6.1.3. Mount the straps as shown in the assembly drawing supplied with your machine.

5.6.1.4. Hand tighten the heater strap. On heaters with multiple straps, alternately tighten each strap until they
can no longer be tightened by hand.

5.6.1.5. Tap around the circumference of the heater band with a soft mallet to insure that the heater band
conforms to the contour of the barrel.

5.6.1.6. Tighten each strap screw to achieve the torque ranges listed below for the proper strap width and screw
type.

Strap Allen Head Pan Head

Width Screw Screw
(inches) (in-lbs) (in-lbs)
3/8 25 25
5/8 30-35 30-35
7/8 60-70 30-35

5.6.1.7. Torque the heater straps after operating through a complete heating cycle. Note, wait until the barrel is
cold to torque.
MHT-1047 Page 5-29 MHTM(AB)-1/01
MAINTENANCE MANUAL INJECTION UNIT MAINTENANCE

5.6.2. MINERAL AND THIN BAND INSULATED

5.6.2.1. Clean the barrel surface with a cosmoline type remover to ensure a clean, grit and oil free surface.

5.6.2.2. Slide the heater band over the end of the barrel and into position. If the heater band was designed to be
expanded, open it up and place on the barrel after removing the clamping bars. Note: do not open and
close the expandable heaters more than three times.

5.6.2.3. With the clamping bars installed and slightly tightened (approx. 1/4 turn), rotate the heater to insure that
it is seated.

5.6.2.4. Insure that the clamping bars are seated down on the clamping tabs. If necessary, use a soft mallet and
tap on the top of the bars to seat the bars down on the heater tabs.

5.6.2.5. Tighten the clamping bar screws to a torque of 8 ft-lbs. Where multiple clamping bars are provided,
alternately tighten each screw to reduce potential binding.

5.6.2.6. Torque the heater clamping bars to 8 ft-lbs after operating through a heating cycle. Note, wait until the
barrel is cold to torque.

5.6.1. WIRING TERMINALS (All Bands)

5.6.3.1. Check that the nuts on the heater band studs are tight. If necessary, torque the nuts to 20 in-lbs

5.6.3.2. Install the wire on the heater band stud.

5.6.3.3. Install the nut on the stud and torque to 17 in-lbs.

5.8 SCREW MOTOR INFORMATION

These machines are equipped with High Torque Low Speed HMB Series Motors. Refer to the following information for
screw motor maintenance. If your machine is equipped with a different motor, refer to the manufacturer's information
when replacing the motor.

5.8.1. FILLING THE MOTOR HOUSING

5.8.1.1. Remove the upper most port plug.

5.8.1.2. Fill the motor through the port, using clean NAS Class 7 hydraulic oil. When the motor is full, oil will
remain visible at the top of the port.

5.8.1.3. Install the port plug in the original core.

5.8.2. MOTOR START-UP

5.8.2.1. Insure that the injection system relief valve is not set higher than the maximum motor pressure rating.

5.8.2.2. Insure that the oil temperature is between 90° and 130°F. (Oil temperature must never exceed 130°F.)

5.8.2.3. Insure that the barrel temperature is at the correct temperature for the material being processed.

5.8.2.4. Jog the motor to insure that the lines are open and the motor rotates in the proper direction.

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INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

NOTE

AFTER INSTALLING THE MOTOR AND FILLING WITH OIL, A RUN-IN PERIOD IS NECESSARY TO EXHAUST ANY
AIR FROM THE SYSTEM AND TO SEAT THE MOTOR COMPONENTS.

5.8.2.5. At start-up, it is recommended that the flow rate for the screw be set to low and gradually increased by
small increments, allowing the screw to rotate at each increment for a short period of time.

5.8.2.6. At start-up, check each hydraulic system component for localized heat. If a component is warming at
an accelerated rate, it may be an indication of improper operation.

5.8.2.6. Refer to Section 9 for Temperature Auto Tuning procedure for calibrating barrel temperatures.

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 INJECTION UNIT MAINTENANCE MAINTENANCE MANUAL

MHT-1047 Page 5-32 MHTM(AB)-1/01

 SECTION 6

HYDRAULIC SYSTEM MAINTENANCE

6.1 GENERAL

The hydraulic system consists of an oil reservoir, pumps, pressure and flow regulation valves, directional valves
(both proportional and 24 volt DC types), filter, strainers, heat exchanger, hydraulic motor, relief valves (both manually
adjustable and proportional types), and the necessary manifolds, hoses and pipes to complete the various flow paths.
All powered machine motions are controlled by the hydraulic system.

The hydraulic system is equipped with many standard features that allow for oil temperature control and alarms for
oil temperature and filtration. Standard features include; low oil level alarm, dirty filter (bypass) alarm and high oil
temperature alarm.

The hydraulic system is completely contained on the machine and is powered by an electric motor(s) driving the
hydraulic oil pumps. The various clamp, injection, and ejector strokes are performed by hydraulic cylinders. Screw
rotation is performed by the hydraulic screw-drive motor. The speed, force, and direction of each actuator is regulated
by valving. Electrical control of the hydraulic system is provided through selector switches, timers, solenoid valves,
limit switches and linear positioning devices to coordinate clamp and injection movement, and a microprocessor
control system.

For a basic description of the hydraulic system, refer to Section 1 in the Operator Manual. For additional informa-
tion on a specific machine, refer to the machine's Hydraulic Diagram and the manufacturer's component information
inserted at the end of this section.

6.2 HYDRAULIC OIL

6.2.1. DESCRIPTION

Oil in hydraulic systems perform the dual functions of lubrication and transmission of power. It constitutes a
vital factor in the hydraulic system, and careful selection of it should be made with the assistance of a repu-
table supplier. Proper selection and maintenance of oil assures long life and satisfactory operation of the
system components, particularly hydraulic pumps and motors.

Some of the factors especially important in the selection of oil for use in a hydraulic system are:

6.2.1.1. The oil must contain the necessary additives to ensure high anti-wear characteristics. Not all hydrau
lic oils contain this in sufficient amounts.

6.2.1.2. The oil must have proper viscosity to maintain adequate sealing and lubricating quality at the expected
operating temperature of the hydraulic system. Viscosity is the measure of resistance to flow. The
recommended hydraulic oil has a specific viscosity range based on the needs of the system and
limitations of critical components. We recommend that certain minimum viscosity ranges of the oil at
start-up and during running be maintained.

Very high viscosities at start-up temperatures can cause cavitational damage to pumps. Continuous
operation at moderately high viscosities will tend to hold air in suspension in the oil while passing
through the reservoir which can cause early failure of pumps and motors and possible erosion of valves.
Low viscosities result in decreased system efficiency and impairment of dynamic lubrication. Assurance
should be obtained from your oil supplier that the viscosity of the oil being used will not be less than the
minimum recommended at the maximum oil temperature encountered.

6.2.1.3. The oil must provide good demulsibility, contain rust and oxidation inhibitors, and anti-foaming additives
for satisfactory system operation and maximum component life.

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL
6.2.2. SPECIFICATIONS

We recommend AW 46 Anti-Wear type Hydraulic Oil with a viscosity of 215/240 SUS @ 38°C (100°F) or
its equivalent in grade and quality. Refer to the machine specification chart and/or installation drawing for
hydraulic reservoir capacity. Refer to Table 6-1 for permissible oil grades.

The system filter should be changed initially after the first week of operation, then checked and changed when
required at subsequent intervals.

In-Line Piston
Mobil Oil Type Viscosity Pump Start-Up Operating Max.
or Equivalent SUS @ 38°C (100°F) Min. Temp. Temp. Range Temp.**

AW 32 150/165 5.6°C (42°F) 35.6°C (96°F)-44.4°C (112°F) 54°C (130°F)

AW 46* 215/240 12.2°C (54°F) 43°C (110°F)-54°C (130°F) 54°C (130°F)
AW 68 315/360 18.9°C (66°F) 51.1°C (124°F)-54°C (130°F) 54°C (130°F)

* Recommended Grade
** Do NOT operate pumps at oil temperature above 54°C (130°F).

Table 6-1. PERMISSIBLE OIL GRADES/OPERATING TEMPERATURE

6.2.3. TEMPERATURE

Water flow is regulated through the heat exchanger to maintain the temperature of the hydraulic oil between
the ideal setting of 43°C to 54°C (110°F to 130°F). This temperature can be determined by monitoring the oil
temperature on the Temperature Screen.

Fill the tank through the fill cap located on the upper tank inspection cover plate. This cap can be accessed by
removing the cover plate located on the machine base just below the purge guard. Fill the tank to the upper
level of the sight glass which is located below the operator control panel.

NOTE: WE RECOMMEND THAT THE OIL BE ANALYZED QUARTERLY. MOST FLUID SUPPLIERS CAN
ANALYZE SAMPLES TAKEN FROM THE OIL TANK AND CAN RECOMMEND ADDITIVES TO REPLACE
THOSE LOST THROUGH HEAT AND TIME. USING THIS PROCEDURE, SEVERAL YEARS OF SERVICE
CAN BE OBTAINED WITHOUT A TOTAL OIL TANK DRAIN AND REFILL.

CAUTION

DO NOT START THE PUMP(S) IF THE OIL TEMPERATURE IS BELOW THE MINIMUM START-UP TEM-
PERATURE SEE THE PREOPERATIONAL CHECK LIST IN SECTION 4 OF THE OPERATOR MANUAL
FOR START-UP PRECAUTIONS.

6.2.4. GENERAL

Oil in a Hydraulic System performs the dual functions of lubrication and power transmission. Proper servicing
of the Hydraulic System will assure satisfactory life and operation of its components.

Typically oil provided to customers falls in the NAS Class 12 or ISO 21/18 range. This class of oil must not be
used in your injection molding machine as it has the potential to cause premature wear of hydraulic compo-
nents. Refer to the following procedure for the recommended filtering procedure.

6.2.5. FILTERING

When filling your machine from a 55 gallon drum or 200 gallon tote, the methods are basically the same.
Regardless of the method, the oil must be filtered to at least an NAS Class 7/ISO 16/13 cleanliness level.

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE
Drop Bar Alarm
Limit Front Gate Light
Front Guard Limit Switch Injection
Switch Operator
Limit Switch (5LS) Carriage
(106LS) Control
(61LS) Position Limit
Panel
Switch (22LS)
VAN
VAN DORN
DORN
Front Fixed Front Operator
Guard Gate

Machine I.D.
Data/Name
Plate
Purge Guard Electric Motor/
Dump Valve Oil Level Power/Control
Limit Switch Pump Assembly
Limit Switch Gauge Module Cabinet
(120LS) (99LS)
Remove cover to access Oil
Float Switch and Oil Tempera-
ture Thermocouple

Solenoid TQ

Mold Height
Adjustment
- Hydraulic
Interlock
Injection Mani- Pump Manifold -
fold - Solenoids Injection Manifold Solenoids GG1, Solenoid WV Clamp/Eject Manifold
G, GC, C1, - Solenoids G, (Water Valve) - Solenoids A, B, CN,
GG2, VP, Y, Z
GG3, H, L, LC, GC, GG1, H, L, (650 Ton & 500 CE, NE, RT, R, S, T,
XH (650 Ton & LC, VP, Y, Z, XH Ton High Speed DHL
500 Ton High (85 to 500 Ton
machines only)
Speed ma- machines only)
chines only)

Figure 6-1. FRONT AND REAR VIEW OF MACHINE

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL
When filtering the oil use a portable non-bypass filter with a three micron filter element. The recommended
GPM's of the system should equal 10, +2 GPM. When using a 5 to 10 micron filter element, circulate the oil in
the container so that the oil passes through the filter a minimum of six times. At 10 GPM, approximately 33
minutes is required to circulate the oil in a 55 gallon drum and approximately 2 hours is required to circulate
the oil in a 200 gallon Tote.

6.2.6. CLEANLINESS

Visually inspect the hydraulic reservoir prior to filling to assure the tank is clean and free of contaminants, e.g.,
moisture, paint or metal chips, lint, rust, scale, etc.

Oil must be filtered to NAS class 7 (ISO 16/13) cleanliness level (particle counts in 100ml samples), prior to
being pumped into the machine.

Size Range Particle

Microns Count
5-15 32,000
15-25 5,700
25-50 1,012
50-100 180
over 100 32

Always use clean transferring equipment and filter the oil (5 microns) when filling the reservoir. It is appropri-
ate to assume that even new oil is not clean.

Fill the tank through the fill cap located on the upper tank inspection cover plate. This cover plate can be
accessed by removing the cover plate located on the machine base just below the purge guard. Fill the tank to
the upper level of the sight glass which is located below the operator’s control panel.

6.3 OIL TANK

6.3.1. CAPACITY

The capacity of the tank is listed on the Specifications Chart located in Section 1 of the Operator Manual.

6.3.2. OIL LEVEL INDICATORS

The machine is equipped with two methods of determining proper oil level; a sight gauge and an oil float switch.

The sight gauge, located on the operator’s side of the reservoir, indicates the level of oil. The oil level should
be maintained at the high mark of the gauge.

An oil level float switch, located in the oil tank, is accessible after the tank cover, located below the purge
guard, is removed. This float switch is factory set to allow the switch contacts to close when the hydraulic oil
level falls below 50mm (2 inches) above the top of the pump inlet strainer. If repair or replacement of this float
switch is required the switch must be readjusted to its factory setting. Permanent damage to the hydraulic oil
pump could result if the oil level falls below the safe level. If the switch is adjusted properly and the oil level
falls below the safe level an alarm light and bell will activate. Also, a fault message will appear on the Control
Panel Screen.
CAUTION

THE MACHINE SHOULD NOT BE STARTED IF THE OIL LEVEL IS BELOW THE LOW MARK ON THE OIL
RESERVOIR LEVEL GAUGE.

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE
6.3.3. TANK MAGNETS

The HT machine models use a magnet immersed in the oil reservoir to trap ferrous metallic particles. This
device, which is accessible when the tank cover (below the purge guard) is removed, should be removed and
cleaned quarterly.

6.3.4. AIR BREATHER/FILTERS

The hydraulic tanks are supplied with an air breather or filter to clean the air that enters the tank. These
machines are equipped with a spin-on canister type of air breather/filter (located at the back of the oil reser-
voir). The filter elements should be changed quarterly or after every 500 hours of operation, whichever occurs
first.

6.3.5. PUMP INLET STRAINER

All machine models are equipped with pump inlet line strainers that use 60 mesh wire screen to trap dirt or
foreign objects of 0.25mm (0.01 inch) or larger. These strainers are installed to protect the pumps from large
contaminants and must be cleaned quarterly. They are located on each pump inlet line, inside the oil reservoir.

6.4 HYDRAULIC OIL TEMPERATURE CONTROL (Refer to Figure 6-1.)

This machine is equipped with several components that allow for automatic control of the hydraulic oil temperature.
The list includes:
• A high capacity heat exchanger for heat transfer.
• A water inlet line strainer to help prevent deposit buildup within the heat exchanger.
• A water valve to control water circulation through the heat exchanger.
• A thermocouple to sense actual oil reservoir temperature.
• A high oil temperature alarm that is programmed to inhibit machine recycle.
• An oil preheat feature.

6.4.1. HEAT EXCHANGER

6.4.1.1. Description

The heat exchanger used on this machine is a high capacity unit rated for maximum heat transfer at the
highest machine oil flow rates. The heat exchanger is equipped with a water regulation valve to maintain
the oil temperature within the operating range, not to exceed 54°C (130°F). This unit must be connected to
a suitable water supply. Refer to the Installation, General Arrangement or Piping Drawing for the correct
pipe connection sizes. The heat is transferred from the hydraulic fluid, which passes through the shell of
the unit, to the water flowing through the small brass tubes inside the shell.

6.4.1.2. Preventive Maintenance

To minimize the build up of scale deposits inside the heat exchanger some form of water treatment may
be desired. Good maintenance requires an occasional removal of deposits which could cause reduced
heat transfer. If the heat exchanger will not be in service for a short period of time, the water should be
circulated through the heat exchanger on a daily basis or the heat exchanger should be drained and blown
dry with air. If the machine will remain idle while being exposed to below freezing temperatures, completely
drain the heat exchanger and blow dry with air.

6.4.1.3. Inspection

Although a heat exchanger requires very little maintenance, it should be inspected periodically to ensure
continued satisfactory performance. Perform the following steps:
6.4.1.3.1. Match mark the bonnets to the housings on both sides.
6.4.1.3.2. Remove the bonnets. Inspect all tubes carefully for possible erosion, corrosion, and foreign
materials.
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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

6.4.1.3.3. Inspect all anodes to insure that they are neither excessively corroded nor insulated with scale.
Scrape away any buildup.
6.4.1.3.4. Inspect and clean strainer to prevent foreign matter from entering the exchanger.
6.4.1.3.5. Assemble, insuring that the bonnets and housings are matched, per the marks made in Step
6.4.1.3.1.above. NOTE: It is recommended that both the gaskets be replaced.

6.4.1.4. Cleaning

The interior of the tubes may be flushed by forcing water through them. Brushes, rods, or other cleaning
tools may be required to remove more stubborn deposits. If a special water or air gun is available, rubber
plugs can be forced through the tubes. A cleaning solution can also be circulated through the exchanger to
clean both the interior and exterior of the tubes. For most conditions, a mild alkaline solution, for example
Oakite, is satisfactory. A weak solution of hydrochloric acid may be required for hard scaling. Circulate the
solution through the shell and/or tubes until clean. Insure that all chemicals have been flushed from the
exchanger before returning it to service.

Always be aware of any special hazardous materials handling that is required when using chemicals to
clean the heat exchanger.
NOTE

THESE MACHINES ARE EQUIPPED WITH A SELECTABLE OIL PREHEAT FEATURE WHICH UTILIZES
ONE OF THE FIXED PUMPS TO REDUCE MACHINE WARM-UP TIME PRIOR TO START-UP.

6.4.2. WATER CONTROL

6.4.2.1. Strainer

The water strainer, located on the inlet line of the heat exchanger, must be inspected and cleaned on a
periodic basis. These inspection intervals will depend on the water supply conditions. Begin inspection of the
strainer on a weekly basis, then increase or decrease as conditions warrant. The strainer can be cleaned
by removing it from the valve and washing with soap and a soft bristled brush.

6.4.2.2. Water Valve

A solenoid operated directional valve (24 volt DC), referred to in the wiring diagrams as the water valve (WV),
is located in the water outlet line. This valve is used to control the flow of water through the heat exchanger.
The only required maintenance is a periodic inspection of the valve for water leakage. The following is a brief
functional description of this valve.

The maximum oil temperature limit is set at the factory to 130°F. The oil temperature is operator selectable,
up to a setting which is lower than the High Oil Temperature Alarm setting. The oil temperature setting is the
Oil Set parameter, located on the Temperature Screen.

A thermocouple (Type J), submerged in the oil tank, senses the actual oil temperature. The signal from the
thermocouple is input to the controller. This signal is then used to generate the oil temperature display and
regulate the oil temperature. When the oil temperature, as sensed by the thermocouple, reaches the
operator selected temperature, a 24 volt DC signal will be sent to the water valve (WV) solenoid from the
controller. When the valve is energized, water will begin to circulate and the temperature of the oil should
begin to decrease. The amount of time required to reduce the oil temperature will depend on water tempera-
ture and rate of flow (lpm [gpm]). These two variables play a key role in proper oil temperature control. If the
oil temperature continues to rise to the High Alarm setpoint (typically 54°C [130°F]), the alarm bell will
sound, the alarm light will illuminate, and the machine cycle will be inhibited. If the alarm setpoint is reached
during a cycle, the current cycle will be completed before the machine is inhibited. Refer to the Trouble-
shooting Section of this manual for possible causes for a high alarm condition.

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

6.4.2.3. Oil Preheat Feature

The machine is equipped with an Oil Preheat Feature which allows warm-up of the hydraulic oil to the
selected setpoint. Refer to the Temperature Screen description in Section 3 of the companion Operator
Manual to select the Preheat Function on. When this feature is selected on, the pump will output oil into
the system at a specific flow rate and pressure limit. Certain machine operations will be inhibited while the
preheat feature is selected on, regardless of the actual temperature of the oil.

6.5 HYDRAULIC OIL FILTER

6.5.1. DESCRIPTION

These machines are equipped with one or two 3 micron pressure filters. A mechanical indicator, located on
the filter housing, will indicate filter condition: Clean, Needs Cleaning, or Bypass. The indicator position
should be monitored daily. If the indicator is in the Needs Cleaning position throughout the entire machine
cycle, steps should be taken to change the filter element before it reaches the Bypass phase. This filter has a
built-in bypass valve that allows the circuit to continue to operate, but in an unfiltered condition. Bypassing
prevents dirt from being pushed through the clogged filter at full pressure. An electrical sensing switch will
signal the controller when the filter is dirty. The Oil Pressure Filter By-Pass Switch (1OFS), located on the top
of the filter, senses when oil is forced through the bypass valve due to the filter elements being blocked. When
this condition occurs, the Fault Indicator Panel will display a fault condition indicating that the oil filter is
blocked.

6.5.2. OIL FILTER MAINTENANCE

When the filter requires replacement refer to the following procedure:

6.5.2.1. Turn the pump inlet line shut-off valves to the off position.
6.5.2.2. Place a container to catch oil under the filter assembly.
6.5.2.3. Remove the bolt at the bottom of the filter body and remove the body from the filter base.
6.5.2.4. Remove the old element and replace with the correct size and style element. (Refer to the Hydraulic
Drawing.)
6.5.2.5. Before assembly, coat the O-ring seal with the hydraulic oil, then assemble the filter insuring that the
seal is not pinched.
6.5.2.6. After the shut-off valves have been reopened, jog start the pump motor to avoid possible cavitational
damage to the pumps.

6.6 HYDRAULIC PUMPS

6.6.1. FIXED DISPLACEMENT

The single, double, or triple pumps used are high performance fixed displacement, balanced intravane design,
with replaceable cartridges.

6.6.2. VARIABLE VOLUME (Refer to Figure 6-2 for a schematic diagram of a variable volume pump.)

The variable volume pump is an in-line piston design with a CV type control. This control consisting of a
pressure and a flow compensator can be used to limit pump outlet pressure and also regulate pump output to
match load requirements. Through use of the CV Control we can realize substantial energy savings by
reducing horsepower to the load.

The pressure compensator operates by sensing pressure on the outlet of the pump. If outlet pressure reaches
the pressure compensator setting, the compensator spool will shift directing fluid to the control piston in the
pump. This action will destroke the pump, shifting it to minimum output. With the pump destroked, maximum
system pressure can be maintained without diverting the oil to tank over a pressure relief valve.

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL
The flow compensator is controlled by one of two means; a pressure drop across XH or system pressure
determined by LC. In the first means of control, the pressure drop across XH is communicated back to the flow
compensator spool. The load induced pressure (on the secondary side of XH) along with the compensator's
spring force (typically set at 200 to 275 psi) works against the pump outlet pressure which is in turn acting on
the opposite end of the compensator spool. The two forces acting on the spool drive it to a position that regu-
lates the fluid supplied to the pump control piston which results in matching pump output to load requirements.
By controlling the metering orifice size (valve XH) and the pressure drop across it, an exact flow rate can be
achieved. When using the second means of control, a control signal from the Pathfinder will be used to energize
solenoid LC. This will typically occur during machine sequences where a faster response is desired. When the
solenoid is energized the system pressure will shift the flow compensator to a position which results in full flow
output from the pump.

Both the fixed displacement and variable volume pumps are driven by one or more electric motors, depending
upon model and options, which are connected to the pumps through flexible couplings. The direction of
rotation is indicated by an arrow on the front of the pump.

6.6.3. START-UP PRECAUTIONS

Use the following precautions before starting a new machine or a machine with a newly replaced pump.

6.6.3.1. Insure that the oil tank is filled to the proper level.

6.6.3.2. When replacing a pump under low temperature conditions, insure that the pump has warmed to a
minimum start up temperature of 54oF, before starting the pump motor.

6.6.3.3. Follow the Machine Start-up Procedure outlined in Section 4 of the Operator Manual.

6.6.4. PUMP REPAIR AND/OR REPLACEMENT PROCEDURE

Perform the following procedure to repair or replace a fixed or variable volume pump.

25
PSI

ON STROKE
200
PSI
Bias
75 Piston
L PRESS.
COMP.
40 HP
GPM @ Yoke
1200 RPM
FLOW
COMP. 2350
H PSI
Drive
Shaft

Piston
Figure 6-2. PUMP DIAGRAM ← Destroke
On Stroke → Valve
Control Block
Piston

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE
6.6.4.1. Refer to the Shut Down Procedure outlined in Section 4 of the companion Operator Manual and shut the
machine Off.

6.6.4.2. Turn off, lock out, and tag all power disconnects.

6.6.4.3. Turn the pump inlet line shut off valve to the closed position.

6.6.4.4. Remove the inlet and outlet lines from the pump. Disconnect case drain and load sense lines.

6.6.4.5. Cap all machine and pump openings to prevent contaminates from entering the openings.

6.6.4.6. Remove the pump-to-motor coupling housing cover. (Remove the coupling only if the pump is the
variable volume or the first fixed pump attached to the motor.)

6.6.4.7. Remove the set screw from the coupling hub (pump side).

6.6.4.8. Remove the cap screws fastening the pump to the coupling housing.

6.6.4.9. Remove the pump by sliding the pump shaft out of the coupling hub.

6.6.4.10. Make necessary repairs by referring to the Manufacturer’s Manual or replace the pump.

6.6.4.11. Before installing the pump assembly, clean and install the coupling according to the manufacturer’s
instructions paying close attention to the hub spacing dimensions.

6.6.4.12. After the pump has been assembled to the motor and all the line connected, open the inlet line shut-off
valve and loosen the drain plug on the pump until oil begins to leak around the drain plug. Tighten the
drain plug.

6.6.4.13. If repairing or replacing a variable volume pump, refer to the Machine Set-Up Section of this manual
(Section 9) to adjust the pump. Refer to the Start-Up Procedures in Section 4 of the companion Opera
tor Manual to begin operating the machine.

6.7 HYDRAULIC CYLINDERS

6.7.1. GENERAL

Various cylinders are provided to control linear movement of mechanical devices throughout the system. The
following are brief operational descriptions of the cylinders.

6.7.1.1. Clamp Cylinder: This cylinder provides movement of the toggle mechanism. The open stroke is adjust-
able by changing the Mold Open position setpoint. The cylinder is equipped with a cushion adjustment valve,
located on the cylinder head and is used for deceleration during closing. The cushion is factory set and
should not require further adjustment. However, when repairing or replacing a cylinder, use the following
guidelines;

6.7.1.1.1. Adjust the Mold Height Reverse so that the clamp closes fully (linkage fully extended) without
developing tonnage.
6.7.1.1.2. Open and close the clamp while adjusting the cushion control valve (CCW) for less cushion.
Adjust the valve until a noticeable ‘slam’ is detected when the cylinder rod reaches the maxi
mum stroke.
6.7.1.1.3. Turn the valve in (CW) until smooth deceleration occurs.

When repairing or replacing a cylinder, insure that a custom fit spacer (located between the cylinder rod
and crosshead) is also installed. This spacer is required to attain the correct linkage breakpoint (refer to the
Breakpoint Adjustment in the Clamp Section of this manual and the Clamp Assembly Drawing). If the
spacer is misplaced, consult the factory for replacement spacers.
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 HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

6.7.1.2. Hydraulic Ejection Cylinders: A cylinder is provided for movement of the ejector plate. The stroke is
determined by the remote setting of the Ejector Forward Position, the zero position for retract, and
mechanical stops in the forward and retract positions.

6.7.1.3. Carriage Positioning Cylinder: This cylinder provides movement for the injection carriage assembly. The
cylinder movement is controlled by means of a solenoid operated directional valve.

6.7.1.4. Mold (Die) Height Cylinder Lock: These machines are equipped with a Jergens® Cylinder Lock, located
in the mold height motor mounting plate (refer to the Clamp Assembly Drawing). This device is used to
prevent the ring gear from turning, thus preventing incorrect or undesirable mold height dimensions.
While the pump motor is operating, the cylinder lock remains pressurized. Depressurizing only occurs
during intentional adjustments.

6.7.2. CYLINDER MAINTENANCE

These cylinders generally require minimal maintenance. However, after extended periods of time, it may
become necessary to replace such items as piston rings, wipers, packing, and seal kits. These kits are avail-
able through the Van Dorn Demag Parts Department. The lifetime of the hydraulic cylinders, as with all hydraulic
system components, can be prolonged by providing system oil that is filtered properly and is of the correct
temperature.

6.8 HYDRAULIC MOTORS

6.8.1. SCREW DRIVE

The HT machines feature an in-line or rotating ram injection units that utilizes an hydraulic radial piston screw
drive motor with the exception of the 3 ounce unit that uses a gear type motor. On 170 through 650 HT model
machines with injection units larger than 20 ounces, will have a dual torque hydraulic radial piston screw drive
motor furnished as standard. When the high speed/low torque feature is selected solenoid TQ will energize
which reduces the motor displacement which in turn reduces the torque. When low speed/high torque is se-
lected solenoid TQ remains deenergized which increases the motor displacement which in turn increases the
torque. Refer to the Injection and/or Screw Drive Assembly Drawings for motor removal. It is recommended that
the manufacturer or their representative be contacted for motor repair.

6.8.2. MOLD HEIGHT

This machine is equipped with a power operated mold height adjustment which utilizes a Char-lynn® orbital
bidirectional motor. A pinion gear, keyed to the motor shaft, meshes with the ring gear, the ring gear in turn,
meshes with the tie rod adjusting nuts.

6.9 MANIFOLDS

This machine is equipped with two or three manifolds, depending on the size of the machine; Clamp/Eject/Core
Manifold, and Injection and/or Pump Manifold. Figures 6-3 through 6-11 are representations of the manifolds together with
an example listing of the solenoids used on the manifolds. Refer to the valve manufacturer's descriptions of the valves
and your specific Hydraulic Diagram for additional information. Also refer to the Machine Setup Procedure in Section 9 of
this manual for information on valve adjustments and settings.

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202 L H

(TopView)

XH

201

LC 204
209

Z 212 Y

(Left Side View) (Front View)

Figure 6-3A. EXAMPLE OF AN INJECTION MANIFOLD (85 and 120 Ton Machines)

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 HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

206
213
G

GC

(Right Side View) (Back View)

Figure 6-3B. EXAMPLE OF AN INJECTION MANIFOLD (85 and 120 Ton Machines)Continued

Desig Type Function

201 Prop. Direct. Valve Screw/Inject/Eject Spd Control

XH Prop. Sol. Screw/Inject/Eject Volume
202 Sol. Operated Direct. Valve Inject/Inject Ret. Control
L Sol.( 24 Vdc) Inject Retract (Pullback)
H Sol. (24 Vdc) Inject Forward
203 Shuttle Valve Load Sense Pressure
204 Sol. Operated Direct. Valve Load Sense Control
LC Sol.( 24 Vdc) Load Sense On/Off
205 Relief Valve Cartridge Insert Relief, Main Stage
206 Prop. Pilot Relief Valve Prop. Pressure Control
207 Relief Valve Control Cover Main System Relief
G Prop. Sol. Main Pressure Control
208 Cartridge Insert Clamp/Eject Separate
209 Cart. Valve Control Cover Clamp/Eject Separate
211 Check Valve Module Nozzle Seal Protect
212 Sol. Operated Direct. Valve Nozzle Seal Control
Y Sol. (24 Vdc) Inject. Carriage Forward
Z Sol. (24 Vdc) Inject. Carriage Retract
213 Sol. Operated Direct. Valve Relief Select
GC Prop. Sol. Relief Select

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 MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

206

(TopView)

B 101 A

RT 102 R

CE

103

CN

(Left Side View)

(Front View)

Figure 6-4A. EXAMPLE OF A CLAMP/EJECT MANIFOLD (85, 120 , 170, and 230 Ton Machines)

MHT-1047 Page 6-13 MHTM(AB)-1/01

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107
DHL

(Right Side View) (Back View)

Figure 6-4B. EXAMPLE OF A CLAMP/EJECT MANIFOLD (85, 120 , 170, and 230 Ton Machines) Continued

Desig. Type Function

101 Sol. Operated Direct. Valve Mold Ht. Adjust Control
A/B Sol. (24 Vdc) Mold Ht. Forward/Mold Ht. Reverse
102 Sol. Operated Direct Valve Eject. Forward/Retract Control
R/RT Sol. (24 Vdc) Eject Forward/Eject Retract
103 Prop. Direct. Valve Clamp Speed & Direct Valve
CN Prop. Sol. Clamp Close Open Control
CE Sol. Operated Direct. Valve Clamp Open Enable (supplied w/Motion Option)
104 Sol. Operated Direct. Valve Core Pull/Set Control (Option)
S/T Sol. (24 Vdc) Core Set/Core Pull (Option)
105 Pressure reducing valve Core Pressure Control
106 Check Valve Core Volume Protection
107 Sol. Operated Direct. Valve Die Height Lock
108 Pilot Oper. Check Module Die Height Lock
DHL Sol. (24 Vdc) Die Height Lock

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L H

202

203

201 XH

LC 204

210
206 217
C1
G

212
215
GG1

Y Z
221

(Left Side View)

(Front View)

Figure 6-5A. EXAMPLE OF AN INJECTION MANIFOLD (170, 230, and 300 Ton Machines)

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

GC
219

(Right Side View) (Back View)

Figure 6-5B. EXAMPLE OF AN INJECTION MANIFOLD (170, 230, and 300 Ton Machines)

MHT-1047 Page 6-16 MHTM(AB)-1/01

MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

Desig Type Function

201 Prop. Direct. Valve Screw/Inject/Eject Spd Control
XH Prop. Sol. Screw/Inject/Eject Volume
202 Sol. Operated Direct. Valve Inject/Inject Ret. Control
L Sol.( 24 Vdc) Inject Retract (Pullback)
H Sol. (24 Vdc) Inject Forward
203 Shuttle Valve Load Sense Pressure
204 Sol. Operated Direct. Valve Load Sense Control
LC Sol.( 24 Vdc) Load Sense On/Off
205 Relief Valve Cartridge Insert Relief, Main Stage
206 Prop. Pilot Relief Valve Prop. Pressure Control
207 Relief Valve Control Cover Main System Relief
G Prop. Sol. Main Pressure Control
208 Cartridge Insert Clamp/Eject Separate
209 Cart. Valve Control Cover Clamp/Eject Separate
210 Sol. Oper. Direct. Valve Clamp/Eject Separate
C1 Sol. (24 Vdc) Clamp/Eject Divide
211 Cartridge Valve Fixed Pump Relief
212 Sol. Operated Direct. Valve Fixed Pump Unload
213 Cartridge Valve Insert Fixed Pump Check
214 Relief Valve Cartridge Insert Fixed Pump Relief
215 Cartridge Valve Cover Fixed Pump Check
GG1 Sol. (24Vdc) Pump Adder
216 Relief Valve Cartridge Var. Pump Pressure Control
217 Var. Pump Relief Cover Var. Pump Pressure Control
219 Sol. Operated Direct. Valve Pressure Comp. Off/On
VP Sol. (24 Vdc) Pressure Comp. Off/On
220 Check Valve Module Nozzle Seal Protect
221 Sol. Oper. Direct. Valve Nozzle Seal Control
Y Sol. (24 Vdc) Inject. Carriage Forward
Z Sol. (24 Vdc) Inject. Carriage Retract

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B 101 A

(TopView)

B 101 A

RT 102 R

107

CE
103

CN

(Left Side View)

(Front View)

Figure 6-6A. EXAMPLE OF A CLAMP/EJECT MANIFOLD (300 and 400Ton Machines)

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

DHL 107

(Right Side View) (Back View)

Figure 6-6B. EXAMPLE OF A CLAMP/EJECT MANIFOLD (300 and 400Ton Machines)

Desig. Type Function

101 Sol. Operated Direct. Valve Mold Ht. Adjust Control
A/B Sol. (24 Vdc) Mold Ht. Forward/Mold Ht. Reverse
102 Sol. Operated Direct Valve Eject. Forward/Retract Control
R/RT Sol. (24 Vdc) Eject Forward/Eject Retract
103 Prop. Direct. Valve Clamp Speed & Direct Valve
CN Prop. Sol. Clamp Close Open Control
CE Sol. Operated Direct. Valve Clamp Open Enable (supplied w/Motion Option)
104 Sol. Operated Direct. Valve Core Pull/Set Control (Option)
S/T Sol. (24 Vdc) Core Set/Core Pull (Option)
105 Pressure reducing valve Core Pressure Control
106 Check Valve Core Volume Protection
107 Sol. Operated Direct. Valve Die Height Lock
108 Pilot Operated Check Module Die Height Lock
DHL Sol. (24 Vdc) Mold Height Lock

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L H

(TopView) 202

203

201 XH

204

LC

210
206 217
C1

212
215 GG1

Y Z
221

(Left Side View)

(Front View)

Figure 6-7A. EXAMPLE OF AN INJECTION MANIFOLD (400 Ton Machines)

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GC
219

(Right Side View) (Back View)

Figure 6-7B. EXAMPLE OF AN INJECTION MANIFOLD (400 Ton Machines)

MHT-1047 Page 6-21 MHTM(AB)-1/01

HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

Desig Type Function

201 Prop. Direct. Valve Screw/Inject/Eject Spd Control

XH Prop. Sol. Screw/Inject/Eject Volume
202 Sol. Operated Direct. Valve Inject/Inject Ret. Control
L Sol.( 24 Vdc) Inject Retract (Pullback)
H Sol. (24 Vdc) Inject Forward
203 Shuttle Valve Load Sense Pressure
204 Sol. Operated Direct. Valve Load Sense Control
LC Sol.( 24 Vdc) Load Sense On/Off
205 Relief Valve Cartridge Insert Relief, Main Stage
206 Prop. Pilot Relief Valve Prop. Pressure Control
207 Relief Valve Control Cover Main System Relief
G Prop. Sol. Main Pressure Control
208 Cartridge Insert Clamp/Eject Separate
209 Cart. Valve Control Cover Clamp/Eject Separate
210 Sol. Oper. Direct. Valve Clamp/Eject Separate
C1 Sol. (24 Vdc) Clamp/Eject Divide
211 Cartridge Valve Fixed Pump Relief
212 Sol. Operated Direct. Valve Fixed Pump Unload
213 Cartridge Valve Insert Fixed Pump Check
214 Relief Valve Cartridge Insert Fixed Pump Relief
215 Cartridge Valve Cover Fixed Pump Check
GG1 Sol. (24Vdc) Pump Adder
216 Relief Valve Cartridge Var. Pump Pressure Control
217 Var. Pump Relief Cover Var. Pump Pressure Control
219 Sol. Operated Direct. Valve Pressure Comp. Off/On
VP Sol. (24 Vdc) Pressure Comp. Off/On
220 Check Valve Module Nozzle Seal Protect
221 Sol. Oper. Direct. Valve Nozzle Seal Control
Y Sol. (24 Vdc) Inject. Carriage Forward
Z Sol. (24 Vdc) Inject. Carriage Retract

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

B 101 A

(TopView)

B 101 A

RT 102 R

107

CE
103

CN
(Left Side View)

(Front View)

Figure 6-8A. EXAMPLE OF A CLAMP/EJECT MANIFOLD 500 and 650 Ton Machines)

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107
DHL

(Right Side View) (Back View)

Figure 6-8B. EXAMPLE OF A CLAMP/EJECT MANIFOLD 500 and 650 Ton Machines)

Desig. Type Function

101 Sol. Operated Direct. Valve Mold Ht. Adjust Control
A/B Sol. (24 Vdc) Mold Ht. Forward/Mold Ht. Reverse
102 Sol. Operated Direct Valve Eject. Forward/Retract Control
R/RT Sol. (24 Vdc) Eject Forward/Eject Retract
103 Prop. Direct. Valve Clamp Speed & Direct Valve
CN Prop. Sol. Clamp Close Open Control
CE Sol. Operated Direct. Valve Clamp Open Enable (supplied w/Motion Option)
104 Sol. Operated Direct. Valve Core Pull/Set Control (Option)
S/T Sol. (24 Vdc) Core Set/Core Pull (Option)
105 Pressure reducing valve Core Pressure Control
106 Check Valve Core Volume Protection
107 Sol. Operated Direct. Valve Die Height Lock
108 Pilot Oper. Check Module Die Height Lock
DHL Sol. (24 Vdc) Mold Height Lock

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

(TopView)

(Front View)

Figure 6-9A. EXAMPLE OF AN INJECTION MANIFOLD (500 Ton Machines)

MHT-1047 Page 6-25 MHTM(AB)-1/01

HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL

(Back View)

(Right Side View)

Figure 6-9B. EXAMPLE OF AN INJECTION MANIFOLD (500 Ton Machines)

MHT-1047 Page 6-26 MHTM(AB)-1/01

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Desig Type Function

201 Prop. Direct. Valve Screw/Inject/Eject Spd Control

XH Prop. Sol. Screw/Inject/Eject Volume
202 Sol. Operated Direct. Valve Inject/Inject Ret. Control
L Sol.( 24 Vdc) Inject Retract (Pullback)
H Sol. (24 Vdc) Inject Forward
203 Shuttle Valve Load Sense Pressure
204 Sol. Operated Direct. Valve Load Sense Control
LC Sol.( 24 Vdc) Load Sense On/Off
205 Relief Valve Cartridge Insert Relief, Main Stage
206 Prop. Pilot Relief Valve Prop. Pressure Control
207 Relief Valve Control Cover Main System Relief
G Prop. Sol. Main Pressure Control
208 Cartridge Insert Clamp/Eject Separate
209 Cart. Valve Control Cover Clamp/Eject Separate
210 Sol. Oper. Direct. Valve Clamp/Eject Separate
C1 Sol. (24 Vdc) Clamp/Eject Divide
211 Cartridge Valve Fixed Pump Relief
212 Sol. Operated Direct. Valve Fixed Pump Unload
213 Cartridge Valve Insert Fixed Pump Check
214 Relief Valve Cartridge Insert Fixed Pump Relief
215 Cartridge Valve Cover Fixed Pump Check
GG1 Sol. (24Vdc) Pump Adder
216 Relief Valve Cartridge Var. Pump Pressure Control
217 Relief Valve Cover Var. Pump Pressure Control
219 Check Valve Module Nozzle Seal Protect
220 Sol. Oper. Direct. Valve Nozzle Seal Control
Y Sol. (24 Vdc) Inject. Carriage Forward
Z Sol. (24 Vdc) Inject. Carriage Retract
221 Cartridge Valve Cover Pump Relief
222 Sol. Operated Direct. Valve Pump Unload
GG2 Prop. Sol. Pump Adder
223 Cartridge Valve Insert Pump Check
224 Relief Valve Cartridge Insert Pump Relief
225 Cartridge Valve Cover Pump Check
226 Relief Module Clamp Open & Variable Pump Press. Control
227 Sol Oper. Direct. Valve Relief Valve Set
GC Sol. (24 Vdc) Relief Select

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204 L 202 H

LC

(TopView)

201 XH

C1 210

212 GG1

(Left Side View) (Front View)

Figure 6-10A. EXAMPLE OF AN INJECTION MANIFOLD (650 Ton Machines)

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216

GC

206

(Right Side View) (Back View)

Figure 6-10B. EXAMPLE OF AN INJECTION MANIFOLD (650 Ton Machines)

Desig Type Function

201 Prop. Direct. Valve Screw/Inject/Eject Spd Control

XH Prop. Sol. Screw/Inject/Eject Volume
202 Sol. Operated Direct. Valve Inject/Inject Ret. Control
L Sol.( 24 Vdc) Inject Retract (Pullback)
H Sol. (24 Vdc) Inject Forward
203 Shuttle Valve Load Sense Pressure
204 Sol. Operated Direct. Valve Load Sense Control
LC Sol.( 24 Vdc) Load Sense On/Off
205 Relief Valve Cartridge Insert Relief, Main Stage
206 Prop. Pilot Relief Valve Prop. Pressure Control
207 Relief Valve Control Cover Main System Relief
G Prop. Sol. Main Pressure Control
208 Cartridge Insert Clamp/Eject Separate
209 Cart. Valve Control Cover Clamp/Eject Separate
210 Sol. Oper. Direct. Valve Clamp/Eject Separate
C1 Sol. (24 Vdc) Clamp/Eject Divide
211 Cartridge Valve Cover Fixed Pump Relief
212 Sol. Operated Direct. Valve Fixed Pump Unload
GG3 Sol. (24Vdc) Pump Adder
213 Cartridge Valve Insert Fixed Pump Check
214 Relief Valve Cartridge Insert Fixed Pump Relief
215 Cartridge Valve Cover Fixed Pump Check
216 Sol. Oper. Direct. Valve Relief Valve Set
GC Sol. (24 Vdc) Relief Select

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316
X Y

(TopView)

302

308 GG2 309

313

314

GG1

(Left Side View) (Front View)

Figure 6-11A. EXAMPLE OF AN PUMP MANIFOLD (650 Ton Machines)

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MAINTENANCE MANUAL HYDRAULIC SYSTEM MAINTENANCE

(Right Side View) (Back View)

Figure 6-11B. EXAMPLE OF AN PUMP MANIFOLD (650 Ton Machines)

Desig. Type Function

301 Relief Valve Cartridge Insert Var. Pump Pressure Control
302 Var. Pump Relief Cover Var. Pump Pressure Control
305 Cartridge Valve Insert 42 GPM Pump Check
306 Cartridge Valve Cover 42 GPM Pump Check
307 Relief Valve Cartridge Insert 42 GPM Pump Relief
308 Cartridge Valve Control Cover 42 GPM Pump Relief
309 Sol. Operated Direct. Valve 42 GPM Pump Check
GG2 Sol. (24 Vdc) 42 GPM Pump Adder
310 Cartridge Valve Insert 25 GPM Pump Check
311 Cartridge Valve Cover 25 GPM Pump Check
312 Relief Valve Cartridge Insert 25 GPM Pump Relief
313 Cartridge Valve Control Cover 25 GPM Pump Relief
314 Sol. Operated Direct. Valve 25 GPM Pump Unload
GG1 Sol. (24Vdc) 25 GPM Pump Adder
315 Check Valve Module Nozzle Seal Protect
316 Sol. Oper. Directional Valve Nozzle Seal Control
Y Sol. (24Vdc) Inj. Carriage Forward
Z Sol. (24Vdc) Inj. Carriage Retract

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL
6.10 VALVE DESCRIPTIONS

The following are descriptions of the basic types of valves. Some valves are adjusted electronically, by means of the
Pro-Set 700® Controller, while others are manually adjusted. These adjustments are detailed in the Machine Set-Up
Section of this manual.

6.10.1. PROPORTIONAL PRESSURE CONTROL VALVE

This valve, which is labeled as 'G' receives a 0 to 10 volt DC control signal from
the Analog Terminal board. Because the maximum rating (3050 psi) of the valve
exceeds the machine's maximum pressure rating, the control system calibration
voltage settings are used to limit the valve's maximum pressure. The proportional
valve mounts to a cover which allows it to control a cartridge relief valve in the
manifold.

The pressure setting of the valve is directly proportional to the input signal from the
controller. When the proportional relief valve solenoid receives an electrical signal,
the movement of the solenoid armature provides force against the relief valve ball
increasing the hydraulic pressure required to unseat it. Movement of the ball off the Figure 6-12. TYPICAL PRO-
seat allows pilot oil on top of the cartridge relief valve to vent to tank, permitting PORTIONAL PRESSURE
control of the main system pressure. RELIEF VALVE

Internal electronic controls within the valve

housing provide signal conditioning for precise
repeatable control of system pressures.

6.10.2. SOLENOID CONTROLLED/PILOT OPER

ATED DIRECTIONAL VALVES (Refer to
Figure 6-13.)

This valve consists of main valve with housing,

control spool, two return springs, plus pilot valve
and two solenoids. The control spool of the main
valve is held in the center position by the tension
of the two springs. In the center position, the
spring chambers are connected to tank without Figure 6-13. SOLENOID CONTROLLED/PILOT
pressure by means of the pilot valve. Fluid is OPERATED DIRECTIONAL VALVES
supplied to the pilot valve via the pilot pressure
line. The main spool is operated hydraulically by means of the pilot valve, which is equipped with two DC
controlled wet pin solenoids. When a solenoid is energized, the pilot valve will be actuated and pilot pressure
will affect one of the two ends of the control spool, shifting it into position. This opens the ports to the required
position (P to A, B to T, or P to B, A to T). When the solenoid is deenergized, the pilot valve returns to the
center position via the springs. The control fluid is forced from the spring chamber, via the pilot valve, into the
tank line.

6.10.3. PROPORTIONAL DIRECTIONAL VALVE ( Refer to Figure 6-14.)

HT Machines are equipped with two proportional flow directional valves labeled CN and XH. Both valves
require a 0 to + 10 volts DC command signal. The polarity and signal voltage level are determined by the
control system based on the operator's desired flow setting and the full scale voltage calibration value. The
valve labeled CN is used to control clamp speed and direction. The XH valve is used to control injection
speed, screw rotate, ejection, and core movement. The valves consist of a four position pilot stage and a three
position main stage. The pilot stage consists of the proportional solenoid with an integrated position trans-
ducer. The main stage consists of a spool to control both direction and flow and also a position transducer for
monitoring spool position. The position of the spring centered main stage spool is superimposed on the pilot
valve signal to control the main spool position. During operation the pilot spool moves from its spring versus
MHT-1047 Page 6-32 MHTM(AB)-1/01
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power supply voltage position to either direction
position based on the level and polarity of the control
signal. The pilot valve will move to a fourth position
(fail safe) if power supply voltage is removed for any
reason. During operation the main stage spool shifts
from its spring centered position in a direction and to
a specific position that is proportional to the operator
setpoint. The CN valve contains an additional two
position solenoid operated directional valve (CE)
which is interlocked to the front operator gate limit
switch (5LS). When the front operator gate opens,
limit switch 5LS opens and removes power from the
CE solenoid which is connected in series with the
switch. When the solenoid deenergizes pilot oil to
the main spool will be blocked, preventing the valve
from shifting.

Each valve is controlled by a pilot valve having an

integrated electronic amplifier that generates the
drive signal. These amplifiers receive a command
signal (operator entered setpoint) from the analog
terminal board and also a feedback signal from the
main stage and pilot valve LVDT. The amplifier circuit
makes a comparison between the operator entered Figure 6-14. PROPORTIONAL DIRECTIONAL VALVE
setpoint value and the actual (feedback) value for the
spool position and the resulting deviation is processed and passed to the control solenoid as a correcting
variable. The amplifier cards are an integral part of the valve and are not manually adjustable, however the main
spool position transducer feedback signal is brought back to the electrical control cabinet for valve troubleshoot-
ing purposes.

6.10.4. CARTRIDGE VALVES (Refer to Figure 6-15.)

Cartridge valves are relatively simple devices. Through proper application of these valves, faster acceleration
rates with less shock can be attained. The two-way directional cartridge valves are also referred to as logic
elements. They are comprised of a cartridge assembly and a cover
with control porting. The cartridge assembly is composed of a
sleeve bushing with seating surface and a poppet which is normally
held on its seat with a spring.

The cartridge has two main flow ports, A and B, and pilot ports X
and Y. The poppet will be either open, closed, or modulating
depending on the pressure level in each of the ports. To control
various functions on the machine different valve and cover ar-
rangements are used. The cover holds the cartridge assembly in a
manifold cavity and contains pilot pressure passages and an
Figure 6-15. CARTRIDGE RELIEF VALVE
orifice to control the opening and closing rates of the poppet.
Depending on valve function requirements, the type of cover used
will vary. The following are the available types of covers.

6.10.4.1. Pilot Valve Interface Cover: Either single or double solenoid operated directional valves can be
mounted to control pilot pressure.

6.10.4.2. Shuttle Cover with Directional Valve Interface: This cover combines pilot valve and shuttle for
simplicity of installation and immediate valve response.

6.10.4.3. Pressure Adjusting Cover: This cover provides a relief valve function.

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HYDRAULIC SYSTEM MAINTENANCE MAINTENANCE MANUAL
6.10.5. MANUALLY ADJUSTED RELIEF VALVES

Relief valves are used to provide protection against overloading of system components or to limit the force or
torque which can be exerted by a hydraulic cylinder or motor. A relief valve is installed with one port connected
to the pressure line and the other to the reservoir. When pressure at the inlet to the pilot adjusting head
exceeds the spring force, a ball, or poppet, is forced off its seat and fluid flows to the reservoir causing a
pressure imbalance at the main spool or poppet. Fluid at controlled pressure flows past the poppet seat as the
poppet moves in response to the imbalance. When pressure drops to the valve setting, the ball or poppet
reseats and the valve closes. These valves are used to limit the pressure at the output of the fixed and variable
volume pumps.

6.10.6. PRESSURE REDUCING VALVE

The pressure reducing valve is used to limit secondary (outlet) system pressure. The HT model machines use
one such valve when the core pull option is supplied. The valve will be located on the Clamp/Eject/Core
Manifold.

The pressure reducing valve functions similar to the pressure relief valve described previously, however it
monitors outlet pressure rather than inlet pressure. Actuator pressure is limited to the reduced pressure setting
as the valve spool closes off the outlet. Although the available pressure for setting and pulling cores is limited
by the operator screen setting (up to the manual setting of the pressure reducing valve), once the core is set,
the pressure reducing valve prevents higher pressures that are present in the system from being communi-
cated to the core circuit.

6.10.7. CHECK VALVE

A check valve consists of a valve body with inlet and outlet ports and a moveable member (either a ball or
poppet) that is biased by spring pressure. Fluid is only allowed to pass through a check valve in one direction.
When the pressure at the check valve inlet is high enough to overcome the spring pressure biasing the
poppet, the poppet is pushed off its seat and fluid passes through the valve. When fluid flow attempts to enter
through the outlet, the poppet which is held against the seat by the spring, blocks the flow. If the fluid is under
any pressure, the resultant force adds to the spring which assures no flow.

MHT-1047 Page 6-34 MHTM(AB)-1/01

 SECTION 7

ELECTRICAL MAINTENANCE

7.1 MACHINE ELECTRICAL SYSTEM

A description of the Operator Control Screens has been discussed in Sections 3 of the Operator's Manual. This
section will cover the system components, controller hardware, and Engineering Screens.

When performing any work on the electrical system components, insure that all power has been disconnected,
locked out, tagged, and verified with a voltage testing instrument.

The system for the control of the machine consists of four main parts. These are the input elements, the logic
elements, the output elements, and the protective elements.

The input elements consist of limit switches, pressure switches, temperature sensors, timer setting selector or
pushbutton switches, and other pilot devices which provide the necessary information to the decision elements.

The logic elements are composed of microprocessor circuits that determine and provide the commands needed for
proper control of the output elements using the information received from the input elements and the control panel
settings.

The output elements consist of solenoids, motor starters, contactors, or other power devices required to initiate the
actual operation.

The protective elements consist of power disconnects, fuses and overload protection. A brief description of some of
these devices with maintenance tips will follow.

Refer to the Troubleshooting Section of this manual for information on isolating fault conditions. Always refer to the
machine’s control wiring and power circuit drawings when troubleshooting the machine. We recommend that instru-
ments such as a voltmeter, ohmmeter, and a clamp-on style ammeter be kept on hand to save time when troubleshoot-
ing.

7.2 SAFETY PRECAUTIONS

The following is an outline of safety precautions which should be followed while operating, maintaining or trouble-
shooting a machine. All of these are covered in greater detail in the Safety Features Section of this manual. PLEASE
READ IT.

7.2.1. Do not operate or work on this machine unless thoroughly instructed on operating procedures.

7.2.2. Do not operate the machine unless all protective devices are in place and functioning properly.

7.2.3. Turn all power disconnects to the off position and lock out the disconnect handles with padlocks and
install the proper Danger Tag.

7.2.4. Ground the machine control cabinet(s) and auxiliary equipment per all applicable codes. Check for
proper ‘ground’ on a scheduled basis along with other items on your Preventive Maintenance Checklist,
located in Section 3 of this manual.

7.2.5. Do not modify any hydraulic or electrical circuits without written authorization from Van Dorn Demag
Corporation.

7.2.6. Check all safety devices at the start of each shift, after each mold change, and after performing any
maintenance work.

7.2.7. Keep electrical enclosure covers and doors closed.

7.2.8. Never place obstructions near the electrical control cabinet doors that could prevent ready access.
MHT-1047 Page 7-1 MHTM(AB)-1/01
 ELECTRICAL MAINTENANCE MAINTENANCE MANUAL
7.2.9. Pay attention to the high voltage sign and follow safety precautions.

7.2.10. When performing electrical maintenance on the machine:

7.2.10.1. Remove rings, bracelets, watch bands, etc. before opening any electrical enclosure. ACCIDENTAL
CONTACT WITH LIVE CIRCUITS CAN BE DEADLY.

7.2.10.2. When power disconnects are physically turned off, and work must be performed on electrical devices
and connections NEVER ASSUME THAT THE POWER IS OFF. These are mechanical devices and
subject to failure. Check for voltage on the load side of the disconnect device with a good voltage
testing instrument.

7.2.11. Electrostatic discharge can cause permanent failure to

static sensitive parts. When working with static sensitive
parts use the following safe handling practices:

7.2.11.1. Transport and store circuit cards and memory chips

in antistatic containers.

7.2.11.2. Allow a few seconds discharge time, after powering ATTENTION

down the controller, before removing circuit cards. STATIC SENSITIVE
ELECTRONIC DEVICES
7.2.11.3. Connect a wrist strap from your arm to chassis
ground prior to handling memory chips and circuit
HANDLING PRECAUTIONS REQUIRED.
cards.
USE THE PROVIDED GROUNDING STRAP
WHEN HANDLING.
7.2.11.4. Handle circuit cards by the sides only, avoid touch
ing electrical components and terminals.
DO NOT REMOVE OR INSERT
CARDS (MODULES) WITH POWER ON.
7.3 WIRING SYSTEM

The wires are enclosed in either troughs (duct work), flexible

conduit, or rigid conduit to conform to the National Electrical Code. The wires are color coded as follows, with the
exception of purchased prewired cabling :

Black- Power Conductors

Red- AC Control Conductors
White- AC Current Carrying Grounded Conductors
Blue- DC Control Conductors
Green- Equipment Grounding Conductors

The wires are also labeled with a number designation as per the electrical schematics.

7.4 PUMP MOTOR

7.4.1. DESCRIPTION

These motor(s) are the three phase induction, dual voltage type, with a high breakdown torque feature. The
motor(s) are “Thermally Protected”, which means that they have a built-in protection against overcurrent, using
the automatic reset style protectors (no external button) that reset automatically as the motor cools.

The Full Load Amperage rating (F.L.A.), of the motor is the amount of current that the motor draws during normal
load. At the time of initial machine pump start up, it is normal for the current draw to be 3 to 4 times the F.L.A.
rating. When the output of a high volume pump is added into the system e.g., during Boost for Injection, Screw
Rotation, etc., the current draw at this time will increase 1.5 to 2 times the F.L.A. rating. For this reason, we
use special motors that are capable of high intermittent overloads. Refer to the Installation Section of this
manual for machine current ratings.
MHT-1047 Page 7-2 MHTM(AB)-1/01
MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

Operation at high overloads for abnormally high percentages of cycle time (30 to 50% of cycle) may overheat the
motor and trip the temperature overload device.

7.4.2. INSTALLATION

Drip proof motors are designed for operation in well ventilated areas where the atmosphere is reasonably free of
dirt and moisture. If stored, keep motors in a clean, dry place.

Accurately align the motor coupling half with the pump coupling half. DO NOT use a rigid style coupling in place
of a flexible style coupling.

Mounting bolts must be carefully tightened to prevent changes in alignment and possible damage to equipment.

Dual voltage motors can be connected for the desired voltage by following instructions on the nameplate or
connection diagram. To reverse rotation of a three-phase motor, interchange two line leads.

7.4.3. MAINTENANCE

Inspect motors and coupling(s) at regular intervals depending upon service. Keep motors clean and ventilation
openings clear. With the motor stopped and still warm, lubricate the motors and couplings with the proper
lubricant.

7.4.3.1. General Electric Motors Lubrication

If the motor is supplied with grease fittings, lubricate the motor(s) at 6 month intervals with Mobilgrease CM-
L or equivalent. With the motor warm and stopped, perform the following.

7.4.3.1.1. Drive End: Remove the upper pipe plug and insert a lubrication fitting in its place. Then
remove the bottom pipe plug for grease relief. Be sure the lube fittings are clean. Using a low
pressure hand operated grease gun, pump clean, recommended grease until new grease
appears at the relief hole. After lubricating, allow the motor to run for ten minutes before
replacing the relief plug.

7.4.3.1.2. Opposite Drive End: For drip-proof motors, follow the same procedure as for the drive end.

7.4.3.2. Reliance Electric Motors Lubrication

If the motor is supplied with grease fittings, lubricate the motor(s) at 6 month intervals with Mobilgrease CM-
L or equivalent. The motor may be lubricated with the motor running or stationary. Stationary with the motor
warm is preferred. .

7.4.3.2.1. Locate the grease inlet. Clean the area. Remove the pipe plug and insert a grease fitting in its
place. (If the motor is not equipped with grease fittings.)

7.4.3.2.2. If the motor is equipped with a grease drain plug, remove the plug and loosen any hardened
grease that may block the drain.

7.4.3.2.3. Using a low pressure hand operated grease gun, pump clean grease that is of the recom
mended type, and in the volume listed below.

Volume in Cubic Inches

Frame Size 1800 RPM and slower
182 through 215 0.5
254 through 286 1.0
324 through 365 1.5
404 through 449 2.5
MHT-1047 Page 7-3 MHTM(AB)-1/01
ELECTRICAL MAINTENANCE MAINTENANCE MANUAL

7.4.3.2.4. After lubricating, allow the motor to run for two hours before replacing the pipe plug in the
grease drain.

7.4.3.2.5. Note that the grease may not relieve from the drain. Use only the volume listed in Step
7.4.3.2.3.

7.4.3.3. Lubricate Pump-to-Motor Coupling. Remove both pipe plugs then insert a grease fitting in one hole.
Using a hand operated grease gun, force grease until clean grease flows from the opposite hole.
Remove the grease fitting and reinstall pipe plugs. Lubriplate 1241 or equivalent is recommened.

7.5 BARREL AND NOZZLE TEMPERATURE CONTROL

7.5.1. GENERAL

The temperature control for each of the barrel and nozzle zones consists of a Type J Thermocouple and a
resistive type heating band element. Solid state drivers are used to energize the mercury contactors that supply
the heating band elements.

7.5.2. THERMOCOUPLES

A Type J Thermocouple is furnished for the nozzle and each of the barrel zones for individual zone monitoring.
These thermocouples are composed of two dissimilar metals; the positive material is iron and the negative
material is constantan. When heat is applied to the junction of these two metals, a DC voltage is developed
across the junction, which is then used by the digital control module to control barrel and nozzle temperature.

The thermocouples in the barrel zones are a variable depth design. With this style coupling it should be posi-
tioned so that it is bottomed out and the thermocoupling casing is compressed slightly.

7.5.3. HEATER BANDS

7.5.3.1. Description

The heater bands on the barrel are divided into three zones for most models (some smaller models have two
zones—vented barrel packages [option] are divided into four zones). Refer to the machine’s power circuit
drawing. The individual bands are split and strapped to the barrel for ease of removal and installation. The
nozzle zone band can be easily removed from the nozzle by loosening the band’s strap screws and sliding
off the end of the nozzle. When replacing the barrel and/or nozzle heater bands, the heater band wires can
be disconnected from the heater connection box - INSURE THAT POWER IS OFF.

7.5.3.2. Maintenance

For longer heater band life, the bands should be tight against the barrel. If they are not tightly secured, it is
possible for the band to expand away from the barrel. This would cause air gaps between the barrel and
heater bands resulting in poor heat transfer, excessive heat loss, wasted electrical energy and shorter
heater band life. Therefore, tighten the band strap screws monthly.

Keeping the bands free of dirt, oil, plastic material, etc., can also prolong heater band life. Built up deposits
around terminals can eventually short-out the band.

Maintenance of temperature controls and thermocouples can also be important to heater band life. If the
bands are overheated, due to a faulty controller, premature failure may result.

When changing a heater band, or when trying to establish whether or not a heater band has failed, use the
following sequence:

7.5.3.2.1. Refer to the specific electrical schematics accompanying this manual.

MHT-1047 Page 7-4 MHTM(AB)-1/01
MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

7.5.3.2.2. Turn power disconnects off, lock out, and tag.

7.5.3.2.3. Disconnect all heater zone connections.

CAUTION

INSURE THAT THE SHIELD AND BANDS ARE NOT HOT.

7.5.3.2.4. Remove the heater barrel metal shield.

7.5.3.2.5. Disconnect all wires from the band(s) in question. (Use an ohmmeter at this point to make sure
there are no open or grounded bands).

7.5.3.2.6. Remove the hold-down strap from the band if it is defective. Remove the band by SPREADING
AS LITTLE AS POSSIBLE (so as not to destroy the heating element in the band) and sliding
the band forward to the front of the barrel.

7.5.3.2.7. Assemble in reverse order. Adjacent heater band joints should be staggered in order to elimi-
nate cold spots. It is advisable to check continuity when a band is replaced before the entire
assembly is completed.

7.5.3.2.8. Refer to Section 5, Injection Unit Maintenance, for additional information on the heater bands.

CAUTION

DO NOT ALLOW THE HEATER BAND TERMINAL POST TO ROTATE WHILE TIGHTENING HEXAGON NUTS.
DAMAGE MAY RESULT TO THE BAND IF THIS OCCURS.

MHT-1047 Page 7-5 MHTM(AB)-1/01

ELECTRICAL MAINTENANCE MAINTENANCE MANUAL

Solenoid TQ

Mold Height
Adjustment
- Hydraulic
Interlock
Injection Mani- Pump Manifold -
fold - Solenoids Injection Manifold Solenoids GG1, Solenoid WV Clamp/Eject Manifold
G, GC, C1, - Solenoids G, (Water Valve) - Solenoids A, B, CN,
GG2, VP, Y, Z
GG3, H, L, LC, GC, GG1, H, L, (650 Ton & 500 CE, NE, RT, R, S, T,
XH (650 Ton & LC, VP, Y, Z, XH Ton High Speed DHL
500 Ton High (85 to 500 Ton
machines only)
Speed ma- machines only)
chines only)

Figure 7-1. VALVE SOLENOID LOCATIONS

7.6 VALVE SOLENOID IDENTIFICATION

The following is a list of various directional valve solenoids, their location and their function, as provided on the HT
Injection Molding Machine.

Identification Valve Type Location Name/Function

Elect. Hyd.

A/B 101 S. O. D.—24 Vdc Clamp/Eject Man Mold Height Forward/Reverse

C1 210 S. O. D.—24 Vdc Inject Man Eject/Clamp Divide (not on 85 or 120HT)
CE 103 Prop. Direct. Clamp/Eject Man Clamp Close Enable
CNE 112* S. O. D.—24 Vdc Clamp/Eject Man Clamp Motion Option*
CN 103 Prop. Direct. Clamp/Eject Man Mold Close/Open-Direct & Spd Control
DHL 107 S.O.D. —24 Vdc Clamp/Eject Man Mold Height Lock
G 206 Prop. Relief Inject Man System Press Control
GC 227 S. O. D.—24 Vdc Inject Man Relief Valve Set
GG1 212 S. O. D.—24 Vdc Inject Man Fixed Pump Adder/Press Control
GG2&up See Hyd Diag S. O. D.—24 Vdc See Hyd Diag. Fixed Pump Adder/Press Control
H/L 202 S. O. D.—24 Vdc Inject Man Injection Forward/Reverse (Decomp)
LC 204 S. O. D.—24 Vdc Inject Man Load Sense On/Off
NE 107* S. O. D.—24 Vdc Clamp/Eject Man Clamp Motion Option*
R/RT 102 Prop. Direct. Clamp Eject Man Eject Forward/Retract
S/T 104 S. O. D.—24 Vdc Clamp/Eject Man Core Set/Core Pull
WV 16 Water Control Valve Heat Exchanger Water Valve (Oil Cooling)
XH 201 Prop. Direct. Inject Man Screw/Inject Control
Y/Z 220 S. O. D.—24 Vdc Inject Man Inject Carriage Forward/Retract

* Note: Valve 103 (CE) is provided as standard. When a Clamp Motion Option is supplied,
Valve 112 (CNE) is provided.

MHT-1047 Page 7-6 MHTM(AB)-1/01

MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

Front Gate
Limit Switch
Front Guard
Limit Switch Drop Bar Limit (5LS) Alarm Injection
Switch (106LS) Light Operator Carriage
(61LS) Control Position Limit
Panel Pressure
Switch (22LS)
Gauge
VAN DORN
VAN DORN
Front Fixed Front Operator
Guard Gate

Machine I.D.
Data/Name
Plate
Front Gate Purge Guard Oil Level Power/Control Electric Motor/
Dump Valve Limit Switch Gauge Module Cabinet Pump Assembly
(120LS) (99LS) Main Circuit
Oil Tempera-
ture Gauge Breaker
Remove cover to
access Oil Float
Switch and Oil
Temperature
Thermocouple

Redundant Rear
Guard Limit Ejector
Screw Drive Feed Throat Position Clamp Position
Heater/TC Switch (1ALS)
Hydraulic Cooling Control Sensor Sensor
Connection
Motor Valves Box Clamp
Cylinder

Mold Height
Adjustment
Hydraulic
Motor Interlock
ass'y
Hydraulic Pressure Core Pull Limit Mold Height
Oil Filter
Transducer (behind Switch Connection Rear Guard Limit Switch
Bypass
manifold) Box (14LS/15LS) Limit Switch (3LS)
Switch
(1LS)

Figure 7-2. MACHINE ELECTRICAL SENSING DEVICE LOCATIONS

MHT-1047 Page 7-7 MHTM(AB)-1/01

ELECTRICAL MAINTENANCE MAINTENANCE MANUAL
7.7 SENSING DEVICES CHART

The following table lists the various electrical sensing devices used on the HT Injection Molding Machine. Refer also
to Figure 7-2 for machine location.

Switch or Sensing Device Location Name/Function

Function Type

1LS Limit Switch Rear Guard Rear Guard Closed

1ALS Limit Switch Rear Guard Redundant Rear Guard
3LS Limit Switch Clamp Link Plate-Rear Side Mold Height Adjust/Overtravel
5LS Limit Switch Front Operator Gate Front Gate
1OF Micro-Switch Oil Filter—Non-Oper. Side Oil Filter Bypass
1FS Micro-Switch Oil Reservoir—Top Side Oil Level
14LS* Limit Switch Receptacle Box—Rear Side Core Is Out
15LS* Limit Switch Receptacle Box—Rear Side Core Is In
22LS Limit Switch Injection Unit—Oper. Side Injection Carriage Fwd/Ret
61LS Limit Switch Clamp End—Oper. Side Front Guard Closed
99LS Limit Switch Purge Guard Purge Guard Closed
106LS Limit Switch Stop Bar Safety Flag Up
120LS Limit Switch Below Front Operator Gate Dump Valve - Hydraulic Safety

Door Inter- Micro-Switch Pathfinder Control Cabinet Door Interlock**

Lock Switch

Clamp Linear Position Link Plate - Top Side Clamp Position Detector
Position Sensor

Eject Linear Position Ejector Box/Movable Platen Ejector Position Detector

Position Sensor —Oper. Side

Screw Linear Position Injection Unit—Oper. Side Screw Position Detector

Position Sensor

Cavity Press. Pressure Receptacle Box—Rear Side Mold Cavity Pressure Detector
(Option) Sensor

Inject./Back Pressure Injection Manifold—Rear Injection Pressure Detector

Pressure Sensor Side

Screw Speed Proximity Injection Unit—Near Screw Speed Detector

Tachometer Switch Hydraulic Motor(Top Side)

Barrel/Nozzle Thermocouple Barrel/Nozzle-Rear Side Barrel/Nozzle Zone Temperature Control

Temp. TC (Type J)

Oil Temp. Thermocouple Oil Reservoir-Top Side Hyd Oil Temp Detector
TC (Type J)

Control Thermocouple Inside Control Cabinet Control Cabinet Temp. Sensor

Cabinet Temp (Type J)

* Option
** Used on larger machines equipped with separate auxiliary power control panel.

MHT-1047 Page 7-8 MHTM(AB)-1/01

MAINTENANCE MANUAL ELECTRICAL MAINTENANCE
7.8 MONITORING DEVICES

7.8.1. CLAMP LINEAR POSITIONING

The clamp position is monitored by a linear potentiometer that is mounted between the clamp housing and the
rear of the crosshead. The return 0 to 10 volt DC signal from the potentiometer is sent to the analog terminal
strip where it is passed on to the QDC1 module. The QDC1 module converts the signal to a numeric value for
screen display. The linear potentiometer is mounted in such a way that when the clamp is fully closed, the
voltage output is equal to approximately 0 volts DC. As the clamp opens the voltage increases proportionally to
the position of the clamp (up to 10 VDC). When the actual clamp position, as read by the sensor, reaches the
operator selected clamp position setpoint, the control system allows the various machine actions and functions
to occur or continue, according to the programmed sequence. When the clamp is fully closed, the actual clamp
position displayed on the screen should read 0.00 inches which is the mold safe position. While operating in the
Semi or Automatic Modes, when the control system senses the clamp at the mold safe position (0.00 inches)
the Clamp Pressure Build-up Sequence will be signalled to start.
Periodically it may be necessary to zero the clamp position axis (plus, after every mold change). To zero the
position, perform the following steps.
7.8.1.1. Select the Clamp Close Profile Screen.
7.8.1.2. Cursor to and select the Edit X-tions prompt.
7.8.1.3. Cursor to and select the Setup prompt.
7.8.1.4. Manually close the clamp completely.
7.8.1.5. Note the clamp position on the screen, cursor to and select the Zero Axis prompt.
7.8.1.6. The clamp position should now read zero.
7.8.1.7. Press the Download pushbutton to save the setpoints to the PLC module.

7.8.2. EJECTOR LINEAR POSITIONING

The ejector position is monitored by a 0 to 10 volt DC, linear potentiometer. The 0 to 10 volt signal from the
potentiometer (which is proportional to the ejector position) is sent to the analog terminal strip where it is
passed on to the QDC1 module. The QDC1 module converts the signal to a numeric value for screen display.
The linear potentiometer is mounted in such a way that when the ejector is fully retracted the actual position
displayed on the screen should read 0.00 inches. During the Semi or Auto Mode of operation, when the ejector
retracted position is reached the clamp will close and/or the machine will start the next cycle.
Periodically it may be necessary to zero the ejector position. To zero the position, perform the following steps.
7.8.2.1. Select the Ejector Profile Screen.
7.8.2.2. Cursor to and select the Edit X-tions prompt.
7.8.2.3. Cursor to and select the Setup prompt.
7.8.2.4. Completely retract the ejectors.
7.8.2.5. Note the ejector position on the screen, cursor to and select the Zero Axis prompt.
7.8.2.6. The ejector position should now read 0.00 inches.
7.8.2.7. Press the Download pushbutton to save the setpoints to the PLC module.

7.8.3. SCREW POSITION SENSING

Injection piston positioning is monitored by a 0 to 10 volt DC, linear potentiometer which provides an indication
of screw positions: screw forward and retract, cushion, selectable sprue decompress (pullback before screw
rotate), and after boost (velocity) cut-off by position, and multi-steps of velocity and back pressure profiling. The
0 to 10 volt output from the potentiometer is sent to the analog terminal strip where it is passed on to the QDC0
module. The QDC0 module converts the signal to a numeric value for screen display. The linear potentiometer is
mounted in such a way that when the screw is fully forward the actual position displayed on the screen should
read 0.00 inches.
Periodically it may be necessary to zero the screw position. To zero the position, perform the following steps.
7.8.3.1. Select the Injection Profile Screen.
7.8.3.2. Cursor to and select the Edit X-tions prompt.
7.8.3.3. Cursor to and select the Setup prompt.
7.8.3.4. Run the screw to it's full forward position.
7.8.3.5. Note the screw position on the screen, cursor to and select the Zero Axis prompt.
MHT-1047 Page 7-9 MHTM(AB)-1/01
ELECTRICAL MAINTENANCE MAINTENANCE MANUAL

7.8.3.6. The screw position should now read 0.00 inches.

7.8.3.7. Press the Download pushbotton to save the setpoints to the PLC module.

7.8.4. SCREW SPEED SENSING

Screw Speed is sensed by a proximity switch mounted over the screw drive shaft. As the motor rotates a pickup
on the shaft is sensed by the switch which uses the number of pulses over a time period to determine the speed
of the motor. The pulse information is sent to the analog terminal strip where it is passed on to the QDC0
module. The QDC0 module converts the signal to a numeric value for screen display. When the screw motor is
not rotating, the actual rpm's displayed on the screen should read 000. In addition to sensing when the screw
motor is turning and number of revolutions per minute, the actual reading will also be compared to operator
entered setpoint values to limit the rotating speed. The number of pickups (pulses per revolution) on the machine
is determined by the size of the injection unit and should remain at the value entered at the factory.

7.8.5. INJECTION PRESSURE SENSING

The Injection Boost, Transition, and Back Pressure are monitored by a pressure transducer mounted on the
back side of the Injection Manifold. The pressure information is sent to the analog terminal strip where it is
passed on to the QDC0 module. The QDC0 module converts the signal to a numeric value for screen display.
Periodically it may be necessary to zero the injection pressure sensor. To zero the pressure sensor, perform the
following steps:

7.8.5.1. Turn the pump motor(s) off.

7.8.5.2. Press the Setup pushbutton, cursor to and select "Inputs".
7.8.5.3. Cursor to the Screw Pressure prompt.
7.8.5.4. Cursor to the Screw Minimum Pressure field and enter 0000.
7.8.5.5. Note the Real Time Value on the screen, enter this number in the Analog Signal at Minimum Pressure
field.
7.8.5.6. Enter the maximum rated injection pressure for your machine on the Injection Profile Screen.
7.8.5.6. With the pump(s) running and the barrel at operating temperature press and hold the injection forward
pushbutton.
7.8.5.7. Using a calibrated gauge monitor the injection pressure at the gauge port located on top of the
injection cylinder.
7.8.5.8. Enter this value in the Screw Maximum Pressure field.
7.8.5.9. Note the Real Time Value on the screen, enter this number in the Analog Signal at Maximum Pressure
field.
7.8.5.10. Turn the pump motors off, press the Download pushbutton to load the setpoints in the PLC module.

7.9 Pro-Set 700® SYSTEM STRUCTURE

The Allen Bradley Pro-Set 700® Series Control System, provides the molder with the sophisticated control capabili-
ties to ensure cycle-to-cycle repeatability and machine efficiency. Fast and accurate machine set up, self-diagnostics,
and process monitoring, are just a few of the standard features designed into the system that help the molder optimize
product quality, consistency, and productivity, and thus overall profitability. The hardware for the Pro-Set 700® Control-
ler consists of an Operator Interface (station), Printed Circuit Boards, a Rack Assembly, and Power Supplies. Refer to
the Control Wiring Prints furnished with your machine for specific components and connections.

7.9.1. OPERATOR INTERFACE

Interfacing between the operator and the machine is accomplished via an operator interface, which is mounted
next to the front operator gate. The operator interface controls the machine setup and operation. Through the
operator interface all operating parameters can be set, including; speed, position, pressure, rpm, load, etc. The
operator interface on the Pro-Set 700® is a small, lightweight, ergonomically-designed and environmentally-
sealed interactive computor built for continuous use in harsh industrial environments. It is based on the 80486
processor and utilizes innovative flat panel display technology.
MHT-1047 Page 7-10 MHTM(AB)-1/01
MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

FRONT VIEW SIDE VIEW

POWER
COMM A.
CONNECTOR
SERIAL
PORT 1

FUSE

EXTERNAL
FLOPPY KEYBOARD
CONNECTOR

DB 25 EXTERNAL
SPEAKER
FEM END
PARALLEL
PORT

COMM B.
SERIAL
PORT 2

EXTERNAL
FLOPPY

CH 3
1 2
A 1

DB 25
REMOTE CH
PRINTER/ MALE END 1
DH +/ NETWORK
KEYBOARD PORT AU1 B

1
2
NETWORK CH 3
PORT
1 4
10-BASE 7
C 5
6

Figure 7-3. PRO-SET 700® OPERATOR PANEL LAYOUT

The OI's display area is a touch screen. A finger touch makes menu choices, activates commands, and
changes displays. Messages menus, and selections appear on the touch screen.
The touch surface features a matte-finish hard coat, impervious to most chemicals and resistant to most forms
of abuse. The OI uses a liquid Crystal Display (LCD) with a 640 X 480 pixel VGA resolution. The entire front
surface of the OI, not just the display area, is touch-sensitive. Pro-Set 700® has pre-defined the buttons
surrounding the touch screen to meet various injection-molding needs.

7.9.1.1. OI SYSTEM BOARD - MAIN LOGIC BOARD contains the following components:

7.9.1.1.1. 486 class PC/AT compatible core logic.

7.9.1.1.2. Local bus IDA supporting ATA and ATA-2 2.5" hard drives.
7.9.1.1.3. PC/AT compatible floppy disc drive controller supporting 3.5", 1.44 Mbyte drives.
7.9.1.1.4. Minimum of 125K of FLASH EPROM memory containing:

7.9.1.1.4.1. BIOS (Basic Input Output System).

7.9.1.1.4.2. VGA BIOS.
7.9.1.1.4.3. Extended BIOS.

7.9.1.1.5. Four 72-pin SIMM sockets, supporting up to 52 Mbyte of DRAM memory in 4 Mbyte and
16Mbyte SIMMS.

MHT-1047 Page 7-11 MHTM(AB)-1/01

ELECTRICAL MAINTENANCE MAINTENANCE MANUAL
408 2.5A 430 CO1FU
700 2.5A 710 GHFU
408 2.5A 431 CO2FU
700 2.5A 711 XFU
408 2.5A 432 8CFU
700 2.5A 712 CNFU
402
700 2.5A 713 ECVFU 402
402
700 2.5A 714 CPFU 402
402
700 2.5A 715 ECPFU 404
404
700 408
700 408
700 408
702 408
702 408A
702 408A
702 411
702 430
800 430A
800 430B
802 431
802 431A
SHLD 431B
SHLD 432
SHLD 432A
SHLD 452
SHLD 452
SHLD 452
SHLD 452
SHLD 455
SCW 455
INW 455
CAVW PSS
CAVA ESRB
CAVB SPARE
COM 502
EJW 502
CPW 502
CLW 502
710A 502
712B 502
713A 502
GHFB+ 502 100614
GHFB- 502 100615
GH+ 502 100615
GH- 502 101012
X+ 502 101015
X- 502
CNFB+ 502
CNFB- 502
CN+ 502
CN- 502
CP+ 502 SPARE
CP- 502
ECV+ 503
ECP+ 503 501
ECP- 503 501
IL 1 504
IS 1 504
SPARE 501
504
504
504A 502
504A
502
504A
TB 1 TB 2
L25 502
100604
100605 SPARE
Figure 7-4. TYPICAL ANALOG TERMINAL STRIPS 100606
100607 SPARE
100610
100611
100612

MHT-1047 Page 7-12 MHTM(AB)-1/01

MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

POWER SUPPLY
AB 1771-P7

PLC 5/40E

PROCESS CONTROL MODULE

AB 1771 QDC0

PROCESS CONTROL MODULE

AB 1771 QDC1

TEMPERATURE CONTROL MODULE

AB 1771 TCM

SPARE

RACK 0
INTERFACE MODULE
AB 1771 SPI

16PT 24VDC OUTPUT MODULE

AB 1771 OBD

16PT 24VDC INPUT MODULE

AB 1771 IBD

16PT 24VDC ISOLATED OUTPUT

AB 1771 OQ16

16PT 24VDC ISOLATED OUTPUT

AB 1771 OQ16

16PT 24VDC INPUT MODULE

AB 1771 IBD
RACK 1

SPARE

SPARE

Figure 7-5. CONTROLLER CIRCUIT CARD CONFIGURATION

MHT-1047 Page 7-13 MHTM(AB)-1/01
ELECTRICAL MAINTENANCE MAINTENANCE MANUAL

7.9.1.1.6. Local bus VGA flat-panel controller with bit acceleration features supporting 640X480 by 16 and/
or 256 colors.
7.9.1.1.7. Batery-backed, real-time calender clock with an estimated life of seven years.

7.9.1.2. OI COMMUNICATIONS consists of the following:

7.9.1.2.1. DB-25 parallel port connector.

7.9.1.2.2. COM A: 25 pin Sub-D connector capable of either RS-232E or RS422A/425 serial communica-
tions.
7.9.1.2.3. COM B: An industry standard (IBM compatible) 9 pin Sub-D connector for RS232E serial
communications.
7.9.1.2.4. Ethernet connectors: RJ-45 10-Base T connector, a female DC-15 AUI connector.
7.9.1.2.5. Externarl floppy drive connector.
7.9.1.2.6. Standard 5 pin DIN keybord connector for 101-key enhanced PC/AT compatible keyboard.
7.9.1.2.7. External speaker jack.
7.9.1.2.8. Additional expansion slots.

ATTENTION

7.9.2. STATIC SENSITIVE ELECTRONIC DEVICES

HANDLING PRECAUTIONS REQUIRED. USE THE PROVIDED GROUNDING WRIST STRAP WHEN
HANDLING.
DO NOT REMOVE OR INSERT CARDS (MODULES) WITH POWER ON.

ATTENTION
STATIC SENSITIVE
ELECTRONIC DEVICES

HANDLING PRECAUTIONS REQUIRED.

USE THE PROVIDED GROUNDING STRAP
WHEN HANDLING.

DO NOT REMOVE OR INSERT

CARDS (MODULES) WITH POWER ON.

MHT-1047 Page 7-14 MHTM(AB)-1/01

MAINTENANCE MANUAL ELECTRICAL MAINTENANCE
DANGER

IMPROPER HANDLING CAN CAUSE A LITHIUM BATTERY TO CATCH FIRE AND EXPLODE. DO NOT
RECHARGE OR DISASSEMBLE THE BATTERY. DO NOT EXPOSE THE BATTERY TO WATER, OPEN
FLAMES, OR TEMPERATURES ABOVE 100° C (212° F). ALWAYS REMOVE POWER FROM THE RACK
PRIOR TO REPLACING THE BATTERY.

WARNING

TO PREVENT THE LOSS OF DATA, SETPOINTS, ACCESS CODES ETC., BEFORE REPLACING THE
LITHIUM BATTERY INSURE THAT THE CAPACITANCE BACKUP CIRCUIT HAS BEEN FULLY
CHARGED BY MAINTAINING POWER TO THE CARD RACK FOR A MINIMUM OF EIGHT HOURS.

A replaceable 3 volt AA Lithium Battery is mounted inside the Operator Panel. The voltage level of the
battery can be measured across the positive and negitive terminals. Note that if the voltage falls below
approximately 2.0 volts, the battery for all practical purposes is dead. Replacement batteries which must be
the same type, size, and voltage and are available through the Van Dorn Demag Parts Department. Always
ensure correct polarity when replacing batteries.

7.10 CONTROLLER INSTALLATION

7.10.1. MODULE REMOVAL AND INSTALLATION

Refer to Figure 7-3 for the Control Card Rack assembly. When replacing a card, first lift the cover that secures
the cards into the rack. There will be a locking tab located at the top right side of each card, firmly press the tab
to the top rear of the rack. This should unlock the module and allow it to be tilted towards you and out of the
rack. At this point the module can unpluged and removed or replaced. Carefully reverse the procedure to
reinstall the module. Note: Insure that the locking tab is secured. The operation of the machine could be
affected if a module is not securely mounted to the back plane.

Note: Do NOT switch cards from one machine to another. Firmware variations between machines may not
match. Also, do NOT switch card positions in the rack. Connecting the wrong module into a position on the
backplane could cause permanent damage to the controller and/or module. Refer to the Control Wiring Diagram
supplied with your machine for module card locations.

7.10.2. MODULE WIRING

The majority of the controller connections are accomplished via the back plane. The wiring connections to and
from the sensors, valves, etc. are made through wiring terminals. Refer to the Control Wiring drawing supplied
with the machine for detailed connections and wiring.

The System Power Supply must be connected to either a 115 or 220 volt AC input. (Range of 94 to 132 or 187
to 264 volts AC) Input connections should be made to the front panel terminals labeled L1, N, and ground.
Insure that the voltage selector switch is set to the appropriate voltage.

7.10.3. GROUNDING

Electrical Safety grounding should follow the recommendations of the National Electrical Code and all local
codes. In addition to safety ground, a good earth ground is required to insure that true ground potential exists in
the panel and at each module. This will insure that all signals are referenced to the same ground. Refer to the
Installation Section of this manual for additional grounding information.

Earth ground (not from a water pipe ) should be brought into the panel using a braided copper ground strap or
with a No. 6 (or larger) gauge wire. Earth ground should also be connected to the machine as per all national
and local codes. Be sure that the ground connection makes good metal-to-metal contact with the panel.
MHT-1047 Page 7-15 MHTM(AB)-1/01
MAINTENANCE MANUAL ELECTRICAL MAINTENANCE

Remove all paint and any metal filings, and bolt the ground connection directly to the panel. On the inside of the
panel connect a similarly sized wire to the ground distribution block.

Each card should be connected to the ground distribution block using No. 16 or No. 18 gauge wire. Do not
daisy chain the ground connections from module to module as this could cause ground loop problems. Be
extremely ‘ground-conscious’ to maintain immunity from electrical noise transients, power surges, and lightning
transients. Refer to the Wiring Diagram supplied with your machine for specific ground wires.

7.10.4. AC POWER ELECTRICAL NOISE CONSIDERATIONS

For optimum performance, electronic instruments should not be operated at the low end of their input voltage
rating for extended periods of time. If the electrical service is subject to brownouts or low voltage conditions, a
voltage regulating transformer may be required. Use of this type of transformer will provide normal operating
voltages to the instruments under both high and low line voltage conditions. Size of the transformer must be
suitable to accommodate the entire control system.

Another major consideration is electrical noise. Plant environments are typically very noisy due to the action of
solenoids, relays, motor starters, and motors. These modules contain filters to provide system noise rejection.
Even so, ground connections and improper grounding techniques can create electrical noise problems. It is
extremely important, therefore that good ground connections be made and that ground loops be avoided.

Isolate AC lines from low level DC lines. The most critical wire routing in a panel and on the machine will include
the linear positioning transducer signals, transducer voltage supply and hydraulic pressure sensor leads. Be
especially careful in the routing of thermocouple leads as well. Induced switching transients can create unstable
operating conditions. The wiring and shield connections should be kept as short as possible for these reasons.

If you have any doubts whatsoever regarding any connections you are intending to make, call the Van Dorn
Demag Service Department, for assistance and/or approval.

MICROPROCESSOR CONTROLS CAN LOSE

SETPOINTS AND/OR ACTUAL DATA AND CAN
MALFUNCTION AS A RESULT OF ELECTRICAL NOISE IN THE
CONTROL SYSTEM.

TO AVOID THESE PROBLEMS:

DO NOT:
1 - INSTALL RELAYS OR OTHER DEVICES IN
THE CONTROL PANEL.
2 - OBTAIN POWER FOR OTHER DEVICES FROM
THE CONTROL TRANSFORMER.
3 - RUN WIRING FROM OTHER DEVICES ALONG
WITH MACHINE CONTROL WIRING.
DO:
PUT NOISE SUPPRESSORS ON ANY DEVICES
CONNECTED TO INPUTS OR OUTPUTS OF THE
CONTROL.

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ELECTRICAL MAINTENANCE MAINTENANCE MANUAL

7.11 CONTROLLER MAINTENANCE

7.11.1. OPERATING ENVIRONMENT

Modules are installed in a suitable enclosure which will minimize or prevent the accumulation of dust, dirt, or
other particles which could build up and clog the cabinet ventilation slots. The slots provide a means for free air
flow which is necessary to ensure adequate heat dissipation. Periodic inspections should be scheduled to
insure that the slots do not become clogged.

CAUTION

CLEANING SHOULD BE PERFORMED USING A VACUUM CLEANER. DO NOT USE COMPRESSED AIR AS THIS
COULD FORCE PARTICLES INTO THE MODULES AND ACTUALLY WORSEN CONDITIONS.

Air temperature within the enclosure must not exceed 140°F (60°C) for the system modules. Sufficient space
between the cards is provided. This space is necessary to allow for installation of wire troughs and also for free
air flow around cards.

Since the enclosure contains other components that could cause heat generation above 140°F (60°C), fans are
installed in the control cabinet doors, to provide a positive pressure and adequate air flow. Air filters are installed
on the front panel door to keep out dirt and other contaminants. These filters must be cleaned weekly by
removing the snap-on vent cover, removing the filter, washing in solvent and blowing dry in the reverse direction
to normal air flow.

7.11.2. SUMMARY

7.11.2.1. Insure that all cards and connectors are firmly seated and secured.
7.11.2.2. Inspect module ventilation slots to ensure they are not clogged. Clean with vacuum cleaner
only.
7.11.2.3. Periodically inspect the fans for proper operation.
7.11.2.4. Clean the air intake filter weekly.

MHT-1047 Page 7-17 MHTM(AB)-1/01

 SECTION 8

TROUBLESHOOTING

8.1 MACHINE TROUBLESHOOTING

The following section of this manual is designed to help maintenance personnel isolate the cause of a fault condition.
Once recognized, refer to the appropriate section of this manual along with the drawings supplied with your machine to
adjust, repair, and/or replace the faulty component.

The following hints should be considered prior to becoming involved in lengthy troubleshooting procedures. When
troubleshooting, always refer to your control and hydraulic diagrams as well as the sequence diagram which is currently
supplied as a part of the hydraulic diagram. It is recommended that prior to troubleshooting the system, maintenance
personnel possess a good understanding of the information contained in both the Operator and Maintenance Manuals,
especially the information contained in the Safety Section.

A voltmeter will be necessary to verify electrical signals and pressure gauges will be required to check the hydraulic
system pressures.

8.1.2. ELECTRICAL

Most electrical fault conditions are the result of active components such as limit switches, solenoids, etc. Because
a limited number of causes result in a specific malfunction, it is usually a simple matter to isolate a malfunction to
an electrical or hydraulic malfunction. A logical thinking process is the key to efficient troubleshooting. Refer to the
following example for some basic troubleshooting techniques.

8.1.2.1. The mold will not close (in semi auto or auto) — The first consideration should be to insure that the Front
Gate limit switch (5LS) is actuated. Remember that the safety features play an important part in the
machine's operation. Refer to the Sequence Diagram, it will show both standard and selective sequences
and indicate which solenoids, limit switches, timers, etc. must be actuated for a specific function to occur.
For this example, the Mold Fully Open (6LS), Screw Fully Retracted (7LS), and Ejector Retracted (8LS)
limit switches (or linear positioning devices) all determine whether or not the clamp will close.

Use the Pro-Set 700® Diagnostics system if a failure is encountered. There are several procedures which can be
followed to isolate the failure to a particular module, device, or connection. These procedures are outlined later in
this section of the manual.

The Pro-Set 700® Controller incorporates a modular design. If a module within the controller should fail, it can be
easily replaced without having to perform any rewiring. Refer to the Electrical Maintenance Section of this manual
for an explanation of the individual modules and their functions within the system.

Because the machine operates in an orderly sequential manner it is recommended that maintenance personnel take
the time to learn the sequence of operation, so that if a fault should occur, the time required to isolate the fault will
be minimum. Monitor the Diagnostics Screen and refer to the Hydraulic Sequence Diagram while the machine is
operating, to associate the machine steps with the actuation of the various valves and sensors. The Pathfinder
Control System is designed with diagnostics capabilities which notify the operator of a fault condition. This feature
together with the capabilities to monitor Input, Output, and Memory Logic signals allows personnel to isolate the
cause of various faults.

HTM-1047 Page 8-1 MHTM(AB)-1/01

TROUBLESHOOTING MAINTENANCE MANUAL

8.1.2. HYDRAULIC

This machine has been designed using commercial and Van Dorn Demag components to operate the machine smoothly
and efficiently. Problems could occur as a result of changing or substituting component parts. Each component must
be compatible with and form an integral part of the total system.

8.1.2.1. Examples of substitutions

8.1.2.1.1. An inadequate size strainer on the inlet side of the pump can cause cavitation.
8.1.2.1.2. Inadequate line sizes or fittings and sharp bends will restrict hydraulic flow.

8.1.2.2. Knowing the system is the greatest aid to troubleshooting. Every component has a purpose.

8.1.2.2.1. Know that a solenoid controlled directional valve can be manually actuated to allow detection
of a faulty valve. (NOTE: Exercise extreme caution when checking solenoid operation,
machine motion could occur. Always follow safe maintenance practices.)
8.1.2.2.2. Each system component has a maximum rated speed, torque, or pressure. Overloading the
components will increase the likelihood of failure.
8.1.2.2.3. Remember that if a pressure setting is too low, reduced actuator speed may result.

8.1.2.3. Learn the machine's operating sequence to develop systematic troubleshooting procedures. Tracing flow
paths can often be accomplished by listening for flow in the lines or feeling the lines for warmth.
Recognizing trouble indicators is acquired through experience.

8.1.2.3.1. Excessive heat at the motor, pump, or relief valve may be caused by: worn or damaged parts
within the component, an incorrect valve setting, excessive load, overheated fluid, etc. (Note
that overheated fluid may be caused by a faulty cooling system, incorrect fluid viscosity, dirty
or low fluid level, improper setpoints, system pressure relief or unloading valve set too high,
or worn pump, valve, motor, cylinder or other component.
8.1.2.3.2. Excessive noise at the pump may be caused from cavitation, air in fluid, misaligned coupling,
or a worn or damaged pump. Excessive noise at a relief valve may be caused by its setting
being too low or too close to another valve setting, or a worn poppet or seat.
8.1.2.3.3. Low or total loss of fluid flow may be caused by a faulty or inoperative pump, flow control valve
that is faulty or set too low, the entire flow passing over a relief valve or unloading valve, an
incorrect setting for the relief or unloading valve, a worn pump, valve, motor, cylinder, or other
component, or a directional control valve set in the wrong position, etc.
8.1.2.3.4. A total loss of pressure may be the result of no fluid flow. Low pressure may be caused by;
a pressure control valve set too low or a damaged pump, motor, or cylinder. Erratic pressure
may be the result of; air in the fluid, worn relief valve, contaminated fluid, or a worn pump,
motor, or cylinder.

8.1.2.4. The following are some simple maintenance procedures which have a great effect on hydraulic performance.

8.1.2.4.1. Maintain a sufficient quantity of oil in the oil reservoir

8.1.2.4.2. Maintain the recommended hydraulic oil temperature.
8.1.2.4.3. Maintain fluid cleanliness by changing filters and cleaning strainers.
8.1.2.4.4. Insure that the pump inlet connections are tight to prevent aeration.

For additional information concerning the hydraulic system, refer to the manufacturer's component information.

MHT-1047 Page 8-2 MHTM(AB)-1/01

MAINTENANCE MANUAL TROUBLESHOOTING
8.2 SEQUENCE DIAGRAM

The Sequence Diagram, refer to the example in Figure 8-2 or the Hydraulic Diagram supplied with your machine, is
part of your system's Hydraulic Diagram. This chart is designed to illustrate the various machine sequences from the
point of their initiating signals to their resulting functions. An X located below a solenoid indicates that the solenoid is
energized. The state of the proportional valve is listed below the valve title with any additional notes located to the right of
the diagram. For example, after the function; Clamp Slow Down with Low Pressure has been completed and the machine
reaches the Lock-up (Mold Safe) Position (10LS made) in Step 3, the following conditions must be met to perform the
Function - Close Prefill - Start 2TD Mold Safe Delay (Refer to Figure 8-2.):

Initiating Signal — 10LS made (Mold Safe Position)

Solenoid Y activated — Injection Carriage Forward
Solenoid BU activated — Clamp Buildup
Solenoid JJ activated — Prefill Close
Solenoid CE activated — Clamp Enable
Solenoid CN activated — Clamp Volume (Operator Selectable)
Solenoid CP activated — Clamp Pressure (Operator Selectable)
Note: During the Mold Safe Sequence, all other solenoids are de-energized, while zero is applied to all the other
proportional valve solenoids.
Resulting Function — Close Prefill - Start 2TD Mold Safe Delay

Figure 8-2. EXAMPLE OF TYPICAL SEQUENCE CHART

HTM-1047 Page 8-3 MHTM(AB)-1/01

TROUBLESHOOTING MAINTENANCE MANUAL

8.3 MACHINE TROUBLESHOOTING GUIDE

Most machine operations that cause loss of cycle time, erratic machine operation, or inhibit machine operation,
trigger an error message on the control panel. A listing of some of the basic types of machine faults, as well as some
that may not appear as an error message are listed in the following steps. These examples are not intended to be all
inclusive, but should be used as a guide to logical troubleshooting techniques.

8.3.1. Clamp will not Close

8.3.1.1. Insure that the Front Operator Gate is closed (5LS and safety gate hydraulic interlock valve actu-
ated).

8.3.1.2. Insure that the Ejector Fully Retracted position has been reached.

8.3.1.3. If operating in the Semi or Auto Mode, insure that the screw is at the Shot Size Position (LP7).

8.3.1.4. If operating in the Auto Mode, insure that the Mold Open Timer (TR1) is timed out.

8.3.1.5. Check the Clamp Close Speed Setting.

8.3.1.6. Check operation of the Clamp Enable solenoid (CE) valve.

8.3.1.7. Check operation of the Clamp Pressure Build Up solenoid (BU) valve.

8.3.1.8. Check operation of the Prefill Close solenoid (JJ) valve.

8.3.1.9. Check operation of the Clamp Proportional Pressure Relief Valve (CP). Note that a quick way to
check the operation of the valve is to reset the mold open position setpoint to a value that is greater
than the current value, then attempt to open the mold. If the clamp opens further, the problem is
most likely safety related, for example, either the CE or the hydraulic interlock valve operation is
being blocked.

8.3.2. Clamp Closes Slowly

8.3.2.1. Check Low Pressure Speed setting.

8.3.2.2. Check Low Pressure/Slow Close Position setting (9LP).

8.3.2.3. Check operation of the CP Proportional Relief Valve.

8.3.2.4. Check for proper operation of the Clamp Volume proportional control valve (CN).

8.3.2.5. Check for operation of the Clamp Regenerative Control solenoid (RG) during close clamp operation.

8.3.3. No Clamp Low Pressure/Slow Close

8.3.3.1. Check Low Pressure/Slow Close Position setting (9LP).

8.3.3.2. Check Low Pressure/Slow Close Speed and Pressure setpoints.

8.3.3.4. Check operation of the CP Proportional Relief Valve.

8.3.3.5. Check for proper operation of the Clamp Volume proportional control valve (CN).

8.3.4. Clamp Movement does not Function Smoothly

MHT-1047 Page 8-4 MHTM(AB)-1/01
MAINTENANCE MANUAL TROUBLESHOOTING

8.3.4.1. Check the tie rods and associated bushings for signs of scoring, hot spots or lack of lubrication.

8.3.4.2. If a problem occurs only in the Low Pressure/Slow Close Sequence, check that the Pressure
setting is sufficient.

8.3.4.3. Check machine level.

8.3.4.4. Check clamp main ram gland packing, if work was recently done in this area. Packing may be too
tight. Check Section 4 of this manual for the correct gland packing maintenance procedure.

8.3.5. Clamp Slams When Closing

8.3.5.1. Check Low Pressure/Slow Close Position setting (9LP).

8.3.5.2. Check Low Pressure/Slow Close Flow and Pressure setpoints.

8.3.5.3. Check the clamp position sensor zero calibration.

8.3.5.4. Check operation of the Clamp pressure proportional relief valve CP.

8.3.5.5. Check operation of the Clamp proportional directional valve CN.

8.3.6. Clamp Slams When Reaching the Full Open Position

8.3.6.1. Check the Open Slow Speed setting entered on the Clamp Setup Screen.

8.3.6.2. Check the Mold Open Slow Position setting on the Clamp Setup Screen (12LP).

8.3.7. No Injection Start

8.3.7.1. Insure that the Front Operator Gate is closed. (5LS) (All modes of operation)

8.3.7.2. Check Purge Guard Limit Switch position and operation (99LS). (All modes of operation)

8.3.7.3. Check for proper barrel heats — Temperature Low.

8.3.7.4. Injection Unit Selector Switch must be On.

8.3.7.5. Check for obstructions in the mold area which could prevent the mold from closing completely.

8.3.7.6. Check Mold Safe Position setting (10LP). (May prevent Clamp Lockup in Semi or Auto Modes.)

8.3.7.7. Check Clamp Lock-Up Dimension (in.) Setting and also the Clamp Lock-up Pressure (1PS) setting
(setpoint in Tons). 1PS must be set less than the setting for Clamp Lockup Tonnage (setpoint in
PSI).

8.3.7.8. Check clamp pressure transducer readout.

8.3.7.9. Check operation of the Proportional Flow/Pressure Control Valve GH.

8.3.8. No Injection Velocity (Boost) Sequence (Hold Sequence operating properly)

8.3.8.1. Check Boost Timer setting.

HTM-1047 Page 8-5 MHTM(AB)-1/01

TROUBLESHOOTING MAINTENANCE MANUAL
8.3.8.2. Check Boost Cutoff by Position setting, if selected.

8.3.8.3. Check Boost Cutoff by Pressure setting, if selected.

8.3.8.4. Check Boost Cutoff by Cavity Pressure setting, if selected.

8.3.8.5. Check Injection Speed and Pressure settings.

8.3.9. Screw Will Not Rotate

8.3.9.1. Insure that the front gate is closed (5LS).

8.3.9.2. Insure that the Purge Guard is in position and limit switch 99LS is actuated.

8.3.9.3. Insure that the actual temperature readings on the barrel and nozzle heater zones are at the set
temperatures — Temperature Low.

8.3.9.4. Check Screw Rotate solenoid valve (X) operation.

8.3.9.5. Check Screw Motor operation.

8.3.10. Screw Rotates But Does Not Retract

8.3.10.1. Insure that the feed throat is not bridged with material, the shutoff is open, and the hopper is not
empty.
8.3.10.2. Insure that the actual temperature readings on the barrel and nozzle heater zones are at the set
temperatures and that the temperatures are proper for the material being processed.

8.3.10.3. Check for barrel obstructions.

8.3.10.4. Check for excessive Back Pressure.

8.3.11. No Back Pressure (minimum 50 psi)

8.3.11.1. Insure that the Back Pressure feature is selected On.

8.3.11.2. Ensure sufficient Back Pressure settings on the Recovery Profile Screen.

8.3.11.3. Ensure proper settings for the position parameters on the Recovery Profile Screen.

8.3.11.4. Check operation of the Injection Solenoid (H). (Must be energized during screw rotation for controlled
Back Pressure.)

8.3.11.5. Check Pullback (Back Pressure) Limit adjustment on the Injection Calibrate Screen. (This should be
set to limit pressure to 300 psi.)

8.3.12. No Screw Pull Back or Pulls Back Slowly

8.3.12.1. Check Screw Pullback Delay Timer operation.

8.3.12.2. Check Shot Size Position Setting (7LP).

8.3.12.3. Check for sufficient Speed and Pressure settings.

8.3.12.4. Check Screw Pullback solenoid operation (L).

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MAINTENANCE MANUAL TROUBLESHOOTING

8.3.13. Clamp Will Not Open

8.3.13.1. Check for sufficient Open Slow Speed setting.

8.3.13.2. In all modes of operation — The front gate must be closed and (5LS) Limit Switch must be actuated.
(If the Optional Motion/No Motion switch is selected On, the clamp should open in the Semi Mode
only, Motion/No Motion has no affect in Auto Mode).

8.3.13.3. Check Clamp Decompress solenoid (DE) operation.

8.3.13.4. Check Proportional Valves (CN and CP) operation.

8.3.14. No Mold Open Slow

8.3.14.1. Check the Mold Open Slow Position setting on the Clamp Setup Screen (12LP).

8.3.14.2. Check the Mold Open Slow Speed setting.

8.3.15. Hydraulic Ejectors Will Not Move Forward

8.3.15.1. In all modes — The front gate must be closed and (5LS) Limit Switch must be actuated. (If the
Optional Motion/No Motion switch is selected On, the clamp should open and the Ejectors should
move forward in the Semi Mode only, Motion/No Motion has no affect in Auto Mode).

8.3.15.2. Insure that the Hydraulic Ejector is selected On.

8.3.15.3. Check for obstructions at the movable platen or a misadjustment of the ejector plate mechanical
stops.

8.3.15.4. In the Manual Mode insure that the clamp is at the Full Open Position (6LP).

8.3.15.5. In the Semi or Auto Modes, check the Eject Start Position setting (34LP).

8.3.15.6. Check the Ejector Forward Speed and Pressure setpoints, located on the Eject/Core Screen.

8.3.15.7. Check operation of the Eject Forward Solenoid valve (R).

8.3.15.8. Check operation of the Eject Proportional Flow Control valve (ECV) located on the Pump Manifold.

8.3.15.9. Check operation of the Eject Proportional Pressure Control valve (ECP) located on the Pump
Manifold.

8.3.16. Hydraulic Ejectors Will Not Retract

8.3.16.1. Insure that the Front Operator Gate is closed and 5LS Limit Switch is actuated.

8.3.16.2. Check the Ejector Retract Speed and Pressure setpoints located on the Eject/Core Screen.

8.3.16.3. Check operation of the Eject Proportional Flow Control valve (ECV) located on the Pump Manifold.

8.3.16.4. Check operation of the Eject Retract solenoid (RT).

8.3.16.5.Check operation of the Eject Proportional Pressure control valve (ECP), located on the Pump Mani-
fold.

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MAINTENANCE MANUAL TROUBLESHOOTING

8.4 STANDARD ERROR AND OPERATION MESSAGES

The Error and Operation Messages are designed to notify personnel of an unmade condition or a malfunction, and to
aid service personnel in isolating a malfunction to a specific component or module.

There is a seperate, more complete list of alarms especially for the Pro-Set 700® control that is include in the
user manuals supplied with the control system.

The following Error and Operation Messages will appear on the display, when they are sensed by the control sys-
tem. The messages that contain three numbers and end in Output Error, are the result of an illegal or missing signal at
the control system's output. Note that if optional equipment has been installed, additional error messages may appear.

XXX OUTPUT ERROR

The XXX represents an output device, for example, SOL WV OUTPUT ERROR. This indicates that the
output signal to the listed device was not detected. Check output source voltage, output card, wiring,
supply voltages, and also check for a possible short at the device. Note, to reset the error it may be
necessary to toggle the machine power off then on.

AUTO HEATER STARTUP IN PROGRESS

This message indicates that the Auto Heater function is active and is heating to the temperature
setpoints listed on the Temperature Screen. Refer to the Temperature Screen for information on the
Auto Heater Setup.

AUTOMATIC HEATER STARTUP MODE IS ENABLED

When the Auto Heater Startup feature is selected on, all semi and auto machine operations will be
inhibited. Select the feature off to enable the semi and auto modes of operation. Refer to the Auto Heat
Setup window located on the Temperature Screen.

AUTO HEATER STARTUP TIMED OUT

This message will be displayed if the Auto Heater function has been enabled and the heater bands have
been energized for more than two hours without operator intervention. If the Heat function (Temperature
Screen) is not selected on, within the two hour time period, in addition to the message being displayed,
power will be removed from the heater bands.

AUTO PURGE IS SELECTED ON

This message indicates that the Auto Purge Cycle has been selected on and a machine function was
called for. Note that while the machine is running the Auto Purge Cycle, all other machine functions will
be inhibited.

AUTO PURGE NOT SELECTED

This message indicates that the Purge pushbutton was pressed while the Auto Purge feature was not
enabled.

BARREL TEMPERATURE ABOVE HIGH DEV LIMIT

Indicates that the actual temperature of the designated zone exceeded the high deviation limit (Deg + on
the Temperature Screen). The deviation limits should be set to values which will be attained prior to the
point where excessive heat will affect the part quality. In addition to the error message being displayed,
the alarm bell and light will also be activated and cannot be reset until the cause of the high deviation is
corrected.

BARREL TEMPERATURE ABOVE HIGH LIMIT

Indicates that one or more of the barrel zone temperatures has exceeded the High Alarm Limit.

MHT-1047 Page 8-8 MHTM(AB)-1/01

TROUBLESHOOTING MAINTENANCE MANUAL

BARREL TEMPERATURE BELOW LOW DEV LIMIT

Indicates that the actual temperature of the designated zone is less than the low (Deg - on the Temperature
Screen) deviation limit. The deviation limits should be set to values which will be attained prior to the point
where low heat will affect the part quality. In addition to the error message being displayed, the light will be
illuminated and the Screw Rotation, Injection, and Pullback sequences will also be inhibited.

BARREL TEMPERATURE BELOW LOW LIMIT

Indicates that one or more of the barrel zone temperatures fell below the Low Alarm Limit. This condition is
usually indicative of a defective thermocouple. In addition to the error message being displayed, the light
will be illuminated if the Injection Function is on and Screw Rotation, Injection, and Pullback will also be
inhibited.

CABINET TEMPERATURE WARNING - CHECK FAN

Indicates that the temperature of the Control Cabinet exceeded a preset cabinet temperature warning limit.
Check the fan for proper operation and clean the filter.

CLAMP IS NOT DECOMPRESSED

Indicates that the pressure at the clamp pressure sensor did not fall below the manufacturer set decom-
press setting within the designated time period.

CLAMP LOCKUP FAILED, CYCLE ABORTED

Indicates that the clamp pressure did not build to the PS1 setting within a fifteen second time period. This
condition usually indicates defective pumps, excessive leakage, or the PS1 setpoint is set higher than the
tonnage setpoint.

CONTROL IS OFF
Indicates that the Control Switch, located below the operator panel, is in the off position or not suppling the
proper signal.

CORE NOT IN - LS 15
Indicates that the tripper on 15LS limit switch has not been made. If this message occurs, check the
position of the core assembly and the operation and position of limit switch 15LS.

CORE NOT OUT - LS14

Indicates that the tripper on 14LS limit switch has not been made. If this message occurs check the
position of the core assembly and the operation and position of limit switch 14LS. This condition will not
allow ejector or clamp movement.

CORE SEQUENCE SWITCH NOT ON

Indicates that the operator attempted to set core parameters without first selecting a Core Sequence.
Refer to the Eject Setup Screen description in Section 3 of this manual for additional information.

CYCLE STOPPED, PROD MON OUT OF TOLERANCE

Indicates that the function selected for production monitoring fell outside the operator entered tolerance
value. Refer to Section 3 in the operation manual for information on the Production Monitoring feature.

CYCLE STOPPED, SPC OUT OF TOLERANCE

Indicates that the function selected for SPC monitoring fell outside the operator entered tolerance value.
Refer to Section 3 in the operation manual for information on the SPC feature.

EJECTOR IS NOT FORWARD

Indicates that the ejector plate was not detected in the forward position. If this condition should occur,
machine cycling will be inhibited. Check for obstructions and also the Eject Forward position setpoint.

HTM-1047 Page 8-9 MHTM(AB)-1/01

MAINTENANCE MANUAL TROUBLESHOOTING

EJECTOR IS NOT RETRACTED

Indicates that the ejector plate was not detected in the retracted or zero position within a designated
time period. If this condition should occur, machine cycling will be inhibited. Check for obstructions and
also refer to the Clamp Calibrate Screen and zero the ejector sensor.

EJECTION IS OFF
Indicates that the Ejection feature has been selected off, and an eject function was called for while
operating in the Manual Mode.

EJECT START POSITION NOT ATTAINED

Indicates that the Eject Start position was not reached prior to the Mold Full Open Position. Check the
setpoint for the Eject Start Position in relation to the Mold Fully Open position. Also check the operation
of the clamp and ejector position sensors.

FRONT GATE IS OPEN, LS5

Indicates that the 5LS limit switch has not been made. This condition will inhibit the clamp from closing.
If this message occurs, close the front gate then if necessary, check the position of the limit switch
tripper.

FRONT GATE OPENED WITH PREHEAT ON

Indicates that the Preheat Function has been selected on but is disabled by an open Safety Switch
(LS5) signal. To resume Oil Preheat insure that the Front Gate is closed and the Front Gate Safety
Limit Switch is made.

FRONT GATE OPEN WITH MOLD SAFE, LS5

This message indicates that the front gate was opened while the machine was in the Lock-up Position.
If the gate is opened at this time, the machine will drop cycle and the cycle will need to be reinitiated.

FRONT GATE NOT CYCLED

Indicates that the Front Gate requires cycling before the machine will recycle while operating in the
Semi Mode or will start the initial cycle when operating in the Auto Mode.

FRONT GUARD IS OPEN, LS61

Indicates that the 61LS limit switch has not been made. This condition will shut the pump motors off. If
this message occurs, secure the front guard then if necessary, check the position of the limit switch
tripper.

INJECTION CARRIAGE NOT FORWARD, LS22

Indicates that the tripper on 22LS limit switch has not been made. If this condition should occur during a
machine cycle, the Injection Functions will be inhibited. Check the position of the injection carriage and
the operation of limit switch LS22.

INJECTION UNIT IS OFF

Indicates that the Injection Unit has been selected off and the Injection unit functions are inhibited. See
Inject Setup Screen.

LOW OIL LEVEL, FS1

Indicates that the oil has dropped below a safe operating level, as detected by float switch 1FS. If this
condition occurs, the machine will complete the current cycle then inhibit all additional cycles.

LOW PRESSURE OVERTIME

Indicates that the clamp did not travel from the Close Slow position to the zero position within the
operator set time period. This condition usually indicates a blockage between the mold halves or an
incorrect entry for the Close Slow Time Setpoint.

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TROUBLESHOOTING MAINTENANCE MANUAL

MAXIMUM CABINET TEMPERATURE EXCEEDED

This message indicates that the cabinet temperature exceeded the preset maximum limit. When this
error is detected the Auto and Semi machine functions will be inhibited.

MANUAL MODE NOT SELECTED

This message indicates that a manual function was called for while the machine was operating in the
Semi or Auto Mode.

MOLD IS NOT FULLY CLOSED

Indicates that the mold was not detected in the fully closed position (LP11). If this condition should
occur, machine cycling will be inhibited. Check for obstructions and also check the Clamp Zero Calibra-
tion.

MOLD IS NOT FULLY OPEN

Indicates that the mold was not detected in the Full Open position (LP6). If this condition should occur,
machine cycling will be inhibited. Check for obstructions and also the setpoint for the Full Open Posi-
tion.

OIL FILTER IN BYPASS, OFA or OFB

Indicates that an oil filter is clogged and the oil is no longer being totally filtered. This condition will not
inhibit machine operation but it should be noted that when a filter is in bypass, oil is not being filtered or
only being partially filtered. Replace the oil filter as soon as possible.

OIL PREHEAT IS COMPLETE

This message indicates that the Preheat sequence has been completed and the oil is at operating
temperature.

OIL PREHEAT IS ON
Indicates that the Preheat Function is active. This condition will not inhibit manual operation but will
inhibit machine cycling until the preheat sequence is complete. The Preheat sequence will automati-
cally switch off when the oil is at operating temperature.

OIL TEMPERATURE; HIGH ALARM EXCEEDED

Indicates that the actual oil temperature is greater than the factory set high oil temperature limit.

OVERALL CYCLE TIMER TIMED OUT

Indicates that the machine did not complete a cycle within a designated time period. Check the Overall
Cycle setpoint, entered on the Clamp Setup Screen, to ensure an adequate amount of time for the
cycle. Also check for conditions that could increase cycle time, for example, lack of material.

PRODUCTION COMPLETE
This message is used in conjunction with the machines Production Monitoring feature. When this
message appears the number of required parts has been produced for the current production run. Refer
to the description of the Production Monitor feature for additional information.

PUMP MOTOR IS OFF

Indicates that the pump motors have not been started or that the motors have been shut off.

PUMP ON WITH SAFETY GATE OPEN

This message indicates that the front operator gate shows an open circuit while the pumps motors are
running. This is a false error probably resulting from a loose or disconnected cable connector.

PURGE GUARD OPENED WITH PREHEAT ON

Indicates that the Preheat Function has been selected on but is disabled by a Purge Guard Open
signal. To resume Oil Preheat insure that the Purge Guard is closed and the limit switch is tripped.

HTM-1047 Page 8-11 MHTM(AB)-1/01

MAINTENANCE MANUAL TROUBLESHOOTING

PURGE GUARD OPEN WITH LOCK-UP, LS99

This indicates that the Purge Guard limit switch is not tripped when the machine is in the Lock-up
Position. Insure that the Purge Guard is down and the limit switch is tripped.

PURGE GUARD IS OPEN, LS99

Indicates that the 99LS limit switch has not been made. This condition will inhibit the injection unit
functions as well as the Semi and Auto Modes of operation. If this message occurs, close the purge
guard and check the position of the limit switch tripper.

PURGE IN PROCESS. PRESS PURGE TO HALT

This message indicates that the Auto Purge Cycle is active. Note that while the machine is running the
Auto Purge Cycle, all other machine functions will be inhibited. Press the Purge key to temporarily
suspend the Auto Purge Cycle. Pressing the Purge key again will allow the purge cycle to resume. To
abort the purge cycle, the Auto Purge Sequence must be disabled by accessing the Auto Purge
window from the Inject Setup Screen and selecting Enable off. Note, to select the feature off highlight
the Enable prompt and press the Enter key.

REAR GUARD IS OPEN, LS1

Indicates that the 1LS rear guard limit switch has not been made. This condition will stop pump motor
operation. If this message occurs, close the rear guard, then if necessary, check the position of the
limit switch tripper.

REAR GUARD IS OPEN LS1A

Indicates that the 1ALS redundant rear guard limit switch has not been made. This condition will inhibit
the clamp from closing. If this message occurs, close the rear guard then if necessary, check the
position of the limit switch tripper.

SCREW DECOMPRESSION ABORTED

Indicates that the screw did not pull back the operator designated distance, as determined by the
Decompress Before or After Position setting. If this condition should occur, machine cycling will be
inhibited. Check the setpoint entries for Decompress Before and After Rotate and/or the operation of
the screw position potentiometer. Note that this condition is generally caused by Low Pressure
setpoint entry that is set too low.

SCREW IS NOT RETRACTED

Indicates that the screw was not detected in the retracted position (LP7). If this condition should occur,
machine cycling will be inhibited. Check the setpoint entry for the Shot Size Position.

SCREW ROTATE TIMER TIMED OUT

This message indicates that the Actual Screw Rotate Time was longer than the setpoint limit. If this
condition occurs, the current machine cycle will be completed and all additional cycles will be inhibited
until the Auto Mode is reset.

TRY AGAIN; FIRST TRY

Indicates that the clamp did not reach the Mold Safe Position with the Try Again Function selected on.
With the function active, the machine will try a second time to reach the Lock-up or Zero Position as
described in the Try Again description in Section 3 of the operation manual.

MHT-1047 Page 8-12 MHTM(AB)-1/01

 TABLE OF CONTENTS

SECTION 9

MACHINE SET-UP

PARAGRAPH SUBJECT PAGE

9.1 GENERAL INFORMATION .............................................................................................. 9-1

9.2 GENERAL NOTES..................................................................................... ..............9-2

9.3 PRELIMINARY PROCEDURES AND SETPOINT ENTRIES ............................................ 9-2

9.4 MACHINE SETUP PROCEDURES ................................................................................ 9-2

9.4.1-3 INITIAL PROCEDURES................................................................................9-2

9.4.4 VARIABLE VOLUME PUMP PRESSURE COMPENSATOR ............................ 9-2
9.4.5 VARIABLE VOLUME PUMP FLOW COMPENSATOR ..................................... 9-3
9.4.6 VALVE #211 ADJUSTMENT ............................................................................. 9-3
9.4.7 VALVE #221 ADJUSTMENT ............................................................................. 9-4
9.4.8 VALVES #308 & 313 ADJUSTMENT ................................................................ 9-4
9.4.9 CLAMP POSITION SENSOR ADJUSTMENT .................................................... 9-4
9.4.10 EJECT POSITION SENSOR ADJUSTMENT ..................................................... 9-6
9.4.11 SCREW POSITION SENSOR ADJUSTMENT ................................................... 9-6
9.4.12 SCREW ROTATE PROXIMITY SWITCH ADJUSTMENT ................................... 9-6
9.4.13 INJECTION PRESSURE TRANSDUCER ADJUSTMENT ................................... 9-6
9.4.14 CALIBRATION OF BARREL TEMPERATURES............................................. 9-9

9.5 PROPORTIONAL VALVE SPAN AND OFFSET INTITAL SETTINGS............................ 9-11

9.5.5 ADJUSTING VOLUME OR SPEED VALVES (XH,CN,RRT)............................ 9-11

9.5.6 ADJUSTING PRESSURE VALVE (G).......................................................... 9-12

9.6 RECOMMENDED INITIAL SETPOINT VALUES ................................................ ...........9-12

9.7 FULL AUTO MODE CALIBRATION FOR PROPORTIONAL VALVES ........................... .9-19
9.8 SAVING CALIBRATION VALUES .................................................................................. 9-24

MHT-1047 Page 9-i MHTM(AB)-1/01

MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE
SECTION 9
HT METRIC TOGGLE CLAMP WITH
ALLEN BRADLEY PRO - SET 700® CONTROLS
MACHINE SET-UP PROCEDURE
9.1 GENERAL INFORMATION
DANGER

THESE PROCEDURES SHOULD ONLY BE PERFORMED BY VAN DORN DEMAG TRAINED PERSONNEL. AN
INCORRECT SETUP COULD RESULT IN DEGRADED MACHINE PERFORMANCE AND/OR DAMAGE TO THE
MACHINE. THESE PROCEDURES ASSUME THAT PERSONNEL HAVE BEEN TRAINED IN ELECTRICAL, ME-
CHANICAL, AND HYDRAULIC MAINTENANCE PROCEDURES, AND ARE ALSO FAMILIAR WITH PROPER SAFETY
PRACTICES. CONTACT THE VAN DORN DEMAG SERVICE DEPARTMENT TO SCHEDULE A QUALIFIED SER-
VICE REPRESENTATIVE IF TRAINED PERSONNEL, AT YOUR FACILITY, ARE NOT AVAILABLE.

UNDER NO CIRCUMSTANCES SHOULD THE MACHINE BE OPERATED WITHOUT ALL PROTECTIVE

DEVICES IN PLACE AND FUNCTIONING PROPERLY. SAFETY SIGNS ARE FASTENED TO YOUR MACHINE AT
STRATEGIC LOCATIONS. PERSONNEL MUST UNDERSTAND ALL THE SAFETY INSTRUCTIONS BEFORE WORK-
ING ON THE MACHINE. READ AND UNDERSTAND THE SAFETY SECTION (SECTION 2) OF THE OPERATION
AND/OR MAINTENANCE MANUAL BEFORE PERFORMING THIS SETUP PROCEDURE.
Hydraulic test ports:

#17 — Clamp Manifold (300 thru 650 Ton)

#69 — Clamp Manifold (55 thru 230 Ton)
#92 — Injection Manifold (170 thru 400 Ton)
#110 — Injection Manifold (500 Ton)
#82 — Injection Manifold (55 thru 500 Ton)
#87 — Injection Manifold (55 thru 500 Ton)
#66 — Injection Manifold (55 thru 120 Ton)
#1 — Injection Manifold (170 thru 400 Ton)
#72 — Injection Manifold (55 thru 120 Ton)
#22 — Injection Manifold (650Ton)
#73 — Injection Manifold (650 Ton)
#7 — Injection Manifold (650 Ton)
#70 — Injection Manifold (650 Ton)
#44 — Pump Manifold (650 Ton)
#45 — Pump Manifold (650 Ton)
#46 — Pump Manifold (650 Ton)

VALVE DESCRIPTIONS / LOCATIONS

VALVE DESCRIPTION LOCATION
211 Fixed Pump Relief Valve Injection Manifold
221 (500Ton) Fixed Pump Relief Valve Injection Manifold
308 (650Ton) Fixed Pump Relief Valve Pump Manifold
313 (650Ton) Fixed Pump Relief Valve Pump Manifold
217 (170 to 400) Var. Pump Press. Control Injection Manifold
226 (500Ton) Var. Pump Press. Control Injection Manifold
302 (650Ton) Var. Pump Press. Control Injection Manifold
206 "G" Proportional Pressure Relief Valve Injection Manifold
201 "XH" Proportional Flow Directional Valve Injection Manifold
103 "CN" Proportional Flow Directional Valve Clamp Manifold
102 "RRT" Proportional Flow Directional Valve Clamp Manifold
209 (120Ton) Var. Pump Press. Control Injection Manifold

Table 9-1

MHT-1047 Page 9-1 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

9.2 GENERAL NOTES

9.2.1. This procedure was written to set the entire machine after assembly, therefore all of the steps required
to set the machine are listed below. When replacing components or checking the settings, it may not
be necessary to follow all of the major steps as described below. Adjustments will only be required to
any repaired or replaced components.

NOTE: The Setpoints shown in the following Figures should provide starting values if needed.

9.2.1.1. The initial setpoints for the proportional valve have been entered at the factory prior to shipment.
The objective is to control the voltage to the solenoid so that the range of voltage applied will result
in the full range movement of the valve. Reference paragraph 9.5 if a valve has been replaced or if
fine tuning is required for a specific application.

9.3 PRELIMINARY PROCEDURES AND SETPOINT ENTRIES

NOTE

PERFORM ONLY NECESSARY PROCEDURES. THE UNNECESSARY ADJUSTMENT OF COMPONENTS

COULD RESULT IN MAJOR REWORK, REDUCED MACHINE PERFORMANCE AND/OR DAMAGE TO THE
MACHINE.

9.3.1. Turn the control system on, enter the necessary setpoints and initial values for the machine.
Refer to the tables on pages 9-11 thru 9-16.

9.3.2. Refer to the manufacturer's information concerning the material being used and enter temperature
setpoints for each heat zone. With the barrel at room temperature, tune the barrel temperatures by
Barrel Temperature key and following the detailed instructions that are in Section 5 of this manual. Set
the Barrel High/Low Alarm limits. Insure that the Auto Control mode is selected for each zone or loop
after calibration is completed.

9.3.3. The Jog Speeds and Pressures are controlled independently from the speeds and pressures located
on the Clamp and Injection Profile Screens. These values are only active when the machine is func-
tioning in the Jog or Manual mode of operation.

9.3.4. It is recommended that the machine be operated using the current values and then slightly alter only
those that improve the performance of the machine.

9.3.5. Setpoints shown on screens in manual are generic values and are for reference only. Do not rely on
these values for machine setup.

9.4 MACHINE SETUP PROCEDURES

9.4.1. Verify that the Injection Function is selected On.

9.4.2. After pump repair or replacement, the pump pressure compensator will require adjustment, install a
pressure gauge in Port: #72 on the 55, 85 & 120 HT Injection Manifold; #77 on the 170, 230, 300, and
400 HT Injection Manifold; #87 on the 500 HT Injection Manifold; or #45 on the 650 HT Pump Manifold.

9.4.3. Start the pump motor and preheat the oil to 110°F.

9.4.4. Adjust the Variable Volume Pump Pressure Compensator as follows: Note that when adjusting valve
209 (55,85 and 120 Ton), 217 (170 and 400 Ton), 226 (500 Ton), or 302 (650 Ton) the pump pressure
will have to be increased to allow the valves to reach the pressure readings indicated in Steps 9.4.4.1.
through 9.4.4.4.

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

9.4.4.1. Procedure for 55, 85 and 120 HT machines

9.4.4.1.1. Install a pressure gauge in Port #72 on the Injection Manifold.

9.4.4.1.2. Probe Solenoid LC.
9.4.4.1.3. Adjust Valve #209 fully clock-wise.
9.4.4.1.4. Adjust the Variable Volume Pump Pressure Compensator to 2550 psi.
9.4.4.1.5. Adjust Valve #209 counter clock-wise to 2250 psi.
9.4.4.1.6. Adjust the Variable Volume Pump Pressure Compensator to 2150 psi.
9.4.4.1.7. Lock down the adjusters.

9.4.4.2. Procedure for 170, 230, 300 and 400 HT machines

9.4.4.2.1. Install a pressure gauge in Port #77 on the Injection Manifold.

9.4.4.2.2. Probe Solenoid LC.
9.4.4.2.3. Adjust Valve #217 fully clock-wise.
9.4.4.2.4. Adjust the Variable Volume Pump Pressure Compensator to 2550 psi.
9.4.4.2.5. Adjust Valve #217 counter clock-wise to 2250 psi.
9.4.4.2.6. Adjust the Variable Volume Pump Pressure Compensator to 2150 psi.
9.4.4.2.7. Lock down the adjusters.

9.4.4.3. Procedure for 500 HT machines

9.4.4.3.1. Install a pressure gauge in Port #87 on the Injection Manifold.

9.4.4.3.2. Probe Solenoid LC.
9.4.4.3.3. Adjust Valve #226 fully clock-wise.
9.4.4.3.4. Adjust the Variable Volume Pump Pressure Compensator to 2550 psi.
9.4.4.3.5. Adjust Valve #226 counter clock-wise to 2250 psi.
9.4.4.3.6. Adjust the Variable Volume Pump Pressure Compensator to 2150 psi.
9.4.4.3.7. Lock down the adjusters.

9.4.4.4. Procedure for 650 HT machines

9.4.4.4.1. Install a pressure gauge in Port #45 on the Pump Manifold.

9.4.4.4.2. Probe Solenoid LC.
9.4.4.4.3. Adjust Valve #302 fully clock-wise.
9.4.4.4.4. Adjust the Variable Volume Pump Pressure Compensator to 2550 psi.
9.4.4.4.5. Adjust Valve #302 counter clock-wise to 2250 psi.
9.4.4.4.6. Adjust the Variable Volume Pump Pressure Compensator to 2150 psi.
9.4.4.4.7. Lock down the adjusters.

9.4.5. After repairing or replacing the pump, set the Variable Volume Pump Flow Compensator Differential as
follows: Place the control in Setup mode. Set Manual Jogs to setpoints listed below:

9.4.5.1. Set the Hold Profile Pressure to 1000 psi for the maximum time allowable. On the Screw Jogs Screen,
set the "G" value to approximately 33.3 %. Refer to Figure 9-9.
9.4.5.2. Set the Screw Forward XH setpoint to: 70% on 55, 85 & 120 HT; 65% 170, 230, 300 & 400 HT; and
60% on 500 & 650 HT. Set the Hold Speed Time high enough as needed.
9.4.5.3. Install a pressure gauge in Port: #66 on 55, 85 & 120 HT (Injection Manifold); #01 on 170 through
400 HT (Inject Manifold); #85 on 500 HT (Injection Manifold) and #22 on 650 HT (Injection Manifold).
9.4.5.4. Push the Manual Inject Forward push-button and monitor the pressure on the gauge just
installed, during the Hold Sequence. Adjust the Injection Pressure if necessary to obtain 1000 psi.
9.4.5.5. Remove the gauge and install on Port #72 (Inject Manifold) on 55, 85 & 120 HT, Port #77 (Inject
Manifold) on 170 through 400 HT and Port #27 on 500 HT (Inject Manifold ) and #45 on 650 HT
(Pump Manifold). Call for Injection Forward and compare the pressure to the pressure read in
Step 9.4.5.4. If a difference of 200 psi (275 psi on 55, 85 & 120 HT) is present, adjustment is not

MHT-1047 Page 9-3 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

necessary. If the difference is more or less than 200 or 275 psi, adjust the Variable Volume
Pump Flow Compensator for a pressure differential between 200 to 275 psi.

Note: If an adjustment is made, it will be necessary to reset the pressure in Step 9.4.5.4. to 1000 psi,
and then repeat Step 9.4.5.5.

9.4.6. After repairing or replacing Valve #211, perform the following.

9.4.6.1. Procedure for 170, 230, 300, 400, and 500 HT Machines

9.4.6.1.1. On 170 - 400 HT machines, install a pressure gauge in Port #92 on the Injection Manifold.
On 500 HT machines, install a pressure gauge in Port #82 of the Injection Manifold.
9.4.6.1.2. Probe Solenoids LC and GG1.
9.4.6.1.3. Adjust Valve 211 for 2150 PSI.
9.4.6.1.4. Lock down the adjuster.

9.4.6.2. Procedure for 650HT Ton Machines

9.4.6.2.1. Install a pressure gauge in Port #7 on the Injection Manifold.

9.4.6.2.2. Probe Solenoids LC and GG3.
9.4.6.2.3. Adjust Valve 211 for 2150 PSI.
9.4.6.2.4. Lock down the adjuster.

9.4.7. After repairing or replacing Valve 221 (500 HT only) perform the following.

9.4.7.1. Install a pressure gauge in Port #110 on the Injection Manifold.

9.4.7.2. Probe Solenoid LC and GG2.
9.4.7.3. Adjust Valve 221 for 2150 psi.
9.4.7.4. Lock down the adjuster.

9.4.8. After repairing or replacing Valves 308 and/or 313 (650HT only) perform the following.

9.4.8.1. Install a pressure gauge in Port #46 on the Pump Manifold.

9.4.8.2. Probe Solenoids LC and GG2.
9.4.8.3. Adjust Valve 308 for 2150 PSI.
9.4.8.4. Lock down the adjuster.
9.4.8.5. Install a pressure gauge in Port #44 on the Pump Manifold.
9.4.8.6. Probe Solenoids LC and GG1.
9.4.8.7. Adjust Valve 313 for 2150 PSI.
9.4.8.8. Lock down the adjuster.

9.4.9. After replacing the Clamp Position Sensor, perform the following steps.

9.4.9.1. Manually close the Clamp completely. Select the Clamp Positioning Screen (see Figure 9-1).
9.4.9.2. Loosen the four clamp potentiometer retaining screws and position the potentiometer to achieve
0.5 Volts DC on the Clamp Positioning Screen (Real Time Values), retighten the retaining screws.
9.4.9.3. Enter this same value for the Analog Signal at Minimum Setpoint.
9.4.9.4. Manually open the Clamp to it's full open position or physical limit and note the Real Time Values.
9.4.9.5. Enter the Real Time Voltage Value for the Analog Signal at Maximum Setpoint.
9.4.9.6. Press the Download push-button to save the setpoints to the PLC module (Pro-Set 700® only).

NOTE: IT IS NOT NECESSARY NOR RECOMMENDED TO USE THE ZERO AXIS KEY TO ZERO THE CLAMP.

MHT-1047 Page 9-4 MSU.51-MHTM(AB)-1/01

MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

Clamp Position

Real-Time
Values
2.49 3.70
VDC INCHES
OPEN CLOSED
Name
Plate Active
Clamp Minimum Position 0.00 0.00
CLOSED
Analog Signal at Minimum Position 0.50 0.50
Clamp Maximum Position 17.00 17.00
OPEN
Analog Signal at Maximum Position 9.67 9.67

Clamp Inches
Screw
Pres- Pres-
sure 0.51
sure
9.49

FIGURE 9-1 TYPICAL CLAMP POSITIONING SCREEN

Ejector Position

Real-Time ADVANCED
Values
0.51 0.00
VDC INCHES
RETRACTED Name
Plate Active
Ejector Minimum Position 0.00 0.00
RETRACTED
Analog Signal at Minimum Position 0.51 0.51
Ejector Maximum Position 4.50 4.50
ADVANCED
Analog Signal at Maximum Position 9.49 9.49

Ejector Inches
Clamp
Pres- Pres-
sure 0.51
sure
9.49

FIGURE 9-2 TYPICAL EJECTOR POSITIONING SCREEN

MHT-1047 Page 9-5 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

DOING SO MAY CAUSE DAMAGE TO MOLD IF CLAMP IS NOT FULLY CLOSED AGAINST MOLD.
9.4.10. After replacing the Ejector Position Sensor, perform the following steps. (See Figure 9-2)

9.4.10.1. Manually retract the Ejectors.

9.4.10.2. Loosen the four ejector potentiometer retaining screws and position the potentiometer to achive
0.5 volts DC on the Ejector Positioning Screen (Real Time Values), retighten the retaining screws.
9.4.10.3. Enter this value for the Analog Signal at Minimum Setpoint.
9.4.10.4. Manually move the Ejector to the full forward position or physical limit, note the Real TIme Values.
9.4.10.5. Enter the Real TIme Voltage Value for the Analog Signal at Maximum position.
9.4.10.6. Press the Download push-button to save the setpoints to the PLC module(Pro-Set 700® only) .

Note: Like the clamp, the intent in the above procedure is to establish uniform calibrations from machine to
machine.

9.4.11. After replacing the Injection (screw) Position Sensor, perform the following steps. (See Figure 9-3).

9.4.11.1. Manually advance the screw to the full forward position.

9.4.11.2. Loosen the four screw potentiometer retaining screws and position the potentiometer to achieve
1.5 volts DC on the Screw Positioning Screen Sensor, (Real Time Values), then retighten the
retaining screws.
9.4.11.3. Enter this value for the Analog Signal at Minimum Setpoint.
9.4.11.4. Manually retract the screw to achieve the full stroke or physical limit, note the Real Time Values.
9.4.11.5. Enter this Real Time Voltage Value for the Analog Signal at Maximum Setpoint.
9.4.11.6. Press the Download push-button to save the setpoints to the PLC module (Pro-Set 700® only).

Note: Like the clamp, the intent in the above procedure is to establish uniform calibrations from machine to
machine.

9.4.12. After replacing the Injection (screw) Speed Sensor, perform the following steps. (See Figure 9-4).

9.4.12.1. Turn the pump motor(s) off.

9.4.12.2. Install the Sensor completely until it bottoms out against the pick-up, then turn counterclockwise
approximately 150 degrees.
9.4.12.3. Press the Setup push-button on the Ergo unit, cursor to and select "Inputs".
9.4.12.3. Cursor to the Screw RPM Prompt.
9.4.12.4. Cursor to the Screw Minimum RPM field and enter 0000.
9.4.12.5. Note the Real Time Voltage Value on the screen, enter this number in the Analog Signal at
Minimum RPM field.
9.4.12.6. With the pumps running and the barrel at operating temperature, press and hold the screw rotate
button while adjusting the XH Rotate Jog value to achieve the maximum RPM specification as
shown with a hand held tachometer.
9.4.12.7. Enter this reading into the Screw Maximum RPM field.
9.4.12.8. Note the Real Time Voltage Value on the screen, enter this number in the Analog Signal at
Maximum RPM field.
9.4.12.9. Cursor to the High RPM Alarm setpoint, enter a value not to exceed the maximum rated RPM's
for the proper Injection unit size.
9.4.12.10. Return the Jog values to the original setpoints.
9.4.12.11. Press the Download push-button to save the setpoints to the PLC module (Pro-Set 700® only).

9.4.13. After replacing the Injection (screw) Pressure Sensor, perform the following steps. (Figure 9-5)

9.4.13.1. Turn the pump motor(s) off.

9.4.13.2. Press the Setup push-button on the Ergo Unit, cursor to and select "Inputs".
9.4.13.3. Cursor to the Screw Pressure prompt.
9.4.13.4. Cursor to the Screw Minimum Pressure field and enter 0000.

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

Screw Position

Real-Time
Values
2.74 1.12
VDC INCHES MOLD END BACK
Name
Plate Active
Screw Minimum Position 0.00 0.00
MOLD END
Analog Signal at Minimum Position 1.51 1.51
Screw Maximum Position 6.25 6.25
BACK
Analog Signal at Maximum Position 8.40 8.40

Screw Inches
Pres-
sure 0.51
8.40

FIGURE 9-3 TYPICAL SCREW POSITION SCREEN

9.4.13.5. Note the Real Time Voltage Value on the screen, enter this number in the Analog Signal at
Minimum Pressure field.
9.4.13.6. With the pump(s) running and the barrel at operating temperature press and hold the injection
forward push-button.
9.4.13.7. Adjust the Jog value (G) until the maximum injection pressure is reached on the pressure gauge.
9.4.13.8. Enter this value in the Screw Maximum Pressure field.
9.4.13.9. Note the Real Time Voltage Value on the screen, enter this number in the Analog Signal at Maximum
Pressure field. Voltage should be approximately 6.66 volts for Inline injection units, and 7.83 volts for
Rotating Ram units.
9.4.13.10. Return the Jog values to the original setpoints.
9.4.13.11. Press the Download push-button to save the setpoints to the PLC module (Pro-Set 700® only) .

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Screw RPM

Real-Time
Values
0.03 0.2
VDC RPM
Inputs MIN Screw Minimum RPM 0.0
Analog Signal at Minimum RPM 0.03
Inputs Screw Maximum RPM 450.0
MAX
Analog Signal at Maximum RPM 8.38

Screw Position
Screw Pressure High RPM Alarm Setpoint 0.0
HIGH RPM Alarm Time Delay 0.50
Clamp Position
Clamp Pressure RPM
Ejector Position Ejector Cavity
Ejector Pressure Pres- Pres- 0.0
Screw RPM sure sure 450.0
Cavity Pressure

FIGURE 9-4 TYPICAL RPM SETUP SCREEN

Screw Pressure

Real-Time
Values
0.00 0.0
VDC PSI
MI Screw Minimum Pressure 0.0
Analog Signal at Minimum Pressure 0.10
MAX Screw Maximum Pressure 2000
Analog Signal at Maximum Pressure 6.75

High Pressure Alarm Setpoint 0.0

HIGH Pressure Alarm Time Delay 0.50

Screw PSI
Clamp
Posi- Posi-
tion Min 0
tion Max 2000

FIGURE 9-5 TYPICAL INJECTION PRESSURE SCREEN

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE
9.4.14 CALIBRATION OF THE BARREL TEMPERATURES

NOTE: All Zones must be below 100° F before you begin this procedure. Nozzle should be up against the mold.

9.4.14.1 Calibration of the barrel temperature zones is referred to as Tuning Assist. The control will automati-
cally tune the temperature zones whenTuning Assist is selected.

9.4.14.2 The following procedure should be done any time that a heater band, thermocouple, screw or barrel has
been changed. The barrel should be full of material and all covers installed. The nozzle tip should be in
contact with the mold and the barrel should be at room temperature.

9.4.14.3 Go to the temperature Group #1 screen by pressing the Temperature group #1 screen by pressing the
Barrel icon at the top of the screen. Refer to Figure 9-6.

9.4.14.4 In the Run Setpoint row, enter the proper values for the material being used for each barrel zone. In the
"Man Output SP" row, make sure all the values are 0.00. In the Auto or Manual row, select all of the
barrel zones to Manual. In the Run or Standby row, select all zones for Run. In the On or Off row,
select all of the zones On.

9.4.14.5 Now press the Barrel Heats push button on the Redi-Panel to turn the heats on.

9.4.14.6 Now press the Tuning Assist key on the Temperature Group #1 screen to go to the Tuning assist
screen. Refer to Figure 9-7.

9.4.14.7 Now, press the Tuning Assist Start key on the Tuning Assist screen. In about 10 seconds a yellow
flashing message will appear at the bottom of the screen. The message will state Tuning Assistant
Working to indicate that the process has begun.

9.4.14.8 Now, return to the temperature group #1 screen by pressing the Barrel icon.

9.4.14.9 In the Auto or Manual row, select all of the barrel zones to Auto.

9.4.14.10 When all of the zones actual values match their setpoint values, return to the Tuning Assist screen.

9.4.14.11 The Done/Success row should have two check marks for each zone indicating the successful comple-
tion of the tuning process. If there are not two check marks for each zone, turn the heats off by
pressing the Barrel Heats push button on the Redi-Panel.

9.4.14.12 Return to the Temperature Group #1 screen and set it up as before. Then press the Set-up key to
access the Temperature Group #1 setup screen.

9.4.14.13 Now, make sure that all of the setpoint values match the values shown here on this screen. Then press
the Second Setup key to go to the Second Setup screen.

9.4.14.14 Now, verify that all of the setpoint values match the values on the screen shown here. Then press the
Third Setup key to go to the Third setup screen.

9.4.14.15 Now, verify that the setpoint values match the values on the screen shown here.

9.4.14.16 Allow the barrel to cool down to room temperature and do the Tuning Assist procedure again. If it fails
again, return to the Third Setup screen.

9.4.14.17 Go to the Heat Max Time row and lower the value for the zone or zones that failed. These values
control how long a zone will heat in seconds during Tuning Assist.

9.4.14.18 Now, allow the barrel to cool down again and when it has, re-do the Tuning Assist procedure again. It
may be necessary to repeat this process several times in order to get a sucessful result.
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FIGURE 9-6 TEMPERATURE GROUP #1 SCREEN

FIGURE 9-7 TEMPERATURE GROUP #1-TUNING ASSIST SCREEN

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

9.5 PROPORTIONAL VALVE SETUP PROCEDURES - CONFIGURING THE QDC MODULE OUTPUTS

NOTE: The below entries will be made as a percentage of the full operating range, NOT voltage, if a valve
operating on -10 / +10vdc requires 1/2 of its maximum flow in a certain direction a entry of either
25% (equal to -5vdc) or 75% (equal to +5vdc) must be entered. A entry of 0% would equal -10vdc
and 100% would equal +10vdc, leaving a entry of 50% to equal 0vdc or no flow. The above chart
shows the operating ranges for each proportional valve.

Valve XH CN G R RT
Operating Range -10 / +10vdc -10 / +10vdc 0 / +10vdc -10 / +10vdc
Function Injection/ Clamp System Ejection
Screw Rotate Open/Close Pressure Control Forward/Reverse

Table 9-2. PROPORTIONAL VALVE INFORMATION /OPERATING RANGES

9.5.1. The following machine functions or cycles have been configured for each proportional valve, the QDC
Module should not need reset at start-up. If a valve has been replaced fine tuning of that valve may be
required in each of the listed Valve Setup Screens.

9.5.1.1. 1st Clamp Close. Valves/Jogs

9.5.1.2. 2nd Clamp Close.
9.5.1.3. 3rd Clamp Close.
9.5.1.4. Clamp Low Pressure Close. Screw Jogs
9.5.1.5. Injection. Clamp/Eject Jogs
9.5.1.6. Pack. 1st Clamp Close
9.5.1.7. Hold. 2nd Clamp Close
9.5.1.8. Pre-Decompress. 3rd Clamp Close
9.5.1.9. Plastication. LP Close
9.5.1.10. Post-Decompress. Injection
9.5.1.11. 1st Clamp Open. Pack
9.5.1.12. 2nd Clamp Open. Hold
9.5.1.13. 3rd Clamp Open. Pre-Decompress
9.5.1.14. Open Slow. Plastication
9.5.1.15. Ejector Advance. Post-Decompress
9.5.1.16. Ejector Retract. 1st Clamp Open
2nd Clamp Open
9.5.2. To access any of the Valve Setup Screens press the Setup button. 3rd Clamp Open
Open Slow
9.5.3. Cursor to and select the “Valves/Jogs” prompt. Ejector Advance
Ejector Retract
9.5.4. Cursor to each screen to fine tune the valve’s output percentage either
up or down to achieve smooth machine operation. On Screen Pop Up Window

9.5.4.1. To view the adjustable range for a specific field or setpoint, cursor to the field to be adjusted.
The minimum and maximum limits will appear in the Data Entry field located in the lower right
hand side of the screen.
9.5.4.2. If there are no limits in the Data Entry field, press Enter to view a pop up window containing
the available selections.

9.5.5. Adjusting Volume or Speed valves (XH, CN, RRT).

9.5.5.1. Set the machine mode for Open Loop.

9.5.5.2. Increase or decrease the Maximum % Output values until the readout equals the setup values.
9.5.5.3. Adjust the setup values to the minimum rated values.
9.5.5.4. Increase or decrease the Minimum % Output values until the readout equals the setup values.
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MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL
9.5.5.5. Return the setup values to the original setpoints, press the Download button to save the
setpoints into the PLC module. Note: Maximum % output for Ejector proportional valve is set
at 45% to prevent ejectors from drifting forward.

9.5.6. Adjusting Pressure valves (G). Refer to Figures 9-8 and 9-9.

9.5.6.1. Use the Jog functions to determine the Minimum values required to achieve slight movement.
9.5.6.2. Reference the machine Hydraulic prints to determine the Maximum pressures.
9.5.6.3. These values will be transferred into the appropriate Profile Calibration Screens.
9.5.6.4. Return the Jogs to the original Setpoints, press the Download button to save the setpoints into
the PLC module.

Machine Clamp Eject Die Height

Size Stroke Stroke Min Max
55/ 85 12.0 3.0 4 16
120 14.0 3.0 6 16
170 17.0 4.5 6 18
230 20.0 4.5 7 22
300 24.0 6.0 8 25
400 26.0 6.0 8 28
500 30.0 6.0 10 31
650 35.5 8.0 12 34
Table 9-3. CLAMP AND EJECTOR SENSOR INFORMATION ( inch units)

9.6 RECOMMENDED INITIAL SETPOINT VALUES

9.6.1. The following tables list the standard recommended setpoints that the machines were tested with at the
factory. This should provide a starting point if various components have been replaced, these values
may require slight adjustment for specific machines and/or materials being processed.

NOTE: ALL RAMPS ARE TO BE SET TO ZERO INITIALLY, ADJUSTMENT SHOULD BE MADE ONLY TO
ACHIEVE SMOOTH MACHINE OPERATION. IF PICKER IS USED, DO NOT RAMP ANY CLAMP
OPEN PROFILES. RAMPING MAY CAUSE CLAMP TO STOP AT DIFFERENT POSITIONS.

9.6.1.1. 55HT thru 170HT Setpoints (Maximum Sepoints located on prints for various Injection units).

9.6.1.1.1. Positioning / Pressure / Speed Sensors (Inputs Screens):

9.6.1.1.1.1. Injection Positioning Signal at Minimum 1.5 VDC.

9.6.1.1.1.2. Injection Pressure Signal at Minimum 0.0 VDC.
9.6.1.1.1.3. Clamp Positioning Signal at Minimum 0.5 VDC.
9.6.1.1.1.4. Clamp Pressure Signal at Minimum 0.0 VDC.
9.6.1.1.1.5. Ejection Positioning Signal at Minimum 0.5 VDC.
9.6.1.1.1.6. Ejection Pressure Signal at Minimum 0.0 VDC.
9.6.1.1.1.7. Screw RPM Signal at Minimum 0.0 VDC.

9.6.1.1.2. Valve Calibrations, Jog/Valves Screens, listed as percentages of maximums.

XH Valve G Valve CN Valve G Valve EJ Valve

JOG - Rotate set per spec 0 50 0 50
JOG - Screw Fwd 60 18 50 0 50
JOG - Screw Retract 55 18 Max. 50 0 50
JOG - Clamp Close 99 0 55 set for lockup 45
JOG - Clamp Open 99 0 40 set to unlock 45
JOG - Eject Fwd 99 0 50 18 55
JOG - Eject Retract 99 0 50 18 45

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

SETPOINT RECOMMENDED SETTING FOR:

LIMIT 55 85 120 170 230 300 400 500 650
Low Press Close Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %=
Pressure 1000 psi 1000 psi 1000 psi 1000 psi 1000 psi 1000 psi 1000 psi 1000 psi 1000 psi
Clamp Maximum Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %=
Pressure 1340 psi 2075psi 1700psi 1550 psi 2200 psi 1550 psi 2200 psi 1800 psi 1600 psi
Back Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %= Max %=
Pressure 300psi 300 psi 300 psi 300 psi 300 psi 300 psi 300 psi 300 psi 300 psi
Screw Pullback Max %= Max % = Max % = Max % = Max % = Max % = Max % = Max %= Max %=
Pressure 500psi 500 psi 500 psi 500 psi 500 psi 500 psi 500 psi 500 psi 500 psi

Table 9-4. TYPICAL SETPOINT LIMITS (Reference specific machines Hydraulic print)

Injection Machine Size/Screw Speed Range (RPM)

Unit Size 55 85 120 170 230 300 400 500 650
0.5F 420 — — — — — — — —
1.5F Opt. — — 380 — — — — — —
1.7F 420 — — — — — — — —
2.3F 320 320 320 320 — — — — —
3F 320 320 320 — — — — — —
3.7F Opt. — — — 450 — — — — —
–5F — 410 410 410 — — — — —
5F Opt. — 435 500 435 — — — — —
6F — 335 380 — — — — — —
6F Opt. — — 450 — — — — — —
6.2F Opt. — 450 450 — — — — — —
8F — 290 360 360 360 360 — — —
8F Opt. — — 435 450 450 450 — — —
14F — — 230 290 290 290 — — —
14F Opt. — — — 325 420 450 — — —
20F — — — 250 250 250 250 — —
20F Opt. — — — 295 380 400 400 — —
30F — — — — 220 220 220 220 —
30F Opt. — — — — 270 335 370 370 —
48F — — — — — 180 190 190 190
48F Opt. — — — — — 225 260 285 285
60F — — — — — — 180 180 180
60F Opt. — — — — — — 220 235 315
80F — — — — — — 139 160 160
80F Opt. — — — — — — — 190 250
125F — — — — — — — — 140
125F Opt. — — — — — — — — 145
260F — — — — — — — — 76

Note: Specifications for units not listed in this chart, can be located in Section 1 of the companion Operator
Manual.

Table 9-5. MAXIMUM SCREW ROTATE SETTINGS ON STANDARD AND

OPTIONAL HIGH SPEED INJECTION UNITS

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MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

Machine Injection Maximum Injection

Size Unit Size Velocity Stroke
ounces in/sec inches

0.5F 13.5 3.00

55 1.7F 8.6 4.00
2.3F 7.7 5.31
3F 7.67 5.31
5F 5.67 6.25
85 6F 4.9 6.75
8F 4.4 7.63
1.5F 10.3 5.31
3F 10.3 5.31
3.7F 10.2 6.25
5F 7.6 6.25
120 6F 6.5 6.75
8F 5.9 7.63
14F 3.8 8.88
3F 14.6 5.31
3.7F 14.0 6.25
5F 10.8 6.25
6.2F 10.8 7.63
170 8F 8.3 7.63
14F 5.3 8.88
20F 4.1 10.13
8F 10.8 7.63
14F 6.9 8.88
230 20F 5.3 10.13
30F 4.1 11.50
8F 13.4 7.63
14F 8.6 8.88
20F 6.6 10.13
300 30F 5.1 11.50
48F 3.8 13.00
20F 7.5 10.13
30F 5.8 11.50
48F 4.4 13.00
400 60F 3.8 14.31
80F 3.0 14.63
30F 7.8 11.50
48F 5.9 13.00
500 60F 5.1 14.31
80F 4.1 14.62
48F 7.9 14.31
60F 6.8 14.31
80F 5.4 14.62
650 125F 4.1 16.75
260F 2.5 21.00

Table 9-6. INJECTION SENSOR INFORMATION

Note: Specifications for units not listed in this chart can be located in
Section 1 of the companion Operator Manual.

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

FIGURE 9-8 CLAMP/EJECT JOGS SCREEN

FIGURE 9-9 SCREW JOGS SCREEN

MHT-1047 Page 9-15 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

Valve Min. % Output Max. % Output

Pressure G 0.3% 45.5%

Clamp Close Velocity CN 54.0% 65.0%

During Pressure XH -99.0% CN 65.0% G -65.5% EJ -45.0%

Low Pressure Close Pressure G 0.3% 14.0% (1000psi)

During Profile XH -99.0% CN 65.0% G -14.0% EJ -45.0%

Lock - Up
End of Profile XH -99.0% CN -99.0% G -36.0% EJ -50.0%

Pressure G 0.3% 63.0% (2000 Psi)

Injection Velocity XH 54.0% (per spec for Injection unit)

During Profile XH -68.0% CN 99.0% G -63.0% EJ -50.0%

Pressure G 0.3% 63.0 to 67.0%

Injection Pack and Hold
During Profile XH -70.0% CN -99.0% G -65.0% EJ -50.0%

Pre/Post Decompress During Profile XH -59.6% CN -99.0% G -18.0% EJ -50.0%

Pressure G 0.3% 13.0%

Plastication Volume XH 48.0% (per spec for Injection unit)

During Profile XH -33.0% CN -99% G -13.0% EJ -50.0%

Pressure G 0.3% 45.0%

Clamp Open Velocity CN 46.0% 33.0% (15 in/sec)

During Profile XH -99.0% and EJ -45.0%

Pressure G 0.3% 45.0%

Clamp Open Slow Velocity CN 48.0% 28.0% (10 in/sec)

During Profile XH -99.0% and EJ -45%

Pressure G 0.3% 45.0%

Eject Advance Velocity EJ 54.5% 62.0% (10 in/sec)

During Profile XH -99.0%

Pressure G 0.3% 45.0%

Eject Retract Velocity EJ 45.0% 34.5% (10 in/sec)

During Profile XH -99%

TABLE 9-7 SETUP SCREENS MINIMUM AND MAXIMUM PERCENTAGES

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

FIGURE 9-10 LOW PRESSURE CLOSE VALVE SCREEN

FIGURE 9-11 TYPICAL INJECTION VALVES SETUP SCREEN

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MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

FIGURE 9-12 PACK VALVES SCREEN

Note: Changing setpoints for % Output Command will also change setpoints on Profile screen and vise-versa.

FIGURE 9-13 TYPICAL EJECTOR VALVES SCREEN

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

9.7 FULL AUTO MODE CALIBRATION FOR PROPORTIONAL PRESSURE AND FLOW VALVES

Calibrating the Clamp and Eject Units

9.7.1. To cycle the clamp and eject units without the injection unit, retract the carriage until LS22R is
made.
9.7.2. Retract the screw.
9.7.3. From the Plastication Screen, select Edit Shot. See Figure 9-14.
9.7.4. Enter a value of 0.00 for Pre-Decompress, Cushion, Shot Size and Post-Decompress.
9.7.5. From the Injection Screen, select Edit X-Tion.
9.7.6. Enter a value of 0.00 for the Transition Position.
9.7.7. Select the Maintenance Screen by pressing the Maint icon.
9.7.8. Select the FUNC SELCT key on this screen to go to the Function Select screen.
9.7.9. Select all of the Injection functions for OFF.
9.7.10. Select the MACH DIAGS key to go to the Machine Diagnostics screen. Refer to Figure 9-15.
9.7.11. Select the Plastic Calibration Enable to ON, and the Inject Calibration Enable to OFF. This allows the
machine to cycled in the Auto Mode while the Injection unit is disabled.
9.7.12. Select Open Loop Mode on the Clamp Close/Open Profile screens (Figure 9-16). Set ERC to Disabled.
9.7.13. Set the clamp stroke to 1-inch less than maximum. Set clamp velocities to maximum.
Note: It may be necessary to use several segments for smoother clamp motion.
9.7.14. With the mold at the fully open position and the ejectors at the fully retracted position, press the AUTO
button on Redi-Panel, then open and close the front gate. This will start the Auto Cycle.
Note: The ejectors will always cycle once at the beginning of Auto Cycle.
9.7.15. Monitor the Actual velocities and pressures on the Clamp Close and Open Profile screens. Adjust the
CN and G setpoints on the Clamp Close and Open Valve screens until the Actual values exceed the
maximum setpoint values. Refer to Figure 9-10.
9.7.16. Return to the Clamp Close and Open Profile screens and select the Velocities to Closed Loop and the
ERC for Velocity to Enabled.

0.00
0.00
0.00
0.00

0.00
0.00

FIGURE 9-14 PLASTICATION PROFILE (EDIT SHOTSCREEN)

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MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL
9.7.17. Return to the Clamp Close and Open Valves screens and adjust the G setpoints until the Actual
pressure for First, Second and Third Clamp Close and Open is 1000 psi, and Open Slow is 150 psi.
This allows for smoother clamp motion.
9.7.18 Verify clamp open and close velocities at maximum and at 50% of maximum setpoint to verify linearity.
9.7.19. Follow this same procedure for calibrating the Eject velocities and pressures.
9.7.20. Monitor the Actual velocities and pressures on the Eject Forward and Retract Profile screens.
Refer to Figure 9-17.
9.7.21. Select the Eject Forward and Retract Valves screen (see Figure 9-13), and adjust the EJ and G valves
until the Actual values match the setpoint values. The Eject pressures should be left at 2000 psi.
Note: The press is now ready to have a mold installed. A Flow Test mold is preferred or one capable of
using 90% of the shot size for the Injection Unit.

Calibrating the Injection Unit

9.7.21. Before proceeding, insure mold is installed, material is in the hopper, and the barrel is up to operating
temperature.
9.7.22. Return to the Maintenance Function Select Screen, then select Injection and Post-Decompress to ON.
9.7.23. On the Machine Diagnostics Screen (see Figure 9-15), select the Injection Calibration Enable to OFF
and the PlasticCalibration Enable to ON.
9.7.24. On the Plastication Screen (see Figure 9-14), enter a value of 300 for Back Pressure. Select Edit Shot
and enter values of 0.00 for Pre-Decompress, 0.25 for Cushion, a value close to 90% of maximum shot
size, and a value of 0.25 for Post-Decompress. In the Screw RPM box, enter the maximum value for
screw RPM's.
9.7.25. On the Injection Screen (see Figure 9-18), select Number of Segs., and select at least five segments.
Select the EXIT icon to return to the Injection Screen and enter maximum values for injection velocity
and stroke. From this screen, select Edit X-tions and set the parameters as follows:

9.7.25.1. Transition Limits 25 sec.

9.7.25.2. Position 0.30 in.
9.7.25.3. Screw Pressure 2000 psi.
9.7.25.4 Cavity Pressure 0 psi.
9.7.25.5. Limiting Screw Pressure 0 psi.
9.7.25.6. Injection Pressure 2000 psi.
9.7.25.7. Transition Pressure Mask Pos value greater than cut-off position
9.7.25.8. Pressure Limiting Inhibit Pos 0.00 in.

9.7.26. On the Pack/Hold Profile Screen (see Figure 9-19), enter a value of 2000 psi for Pack and Hold Pres
sure. Enter a value not less than 2 seconds for Pack and Hold. It may be helpful to use multiple
segments for both Pack and Hold.
9.7.27. Select Edit X-tions and enter a value of 0.25 for Cushion Length, and a value of 20 for both Pack and
Hold Flow Setpoints. Enter a value for Cure Time which is high enough to allow for proper curing.
9.7.28. With the carriage retracted and LS22R made, rotate the screw to shot size. Then retract the screw to
the fully retracted position.
9.7.29. Run the carriage forward until the nozzle is in contact with the sprue bushing. Adjust the trip dog on the
sprue break cover until LS22F is made.
9.7.30. On the Plastication Screen (see Figure 9-14), press the Set-up key and set the Plastication to Open
Loop and the ERC to Disabled. The press is now ready for calibrating in Auto cycle mode.
9.7.31. While the press is cycling, monitor the Actual velocities on the Injection Screen. Then select the
Injection Valves Screen (see Figure 9-11), and adjust the XH value for Screw Forward until the Actual
velocities slightly exceed the setpoint velocities.
9.7.32. Select the Pack/Hold Profile Screen and monitor the Actual pressures. Select the Pack/Hold Valves
Screen (see Figure 9-12), and adjust the G value for both Pack and Hold until the Actual value is slightly
over 2000 psi.
9.7.33. Return to the Plastication Screen and monitor the Actual Back Pressure value and the Actual RPM
value. Select the Plastication Valves Screen and adjust the G value until the Actual value slightly
exceeds the setpoint value. This value should be limited to 150 psi. Then adjust the XH value for Screw
Rotate until the Actual RPM matches the setpoint RPM.
MHT-1047 Page 9-20 MSU.51-MHTM(AB)-1/01
MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

FIGURE 9-15 MACHINE DIAGNOSTICS SCREEN

FIGURE 9-16 CLAMP CLOSE PROFILE SCREEN

MHT-1047 Page 9-21 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

Ejector Profile Mode: Manual

Part Name: 12047785-12066046-PM-A-3 Phase: Idle
Pressure vs Position
Ejector Pressure
1926

Advance Tip Retract

1 2 3 Segment 1
10.00 Setpoint 6.00
0 Actual 0
4.50 End Pos SP 1.00
0.00 Execute Time 0.00
Retract Tip Advance
3 2 1 Segment 1 Ejector Positioning 0.01
6.00 Setpoint 6.00
0 Actual 0 Number of Strokes
0.10 End Pos SP 2.10 2
0.00 Execute Time 0.00
in/sec
Number
Edit General
of Setup
X-tions Setup Min 0
Segs.
Max 10.00
Alm # 0568 09:22:40 11/18/98 CONTROL POWER SW SS1 OFF Alm Count: 0015

Ejector Profile Mode: Manual

Part Name: 12047785-12066046-PM-A-3 Phase: Idle
Pressure vs Position
Ejector Pressure
1926

Enable/Disable Ejector Profile Enable

Enable/Disable TIP Strokes Enable
Ejector Strokes Required 2
Clamp Position for Ejector Start 16.50
Ejector Positioning 26.93
Min Clamp Posn for Ejector Action 6.00
Max Ejector Posn for Clamp Close 2.10 Number of Strokes
Ejector Forward Dwell Time 0.00 2
Ejector pressure Setpoint 2000
in/sec
Number
Edit General Zero
of Setup
Segs. Setup Axis Min
Segs.
Max 10.00
Alm # 0568 09:22:40 11/18/98 CONTROL POWER SW SS1 OFF Alm Count: 0015

FIGURE 9-17 EDIT X-TIONS SCREEN (FROM EJECTOR PROFILE SCREEN)

MHT-1047 Page 9-22 MSU.51-MHTM(AB)-1/01

MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE
Injection Profile Mode: Manual
Part Name: 12047785-12066046-PM-A-3 Phase: Idle
Pressure vs. Position
P
Cavity Pressure r
0.00 e
s
Screw Pressure s
-346 u
r Start Position
End of Hold e 5.7
Position Screw Position 1.31
0.00
11 10 9 8 7 6 5 4 3 2 1 Segments
10.00 10.00 10.00 10.00 10.00 Velocity SP
0 0 0 0 0 Velocity Act
0.00 1.00 1.00 1.00 1.00 End Posn SP
0.00 0.00 0.00 0.00 0.00 Pressure Act
in/sec
Number
Edit
of Setup
X-tions Min 0.0
Segs.
Max 10.81
Alm # 0568 09:22:40 11/18/98 CONTROL POWER SW SS1 OFF Alm Count: 0015

Injection Profile Mode: Manual

Part Name: 12047785-12066046-PM-A-3 Phase: Idle
Pressure vs. Position
P
Cavity Pressure r
0.00 e
s
Screw Pressure s
-346 u
r Start Position
End-of Hold e 5.7
Position Screw Position 1.31
0.00
Transition Limits Actual Transition Pressure Mask Position
Injection Time 8.00 8.00
0.70
Flow Position 0.25 0.00
100.00 Screw Pressure 2000 0
Cavity Pressure 0 0
Limiting Screw Pressure 0 0
Seconds
Number Zero
Edit Inject
of Setup
Segs. Min 0.0
Segs. Axis
Max 99.0
Alm # 0568 09:22:40 11/18/98 CONTROL POWER SW SS1 OFF Alm Count: 0015

FIGURE 9-18 EDIT X-TIONS SCREEN (FROM INJECTION PROFILE SCREEN)

MHT-1047 Page 9-23 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

2000 2000
2000 2000
2.00 2.00

0
2000

FIGURE 9-19 PACK /HOLD PROFILE SCREEN

9.7.34. On the Pre-Decompress and the Post-Decompress Valves Screens, set XH to 62.50 and G to 18.00.
These values should be set low to allow for a smooth decompress without overtravel.
9.7.35. When all of the Actual velocities, pressures and RPM's match the setpoints, then return to the Injection,
Pack, Hold and Plastication Profile Screens and select Closed Loop and ERC for Enabled. Run the
cycle several times and verify that the Actual pressure matches the setpoint pressure. Then decrease
the pressure setpoint by 50% and run the cycle several times again to verify linearity.
9.7.36. Once this is complete, return to the Machine Diagnostic Screen and select the Plastic Calibration
Enable to OFF.

9.8 PROCEDURE FOR SAVING CALIBRATION VALUES

9.8.1. To save all of the calibration values to the PLC Control, press the Part Storage icon on the right side of
the Ergo Unit to go to the Mold Part Storage Screen (Figure 9-20).

9.8.2. Now, press the Machine Setups key at the bottom of this screen to go to the second Mold/Part
Storage Screen. Refer to Figure 9-21.

9.8.3. First, using the arrow keys, cursor to the 1st Item line and verify that the information shown in green
matches the machine size and serial number. If it does not match, then press the Change Names &
DESCS key and enter the correct information.

9.8.4. Next, press the Save & Restore key. And then press the Save key.

9.8.5. This should complete the Calibration Procedure.

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MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

FIGURE 9-20 MOLD PART STORAGE SCREEN - MACHINE SETUPS

FIGURE 9-21 MOLD PART STORAGE SCREEN

MHT-1047 Page 9-25 MSU.51-MHTM(AB)-1/01

MACHINE SET-UP PROCEDURE MAINTENANCE MANUAL

MHT-1047 Page 9-26 MSU.51-MHTM(AB)-1/01

MAINTENANCE MANUAL MACHINE SET-UP PROCEDURE

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