Avis-II Dc280 Eng

ISO 9001:2008
Certificate No. FM37608
HOT
CHAMBER
DIE
CASTING
MACHINE
INSTRUCTION
MANUAL
MODEL: DC280
AC440V x 3 60Hz
Siemens Computer
Serial No: 1611600501
力勁機械國際有限公司
L. K. MACHINERY INTERNATIONAL LTD.
Member of L.K. Group
Contents
Foreword
Chapter 1 Machine Specification
Chapter 2 General Machine Information
Chapter 3 Safety, Cautions, Labels &Procedures
Chapter 4 Machine Installation and Preparation
Chapter 5 Machine Operation
Chapter 6 Machine Control System
Chapter 7 Machine Start-up
Chapter 8 Safety Operation
Chapter 9 Machine Maintenance
Chapter 10 Faults and Solutions
Chapter 11 Machine Parts
Chapter 12 Drawings
Appendix
L. K. Machinery TC—1
Contents L. K. Machinery
~ Blank Page ~
Tc2—2
foreword L. K. Machinery
FOREWORD
Thank you for purchasing our machine. We sincerely hope that our machine will
help you to be more competitive and to give you years to service.
Please read this manual and get a good understanding of the machine operation
and safety features. This manual will help you to become more familiar with the
structure, performance and adjustment. In turn, this will help you to put the
machine into production quickly and efficiently.
The L.K. machine is designed with high quality servo driven pump, advance
hydraulic components and industrial grade controller which facilitates fast
operation, short production cycles, easy operation, good response, high
efficiency, energy saving and reliable performance.
With continual improvements and innovations that are occurring almost

everyday in the field of hydraulics, electronics, pneumatics and design and
manufacturing processes, minor parts of this manual may be different from the
machine, please contact us for clarify if you find different.
Always indicate the type and serial number of the machine when requesting
spare parts or technical service.
If you have any questions about the operation of this machine that is not
covered in the manual, or if you are experiencing any difficulty with the
operation, please do not hesitate to contact us. We will do our utmost to answer
your questions and help you to optimal your production.
Without the written consent from LK, the manual is not allowed to reproduce or
photocopy, in full or in part.
力勁機械國際有限公司
L. K. MACHINERY INTERNATIONAL
Ltd. Member of L. K. Group
©Copyright by L. K. Machinery. All rights reserved. Except as permitted under law, no part of
this publication may be reproduced in any form or any means without the written permission of
the publisher.
Phone: +(852) - 3412 5500 Fax: +(852) - 3412 5522
E-mail: [SALES] sales@lkmachinery.com.hk

Website: http://http://www.lktechnology.com
Head Office: Unit A, G/F. & Unit A, 8/F., Mai Wah Industrial Building, 1-7 Wah Sing Street,
Kwai Chung, N.T., Hong Kong
FW—1
foreword L. K. Machinery
~ Blank Page ~
FW—2 FW-CU-0006
Chapter 1
Machine
Specification
Section Contents Page

1.1 Machine Configuration 1-2
1.2 Machine Specifications 1-3
01- L. K. Machinery Ch1—1

Chapter 1 L. K. Machinery
1.1 Machine Configuration

Chapter 1
Customer Country Mexico

Machine model no. DC280
Machine serial no. 1611600501
Shipping date March 17, 2016
SPECIFICATION
Rated voltage 440V x 3 phase

Rated frequency 60Hz
Controller Siemens
Interface screen HMI GX05502 10.2”
Options ordered Sprayer (SD-02A)
Extractor (ET-02A)
CONFIGURATION SPECIFICATION
Front safety door Manual
Rear safety door Manual
Die clamp position control Position transducer
Ejector position control Position transducer
Injection stroke control Encoder
Shot position Two (0,-125)
Fast injection speed control Proportional Control
Core pulling device 1 set
Tie bar extraction N/A
Furnace Electrical furnace
Hydraulic Cooler SL-518W1
Test run with hydraulic fluid Water glycol
Ch1—2
L. K. Machinery Chapter 1
1.2 Machine Specifications

Metric
LOCKING UNIT
Unit
Chapter 1
Clamping force 2800 kN
Die closing stroke 460 mm
Ejector Force 158 kN
Ejector Stroke 100 mm
Die height (min-max) 250-650 mm
SPECIFICATION
Platen size (H x W) 860x860 mm
Space between tie bars 560x560 mm
INJECTION UNIT
Shot position (0=center) 0 -125 mm
Shot force 158 kN
Casting stroke 200 mm
Transverse stroke 200 mm
Injection plunger diameter 70 80* mm
Shot weight (Zn) 3.8 5 kg
Working pressure 41 31.4 MPa
Max. casting area 681 888 cm²
GENERAL DATA
Working pressure 14 MPa
Melting Pot Capacity 110 L
Diesel furnace* 6.3 kg/h
Power consumption
Electrical furnace 42 kW
Hydraulic oil tank capacity 500 Liter
Nozzle Heating Power 5 kW
Machine weight 11000 kg

Machine dimension
4910X1950X2540 mm
(L x W x H)
Ch1—3
Chapter 1
SPECIFICATION
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Ch1—4
[ End of Chapter ]
Chapter 2
General Machine
Information

2.1 Machine Overview 2-2
2.2 Control System Overview 2-4
2.3 Clamping Mechanism Overview 2-5
2.4 Injection System Overview 2-7
2.5 Hydraulic System Overview 2-8
2.6 Lubrication System Overview 2-8
2.7 Cooling System Overview 2-8
2.8 Safety Door System Overview 2-9
2.9 Machine Base Overview 2-9
02 HC 0001 L. K. Machinery Ch2—1

2.1 Machine Overview

This machine is a high pressure hot chamber die casting machine and it is designed to
serve for many years. It is typically used in die casting industries for manufacturing Zinc
alloy products or low melting point alloy metal products.
The machine comes in as three main units, the main machine itself , furnace as well as the
control cabinet. The complete unit is primarily composed of machine base and frame,
Chapter 2
clamping mechanism, injection system, lubrication module, electrical and hydraulic circuits.
In operation, the furnace is used to melt the alloy metal. A die has to be provided to be
mounted onto the machine (the die should be provided by the user and it is made according
to the products required). Its injection chamber (gooseneck) and plunger are immersed in
the furnace in which is filled with molten metal. The machine will close the die. The molten
metal under high pressure is injected through the gooseneck into the die mounted on the
GENERAL MACHINE INFORMATION
platen, then it is cooled and solidified until the castings is formed and extracted.
The hot chamber machines includes a number of advanced technologies, and are well
manufactured to achieve excellent performance, fast, reliable, as well as energy saving
executions. It is simply a very user friendly and efficiency equipment to understand and
operate. Besides, the machine is completely controlled by reliable PLC interface, whose
program are developed by experienced engineers for user-friendly performances. Above
all, most components on our machines are brand name off the shelf products that makes
maintenance and servicing very easy and readily. This chapter will give a general
description of the machine and every one of its sub-system, details operation will be
provided in the operation chapter.
Clamping unit
Operation
Safety door Injection
Main box
unit
cabinet
Electric
furnace
Clamping
Lubrication Cooling
end electric Machine
system system
box base
(The above picture is using DC88 for reference)
Ch2—2 02 HC 0001
Back safety Toggle Safety

door cover
accumulator
Chapter 2
Injection

manifold
Clamping
unit
Clamping
unit slide
base
cooler Servo driven
pump
Front safety
door
A frame
Machine
base
Operation Injection
box Engage
cylinder
cylinder
02 HC 0001 Ch2—3
2.2 Control System Overview

The operations of the Hot Chamber die casting machine are controlled by a sophisticated,
on-board programmable logic controller (PLC) and the control system basically comprises
of following two sections;
Chapter 2
2.2.1 Main Control Cabinet

The main control cabinet has consisted of most control components used for this machine
and it is protected by a metal fabricated cabinet.
2.2.2 Operator Control Panel

Operator control panel consists of manual operation switches( press buttons and selectors)
and HMI. On the panel, the operator can control most manual operation for die set up and
machine adjustment. Further, the operator can use the control panel for running normal
production operation.
Main operator panel

Main cabinet
Ch2—4 02 HC 0001
2.3 Clamping Mechanism Overview

The clamping mechanism of the hot chamber die casting machine is designed to ensure
precision alignment and to act as a guide to execute reliable and accurate die closing and
opening. Most importantly, the locking mechanism has to provide the sufficient locking
force that keeps the die halves in tight during high-pressure injection. As well, the functions
Chapter 2
of core puling and casting ejection are also incorporated in this clamping system. The
following describes the sub-systems of the clamping mechanism:
Fixed platen
Toggle mechanism
Die adjustment

mechanism
Tie bar
Die close
cylinder
Ejector mechanism
Rear platen
2.3.1 Toggle Mechanism

The die casting machines come with a heavy-duty, hydraulically driven toggle linkage lock
-up mechanism. The toggle linkage system is a mechanical levers system to provide large
clamping force by using a small hydraulic cylinder to stretch the tie bars. The stretched tie
bars will generate the required clamping force while the toggle linkage is in straight position
and the die height is adjusted properly. This design features reliable and accurate
clamping, compact structure, low energy consumption and easy maintenance. The platens
and toggle links are made from single casting pieces or steel plate, and the toggle pins are
machined precisely from heat-treated alloy steel. All these play an important role in
ensuring the stiffness and the reliability of the clamping mechanism.
02 HC 0001 Ch2—5
2.3.2 Hydraulic Ejector Mechanism

The hydraulic ejector mechanism is located at the back of the moving platen. The ejector
plate can be moved forward and backward by a hydraulic cylinder. There will be holes on
the ejector plate for installed pull back ejector pin and there are some additional holes on
the moving platen for bumper ejector pins (please refer to the platen drawing).
Chapter 2
By the position transmitter, the ejector stroke and the ejection frequency can be set through
HMI.
2.3.3 Core Pulling Mechanism

Depending on the order, this machine has got a number of hydraulic valves (core pulling
valves) and limit switches input for the user to install core pulling cylinders or other core
pulling devices (the number depends on the order). The sequence of each core pulling
assembly can be regulated freely through the main control panel, either core active before
die close or core active after die close. Each set of core pulling device will include one core
pulling direction valve and two limit switches (for feed back the position of the core).
2.3.4 Die Height Adjustment Mechanism

This machine is incorporating hydraulic motor and gear drive mechanism to perform the die
height adjustment. The die height depends on the position of the rear platen, the die
adjustment mechanism will move the rear platen forward (towards the fix platen) or
backward (away from the fix platen) to provide suitable die height for fitting the die as well
as to provide required clamping force. The adjustment mechanism is driven by a hydraulic
motor which turn the four lock nuts mounted on the rear platen, thus moving the rear platen
along the rear end of the tie bars.
The moving speed during die height adjustment can be changed by regulating the pressure
(and quantity of the oil) that goes into the hydraulic motor.
2.3.5 Hydraulic engagement Mechanism

This system consists of two hydraulic cylinders installed on the A-frame. They are
connected with the fix platen. In each cycle, the piston rods of the cylinders will move back
and forth. The fix platen engages and disengages with the nozzle before each injection.
Ch2—6 02 HC 0001
2.4 Injection System Overview

The injection system of the machine is powered by the hydraulic pump and the
accumulators. After reaching the required die closing force , the nozzle head engage to
the die. Then the machine enters the injection phase.
The system has provided two phase injection: 1st phase, 2nd phase The first phase
Chapter 2
injection, or the so called slow speed injection, is purposed to let the plunger slowly close
the inlet of the gooseneck while the plunger head passes through the gooseneck pouring
hole. Then the plunger will push the molten metal to fill the runner in the die cavity. After
that, when the molten metal reach the gate way of the die, it should be set to switch to the
second phase injection, or the fast speed injection, to push the molten metal to fill up the
casting cavity.
When the melting metal cools down and solidifies near the nozzle head area, it cannot go

back to the gooseneck through the nozzle. At that moment, the nozzle can be disengaged
from the die. The melt remains at the die while cooling down. The disengagement separate
the cooling die from the heated nozzle. This can prevent the melting metal solidified and
jam the nozzle head.
The speed of the injection is adjusted by changing the opening of the injection valve which
can be adjusted by manual or by the controller (option).
There is a set of accumulation for injection. It is for the 2nd phase injection . The
accumulators have to be charged up to provide sufficient hydraulic power for the injection,
and the charging will be controlled by the controller for each cycle.
The injection accumulator is mounted directly on the end cap of the injection cylinder, it
reduces the amount of hoses, pipes and connections which in turn reduce pressure loss.
As such, injection energy is remarkably increased.
2nd injection
control valve
Fast injection
accumulator
02 HC 0001 Ch2—7
2.5 Hydraulic System Overview

The hydraulic system is one of the most significant elements for our die casting machine. It
powers the whole machine, enabling the operation of the clamping, injection, die height
adjustment, and ejection mechanisms. The major components for the hydraulic circuit are
the servo driven pump and numbers of various type of valves.
Chapter 2
The system draws from and stores hydraulic oil in the tank which serves as a machine base
as well. A sight gauge or the oil level indicator is mounted on the base to check oil level.
The condition of the hydraulic oil is critical in the smooth and trouble free operation of the
machine.
2.6 Lubrication System Overview

All friction points are designed with either manual lubrication or auto lubrication.
The automatic lubrication is to apply lubrication oil at the frequently moved points such as
the toggle pin and the cross head links of the clamping system. The oil pump and the
metering distributor carry out predetermined, rationed lubrication to each friction point. The
lubricating frequency is to be set in the PLC logic. As well, the automatic lubricating system
features an alarm, which goes on in case the lubrication is not functioning properly. The
most common situations are that the oil pressure has dropped below the oil level lowers.
For the manual lubrication, it is located primarily on the slide ways and the guide rods of the
platens. The die height adjustment mechanism has to be lubricated manually as well. It is
done by applying grease in one of the grease nipples with the provided grease gun. The
grease is going to form a thin film over the friction points. When the lubrication film is gone,
it is time to re-apply the grease. Please refer to the maintenance chapter for details.
2.7 Cooling System Overview

The machine is equipped with a cooling system for regulating the temperature of the
hydraulic fluid in the hydraulic circuit. The main components of this system are a heat
exchanger. The heat exchanger cools the hydraulic fluid as the fluid runs through the tubes
or plates which are in contact with the running cool water. The hydraulic fluid and the
cooling water are separated so that none of the cooling water will go into the hydraulic
system or vice versa. Depends on machine model and contract, the heat exchanger will be
either a tubular type heat exchanger or a plate type heat exchanger. Alarm of hydraulic
fluid temperature over limit will be provided as an option only.
Ch2—8 02 HC 0001
2.8 Safety Door System Overview

All L.K. Die Casting Machines are equipped with two safety doors with safety interlocks
(operator side and helper side) to provide sufficient protection to the operators and
personal around. The machine is designed in a way that it runs for production only when
the safety doors are closed.
Chapter 2
2.9 Machine Base Overview

The base of all L.K. Die Casting Machines is not only the supporting frame, but also serving
as the hydraulic fluid tank. On the side of the base, there are oil level indicator, temperature
probe (thermometer), suction filters.
02 HC 0001 Ch2—9
Chapter 2
~ Blank Page ~
Ch2—10 02 HC 0001
Chapter 3
Safety, Cautions, Labels &
Procedures

3.1 General Safety 3-2
3.2 Signal Words 3-3
3.3 Safety Labels 3-4
3.4 Additional Cautions 3-8
3.5 Safety Procedures 3-10
L. K. Machinery Ch3—1
3.1 General Safety

The precautions included in this manual are NOT intended to cover all hazards that may
exist in a plant or on this machine. The use of theoretical safety mechanisms and guards,
without applying common sense, will not prevent accidents.
Prevention of accidents requires the constant attention of ALL personnel in the vicinity of
this or any other machine to help make a plant and its equipment safe and to provide a
Chapter 3
safe work environment for the work force. A plant and its related equipment are only as
safe as its personnel are safety minded. Proper maintenance of equipment and use of
personal safety devices will contribute as much towards safety as any number of
mechanical safety devices on this machine.
Safety, Cautions, Labels & Procedures
Ch3—2
3.2 Signal Words

Signal words call attention to the safety sign and designate a degree or level of hazard
severity. The signal words for product safety signs are DANGER, WARNING and
CAUTION.
When no federal, provincial, state or local government code, regulation, standard or

guidelines specifies a particular signal word, selection of the signal word shall be made in
Chapter 3
accordance with the definitions provided below.
DANGER – Indicates an imminently

hazardous situation which, if not
avoided, will result in death or
serious injury.

White lettering on Red Background
Safety Alert Symbol – White triangle
Red exclamation point.
WARNING – Indicates an
potentially hazardous situation
which, if not avoided, will result in
death or serious injury.
Black lettering on Orange Background

Safety Alert Symbol – Black triangle
Orange exclamation point.
CAUITION – Indicates an
potentially hazardous situation
which, if not avoided, will result in
minor or moderate injury.
Black lettering on Yellow Background

Safety Alert Symbol – Black triangle
Yellow exclamation point.
Ch3—3
3.3 Safety Labels

The following is a list of safety labels included with the die casting machine, plastic injection
machine and other auxiliary equipment if ordered.
Under any circumstances, DO NOT REMOVE, or allow to remove, any of the

safety labels that are attached to the machine and equipments. Doing so is extremely
hazardous and, depending on which state or province you are, may even be prosecutable
Chapter 3
by law. In addition, removing any safety label will void the manufacturers warranty.
DIE CASTING MACHINE & PLASTIC INJECTION MACHINE
With this label indicating that

the device has contained high
voltage appliances, caution
has to be taken when opening

the cover of these devices.
Precaution must be taken to
prevent electrical shock.
Power cut off is recommended
when maintenance is required
for these device.
This label indicating that there

is a high risk of danger inside
the device or area, the danger
is prevented by the said safe
guards or gate. Do not bypass
those safe guards or gate to
access the dangerous area or
device, or may cause crushing
injury or death.
This label indicates that there

is a high temperature surface
which may expose to the
operators. Touching the high
temperature surface may
cause injury. Protective
instrument such as glove
should be worn if working near
the said surface.
Ch3—4
This label indicates that the

machine is a complex one
which need well training and
understanding of the manual
before operating the
machine.
Chapter 3
machine has a high speed
moving parts which need
attention to be paid. The
operator should read the

instruction, check the safety
device before operating the
machine.
This label indicates that

there is a risk of crushing
injury when adjusting the
stroke of the ejector without
switching off the main
power. Cut off the power
before making adjustment
of the ejector stroke.
This label indicates there is a

risk of crushing injury in the
injection unit of the machine.
Do not put hands or fingers
into the pour hole, materials
inlet hole of the machine.
Ch3—5

is a high moving parts (such as
robots, die clamping unit)
inside the area. Safety
guards, gate or safety device
are used to protect personnel
from this area. Those safety
device must be active if
Chapter 3
entering the area for

maintenance or set up.

is high pressure accumulator
(s) which must be discharge if
it is to be disconnected or
dismantled.
This label gives warning

message to the use of gas to
charge up the accumulator.
Never use oxygen or air to charge
up the accumulators, use only
pure and dry nitrogen (please
refer to chapter 4 for the charging
of accumulators.).

casting products from die
casting machine is hot.
Operator must wear personal
protective equipment when
working on the machine.
Ch3—6
ADDITION FOR HOT CHAMBER DIE CASTING MACHINE
This label draw attention to

those who operating the hot
chamber die casting machine,
there is a danger regarding the
molten material which may
come out from the gooseneck.
Chapter 3
Remove the plunger from the
gooseneck if working on the
die, nozzle etc.
Ch3—7
3.4 Additional Cautions

Certain precautions, which must be adhered to, are clearly identified by various signal
words. When used in any of the descriptions or procedures in this manual, this term
identifies a mandatory safety requirement which, if not followed, will constitute a violation of
minimum standards necessary to safely operate this machine. The following are some
basic safety precautions. Other precautions are included under the appropriate headings
contained throughout this manual.
Chapter 3
DO NOT operate this machine unless all safety devices are working
properly. CHECK ALL DEVICES prior to starting the machine!
DO NOT enter the die (mold) area to perform maintenance or set-up

without first disconnecting the power supply!!!!!
Do not attempt to have more than one person try to operate the machine
at one time. A single operator has to activate both activation buttons at the same
time !!!
It is the responsibility of the operator to make sure that no one else has
his hands or any other part of his body in the machine when it is operating,
regardless if it is in manual setup mode or automatic cycle mode!!!!
Develop a safety check list for the devices on this machine and perform
regular maintenance to ensure continued AND proper operation.
Study the manual thoroughly BEFORE attempting to install, operate or

maintain this machine!
Only competent, well trained personnel should be permitted to operate

or perform maintenance on this machine!
Explain the operation of this machine and its safety devices to the
operator prior to his operating the machine. Use demonstration as a positive
means of instruction and be CERTAIN the operator FULLY understands the
machine and is qualified to handle it. It is recommended that you question the
operator on the points that were explained to ascertain if he has fully understood
all the instructions.
Ch3—8
Before connecting to your plant power supply line, be sure that the
supply current characteristics correspond to the machine (machine requirements
are shown on the label inside of electric the enclosure).
Before operating this machine, be sure that the responsible parties read
and understand this operation manual as well as the warning plates on the die
casting machine.
Chapter 3
Practice good housekeeping. Keep the machine clean and free from
accumulation of hydraulic fluid, oil, grease, water and trimmed flash. It is difficult, if
not impossible, to perform maintenance when the machine is covered with dirt and
oil.
Ch3—9
3.5 Safety Procedures

Die casting machines or plastic injection machines rapidly inject molten metal into the die/
mold and hold it there under high pressure while the metal solidifies. To accomplish this,
the machine has many moving parts and incorporates a high-pressure stored-energy
hydraulic system. The products are hot when coming out of the die/mold of the machine.
The machine is constructed with guards and safety devices to insure the security of the
machine operator. The following security measures must be taken before operating the
machine.
Chapter 3
3.5.1 Handling of Molten Metal/Plastic

◆ Safety shoes must definitely be worn to protect the feet.
◆ Non-flammable and wear-resisting clothing (prefer cotton, no polyester etc.) with arm
and leg covering, protective spots and leggings as well as gloves must be worn to
protect against burn and snag hazards.
◆ Safety glasses having side eye protection are required. A hood or a mask may be
preferable if working on the furnace.

◆ Always pre-heat any objects until completely dried before immersing into the liquid
metal (i.e. ingot, ladle, etc.).
3.5.2 Machine Operation

◆ Safety shoes must be worn.
◆ Suitable working clothing and safety glasses must be worn.
◆ Ensure that all safety guards and devices are correctly installed and functional.
◆ Never stand in front of the machine when front (operator) safety door or the die is
opening.
◆ Keep all safety guards closed when operating the machine.
◆ Never by-pass safety switches or devices.
◆ Locate and repair all hydraulic fluid leakage as soon as it occurs.
◆ Never use KEROSENE as lubricant or release agent while power is not cut off and
machine is not cooled down.
◆ Read Material Safety Data of the lubricant, oil, and grease used on our machine.
◆ Keep fingers away from pinch point, jagged edges free of oil and grease.
3.5.3 Casting Parts Handling

◆ Gloves, working clothing and glasses should be worn when handling cast parts to
avoid burn.
◆ Keep scrap metal under cover in dry place away from oil, plastic and wood.
3.5.4 Environment
◆ Keep the machine free of excess oil and grease.
◆ Keep the floor clean and dry.
◆ Keep out of die casting machine area all objects, which are stumbling hazards or
Can create fire.
◆ Keep the machine always clean.
For additional information in safety precaution, please refer to chapter 8.
Ch3—10
[ End of Chapter ]
Chapter 4
Machine Installation and Preparation

4.1 Shipping Damage 4-2
4.2 Machine Handling and Unloading 4-3
4.3 Considerations Prior to Installation 4-10
4.4 Foundation 4-13
4.5 Utilities Connections 4-16
4.6 Hydraulic Fluid 4-23

4.7 Lubrication Oil 4-24
4.8 High Temperature Grease for Gooseneck /Nozzle 4-25
4.9 Grease 4-26
4.10 Accumulator Gas and Pressure 4-28
4.11 Die Lubricant 4-29
4.12 Assembly 4-30
4.13 Plunger Rod Length Calculation Method 4-33
4.14 Gooseneck Installation 4-34
4.15 Gooseneck Heating Rods/Bands Description 4-35
4.16 Alloy 4-36
4.17 Check List 4-37
4.1 Shipping Damage

All items are shipped after thorough inspection and in crate if needed. The carriers assume
the responsibility for both apparent and concealed damages which sustained in transit. It is
the responsibility for the buyer to inspect and check the material upon receipt.
Any shortages and damages should be noted on the carrier's PRO bill. A claim should be
filled with the carrier in a timely manner. Failure to enter the claim within the prescribed
limits of the carrier can possibly nullify any such claim and cannot obligate L.K. to accept
any claims.
Chapter 4
MACHINE INSTALLATION & PREPARATION
Ch4—2
4.2 Machine Handling and Unloading

The below instructions should be strictly followed when unloading and assembling the
machine. Make sure the assembly bolts are well tightened before placing the machine in its
final resting place. Thereafter, retighten the assembly bolts once a year.
4.2.1 Preparing for Handling

Some machines have separate control cabinet while some have integrated ones. The die
casting machine for all tonnage are generally shipped in two or three parts separately -
main control cabinet (for separated type), main machine body and furnace.
Chapter 4
(1) Main control cabinet
The two hoisting hooks on top are used for hoisting and handling.
(2) Furnace:
There are hoisting rings on both side of furnace for hoisting and handling.
(3) Die casting machine
For hoisting of the die casting machine, please refer to section 4.2.4

4.2.2 Handling Precautions
Any components or parts must be secured when suspended from the chain or hook. Skillful
or trained personnel and qualified equipments are recommended for performing the lift and
handling job.
Please ensure that the overhead crane and wire rope sling work probably. The safe loading
limit should not be exceeded.
During lifting, the safe working load must not be exceeded.
Parts which are loose from the machine should be packed or placed in suitable containers
before lift.
Pay attention to the centre of gravity of the load - ensure that it is directly under the main
hook.
When lifting large or heavy loads, wind and operator visibility must be considered.
Sudden elevation is not allowed.
Do not drag the loads.
Move the loads as near to the ground level as possible.
Regular inspections should be carried out.
Ch4—3
The machine will be shipped with toggle straight (die close) position.
If a lift cable or rope is used, sufficient protection to the contact surface is needed so that
the it will not create any scratch on the components being lifting.
During the lift of the sheet metal components, such as the front/back doors and other
guards, distortion should be avoided.
When using the wire rope sling, please pay attention to the followings:
Chapter 4
(1) Use only suitable wire rope slings. Never use damaged wire rope slings.
(2) If more than one wire rope sling is used in lifting, pay attention to the angle
between the slings.
Protect some delicate components such as LCD display (if any), operator panel from being
damaged or scraped.
Reference: Occupational safety and Health Council
Ch4—4
4.2.3 Hoisting the Machine

Make sure to use a chain or cable with sufficient rating for the weight of the machine.
If necessary, remove the rear guards (if any) which are in front of the rear platen lift holes.
Pay attention to the balance of the machine while hoisting.
When hoisting, be careful not to damage the pneumatic cylinder on the operator side safety
door. Lift method is illustrated in the next section. Do not hoist the machine with the tie bars,
as this may damage the tie bars.
Chapter 4
Ch4—5
4.2.4 Unloading from Container

If the machine is unloaded from a container, a working platform is required to unload the
main machine body from the container. The working platform can be a truck, a concrete
platform or other means where the height is the same as the container on the carrier. This
can enable the fork-lift truck to go into the container. The main machine body can be half
load on the container and the platform.
The following is an alternative method — to put the whole container onto the ground, or
using a big size fork-lift truck.
Chapter 4
WARNING!
Put down the machine carefully and slowly. This can prevent the accidental dropping of the
machine onto the ground which may kill or seriously injure to person and cause damage on
the machine as well.
Lift up the machine by forklift or crane

and support it by supporting block until
the machine is completely suspended.
1. The forklift should have enough

loading capacity (at least 2/3 of the
main machine body weight) and its
fork can reach the same height as the
desk of the container.
2. Insert the fork to lift up the

machine body
Ch4—6
3. Insert rod roller on each 50~100cm

space under the machine body.
Chapter 4
4. Pull out the machine body carefully.

Important!
Pay attention to the space on each side
when pull out the machine from the
container in order to prevent the damage
on the machine.
5. Carefully pull out the machine until the

suspending hook can reach the hanging
point of the machine.
Ch4—7
6. Hook the wire, then slightly pull up and pull

out the machine carefully.
Chapter 4
7. Pull out the machine further until the

whole clamping unit is out of the container.
8. Check the wires carefully if they are properly hooked. When it is suspended by the
wires pull out the machine more and more until it is out of the container.
Ch4—8
Chapter 4 MACHINE INSTALLATION & PREPARATION
Chapter 4
Ch4—9
L. K. Machinery
4.3 Considerations Prior to Installation

Before locating the machine in the facility, the surroundings should be consider seriously,
not only the production line, but also the requirements of the machine, operating
environment, future expansion and automation.
4.3.1 Operation Surroundings

The machine must be operated at normal room temperature and the working place must be
in-door (no exposure to strong wind, rain nor snow).
Chapter 4
At least 1.5 m (5 feet) of space should be kept all around the die casting machine. Sufficient
distance between 2 machines is needed. This space must be reserved for safety and also
easy maintenance, inspection and the actual casting process.
To avoid people accessing to the dangerous zone, safety fence should be installed (See
the diagram I). Fence around this area is strongly recommended in order to stop any
unauthorized personnel to access dangerous area. In addition, space for tie-bar removal
must also be reserved. The fence is not included in the scope of supply and has to be
supplied by the user.
Ch4—10
Sufficient illumination should be provided to facilitate operator to work on the machine. The
die area and the control panel area should have better illumination because of the
complicated job. Proper lighting can ensure the safety, increase the productivity and also
make it easier to spot any defective castings as well. It can simplify inspection and
maintenance.
Pay attention to the fire prevention. No flammable item is allowed to be located near the
machine and the furnace. Sufficient fire extinguishers or equipments should be located
near the machine and easy to obtain. Dry powder fire extinguishers (class C) is
recommended for normal Zn alloy, Al alloy and Brass alloy die casting (Mg alloy die casting
need Class D fire extinguishers, please refer to the instruction for Mg die casting which is
for Magnesium Die Casting Machine only.).
Chapter 4
Ventilation is important in die casting industry to keep the working environment clean and
comfortable. Detail is given as follow.

e s h A ir
F l
4.3.2 Exhaust Air Extraction and Ventilation

Exhaust air and hot air are mainly from the furnace and the die. According to the type of
furnace used, if the furnace uses fuel for heating, more exhaust air and hot air will be
generated and they must be removed from the workshop in order to keep the work place
clean and comfortable.
Please note that exhaust gas from the fuel heating furnace (gas or diesel) is dangerous in a
closed area, good ventilation is a must.
The exhaust air and heat can be simply discharged out of the workshop by hood and
extraction fan. Please pay attention to the local regulation for any treatment required for
extraction of the exhaust air.
Ch4—11
4.3.3 Working Space

When selecting a location for the machine, consideration should be taken into account for
the flow path of the materials and the castings. Temporary storage area for castings may
be needed and some after machining process, such as trimming, may be required to
located near the machine.
4.3.4 Furnace
The die casting machine integrates a furnace to melt and hold the molten metal for
Chapter 4
production running. There are various types of furnaces available.
4.3.5 Automation and Other Auxiliary Equipment

There are peripherals available to be used with the die casting machine. When installing
the machine, please pay attention to the space, the total height, power and other utilities
required in order to make sure everything can be installed and run smoothly.
4.3.6 Overhead Crane

An overhead crane is required for loading and unload the die which is needed during the
production. The lifting capacity of the crane depends on the weight of the die. The height
of the crane should be enough to prevent the risk of hitting the ventilation hood, piping and
the top manifold of the die casting machine.
Ch4—12
4.4 Foundation
A good solid, well prepared foundation plays an important role for the proper function of the
machine. A good foundation can ensure that the machine will last for long time and will not
suffer any unusual wear or deterioration.
In this manual, L.K. will provide some basic guideline on the foundation and the mounting
method. However, due to different geological location and situation, the user is
recommended to consult professional contractor on building the foundation of the machine.
On-site survey may be required. L.K. will take no responsibility for the information or
suggestion for building of the foundation.
The foundation aims to provide a flat platform for locating the die casting machine, it must
be:
Chapter 4
1. strong enough to prevent any distortion;
2. good leveling;
3. supported by solid rock or strut underneath against sinking.
The foundation is recommended to use Concrete grade C20 or C25. There should be at
least 300mm space from the edge of the equipment. There should be a wire mesh located

around 75mm under the surface for reinforce purpose. The depth of the foundation
depends on the machine weight and the geological on-site.
It is recommended to build a draining channel around the machine so that any water or oil
can be drained into the channel and keep the machine clean and tidy. Cover may be
required for the channel.
A steel bar structure with good support base can also be used to load the machine.
Ch4—13
There are 2 basic ways to mount the machine onto the foundation:
1. Leveling pad
It is a simple way to mount the machine on the foundation, but this is only suitable
for small size machine whose weight is below 30 metric ton. This is suitable for small
machine and temporary working.
Chapter 4
2. Level Adjust-block (wedge mount) with anchor bolts

It is a more formal way for mounting the machine on the foundation. This method
is suitable for all size of machines and it is for permanent working. The following will
describe the method in details.
Ch4—14
4.4.1 Mounting Layout

If level adjust block with anchor bolts are used to secure the machine, please prepare the
concrete foundation according to the enclosed foundation drawing in the chapter 12. On
the drawing, there are pre-ready holes for fixing the anchor bolts while the machine is
mounted. Please note that no hole is required on the foundation for using the leveling pad.
Right
Anchorangle
boltbolt
Die casting machine M24x450
Chapter 4
Fix nut
Slide
Leveldevice
adjust block
Steel
Steelplate,16mm
plate
Leveling nut
Grout inlet
Floor

Build the concrete foundation according to the drawing given, leave the required holes for
the anchor bolts. Normally the concrete foundation need at least 7 days to dry completely.
Put the steel plate and the level adjust block (wedge mount) on top of each hole.
Lift up the machine main body to the nearest desired position, put on the anchor bolts with
the nuts so that the bolts are hanging on the machine base.
Generally put the machine base down onto the level adjusting block and the steel plate.
Minor re-position of the block and plate may be required.
After the machine base completely place on the level adjusting block, grout the anchor
bolts from the inlet provided.
Let the concrete dry completely before making leveling adjustment.
Ch4—15
4.5 Utilities Connections

Once the foundation has been made and the machine had been mounted and leveled, the
utilities such as electricity, water supply and compressed air supply should be connected to
the machine.
4.5.1 Power Supply Connections

Connect the cables between the control cabinet and the machine. The following cables are
needed to be connected:
Chapter 4
1. Signals and small power cables from machine to the control cabinet: multi-core cables
with 24 pins plugs [named as AC(1), DC(2), DC(3), DC(4), … etc.] are provided with
the machine so that these cables can be easily connected to the control cabinet.
2. Motor power cables: these cables connect the main pump motor to the control cabinet.
3. In some cases, there may be some sensitive signals shielded cable which connect the
sensors on the machine to the control cabinet directly (no terminals is allowed).
24-pin plugs
Ch4—16
The machine needs electricity power to run. The electricity power input should be
connected to the main control cabinet. The following illustrates the wiring that comes with
the machine and what has to be performed on-site. Follow the electrical wiring diagram in
chapter 12 to connect the power supply. The power supply should be 3 phase with neutral
line (N line, depend on the order, some location has no neutral line, please check the
electrical drawing given) and grounding line (PE).
Chapter 4
Ch4—17
WIRING SUGGESTIONS:
1. The power supply cables L1, L2, L3, N (neutral) and Ground
(PE) should be provided with an isolator before being lead to
the control cabinet. (Depends on the machine’s specification
and user’s order, the neutral may not be available.)
2. The size of the power supply cables should be selected

according to the machine’s electrical consumption.
Chapter 4
3. The grounding line (PE) must be connected for safety

purpose.
4. It is suggested that the power cables ends are clamped with a crimp for easy fix onto
the terminals. Use insulation tubes on the crimping terminals to prevent electrical
shocks.
The connection of the electricity input power cables should be done by qualified personnel
according to the local regulation and electrical code.
For the power supply cable, suitable size of cable has to be used. Please refer to local
regulation such as GB 5226.1-2002 / IEC 60204-1:2000 / BS6004, BS6231, BS6346 to
select the suitable cable.
Connector width Affordable Current

7mm 10A
8mm 20A
12mm 30A
Ch4—18
4.5.2 Cooling Water Connections

A water chiller or cooling tower system is highly recommended for providing cooling water
for the machine. Tap water is not recommended because of its unstable flow/pressure and
temperature. Additive such as anti-rust, anti-corrosion and anti-fungi may be required to be
added into the circulated cooling water, please consult the supplier of the water chiller or
cooling tower.
The cooling water is used to cool down the hydraulic system of the machine, the fix platen,
the die and the plunger. For details please refer to the connection table and the foundation
drawing in chapter 12.
Chapter 4
WATER SUPPLY REQUIREMENTS:
Item Requirement
Pressure 2 bar – 5 bar
Temperature (water inlet) < 25 ℃
Ch4—19
OIL COOLER DETAIL AND WATER REQUIREMENTS
The machine comes with a high efficiency plate type hydraulic cooler which is used to cool
the hydraulic oil in the machine. The cooler has inlets and outlets for hydraulic oil on the top
and inlets and outlets for cooling water at the sides as illustrated below.
Chapter 4
NOTE:
When connecting the water supply to the cooler, check the supply pressure must not
exceed the upper limit marked on the cooler.
Always use a stop valve in front of the cooler water inlet and after the cooler water outlet for
maintenance purpose.
Only clean water can be used for the cooler. Refer to the Table below for general quality
specifications of cooling water.
Some machine may install with a solenoid valve which will be closed when the machine is
stopped.
Clearing heat conducting pipe once every six months can have a perfect cooling result.
Discharge the inside water in frozen weather if it needs to be deactivate for a long time.
COOLING WATER SPECIFICATIONS:

Cooling Supply
Item Unit water water
PH (25°) 6.5-8.0 6.0-8.0
Conductivity μS/cm <800 <200
Total hardness (CaCO3) mg/l <200 <50
Acid consume (CaCO3) mg/l <100 <50
Chloride ion (Cl-) mg/l <200 <50
Sulphate ion (SO2-) mg/l <200 <50
Iron ion (Fe2+) mg/l <1.0 <0.3
Ion state SiO2 mg/l <50 <30
Sulfid ion (S2-) mg/l 0 0
Ammoniac ion (NH4+) mg/l <1.0 <0.2
Ch4—20
4.5.3 Compressed Air Connections

Compressed air may be required in this machine. It is used for the pneumatic door (option)
and air valves of mechanical safety locks (option). If peripherals such as sprayer, extractor
are used, the required compressed air will be much more, please check the corresponding
manual and instruction for preparing the compressed air supply.
PNEUMATIC DRIVEN DEVICES:
* TAKE-OFF DEVICE (SWEEPER) (OPTION):

Some machines have been provided with unloading device which is mounted on the fixed
Chapter 4
platen for helping to remove casting from the movable die half. It requires small amount of
compressed air for operating.
* PNEUMATIC DOOR (OPTION):

The pneumatic door is an option. It is operated by a pneumatic cylinder which need
compressed air supply to drive the safety door to open or close.

* PNEUMATIC CLAMPING SAFETY LOCK (OPTION):
The pneumatic clamping safety lock is an option. It is operated by a pneumatic cylinder
which needs compressed air supply to release the mechanical safety lock for the clamping
unit.
COMPRESSED AIR SUPPLY:

The compressed air supply should be clean and dry, the required flow rate and pressure
depends on the devices being used.
Item Pressure required Flow rate required
Take off device (option) 3~5 kgf/cm2 5NL/min
Pneumatic safety front door 3~5 kgf/cm2 15NL/min

(option)
Pneumatic safety back door 3~5 kgf/cm2 15NL/min

(option)
Pneumatic clamping safety lock 3~5 kgf/cm2 5NL/min

(option)
Handy sprayer (option) 3~5 kgf/cm2 20NL/min
Total amount:
Remarks: Please sum up the total compressed air consumption according to the options
the machine has got.
Ch4—21
For some devices such as pneumatic safety door, a pressure regulator is provided
to ensure the stability of the air pressure, the followings show how to make
adjustment of the air pressure.
● The adjustment knob is a locking type. Pull the knob away from the body until an
orange band appears. Adjust as necessary and push the knob back into its locked
position to prevent accidental setting change.
● Clockwise rotation of the knob results in a pressure increase and vice-versa.
● Check supply pressure before adjusting the pressure.
COMPRESSED AIR CONNECTION POINTS:

Chapter 4
Mainly used to drive the pneumatic door, air valves of mechanical safety locks (option) and
plunger lubrication. See the foundation diagram in chapter 12 for details
Ch4—22
4.6 Hydraulic Fluid

The machine needs hydraulic fluid to run and the fluid should be provided by the user to be
filled into the machine on-site. Prepare the amount of the hydraulic fluid as per the
specification, select the correct hydraulic fluid according to the following section. Pay
attention to the working temperature. It should not excess 55℃ nor below 15℃.
4.6.1 Recommended Hydraulic Fluid

Depends on the local regulations and the contract’s specification, the machine can use
either mineral based hydraulic oil or water glycol hydraulic fluid (if the user want to use
water glycol hydraulic fluid, this must be specified during placing order of the machine.).
Chapter 4
The machine has been tested operation with one of the hydraulic fluid specified on the
contract/order, thus the machine must be filled with the same type of hydraulic fluid
(mineral based hydraulic oil or water glycol hydraulic fluid). If you are not sure which type of
hydraulic fluid has been used for in-house test, please contact us to clarify.
The followings are some common hydraulic fluids recommended and available on the

market, they claim to be of the same type as each other, please contact your local
distributor for details. (L.K. takes no responsibility for the hydraulic fluid not provided by
L.K., if in case of doubt, please contact us.)
The water glycol hydraulic fluid has contained more than 40% of water. It is a fire resistance
fluid which is more safe in case of fire, but it is more costly and needs more maintenance.
While the mineral based hydraulic oil is a mineral based oil specially for transmitting
hydraulic power, it has a high flash point and it is not easy to burn, but it is still flammable in
case of fire. Thus it is less safe than the water glycol hydraulic fluid. However it is low cost,
requires less maintenance and is widely available on the market. There are hydraulic oil
no. 46 and no. 68 available on the market, the no 46 has a viscosity of 46 mm2/s, while the
no. 68 has a viscosity of 68 mm2/s . It is recommend to us no. 68 for die casting machine,
unless the working environment is very cool, then no. 46 oil can also be used. Please
select the suitable hydraulic fluid according to the local regulation and your own practical
situation, L.K. takes no responsibility on which hydraulic fluid which have been selected.
Ch4—23
TYPE 1 MINERAL BASED HYDRAULIC OIL

Manufacturer Specification
CALTEX Rando HD 68
ESSO Nuto H68
HERCULES Zona 68
JAEGER AWT-868
Chapter 4
MOBIL DTE 26
MORESCO AW-68
PETROFER ISOLURIC VG68C

SHELL Tellus 68
TYPE 2 WATER GLYCOL HYDRAULIC FLUID

CALTEX Hydraulic Safety Fluid
CHEMTREND HF620
HERCULES Zona HFR 32/46
HOUGHTON HS620
MOBIL Hydrofluid HFC46
PETROFER US620
SHELL Irus Fluid C46
Ch4—24
NOTE:
1. The above list are in alphabetic order.
2. Never mix mineral hydraulic oil and water glycol hydraulic oil together for filling the
machine! Please refer to the flushing procedure if it is required to change from one
type of fluid to another type.
3. It is not recommended to mix two different manufacturers’ fluid for filling the machine,
please consult the hydraulic fluid manufacturer for details.
4.6.2 Procedure of Filling the Hydraulic Fluid
Chapter 4
Please follow the procedure below to fill up the machine with the selected hydraulic fluid:
Open the inlet port of the hydraulic oil tank (reservoir) of the die casting machine; pump the
hydraulic fluid into the oil tank until the level rise to the upper limit of the level indicator (level
gauge).
Start the main pump of the machine and run the machine for several cycles, stop and dis-

charge the accumulators’ hydraulic pressure (no need to discharge the gas pressure,
please refer to chapter 7 for first time starting up the machine). This will help the fluid to run
evenly to everywhere of the machine and release any gas inside the fluid.
Check again the level indicator, if the fluid level below the upper limit, add more fluid until
the upper limit is reached.
Remember to close the inlet port so that no alien will go inside the oil tank of the machine.
Oil
Inlet
Level in-
dicator
Ch4—25
4.7 Lubrication Oil

The machine is equipped with central lubrication system. It centrally supplies all lubrication
points of the clamping unit. There are metering devices to control the volume of the
lubricant oil being applied on each point of lubrication. This can ensure each lubrication
point is filled with sufficient oil.
To fill the lubrication tank, open the tank cap. Pour the lubrication oil
into tank with a funnel up to the upper limit level. There is alarm if
the lubrication oil is below the lower limit of the lubrication tank or
there is linkage in the lubrication line (please refer to chapter 10 for
Chapter 4
the trouble shooting.).
High quality lubrication oils are recommended to be used to ensure

normal lubrication and smooth running of the machine.
RECOMMENDED LUBRICATION OIL
CALTEX Waylube 68
ESSO Febis K68
HERCULES Waylube 68
MOBIL Vactra Oil 2
PETROFER Waylubric #68
SHELL Tonna T68
NOTE:
1. The above list are in alphabetic order.
2. It is not recommended to mix two different manufacturers’ oil for filling the machine,
please consult the oil manufacturer for details.
Ch4—26
4.8 High Temperature Grease for Gooseneck /Nozzle
The nozzle body, nozzle head, nozzle nut , heating rod, heating disk ,thermometer and all
bolts for fixing hot work parts work in high temperature. They are parts of the channel for
filling molten metal into the mould. The temperature will be at least 420℃. Apply anti-
seizing and anti-rusting grease on each parts mentioned during installation. Otherwise, the
parts would be mated together and cannot be loosen and separate anymore.
RECOMMENDED HIGH TEMPERATURE GREASE FOR GOOSENECK AND NOZZLE
Chapter 4
ALLPASS ALP
Ch4—27
4.9 Grease
The machine is equipped with grease nipples in some position (such as die
height adjustment gear mechanism, platen / tie bars contact etc.). All grease
nipples should be regularly re-filled with grease. The machine is equipped
with manual grease pumping lubrication system to pump grease to grease
points.
RECOMMENDED NORMAL GREASE
Chapter 4
CALTEX Multifak EP-1
ESSO Beacon EP1
HERCULES Sunny XL-EP 00

MOBIL Mobilux EP1
SHELL ALVANIA EP-1
NOTE:
The above list are in alphabetic order.
It is not recommended to mix two different manufacturers’ grease for filling the machine,
please consult the grease manufacturer for details.
Ch4—28
In case that the mechanism is not working smoothly after long time idle or long time
working, grease which contains Molybdenum disulphide should be used.
CALTEX Molytex EP-1
ESSO Beascon Q2
JAEGER Korniche Moly Paste
Chapter 4
MOBIL Mobilgrease HP 681 Special
SHELL Retinax AM

NOTE:
It is not recommended to mix two different manufacturers’ grease for filling the machine,
please consult the grease manufacturer for details.
Ch4—29
4.10 Accumulator Gas and Pressure

The accumulators will be discharged for safety purpose during shipping transportation.
Only accumulator of big machine (DC400 or above) are disassembled from the machine
during transportation. Please fill the accumulators with nitrogen before running for
production. For accumulator filling procedures and devices, please refer to Appendix -
Hydraulic Piston Accumulator Documentation.
Classic series machines are equipped with bladder accumulators while Avis series
machines are furnished with piston accumulators.
Fill the accumulator only with commercially available nitrogen gas with a
percentage purity of 99.99%.
Chapter 4
Never use oxygen nor air which may have a danger of explosion!
ACCUMULATOR FILLING PRESSURE:

As mentioned in the chapter 2, there is one accumulator on each machine. For DC280 &
DC400, there may be one more gas bottle connecting to the accumulator in order to
provide sufficient volume for the need of high injection pressure.
Producing different casting needs different injection pressure. The optimum filling pressure
should be around 70% of the injection pressure.
RECOMMENDED ACCUMULATOR FILLING PRESSURE
Model Filling pressure (nitrogen)
DC30 40~45 bar
DC50 50~60 bar
DC88 60~70 bar
DC100 75~105 bar
DC130 75~105 bar
DC160 75~105 bar
DC200 75~105 bar
DC280 75~105 bar
DC400 75~105 bar
Please do not charge exceed nitrogen gas into the accumulators.
NOTE:
Accumulator For safety reasons, please carry
regular accumulator safety check
according to local regulations.
Charging
Ch4—30
4.11 Die Lubricant

When running die casting production, the die needs die lubricant to provide lubrication for
molten metal flow inside the die cavity as well as to cool down the die, provide protection
coating, etc.
The die lubricant can be sprayed onto the die by the auto sprayer (a standard stationary
sprayer, a handle sprayer or an auto sprayer robot which is an option. It can be ordered
separately.).
The followings are some common die lubricants available on the market:
Chapter 4
DIE LUBRICANT FOR ZINC
MORESCO HC-100

NICHIBEI ACE-360
PETROFER DIE-LUBRIC 22Zn
NOTE:
For different alloy used and different die complexity, the die lubricant used will be different.
Please consult the die lubricant manufacturer for details.
Ch4—31
4.12 Assembly
Depends on the condition of the machine transportation, the whole machine separates into
3 parts for easy transportation. Before starting the machine, the furnace and hot work parts
are need to be re-assembly.
4.12.1 Electric Heating Furnace

The series hot chamber die casting is equipped with electric heating furnace as standard
feature. An extra electric cabinet and an independent power supply is needed for the
electric heating furnace. In case of using electric heating furnace there maybe an extra
Chapter 4
manual for the furnace. Please follow the instructions on it .

Depend on the contract order, the furnace may use Diesel Burner or LPG/ Natural Gas
Burner instead of the electric heating furnace.
If the diesel burner or natural gas burner is used, please read the instructions below for
installation.
Ch4—32
4.12.2 Furnace installation

1. After the machine base is mounted properly on the foundation, remove the gooseneck
from the A-frame if any.
2. Connect the rail with the support frame in the front part of the machine.
3. Put the furnace onto the rail by a crane. Pull it towards the machine until it reaches the
machine. Put a stopper behind the wheel frame of the back wheel. Fix it with a screw
nut to prevent the furnace from moving.
Chapter 4
4. An emergency outlet is on the furnace body. Whenever there is a leakage on the
melting pot of the furnace, molten metal will come out from this outlet. Replacement is
needed if there is molten metal droplet coming out. Do not wait anymore as molten
metal leakage is dangerous. In order to be safe please put a heat resistant container
or dip a hole under the outlet.

Melting Pot
Furnace
Burner Shield
Emergency Outlet
Ch4—33
4.12.3 Burner Installation and Connection (Option)

The furnace is heated up by a burner or electrical heating elements:
There are two kinds of burners, namely diesel burner and the LPG/ natural gas burner.
Customer needs to install the diesel burner or LPG/ natural gas burner onto the furnace.
Diesel Burner (option)
An oil tank is required to store the diesel. There are two connection systems to connect the
oil tank and the burner. Customer should use either the single oil pipeline system or the
double pipeline system. It depends on whether the oil tank is above the burner or it is below
Chapter 4
the burner. It is more simple to use single oil pipeline system if the oil tank is high enough in
attitude to let oil flow into the burner by gravity. Pay attention to fire prevention and air
ventilation. There will be particulates released during the burning of diesel. After each
installation or filter cleaning, release the gas inside the oil piping.
Details please refer to the attached burner manual. Please pay attention to local regulation
for any treatment required for extraction of the exhaust air.
LPG/ Natural Gas Burner (Option)
The working pressure of the LPG burner is 0.2 bar while LPG is supplied at 10 bar normally.
It is important to install a pressure reducer between the gas supply and the burner.
For the natural gas burner, there is no need to reduce the pressure from the gas supply.
The burner can be directly connected to the supply.
Before connection, check the local authority and follow the local regulation. Local authority
inspection or approval maybe needed for some of the countries.
LPG and natural gas is clean but dangerous gas. Air leakage may course explosion. Extra
attention should be put on the hazard of leakage.
REMARKS: Regular checking is essential. At the same time, please pay attention to local
regulation for any treatment required for extraction of the exhaust air.
Ch4—34
4.13 Plunger Rod Length Calculation Method

For the different gooseneck, the position of the gooseneck inlet varies due to the limitation
of the casting process. Every gooseneck has its own sleeve length, so it is required to
measure the proper plunger rod length for each gooseneck.
Calculation Steps:
1) Use the plunger clamp to clamp the piston rod.
2) Get the length of Y by the formula : Y = X – Z
Chapter 4
Y : length of the plunger rod;
X : distance between the plunger clamp to the top of gooseneck sleeve.
Model DC30 DC50 DC88 DC100 DC130 DC160 DC200 DC280 DC400
Z 18 49 49 44 56 56 54 46 36

Plunger clamp
X
Y=X-Z
Ch4—35
4.14 Gooseneck Installation

When the machine has installed with the furnace, the gooseneck has been removed. Re-
installation is needed after the furnace is installed. The gooseneck is used for injecting and
transferring the molten metal.
Installation steps:
1. Place the gooseneck on the stand base supporting plate and leave a 1~3mm gap
between the side of the gooseneck and the stand base installation surface.
Chapter 4
2. Use the hex spanner to install the two plates of the gooseneck installation surface then
the side plates.
3. Tighten the four screws of the side plates by turns.
4. Further tighten the screws of the two installation surface plates.

Requirement: All the screws should be coated with a high temperature lubricant on the
threads before installation.
Before mounting, it is necessary to coating the gooseneck with NC-8 coating material.
Operation procedure as below:
1. Clean off the scraps and foreign matter on the surface of gooseneck;
2. Preheat the gooseneck firstly before coating, then, brush the coating material on
gooseneck by the hair brush uniformly.
3. After finishing the coating, to achieve good dry effect, should dry the gooseneck fully at
temperature of 200° after natural drying
Cautions :
Regular coating contributes to protect the coated position against molten metal attack.
Thereby, it is in favor of prolonging service life of gooseneck.
Ch4—36
4.15 Gooseneck Heating Rods/Bands Description
1. Normal working temperature: 400℃ to 500℃

2. Keep the heater at the lowest applicable temperature for frequently use, otherwise, the
alloy may accumulate and block in the nozzle body.
The highest temperature of the heater band is 480℃. If the temperature is exceeded,
the working life of the heater band will be shortened and may cause damage.
Chapter 4
Ch4—37
4.16 Alloy
The machine can work with different alloys, such as Zinc alloy and Lead alloy, to produce
different casings. The followings are the composition of some common Zinc alloys.
International Standard Compositions of Zinc Die-casting Alloys
Designation No. No.2 (%) No.3 (%) No.5 (%) ZZnA14Y ZZnA14CU1Y ZZnA14CU3Y
Al 3.9-4.3 3.9-4.3 3.9-4.3 3.5-4.3 3.5-4.3 3.5-4.3
Mg 0.025-0.05 0.025-0.05 0.03-0.06 0.02-0.06 0.03-0.08 0.02-0.06

Chapter 4
Cu 2.6-2.9 0.1 max 0.75-1.25 0.25 max 0.75-1.25 2.5-3.0
Pb 0.004 max 0.004 max 0.004 max 0.005 max 0.005 max 0.005 max
Cd 0.003 max 0.003 max 0.003 max 0.004 max 0.004 max 0.004 max
Sn 0.002 max 0.002 max 0.002 max 0.003 max 0.003 max 0.003 max
Fe 0.075 max 0.075 max 0.075 max 0.1 max 0.1 max 0.1 max
Ni none none none none none none

Zn Rest Rest Rest Rest Rest Rest
Remarks:
1. Composition (In percentage max. unless shown as range)
2. Please consult the alloy supplier to ensure the properties of the alloy used.
3. Reference: Lee Kee Group technical reference data base
Ch4—38
4.17 Check List

After finished all preparation and the installation/ re-assembly of the machine, it can be
started up and operate for the trial run. However, it is strongly recommended to check the
machine thoroughly before the machine starts. It is suggested to have an experienced
service engineer from LK’s agent or LK service team for check before production starts.
Please fill in the form on next page and send to our local agent or our Customer Service
Department for arranging engineers to commissioning the machine.
Chapter 4
Ch4—39
Check list for pre-commissioning condition

Machine model :
Serial no. :
ITEM STATUS
Machine construction
Machine position
Machine assembly
Chapter 4
Cooling water connection
Electrical connection
Compressed air connection
Nitrogen charging for accumulators
Hydraulic oil
Lubrication oil
Grease
Diesel/gas connection for furnace (if any)
Crane for die loading/unloading
Die and accessories for trial
Alloy ingot for trial
Mould releasing agent for trail
Date of the status:
Ch4—40
Chapter 5
Machine Operation

5.1 Operator Panel 5-3
5.2 Main Control Cabinet Panel 5-7
5.3 Mechanical Control Switch and Valves 5-8
05-HC-0001 L. K. Machinery Ch5—1

Chapter 5
~ Blank Page ~
Machine Operation
Ch5—2 05-HC-0001
The machine has been equipped with an industrial grade Programmable Logic Controller
(PLC) which provide control to the operation of the machine. A HMI (Human Machine
Interface) is provided for the operator to input parameters into the machine and the
operator can receive message from the machine for the production. In this chapter, the
control system of the machine will be described and explained.
The die casting machine has got three control sub-systems which need the operator to
access in order to make control for the operation. They are:
1. HMI operation panel and manual control panel
2. Main control cabinet panel
3. Mechanical control switch and valve on the machine
Chapter 5
Machine Operation
05-HC-0001 Ch5—3
5.1 Operator Panel

The operator panel contains two parts: HMI operation panel and manual control panel.
The manual operator control panel is used to initiate various manual actions of the
machine. Most of the actions on the operator control panel are Start – Stop and On – Off
operation.
Chapter 5
Machine Operation
Ch5—4 05-HC-0001
Mode
No. Name State Function
enable
Release The die close action will stop
Auto and
1 Die close After doors closed and the two die close buttons are
Manual Pressed
pressed at the same time, the die will close.
The machine mode is not in die height adjustment mode.
OFF
Die height No die height adjustment can be made.
2 Manual
Off/On The machine mode is in die height adjustment mode. Die
ON
height adjustment is allowed.
Emergency Auto and Release Machine works normally
3
stop Manual Pressed No operation permits, main pump motor stop.
Die Release Die height adjust to thick action stop
4 Thick height Under manual mode and die height adjustment is ON, the
Pressed
Chapter 5
adjust die height adjust to thick is carried out.
Die Release Die height adjust to thin action stop
5 Thin height Under manual mode and die height adjustment is ON, the
Pressed
adjust die height adjust to thin is carried out.
Release No action
6 Start Manual
Pressed The main pump motor will start.
Machine Operation
Release No action
Auto and
7 Stop The main pump power is cut off, the machine stops normal
Manual Pressed
operation.
Slow Die close/open at slow speed under manual mode
Die open/
8 Manual Normal Die close/open at normal speed under manual mode
close speed
Fast Die close/open at fast speed under manual mode
Core 2 in Core 2 moves in
9 Core 2 Manual Core 2 out Core 2 moves out
0 Core 2 stops at current position
Core 1 in Core 1 moves in
10 Core 1 Manual Core 1 out Core 1 moves out
0 Core 1 stops at current position
The machine carries out semi-auto operation, and the
Semi-Auto safety door limit switch sends a signal for every cycle starts
Manual (Manual mode)
11 /Auto/Semi- Manual The machine carries out semi-auto operation, and the
auto Semi-Auto safety door limit switch sends a signal for every cycle starts
(Manual mode)
Manual Manual operation allowed (Manual mode)
05-HC-0001 Ch5—5
Mode
No. Name State Function
enable
ON The power supply to the controller is on.

Power lamp Auto and
12 The power supply to the controller is off, no operation is
Manual OFF
allowed.
Release No action
13 Die open Manual When the two die open buttons are pressed down at the same
Pressed
time, do die opening in manual mode
Release No action
14 Injection Auto Injection carries out in AUTO mode with doors closed, die
Pressed
closed and injection ready indicator is on
Chapter 5
Release Spraying stops

15 Spray Manual
Pressed Sprays when die open end and spray selector is on
Release Sweeper resets
16 Sweeper Manual sweeper moves forward when die open and sweeper selector
Pressed
is on.
Machine Operation
release Ejector moves backward.

17 Ejector Manual Ejector moves forward when die open when the two ejector
pressed
buttons are pressed at the same time.
released No action
18 Door open Manual
pressed Front door open
released No action
19 Door close Manual
pressed Front door close
Press “reset” button, you can do the other operation after clear
20 Reset Manual pressed
the trouble .
Fixed die Close the fixed die is fastened.

20 Manual
clamp
open The fixed die is loosened
Movable die Manual close the movable die is fastened.

22
clamp
open The movable die is loosened
Engage nozzle stops moving back, two engage back buttons
released
Engage Auto and need to be released at the same time
23
FWD Manual In manual mode, Engage nozzle starts moving back, two
pressed
engage back buttons need to be pressed at the same time
Engage nozzle stops moving back, two engage forward
released
Engage Auto and buttons need to be released at the same time
24
BWD Manual In manual mode, Engage nozzle starts moving forward, two
pressed
engage back buttons need to be pressed at the same time
Ch5—6 05-HC-0001
AUTO EXTRACTOR (OPTION)

manual Extractor manual operation is enabled.
1 Manual/auto manual
auto Extractor auto operation is enabled.
Start (with
2 manual pressed Extractor auto running will be triggered.
indicator)
The extraction arm will move forward into die
ADVANCE
zone
3 Arm manual 0 No action
The extraction arm will move backward away
RETREAT
from die zone.
The arm moves forward laterally, with the stroke
ADVANCE
depending on the requirements of the actual die.
0 No action
4 Lateral manual
Chapter 5
The arm moves backward laterally, with the

RETREAT stroke depending on the requirements of the
actual die.
On The gripper will rotate on
5 Finger turn manual
Off The gripper will rotate back.
On The gripper will close to hold the product
Machine Operation
CHOCK
6 manual The gripper will open to let the product drop
CLOSE Off
down.
ADV. The extractor base will move forwards.
7 CHASSIS manual
REV. The extractor base will move backwards.
AUTO SPRAYER (OPTION)
manual Sprayer manual operation is enabled.

1 Manual/auto manual
auto Sprayer auto operation is enabled.
Auto start
2 (with manual pressed Sprayer auto running will be triggered
indicator)
up Sprayer goes up.
3 Up/down manual
down Sprayer goes down.
4 Air blow manual pressed Start air blowing function.
Middle
5 manual pressed Start middle spraying function.
spray
Ch5—7 05-HC-0001
5.2 Main Control Cabinet Panel

The main control panel has several sections to it. The chart below shows the sections
and their functions.
MAIN CONTROL PANEL
See Table 2 for

details
Chapter 5
See Table 1
for details
Machine Operation
Table 1
No. Name Function
When the emergency stop button is pressed, the

1 Emergency lamp
emergency lamp is on.
2 Air switch Power supply circuit breaker.

It is used to short LS circuit of safety door for
debugging. If the door switch is set “on”, die close
3 Door switch
can be available with door open. Only the
professional engineer is authorized to hold the key.
4 Pump Start Start pump motor.
5 Pump Stop Stop pump motor.
Once pressed, all action including main pump
6 Emergency Stop
motor will stop. No action is available.
05-HC-0001 Ch5—8
Table 2
No. Name Code Status Function
1 Selector switch SA1 I Start the heater system of holding furnace
for furnace con- (control system for constant temperature)
trol 0 Stop
T Start the heater system according to the set
time (24T)
2 Electro-thermal SA3 0 Heater system for nozzle stops working
control for nozzle I Heater system for nozzle starts working
3 Electro-thermal SA2 0 Heater system for gooseneck stops working
control for I Heater system for gooseneck starts working
gooseneck
4 Nozzle tempera- ME Controlling nozzle temperature automatically
Chapter 5
ture gauge according to preset temperature (400°C -450°

C)
5 Gooseneck tem- MG Controlling gooseneck temperature automati-
perature gauge cally according to preset temperature (380°C
-400°C)
6 voltmeter V1 Indicate the voltage of system pressure pro-
for working portion valve in different action states.
Machine Operation
pressure
7 voltmeter V2 Indicate the voltage of system flow proportion
for working flow valve in different action states.
Ch5—9 05-HC-0001
5.3 Mechanical Control Switch and Valves

There are several mechanical control need the operator to adjust for the best production
performance. Some machine may has extra options to replace the mechanical control to
electrical control which just need to input parameter on the LCD or through digital switch
control panel as indicated on the next page .
5.3.1 Die Open and Die Close Position, Pressure

and Speed control
The die opening and die closing pressure can be controlled at different position. There
are different die closing and opening pressure to be selected at different position. The
change over position for die open and die close is controlled by position transducer.
Chapter 5
The machine is equipped with a position transducer on the clamping cylinder, the position
of the pressure/speed change over will be input on the controller.
By means of the position transducer which can shows the exact position of the moving
Machine Operation
platen on the controller. There will be no limit switch for setting the change over position,
the position will be set on the controller (please refer to chapter 6 if the machine has got
this option.).
Position
transducer
Die close
confirm
limit switch
(no.6)
Lastly there is a die close end limit switch (no.6) located at the toggle support arm inside
the toggle, this has been adjusted in correct position before delivery and need no further
adjustment until problem happen.
Ch5—10 05-HC-0001
5.3.2 Ejector stroke control

The ejector stroke can be controlled by a position transducer as below. By adjusting the
ejector stroke setting value on ejector screen, different ejector stroke can be available.
Ejector backward confirm signal is supplied by a limit switch.
Position transducer
Chapter 5
Machine Operation
05-HC-0001 Ch5—11
5.3.3 Injection Speed Control

The slow phase (that is the 1st phase) injection is activated by opening the slow injection
valve V404. For the machine, DC30,DC50,DC88,DC100, the slow injection speed is
controlled by the flow control valve V409. By adjusting the nuts of the valve V409, the
plunger forward and backward speed can be changed. For the machine above 100 tons
clamping force, the slow injection speed can be adjusted by turning the two-side
adjustable nut of the valve V404.
V404
V404
Chapter 5
V404 adjustable nut V409

Machine Operation
Apply for DC130,DC160,DC200,DC280,DC400 Apply for DC30,DC50,DC88,DC100
The fast phase (2nd phase) injection speed can be adjusted by the opening of the fast
injection valve V419, this valve is a proportional valve which can be controlled on the
LCD by the controller.
V419 Fast injection

valve
Ch5—12 05-HC-0001
5.3.4 Accumulation Safety Pressure Control

The accumulation safety pressure is controlled by safety pressure control valve V422.
Different values can be set by adjusting valve V422.
V422 accumulation safety

pressure control valve
Chapter 5
V421 auto drain valve
5.3.5 Accumulation Pressure Control
Machine Operation
There is a pressure transducer V530 connected to the fast injection accumulator. The
transducer measures the pressure charging in the accumulator and feed back to the
controller. The controller will comparing the measured pressure with the set pressure for
the accumulator. By adjusting the charging pressure setting on the LCD, the charging
pressure of the fast injection accumulator can be adjusted.
05-HC-0001 Ch5—13
5.3.6 Injection Speed Change Control

As mentioned above, there are mainly two phases of injection :
A. Slow speed phase (1st phase)
B. High speed phase (or 2nd phase)
The position of the plunger is measured by the encoder on the connection rod connected
with the injection piston above gooseneck. The limit switch is also used as the plunger
return confirmation.
The change over from one phase to another phase (slow speed to high speed) is
controlled by the position of the plunger and this is input (changed) by the limit switch or
the encoder via the LCD input.
Chapter 5
Limit switch
Machine Operation
Encoder
Ch5—14 05-HC-0001
5.3.7 Machine Side Control Box

There is a machine side control box which is located at the clamping end of the die
casting machine.
Chapter 5
Machine Operation
At the clamping end of the die casting machine, the control box has got:
i. System pressure gauge

ii. Pressurize (pressure up) button
iii. Thermometer of the hydraulic fluid (option)
iv. Emergency Stop button
v. Shot position change (option)
05-HC-0001 Ch5—15
Each button on the control box has got its own function:
i. The pressurize (pressure up) button, when pressed, the main pump will raise to
maximum system pressure. This button is used for: manually charging up the
accumulators
ii. The thermometer of the hydraulic fluid (option) is an option which can provide
hydraulic fluid temperature monitoring. The thermometer is a dial type
temperature detector and display, it has got a upper limit contact and a lower
limit contact. The upper limit is set at 55 ºC (130 ºF) and the lower limit is set at
15 ºC (60 ºF). If the temperature of the hydraulic fluid is beyond the upper limit
or lower limit, there will be an alarm and the pump will be stopped. The upper
limit and lower limit is pre-set in the factory before delivery, it is not
recommended to adjust without permission from L.K. MACHINERY, or it may
cause damage to the hydraulic system.
Chapter 5
iii. The safety door override switch (option) is used when the die is set up on the
machine, this allow the machine to close the die with the door opened. The
switch must be enable with a key and the key must be kept by the supervisor,
only well trained and authorized persons are allowed to use the key for die set
up.
iv. The Shot position change (displacement) button is an option, it is available only
for those machine which has got the multi-shot position option. The function will
Machine Operation
be explained in next section.

v. The emergency stop buttons can only be used when there is a need of
emergency to stop the machine. Do not use the emergency stop to stop a (the)
machine in normal working, use the pump stop button for a normal stop. When
the emergency stop is pressed, the machine will:
a. the main pump will be stopped;
b. all hydraulic actuators output of the controller will be cut off;
c. the hydraulic pressure of the fast injection accumulators and intensification
accumulators will be released
d. give an alarm showing the emergency stop is pressed.
Ch5—16 05-HC-0001
5.3.8 Shot Position Change (Option)

The machine allows change on the shot position by either manually or hydraulic power as
per customer’s request. The following instructs how to change the shot position for a hot
chamber die casting machine.
1. Change the operation to manual mode, with the main pump started up.
2. Remove the die if any, keep the nozzle fit in the gooseneck. Press the die close
button to straighten the toggle arm .
3. Press the nozzle disengage button so that the toggle unit is pushed far away from
the injection unit.
Chapter 5
4. Put a fixture to stop the toggle unit to slide forward towards the injection unit.
5. Disconnect the nozzle engage cylinder connection nuts or screws (both cylinders).
6. Press the nozzle engage button so that the cylinder rod of the nozzle engage
cylinder will retract out of the holes (in the) of the fix platen.
Machine Operation
7. Stop the main pump.
8. Loose and remove the screws on both sides of the toggle unit (6 pieces).
9. Get the fixture step steel column ready. (please get the desired shot position by
selecting the correct thickness of steel column)
10. If the machine is equipped with hydraulic shot change mechanism, the toggle can be
lift by using the hydraulic system, otherwise, the toggle has to be lifted up by crane.
With hydraulic system, turn on the main pump and select manual mode, put the
key into the “shot position” switch which is located under the toggle unit, turn it to
“ON” position. This will activate the directional valve of the shot position
Change cylinder. (If there is no hydraulic shot change system, the toggle unit has
to be lift up by crane, hanging the toggle unit on the toggle part. Please be
careful not to damage the lubrication pipes when hanging the toggle.)
11. Press the “Pressure charge” button (located next to the “shot position” switch.
Then the whole toggle unit will be raised by the cylinder underneath.
Attention should be paid for the weight balance of the toggle unit when lifting up.
12. Replace the fixture step steel column at the bottom of the toggle unit by the
correct length one. Caution must be taken not to trap the figures (fingers) in between
the column and the toggle unit.
05-HC-0001 Ch5—17
[ End of Chapter ]
13. Turn the “shot position” switch to “OFF” position, this will release the oil inside
the cylinder and the injection unit will fall down gently. (Caution must be taken
when the injection unit is falling down, all persons must be clear from the way of
the falling down. If the speed of falling down is too fast, replace the orifice in the
outlet of the cylinder with smaller diameter.)
14. Put the screws of the toggle unit back into the original position (a different length
of screws may be required.), turn each screw a few turns so that the screws are in
position but not firmly secured.
15. Press the nozzle disengage button to extend the cylinder rods into the holes of the
fix platen, put on nuts to fix the cylinder rods onto the fix platen.
16. Check the position of the nozzle tip center with regarding to the toggle unit (fix
platen). The center should be within +/- 0.3mm tolerance. If the required
Chapter 5
tolerance is not reached, move the toggle unit left or right, or put spacers to make
the center is coincident.
17. Secure the screws of the toggle unit, and the screws of the nozzle engage cylinder
rods.
18. Replace the hole plate at the stationary platen (some plate will need to rotate 180
Machine Operation
degree for matching the shot position, some plate will need to be replaced.).
19. Remove the switch key of the shot position change key and run the machine
normally.
Ch5—18 05-HC-0001
[ End of Chapter ]
Chapter 6
Machine Control System
Section Contents
6.1 General View
6.2 Start Screen
6.3 Injection Setting Screen
6.4 Die /Ejector Setting Screen
6.5 Core Screen
6.6 Assistant Setting Screen
6.7 Product Management Screen
06 HC 0000 L. K. Machinery Ch6—1

6.1 General View

This machine is equipped with a SIEMENS 10” color touch screen. Operator can enter
parameters to operate the machine through the Human Machine Interface. It provides a
more convenient method to setup the machine.
Chapter 6
Controller Operation
Ch6—2 06 HC 0000
6.2 Start Screen
Chapter 6
Once the machine starts up, the computer will make self-checking firstly and
subsequently the above screen will appear later if system is inerrant.
On the screen, user can operate the product setting according to the actual requirement.
Enter to the screen by touching the bottom key.
Note: The first password and user name are necessary to enter the debug and
maintenance screen. Furthermore, project setting screen needs the next higher
password, i.e. the second password and user name.
06 HC 0000 Ch6—3
6.3 Injection Setting

Chapter 6
2nd
injection mode: Limit switch or encoder.
Disengage: Selected, nozzle disengaging available for Auto mode operation.
Cycle; Selected, start the next cycle when the last cycle time is up.
ACC. pressure: Indicating the actual ACC. pressure.

2nd start position : Setting the 2nd injection start position.
2nd injection speed : Setting the opening of injection valve to change the injection speed.
Injection time: Indicating the time setting from shot starts to ends.
Disengage time: It is the delay time from plunger backward end to disengagement start.
Engage time: Under auto mode and without selecting nozzle disengage. It is the time from
engaging end to injection start.
Die open time: It is the time from the 2nd LS being triggered to die opening after injection
and plunger backward.
Cycle time: it works in two cases. Firstly, if it is used for abnormal alarm of cycle LS, it will
alarm if the cycle LS is not effective. Secondly, if the cycle choice selected, the cycle LS is
active, start the next cycle when the cycle time is up; Not selected, start the next cycle
immediately once the auto action is completed.
Ch6—4 06 HC 0000
6.3.1 Injection Assistant Setting
Chapter 6
Acc. Auto-
charge: Selected, the system will charge automatically when the pump is started.
Acc. mode: Pressure and time.
Acc. after Die close: Selected, start Acc after die close; Not selected, start Acc after plunger
backward.
Acc. Time after Die close: It is active when select Acc. after Die close. The system start to
charge after die close end, stop when the setting time is up.
Plunger backward Acc. Time: It is active when not select Acc. after Die close. The system
start to charge after plunger back end, stop when the setting time is up.
Acc. Protection time: If the Acc. Time is over the setting time during Acc. Action , it will stop
the automatic action and alarm.
06 HC 0000 Ch6—5
Chapter 6 L. K. Machinery Co. Ltd.
6.3.2 curse screen

This machine has injection curve display function, shown as below:
Chapter 6
The page shows the pressure-time curve, position-time curve and velocity-time curve.on
the bottom of the LCD. Move the cursor left/right to any position,you can get the actual
value of the curve.
Ch6—6 06 HC 0000
6.4 Die / Ejector Screen
Chapter 6
Die open/close position: Display the current position of the moving platen.
Speed of die close slowly: Setting the speed of die close slowly by adjusting the percent
of system flow.
Speed of die close fast: Setting the speed of die close fast by adjusting the percent of
system flow.
Low pressure protect time:The time calculation starts with die close low pressure start
position , if the machine does not finish the switch from low pressure die close to high
pressure die close in the set protect time,the system will alarm and die open
to the end position.
Speed of die open slowly: Setting the speed of die open slowly.
Speed of die open fast: Setting the speed of die open fast.
Die open end position :Setting the position of die open end.
Ejector forward pressure: Setting the system pressure of ejector FWD.
Ejector backward pressure: Setting the system pressure of ejector BWD.
Ejector forward speed: Setting the speed of ejector FWD.
Ejector backward speed: Setting the speed of ejector BWD.
Ejector forward delay: Setting the delay time before first ejector FWD starts.
Ejector backward delay: Setting the time from ejector FWD to ejector BWD.
Ejector frequency: The frequency of ejecting in each auto cycle.
06 HC 0000 Ch6—7
6.4.1 Die Adjustment Screen

Chapter 6
Pressure: Setting the system work pressure of die thin /thick.

Speed :Setting the system work speed of die thin /thick.
Ch6—8 06 HC 0000
6.5 Core Screen
Chapter 6
Core select: Selected to apply.
Core order: After die close—core pull active after die is closed;
Before die close—core pull active before die is closed;
Core in pressure: Core in pressure setting.
Core out pressure: Core out pressure setting.
Core in speed: Core in flow percentage setting.
Core out speed: Core out flow percentage setting.
06 HC 0000 Ch6—9
6.6 Peripheral screen

Chapter 6
Peripheral robot selection ： there are two robots: sprayer and extractor. If the die casting
machine is equipped with robot, relevant settings must be selected.
Remarks ： It is dangerous not to select relevant settings if the die casting machine is
equipped with robot. Meanwhile, the machine doesn’t work properly when relevant setting
is selected while no robot is equipped.
Ch6—10 06 HC 0000
6.4.1 Sprayer Screen
Chapter 6
Blowing time before spray: Setting the blowing time before spray.
Blowing time after spray: Setting the blowing time after spray.
Spray time: Setting the spray time of fixed/moving platen.
06 HC 0000 Ch6—11
6.6 Assistant Setting Screen

Chapter 6
System pressure: Indicate the actual pressure.

System speed: Indicate the actual speed.
Displacement: Enable the displacement

Displacement pressure: Setting the displacement pressure.
Displacement speed: Setting the speed of displacement.
Spray: If selected, sprayer will be enabled.
Spray interval: Indicating the injection frequency.
Spray time: sets up the constant spraying time.
Oil temperature: If selected, the oil temp. upper/lower limit function.
Current oil temperature: Indicate the current oil temperature.
Oil temp. upper/lower limit: Setting the oil temp. limit.
Cooling loading temp: Setting the cooling loading temp.
Cooling load pressure: Setting the cooling load pressure.
Cooling load speed: Setting the cooling load speed.
Ch6—12 06 HC 0000
6.6.1 Sensor Parameters Screen
Chapter 6
Reset value - die open/close transducer: Setting the reset value when die close to
end ,ensure the display value is 0 or be approach to 0.
Reset value - Acc. Pressure sensor: Reset the value to 0.
Reset value - Oil temperature: Reset the value to 0.
Reset value - Injection pressure sensor: Reset the value to 0.
Reset value - Nozzle engage pressure sensor: Reset the value to 0.
06 HC 0000 Ch6—13
6.6.2 Safety door settings

Chapter 6
Door open when die open: Selected, the door open when die open.
Ch6—14 06 HC 0000
6.6.2 Lubrication Parameters Settings
Chapter 6
Toggle lubrication frequency: The frequency of the die close and die open, lubrication starts
when it meets the setting value.
Toggle lubrication time: Lubrication starts and ends at the setting time.
06 HC 0000 Ch6—15
6.7 Production Management

Chapter 6
Production count: If selected, product will be accumulated in every cycle.

Production count setting: Setting the frequency of auto cycle.
Production count reset: Resetting the production count.
Ch6—16 06 HC 0000
6.7.1 Die Management
Chapter 6
The screen is intended to store the die data, the volume depends on the specific machine
configurations.
Create new die: Touch the button of “create new” to create new die. Numbers or letters can
be set as the name of die.
Die data storage: Input the sequence number of die you want store on the date storage
screen, and then press the “save” to store the current date including die close, die open,
ejector, core, injection, die adjust and so on.
Read the die storage: Read the selected die data.
Delete the die data: Delete the selected die data.
06 HC 0000 Ch6—17
Chapter 6
~ Blank Page ~
Ch6—18 06 HC 0000
Chapter 7
Machine Start-up
7.1 Machine Startup and Adjustment 7-2
7.2 Starting the Holding Furnace 7-6
7.3 Nozzle, gooseneck and Plunger Rod Installation 7-8
7.4 Die Mounting and Testing 7-11
7.5 Last Preparation 7-15
7.6 Semi-auto Operation 7-18
7.7 Auto Operation 7-19
7.8 Auto Cycle Flow Chart 7-21

7.1 Machine Startup and Adjustment

Please read this manual before operating the machine. This can help the user understand
the machine structure, working principle, operating procedure, machine adjustment and
safety precaution.
7.1.1 Preparation for Starting Machine

1. Visual check for every components and sub-assembly of the machine if they are in the
correct position according to this manual. Pay attention to the hydraulic hoses and
pipes, make sure all hoses and pipes are well connected.
2. Check the power, compressed air and cooling water are all properly connected.
3. Prepare all accessories discussed in Chapter 4. Fill in the check list to ensure all items
are ready.
4. Prepare some medium hard block, such as ingots pieces or wooden block, for secure
Chapter 7
the nozzle into the gooseneck.

Machine Start-Up
Ch7—2 07-HC-0003
7.1.2 Machine First Start Up

1. Switch on the power supply.
2. Check if the PLC is running normally (no alarm is indicating.).
3. Set [MANUAL/AUTO] knob switch on the operator panel to MANUAL position.
4. Check the main pump motor rotation direction:
Anti-clockwise when viewed from the pump side just like below photo. If it runs in
opposite direction, cut off the power and exchange any two of the 3-phase wires, reset
and restart the motor.
5. Turn on the main pump, check the system working pressure by pressing the [Pressure
up] button. Observe the system pressure with the pressure gauge on the machine
motor end control box. When pressing the button, the system pressure should be
increased to the maximum working pressure as indicated on the specification sheet.
6. The system pressure has already been adjusted in-factory before delivery. If
Chapter 7
adjustment is required, please contact us.
Caution !
The system safety pressure has been set in-factory before delivery. The safety
valve can only be adjusted by LK professionals. Incorrect adjusting may damage
Machine Start-Up
servo motor-driven pump.
07-HC-0003 Ch7—3
7.1.3 Manual Test

1. Set the [SEMI-AUTO/MANUAL/AUTO] knob switch to the Manual position.
2. Set the [Die Close/Open Speed] to Slow position.
3. Set the pressure (speed) to half value.
4. Test die close/open: The toggle of the machine should be straight while transportation.
Press the [Die Open] button and the toggle should be retracted. The moving platen will
move to left hand side (backward). Press the [Die Close] button and the toggle should
extend and the moving platen will move to right hand side (forward).
5. Test ejector action: Open the die to the open limit. Activate the [EJECTOR] to [FWD]
and [BCK] in order to test on the ejector moving forward and backward.
6. Test engagement: Closed the die first. Press [Engagement On]. The toggle and 3
platens will move towards the nozzle/furnace side and engage firmly. Press
Chapter 7
[Engagement Off]. The toggle unit will move backward.
7. Test die height adjustment: Turn the [Die Height Adj] to ON. Press [Die Thick], the
rear platen will move backward to the motor side. Press [Die Thin], the rear platen will
move forward towards the fix platen.
Machine Start-Up
8. Injection: The machine can be tested for injection under manual mode. Do not install
the plunger rod and piston rings into the gooseneck during the test. Reduce the
injection speed to the minimum level (For hand wheel, suggested to use 1-2 turns; For
digital control, suggested to use 30%). Close the die and engage forward (The engage
limit switch must be activated). Press the two [Die Close] buttons and [INJECTION]
simultaneously. The injection cylinder will move downward. After releasing the [Die
Close] or [INJECTION] button, the injection cylinder will return.
When there is not any die in the machine, the plunger rod and piston rings must NOT be
installed for any injection testing. If the molten metal is inside the gooseneck, the hot metal
will be pushed by the plunger rod and piston rings and then flash into the clamping unit
which does not have a die to hold the metal. This will be very dangerous.
Ch7—4 07-HC-0003
7.1.4 Dry Injection Trial

Injection can be carried out under [Manual], [Semi-auto] or [Auto] mode. For the first trial,
it is recommended to shot without the plunger rod and piston rings and under [Semi-auto]
mode.
Follow the procedure to activate a semi-auto cycle for injection:
1. Reset all the device to home position (Die open to the open limit, ejector return,
plunger return, etc.)
2. Turn the [Mode] switch to [Semi-Auto].

3. Close the safety door (Some machine also need to press the two [Die close]
buttons), the die should be closed automatically.
4. After the die is closed, the toggle unit will engage towards the nozzle/furnace
direction. (The engage limit switch at the back of the toggle must be activated in
order to go to the next step.)
5. Accumulators will be charged up automatically.
Chapter 7
6. The injection cylinder rod will go downward.
7. After the injection time is reached, the injection cylinder rod will return (upward).
8. The die will be opened automatically.
9. If the machine has an auto-door function, the door will be opened automatically.
Machine Start-Up
10. The ejector will go forward and then return (depends on the frequency of ejector).
11. After the ejector is returned, one cycle is completed.
When there is not any die in the machine, the plunger rod and piston rings must
NOT be installed for any injection testing. If the molten metal is inside the gooseneck, the
hot metal will be pushed by the plunger rod and piston rings and then flash into the
clamping unit which does not have a die to hold the metal. This will be very dangerous.
It is not permitted to carry out dry injection at the maximum speed without any
load or safeguarding, otherwise the injection cylinder may be damaged.
07-HC-0003 Ch7—5
7.2 Starting the Holding Furnace

1. Before starting the furnace, open the cooling water system first to ensure perfect
water cooling result and prevent the seals inside injection cylinder and clamping
cylinder from damage.
2. Start the furnace control switch adjacent to the electrical cabinet. Set the furnace
control selector switch to [MANUAL] mode, then regulate the temperature in 400-
420°C to start the furnace.
3. When 400°C is reached on the thermometer of the holding furnace, switch on the
electric control switch for gooseneck until 340°C-380°C is reached. Switch on the
nozzle heater control
4. Put the melting pot onto the furnace. Pay attention to the direction of the pot. Paint a
protective lining on the inner surface of the melting pot. (Moresco NC-8, Morgan
ZIRTEX 25 or similar protective coating solution is recommended)
5. Before the furnace is switched on for the first time, check the resistance between the
heating element and the furnace shell which should be at least 0.5MΩ. If not, heat up
the furnace by another heater in order to reduce the resistance to the required value.
Chapter 7
6. Check all the wires and terminals are secure. Loose contact may cause electrical arc
and damage. Check the grounding line (PE) is well connected .
7. Check the voltage supply in order to fulfill the specification and requirement.
8. Check the 3 pole circuit breaker and the 2 pole circuit breaker are connected.
Switch on the power on the control cabinet . The power indicator should light up.
Machine Start-Up
9. Set the temperature to 100 ℃ according to the procedure in chapter 8, maintain the
temperature for half an hour.
10. Cut small pieces (1-2 kg) zinc alloy ingot and put them into the melting pot until it is
full of the ingot. Pieces are needed to place in ascending order, and close to the
furnace chamber.
Ch7—6 07-HC-0003
11. Set the temperature to 300℃. Maintain for half an hour, and then heat up to 420℃.
Wait until all ingot melt and put in new ingot if space available.
Normally, the molten metal level should be kept above the inlet of the gooseneck. The
distance between liquid level and crucible edge is required and as show below:
Chapter 7
Tonnage H (mm)
DC30 30
DC50 30
DC88 60
Machine Start-Up
DC100 80
DC130 80
DC160 80
DC200 130
DC280 130
DC400 130
If the molten metal is higher than 450°C, the plunger will be stuck in the gooseneck
sleeve.
07-HC-0003 Ch7—7
Note:
1. Set the nozzle temperature to 380°C before turning off the machine in order to avoid
any influence on the working life of the nozzle from high temperature.
2. Furnace should not be operated without starting the cooling water system.
3. Avoid using alloy which is oily or with moisture, otherwise, molten metal will splash
from the holding furnace and cause injury. It is advised to preheat the alloy before
melting.
Always preheat alloy ingots before putting into the furnace. Wet or oily ingots may cause
splash of hot metal from the furnace, and cause serious injury.
Chapter 7
Machine Start-Up
Ch7—8 07-HC-0003
7.3 Nozzle, Gooseneck and Plunger Rod Installation
7.3.1 Nozzle Mount, Dismantlement and Cleaning

NOZZLE MOUNT
1. Check the nozzle and gooseneck for their engagement.

2. Adjust the pressure to 100 to 140 bar
3. Preheat the gooseneck by turning on the gooseneck heater to 400°C .
4. Coat the nozzle head and screw with high temperature anti-seize grease, then screw
on the nut.
5. Place a stop block (a piece of ingot or hard wooden block) between the nozzle and the
fix platen. Press [ENGAGE] button to move the platen forward and push the nozzle
into the gooseneck. Press the [ENGAGE] and [DISENGAGE] buttons for at least 3
times then keep pressing the [ENGAGE] button for at least 3 minutes
6. Check the engagement center of the nozzle and platen (tolerance:0.3 mm).
Chapter 7
NOZZLE DISMANTLEMENT
1. Preheat the nozzle to 400°C.

2. Turn the nozzle nut clockwise to move it towards the gooseneck.
Machine Start-Up
3. A given special wrench in the tool box may be needed to pull out the nozzle.
1. Stationary Platen 8. Plunger connector 15. Melting pot

2. Stop Block 9. Gooseneck heater 16. Nozzle Body Taper
3. Nozzle Head 10. Plunger Rod 17. Gooseneck Taper
4. Nozzle Body 11. Plunger Tip
5. Nozzle Heater 12. Piston Ring
6. Nozzle Nut 13. Gooseneck sleeve
7. A-frame 14. Gooseneck
07-HC-0003 Ch7—9
7.3.2 Nozzle Head Installation

The nozzle head is installed in the nozzle body for guiding the molten metal to cavity. A
proper nozzle head should be used according to the dimension of die feeding hole, the
installation steps are as below,
1. Operate the machine to heat the nozzle body to 400°C ±5°C.
2. The nozzle tip should be coated with high temperature lubricate grease.
3. Clamp the nozzle tip and put it into the nozzle hole.
4. Put a medium hard stop block (a piece of ingot or hard wooden block) against the
stationary plate. Operate the machine for engage movement and last for 3 minutes so
that the nozzle tip can be tightly pressed against the nozzle hole.
5. Disengage to lading the stop block.
7.3.3 Plunger Rod Installation

Chapter 7
Welding between the two surface can prevent the plunger loosing from the plunger head.
However, too much welding would probably lead to cracks on the plunger. Therefore, only
spot welding (2-3mm) should be carried out instead of an inch welding. The pictures has
demonstrated the correct welding.
Machine Start-Up
Ch7—10 07-HC-0003
7.4 Die Mounting and Testing

The following section discuss about the die mounting and adjustment. Proper die setup and
adjustment are essential to proper safety, machine function and good quality castings.
7.4.1 Die Requirement

Different types of die casting machine, die size for the matching requirements are not the
same. If die selected improper in production, will not only affects the quality of the
finished product, but also seriously affect the performance and life of the machine. In
order to ensure the quality of the finished die-casting and our machine long-term and
reliable running, please verify the size of die within the appropriate range before mold is
installed.
Definition for key mounting dimensions of the mold
Chapter 7
Machine Start-Up
Tie bar inner distance H/V: the dimensions of tie bar in horizontal and vertical .
Tie bar center distance H1/V1: the dimension of tie bar in horizontal and vertical .
Mold selection principle
When mold casting mounted into the space between two platen, it is generally required
that the longest side of casting mold should be between: H and 0.7H (horizontal direction)
V and 0.7V( vertical direction)
(1) If the die size is too large, beyond the inner distance of tie bar , could easily lead to
clash the mounting surface, mold damage and be difficult to assemble and disassemble.
（2）If the die size is too small, less than half the center distance of the tie bar , will
cause the machine fixed platen and moving platen local stress concentration under the
clamping force, resulting in deformation, not only affects the quality of products, but also
long-term in this state will eventually lead to damage to the platen, tie bar fracture, down
machine life.
07-HC-0003 Ch7—11
The Figure 1 and 2 below show the deformation after long time using in the situation of
too small die dimension.
The Figure 3 below shows the stress distribution of moving paten under properly using.
Figure 1
Figure 3
Chapter 7
Figure 2
7.4.2 Preparation for Die Mounting

1. Check the injection shot position of the die.
Machine Start-Up
2. Check the size of the die – the die width nor the die length should not exceed the space
between the tie bars.
3. Check the die height if it is within the range of the machine’s die height.
4. Check concentricity of the die inlet hole and the fixed platen inlet hole.
5. Check the ejector holes pattern of the die if they fit the ones on the moving platen.
Check the ejector stroke if it is within the ejector stroke of the machine. Prepare the
ejector rods.
6. Check the number of core pulling device if they are available in this machine. Prepare
the required connection hoses and limit switches.
7. Prepare all connection for the cooling water or oil heating.
8. Check the clamping edge of the die if they fit the location of the T-slot and the die
clamps.
Make sure there is a crane available which the loading capacity can handle the die’s weight
and reach the die casting machine platen.
Ch7—12 07-HC-0003
7.4.3 Die Mounting

1. Use a crane or other hoisting device to lift the die into the die mounting area of the die
casting machine. Pay attention to fit the die to the nozzle head position. Adjust die
position to make the die inlet hole to the nozzle head.
The air ventilation hole(s) in the die must NOT point at any person otherwise it will
result in serious injury.
2. Adjust the die close speed to slow. Close the die in

manual mode until the moving platen press the die
slightly with the bending toggle.
3. Use die clamps to fasten the die onto the fixed platen.
4. While the hoist is still hanging the die, slowly open the
die platen (move the moving platen backward). Check if
the die is firmly mounted onto the fix platen.
Chapter 7
5. Close the die platen to hold the die, mount the moving die half to the moving platen.
6. With the hoist hanging the moving die half, slowly open the die platen. Check if the
moving die half is firmly mounted onto the moving platen.
Machine Start-Up
Make sure the die clamp has mounted the die firmly onto the platen, if the die falls
down, it may damage the machine as well as cause injury. Slowly open the die for
the first time, if the die slide along the platen, stop opening the die immediately and
close the platen to hold the die. Always hoisting the die while opening the platen for
checking the die clamp.
07-HC-0003 Ch7—13
7.4.4 Die Height Adjustment

1. The die height of the machine must be adjusted accordingly in order to clamp the die
properly.
2. The die is hold by the clamping unit with the bending toggle as discussed in the last
section. Press [Die open] to open the die. Press [Mould Thick] to increase the die
height.
3. Measure the actual die height. Adjust the rear platen position by increasing the die
height until it reach the actual die height.
4. Press [Die close] button to close the die. If there is still space between two die halves,
open the die and decrease the die height by pressing [Mould Thin] button.
5. Repeat the above steps until the die cannot be closed. Increase the die height a little
so that the die is just closed.
6. Double check the pressure gauge at the clamping unit end of the machine if the
system pressure go up to the high pressure setting value which is 100 – 140 bar.
Chapter 7
Attention:
A. Please set at least 100 bar for the high pressure die close at the controller for proper
die clamping
B. The clamping force can be calculated by
Machine Start-Up
Rated max. clamping force x Pressure of die close

Clamping force = -------------------------------------------------------------------------------
System maximum pressure
Ch7—14 07-HC-0003
7.4.5 Core Pulling

In case the die has core pulling device, the hydraulic supply can be used and the control
switches from the die casting machine are used to control those core pulling device during
die casting. The number of core pulling control device available on the die casting machine
depends on the contract/order’s specification, please refer to the specification of this
machine in chapter 1.
Usually the core pulling device on the die is a hydraulic cylinder or a motor which has an
inlet and an outlet. The core pulling control device consist of a 4-way 3-position, hydraulic
directional valve. Connect the port A of the core pulling valve to the inlet of the core pulling
device, port B to the outlet. After the valve is energized, the core pulling device will be
actuated. In addition, there are limit switches for the forward and backward control.
Each core pulling device has two different modes of action:

A. Core in before the die close
B. Core in after the die close
This must be selected through the controller according to the design of the core pulling
device of the die. (Refer to chapter 6.)
Chapter 7
If there are more than one core, the actuating sequence of the core pulling will depend on
the sequence of the core pulling installed. For example, the actuating sequence is core 1,
core 2, core 3,……core X. The core out sequence will be reversed, core X , ….. core 3, core
2, core 1. Please refer to chapter 6 for the core pulling control details.
Machine Start-Up
07-HC-0003 Ch7—15
7.5 Last Preparation

7.5.1 Injection Plunger Installation
1. Screw the plunger rod tightly to the plunger head.
2. Install the piston rings.
3. Preheat the plunger head in the furnace for about 20 minutes by immersing the
plunger into the molten metal.
4. Then put the plunger into the steel sleeve inside the gooseneck and fix the plunger
clamps.
5. Cover the half of the plunger clamp and fasten the two screws on it.
Note:
1. The steel ring on the plunger tip should be spanned flexibly.
Chapter 7
2. Please note that there should not be any foreign objects such as alloy scrap attached
on the plunger head while pushing it into the gooseneck.
3. The length of the plunger rod should be appropriate. If it is too long, it will block the
gooseneck inlet.
Machine Start-Up
Ch7—16 07-HC-0003
7.5.2 Parameter Adjustment

1. Adjust the opening stroke 5-10mm (0.2-0.4 inch) longer than that in casting.
2. Move the limit switches backward and forward and use the [EJECTOR] button and set
to ether BWD/FWD to adjust the ejector stroke. Ensure the casting products can be
ejected out freely and the ejector plate can be reset.
3. Connect the hydraulic hose to the core pulling device of the die (if any) and the
required limit switches. Select the core pulling device through the controller.
4. Set the core in/out limit to keep the core puller in proper position.
5. Choose a proper clamping force according to the product being casted. It is
recommended to use the least possible clamping force to make good quality castings,
this can preserve the working life of the machine and the die.
Chapter 7
Machine Start-Up
07-HC-0003 Ch7—17
7.5.3 Auxiliary Equipment Adjustment

1. In most case, the die has to be connected with the water cooling system. In some
case, heating oil is used instead of cooling water.
2. Adjust the stroke, speed and position of the sweeper and the sprayer to ensure good
working performance.
3. Adjust the lubrication device for correct amount of lubricant in each point.
4. To preserve the working life of the die, it is recommended to pre-heat the die for the
first injection shot trial. This can be done by gas heating.
Do NOT use high injection speed and large clamping force in starting up the
machine and initial test. This is hazardous and may cause injury or damage on
machine.
Chapter 7
Machine Start-Up
Ch7—18 07-HC-0003
7.6 Semi-auto Operation

A. Reset the emergency stop switch and the emergency stop indicator lamp is off.
B. 3-phase air switch, 2-phase air switches and power switch of operation panel are all in
connection. Power indicator lamp is on.
C. Input correct parameters and select corresponding functions through the control
cabinet.
D. Press [ START] press button.

E. Turn [Semi-auto/Manual/Auto] switch to Semi-auto mode.
F. Die open/close speed switch 1SA14 in normal position, set to slow speed if necessary.
G. Set Nozzle disengage choice as “YES” in injection screen if it is needed. Set sweeper
choice and sprayer choice as “YES” through the HMI when sprayer robot and take-out
robot are needed.
H. Select air door through the HMI if the pneumatic door is needed .
Chapter 7
I. Close the safety door, press down two die close button at the same time to trigger the
cycle.
J. After a cycle is finished, open and then close the safety door to go into next operation.
Machine Start-Up
07-HC-0003 Ch7—19
7.7 Auto Operation

A. Turn the [Power] switch to [On] and press [Start] to start the operation.
B. Input the correct parameters and select relative functions through the main control
cabinet.
C. Make sure all the [EMERGENCY STOP] buttons are all in reset position.
D. Press [PUMP MOTOR – START] button. The power indicator will light up.
E. Turn [Semi-auto/Manual/Auto] switch to [Auto].
F. Set [Die Close Speed] to [FAST].
G. Set Nozzle disengage choice as “YES” in injection screen if it is needed. Set sweeper
choice and sprayer choice as “YES” through the HMI when sprayer robot and take-out
robot are needed.
H. Select air door through the HMI if the pneumatic door is needed .
I. Close the safety door, then press both [DIE CLOSE] buttons to start the cycle. At the
Chapter 7
same time please make sure the safety doors are closed securely.
J. The machine will run the sequential motions automatically.
Machine Start-Up
Ch7—20 07-HC-0003
[ End of Chapter ]
7.8 Auto Cycle Flow Chart
Chapter 7
Machine Start-Up
07-HC-0003 Ch7—21
Chapter 7
~ Blank Page ~
Machine Start-Up
Ch7—22 07-HC-0003
Chapter 8
Safety Operation
8.1 Safeguard 8-2
8.2 Risk of Dangerous 8-5
8.3 Personal Protection 8-7
8.4 Working Environment 8-8

8.1 Safeguard
This machine has come with extensive safeguarding to ensure operator safety. If any of
the safeguards is removed, do not operate the machine.
Under any circumstances, DO NOT REMOVE, or modify any of the safety

guards which are part of this machine. Doing so is extremely dangerous and, depending
on the local regulation, may even be prosecuted. In addition, removing any safety guard
may void the manufacturer’s warranty.
DO NOT operate this machine unless all safety devices are working
properly. CHECK ALL DEVICES prior to starting the machine!
8.1.1 Safeguard Layout

Clamping end rear cover Top housing plate
Back safety door
Chapter 8
option
safety Operation
Front/back housing plate
Front safety door
Side housing plate
Ch8—2
8.1.2 Safety Door

The machine has come with the front and rear safety doors. The doors are used to protect
the operator from the die clamping as well as any molten metal flash during die casting.
The die clamping is allowed only when the front and rear doors are closed during auto
mode. The injection is allowed only when the front and rear doors are closed and the
machine is under auto mode.
There are two limit switches on each of the safety door to monitoring the status of the door.
Never try to by pass these limit switches, otherwise the protection of the safety door may be
void. The two limit switches are allocated so that when the door is closed, one limit switch
will be pressed (NO) while the other will be released (NC).
Chapter 8
safety Operation
The die clamping of the machine will be very fast. Never try to by pass the
safety doors to enter the die area while die clamping is in proceed, the access to the die
area without safety doors may cause serious injury or death.
During die casting, there is possibility of molten metal flashing from the parting
line of the die. The safety doors are used to stop the flashing that will cause injury to the
operator.
Ch8—3
8.1.3 Hydraulic Safety Lock for Clamping (Option)

Depends on contract/order as well as local regulation, some machine is equipped with an
extra hydraulic safety lock for clamping. The lock is an extra limit switch or a hydraulic
valve which is used to monitor the status of the door. The limit switch or hydraulic valve is
directly connected to the hydraulic circuit of the clamping cylinder. If the door is not closed,
the limit switch or hydraulic valve will cut off the hydraulic power to the closing end of the
clamping cylinder, thus stop any action of die clamping.
Chapter 8
safety Operation
8.1.4 Safety Operation of Pneumatic Safety Doors

(Option)
If the machine is equipped with pneumatic or electrical driven safety door as option, the
door is equipped with a sensing rod or sensing edge to detect any obstruction while it is
closing.
During door is closing, if the sensing rod or sensing edge detects an obstruction, the door
will automatically open and then stop. Re-active the closing door action is required (such
as pressing the door close button again) in order to continue the action.
Ch8—4
8.2 Risk of Dangerous

When operating the die casting machine, the operator must know where is the possible and
risk of dangerous.
The dangerous areas are:

1. Toggle
2. Ejector
3. Die area
4. Nozzle area
Die area
Nozzle Ejector Toggle
Chapter 8
safety Operation
8.2.1 Toggle
When the machine is proceeding die closing and die opening, never access the toggle
area. The toggle mechanism may cause danger to any access of person. Should there be
any access on the toggle mechanism for checking, cleaning or maintenance, stop the main
pump motor, release the accumulators, please refer to chapter 9 for detail.
8.2.2 Ejector
When installing the ejector rods or adjusting the ejector stroke, stop the main pump motor,
release the accumulators.
Ch8—5
8.2.3 Die Area

If it is necessary to access the die area such as installing the die or maintenance of the die
(cleaning, repairing etc.), stop the main pump motor, please refer to chapter 9 for detail.
During die casting, do not stand along the parting line of the die, as flashing may cause
dangerous to person stand on the line of the die parting line.
8.2.4 Nozzle
When accessing the nozzle for checking or cleaning, stop the main pump motor, please
refer to chapter 9 for detail.
During die casting, no person is allowed to stand near the nozzle, because the molten
metal may flash from the nozzle head during injection.
Chapter 8
safety Operation
Ch8—6
8.3 Personal Protection

8.3.1 Personal Wearing
When operating the die casting machine, the operator must wear suitable personal
protection to protect himself against any dangerous risk:
1. Safety goggles with side eye protection

2. Heat resistance glove and arm covering
3. Fire resistance clothes
4. Safety shoes.
8.3.2 Fire Fighting
Chapter 8
Because of the combination of molten metal, furnace fuel, gas torches, hydraulic fluids,
lubricating oil and greases, there is a potential risk of fire around the die casting machine.
As mentioned in chapter 4, it is not allowed to put flammable materials

near the die casting machine and the furnace, and fire fighting
equipments must be available and easy access around the machine.
Further, the operators must be trained to use the fire equipments and
safety Operation
regular fire drill should be hold for emergency evacuation in case of
fire.
Suitable fire extinguishers should be used for different case of fire:
CLASS A: WATER TYPE FIRE EXTINGUISHER – suitable for fire caused by

paper, woods, textiles etc.
CLASS AB: (FOAM) TYPE FIRE EXTINGUISHER – suitable for class A fire as
well as fire caused by flammable liquid such as oil.
CLASS BC: CO2 TYPE FIRE EXTINGUISHER – suitable for class B fire as
well as electrical fire.
CLASS ABC: DRY POWER TYPE FIRE EXTINGUISHER – suitable for class A, class B
and class C fire.
CLASS D: HYDRO SALT POWER FIRE EXTINGUISHER – suitable for class D fire
which is caused by molten metal such as magnesium.
Usually, dry power type fire extinguishers are recommended to be placed in the die casting
workshop.
Ch8—7
8.4 Working Environment

The working environment of the die casting machine is very important for safety and
accident precaution.
8.4.1 Clean and Tidy Work floor

It is always good to maintain a clean and tidy work-floor for die casting. This will result in
comfort working environment, reduce chance of accident and increase working efficiency.
Return all loose or fail equipment to its storage area or maintenance workshop.
Wipe excessive grease and oil from the machine.
Clean floor, scrape any hardened materials to clear the moving path and area.
Remove flash and other foreign materials from inside of the safety doors and from the die
area of the machine.
Always keep the floor clean, check for slippery or dirty.
8.4.2 Handling of Casting

Chapter 8
Several precautions must be taken when handling the castings taken from the machine.
If the casting has not completely solidified during the die is opened, the liquid portion may
blow or pop. Molten metal may spits from the partially opened die and cause injury. The
operator must stay clear of the die parting line until the die is opened fully. If a blow
happens, the cooling time must be increased or the cooling water has to be checked to
avoid a recurrence.
safety Operation
The castings are not touchable when taken out of the die. The hot casting can cause burn
to any person around, attention must be paid to place the castings and the operator must
wear suitable personal protective instruments.
When the castings are taken out from the die, they are untrimmed and are sharp that may
cause injury to persons around. Placing the castings in a suitable place and operator must
wear suitable protective gloves and clothing.
Ch8—8
[ End of Chapter ]
Chapter 9
Machine Maintenance

9.1 General Maintenance 9-2

9.1 General Maintenance

Operational safety and long life of the machine largely depend on regular maintenance and
servicing by qualified personnel. Needless to say, the better the service program will be,
the longer the machine will serve without major failures. The suggested initial maintenance
and preventative maintenance schedule included in the following sections will help to get
the most out of the machine and keep it running well.
A good maintenance schedule should be formulated in order to keep the machine in good
working condition.
1. Initial Checks
2. Safe Checks
3. Daily Checks
4. Periodical checks
i. Weekly checks
ii. Monthly checks
iii. 6-monthly checks
iv. Yearly checks
Chapter 9
MACHINE Maintenance
Ch9—2 09-HC-0001
9.1.1 Initial Checking (Maintenance)

When after first run the machine, initial checking maintenance have to be done in order to
keep the machine in the best condition. This action is very important for the long working
life of the machine.
INITIAL MAINTENANCE:
Item Initial Required Maintenance
Check the nitrogen pressure. If there is a drop of pressure

which exceeds 5 bar in a week, stop the machine and
check for the area of gas leakage.
The checking of the accumulators pressure should be

Accumulator done:
First check after one week of initial run.
Second check on one month running.
Regular check every three months
It is recommended to change the hydraulic oil after first
Chapter 9
Hydraulic oil
500 operating hours, then every 2000 operating hours.
Clean BEFORE filling with oil for the first time and then
Oil tank
after with every fluid change.
The filter has to be clean after first 500 working hours, then
MACHINE Maintenance
Suction filter
clean it every six months.
09-HC-0001 Ch9—3
9.1.2 Preventative Maintenance

A. General
i. Clean metal chips and oil stains on the DCM everyday after work (especially for the
toggle part, sliding part and tie bar).
ii. Check the oil tank, hydraulic pump, hydraulic cylinder, pipe connection and pressure
gauge to ensure there is no oil leakage problem.
B. Hydraulic System
i. Do not use deteriorated or precipitated hydraulic oil. Do not mix the new oil with the old
oil when renewing the hydraulic oil. Cover the tank cover after changing the hydraulic
oil.
ii. When changing the hydraulic oil, the filter element in the oil filtered should be washed
in the clean diesel oil by using a wire brush and dried by using compressed air.
iii. The motor (hydraulic pump) should be cleaned and maintained every half years. The
grease using in bearings should be changed every year. If the grease is darken,
harden, or contains water droplets or precipitates, user should immediately stop the
pump and change the grease.
iv. Check the accumulator pressure every 3 months:
Turn off the main power and check the accumulator pressure when the injection
pressure returns to 0. If the accumulator pressure below the set value, the
accumulator should be refilled with nitrogen.
Chapter 9
v. If the hydraulic valve is blocked, the valve core should be washed in diesel oil or clean
hydraulic oil and dried in compressed air. Cautions: the valve core can only be
dismantled when the valve is blocked.
vi. Choose the proper hydraulic oil according to Chapter 4.
Below are the procedures for changing the hydraulic oil:
1. If the hydraulic oil is not going to be renewed completely, check the compatibility
of the new and old oil before mixing them together. Mix 1(new) : 1(old) oil in a
MACHINE Maintenance
container and mix 1(new) : 2(old) in another container. Put both container under
70-80℃ for 24 hours. The new and old oil are compatible if the mixed oil contains
no precipitates.
2. If the hydraulic oil is going to be renewed completely, drain the old oil and fill the
new oil up to 1/3 ~ 1/2 of oil tank capacity to rinse the oil tank and remove the old
oil.
3. After filling the new oil, test the machine for 10-15min in dry cycle until the
temperature and pressure return to normal.
Ch9—4 09-HC-0001
C. Electrical
i. Fasten the screw of the main cabinet, small control box and wiring box every two
months.
ii. Check the machine wires every day to ensure there is no damage and all wires are
fixed.
iii. Ensure the motor rotation direction is correct by starting the motor manually.
iv. Check all the proximity switches and limit switches are in correct position.
v. When the machine power is cut off, all the control buttons and switches should stay in
their stop position to prevent the electrical devices from damaging.
vi. The adjustable potentiometer on the control panel should be adjusted by professional
personnel only.
vii. The machine should be grounded to protect the operator’s and machine’s safety.
viii. Clean the dust accumulated on the motor cooling fan or in the control cabinet regularly.
Insufficient cooling may be harmful to the servo pump unit.
D. Clamping Unit
i. Toggle is the critical component of the clamping unit. The screw in the toggle part
should be re-fastened every two months
ii. Check the bearing and dust seal of the sliding unit of movable platen regularly and
replace immediately if damaged.
iii. The sliding block of movable platen should be regulated adequately. The sliding unit
will wear easily if it is too tight or the tie bar will deform or damage if it is too loose.
iv. Fast clamping cannot be used during die height adjustment. Die height adjustment can
Chapter 9
only performed when the die is completely opened. Otherwise, the screw thread of tie
bar or the adjusting mechanism may be damaged.
v. Fastened the screw of the sliding unit regularly
vi. The die should be installed at the center of the platen in order to prevent the toggle from
damaging by the uneven force.
vii. Clear the installation holes and surface of the platen and the die before clamping the
die on to the platen with die clamps. Avoid damaging the installation holes.
viii. Do not use anything to stack up the die which will damage the toggle easily. MACHINE Maintenance
ix. The clamping force should be kept to minimum upon fulfilling the production
requirement. High clamping force will facilitate the wear of toggle.
09-HC-0001 Ch9—5
E. Injection Unit
i. Keep the temperature of molten Zinc alloy in the crucible at 410-430°C. Too high
temperature will speed up the wear and corrosion to plunger, steel ring, shot sleeve
and crucible, even block the plunger. The metal is Grey and white in normal
temperature while dark red in too high temperature.( Note: Paint the outer surface of
gooseneck with NC-8 protective paint, so as to prevent the alloy from corrosion.)
ii. Check the thermocouple once half a month. Draw out the thermocouple and clean its
surface. Check if any corrosion occurs. If that is the case, change immediately.
(Note:Paint the surface of thermocouple with NC-8 protective paint)
iii. Skim the metal dross of molten alloy in the crucible. If any dross is brought into the shot
sleeve, it causes damages, even blocks the plunger.
iv. Keep the molten Zinc alloy liquid level be not 3cm below the crucible against the dross
into the shot sleeve to block the plunger.
v. Keep the zinc alloy clean without any moisture, dirt and other contaminants.
vi. Use nozzle body associated with the gooseneck taper.
vii. ensure the nozzle body taper matches with gooseneck.
viii. If any leakage from gooseneck tapered bore occurs ,remove nozzle body immediately,
ix. clean the nozzle body firstly ,then clean gooseneck tapered bore. After nozzle body
cooling down, install it according to the nozzle body installation procedures.
x. During rest time (e.g. mealtime, die change and repair), set the temperature of nozzle
and gooseneck as 350°C against corrosion .set the temperature to 400°C firstly when
recasting.
xi. Remove the plunger and ladle out all molten alloy from crucible before stopping the
machine if the machine is to be deactivated for a long time.
Chapter 9
F. Cooling System
i. Clean the cooling system frequently to prevent the pipes from blocking
ii. Clean the cooling pipes of injection system every year to ensure the cooling pipes can
be accessed and lengthen the working life of sealing components
MACHINE Maintenance
iii. The cooling water used in the machine should be soft water. The cooling water should
be processed by the water softener every half years.
iv. The dirt will be accumulated on the heat exchange surface of the cooler. Clean the
cooler by using the copper rod every half years.
v.
Ch9—6 09-HC-0001
G. Lubrication System
i. Add the grease to all the grease oil port once a month. Caution: The grease filling in the
sliding unit of movable platen should not be too full to prevent its dust seal from shifting.
ii. Check and ensure the lubrication system is supplied with enough oil everyday before
operating the machine.
iii. Check the lubrication pipes weekly to ensure each lubrication pipe can be accessed
iv. Check the oil connection regularly to ensure all connectors are fixed.
v. Choose proper lubrication oil according to Chapter 4. Do not use the mixed lubrication
oil.
H. Heating Elements
i. Heater elements should be preheated by energizing to remove the moisture. put into
operation after cooling.
ii. During rest time, set the temperature of nozzle and gooseneck as 350°C. Its working
temperature is 400-450°C (for zinc alloy casting)
I. Crucible
i. Clean the surface of the crucible prior to operation.
ii. perform preheat treatment before metal crucible is used (metal crucible should be
preheated to 200°C and then coated once, preheat again to around 300°C to remove
Chapter 9
the moisture in the crucible and coatings.
iii. Add residue and molten alloy before melting, and then add alloy ingots.
iv. Decline the burner 3°c downward for installation.
v. Dismantle the plunger before stopping machine, then ladle out two third of the melt
from crucible at long shutdown (normally 8 hours or over).
vi. During rest time (e.g. mealtime, die change and repair), set the temperature of molten
alloy below 380°C against corrosion .set the temperature to 410°C~ 430°C firstly when
recasting. MACHINE Maintenance
09-HC-0001 Ch9—7
9.1.3 Preventative Maintenance Schedule

This schedule has summarized the maintenance should be done to the DCM regularly. It is
based on a 16 hour work day. If you are running the machine more than that, you will have
to adjust the schedule to your circumstances.
Required Maintenance Daily Weekly Monthly 6 Months Yearly
SAFETY SYSTEM:
Check if the emergency stop is function normally. O
Check if the safety cover is interlock with the die
O
closing.
Check that all safety guards are in place before
O
operating machine.
Check grounding connection O
Check rear platen die height limit most thin and
O
most thick limit switches are function normally
Check the hydraulic hose if there is any
O
degradation, flaw or cracking.
Check clamping bolts of the die for tightness. O
MECHANICAL SYSTEM:
Check to see if the toggle is not making abnormal
sounds, or sudden motions. If it is report to O
supervisor immediately.
Check the toggle if any loose or deformed. O
Chapter 9
Check tie bars to see if there is any scoring. O
Check main cylinder to see if there is any scoring. O
Check the tie bar nuts if they are loose. O
Check the height of the moving platen, adjust the

O
shoe if necessary.
MACHINE Maintenance
Check the parallelism of the fixed and moving

O
platen.
ELECTRIC SYSTEM:
Always close tightly the cover to prevent dust go
O
into the control cabinet or terminal box.
Check power supply to see if it is ±10% of the rated
O
voltage.
Remove dust from all internal switches and electric
O
parts.
Check all limit switches are in the corresponding
O
position and function properly.
Tighten all terminal and wiring connections. O
Check the backup battery of the PLC if [low battery]
O
indicator is ON
Check the cleanliness of the motor fan air inlet,
O
clean it if necessary.
Ch9—8 09-HC-0001
9.1.3 – PREVENTATIVE MAINTENANCE SCHEDULE – Continued:
Required Maintenance Daily Weekly Monthly 6 Months Yearly

HYDRAULIC SYSTEM:
Check oil level. If level is below mark on oil level
O
gauge, add more oil.
Check oil temperature. O
Check hydraulic oil system pressure. O
Check hydraulic system for oil leaks. O
Clean suction strainer carefully with brush or blow
O
air from inside.
Check hydraulic oil for contamination. O
Check hydraulic oil viscosity. O
Check hydraulic oil filter (if any), change the filter
O
element if required.
Check air breather if it is dirty. O
Check the oil cooler if it is free of scale O
Check accumulators for any drop in gas pressure,
O
re-charge if necessary
Check the fixing screws on all the valves, festinate
O
them if necessary.
PNEUMATIC SYSTEM:
Check incoming air source for leakage. O
Check air filters and water separator, clean or
O
release water if necessary.
Chapter 9
LUBRICATION SYSTEM:
Grease all grease nipples and apply with high
temperature grease on all contact surfaces of tie O
bar, tie bar nuts and stationary platen.
Check the central lubrication system for
performance. The auto lubricating system should be
O
active when starting the machine, and should be
active with during production. MACHINE Maintenance
COOLING SYSTEM:
Check water temperature. O
Check water filter O
Check water pressure gauge. O
Purge and clean chiller, water tower, etc. O
Test water for mineral content. O
Clean water channels on machines O
SHOT END:
Change seals on rod end. O
Check injection pressure O
09-HC-0001 Ch9—9
DIES:
Check if die is mounted firmly on the platens. O
Check die water cooling system and clean. O
Verify die water cooling circulation O
Clean the die from grease, oil, die lubricant O
HOUSEKEEPING:
Clean machine, control cabinet (s) and
O
surroundings.
Update machine logbook. O
Touch up paint. O
Chapter 9
MACHINE Maintenance
Ch9—10 09-HC-0001
9.1.4 Service Contract

Service contracts and customer assistance agreements are available for L.K.
MACHINERY products. For more information contact our service department.
9.1.5 Disposal of Fail Components / Waste

Dispose of the waste oil according to local regulations and guidelines. Dispose of battery
or PCB, please refer to local regulations and guidelines.
Chapter 9
MACHINE Maintenance
09-HC-0001 Ch9—11
9.1.6 Machine Regular Checking Method

No. Check Point How To Check
Power on the machine to check if the
limited switches corresponding to safety
Check that all safety guards
guards are in normal position, any faults of
1 are in place before operating
limit switch ( short circuit, disconnections
machine.
or not in place) can be showed on the
computer screen.
Check to see if the electrical Power on the machine and press the start
2 motor is not making abnormal button of the electrical motor to see if there
sounds, or sudden motions. is any abnormal sound, or sudden motion.
Activate all emergency stops Press each emergency stop button to
3 buttons to insure proper check if the alarm lamp is on, and if the
working order. buzzer is actuated.
While the cover is closing, we should hit the
Check safeguard system and
4 safety edge of the cover by hand to see if
if cover opens if it hit anything.
the cover opens.
Keep the oil tank over 80% full but the
Check the oil level of the oil black/red warning lines for marking the
5
tank. max./min. level of the oil should not be
exceeded.
There are two lubricating methods, Manual
Chapter 9
mode and Auto mode. In manual mode,

press the lubricating pump button 5-6 times
manually prior to operating the machine to
Check the oil distributor of the
6 see if oil flow is smooth. In Auto mode, the
lubrication system
frequencies and times of auto lubrication
are programmed in the computer, normally,
lubrication is carried out once every 800
MACHINE Maintenance
cycles.
Start the machine to check the pressure
Check the pressure of the
7 gauge, the oil pressure should not be over
hydraulic oil
the working pressure.
Normal temperature is 40-50℃ but not
Check hydraulic fluid more than 55℃ ,the temperature of the
8
temperature pump can be 5℃ higher than hydraulic
fluid.
Check the pressure of the The pressure is normally 70% of the min.
9
accumulator shot pressure
The machine should be dry cycled ten
10 Dry cycles testing times before production to see if the
running is normal
Ch9—12 09-HC-0001
9.1.7 Safe Precaution for Maintenance

When doing maintenance on the machine, safety precaution must be taken in order to keep
the personal safety as well as keep the machine from damage.
Always stop the motor, release accumulators pressure and cut off the power when access
dangerous zone (die area, toggle area, injection area) for checking and perform repairing
job.
When some components are removed from the machine for repairing purpose or the
machine is not ready for operation, put a warning plate on the main switch of the control
cabinet to warn the other people not to operate the machine. Lock the power supply switch
if necessary.
If the accumulators are required to be removed from the machine, release the hydraulic
pressure as well as gas pressure inside the accumulators before dismantle.
Follow the original information to replace the protective components such as fuses,
overload contactors etc. Do not use different components for replacement, if in doubt,
please contact L. K. Machinery Service team.
Always check for the electricity, pneumatic pressure, hydraulic pressure if they are cut
before carry out inspection and repairing job.
Chapter 9
MACHINE Maintenance
09-HC-0001 Ch9—13
~ Blank Page ~
Chapter 9
MACHINE Maintenance
Ch9—14 09-HC-0001
[ End of Chapter ]
Chapter 10
Faults and Solutions

10.1 Troubleshooting 10-2

10.1 Troubleshooting
If there is trouble when operating the machine, it may due to some incorrect procedure of
operation, if it is still not successful to operate, please refer to below for some common
trouble shooting hints.
10.1.1 Troubleshooting Guide

The following is a list of common trouble shooting guide which may help to solve the
problem in operating the machine.
Chapter 10
Ch10—2 10-HC-0001
A. Die Clamping
(I) Die does not close

Step 1: Check the die clamping indicating lamp.
If it lights up. -> Step 3
If it does not light up. -> Step 2
Step 2: If the die clamping indicating lamp does not light up, please check the
following:
(Manual) Door close confirmed.
(Manual) Check if the sweeper, ejector returns to the home position
(Manual) Check if the Core in Before Die Close is confirmed
(Manual) Check if the Core in After Die Close returns to the home position
(Manual) Check if the 14 channels amplifying board works probably
Step 3: If the die clamping indicating lamp lights up, please check the main pressure
gauge.
If it has no pressure indicated. -> Step 4
If it has pressure indicated. -> Step 5
Step 4: If the main pressure gauge has no pressure indicated, please check the
setting of Die Close Pressure. If the setting is correct, please refer to system
main pressure problem.
Step 5: If the main pressure gauge has pressure indicated, please check the
Chapter 10
followings:
The wire wiring connection of the die clamping valve.
If the connection has no problem. -> Step 6
The relay corresponding the door close.
Step 6: If the wire connection of die clamping valve has no problem

Check the condition of spool of the valve by observing the corresponding oil
pipes.
Check the smoothness of the toggle unit.

Check if there is any leakage of the clamping cylinder.
10-HC-0001 Ch10—3
A. Die Clamping
(II) Die does not open

Step 1: Check the die opening indicating lamp.
Step 2: If the die opening indicating lamp does not light up, please check the
following:
(Manual) Check if the plunger has returned to its home position and feedback
the corresponding signal.
(Manual) Check if the sweeper, ejector returns to the home position
(Manual) Check if the Core in After Die Close is confirmed
(Manual) Check if the Core in Before Die Close returns to the home position
Check if the 14 channels amplifying board works probably
Step 3: If the die opening indicating lamp lights up, please check the main pressure
gauge.
setting of Die Open Pressure. If the setting is correct, please refer to system
main pressure problem.
Chapter 10
followings:
The wire wiring connection of the die clamping valve.
If the connection has no problem. -> Step 6
Step 6: If the wire connection of die clamping valve has no problem

pipes.
Check the smoothness of the toggle unit.
Check if there is any leakage of the clamping cylinder.
Step 7: If the die has been clamped for a long time, there is a possibility that it
cannot be opened. Please increase the Main Pressure to its maximum by
pressing the pressure up button besides the main pressure gauge.
Chose quick mode for opening the die. Press open die button.
Ch10—4 10-HC-0001
B. Shot
(I) No shot action

Step 1: Check the injection indicating lamp.
Step 2: If the injection indicating lamp does not light up, please check the
following:
(Manual) Door close confirmed.
(Manual) Check the output signal of die close button and injection button
(Manual) Check if the die close process has ended and has confirmed
(Manual) Check if the engagement if confirmed
(Manual) Check if the Core in is confirmed
Check if the 14 channels amplifying board works probably
Step 3: (Auto) Check the set value of injection time. Confirm the engagement
conformation process has finished.
Step 4: If the injection indicating lamp lights up, please check the main pressure
gauge.
Chapter 10
setting of Main Pressure. If the setting is correct, please refer to system main
pressure problem.
followings:
The injection pressure set value.
The wire wiring connection of the injection valve. If the connection has no
problem. -> Step 7
The condition of the relays of the safety door , die closing conformation and
engagement conformation.
Step 7: If the wire connection of injection valve has no problem

Check if the plunger is jammed
pipes.
10-HC-0001 Ch10—5
B. Shot
(II) Injection Force not Large Enough

Step 1: Check if the working pressure drops more than 10% during injection.
Check the nitrogen pressure of the accumulator. The normal gas pressure
for bladder type accumulator is 40-45 bar, while that for piston type is
50-60bar.
Check if there is a large amount of hydraulic oil flow into the gas chamber for
the piston accumulator.
Step 2: Check the stroke for first phase and second phase injection. Pay attention to
first phase injection stroke; it should not be too long.
Check if the 14 channels amplifying board to ensure that the second phase
injection valve has received the signal.
Check the set value of main pressure and injection pressure.
Step 3: Check if there is any jam in the nozzle and S-shape passage inside the
gooseneck.
Check if the steel ring or the injection sleeve has been worn.
Step 4: Check if the injection rod is too long.

Check if the casting stroke is less than one third of the maximum . That is
the shot weight is too light.
Chapter 10
Ch10—6 10-HC-0001
C. Main Pressure
Step 1: Check the pressure up button besides the main gauge.
Step 2: Check the ammeter on control cabinet which indicates the current in
proportional valve.
If there is no current -> Step 3
If there is current -> Step 4
Step 3: If there is no current , please check the 14 channels amplifying board and
the current of the proportional valve solenoid.
Step 4: Check the condition of the spool of the proportional valve
Step 5: Check the rotation direction of the pump. It should be clockwise.
Step 6: Check the oil temperature, oil level and oil quality.
Step 7: Check the condition of the pump see if it is damaged.
Step 8: Check the digital switch of the main pressure.
Step 9: Check if there is serious leakage of the hydraulic system.
Step10: Check if the PLC works probably.
Chapter 10
10-HC-0001 Ch10—7
D. No Spraying
Step 1: Check the spray indicating lamp.
following:
(Manual) Check [SPRAY] button
(Manual) Check if the open die action confirmed.
Step 3: (Auto) Check [SPRAY CHOICE] ON/OFF switch status

(Auto) Check if the door close confirmed.
(Auto) Check the setting of spraying times and spray timer digital switch
Step 4: Check if the 14 channels amplifying board works probably
Step 5: If the injection indicating lamp lights up, please check spray warding
pressure, spray warding valve.
Check the connection between the spray warding valve and electric cabinet.
Check the fluency of the spray tube.
Step 6: Check if the location of the lubricant.

Chapter 10
Step 7: Check if the viscosity is too high.

Ch10—8 10-HC-0001
D. No Engagement
Step 1: Check the engagement indicating lamp.
following:
(Manual) Check [ENGAGEMENT] button has input but [DISENGAGEMENT]
has no input.
Step 3: (Auto) Check if the die close is confirmed.

(Auto) Check if the door close is confirmed.
(Auto) Check if the core in is confirmed.
Step 5: If the injection indicating lamp lights up, please check the
following:
Check if the injection pressure has been set too low.
Check if the engagement valve works probably.
Check the wiring of the engagement valve and the electric cabinet.
Chapter 10
10-HC-0001 Ch10—9
E. No Disengagement
Step 1: Check the disengagement indicating lamp.
following:
(Manual) Check [DISENGAGEMENT] button has input but [ENGAGEMENT]
has no input.
Step 3: (Auto) Check if the plunger returns to its home position.

(Auto) Check the input of the [DISENGAGEMENT ON/OFF] switch.
(Auto) Check if the disengagement time has finished.
following:
Check if the die open pressure has been set too low.
Check if the disengagement valve works probably.
Check the wiring of the disengagement valve and the electric cabinet.
Chapter 10
Ch10—10 10-HC-0001
E. No Ejection
Step 1: Check the ejecting indicating lamp.
following:
(Manual) Check [EJECTOR] switch input. Make sure no input for [EJECTOR
BACKWARD].
(Manual) Check if the die open has been confirmed.
(Manual) Check if the core is at home position.
Step 3: (Auto) Check if the plunger returns to its home position.

(Auto) Check if there is no input for [EJECTOR BACKWARD].
(Auto) Check the setting of ejection times and ejection timer digital switch.
following:
Check if the ejection pressure has been set too low.
Check if the ejection valve works probably.
Check the wiring of the ejection valve and the electric cabinet.
Chapter 10
10-HC-0001 Ch10—11
F. No Sweeper
Step 1: Check the ejecting indicating lamp.
following:
(Manual) Check [SWEEPER] switch input.
(Manual) Check if the die open has been confirmed.
Step 3: (Auto) Check the input for the [SWEEPER] choice.

(Auto) Check if the die open has been confirmed.
(Auto) Check the setting of ejection timer digital switch.
following:
Check if the sweeper working pressure has been too low. The normal
pressure should be 0.5MPa.
Check if the sweeper valve works probably.
Check the wiring of the sweeper valve and the electric cabinet.
Chapter 10
Ch10—12 10-HC-0001
G. CANNOT ADJUST DIE HEIGHT

Step 1: If the mould thick cannot be adjusted -> Step 2
If the mould thin cannot be adjusted -> Step 3
Step 2: If mould thick cannot be adjusted, please check the followings:

(Manual) Check the input for [MOULD THICK] button. There should not be
input for [MOULD THIN] button.
(Manual) Check that there should not be any input for [AUTO] and
[SEMI-AUTO].
(Manual) Check if the sweeper (if any) has returned to its home position.
(Manual) Check the [DIE HEIGHT ADJ ON/OFF] switch input.
Step 3: If mould thin cannot be adjusted, please check the followings:

(Manual) Check the input for [MOULD THIN] button. There should not be
input for [MOULD THICK] button.
(Manual) Check that there should not be any input for [AUTO] and
[SEMI-AUTO].
(Manual) Check if the sweeper (if any) has returned to its home position.
(Manual) Check the [DIE HEIGHT ADJ ON/OFF] switch input.
Step 4: If hydraulic motor is used for die height adjustment, please check the
followings:
Check the pressure set value.
Check the condition of die height adjust valve and die height adjust motor.
Chapter 10
10-HC-0001 Ch10—13
H DC24V Grounding Protection

If there is not DC24V power output, first check the indicator in the control cabinet whether
the green light is on. The DC24V may connect to the ground for protection when the light
is off. If this situation has lasted for 1.5 seconds, the power supply will be cut off until the
problem has been solved. In this case, reboot the power supply by switching off and on
the main power switch.
Chapter 10
Ch10—14 10-HC-0001
Chapter 11
Machine Parts
(for reference)

11.1 Supplied Parts and Tools 11-2
11.1 Supplied Parts and Tools

The following lists show some standard parts of the machine may be included as
depending on the options selected, and some important maintenance tools that may
needed for working on the machine.
No. Name Code Qty.

1 Zinc alloy electrical furnace 2699-40010 1
2 Furnace track assembly 10973430000 1
3 Injection plunger Φ70 10203101001 1
4 Plunger piston rod 10283100801 1
5 Disassembly nozzle head tool 10763105100 1
6 Disassembly nozzle body wrench 10973130900 1
7 Disassembly lifting screw wrench 10983124100 1
8 Heating rod shield cover 10205407500 1
9 Shield cover sleeve 10033101701 1
10 Separate nozzle body 10203120400 1
11 heating band Φ60 10203121500 1
12 Gooseneck heat insulation cotton mounting plate 10203101600 1
13 Gooseneck heat insulation cotton 10203115100 1
14 Steel ring Φ70 10203100901 3
15 Injection nozzle head A Φ8 1DO01603-130101 1
Chapter 11
16 Injection nozzle head B Φ10 10763130200 1

17 Injection nozzle head C Φ12 1DO01603-130301 1
18 Iron block 10033430601 2
19 steel cushion for lifting (1) 10281200401 4
20 steel cushion for lifting (2) 10281200501 2
Machine Parts
21 Oil can 5900-00097 1

22 Steel ring pliers 5300-00170 1
23 Socket screw 2401-08060 1
24 Hexagonal screw 2402-24220 6
25 Socket screw 2401-10016 2
26 Socket screw 2401-12025 2
27 washer 2406-08000 1
Ch11—2
28 Level pad (KM-190) 2614-00008 8

29 Hexagon wrench 5303-12017 1
30 Instruction manual - 2
31 Certificate - 2
32 Die clamp M20 5303-12017 12
33 Natural gas sprayer - 1
Chapter 11
Machine Parts
Ch11—3
~ Blank Page ~
Chapter 11
Machine Parts
Ch11—4
Chapter 12
Drawings
Item Contents
12.1 Machine Outline
12.2 Foundation Drawing
12.3 Platen Size
12.4 Nozzle head
12.5 Gooseneck assembly
12.6 Clamping unit
12.7 Clamping cylinder assembly
12.8 Ejector cylinder assembly
12.9 Engaging cylinder assembly
12.10 Injection cylinder assembly
12.11 Grease lubrication pipeline layout
12.12 Oil lubrication pipeline layout
12.13 Hydraulic schematic diagram
12.14 Electric Schematic Diagram
12.15 Main cabinet backboard layout
~ Blank Page ~
Chapter 12
Drawings
Ch12-2
Appendix
ISO 9001:2008
Peripheral Device
Instruction Manual
1. Auto sprayer
2. Auto extractor
Fitting for
Model: AVIS-II DC280

Series No: 1611600501
力勁機械廠有限公司
L. K. MACHINERY CO. LTD.
ISO 9001:2008
AUTO SPRAYER
INSTRUCTION
MANUAL
MODEL: SD-01A
SD-02A
力劲机械厂有限公司
L. K. MACHINERY CO. LTD.
V1. 2
0
Contents
1. Technical data .................................................................................................................................................... 1
2. Before start ........................................................................................................................................................ 2
2. 1 Content of the instruction ........................................................................................................................... 2
2. 2 Notes ........................................................................................................................................................... 2
3. SD–A Sprayer appearance ................................................................................................................................. 5
4. Sprayer action .................................................................................................................................................... 6
5. Primary piping ................................................................................................................................................... 7
6. Adjustment......................................................................................................................................................... 7
7. Installation graph ............................................................................................................................................... 8
8. Machine interface .............................................................................................................................................. 9
9. Operate rule ......................................................................................................................................................11
10. Interlock circuit safety check with the DCM and sprayer. ..............................................................................11
11. Breakdown & countermeasures ....................................................................................................................... 12
12. Maintenance and inspection ............................................................................................................................ 14
13. Pneumatic diagram .......................................................................................................................................... 15
14. Electric diagram ............................................................................................................................................... 16
FOREWORD
The products of our company are designed superiorly with excellent quality.
It is simple to operate and maintain, receiving the extensive favorable
comment among users.
In order to make it convenient for users to operate “spray” series of products
of our company correctly, we specially make an operation instruction. This
instruction shows the characteristic of the series of products to “spray”, such
as the performance of the machine and main technical parameter, installing,
debugging, maintaining, etc. Please read this operation instruction carefully
before using the products of our company, and operate according to its
regulation.
1. Technical data
ITEM SD–01A SD–02A

FITTING FOR DCM 88~160T 200~400T
ADJUSTMENT FOR DIE 600mm 800mm
THICKNESS
TRAVELING STROKE ±150mm ±200mm
Height of up and down 180mm 180mm
adjust
Tube of blow 8PCS 12PCS
TRAVEL UPWARD 1. 0sec 1. 2sec
TIME
TRAVEL DOWN TIME 1. 0sec 1. 2sec
AIR PRESSURE 5~6kg/cm2 5~6kg/cm2
Liquid pressure 2~5kg/cm2 2~5kg/cm2
power AC200~220V 50~60Hz AC200~220V 50~60Hz

Operation power DC24V DC24V
1
2. Before start
2. 1 Content of the instruction
Please do read this manual and get a good understanding, which will make you familiar with the
structure, performance and adjustment of the machine so as to put the machine into production as
soon as possible.
Note: Please do not operate the machine which method is not introduced by this manual.
Manufacturer will not take any responsibilities for injury and accidents in misunderstanding the
operating methods.
Please put this manual near to machine so that it can be read as requirement.
2. 2 Notes
● Danger class
● There are 3 classes in safety notes. There might be very dangerous while operating machine.
It might cause injury or death without complying the rules of

DANGER
the warning.
WARNING It might cause serious injury or damage to machine without

complying the rules of the warning.
CAUTION It might cause injury or damage to machine without complying
the rules of the warning.
Safety operation notes:
DANGER
●Moving part range, not allowing entering.
Please do not enter the moving part of spray, or it might cause injury or death by it.
●Do not repair or maintain machine during machine running.

Please cut off power before repairing or maintaining machine during machine
running.
WARNING
●Wear work clothes while operating.
Please wear suitable work clothes while operating. Clothes which are too large is
against safety rules.
2
●Please do not make any alteration to this machine.
Please do not make any alteration to this machine. Manufacturer will not take any
responsibilities for that.
●Grounding
Wires must be well-grounded.
●Please do not open cover of control cabinet.

High voltage circuit inside, do not open cover of control cabinet.
●Please do not touch a running machine.

Please do not touch a running machine, or it might cause injury.
●Stop machine running while power failure frequently.

Please stop machine running while power failure frequently.
CAUTION
●Be clear who is the supervisor
Be clear who is a supervisor in manual operation in order to prevent any mistake.
●Read this instruction carefully

Please read this instruction carefully to understand every item.
●Ensure repairing and maintaining room

Ensure there is at lease 1 meter spare to guarantee safety running.
●Clean up
Clean up sundries around machine and provide enough illumination.
●Ensure checking and maintaining work

Ensure daily checking and maintaining work. Please inform us when there is a
failure.
●Failure and abnormal
3
Please adjust machine according instructions of our technicians when there is failure
and abnormal.
●Operating
Please do not touch operation panel or switches with smeary or wet hands.
●Please do not use in the following locations:

·Environmental temperature below 0°,above 40°.
·Gas.
·Too much metal and carbon dust.
·Strong magnetic field, strong electric field.
·Too much dew.
·High vibration.
●Expression during operating

Cut off power and show an “Operating” board to prevent accidents while working
with ladler, such as checking, repairing, adjusting and cleaning, etc.
●Ensure the safety of standing spot

Ensure the safety of standing spot and wear safety belt when working high above
the ground.
●Disconnect running of related machines

Disconnect related machines to prevent accidents while working with ladler, such as
checking, repairing, adjusting and cleaning, etc. (Die casting, furnace…)
NOTICES OF SAFETY
·Do not operate spray when moving electric parts.
·Please comply the following items：
Stop the running of spray before operating.
◎ Do not adjust spray pipe in a running spray.
·Be sure that there is not anyone around moving range of spray before starting spray.
·For any reason for spray STOP in auto running, the reason must be found out and cleared
up, then ladler can be restarted. If the reason cannot be found and restart spray,
there might be great danger.
·Do not touch switches or buttons with wet hands or with gloves.
·Check the correctness of program data after the setting conditions being changed.
Confirm all actions with manual operation and then start machine.
·Do not touch switch for no reason and do not lean against machine.
·If there is anything abnormal in running, stop machine immediately and consult to
professional personnel.
4
3. SD–A Sprayer appearance
总装图
5
4. Sprayer action
Ascend
Descend
升降下降
Descend 上升
Ascend
T1 air 下
air降
T1blow 吹气
blow
T3 front air
blow前喷雾
后喷雾
中间喷雾
前blow
b/f air 后吹气
上blow
T2 air 升吹气
中间吹气
T1：Set up blow timer 1

T2：Set up spraying(calm mould or acting mould)timer
T3：Set up the blow 2 timer
6
5. Primary piping
A. Air piping
Spraying device of input air pipe size is “1/2"、3/8"，main piping size is
“1"、1/2"or above it，pressure is 5kg/cm2 or above；please install air-filter
in the piping.
B. Supply diastatic water pressure in 2~5kg/cm2，please adjust it in best
mode when working.
C. Piping junction
It must be install air-filter in the piping way. .
6. Adjustment
A、Adjustment for back and forth.
Please tweak loosen screw of the fixed back and forth bamboo before
adjustment, it have fours together . After do it, please boost bamboo
until move it in correctly position, last of all, please tweak tightly the
fours screws.
B、Adjustment rotate angle
Unfasten the two screw of “M10x30”，and rotate consolidation screw,
until parallelism for spray board and in front and back mould. .
C、Adjustment up and down position.
Unfasten setting bolt，adjust the bamboo ,until move to need position for
working.
D、Adjust speed of up and down.
Up and down cylinder have install adjustor, adjust suit speed until it stop
vibration.
E、 Adjust spray water amount
It use the sluice adjust spray water amount where spraying board, it can
adjust each spray water amount where the back of the spray.
F、Adjust angle of spraying.
Adjust the spraying fix and fix pole or spraying angle until machine
working in normally.
7
G、 Adjustment sequence of blow or spray.
It adjustment for setup program. (must according workmanship before
working).
H、 Setup blow and spray timer.
It can Setup spray and blow for longtime or short time by each timer on
the board.
7. Installation graph
A. Sketch map of installation
B. Space diagram of installation
8
8. Machine interface
Allow close mould：Allow machine close mould when link “85”and “86” . them
the spray up in limits
Allow extractor arm advanced: When spray back limits, it output one signal, can
link “87”and “88” ON. It can prevent spray and extractor interference.
Auto close mould: Spray output one signal after spraying . the machine can auto
close mould at that time
Auto spraying star:：When the product take out of machine or extractor take out
product . it output one signal to spray . auto spraying star.
Mould open limit: When the machine mould open limit, it output one signal to
spraying.
Close mould limit: When the machine mould close limit, it output one signal to
spraying.
Extractor retreat limit: When the extractor retreat limit, it output one signal.
Attach morsel: the drawing as follows
Mainframe power 220V
87
9
99
SD–A SPRAYER sequence of action (setup in PLC program)
（1 ）
（）
（）
（1 ）
（）
10
9. Operate rule
(1) Manual operate
A. Manual/auto: choice manual or auto switch
B. up/down: When the switch point to “down”, sprayer let down; else it will up
C. Depress blow button, machine will blow, if depress spray button, it will spray.
Adjust air pressure of blow and spray at manual operates. Adjust amount of spray
on back of shower nozzle and speed until the machine works normally. .
Note: when manual operate, the spray must be on down limit. Otherwise the spray
can’t blow and spraying.
(2) Auto operate
A. When choice “Auto/manual” to auto, choice “up/down” to up. Choice the DCM
“manual/auto” for auto, depress “spray star” button. The spraying begin auto go
round.
B. According of DCM input signal, choice spray auto star and repress the button,
Machine action immediately.
C. When the switch point to “down”, the machine can’t AUTO start.
10. Interlock circuit safety check with the DCM and

sprayer.
Please confirmation safety wiring accuracy before auto operation.
A．When the DCM closing mould, spray can’t down at that time for manual
operation.
B．When sprayer down act, DCM can’t close mould at that time for manual
operation.
11
11. Breakdown & countermeasures
breakdown causal countermeasures

Spray can 1, if DCC AUTO signal (I12) 1. Check DCM auto switch whether or not ok.
not input true 2. Check sprayer auto switch whether or not ok.
Auto spray 2 if spray auto signal (I15) 3. Check extractor back limit switch whether or not
on ok. .
3, if open mould limit(I10) is 4. Check star button whether or not ok. (1B4).
true. 5. Check DCM open mould whether or not ok.
4. If extractor back limit 6. Check line of link DCM 0V and spray line (98).
(I13) true. whether or not ok.
7. check middle relay(KR6,KR4KR7)and socket
8. check signal point (I12,I15,I10,I13,I17)on the relay
(KA6,1B2,KA4,KA7,1B4 ) whether or not ok.
9. Check the really (:KA6, KA4, KA7) the line of link
to DCM.
10. Check the relay of the DCM auto output (R7) and
open mould limit relay (R5) whether or not ok.
11. Check I12, I15, I10, I13, I17 whether or not input
to PLC.
SPRAY 1. Up limit (I110)1LS1and 1. Check up limit 1LS1 (I110) switch and down
alarm in down limit I111 (1LS2) limit1LS2 (I111) switch and the line.
star closure same time. 2. Check relay of KA4 (I10) and KA5 (I11) and them
2. Open mould limit I10 line.
(KA4) and close mould
limit I11 (KA5) in the same
time.
Spray can’t 1. Don’t turn on power 1. Check DCC and spray or extractor power supply.
down supply. 2. Check DCC mould open limit switch.
2,mould don’t open 3. Check back limit of extractor.
12
limits(I10)KA7 4. Check speed valve of adjustment speed.
3. extractor not back to 5. Check “1B3” to “I16” and “O16” to down valve
limit(I13KA7) line and valve (S3).
4. Valve of adjustment speed 6. Check 1B3switch.
down shutdown. 7. check PLCO16 output to inside relay or
5. Down valve coil bad. transistor
(S3).
6. Down switch bad.
(1B3)I16.
7. Down valve bad. (S3).
8. PLC output O16 bad.
Spray can’t 1. Air pressure too below. 1. Check valve and coil. (S1).
Up (smaller 3kg/cm^2) 2. Adjustment discharge again.
2. Shut of adjustment speed 3. Check valve (S3).
valve. 4. Check PLCO16 output inside relay.
3. up valve bad. 5. Check down switch . 1B3.
4. PLC inside relay bad.
Can’t 1. Spraying valve bad. (S1). 1. check valve and coil . (S1)
spraying in 2. Too smaller of discharge. 2. Adjust discharge again.
manual 3. Stop of piping. 3. Check modal piping.
operation 4. Break of spraying valve 4. Check coil of valve coil, CS1 to O18wiring.
line. 5. Check switch and link to (1B5) PLCI18 line.
5. Operation switch bad or it 6. Check PLCI1 and O18 map point relay. .
link line break. (1B5)I18.
6. PLC input (I18) or
outputO18R bad.
Can 1. Spray time too fast. 1. Adjustment spraying timer T2
spraying, 2. Spray timer relay (T2) bad. 2. Adjusted spraying time again. .
but
13
can’t auto
operation.
12. Maintenance and inspection
item contents period

minuteness Minuteness switch ON-OFF ok? Before working
switch It whether loose off?
Electric wave Put out water each week
filter
Fix Screw Whether screw loose off of Spray itself Before working
Slip of move part Oiling oral Each month add
butter
Once
Cylinder Whether loosen of screw. And air piping Before
drop out. working
Ascend and Screw loose? Switch bad? Before
descend axis working
Linkage back Screw loose? Before
track working
Screw of Screw and nut loose? each week
mechanic
Air pressure Pressure gauge 5 kg/cm² confirm Before working
14
13. Pneumatic diagram
15
14. Electric Schematic diagram
Note: Spraying electric Diagram, please refer to DCM (die casting machine)
Electric Diagram.
16
AUTO EXTRACTOR
INSTRUCTION
MANUAL
MODEL: ET-01/02A
力勁機械廠有限公司
L.K. MACHINERY CO.LTD.
Content
1. Before start ...........................................................................................................................................1
1.1 Contents of manual ...................................................................................................................1
1.2 Notes ........................................................................................................................................1
2. Extractor brief introduction....................................................................................................................5
3. Technical data ......................................................................................................................................6
4. Machine installation ..............................................................................................................................7
4.1 Approach of transport ...............................................................................................................7
4.2 Install foundation .......................................................................................................................7
4.3 Hoisting drawing .......................................................................................................................8
5. Machine operation instruction...............................................................................................................9
5.1 Operation Box (located on the side of Die casting machine) ....................................................9
5.2 Operator panel (located on the side of ET-02A)........................................................................9
5.3 Operation instruction ...............................................................................................................10
5.4 Main cabinet panel and instruction..........................................................................................11
5.5 Manual operation ....................................................................................................................12
5.6 Auto operation.........................................................................................................................13
5.7 Safety operation for extractor ..................................................................................................15
6. Machine Maintenance ........................................................................................................................16
7. Drawings ............................................................................................................................................17
7.1 Outline drawing .......................................................................................................................17
7.2 Pneumatic drawing .................................................................................................................18
7.3 Electrical schematic diagram. .................................................................................................18
1. Before start
1.1 Contents of manual
Please do read this manual and get a good understanding, which will make you familiar
with the structure, performance and adjustment of the machine so as to put the machine
into production as soon as possible.
Note: Please do not operate the machine which method is not introduced by this manual.
Manufacturer will not take any responsibilities for injury and accidents in misunderstanding
the operating methods.
Please put this manual near to machine so that it can be read as requirement.
1.2 Notes
● Danger class
● There are 3 classes in safety notes. There might be very dangerous while operating
machine.
It might cause injury or death without complying the rules

DANGER of the warning.
WARNING It might cause serious injury or damage to machine
without complying the rules of the warning.
It might cause injury or damage to machine without
CAUTION
complying the rules of the warning.
DANGER
●Moving part range, not allowing to enter.
Please do not enter the moving part of extractor, or it might cause injury or death
by it
● Do not repair or maintain machine during machine running.

Please cut off power before repairing or maintaining machine during machine
running.
WARNING
● Wear work clothes while operating.
Please wear suitable work clothes while operating. Loose clothes are against
safety rules.
● Please do not make any alteration to this machine.
1
Please do not make any alteration to this machine. Manufacturer will not take any
responsibilities for that.
● Grounding
Wires must be well-grounded.
● Please do not open cover of control cabinet.

High voltage circuit inside, do not open cover of control cabinet.
● Please do not touch a running machine.

Please do not touch a running machine, or it might cause injury.
● Stop machine running while power failure frequently.

Please stop machine running while power failure frequently.
CAUTION
● Be clear who is the supervisor
Be clear who is a supervisor in manual operation in order to prevent any mistake.
● Read this instruction carefully

Please read this instruction carefully to understand every item.
● Ensure repairing and maintaining room

Ensure there is at lease 1 meter spare to guarantee safety running.
● Clean up
Clean up sundries around machine and provide enough illumination.
● Ensure checking and maintaining work

Ensure daily checking and maintaining work. Please inform us when there is a
failure.
● Failure and abnormal

Please adjust machine according instructions of our technicians when there is
failure and abnormal.
2
● Operating
Please do not touch operation panel or switches with smeary or wet hands.
● Please do not use in the following locations:

·Environmental temperature below 0°,above 40°.
·Gas.
·Too much metal and carbon dust.
·Strong magnetic field, strong electric field.
·Too much dew.
·High vibration.
● Expression during operating

Cut off power and show an “Operating” board to prevent accidents while working
with extractor, such as checking, repairing, adjusting and cleaning, etc.
● Ensure the safety of standing spot

Ensure the safety of standing spot and wear safety belt when working high above
the ground.
● Disconnect running of related machines

Disconnect related machines to prevent accidents while working with extractor,
such as checking, repairing, adjusting and cleaning , etc.(Die casting, furnace…)
3
NOTICES OF SAFETY
Please comply the following items:
 Do not operate extractor when moving electric parts.
 Stop the running of ladler before operating.
 Do not adjust extractor when it is running.
Install a fence for the extractor.

 ·Be sure that there is not anyone around moving range of extractor before
starting extractor.
 ·For any reason for extractor STOP in auto running, the reason must be found
out and cleared up, and then extractor can be restarted. If the reason cannot
be found and restart extractor, there might be great danger.
 Do not touch switches or buttons with wet hands or with gloves.
 Check the correctness of program data after the setting conditions
being changed. Confirm all actions with manual operation and then
start machine.
 Do not touch switch for no reason and do not lean against machine.
 If there is anything abnormal in running, stop machine immediately
and consult to professional personnel.
4
2. Extractor brief introduction
The extractor is peripheral device of die casting machine, which plays an important roles in
die casting production cell. Its function is to extract the parts and put them on preset
position.
The products of our company are designed superiorly with excellent quality. It is simple to
operate and maintain, receiving the extensive favorable comment among users.
The features as follows:
Be controlled by PLC and transducer, with steady system, reliable performance and easy
operation.
Arm movement driven by transducer, clamp arm and clamp actions powered by pneumatic
cylinder. Multi-work mode can meet different work requirements.
Accurate pneumatic cylinders and ball straight line guideway pair with the performance of
antiwear and long worklife.
In order to make it convenient for users to operate “extractor” series of products of our
company correctly, we specially make an operation instruction.
5
3. Technical data
model
Item unit
ET-01A ET-02A
Air pressure Kgf/cm 2
5 5
power V AC380 AC380
Act axis Axis 4 4
Can adjust high
mm 400 300
Volume
Arm force mm 1785 1885
Adjustment for stroke
mm 100 200
extracting direction
Rotate Angle of
degree 90° 90°
arm
Claw open angle degree 20° 20°
Workpiece weight Kg( Max) 3 8
Machine weight Kg 550 600
Control case weight Kg 150 150
3
Outline size mm (L×W×H) 650X680X1800 650X680X1900
Control case sizes mm3(L×W×H) 650X400X1800 650X400X1800
DC88,DC100,D DC200,DC280,
Fitting for DCM
C130,DC160 DC400
6
4. Machine installation
4.1 Approach of transport
(1) Announcement in transport
 Please use swinging on machine when transport.
 Don’t knock and break machine while transport it.
(2) machine transport approach.
Use suspenders through the two swinging before hang up machine. Visit 2-1.
It could be death or seriously injury when don’t operate not appropriate.
Fix machine arm while hoisting the extractor.
4.2 Install foundation

Use four stud bolt fixed machine on foundation，visit below drawing.
·Foundation must level.
·Install area muse larger than machine arm moving province.
680
650
600
480
D
C
440
620
510
610
640
C
concrete
8－M16 bed stud bolt (custom prepare.
650
7
4.3 Hoisting drawing
8
5. Machine operation instruction
5.1 Operation Box (located on the side of Die casting machine)
5.2 Operator panel (located on the side of the extractor)

(The language type printed on the panel may be varies depending on the order.)
9
5.3 Operation instruction
Number Name mode Function of Operate front-panel
manual/auto manual Machine can perform all sort of acting
1
choice knob auto Must connect to die casting machine
Press the button after selecting auto mode, then
Lamp on
2 Auto start the lamp will keep shine unless malfunction.
shine
Machine can’t run auto mold at that time.
Machine arm can go in DCC mould when DCC
3 forward mould and door open limit. Sprayer must up
Arm knob
limit.
4 retreat Arm retreat action when it in manual mode.
Crossly forward Machine crossly action in manual mode.
5
knob retreat Machine crossly retreat.
Open Claw opens when machine in manual mold.
6 Clamp knob
close Claw close when machine in manual mold.
ON Arm turn round when machine in manual mode.
Clamp arm
7 Off Arm rotates reseat when machine in manual
knob
mode.
E-stop pressed Put off machine power while depress It.
8
button
10
5.4 Main cabinet panel and instruction
(The language type printed on the panel may be varies depending on the order.)
警报器
ALARM
电源指示横行前待取出确认

吹气使用
POWER LAMP AIR BLOW USE LATERAL BEFORE EXTRACTOR CONFIRM
OFF ON OFF ON 1 0 2
Number Name function

When incorrect operation and machine malfunction occurs,
1 alarm
the alarm will give a sound.
When the control system powers on, the power lamp will be
2 Power lamp
on.
3 “ON”, the sprayer takes part in auto cycle; “OFF”, the
Air blow use
sprayer is not selected.
Available on auto mode. If the setting is as “on”, when next
Lateral cycle starts, the extractor will advance laterally to lateral
4
before front waiting position.
It is three-way selector. The selector 1/2 position means
Extractor that limit switch1/2 is chosen to check product. If the
5
confirm selector is in middle position, only when two limit switches
(LS1 and LS2) are on, the product can be judged good.
11
5.5 Manual operation
When manual/auto selector is set as”manual”, the following actions are permitted.
（1） arm go forward : if the signal of mould limit ,door open limit and sprayer up
limit ,them when the switch choice to “ON”，arm should advanced. If not satisfy,
machine stop immediately.
（2） Arm retreat: when arm retreat switch put on, arm should back, until move to high
speed limit and back limit, the speed slow star while high speed limit on. And stop
while back limit on. Adjust arm acting until fair and softly.
（3） crossly : arm cross moving to forward limit when crossly switch on. Adjust the
cylinder conditioner until moving fair and softly.
（4） Claw: choice the switch on or off, claw should open or close.
（5） Clamp rotate arm: choice rotate switch on or off, clamp arm should rotate.
12
5.6 Auto operation
Correct for link of DCC and extractor wiring. Turn on power after confirm wiring on error;
manipulation extractor arm back to limit position, and put knob on middle position. crossly
knob point to back, and claw knob point to open ; rotate arm knob point to rotate back ;the
machine have go to home position, it can operation.
In auto mode, press auto button, the machine will start and the auto lamp keeping on at
the same time.
(1) general work mode :
(close mould limit signal→(open limit signal) →arm→(advanced high speed)
→advanced speed slow down
↓
↑
(arm stop)
rotate arm retreat ↓
↑ crossly forward
↓
clamp open (limit and stop)
↑ ↓
eject limit
(retreat rotate
↓
limit)
clamp lcose
↑ ↓
crossly retreat
arm rotate back
↓
↑
(retreat limit) ←slow down retreat←(retreat high speed limit) ←arm
retreat←(retreat limit)
←——check signal——→
Note: a．if machine don’t check product，the machine should stop and alarm immediately.
b．in mark of “() ”contents is DCM or extractor signal.
13
(2) Arm advance waiting work mode (waiting on the side of DCM)
mould close arm advanced Stop at waiting Mould open Arm

→ → → →
limit waiting place limit advance
↓ ↓
High speed
Rotate retreat
limit
↓ ↓
Slow down
Clamp open
advance
↓ ↓
Cross Arm stop
Rotate limit Cross forward → ←
advance advance
↓ ↓
Rotate arm Cross
limit advance limit
↓ ↓
Retreat limit Eject limit
↓ ↓
Slow down Clamp close
↓ ↓
Arm retreat
← Arm retreat ← Retreat limit ← Cross retreat
high speed limit
14
5.7 Safety operation for extractor
(1) Check machine surface every day before turning on the machine.
(2) According require of machine, please add lubrication oil periodically.
(3) Turn off power after knock off.
(4) When machine alarms, you must turn off power before maintenance.
(5) During machine running, permit entering the working zone of die casting machine.
15
6. Machine Maintenance
(1) Check air pressure before running machine; if it not normally, pleases adjustment
pressure until attain machine requisition.
(2) Check amount of lubricant in atomize (use lubricant mold: 1# ISOVG32), adjustment
out of lubricant amount, keep it have 1-12 Drop each minute.
(3) Clear greasy dirt and dust on machine superficial and machine part, check airs line,
adapter, all air value, if it reveal air, pleas disposal it until machine ok.
(4) Check the screw of miniature switch, and check switch of cam. If the screw loose,
please fix it. Add oil each month in machine junction axis and turn about part once.
(5) Please put out of the water in electric wave filter ,the strainer replace each half years.
16
7. Drawings
7.1 Outline drawing
17
7.2 Pneumatic drawing
L. K. Machinery Co., Ltd.
7.3 Electrical schematic diagram see the DCM instruction manual chapter 12.
18
L.K. Group
L. K. Machinery Co. Ltd.
Add: Unit A, G/F., Mai Wah Industrial Building, 1-7 Wah Sing Street, Kwai Chung, N.T., Hong Kong
Tel: +852 - 3412 5500
Fax: +852 - 3412 5511
Shenzhen Leadwell Technology Co. Ltd. / L. K. Machinery (Shenzhen) Co. Ltd.

Add: L.K. Industrial Zone, Qinghu Village, Longhua Town, Baoan District, Shenzhen, China
Tel: +86 - 755 2812 3321
Fax: +86 - 755 2812 3320
Zhongshan L.K. Machinery Co. Ltd.

Add: Guang Fu Da Dao Dong Shen Zheng ZhongShan, China
Tel: +86 - 760 2825 231
Fax: +86 - 760 2228 078
Shanghai Atech Machinery Co. Ltd.

Add: 42 Min Yi Road, Xin Qiao Development Area, Song Jiang District, Shanghai, China
Tel: +86 - 21 5768 6188
Fax: +86 - 21 3764 3555
Shanghai L.K. Machinery Co. Ltd.

Add: 6 Min Yi Road, Xin Qiao Development Area, Song Jiang District, Shanghai, China
Tel: +86 - 21 5764 070
Fax: +86 - 21 5764 070
Ningbo L.K. Machinery Co. Ltd.

Add: No.402 Songhua Jiang Road BeiLun Ningbo, China
Tel: +86 - 574 8687 5581
Fax: +86 - 574 8611 6528
Fuxin L.K. Northern Machinery Co. Ltd.

Add: No. 306 Haixin Road, Tai Ping District, Fuxin, Liaoning, China
Tel: +86 - 418 2482 086
Fax: +86 - 418-2462 318
L.K. Machinery Corp.

Add: Room A4, 5/F, No.502 Jiuru 1 st Road, Sanmin District, Kaohsiung City 80765, Taiwan, R.O.C.
Tel: +886 - 7390 0061
Fax: +886 - 7390 0747
L. K. MACHINERY USA, INC

Add: 20762 East Carrey Road Walnut, Ca
91789 USA
Tel: +909 - 5949 447
Fax: +909 - 5948 133
Quantum Machinery International INC

Add: 210 Brunel Road, Mississauga, Ontario
Canada L4Z1T5
Tel: +905 - 7129 220
BC-CU-0006
[ End of Product Instruction Manual ]

Avis-II Dc280 Eng

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Avis-II Dc280 Eng

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ISO 9001:2008

Certificate No. FM37608

Serial No: 1611600501

Chapter 1 Machine Specification

Chapter 2 General Machine Information

Chapter 3 Safety, Cautions, Labels &Procedures

Chapter 4 Machine Installation and Preparation

Chapter 5 Machine Operation

Chapter 6 Machine Control System

Chapter 7 Machine Start-up

Chapter 8 Safety Operation

Chapter 9 Machine Maintenance

Chapter 10 Faults and Solutions

Chapter 11 Machine Parts

With continual improvements and innovations that are occurring almost

Phone: +(852) - 3412 5500 Fax: +(852) - 3412 5522

E-mail: [SALES] sales@lkmachinery.com.hk

Section Contents Page

01- L. K. Machinery Ch1—1

1.1 Machine Configuration

Customer Country Mexico

Rated voltage 440V x 3 phase

1.2 Machine Specifications

Nozzle Heating Power 5 kW

Machine weight 11000 kg

Section Contents Page

02 HC 0001 L. K. Machinery Ch2—1

2.1 Machine Overview

(The above picture is using DC88 for reference)

Back safety Toggle Safety

GENERAL MACHINE INFORMATION

2.2 Control System Overview

2.2.1 Main Control Cabinet

2.2.2 Operator Control Panel

Main operator panel

2.3 Clamping Mechanism Overview

GENERAL MACHINE INFORMATION

2.3.1 Toggle Mechanism

2.3.2 Hydraulic Ejector Mechanism

2.3.3 Core Pulling Mechanism

2.3.4 Die Height Adjustment Mechanism

2.3.5 Hydraulic engagement Mechanism

2.4 Injection System Overview

GENERAL MACHINE INFORMATION

2.5 Hydraulic System Overview

2.6 Lubrication System Overview

2.7 Cooling System Overview

2.8 Safety Door System Overview

GENERAL MACHINE INFORMATION

Section Contents Page

3.1 General Safety

3.2 Signal Words

When no federal, provincial, state or local government code, regulation, standard or

DANGER – Indicates an imminently

Safety, Cautions, Labels & Procedures

Black lettering on Orange Background

Black lettering on Yellow Background

3.3 Safety Labels

Under any circumstances, DO NOT REMOVE, or allow to remove, any of the

DIE CASTING MACHINE & PLASTIC INJECTION MACHINE

With this label indicating that

has to be taken when opening

This label indicating that there

This label indicates that there