UNION POWER series

UNION POWER Machinery

MANUAL BOOK

NINGBO UNION POWER MACHINRY CO.,LTD

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 Company profile

Ningbo Union Power Machinery Co., LTD is a high -tech

manufacturer which is professional in plastic injection molding machine

for special materials. We have got the ISO ： 9001-2008 quality system

certificate at the beginning of the establishment. It is well known

enterprises of plastic machinery at home and abroad.

Union Power machinery has more than 15 years practical

experience in the various thermosetting material produ ction area. By

the introduction of Europe technology and combine with the advantage

of Japan, we develop the LD series thermosetting special injection

molding machine, BMC series special injection molding machine and

SR series liquid silicone special injec tion molding machine.

Also UNION POWER Machinery is professional other general

materials like PET, PE, PVC, PP, PC,NYLON etc.

With the new management concept and professional technology,

Union Power machinery develops very fast, the machines are exported

to Europe, middle East, south America, Southeast Asia, Africa market.

UNION POWER aims to supply good quality machines for all

customers.

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 Preface
Thank you very mach for you purchase of the UNION POWER Injection Machine.

This instruction manual is one section of the product.

This instruction manual provides detailed instructions for safe operation of the machine.
To allow the machine display its full productivity and performance.

Please read this instruction carefully after the machine is put into operation. Then provide proper
handling and careful maintenance.

It is remember that safety team in the “safety warning” page in order to avoid danger of
person and machine by fault.

Attention: safety information

Note: pay special attention

SAFETY WARNING

The machine must be grounded.

Each switch button must be at correct position before starting machine.
Do not touch live electricity parts after starting machine.

Check main cable often, if cover of main cable has expose, broken and
dehisced, must be changed.

To ensure switch off power supply of machine when you maintain.

To ensure ground terminal of main electrical box connect with earthing
cable lie hidden in the earth.

The resistance of earthing cable must fit requirement specified, and the
earthing cable must be laid as requirement specified.

Attention:

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 Be caring for firing when cleans the oil boxes by gasoline, otherwise, it
should occur dangerous to you or detonate the machine.
Do not fire before he gasoline have not emanated completely as finished clean.
You must be attention not to fire after open machine’s package, because the oil box of machine
has cleaned by gasoline before the machine leave factory.

Do not allow changing or removing the safety devices

The safety devices equipped in the machine are good help you or your conducts made.
The machine should be operated at normal state and safety devices work well.
Do not allow changing or removing the safety devices, but our company is irresponsible for in
case of fault of machine in accident.

You must operate the machine only at operation area; never allow operation other any place.

Customer Service contact: 0086-13705741165

Business Dept：0086-13705741165

Technical Dept：0574-88006828

Fax：0574-88006268

ADD: MINLE, GAOQIAO TOWN, HAISHU, NINGBO, CHINA

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 Content
1. Company profile

1.1 Company profile .............................................................. .....................01

2. Machine installation

2.1 Lifting machine.....................................................................................07

2.2 Unloading, antirust................................................................................07
2.3 Installation and commissioning.............................................................08
2.4 Cooling water pipes connection.............................................................10
2.5 Hydraulic oil..........................................................................................11

3. Safety

3.1 Maintenance and repair security.............................................................15

3.2 Poisonous gas, fog and powder...............................................................16
3.3 Quickly decomposed plastic....................................................................17
3.4 cautions....................................................................................................17
3.5 Safety equipment.....................................................................................17
3.6 Electricity safety devices.........................................................................19

4. Starting Operation

4.1 Preparation..............................................................................................20
4.2 Electricity voltage...................................................................................20
4.3 Hydraulic oil pre-heating........................................................................20
4.4 Hydraulic system oil monitoring............................................................21
4.5 Electric-thermal starting.........................................................................21
4.6 Manual operations..................................................................................21
4.7 Semi-automatic operations.....................................................................21
4.8 Automatic operations.............................................................................21

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 4.9 Mould loading........................................................................................22
4.10 Dismounting of screw and barrel.........................................................24
4.11 Adjustment of back pressure................................................................25

5. Machine maintenance

5.1 Caution......................................................................................................25
5.2 Testing items................................................................................... ..........26
5.3 Lubrication.................................................................................................28
5.4 Cleaning of the barrel and screw................................................................28
5.5 nozzle.........................................................................................................34
5.6 Replacement of hydraulic oil.....................................................................35
5.7 Air filter .....................................................................................................36
5.8 Cleaning the oil filter .................................................................................36
5.9 Check the hoses loop .................................................................................37
5.10 Cleaning the transparent window of protective door ........................... ..37

6. Annex

6.1 Hydraulic system...................................................................................... .38

6..2 lubrication ............................................................................................... .39
6.3 Temperature setting table of plastic and barrel...........................................40
6.4 With the physical and chemical properties of raw materials and plastic
injection molding performance .......................................................................... .41
6.5 Selection maintenance of Hydraulic oil and lubrication oil..................... ..42
6.6 Electric theory diagrams........................................................................... .55
6.7 Action sequence of solenoid oil .................................................... ....... ....57

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2. Machine installation
2.1 Lifting machine

Lifting as shown below

Note: The adjustment before tailgate lifting and the position of two board to transfer smoothly.

2.2 Unloading and antirust

2.2.1 Unloading

When the injection molding machine has been delivered to you , removing all of the packaging。
Check whether there is something damaged with the machine and whether it is confirmation in
good conditions before lifting.

If the machine gets damage during transportation, be sure to report in time and make a record.

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The crane must have sufficient lifting capacity;
For the weight of machine, please refer to Fig 2-1.

If the machine is needed in the workshop to move without lifting machine, you should use
bowling accurately.

Caution: Manufacturer is not responsible for any loss incurred during transit.

2.2.2 Antirust

All the exposure parts, such as leaders, tie-bars and surface of platens should be wiped antirust
before transporting. It can be mixed with the bearing lubricating oil and hydraulic oil on the
surface of membrane protective layer of good without any problems.

Note: All in the machine to rust protection, while no effect on the operation of this anti-rust agent
places to stay .
It provides the basic resistance for your machine to the corrosive influence of the external
environment protection.

Antirust should be wiped , But only in the case of need.

Note ：Do not remove antirust oil with impregnate.

2.3 Installation and commissioning

2.3.1 Installation foundation

If the machine will be installed on a concrete base, make sure that it’s strong enough.

Leveling pad can be also be sued for the purpose of leveling as well as a vibration absorbent.

Refer to the clause 2.3 to use foundation bolts to fix the machine on an intensified concrete floor.

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2.3.2 Foundation bolt and shockproof
Block should be distributed in the bolt to keep steady.
Tighten the foundation bolt by leveraging to lock the machine.

attached list：Leveraging the rod recommended values

Foundation bolt specifications Leveraging the rod length

M16 550
M18 600
M20 700
M24 850

2.3.3 Installation and commissioning

☆The machine is properly installed in the prepared base ---- reinforced concrete foundation and
keep horizontally with Adjustment block.
☆Applied a level of precision while measuring instrument. Balancing anchor for the
horizontal and vertical anchor rod .Level meter placed horizontally first and then vertically !

Horizontal measurement need an auxiliary ruler.

acceptance tolerance：

horizontally 0.16mm/m
vertically 0.24mm/m

☆ After the machine is in a correction, Foundation bolt loaded and

sealed with cement to support surface .

Caution!
You can’t tighten the nut of foundation bolt until Cement keeps
solid
pay attention to maintenance ( period of maintenance in summer is
five days and in winter is seven days )

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 ☆Release locking nut when using seismic machine foot

Caution！
In order to avoid the equipment foundation of machine damage, we recommend running 4 weeks
after detection and correction at machine.

We also propose every 12 months to correction of machine detection.

2.4 Cooling water pipe connection

2.4.1 Connection of cooling water pipes

Refer to the next picture to connect the cooling water inlet and outlet
pipe.
Specific location, please refer to the installation foundation(Chapter
2.3)
connecting：
Inlet port of cooler： Rc1”
Outlet port of cooler： Rc1”
Inlet port of mold： Rc1”
Outlet port of mold： Rc1”
Soft rubber tube with valve is recommended to adopt
Permitted hydraulic pressure(MAX.):8bar
The pressure difference between inlet and outlet should be ≧bars

Note：
Cooling water must be clean.
Cooling water not filtered which directly come from river or other
source can cause cooler jam.
Distribution of water in：

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 ☆ Hydraulic oil
☆ Screw bat of feed hopper
☆ Mold cooling

2.4.2 Cooling water system----diagram

2.4.3 Cooling water wastage for oil cooling（L/min）

Model Temperature at inlet

Pump power
15℃ 20℃ 25℃
9 26 30 34

2.5 Hydraulic oil

☆ Machine should be injected the clean hydraulic oil through the air filter until the liquid level
gauge indicating the oil level is higher than that of middle scale.

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 Note !
Operation of the machine,the new hydraulic oil often can not be
adequately filtered.therefore we recommend treatment through micro
filter filter hydraulic oil (10μm).
Different brands and types of hydraulic oil cannot be mixed.
Hydraulic pump can’t start after the hydraulic oil is injected.which
facilitates gas discharge.
Do not start after the hydraulic oil is injected into the machine in
three hours. in order to facilitate the hydraulic oil in the gas
discharge . Follow the hydraulic oil provided by suppliers MSDS.

2.5.1 Electric wiring

table2：grounding cable section
model Grounding cable section PE wire
95mm2 50mm2

2.5.2 Wire Connection Precautions----power

☆ Only when good condition is confirmed the three-phase ,380V and 50 Hz frequency can
be supplied.

Caution !

Connect the power supply must be performed by experienced electrician.

At the same time the specifications and regulations of the power supply company must be
enclosed .

The power supply is connected with the main power switch on the QS electric control box.

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Refer to appendix circuit---main circuit schematic diagram.
User-supplied power supply must have sufficient capacity, which are more1.5 times than the total
power of the machine . The over current protection devices and overvoltage protection devices
must be installed.
The machine must be grounded. Grounding practices are as follows ( see diagram )：
Connect a wire ( wire cross-section see table ) to the grounding screw on the right side of the
machine , the other one connected to a ground rod or welded to a copper plate and buried in
the easy to dry land.

2.5.3 Pump Motor Steering Detection

Oil pump motor on/off
When power is connected , the pump motor 1-M1 steering must be
re-tested.

Note !
Hydraulic oil must be injected enough.
Turn on the main switch QS。
Click the button of operation panel button to start the pump motor M1.
Detect whether the same motor turning the steering direction of the
arrow on the cover are the same . If you turning isn’t right, please

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 exchange the power terminals L1 and L2 .

Note ! If the pump motor rotation is incorrect which may damage

hydraulic motor.
3. Safety
3.1 General safety rules
Operators must be trained for the operations, maintenance and inspection before operating the
machine. the person who has not been trained and licensed is absolutely prohibited
to operate the machine.
For maintenance of safety device, please feel free to contact our
company.

Caution !
The safety equipment fitted on the machine is there for you safety
and that of the production of goods.
The machine should only be operated when all safety equipment is
in working order. to remove ,by-pass, or make safety equipment
inoperative is not permitted. the safety equipment also includes
the safety program contained in the software. don’t carry out any
changes to this program
If the security device is not working properly or wrong , the
machine must be closed immediately.
☆ Press the emergency button to stop either SB1 or B2.
☆ Turn off the main switch QS.
Caution：
The operator must operate in the operational areas , such as in the
non- operating area in accident , the Company is not responsible.

Operator should operate the machine in operation area. see the followed diagram.

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3 Safety
3.1Maintenance and repair security

Caution：
All maintenance and repair work only execute when the main switch QS
is closed and placed in "O" position.

Employers are obliged to inform the operator about the safety equipment
construction, knowledge of operation and function, and in which
dangerous area, how to protect the health and safety.
For operation and maintenance,repair is usually not seen easily,idle
people are strictly prohibited to enter when the machine is working.

Caution：
Any processing which will damage to the machine safety equipment
should be stopped.

Operators must be qualified. safety equipment are not allowed to

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 discharging.

Caution：
Safety equipment is not allowed without the agreement to make changes
or replacement.

3.2 Poisonous gas, fog and powder

The poisonous gas, fog and powder can be expelled form some resin when Heated excessively,
such as PTFE,PVC.
If the poisonous gas fog and powder can’t be eliminated by adjusting the machine’s parameter, it’s
necessary to install a ventilating fan running together with the machine.
Following as diagram of ventilating fan’s installation:

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3.3 Quickly decomposed plastic
Some kinds of plastic, such as poly-toluene PVC, can be caused to decompose and explode after
being heated long time.
Rules of keeping accident away:
Process various plastic strictly according to their characteristic and processing requirement,
especially, the processing temperature of barrel and stay time in the barrel.
Shorten the material’stay time in the barrel if the machine is sensitive to heat.In case of intermit of
injection operation or change processing material, clean the barrel with polyethylene (PP)or PE
etc, and then stop heating.

3.4 Cautions
The area is clamp unit between fixed platen and moving platen. because the machine can bring
the largest clamp force, and make person extrusion if you put your hand or body into there.
Nozzle unit. During the machine working, the nozzle has brought about hotter temperature and
spray hotter plastic material melted to make scald.
Injection barrel unit. the barrel surface is very hotter and the heating band terminal is living
electricity during the machine running, so it makes scald and get an electric shock.

3.5 Safety equipment

3.5.1 Safety devices distribution

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 position name
1 Moving door of mould area-operator
2 Moving door of mould area-opposite operator
3 Fixed door of clamping system-operator
4 Fixed door of clamping system-opposite operator
5 Fixed door of clamping system-The rear tail plate
6 Injection of a fixed door -operator
7 Hopper inner tower
8 The barrel cover
9 Mechanical safety baffle
10 Electrical control box door

3.5.2 Description of safety devices

The safety devices include safety door and locking-self mechanism.
All safety doors are very important to avoid personal to damage by splashing melted material and
prevent person form danger zone.
 The locking-self mechanism will stop all damage action at any door opening.

3.5.3 Front safety door

☆it permit operation place.All damage action such as “close mold”,“nozzle forward”and
“injection”does not work until the safety door closed.
☆There are two systems electricity and hydraulic to control damage running.

3.5.4 Mechanism safety devices

This device function prevents the safety form moving.

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3.5.5 Safety door for nozzle
☆It is monitored by limit switch S3 .
☆Once the rear safety door opened,the limit switch S3 close so clamping valve can’t work.
☆The moving mold is able to begin clamping after rear safety door closed.

3.5.6 Safety door for nozzle

The safety door prevents personal from touching hot nozzle or sprayed melted material.The limit
switch S8 monitors the door.

3.5.7 Safety door limit switch

The safety door limit switch serves to interrupt the mold closing.
It is monitored by limit switch S9/S10.limit switch is able to start after the safety door closed.

3.5.8 Barrel cover

The cover fixed on heating ring,it prevents personal form touching hot barrel.
3.5.9 Fixed door
All of fixed doors have tightened by bolts.Do not remove.

3.6 Electrical safety devices

Electrical safety devices include:
Ground wire,protective housing of electrical components (touch in danger) and emergency brake
button.

3.6.1 Regulation
Our machine's electrical installation in accordance with EN60204-1rules.The operator and the
employer must comply with these rules.

3.6.2 Ground wire

☆All machines have a ground wire electrical components ,in particular the electric heating
section .Heating coil must be checked regularly to ensure that in normal working condition.

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☆the ground wire of hopper can not be removed to prevent static electricity generated when
pouring .

3.6.3 Emergency brake buttonSB1/SB2

☆function
The machine stop all actions if you press the red button.motor and plasticizing cylinder heating
are also closed,main circuit of liquefaction system is disconnected.
For safety consideration, once the emergency stop button is activated , it stays in the pressed
position.

4. Starting up, auxiliary equipment and appendix equipment

4.1 Preparation
4.1.1 Master operating essentials of controller
Read this machine operating manual of dedicated microcomputer controller, are familiar with the
operation method of the controller.
4.1.2 Check
be sure all thing of machine is ready. The machine shall be in good condition in all aspects,
especially the safety unit. The oil level in the tank and lube pump shall be above the midline. The
cooling water and the power supply shall be ready. Only after all the above have been confirmed
can the operation.

4.2 Electricity voltage

First ,inspection the voltage and frequency fit the machine specified .Then switch on main switch
QS and air circuit breaker.It appears words and figure on the menu of computer.

4.3 Hydraulic oil pre-heating

Start hydraulic oil pump motor.The pump provides pressures 60bar to hydraulic system during
hydraulic oil pre-heating.Hydraulic oil temperature receive 45℃ operation temperature quickly.
Caution！
In oil pre-heating process,all other machine operation is prohibited.
When oil temperature is low,oil viscosity is too high and makes oil filter blocked,system will give

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alarm.
When oil temperature is over 60℃,the running of machine will stop and give alarm on display.
When oil temperature is over63℃,pump will stop and give alarm on display.

4.4 Hydraulic system oil monitoring

Oil temperature:
Machine control system automatic controls oil temperature;machine will stop in case of oil
temperature too high.
Oil filter contamination Pressure filter F3 and F2 return oil filter pollution monitoring through a
gland switches .
When the filter is clogged , capping the switch sending the wrong message and screen appears
error message .
4.5 Electric-thermal starting
The barrel begins to be heated by“electric -thermal”button.In general,it takes about 30 minutes to
the heating temperature setting.
Special attention to:prohibit action of“plasticizing”and“injection”strictly.

4.6 Manual operations

Staring machine first should be set lower pressure and speed in the action data page.You can press
each key to observe machine action correctness.

4.7 Semi-automatic operations

Close safety door and then press semi auto button to start semi auto operating cycle. There is no
any trouble after one cycle finished, while open-close safety door again the machine enters second
semi-auto working cycle. In general you can ensure the semi auto operation is normal after 3-5
cycle of normal processing.

4.8 Automatic operations

Close safety door and then press automatic button to start automatic operating cycle. It makes sure
the function of automatic operation normally after 3-5 cycle of normal processing.

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4.9 Mounting of mold
4.9.1 Preparation before mounting of mold
*measuring the length 、width、height of mold.compare space between tie bars and mold height
of technical parameter in chapter1.1, make sure if the mold can install on this machine.
Measurement of the mold locating ring diameter and the head plate mold positioning hole
diameter , gate size and the distance to the template positioning surface,compare with mold
mounting dimensions in section 1.2 ,confirm whether the nozzle mold and a good match with the
template .make sure if mold、templet and nozzle can match well.
Measuring with the template mold ejector hole size and position ,compare with Section 1.2
confirm whether match.
*The mold thickness is on the basis of the thickness of the template. mold thickness is larger
about 20mm than the actual thickness , then according to the smooth mold products after
stripping down to open the space required distance setting mode spacing ,have the mode spacing
reaches the set value with the manual adjustment mode, set " ejector stroke ."
*Adjust mechanical safety device .Loosen the Mechanical safety rod to lock nut ,back through a
spin precession and move around a bumper,close to the end of head-banging Insurance bezel and
tighten bumper .
*prepare for plate, plate pads,bolts, nuts , flat washers,spring washers , wrenches, pipe
wrenches,etc.

4.9.2 Step of mounting

Mounting process should be under “manual” mold .the oil pump motor must be turned off if
someone puts hands into clamping area.
Step1：turn on the oil pump motor；
Step2：open mold by manual。Start template ；
Step3：have the injection pedestal move to right;
Step4：turn off oil pump motor.
Step5：Adjust the ejector pin number to make it match with the mold；
Step6：Lifted groups of mold slowly into clamping area, the retaining ring into the head
plate mounting holes , bolts , clips , etc. have die and the head plate fix ;
Note:the ratio of length(H) and the diameter (D) of the fastening bolt ranges 1.5-1.8

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Step7：start the oil pump motor，To jog for mould closing and mould adjustment , the
two plates in contact with the mold gradually until close
Step8 ： turn off the oil pump motor ， fix mold and 2-platen with bolts and
platen.Tighten all the nuts on the plate to ensure the mold will not loose when mold
opens .
Step9 ： Remove the hoisting rope,set the switch -mode position,pressure and velocity
(high clamping pressure is molding pressure) and the "transfer mode" parameter.
Step10：start the oil pump motor,open mold to the end.
Step11：close the safety door，Press the" secondary adjust mold " function key to enter
the auto adjustment,open and close safety door again ,the machine will adjust mold
automatically.machine will revert to manual control after adjustment finished.
Step12 ： Turn off the oil pump motor after the operations of “open mold and close
mold”by manual mode.
Step13: Connect other pipeline which is relative mold, such as cold,heart
pumping ,mold temperature.

4.9.3 Injection working step

step1 ： First setting the barrel temperature to suitable plastic temperature,then wait 15
minutes and start next step after receiving setting data.
step2：Feeding material into hopper according to feeder requirement.
step3 ： Setting end position and back pressure of plasticizing and screw rotate speed
according to weight of product and raw martial ratio.Then setting each injection
section and time or pressure of holding pressure according to molding requirement.
step4：Start oil pump motor,press close mold button until close end mold.
step5：The carriage moves forward by pressing “carriage adv”
step6 ： Stopping charging automatically after the screw turn to setting position by
“plasticizing”key.
step7 ： First inject and then stands holding pressure state by “injection”key,finally
injection finished.
step8：Begin charging material of next mold by “plasticizing”key.
step9 ： Before pressing “open mold”key,should have cooling time energy,then press

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“eject”key,finally open safety door and take the product.
step10: Observe molding product quality and do step3 and step 9 again until the
product is good.
step11：Test the product and start semi auto operation or automatic operation.

4.9.4 Treating after finishing the injection

a) Finish working
First shut hopper baffle and turn off electricity of barrel,then clamping at low pressure by
manual,the carriage and screw retract to end position,finally and switch off oil pump motor and
turn off all electricity power.
b) Change material and change mold
First shut hopper by baffles and turn off electricity of barrel, and then remained melts material in
the barrel several times.

4.10 Dismounting of screw and barrel

Step 1：Move injection unit backward end position in the manual mode.
Step 2：Remove cover of barrel and hopper.
Step 3：Turn off heating and cooling of barrel and screw.remove
contact of heating ring and thermocouple, and pipe joint of
cooling water.
Step 4：Press SCREW ADV to get to the proper position.
Step 5：Remove the semi-ring3 .
Step 6：Press SCREW RET to have injection back block and screw back
section separate and remove the end.

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 Step 7：Mounting the M16 screw ring to ensure the harness is within the
shackle, hanging hook to straighten the rope.
Step 8：Loosen the locking screw and unscrew the barrel nut 2 .
Step 9：Remove the bolt of fore lid，remove the front panel 1 .
Step 10:Lifting slowly, separate barrel form injection fore lid to
put them in a square block V groove cutting.
Note !
Even on condition of the electric is off or insulation, in the position of
heating tube, heating coil still connect the ground of high voltage.
For repairing and removing of the heating system, the main switch should be
turned off all the time.

4.11 Adjustment of backpressure

When preplastication feeding , control cylinder oil injection pressure with V11, resulting in the
screw backpressure to facilitate the gas discharge. Backpressure level is determined by the
observation of the quality of products.（in general the backpressure is about0.5-1.5Mpa）.

5 Machine maintenance
5.1 Cautions
In order to ensure the safety of the operator and give full play to the efficiency of the machine and
extend the life of the machine, when machine in use process, you must pay attention to the
following:

 In the absence of familiar with the machine the performance and operating procedures of the
machine which are not allowed to start the machine .operator must be trained and familiar
with the structure and properties of injection molding machines .
 In the absence of safety equipment to ensure good effective ,Do not start the machine .
 Don't contact some part of the sports, heating when the machine is running.
 In addition to the security mould, two people don’t operate a machine at the same time.
 No raw materials of screw or barrel should not be adopted with high screw speed ( 30 rev /

25
 min once ).For raw material is full of screw groove , then have screw rotation speed increase
to the required value to avoid scratch screw or cylinder because of the idle speed is too high
or too long .
 It will take 3 minutes of heating cylinder from room temperature to the desired temperature,
the residual in the cylinder in the case of cold material to be incubated for 10 minutes before
starting the screw for feeding, in order to ensure residual cold material melt adequately to
avoid damage to the screw . Before barrel temperature of each molding process does not
reach the set temperature,the motor can not start pre-plastic , otherwise it will damage the
machine .
 The machine starts running when the temperature of cooling water rises 5 ℃ ~ 10 ℃ ( if
there is no water in cooler water ,you must fill with water ) turn cooler valve gradually and
adjust the amount of water ( usually cooling water rate takes 75 l / min or more ) ,ensure the
oil temperature to be below 55 °.
 Emphasis on machine lubrication, it must be executed strictly according to operational
requirements . In case of lack of oil operation , it will wear parts, in particular a connecting
rod and steel sleeve of clamping mechanism, if lack of oil may be bitten, and unable to
work .
 Electric heating coil in use, due to thermal expansion ,it may be loose, check regularly and
found abnormal, please be ready to tighten .
 To set ground wire, periodically check the insulation of the electrical components to avoid
electric shock.
 The machine used for the first time and without long-term , the first several minutes of idling
after oil pump starts.

5.2 Test items

5.2.1 Daily check

☆Correct work clothes wear.

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☆ If heating ring looses or disconnects.
☆Nozzle temperature control of the " 0 " .
☆The electrical switches, especially safety door and emergency stop switch.
☆Mold fixing screws.
☆Circulating cooling water supply .
☆Hydraulic oil tank oil level .
☆Check oil line pipe joints of lubricating oil tank, each lubrication point whether there is
oil leakage .

5.2.2 Weekly check

☆The lubrication of all moving parts of the machine is normal.

☆If the screw of position switch looses.
☆If thermocouple contacts are normal.
☆Ground wire resistance.

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☆Various pressure tubing and fittings for leaks .

5.2.3 Regular check

☆Observe whether the hydraulic oil is dirty every three months and consider renewal oil,
cleaning oil filter ,the tank vent filter and back oil filter, replace the filter if necessary.
☆Every 2000 machine hours , transfer mold parts threaded rod lubrication, checking high
pressure hoses, replace if necessary .
☆5000 machine hours per day , replace hydraulic oil and the fuel tank vent filter .
☆25,000 machine hours per day , at the latest five years, according to the actual situation, replace
hydraulic cylinder seals, friction ring and the high pressure hose .

5.3 Lubrication
lubricating oil need add a thin oil and hydraulic oil , so as not to affect the lubricating effect .
Machinery lubrication points refer to the attacUPent for lubrication Fig.
The use of lubricants reference to the relevant attacUPents.
Centralized lubrication fixed quantitative system is controlled by the computer.
General Settings mold 30-50 times per refueling time , each about 10 seconds .

Note：

New machine lubrication pipe leak test after repair ,firstly you should trickle oil “by manual” for
each lubrication piping and lubrication point .

5.4 Cleaning of the barrel and screw

Caution !
It is necessary to clean up the barrel when new material is used.Normally it’s no need to clean up
the barrel until color change injection has amounted to 20-30times.You need to do partial or
complete cleaning depending on the contamination.
Cleaning including partial cleaning and complete cleaning.
If the product has got some dirt on the same locality of surface,you should clean nozzle hole and

28
seal surface of barrelhead.
The uneven and thin spots on the products indicate that there exist problems at the hopper entry
hole,screw,non-return valve on the nozzle.In this case ,the barrel should be cleaned up completely.

5.4.1 Partial cleaning

Even if screw had the process of self -cleaning ,the screw head and check ring which closes to the
back of nozzle are polluted by granular material and accumulated by residue of material.
If the residual material is non- sticky , it is usually concentrated for cleaning seals, nozzle holes
and the sealing surface of the cylinder head , meanwhile, checking the screw head .

Caution！

Wear protective gloves and goggles or mask during working.

5.4.2 Complete cleaning

If there is uneven moldings and subtle blemishes. These problems mainly occur in the feed area,
screw, check valve or cylinder head parts.
Which need complete cleaning!
Especially screw barrel and nozzle , the sealing surface between the screw and the screw head is a
very dangerous place .
The occurrence of these stains may be that sealing surface force is not enough or because of
thread lubricant leaking out excessively .

5.4.3 The preparation steps

If you must clean screw barrel , purge and remove in accordance with
section 4.6.
Note ：
Cooling the screw barrel completely is not allowed. Extrude the residual
material from the nozzle opening as much as possible. Injection rate is
medium .

29
 Cation ！

You must wear protective masks and glasses during maintenance and
cleaning work ,especially for heating screw barrel !
If the molding process is complicated , difficult to clear , such as polyamide or polycarbonate ,
etc., on the barrel for cleaning. Then a material such as acrylic , polystyrene or polyethylene
plastic , for barrel cleaning. Check temperature of the screw before replacing the material if
possible, screw barrel should be performed by experienced personnel . If you need training ,
please contact our service department.
Cleaning the barrel maybe give off bad out poisonous gas that brings inconvenience to the
operator.
Some molding at high temperatures emits fog that will accelerate corrosion of parts of the
machine polishing .
for this reason , the cleaning area should be separated from the machine operating area .
Ventilation must be good.

5.4.4 Cleaning heating screw barrel

Caution！

If overheating the screw barrel , resulting gases forced out of the screw
from the barrel ( risk of injury ) .It is dangerous when material in the
barrel is not cleaned ( steps below ) .
☆ In the case of supervision , heat the removed cylinder with all of the
heating ring .
☆ Remove the nozzle and pull the plug after heating about 15minutes！
☆ In monitoring cases, re-heated screw barrel until it can turn the screw
gently.Material decomposition reaction was observed . To maintain
adequate ventilation .
☆ Remove the heating ring of cylinder head. Unscrew the cylinder
head .
☆ To help collect residual material ,extract screw after the screw
coupling constant between the template and the stop position.

30
 ☆ Reheat the barrel until the excess dissolved material flowing out from
the barrel wall.
☆ Wrap a wooden stick with cloth and scrape residual material.wrap the
wire brush with a layer of cloth in the same way,it is bigger 2mm than
barrel hole,clean the barrel with a flexible rotating shaft.Then polish
with gauze (grade 240-280) . Gauze should be wrapped around the
wire brush .

Note！

When the friction , do not grind the surrounding areas of sealing

surface.

☆ In order to avoid wearing the sealing surface,insert a brush in the

barrel before rotating shaft .Clean threads with a wire brush.
☆ If the cylinder is to be placed in the warehouse , smear anti-rust oil
for all parts . Before reinstalling , painted all threads HSC ointment .

Caution！

Mounting parts , all parts of the temperature must be balanced!

Note ！

You must wear protective masks and glasses during

maintenance and cleaning work ,especially for heating screw
barrel !

5.4.5 Clean up the screw

Caution ！

When dealing with the screw , to avoid being hit cracks ( there is the
danger of broken screw)
Any resident material left on the screw, bake it with low fire to
remove . We recommend using propane flame gun .

31
 Note ！

Do not have the screw produce annealed. Please be very careful when
using a flame gun .

Note ！

To prepare the ventilation conditions , because it will produce smoke.

☆ Do not heat the screw at a certain point ; heat the
surface and rotate screw uniformly . Otherwise, the side
of the screw will cause thermal stress distortion .
☆Screw temperature should not exceed 400 ℃, including screw
thread , because it will reduce the hardness and wear resistance of
the screw .
☆ Please pay more attention when dealing with non-return valve on
the screw . Check ring thin wall portion on the heating
temperature increase rapidly.
☆ Clean screw with a wire brush ,polishing surface of screw with
emery cloth.
☆ Be careful with the internal thread residual material which flame
burn .Then clean the threads thoroughly with a wire brush .
Wipe HSC-ointment when the screw on the screw head .

Note！

Whenever you should not use any other kind of lubricating oil or
grease to lubricate the screw thread.These lubricants coking
reaction at high temperatures . Leaving a residue that might get
stuck screw head .

Caution ！

Pay attention to the location of thrust collar during installation!

Note！

When performing maintenance work , especially for heating

screw barrel ,we must wear a protective mask and glasses !

32
5.4.6 Clean up the screw head

Install screw handle (Engraved with the keyway in the screw

part)，nip the screw head with wrench and have it disengage it
from the screw according to the sketch ，do not damage shut off
ring.
Attention -thread for the left-hand thread！

Caution！

Specially, you must wear protective gloves, eyeglass and face

cover during removing hot screw and barrel at repairing.
☆ Clean up the screw tip with steel wire , polishing thrust ring
and pressure ring with emery cloth . （The size of sand：
240-280）。
☆ Be careful in burning the residual material on the internal
thread with fire. then clean screw tip with wire brush and wipe
screw thread of screw head with HSC- ointment.

33
 Note！
Pay attention shut off ring of screw tip installed position.

Note！

Mounting parts ,the temperature of all parts must be

balanced !

5.5 Nozzle

5.5.1 Open nozzle

☆Burn plastic away form nozzle.
☆Then clean it with iron brush ,and then fine it with fine
emery cloth.
Do not grind around of seal surface！

34
 Note:

Mounting parts, all the parts of the temperature must balance!

Caution！

For maintenance，especially for the heated screw barrel who

must wear protective masks and glasses！

5.6 Replacement of hydraulic oil

suggestion：
Refer to the maintenance plan and in accordance with section 5.2
supplier's instructions to establish the frequency of updates .
The use of life rule filtering will extend the filter by external oil filter,
improve the reliability of hydraulic system. We can use the filtration car
equipment.
Connecting barrel pump or siphon device empty
tank through the mailbox oil port a.
Caution！
It is very important to clean up the oil tank , If there is any residual oil
left, will lead to new oil aging.
Check the bottom of the tank if there is residual . ( Slurry )
If necessary ,open the tank cover for cleaning.
Refill the tank to the marking after the cleaning process is finished.
Hydraulic oil must meet quality standards GB7631.2-87
(China National Standard).
Different product names hydraulic oil can not be mixed.
Pay attention to pollution control：
Old oil must be handled
Returned to the oil suppliers , etc.

35
5.7 Air filter

☆ Open the cover

☆ Change air filter core
☆ Screw and close one
Note !
Air filter of oil tank is an important useful part.the operations must observe
the maintenance section 6.2 strictly .
The cover of air filter must be screwed in good ,otherwise cause leakage.
Do start motor until the air filter is installed correctly.

5.8 Clean the oil filter

Mounting points
In the tank that has the oil filter .
☆ Tools required:

36
 ☆ A soft brush in order to permit the solvent used for cleaning .
☆ Clean oil tank .
Remove the filter
☆ Turn off the machine
☆ Hydraulic oil extraction
☆ Open the tank cover
☆ Loosen the filter , remove

5.9 Check the hoses hoop

Refer to Section Maintenance plan of chapter , decide how long to be tested.

Hose loop must be detected in accordance with the following standards and
there must update if one of violations .

☆ Epidermal damage affected inside the snake network.

☆ Brittle crust.
☆ Deformation has changed the natural of shape hoses and hose lines,not
only at normal pressure but also in the case of compression or
bending , such as the skin cut away or partially the bubble -shaped bulge.
☆ Rent.
☆ Damage or deformation of the sealing function : subtle enough to replace the
damage .
☆ Hose breaks away from the collar to work .
☆ Due to corrosion, functionality and strength of collars decrease.

☆ Storage time and working life exceed.

5.10 Cleaning the transparent window of protective door

Clean with warm water by using the weak detergent and soft cloth .
Note !
No matter how don’t use hard and great friction cloth and solvent to clean.

37
6.1 Hydraulic system

38
6.1.1 List of hydraulic parts

No ITEM quantity

1 Back pressure valve 1

2 Proportional valve 1

3 Injection valve 1

4 Mold opening &closing valve 1

5 Superposition valve 1

6 Turrets valve 1

7 Mold adjust valve 1

8 Core-pulling valve 1

9 Ejector valve 1

10 Preplasticization valve 1

11 Line driver valve 1

12 Brake valve 1

6.2 Lubrication

39
 □MoS2 二氧化钼油脂 Δ00 井号锂基脂
note：

1. In this system , it is recommended to use M0S2 grease , lithium grease No. 00

2. In 1,4,5 , it need to grease once a month( new machine in 6 month, it is about twice a month) .

3. the automatic lubrication system grease is set by the computer at the 2,3,6,7 automatic

lubrication system plus oil, grease once every 500-700 mold , refueling time is 5-10 seconds , you

should always check grease of lubricating oil tank if it is enough.

6.3 Temperature setting table of plastic and barrel
The following table is the relationship between barrel temperature and plastic parameters ,this

table is only for your reference.

Plastic Specific Melting shrinkage Mold Barrel temperature

name gravity point （%） temperature

min max nozzle Middle piece end-piece

. . min. max. min. max. min. max.

PS 1.07 100 0.4 10 75 180 260 200 260 160 250

HIPS 1.00 100 0.4 5 75 220 270 190 260 160 250

ABS 1.05 110 0.6 50 80 190 250 180 240 170 240

LDPE 0.92 120 1.5-5 35 60 230 310 220 300 170 220

HDPE 0.95 130 2.0-5 35 60 230 310 220 300 170 220

PP 0.91 176 1-2.5 50 80 210 300 180 260 160 240

PVC 1.45 90 1.0-0.5 10 60 170 220 160 195 150 195

PMMA 1.19 100 0.5 50 90 180 230 160 240 140 220

PA6 1.13 216 0.8-1.5 50 80 210 230 210 230 200 210

PA66 1.14 265 2.25 50 80 250 280 240 280 220 280

CA 1.3 230 0.5 40 75 180 200 170 190 150 180

PC 1.2 150 0.8 80 99 250 320 260 340 280 350

POM 1.41 175 2.0 50 90 190 210 175 220 160 210

SAN 1.09 115 0.2 50 80 250 250 180 230 170 220

40
 6.4 With the physical and chemical properties of raw materials and plastic
injection molding performance
Material Specific gravity Mel.point(℃) Inj.pre(bar) Shrinkage%
PS 1.07 100 700-2100 0.4
HIPS 1.06 100 700-2100 0.4
ABS 1.05 110 500-1800 0.6
SAN 1.09 115 700-2300 0.2
LDPE 0.92 120 500-2100 1.5-5
HDPE 0.95 130 700-1400 2-5
UUPPE 0.94 130 700-1400 2-5
EVA 0.94 80 500-1400 1
PP 0.91 176 700-1400 1-2.5
PVC 1.30-1.58 75-105 700-2800 0.1-0.5
PVC 1.16-1.35 75-105 500-1800 1.5
PMMA 1.19 100 700-1400 0.5
POM 1.41 175 700-1400 2
POM 1.41 175 700-1400 2
PA6 1.13 216 500-1400 0.8-1.5
PA12 1.01 179 500-1400 0.3-1.5
PA66 1.14 265 500-1400 2.25
PAST 1.1 216 500-1400 0.8-1.8
PET 1.37 258 700-1400 2.25
PBT 1.35 250 700-1400 1.5-2.0
UP 2.0-2.1 700-2100 0.5-0.8
CP 1.10-1.23 230 500-2100 0.5
CP 1.10-1.23 230 500-2100 0.5
CAP 1.2 230 500-2100 0.5
CAB 1.2 210 500-2100 0.5
PC 1.2 150 700-2300 0.8
EP 1.9 700-1400 0.2
EP 1.9 700-1400 0.2
PTFE 2.12-2.17 310 400-1400 3.5-6

FEP 2.15 275 400-1400 4

41
6.5 Section and maintenance of hydraulic oil and lubricant oil

6.5.1 Section and maintenance of hydraulic oil and lubricant oil

As the largest professional manufacturer and seller of injection molding machine,based on many
years of experience in this filed.it shows you their design and the latest technology of manufacture
by providing you with this kind of machine.
In order to use our plastic injection molding machines efficiently, more important is preventing or
reducing the use of reliable and high-performance hydraulic device hydraulic device which is out
of order.
On the other hand,what’s more,the use of hydraulic oil is very important for hydraulic pressure
and maintain it properly.
Experience has shown that :occurs in the majorities of hydraulic devices which result form
incorrect and improper use and maintenance of hydraulic oil.
Here we provided the information can help you to choose suitable hydraulic oil and lubricant
oil,test properly and maintain machine in order to reduce the fault and have the machine run
efficiently for long time.
6.5.2 Hydraulic oil
As the medium for power transmission,the hydraulic oil is used for lubricating the surfaces of
metals.Since the variety and higher performance of the hydraulic equipment,the requirement for
hydraulic oil is stricter.

6.5.2.1 Performance requirements for hydraulic oil

In general, hydraulic oil should:
（1）Flow freely under the working conditions;
（2）Form appropriate seal in the moving accessories;
（4）Have no physical or chemical changes while working;
（5）Anti-rust and anti-corrosion;
（6）Resist certain load and reduce the wear of moving components;
（7）Separate moisture, dirt and other foreign substances quickly while static;
（8）Suitable for sealing,etc.during the working;
（9）Fine resistance;

42
6.5.2.2 Type of hydraulic oil
Hydraulic oils can be classified into the following categories:

Low temperature oil

General type ( turbo RδO) wide temperature
Mineral oil wear-resisting hydraulic oil hydraulic oil

High precision energy

Hydraulic oil
saving hydraulic oil
Oil -water emulsion
Emulsion Water-in- oil
Moisture emulsion
hydraulic oil

Water ethanol type moisture fluid

Synthetic fluid Nitric ester(flame resisting hydraulic fluid)

Fatty acid hydraulic fluid ( waterproof )

6.5.2.2.1 Mineral hydraulic oil

The mineral hydraulic oil is the most one at present.according to different boiling points,the crude
oil with different viscosity can be produced.Therefore,this category is widely used,The crude oil
will have a variety of applications upon adding suitable additives.such as common hydraulic;wear
resisting hydraulic oil,wide temperature hydraulic oil,energy saving hydraulic oil etc.

6.5.2.2.2 The flame resisting hydraulic oil

The flame resisting hydraulic oil can be classified into two types roughly,one is with moisture and
other is synthetic oil .Moisture flame resisting hydraulic oil includes oil in water and water in oil
emulsions,water ethanol and high moisture hydraulic fluid.
The synthetic oil includes mono phosphate ester,fatty acid,etc,which are used under circumstances
where exists combustion hazard.
Generally speaking ,in terms of the lubricating quality,stability and sealing features,the flame
resisting hydraulic oil and the synthetic oil are not as good as mineral oils.please consult the
supplier concerning these two categories.
In the past ,the mineral hydraulic oil ws used fro lubricating injection-molding machines.Due to

43
the moisture and explosion risks,the flame resisting hydraulic oil has replaced it in the recent
years.Among types of the flame resisting hydraulic oil ,water ethanol hydraulic oil is highly
recommended by the fire deportment .In addition,this type of hydraulic oil becomes popular for
its convenient application and disposal.
The selection of hydraulic oil is mainly based on the viscosity, lubricating performance, the
oxidation stability;shear stability, flame resistance and its effect on the sealing material.

6.5.3 Selection of hydraulic oil

6.5.3.1 Select the type

The standards set forth in Table 2 is to choose the criteria used hydraulic oil , the use of hydraulic
equipment and the environment which will decide to choose mineral oil or non-combustible fluid ,
other factors must be considered include: types of hydraulic pumps and other devices , the use of
pressure and temperature , the quality of fluid lubricating, economy and Seal suitability of
material used etc.
Item Comment
Requirements for flame retardant Mineral oil, non-flammable fluid ( or oil )
The type of pump Adaptive viscosity
The range of temperature Low and high temperature , high viscosity oil
During the use of the external leakage , metal, Economic considerations
or other foreign material mixture
Limit of available pressure General use or wear oil
The risk of water mixture Common types and anti- milk and trademarks

Check lubrication considered Considering the type of oil and Trademarks

Economy Consider the life of oil (fluid ) and quality of

the finished product

6.5.3.2 Selections

As the hydraulic oil is the medium for power transmission, so the normal operation and fault
conditions listed in table 3 would help to identify if the viscosity of the hydraulic oil is suitable .
For that reason, appropriate viscosity must be selected to maximize the fit of the structure of
hydraulic equipment , the oil temperature and transmission pressure etc. to obtain high efficiency

44
and performance.

Table 3 fault caused by incorrect viscosity selection

When the viscosity is too high
Increase the internal friction
The opening and valve etc., increase the
oil flow resistance
temperature rise
Not functioning smoothly
Increase the pressure loss of hydraulic
system
Increase power consumption
when the viscosity is too low
increase internal and external leakage
Increased pump slide
Increased wear sliding parts
Reduce the pressure of the hydraulic
system
Reduce the working accuracy

6.5.3.3 Lubrication performance

One function of the hydraulic fluid acts as a lubricant , at higher pressure , faster hydraulic
equipment is developed , which is increasingly important . In many cases, the hydraulic oil pump
lubrication performance can be based on the amount of wear to judge : for reason is not only the
operating conditions of the hydraulic pump means the worst , but also the pressure of today's
equipment is rising trend has a direct effect on the pump , because increased contact pressure of
the pump lubricating surface and rise the temperature ,moreover ,it relates to some factors about
device configuration.

6.5.3.4 Other quality

In the choice of hydraulic oil , if the viscosity and lubricating properties of the oil is suitable for
use of the occasion , the general it might have no problem, but in order to be able to use the
hydraulic oil reliably and extend the life of equipment of the oil , it is necessary to consider the
following descriptive performance characteristics and quality .
（1）oxidation stability
Hydraulic oil oxidative stability affects the life of the oil directly , require less fuel tank and the
high speed running under a compact hydraulics ,it often leads to substantial increase in oil

45
temperature and heat can cause oxidation and deterioration of hydraulic oil .The result of
oxidation and deterioration accelerated formation of sludge , thus it affects the filters, valves and
other components of hydraulic circuit functions , hydraulics also increase corrosion and wear.
Hydraulic oil oxidation stability on the extent of the aid turbine oil oxidation stability test to
determine , the usual approach is not that simply based on the total oxidation plants to estimate
the volatility of the oil longevity , but according to the amount of sludge , because the tendency to
form an oxide sludge is considered as an important factor .
（2）Shear stability
High -viscosity hydraulic oils generally contain high-molecular additive or a lower viscosity
increase in volume flow point additive , and the pumps, valves and other parts of the shearing
action of hydraulic circuit may reduce the viscosity . Therefore, in order to maintain a suitable
viscosity range, it is necessary to select hydraulic oil of a characteristic with excellent shear
stability .
（3）inflaming retarding
Incombustibility mainly depends on the fluid components of hydraulic oil , table 4 lists hydraulic
fluid commercially available example of the results of fire tests.
（4）the effect of sealing material
According to the type of hydraulic oil , the seals and the materials of hydraulic device for use will
increase swell , harden or dissolve so that it results in leakage of hydraulic oil . Therefore, the
stability of oil for consideration is very important .
We have pointed out the selection of hydraulic oi should be noted that is the main performance
characteristics , other features including rust , moisture stability and resistance to emulsification
solutions and so on.
When selecting the type of oil , it is necessary to consider all of these performance characteristics.
table4 Hydraulic fluid flame retardant evaluation test examples

46
 type visc viscosity Point of Incombustibility estimation test
osit flammability
y
orig coefficient ℃ burning point Incombustib Heat High pressure Pipeline
in ility manifold injection eliminato
estimation France method r
test
37. ℃ ℃ (Experim
8℃ ents)
Mineral 35. 109 224 245 340 Violent catch fire 3
oil） 7 burning
after
ignition
organic 48. 8 236 368 500 no Slight burning 80
phosphate 5 near the fire
source
Water 46. 205 no no 400 no no-nignition 66
glycol 3
Oil in 107 140 no no no Slight burning 50
water near the fire
emulsion source

6.5.4 Control and maintenance of hydraulic oil

Regardless of how the hydraulic oil is , if you don’t properly maintain and focus on , it will cause
damage. Therefore, we should establish certain procedures to maintain the oil itself
properly,machine operation and hydraulic equipment , please pay special attention to the
maintenance of hydraulic oil .
6.5.4.1 Hydraulic oil maintenance items
General maintenance items can be divided into the following three types :
(1)Hydraulic oil del impurities : judged by viscosity, total acid valve or color .
(2)Foreign material contamination :judged by to an important or using computational methods
(3) Appearance: mainly based on color to judge.
The last type of which is the simplest, but it may be not correct and may change the oil
prematurely and waste of money .
The following items will have greater practical value.
（1）Viscosity change
Viscosity is an important project of the maintenance. the changes of viscosity not only affect the

47
performance of the hydraulic system directly, but also their working life.
Oxidation deterioration caused by heat will increase the viscosity, and decrease in viscosity is due
to increase viscosity Index or decrease the flow point additives used, such as high molecular
weight substances caused by shearing , which is a special problem of high viscosity index
hydraulic oil . In addition,the cause of sudden changes in viscosity is which added in supply, used
the inappropriate types of oil.
（2）The increase in total acid value (after decrease)
Change in total acid base oil according to whether the change in the type of additives . But in
general , if the additive is present in a total loss of acid will be reduced over time , with the
intensification of oxidative deterioration occurs when the total acid value will rise. Although the
change in total acid value will increase as oil changes in the conditions of use , but it is best
regular to test total acid value .
（3）Moisture
It must pay special attention when you use mineral hydraulic oil. Thus ,water is mixed with the
emulsion ,harmful to the lubrication, causing rust and other problems and shorten the service life
of the hydraulic unit and the oil .
In severe cases, the presence of water can be perceived by the naked eye .
（4）Color
The color change of the hydraulic oil change with the viscosity of the oil and the type of additives
inside oil and quantity,it is necessary to compare it with new oil.generally,aggravated when
thermal oxidation or deterioration caused , its color tends to deeper . In working condition
inspection, the change is as simple guide .
（5）Contamination extent
When the hydraulic oil contains impurities , which are often detrimental to the performance and
reliability of the hydraulic unit . So the important part of the maintenance of preventing
contamination that commonly used to estimate the degree of pollution that there are two kinds
of methods :gravimetric and statistics .
a) In terms of weight: the amount of pollutants of conventional hydraulic equipment should be
more than 10 mg / 100 ml . In the numerical control equipment , it should be not more than 5 mg /
100 ml .
b) In terms of statistical : hydraulic equipment used in servo valves , the ideal oil maintenance to

48
keep pollution levels in the NAS segment 7 or higher.
Table 5 NAS pollution standards (quantity per 100 mg )
Specifications grade
Classification 00 0 1 2 3 4 5
( Microns )
5-15 125 250 500 1000 2000 4000 8000
15-25 22 44 89 178 356 712 1425
25-50 4 8 16 32 63 126 253
50-100 1 2 3 6 11 22 45
100above 0 0 1 1 2 4 8
6 7 8 9 10 11 12
5-15 16000 32000 64000 128000 256000 512000 1024000
15-25 2850 5700 14000 22800 45600 91200 182400
25-50 506 1012 2025 4050 8100 16200 32400
50-100 90 180 360 720 1440 2880 5760
100above 16 32 64 128 256 512 1024

Table 6 various pollutants impact on the hydraulic system

type of Contaminant
Oxidation products
Sludge
Water
Air
Air
Hydraulic oil outside the oil
Small metal particles dirt
Coating small pieces
small particles of friction
rubber fine particles
Sand
filaments, fibers
Type of failure may occur Reasons and Precautions
Cause metal corrosion Hydraulic oil decomposition, mixing high
temperature and water will cause the fault
Impede function Oil decomposition, high temperature flow can
cause the problem
Forming emulsion Condensation or leaks cooler
soluble Defoamer suppression
insoluble The rapid decline in pressure,Packing failure
the mixture , but sometimes The improper design of oil tank
the reaction
insoluble , from the catalyst Water pollution occurs , a small amount of rust
which occurs in the pipes and tank can control ,
washed out properly before or after the
installation
Insoluble, affect the function Paint properly and the inner old paint falls off
worn equipment impede Floating fine particles in the air
function
impede function Damaged seals, check the seals, the sealing
material
Wear.Damage,stunted Flow from the air and improper cleaning
function castings into the oil
impede function Cleaning after unloading , flushing of hydraulic
tank inappropriately, in the use of packing, to
avoid the possible filaments into the oil material

49
6.5.4.2. Quality control on hydraulic oil

The items measuring the quality of hydraulic oil include:viscosity,

Lubricating performance,oxidation stability,shear stability,flame resistance and its effect on the
sealing material.general samples for
Control reference regarding the hydraulic oil applied on industrial machine.
It is difficult to establish a set of fixed values since the control on hydraulic oil and its referential
values change with the types of hydraulic oil,additives added or not,quality of additives
added,listed in the above are reference only.

Testing items Referential value

Viscosity change ±10%
The increase in total acid value(after 0.4mg KOH/g
decrease)
Moisture 0.1% or cloudy
Insoluble compositions 0.05%
Color Dramatic change
Contamination extent 7mg/100mg

6.5.4.3 Maintenance of hydraulic oil

Following should be checked before the operating process.
（1）Oil level
Under the normal circumstances,the lowest oil level should not be below the middle of the oil
level gauge.If the oil level is below the midline,the machine must be shut down immediately for
adding oil.
The oil can be added form the inlet of the air filter and must be the same as in the oil tank.
（2）Oil temperature
When the oil temperature is too low, please begin production before the blank line of the machine
to make it appropriate heating . During normal operation , please also adjust the cold cutting
device to ensure that the hydraulic oil temperature does not exceed 55℃.When the hydraulic oil
overheats, the oil lubricating film is not as normal as covering , sealing materials will damage ,the
pump efficiency will be affected .
（3）Oil pressure
The oil pressure should be kept within the normal range.Too high or too low will cause bad

50
effects to the machine.
（4）Noise of the pump
The abnormal noises may come form the block in the filter,air absorbed into the oil,over high
viscosity of the oil or the foreign substances in the pump,etc.
（5）Leakage
Check connections,flange and hoses or leakage arising form the metamorphic sealing materials.

6.5.4.4 Maintenance of hydraulic equipment

It must be carry out inspection and replacement of hydraulic oil work carefully and
thoroughly,flushing work and so on.

6.5.4.4.1 Supply of filling the tank and add oil

(1) Please poured oil through the air filter . In the filling of oil , remove the cap and the cap , but
don’t put them on the factory floor , grain dust , filaments may stick to the place on the inner
surface .
(2) Since the inner diameter of the filler is about 50 mm, therefore , the 1.5 inch tube from the
supply pump is easily inserted to supplement the oil. The air cleaner has a 100 mesh filter , if it is
clogged , the oil flows out from the filter and spilled on the floor. please note that when you use
the oil feed pump. If you do not use the filter , remove the oil tank cap to join , please ensure that
the oil is not contaminated by foreign objects stick .
(3) Oil tank device of large machine, without the use of filter, please use at least 100 mesh filter
and ensure that device or pump for the hydraulic oil is completely clean. We recommend filling
the tank , using a flushing device .
(4) Not only in the tank filling machine for the first time, and when added with new oil supply,
you’d better consult the advice of the oil supplier,and get their help, because these companies are
willing to help you.
(5) After the exchange of hydraulic oil , leave it 3 to 5 hours prior to starting the pump motor so
that the air bubbles remove floating precipitate .

6.5.4.4.2. Periodic testing of oil properties

51
If the oil is dirty soiled or deterioration deterioration will shorten the life of the machine and may
malfunction. Therefore , it is necessary to test the oil periodically to detect a change in
performance . Strictly speaking, these tests should be carried out experiments in the oil company .
However, the user is possible to use visual inspection methods to understand the oil properties.
please take samples from the hydraulic oil tank after shutting down, because then the oil is
sufficiently stirred.
（1） The user can carry out testing
a) appearance test
To put samples of new oil and using oil into test tubes, compare their color, clarity, such as
precipitation of floater and the water sedimentation at the bottom of tube.
b）dropping test
Adopting this test method and comparing with the new oil can understand the oil properties.
Please a drop of oil in usage on the filter paper and study after 2 ~ 3 hours. If the oil is dirty or
bad, it will be observed pollutants easily .
（2） Oil company's qualitative and quantitative testing
If the above description of the two kinds of tests reveals the oil is not normal,on the basis of test
experiment of supplier,it is necessary for us do further test.
According to above two test results,service technicians of experienced of oil companies who can
make sure immediately that the oil should be exchanged by new or bring the samples back to their
laboratory for detailed testing to get the result.
（3） Periodic test cycle
Appearance or drip test by one day per month.
After if oil company exchange new oil for a month, 2 months and 3 months for qualitative and
quantitative testing, then every three months for the above tests. When buying new oil, it is
recommended that users sign special contracts about checking the oil with oil supplier.
（4） Limits on the use of hydraulic oil
To ensure limits on the use of hydraulic oil in the hydraulic device, judgment mainly based on
the following items listed .
Deterioration of the oil itself : According to the results of the test of above-mentioned qualitative
and quantitative , the oil company will decide whether the deterioration has been developed to the
point that oil must be changed .

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Degree of pollution :we should make comments about the extent of oil pollution . Hydraulic
equipment must be maintained for the degree of oil pollution within the limits listed below ,
maintenance is particularly important,after oil is purchased and put into use after within 3
months .Frankly speaking, during this time it will determine the length of life of the hydraulic
unit ,

table：
Measurement methods Gravimetric method，Weight of the Statistical Methods
particles/100mg
Permissible extent of 7ml NAS11grade
oil pollution

Note:As a result of statistical methods can only gather statistics particles of 5 microns or larger , and the

measured value of the repetition accuracy is poor, so number is only for reference.

6.5.4.4.3 Washing
（1） The purpose and procedures
The first, rinse off the metal particles , sand and dust may enter the fuel tank and pipes when
flushing machine manufacture, assembly or installation. The second ， flushing of the hydraulic
device is used after a period of time , clean the device. We think you'd better ask the oil
company's maintenance specialists with their equipment in your plant rinse .
（2） In exchange oil flushing
Regardless of how the hydraulic oil is good , particles which other movable parts and the wear of
the pumps of hydraulic equipment will enter the oil after it is used a period of time, and the
deterioration of oil may cause the formation of sludge and dirt . Therefore, it is necessary to
change the oil , as mentioned the hydraulic oil is used correctly , it is generally believed that the
working life is about 2-3 years , once it begins to deteriorate , then the oil will useless. In this case,
not you should change oil but also we recommend that you wash equipment .
First,drain off the oil completely , then wipe oil tank with a sponge ,flush with oil as the same as
viscosity ,flush with a low pressure flushing device. It is possible to remove all metal particles of
worn devices and a variety of sludge and dirt with 4-8 hours washing . Of course, drain the oil as
far as possible after flushing .
（3） Flush when the old oil is polluted by water or chemical
Based on the above , when you decide to use special-purpose flushing oil , the user should consult

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with oil company experts and our maintenance personnel to select oil of the correct type , to
decide how to carry out the work of washing equipment .

6.5.4.4.4 Maintenance
（1） select appropriate oil.
（2） check the status of the oil through regular tests
（3） The oil temperature is maintained in the appropriate range(45±5℃)
（4） Flushing equipment is required when exchanging new oil.

6.5.5 Lubricating oil and grease

6.5.5.1 Selection of lubricating oil

In addition to hydraulic oil, used lubricating oils include gear oils and grease the sliding surfaces .
In the selection of such oils ,please refer to the proposed type of oil and viscosity data ,it is
important to limit the type of oil used as little as possible . In this case, please refer to the
recommendation in chapter 3 .

6.5.5.2 Maintenance of lubricating oil

Hydraulic oil can be purchased , and almost immediately available for Oil Change,
It differ form lubricating oil,it must be long-term storage , maintenance and storage of the oil
areas to be cautious .
（1） Oil drum must be stored on wooden floor.
（2） The oil barrel oil should be properly sealed;keep away from water.
（3） protect the oil containers form exposure to sunshine.
（4） The storage temperature for the oil should not exceed 40℃.
Plastic injection molding machine recommended：
Hydraulic oil ： Mobil DLE26
shell Tellus Oil68
Brand shanghai 46~68 anti-wear hydraulic oil
lubricating grease： MOS2 grease
00 lithium grease

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 1 ordinary lithium grease
3 ordinary lithium grease

Lubricating oil： 220

Cooling water ： 1/2flow of oil pump
The volume of the fuel tank ： refer to technical parameter

6.6 Electrical principle, control circuit, the original table

6.6.1 Electrical system
The machine adopt the power with three-phase four wire ,380V,50HZ，Using a dedicated
computer core control . The main components are imported brand-name products .
It mainly divided into hydraulic control,heating control and action limit control.
1、QS for the three-phase power switch , as also the hydraulic circuit protection device of the
motor M1 . When closed QS , the system is charged to perform various operations. Press" motor "
button on the computer panel to start hydraulic pump motor M1 : Press the "motor" button and the
emergency stop button to stop the pump motor .
The main circuit in the motor , three-phase AC protect component through contactor KM1 and
thermal relay FR, driven pump motor overload M1 , current setting value is set, the user can not
adjust at random.
Temperature setting , adjustment and display are finished by the computer . When the thermostat
circuit QF3 ~ 8 is closed , press the hotkey electricity board computer operation , the fixed relay
KM11 ~ KM16 were connected heater to heating. Heaters are divided into six groups , five
groups mounted on the barrel , stabilizing around the set value .
2、The process of the machine speed and pressure switch, plastic shoes, injection to keep pressure
switch points, multi-stage injection process is controlled by electronic scale to convert the control
box. Electronic scale measurement bencUPark - zero has adjusted accurately , users do not move
the location of the electronic scale, to damage the system measurement accuracy. The switch
position are set by computer, see " computer manual ."
3、S1, S2, S3 are for the safety door switch , when the safety door is opened , position switch will
turn off, the clamping unit will stop working in order to ensure personal safety. SB1, SB2 are for
the machine emergency stop switch, in case of emergency , press one of the current action to stop

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the machine , shut off pump motor power to avoid further incidents .
4、Machine parameter setting , adjustment, and operation of computer systems internal links refer
to " computer operating manual ."

6.6.2 The main circuit of the motor

6.6.3 Assumption diagram

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6.6.4 Parts and standard list
NO. name code quantity note

（1） Oil seal Φ155x110x16 1

（2） Cup oil 6012 2

（3） thrust ball bearing 51315 1

（4） deep groove ball bearing 6113 1

（5） Circlip 62 1

（6） tapered roller bearing 30212 1

（7） Hydraulic motor 3-400 1

1 oil seal cover -01-17 1

2 coupling -01-20 1

3 Table backboard -01-19 1

4 Bearing cap -01-21 1

6.7 Action sequence of solenoid oil

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