DAPAI Wi270Se II 塑料注射成型机

PLASTICS INJECTION MOLDING MACHINE

使用说明书
O P E R AT I O N M A N U A L

苏州大牌机械科技有限公司
SUZHOU DAPAI Technology Co., Ltd.
 Suzhou Top Brand Machinery Technology Co., Ltd.

Directory
DAPAI Wi140Se IIInjection Molding Machine Parameter Table...........................- 4 -
Chapter One Machine Purchase Preparation......................................................- 5 -
Chapter Two Machine Installation...........................................................................- 7 -
2.1 Preparation work before installation...............................................................- 7 -
2.2 Loading and unloading of equipment............................................................- 7 -
2.3 Start installation......................................................................................................- 8 -
2.4 Add hydraulic oil....................................................................................................- 8 -
2.5 Connection of safety protective ground wire...............................................- 8 -
2.6 Connection of power cord..................................................................................- 8 -
2.7 Lubrication of lubricating oil..............................................................................- 9 -
2.8 Recommended lubricating oil............................................................................- 9 -
Chapter Three Safety device..................................................................................- 10 -
3.1 Main safety signs of the machine..................................................................- 10 -
3.2 Electrical safety device.......................................................................................- 15 -
3.3 Mechanical safety device..................................................................................- 16 -
3.4 Mechanical aspects of attention.....................................................................- 17 -
3.5 Electrical equipment...........................................................................................- 17 -
3.6 Hydraulic equipment..........................................................................................- 18 -
3.7 Other aspects........................................................................................................- 18 -
Chapter Four Operating steps ...............................................................................- 20 -
4.1 Inspection before operation ...........................................................................- 20 -
4.2 Start and stop the oil pump motor .............................................................. - 20 -
4.3 Clamping, opening and stroke switch ......................................................... - 21 -
4.4 Hydraulic ejection stroke switch....................................................................- 21 -
4.5 Injection device (injection stroke or nozzle) and stroke switch ........... - 22 -
4.6 Install mold .......................................................................................................... - 22 -

-1-
 Suzhou Top Brand Machinery Technology Co., Ltd.
4.7 The plasticizing, metering, injection and anti-dribbling (retraction)
operations of the screw ..............................................................................................- 24 -
4.8 Automatic operation .........................................................................................- 25 -
4.9 Work completed (shut down the machine) ............................................... - 25 -
4.10 Remove mold (completely under manual control) .................................. - 26 -
Chapter Five Common operating faults and troubleshooting methods of
injection molding machine ........................................................................................ - 27 -
5.1The causes and solutions of injection molding defects ..............................- 29 -
（1）Finished products are incomplete ..........................................................- 29 -
(2）Product shrinkage ..........................................................................................- 30 -
（3）Finished products sticking to the mold .................................................. - 31 -
（4）Runner (gate) sticking to the mold ..........................................................- 31 -
（5）Flash (burrs) .................................................................................................... - 32 -
（6）Finished product cracking during mold opening or ejection .......... - 32 -
（7）Joint line / Weld line .....................................................................................- 33 -
（8）Flow marks ...................................................................................................... - 33 -
（9）Dull surface finish on the product ............................................................- 34 -
(10) Silver streaks....................................................................................................- 34 -
（11）Product deformation................................................................................. - 35 -
（12）There are air holes in the finished product. ........................................- 36 -
（13）Black streaks ................................................................................................. - 37 -
（14）Black spots .................................................................................................... - 37 -
（15）Unstable period ...........................................................................................- 37 -
Chapter Six The use of hydraulic oil and lubricating oil .............................- 39 -
6.1 Hydraulic oil .........................................................................................................- 39 -
6.2 The required properties of hydraulic oil ..................................................... - 39 -
6.3 Hydraulic oil control and maintenance ....................................................... - 39 -
Chapter Seven Maintenance and upkeep ................................................................- 49 -

-2-
 Suzhou Top Brand Machinery Technology Co., Ltd.
7.1 The installation and removal of plasticizing components .....................- 49 -
7.2 Maintenance and care ......................................................................................- 50 -
7.3 The maintenance of hydraulic system .........................................................- 51 -
7.4. The maintenance of the clamping unit components .............................- 52 -
7.5. The maintenance of the injection unit components .............................. - 53 -
7.6. Protection against toxic smoke .....................................................................- 54 -
7.7. The protection against noise .........................................................................- 54 -
7.8 Inspection items ............................................................................................... - 55 -
Chapter Eight Related dimensions and outline drawing for mold installation
...............................................................................................................................................- 57 -
8.1 Dimensional drawing for mold installation ...................................... - 5 -
8.2 Dimensional drawing of machine outline ............................................- 59 -
8.3 Dimensional drawing for foundation bolt installation ............ - 60 -
8.4 Hoisting diagram ................................................................................................. - 61 -
Chapter Nine Other various attached drawings ................................................... - 62 -
9.1 Mechanical drawings .......................................................................................... - 62 -
9.2 Hydraulic drawings ............................................................................................- 69 -
9.3 Electrical drawings ............................................................................................... - 77 -

-3-
 Suzhou Top Brand Machinery Technology Co., Ltd.

DAPAI Wi270Se II Injection molding machine

parameter table
Explanation UNIT Wi270Se II
Internationally recognized
model
—— 1400/270
Injection system INJECTION
Screw diameter mm 50
Screw (L/D ratio) L/D 25
Theoretical injection
volume
cm3 589
Actual injection volume g 683
(PS) oz 24.1
Injection pressure Bar 2464
Injection rate cm /s
3
259
Plasticizing capacity g/s 26
Maximum screw speed r/ mm 116
Clamping system CLAMPING UNIT
Clamping force kN 2700
Internal distance between
tie bars
620×570
Minimum mold dimensions
(H x V)
mm×mm 450×450
Mold opening mm 560
Minimum mold thickness mm 250
Maximum mold thickness mm 700
Maximum distance between
templates
mm 1260
Ejection stroke mm 150
Ejecting force kN 77
Number of ejector pins Pcs 7
Power/Heating POWER UNIT
System pressure Bar 175
Motor power kW 30
Heating power kW 19
Others GENERAL
Fuel tank capacity （升） 300
Mechanical dimensions(l
× w ×h)
m × m × m 6.3×1.5×2.2
Machine weight Ton 8.3

-4-
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter One Purchase preparation

1 How to choose an injection molding machine?Determine the
specifications of the injection molding machine.
1.1Based on the weight of the injection molded product, calculate
the injection volume that the injection molding machine should have.

(1)When the injection molded product is made of polystyrene, the

injection volume that the injection molding machine should have
is Wps.
Wps = (Weight of the product + Total weight of the gate system)
÷ (0.75 ~ 0.9)
That is, Wps = (1.3 ~ 1.1) × (Weight of the product + Total weight
of the gate system)
(2)If the product is made of other plastics (named plastic X),
following the above method, first calculate the theoretical injection
volume of this plastic that it should have, which is Wx: Wx = (1.3 ~ 1.1)
× (Weight of the product + Total weight of the gate system). However,
the injection volume of the injection molding machine cannot be simply
determined by Wx. It must be converted into the Wps value. The conversion
formula is: Wps = 1.05 × Wx ÷ p, where p is the specific gravity of
a certain plastic.

1.2 Calculate the clamping force P based on the vertical projection

area of the injection molded product on the template (front plate or rear
plate)：
Clamping force = Clamping force constant × Projection area of
the product
That is, P = Kp × S
Where P is the clamping force (t); S is the vertical projection

-5-
 Suzhou Top Brand Machinery Technology Co., Ltd.
area of the product on the template (cm²);
2
Kp—Clamping force constant（t/cm ）,Kp The values are listed
in the following table (Table 1).

Table 1 Clamping force constant Kp

（For injecting relatively precise products）
Name of Other
plastic PS PE PP ABS Nylon Acegal glass fibre engineering
plastics

Kp 0.30～ 0.64～ 0.64～ 0.64～ 0.64～

（t/cm ）2 0.32 0.32 0.32
0.48 0.72 0.72 0.72 0.72
1.3 The inner spacing dimension of the injection molding machine's
tie bars (guiding columns) is determined by the outer contour dimensions
of the mold. The former is larger than the latter.
1.4 The required mold opening stroke of the injection molding
machine is determined by the height of the product. The latter should
be greater than the former.

1.5 Other minor factors also need to be considered.:

(1)The clamping force of the injection molding machine should
be adapted to the height of your mold.
(2)Ejector stroke and ejector force.
(3)Process factors.

-6-
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter Two
The installation of the machine
2.1 Preparation work before installation
2.1.1 Hydraulic oil and lubricating oil are important components
during the operation of an injection molding machine. Therefore, they
should be strictly selected and applied. The working hydraulic oil should
be anti-wear hydraulic oil No. N46, and the lubricating oil should be
N220 gear oil and No. 3 lithium-based grease.

2.1.2 Electrical and cooling water

After purchasing the injection molding equipment, the first thing
users need to prepare is the power supply required for this equipment.
This includes power sockets, wires, the capacity of the power source,
the source and layout of cooling water, and whether a cooling tower needs
to be purchased, etc. Some parts of the machine may be different from
what our company has provided orally or in writing. Users should
appropriately adjust the relative positions of the power supply and water
source during the installation of the equipment to ensure the smooth
layout of wires and water pipes.
2.2 The loading and unloading of the equipment
Remind users to pay attention to the following points：
① When lifting, ensure that the lifting is balanced to prevent
tilting and guarantee safe and stable ascending and descending；
② Select an appropriate crane. Check if the steel wire rope, hook,
etc. are damaged and whether they have the ability to ensure safe lifting；
③ To ensure that during the lifting process, parts of the equipment
that are easily crushed or scratched by steel wire ropes, hooks, steel
bars, etc. are properly padded and isolated with waste cloth, cork, or
thick paper to prevent unnecessary damage to the equipment.

-7-
 Suzhou Top Brand Machinery Technology Co., Ltd.
2.3 Start installation
After verifying that the equipment is complete and undamaged, refer
to the machine's overall dimensions drawing. If necessary, place
anti-vibration pads under the machine's anchor bolt holes to ensure that
the entire machine is in a stable, reliable, and level position.
2.4 Add hydraulic oil
When refueling, the oil should be filtered through an air filter or added via an
oil filtration trolley. The added oil should reach the upper limit of the oil level gauge.
2.5 Connection of safety grounding wire
Users must connect the safety grounding wire properly.
2.6 Connection of power cord
After installing the injection molding machine on the ground,
connect the safety grounding wire. Check if any machine components or
wires have loosened or damaged during transportation. Only when
everything is confirmed to be in good condition can the three-phase power
supply be connected. The power supply voltage is 380 volts. The wiring
of the three-phase power supply should ensure that the motor drives the
oil pump to rotate in the correct direction. (Please note: Do not start
the oil pump until enough suitable hydraulic oil has been filled into
the tank of the hydraulic system.)

-8-
 Suzhou Top Brand Machinery Technology Co., Ltd.
2.7 Lubrication of lubricating oil
If the lubricating oil used has too high viscosity or does not meet
the requirements, it may result in insufficient or no oil supply to the
lubrication points, causing abnormal operation of the equipment. More
importantly, it will affect the service life (especially the lubrication
points of the hinge components). For equipment with a centralized
lubrication system, the oil quantity in the lubrication pump should be
checked before supplying lubricating oil. Later, it is even more
important to closely monitor and appropriately replenish the oil
quantity.
2.8 Recommended lubricating oil

Lubrication points Runbei oil Mobil oil product

product number number
Hydraulic oil HM46#Anti-wear DTE Excel 46 Hydraulic oil
hydraulic oil
Clamping Mold Joint oil ep gear oil EP220
Lubrication Center Pin GS220
Steel Sleeve
Injection bearing 3#Lithium-based Grease EP2
grease LIEP2
Die Adjustment Gear O#MoS₂ (LIEP0) Grease EP2
Manual lubrication Extreme pressure Grease EP0
pump grease LIEP00
Other parts 3#Lithium-based Grease EP2
grease LIEP2

-9-
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter Three Safety device

For the safety of operators and maintenance personnel, this machine
is equipped with some reliable safety devices when the machine
malfunctions or operates abnormally. These safety devices must be checked
before starting to operate the machine to ensure that they can operate
correctly when needed. If any looseness, insensitivity, or unreliability
is found, inspection, maintenance, and replacement should be carried out
immediately.
3.1 The main safety signs of the machine
Label sample Installation
position
melt glue
cylinder cover

melt glue
cylinder cover

Injection
shield

Control
electrical box
door;
Drive box door.

- 10 -
Suzhou Top Brand Machinery Technology Co., Ltd.
Junction box

Left door of
control
electrical box

Breaker
position

Front and rear

safety doors

Front and rear

safety doors

- 11 -
Suzhou Top Brand Machinery Technology Co., Ltd.
Do not step on
this position.
There may be no
fixed rules on
the machine.
The
interpretation
rights belong
to the company.
Front and rear
safety doors

Front safety
door or side
sealing plate
of head plate
(operating
side)

- 12 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 13 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 14 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
3.2 Electrical safety device
3.1.1 Emergency stop button switch
Use this button to stop the machine in an emergency. When pressed,
the oil pump drive motor stops running and the machine stops operating.
To reset, turn this button to the right. It is located below the operating
panel and is very conspicuous. When an emergency stop is not required
but you need to stop the oil pump motor under normal circumstances, use
the operating selection switch. Ensure that all switches are in the
correct position. Stop the oil pump motor using the button or by pressing
the emergency stop button.
3.1.2 Safety door and safety door limit switch
The position of the safety door limit switch can be referred to in
the travel switch distribution diagram in the circuit diagram. The
hydraulic protection safety device of this machine is an optional
function and can be added when needed. The safety door limit switch can
interrupt the circuit of the mold closing action. When the safety door
is opened, the limit switch opens to interrupt the electrical circuit,
with a dual-circuit control function of normally open and normally closed,
effectively preventing the mold closing action from proceeding.
3.1.2.1 Regular inspection
（1）Ensure that the safety door can open and close smoothly；
（2）Look for damage factors to the safety door (door, guide rail,
roller, etc.)；
（3）To clarify the correct matching of the safety door limit switch
(screws, actuators, etc.)；
3.1.2.2 Attention：
（1）Because the safety door and limit switch are provided to protect
the operator, do not move or change their positions in any case.
（ 2 ） If the safety door cannot open and close correctly or is
malfunctioning, it should be repaired and adjusted immediately.

- 15 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
3.3 Machine safety device
Clamping safety device
If the mold opening operation is carried out while a safety door is
open, the mechanical safety block will automatically drop during the
rearward movement of the mechanical safety lever. This ensures that when
a mold closing operation attempts to proceed due to a fault in an
electrical or hydraulic circuit, the safety block will prevent the
forward movement of the safety lever, thus preventing the mold closing
from occurring.

Attention 1：Do not move the safety lever, block or protective rod
cover.
Attention 2：Don't forget that when the machine stops中途 during the
mold opening and stopping process, the mechanical safety device does not
function.
Attention 3：Failure to follow the operating instructions given here
may result in serious dangers, especially machine malfunctions and
failures.
Precautions before using the equipment
Before using the equipment, if the user finds any deficiencies in
the design or manufacturing that may affect the use or safety protection,
and wishes to make further improvements, including the mechanical
structure, part circuit system, hydraulic system, etc., they can contact
our company, the nearest office or agent. Regarding any improvements made
to the machine by the user, our company shall not be liable for any
accidents or damages caused by such improvements, especially those
related to safety maintenance and parts, circuits related to electrical
and hydraulic systems. When inspecting the machine or performing any work
on it, before coming into contact with any moving parts, pressure, or
electrical components, always keep safety operation in mind and be sure
to cut off the power supply of the oil pump motor first to ensure safety.
- 16 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
3.4 Mechanical Precautions
3.4.1 The heating barrel cover part is designed to prevent heat loss
and electric shock. Therefore, do not place anything on top of the heating
barrel to avoid indentation and deformation, which may damage the barrel
cover. Do not touch it with any part of your body either.
3.4.2 Initial setting of screw speed
In order to extend the service life and ensure the quality of the
newly installed machine screw, after starting the machine, the screw
should rotate at a low speed and high torque, approximately within the
range of 60 revolutions per minute (50% of the computer display speed).
This should be maintained for about one month, and then the speed can
be gradually increased.
3.5 Electrical equipment
3.5.1 Connect to three-phase power supply
Connect the three-phase power supply (A, B, C) wires and the neutral
wire (N) to the terminals on the middle of the board (see the machine
installation section).
3.5.2 Check the rotation direction of the oil pump motor.
3.5.3 Shutdown: When finishing work or in the event of a sudden
power outage, disconnect the power switch for safety and to protect the
electrical equipment.
3.5.4 Ground wire (see the machine grounding section)
Is there a ground wire? Is it damaged? If not, it should be properly
reconnected.
3.5.5 The door of the electrical control box
When operating the machine or preparing to operate it, always
remember to keep the door of the electrical control box closed. (If for
other reasons or when inspecting the machine, the first thing to do is
to cut off the power supply connected to the machine.)

- 17 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
3.6 Hydraulic equipment
3.6.1 The hydraulic oil has a viscosity of 32-68 CST at 40℃.
3.6.1.2 Pay attention to the oil level reaching above the center line.
2.6.1.3 Pay attention to keeping the temperature of the hydraulic
oil between 15℃ and 55℃ (the most suitable operating temperature is
between 40℃ and 50℃).
3.6.2 Lubricating oil
3.6.2.1 Use 32-68CST/40℃ lubricating oil, 0#-3# lithium-based
grease, and molybdenum disulfide grease.
3.6.2.2 Before starting the machine, lubricate the machine
comprehensively by hand to ensure that all lubrication points are well
lubricated.
3.6.2.3 The lubrication of the oil cup on the movable part of the
injection part should be carried out before the machine starts, and a
manual oil injection gun can be used.
3.6.2.4 This machine is equipped with a centralized lubrication
device. Before starting, fill the oil to the indicated oil level. Check
the oil level in the device every day and refill the lubricating oil before
the oil level drops below the indication line.
3.6.2.5 Some lubrication points use lithium-based lubricating
grease. Please refer to the lubrication diagram on the machine for
specific locations.
3.6.2.6 System oil pressure
Note that the oil pressure should be lower than the maximum pressure
of the hydraulic system listed in the technical parameters table. If a
pressure exceeding this range is used, it may cause serious damage to
the machine.

3.7 Other aspects

The parts and spare parts that arrive with the injection molding
machine are all designed and manufactured for the injection molding
machine. They must not be used for other purposes. If they are used for
- 18 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
other purposes, our company will not be responsible for any damage, as
these parts are specifically designated for the injection molding machine.
These parts should be properly stored to prevent rust, scratches, aging,
etc.

- 19 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter Four Operation Step

Please follow the safety operating procedures from start to finish
during operation.
4.1 Pre-operation inspection
4.1.1 Connect the circulating cooling water, and the inner diameter
of the water pipe connected to the cooler is φ25.
4.1.2 Connect the power supply to the injection molding machine.
4.1.3 Check the temperature thermocouple plug and wiring on the
feeding barrel (After ensuring they are normal, turn on the power switch
of the heater and adjust the temperature to suit the material being
plasticized.
4.2 Start and stop the oil pump motor
1.2.1 After selecting the switch according to the following steps,
the oil pump motor can be started and stopped.
Step 1：Connect the machine to power supply
Step 2：Press the motor start button to start the motor.
Step 3：Press the motor start button again to stop the motor (If the
emergency stop button is pressed, the injection molding machine will also
stop).
4.2.2 Precautions：
（1）Before starting, ensure that the hydraulic oil level is above
the center line.
（2）Open the safety door.
（3）Do not start the oil pump motor if any hydraulic device (valve,
filter, oil pipe, etc.) is disconnected.
（4）Check the rotation direction of the oil pump for a moment when
powering it on.
（5）To reverse the rotation direction, the phase wiring of the power
supply should be reversed.
（6）When the oil pump is running, listen for any abnormal noises.

- 20 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
4.3 Clamping, opening and stroke switch
4.3.1 Clamping operation
Step 1：Close the safety door；
Step 2：Set the machine operation mode to manual；
Step 3：Clamping start.
4.3.2 Opening operation
Step 1：Set the machine operation mode to manual；
Step 2：Opening start.
4.3.3 Mold moving limit switch
（1）The high-pressure mold clamping stroke switch and the mold
closing stop switch have been adjusted at the factory and generally do
not need to be changed. If adjustment is necessary, the high-pressure
mold clamping stroke switch should be set to operate when the two surfaces
of the mold just start to touch, and the mold closing stop should operate
when the mold clamping toggle is completely extended.
（2）The position of the mold opening stop limit switch depends on
the installed mold (product). It should be noted that over-stroke should
be avoided.
4.4 Hydraulic ejection stroke switch
Before adjustment, start the oil pump motor and press the ejection
button.
The ejection action will only proceed when the mold opening stop
limit switch operates. For safety reasons, do not attempt to remove the
molded product during ejection.
4.4.1 Continuous ejection action
The injection molding machine has the setting and use
characteristics of continuous multiple ejections and multiple
vibrations.
4.4.2 Ejection stroke switch
（1）The closing mold action will not proceed unless the ejector pin
retraction stop limit switch operates (please pay special attention to

- 21 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
this point).
（2）The ejector pin forward stop limit switch is used to control
the ejection stroke. When setting, the initial stroke setting should be
as short as possible, and then gradually adjusted until the appropriate
stroke is obtained. Using this method for adjustment can avoid damaging
the mold.
4.5 Injection device (injection stroke or nozzle) and stroke switch
4.5.1 If you want the injection device to move forward, you can
press the seat advance button.
4.5.2 If you want the nozzle to retreat, you can press the seat
retraction button.
4.6 Install the mold
4.6.1 Before installing the mold
（1）If the locating ring is installed on the mold, it is very simple
to center the nozzle when installing the mold.
（2）Adjust the mold closing and installation device, the limit
switch on the mold closing side of the ejector pin stroke, etc., so as
to prevent the mold from being damaged when adjusting the mold thickness.
4.6.2 Mold installation (all manual control)
Step 1：When the movable template is not in the mold opening stop
position.
（1）Start the oil pump motor；
（2）Open the mold to allow it to open；
（3）Move the nozzle backwards；
（4）Turn off the oil pump motor；
Step 2：Position the ejector pin to fit the mold properly.
Step 3：Press the mold adjustment button.
Step 4：Hoist the paired mold halves so that they do not separate.
Regarding the size of the bolts, please refer to the mold adaptation
drawing. The depth H of the screw should be 1.5 to 1.8 times the diameter
φD of the bolt.

- 22 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Step 5：Turn on the oil pump motor
Step 6：Press the mold closing button, and the mold gradually closes.
Step 7：After the mold is completely closed, perform the nozzle
contact operation. Ensure that the nozzle contacts the mold accurately.
Before actual contact, press the seat advance button. If the nozzle is
not properly aligned to the center, make up-and-down and left-right
adjustments as needed.
Step 8：Turn off the oil pump motor
Step 9：Tighten the bolts on the fixed template and movable template
of the mold halves.
Note：Securely position the mold to prevent it from falling during
mold opening.
Step 10：Remove the belt or steel wire rope used for lifting.
Step 11：Position the limit switch on the mold closing side to match
with the mold.
Note：The limit switch includes the mold opening stop, low-pressure
mold protection, high-pressure mold locking, slow mold opening one, and
slow mold opening two switches.
Step 12：Start the oil pump motor.
Step 13：Press the fine-tuning switch to start manual adjustment.
Step 14：Set the switching mold pressure and flow rate during mold
adjustment, as well as the pressure and flow rate for mold adjustment.
Step 15：Repeat the mold opening, adjustment (either increasing or
decreasing), and mold closing procedures to ensure that the toggle joint
can just straighten when the mold is closed. Meanwhile, observe the value
of the pressure gauge to adjust the appropriate clamping force.
Step 16：Readjust the limit switch on the mold closing side.
Step 17：Press the fine-tuning switch to end the mold adjustment.
Step 18：During the product trial molding, based on the quality of
product formation, repeat steps 13 - 16 to minimize the clamping force
as much as possible under the premise of qualified products, which is

- 23 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
conducive to the service life of the machine.
If using the automatic mold adjustment function, the basic
operations are as follows：
Continuing from step 12, replace the above steps 13 - 16 (for detailed
instructions, please refer to the corresponding part of the computer
operation manual).
Step 13：Open the mold to the end of the opening stroke. Adjust the
slow opening switch to the positioning position.
Note：If a position gauge is used, the slow opening position must
be greater than the high-pressure closing position.
Step 14：Setting of opening and closing mold parameters and mold
adjustment parameters
Step 15：Close the safety door and press the fine adjustment key.
Step 16：Switch the safety door on and off again. The machine will
automatically adjust the mold. After the mold adjustment is completed,
the machine will return to manual mode.
Manually control the repeated closing and opening of the mold, and
perform the forward and backward movement of the injection seat. Conduct
a comprehensive inspection to ensure the safe installation of the mold
and the correct adjustment of the limit switch.
4.7 The operations of plasticizing and metering, injection, and
anti-dribbling (retraction) of the screw
In order to protect the screw, the operation of the screw should start
only after the temperature of the heating cylinder reaches the set
temperature: 15 to 30 minutes.
1.7.2 Metering operation (rotation of the screw)
Press the melt button, and the screw will rotate and gradually
retract to the stop (pre-plasticization stop) metering position, and then
stop rotating. You can also press the melt button again to stop it.
1.7.2 The injection operation (the screw moves forward) starts when
the injection button is pressed.

- 24 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
1.7.3 Screw anti-dribbling (retraction)
Press the injection retraction button, and the screw will start to
retract.
4.8 Automatic operation
1.8.1 Before starting the automatic operation, check the following
① to ⑦.
①Check that the operator and the surrounding machinery meet the
safety requirements.
②Check that each safety device functions correctly.
③Ensure that all limit switches are positioned correctly or that
the position of the position gauge is set correctly.
④Check that the pressure and flow rate of each movement are adjusted
correctly.
⑤Check the correctness of each operation mode (automatic cycle
mode).
⑥Ensure that the temperature of the heating barrel is suitable for
the resin being processed.
Manually control and start the injection molding machine according
to items ② to ⑦ above, and check each of the above items.
1.8.2 Carry out automatic operation
①Start the oil pump motor. (Refer to the start and stop procedures
of the oil pump motor in Chapter 4)
②Press the automatic button.
③Close the safety door. (The mold closing and injection cycle
starts)
4.9 After work is completed (shut down the machine)
1.9.1 Just before the molding is completed or just before a
temporary stop.
①Press the heating button to turn off the heater power supply. (If
it is a temporary short-term shutdown, do not turn off the heater power
supply.)；

- 25 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
②Close the hopper baffle.
1.9.2 When the material runs out or the required number of products
has been molded and it is necessary to turn off the electric heater and
shut down the machine.
Not only to heat the barrel as quickly as possible during the next
clamping operation, but also to prevent the dissolved resin from
remaining in the barrel, the remaining material in the heated barrel
should be thoroughly cleaned out.
(Because the plasticized material may explode, special care must be taken
to avoid combustion during cleaning.)
1.9.3 Manually control the machine to close the mold (but do not apply
high pressure during mold closing) and retract the injection unit and
screw to the stop position.
1.9.4 Turn off the oil pump motor, disconnect the operating power supply,
and also disconnect the main power supply of the injection molding
machine.
1.9.5 Color change or material change: (1) Thoroughly clean the barrel;
(2) When changing materials or colors, it will depend on the type of
material used. After reducing the plasticizing temperature of the heated
barrel, then proceed with the color change or material change.
4.10 Demoulding (carried out completely under manual control)
Step 1：Start the oil pump motor.
Step 2：Close the mold completely.
Step 3：Turn off the oil pump motor.
Step 4：Open the safety door, install the bolts on the mold, and thread
the steel wire rope for lifting.
Note：When the injection molding machine is started, it should be ensured
that the two halves of the mold do not separate.
Step 5：Remove all the clamping parts of the mold.
Step 6：Start the oil pump motor.
Step 7：Press the mold opening button to open the mold.
Step 8：When the mold opening operation is completed, stop the oil pump
motor.
Step 9：Lift the mold out of the injection molding machine and place it
in an appropriate location.

- 26 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter Five
Common Operating Faults and
Troubleshooting Methods for Injection Molding
Machines
The following is a summary of the experience in product maintenance and
operation of our company. Please refer to it for assistance.
fault Cause Solution
The wiring of the proportional valve is Check if the proportional pressure
loose or the coil is burned out valve is powered on
Impurities block the control oil port of the Remove the proportional pressure
proportional pressure valve valve and clean out the impurities.
The oil pump The hydraulic oil is contaminated, and
motor and impurities accumulate on the surface of the Clean the oil filter and replace
oil pump oil filter, resulting in damage due to the hydraulic oil.
start, but contaminated pressure oil.
there is no Internal leakage of the oil pump, caused by
pressure. prolonged use, internal wear and tear, or Repair or replace the oil pump.
damage due to contaminated pressure oil.
Oil leakage from the oil cylinder, oil
Eliminate the leakage points.
pipes, and joints.
Check if the valve core moves
The valve core is jammed.
normally.
The wiring of the safety door travel switch Connect the wire ends properly or
is loose, broken or damaged. replace the travel switch.
The coil of the mold locking solenoid valve
Clean or replace the mold locking
may have shifted inward, causing the "valve
The mold is and opening control valves.
core" to jam during movement.
not locked
The directional valve may not return to its
Clean the directional valve
original position.
The ejector pin cannot return to its Check if the ejector pin movement
original position. is normal.
The coil of the injection solenoid valve may
have burned out, or foreign objects may have Clean or replace the injection
No injection entered the directional valve and jammed the solenoid valve.
valve core movement.
Low pressure Increase the injection pressure.

- 27 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Adjust the temperature controller
to raise the temperature to the
required point. If adjusting the
temperature controller still
The temperature is too low during injection
cannot raise the temperature,
molding.
check whether the heating barrel
and fuses are burnt out or
loose/broken. If they are damaged,
replace them with new ones.
The wiring of the injection directional Connect the wire ends of the
valve is loose, broken, or has poor contact. directional valve properly.
The limit switch is malfunctioning or in the Adjust the position of the limit
wrong position. switch
Adjust to the appropriate flow
The throttle valve is not properly adjusted.
rate.
The coil of the melt solenoid valve may have
No melting burned out, or foreign objects may have Clean or replace the melt control
or slow entered the directional valve and jammed the valve.
melting of valve core movement.
plastic Check if the heating barrel is
burnt out (at this time, the melt
Insufficient temperature causes motor motor should be strictly
overload prohibited from starting,
otherwise the screw will be
damaged).

fault Cause Solution

The melt The back pressure during melt retreat is too
Adjust or replace the injection
screw is high, or the throttle valve is damaged or
one-way throttle valve.
rotating, improperly adjusted.
but the Insufficient water circulation leads to
plastic excessively high temperature, causing the Adjust the water flow rate and
material plastic material to be blocked when entering remove the glued blocks.
does not the screw.
enter the
There is no material in the hopper. Add material to the hopper.
barrel.
The limit switch for the injection unit
movement has been actuated by the adjusting Adjust
block.
The
The coil of the solenoid valve for the
injection
injection unit movement may have burned out
unit does Clean or replace the solenoid
or there may be foreign objects inside the
not move valve.
directional valve jamming the spool
movement.
Clean the guide posts and mold
Cannot
The guide post wire has burned out due to adjustment nuts, repair the burned
adjust the
lack of cleanliness or lubricating oil. areas, and apply molybdenum
mold
disulfide grease for lubrication。

- 28 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
The coil of the mold adjustment solenoid
valve may have burned out, or there may be Clean or replace the solenoid
foreign objects inside the directional valve.
valve jamming the spool.
The mold opening stroke switch is not Adjust or replace the stroke
pressed down or has malfunctioned. switch.
The fixing screws of the slow solenoid valve Adjust until there is an obvious
The mold are loose, or the valve core is jammed. slow speed.
makes noise The adjustment position of the mold opening
when stop stroke switch is too far forward, Adjust the mold opening stop switch
opening causing the piston to hit the cylinder to an appropriate position.
barrel cover when the mold opening stops.
The machine hinge, steel sleeve or hinge
edge are worn, or the fixing screws in a Adjust or replace
certain part are loose.
It should be adjusted to the
The The oil pump pressure is too high. required pressure of the rubber
temperature compound.
of the Pump damage and low pressure oil
Check the oil pump and oil quality.
pressure concentration
oil is too The pressure oil volume is insufficient. Increase the pressure oil volume.
high The cooling system is faulty, resulting in
Repair the cooling system.
insufficient water supply.
The semi-automatic cycle of this machine is
realized by the stroke of mechanical actions
triggering various electrical travel First, observe at which stage the
switches and time relays to send out semi-automatic action fails. Refer
Semi-automa electrical signals and control the oil to the "Action Cycle Diagram" to
tic failure valves. If each action is normal in manual find the corresponding control
mode, but the semi-automatic function element, and then check and resolve
fails, it is mostly due to the electrical the issue.
travel switches and time relays not sending
out signals.
The photoelectric sensor fails, caused by To restore the function of the
loose fixing screws or poor focusing. photoelectric sensor
Full
automatic The time relay fails or is damaged. Adjust or replace the time relay.
operation
The heating tube is damaged. replace
failure
The thermocouple is poorly connected. fasten
The thermocouple is damaged. replace

5.1 The Causes and Solutions of Injection Molding Defects

Incorrect operating conditions, damaged machines and molds can cause
many molding defects. The following are some solutions for reference.
In order to reduce the downtime and quickly identify the causes of
operating problems, operators should record all the best injection
- 29 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
molding conditions on the "Injection Molding Condition Record Form" for
future reference when solving problems. To the best of our knowledge,
the appendix information provided here is not completely accurate.
However, we do not assume any responsibility for the accuracy and
completeness of this information. Please determine the availability of
the information by yourselves.
（1）The finished product is incomplete
Cause Solution
The plastic temperature is too low Increase the temperature of the melt
cylinder
The injection pressure is too low Increase the injection pressure
The injection volume is insufficient Increase the injection volume
The gate bushing and nozzle are not Readjust its fit
properly aligned, causing plastic
overflow
The injection time is too short Increase the injection time
The injection speed is too slow Increase the injection speed
Low pressure adjustment is improper Re-regulate
The mold temperature is too low Increase the mold temperature
The mold temperature is uneven Reroute
The mold has poor ventilation Add appropriate vents in proper positions
The nozzle temperature is not low Increase the nozzle temperature
The plastic injection is not uniform Re-open the mold overflow port position
The runner or overflow gate is too small Increase the size of the runner or
overflow port
The plastic internal lubricant is Increase the lubricant
insufficient
Back pressure is insufficient Slightly increase the back pressure
Wear of the rubber ring and melt screw Dismantle
Insufficient injection volume Change to a larger specification
injection molding machine
The product is too thin Use nitrogen injection

(2）Product shrinkage
Cause Solution
Insufficient material feeding in the mold Increase the injection volume
Insufficient melt volume Increase the melt volume
Injection pressure is too low High injection pressure
Back pressure is insufficient High back pressure
Injection time is too short Extend the injection time

- 30 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
The injection speed is too slow High injection speed
Unbalanced overflow port The overflow port of the mold is too small
or in the wrong position.
The nozzle hole is too small. The plastic Repair or replace the injection nozzle
solidifies in the runner bushing, reducing
the effect of back pressure.
Material temperature is too high Low material temperature
Improper mold temperature Adjust to the appropriate temperature
The cooling time is insufficient. Prolong the cooling time
Excessive pressure accumulation sections The injection termination should be at
the very front end.
The product itself or its ribs and pillar Review the finished product design
positions are too thick.
Excessive injection volume Replace with a thinner screw rod
Wear of rubber ring and melt screw Dismantling and maintenance
The gate is too small, and the plastic Increase the gate size
solidifies, losing the back pressure
effect.
（3）Finished product sticking to the mold
Cause Solution
Filling material is too full Reduce the injection pressure, time,
speed, and injection volume
Injection pressure is too high Reduce the injection pressure
Excessive injection volume Reduce the injection volume
Injection time is too long Reduce the injection time
Material temperature is too high Reduce the material temperature
Uneven feeding causes partial Change the size or position of the
over-saturation overflow port
Mold temperature is too high or too low Adjust the mold temperature and the
relative temperature on both sides
There is a draft angle for demolding in the Repair the mold and remove the chamfers
mold
The mold surface is not smooth Polish the mold
Demolding causes vacuum Slow down the mold opening or ejection,
or add air intake equipment to the mold
The injection molding cycle is too short Strengthen cooling
Insufficient release agent Slightly increase the amount of release
agent

（4）The runner (sprue) sticks to the mold

Cause Solution
The injection pressure is too high Reduce the injection pressure
- 31 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
The plastic temperature is too high Lower the plastic temperature
The runner is too large Modify the mold
The runner is not cooled enough Extend the cooling time or lower the
cooling temperature
The draft angle of the runner is Modify the mold to increase the angle
insufficient
The runner bushing does not align Readjust its fit
properly with the nozzle
The inner surface of the runner is rough Maintain
or has an improper draft angle for
demolding
The outer hole of the runner is damaged Maintain
No runner catch pin Add a catch pin
The packing is too tight or overfilled Reduce the injection volume, time and speed
Insufficient mold release agent Slightly increase the release agent dosage
（5）Flash and rough edge
Cause Solution
The plastic temperature is too high Lower the plastic temperature and the mold
temperature
The injection speed is too high Reduce the injection speed
The injection pressure is too high Reduce the injection pressure
The filling is too full Reduce the injection time, speed and dose
poor parting line or mismatching Maintain
surface
The clamping pressure is insufficient Increase the clamping pressure or replace
the injection molding machine with a higher
clamping pressure
（6）The finished product cracks during mold opening or ejection
Cause Solution
Overfilling of the mold Reduce the injection pressure, time,
speed, and injection volume
Mold temperature is too low Increase the mold temperature
The demolding angle is insufficient in Maintain
some parts
Has a draft angle for demolding Maintain
The finished product cannot be balanced Maintain
during demolding
There are insufficient ejector pins or Maintain
they are in the wrong position.
A vacuum phenomenon occurs locally during Open the mold at a slow ejection speed and
demolding add air intake equipment.
Insufficient release agent Slightly increase the amount of release
agent
- 32 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Poor mold design results in excessive Improve the finished product design
residual stress in the finished product.

The timing or position of the side slider Maintain

action is incorrect.

（7）Joint line
Cause Solution
Plastic melt is not good Increase the plastic temperature, raise
the back pressure, and speed up the screw
rotation speed.
Mold temperature is too low Increase the mold temperature
Nozzle temperature is too low Increase the nozzle temperature
Injection speed is too slow Speed up the injection process
Injection pressure is too low Increase the injection pressure
Plastic is contaminated or mixed with Check the plastic
other materials
There is too much release agent Minimize the use of release agents or
avoid using them altogether
The runner and overflow gate are either Adjust the mold
too large or too small
The weld line is too far from the gate Adjust the mold
Air in the mold cavity is not completely Add more vent holes or check if the
vented existing vent holes are blocked
Insufficient melt volume Use a larger injection molding machine
Too much mold release agent Do not use or reduce the use of release
agents
（8）Flow mark
Cause Solution
The plastic is not properly melted Increase the plastic temperature, raise
the back pressure, and speed up the screw
rotation speed
The mold temperature is too low Increase the mold temperature
Improper mold cooling Readjust the mold water pipe
The injection speed is too fast or too Adjust the appropriate injection speed
slow
The injection pressure is too high or too Adjust the appropriate injection
low pressure
The plastic is contaminated or mixed with Check the plastic
other materials
The overflow port is too small, causing Increase the overflow port size
injection marks
The thickness of the finished product Change the finished product design or the

- 33 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
section varies too much location of the overflow port
（9）The finished product surface is not glossy
Cause Solution

The mold temperature is too low Increase the mold temperature

The plastic dosage is insufficient Increase the injection pressure, speed,
time and dosage
There is an excessive amount of Wipe clean
release agent in the mold
The plastic drying process is not Improved drying process/treatment
properly handled
There is water on the inner surface Wipe and check for any water leakage
of the mold
The inner surface of the mold is not Polish the mold
smooth

(10)Silver streaks and Bubbles

Cause Solution
Plastic contains moisture Thoroughly dry the plastic
Lower the plastic temperature
The plastic temperature is too high Replace the injection molding machine with
or the plastic has stayed in the a smaller injection volume
barrel for too long. Lower the temperature of the nozzle and the
front section
Decomposition of other additives in Reduce its usage or replace it with a
plastic such as lubricants, dyes, substitute that can withstand higher
etc. temperatures.
The other additives in the plastic
Mix thoroughly and evenly
are not mixed evenly
The injection speed is too fast Slow down the injection speed
The injection pressure is too high Reduce the injection pressure
The melt speed is too low Increase the melt speed
The mold temperature is too low Increase the mold speed
The plastic particles are of uneven
Use granular and uniform raw materials
size
Lower the temperature of the rear section of
There is air trapped in the melt the melt cylinder, increase the back
cylinder. pressure, and reduce the length of the
compression section
Adjust the size and position of the overflow
The plastic flow in the mold is port, maintain an average mold temperature,
improper and ensure an even thickness of the finished
product

- 34 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

（11）Finished product deformation

Cause Solution
The top of the finished product is Lower the mold temperature, extend the
not yet cooled cooling time, and reduce the plastic
temperature
The plastic temperature is too low Increase the plastic temperature and raise
the mold temperature
The shape and thickness of the Mold temperature zone control, fixing with
finished product are asymmetric a shaping frame after demolding, and
changing the forming design
Excessive filling material Decrease the injection pressure, velocity,
duration and quantity
The feeding at several overflow Modify the overflow opening
ports is uneven
The ejector pin system is unbalanced Improve the ejection system
The mold temperature is uneven Adjust the mold temperature
The plastic near the overflow port Adjust the injection time up or down
is too loose or too tight
Poor pressure maintenance Extend the dwell time under pressure

- 35 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
（12）There are air bubbles in the finished product

Cause Solution
The filling amount is insufficient Increase back pressure and injection pressure
to prevent excessive shrinkage of
the finished product.
The cross-section of the finished Change the finished product design or the
product shows that the ribs or overflow port position
columns are too thick.
The injection pressure is too low Increase the injection pressure
The injection volume and time are Increase the injection volume and injection
insufficient time
The gate overflow outlet is too Increase the gate and overflow port size
small
The injection speed is too fast Slow down the injection speed
The plastic contains moisture The plastic is completely dry
The plastic temperature is too high, Lower the plastic temperature
causing decomposition
The mold temperature is uneven Adjust the mold temperature
The cooling time is too long Reduce the in-mold cooling time and use water
bath cooling
The water bath cooling is too rapid Reduce the water bath time or increase the
water bath temperature
The back pressure is insufficient Increase the back pressure
The temperature of the melt cylinder Lower the temperature of the nozzle and the
is improper front section, and raise the temperature of
the rear section
The shrinkage rate of the plastic is Use other plastics with a lower shrinkage rate
too high

- 36 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
（13）black lines
Cause Solution
plastic overheating Reduce the temperature
The plastic temperature is too high Lower the plastic temperature
The melt glue speed is too fast Reduce the melt speed
The screw and the melt glue cylinder are Maintain
eccentric, resulting in excessive
friction heat
The nozzle hole is too small or the Readjust the aperture size or temperature
temperature is too high
The injection volume is too large Replace with a smaller injection molding machine
There are dead corners in the melt glue Inspect the contact surface between the nozzle and the
cylinder that cause the plastic to melt cylinder for any gaps or signs of corrosion.
overheat

（14）Black spots

Cause Solution
Perform a complete empty shot, disassemble and
The overheated part of the plastic
clean the melt cylinder, lower the plastic
adheres to the inner wall of the melt
temperature, shorten the heating time, and
cylinder.
enhance the plastic drying process.
The plastic is mixed with impurities Inspect the plastic and perform a complete
such as paper scraps, etc. empty shot
Lower the injection pressure and speed, reduce
the plastic temperature, strengthen the mold
Coking spots occur during injection
venting holes, appropriately decrease the
into the mold
clamping pressure, and change the location of
the overflow port.
There are dead spots in the melt Check the contact surface between the nozzle
cylinder that cause the plastic to and the melt cylinder for any gaps or
overheat. corrosion.

（15）Unstable period
The causes and countermeasures of various molding defects listed above are mostly
related to the stability of the cycle. The proper plasticization of plastic in the
melt cylinder or the temperature control of the mold is the result of heat transfer
balance. That is to say, throughout the entire injection molding cycle, the plastic
in the melt cylinder receives friction heat from the rotation of the screw and heat
from the heating ring. The heat energy enters the mold along with the injection of
plastic. The heat energy of the mold comes from the constant interaction between the
plastic and the mold, and is lost during the ejection of the finished product,
dissipated into the air, or carried away by the cooling water. Therefore, if the

- 37 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
temperature of the melt cylinder or the mold is to remain constant, it is necessary
to maintain the heat transfer balance in and out. To maintain the heat transfer balance,
a stable injection molding cycle must be maintained. If the injection molding cycle
time becomes shorter and shorter, the heat energy in the melt cylinder will be
insufficient to melt the plastic, while the heat energy in the mold will be more incoming
than outgoing, causing the mold temperature to keep rising. On the contrary, there
will be opposite results. Therefore, in any injection molding operation, especially
manual operation, it is necessary to control a stable cycle time and try to avoid uneven
speeds. If other conditions remain unchanged, then:
- Accelerating the cycle will cause: short shots, shrinkage and deformation of finished
products, sticking to the mold.
- Slowing down the cycle will cause: overflow, flash, sticking to the mold, deformation
of finished products, overheating of plastic, and even burning, and the charred
material 残留 remaining in the mold may also cause mold damage. The overheated plastic
in the melt cylinder may also corrode the melt cylinder, and black spots and streaks
may appear on the finished products.

- 38 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter six
The use of hydraulic oil and lubricating oil

In order to use our injection molding machine with the highest

efficiency, keep our equipment in the best working condition, and
more importantly, prevent or reduce the failures of
high-performance mechanical components and hydraulic devices,
reduce wear and tear, and extend their service life, we should
strictly use and maintain hydraulic oil.
Past experience has shown that the vast majority of failures
occurring in hydraulic systems are due to incorrect or improper
use and maintenance of hydraulic oil.
6.1 Hydraulic oil
The hydraulic oil used in the hydraulic device of this machine
not only serves as a power transmission medium but also lubricates
the surfaces of metal parts.
6.2 The required properties of hydraulic oil
Generally speaking, hydraulic oil requires the following
performance characteristics：
(1)Flow freely under operating conditions.
(2)The oil forms a proper seal in the moving parts.
(3)When in use, there are almost no physical or chemical
changes.
(4)Anti-rust and anti-corrosion
(5)Be able to withstand loads appropriately and reduce the
wear of moving parts.
(6)When at rest, it can quickly separate water, dirt and other
impurities so that they can be eliminated from the hydraulic
system.
(7)In use, it is suitable for sealing, etc.
(8)According to the purpose, it is flame-resistant.
(9)Does not easily produce foam.
6.3 Hydraulic Oil Control and Maintenance
If hydraulic oil is not properly maintained and handled, it can
- 39 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
cause damage. Therefore, we should establish certain procedures to
properly maintain the oil itself. When maintaining the operation
of machines and hydraulic equipment, please pay special attention
to the maintenance of hydraulic oil.
6.3.1 Hydraulic Oil Maintenance Items
In general, maintenance items can be roughly classified into the
following three types:：
(1)Impurities in hydraulic oil: Judged based on viscosity, total
acid value, or color.
(2)Foreign matter contamination: Judged based on weight or by
using calculation methods.
(3)Appearance: Mainly judged based on color.
The following items will have greater practical value.
①Viscosity change
Viscosity is an important item in maintenance because changes
in viscosity directly affect the performance of hydraulic devices
and also influence their working life. Oxidation and degradation
caused by heat will increase viscosity, while a decrease in
viscosity is due to the shearing of additives such as polymers used
to improve the viscosity index or reduce the pour point. This is
a special problem for high-viscosity index hydraulic oils. In
addition, the reason for sudden changes in viscosity is the use of
inappropriate types of oil during replenishment.
② Change in total acid value
The change in total acid value will vary depending on the base
oil, whether additives are used, and the type of additives.
However, generally speaking, if additives are present, the change
in total acid value will vary with the conditions of oil use, but
it is still best to regularly test the total acid value.
③ Water in oil
When using mineral hydraulic oils, special attention must be
paid because the mixing of water can cause emulsification, which
is harmful to lubrication, causes rust and other problems, and
shortens the service life of hydraulic devices and the oil. In
severe cases, the presence of water can be detected by the naked
eye.
④ Color
The color change of hydraulic oil will vary with the viscosity
of the oil, as well as the type and amount of additives added to
- 40 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
the oil. It is necessary to compare it with new oil. However,
generally speaking, when oxidation and heating intensify,
causing deterioration, the color tends to darken. During the
inspection of the working state, this change can serve as a simple
guide.
⑤ The degree of pollution
When hydraulic oil contains impurities, this is often harmful
to the performance and reliability of hydraulic devices.
Therefore, preventing pollution is an extremely important part
of maintenance. There are two methods commonly used to estimate
the degree of pollution: the gravimetric method and the
statistical method.
a)In terms of the gravimetric method: In conventional
hydraulic equipment, the amount of pollution should not exceed
10 milligrams per 100 milliliters, while in numerical control
equipment, it should not exceed 5 milligrams per 100 liters.
b)In terms of the statistical method: When servo valves are
used in hydraulic equipment, the ideal oil maintenance is to keep
the pollution level at NAS Class 7 or higher. These NAS
classification or grade numbers are listed in Table 2 below.
Table 3 The impact of impurities on hydraulic circuits is listed.
Table 2 NAS Contamination Standard (Quantity per 100 milliliters)

Specificati
on
classificati Level
on

μm 00 0 1 2 3 4 5
5—15 125 250 500 1000 2000 4000 8000
15—25 22 44 89 178 356 712 1425
25—50 4 8 16 32 63 126 253
50 一 100 1 2 3 6 11 22 45
Over 100 0 0 1 1 2 4 8
6 7 8 9 10 11 12
5 一 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
Over 100 16 32 64 128 256 512 1024

- 41 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Table 3 The impact of various pollutants on hydraulic systems
Pollutant Possible types of Reasons and points of
type failure attention
Oxidation Cause metal corrosion The hydraulic oil will decompose, and high
product temperature or water contamination will
cause this fault.
Oil sludge Impede function Oil decomposition, high temperature, and
turbulence can cause this problem.
Water Form an emulsion Condensation or cooler leakage
Air Solubility Inhibit with defoaming agent
Air Insolubility Pressure drops rapidly, packing failure
Oil other than Will mix, but sometimes Improper tank design
hydraulic oil react
Metallic small Insoluble and acts as a Water pollution occurs, and a small amount
particle dirt catalyst can be controlled with rust inhibitors. The
rust inhibitors remain in the pipelines
and(oil tank) and are not properly flushed
away before or after installation.
Coating flakes Insoluble and affects Improper painting or peeling of the internal
functionality coating of the old tank
Friction-generat Worn-out equipment Fine particles floating in the air
ed particles hinders functionality
Rubber fine Hinder Damaged seals, check seals and sealing
particles materials
sand Wear, damage, and Enter the oil from the air or from improperly
hindered functionality cleaned castings
When cleaning after disassembly, do not
Filament, fiber Hinder flush the pressure grooves improperly. When
using packing materials, avoid materials
that may allow fine fibers to enter the oil.

6.3.2 Control reference value

Due to the fact that the control and maintenance values of
hydraulic oil will vary depending on the type of oil, whether
additives are used, the amount of additives added, the
operating conditions of the hydraulic equipment, and the
required accuracy, it is difficult to establish a fixed set
of values. However, for reference purposes, Table 7 below lists
examples of control and maintenance reference values for
hydraulic oil used in industrial machinery.
Oil needs to be replaced frequently, and the reason is
contamination rather than the deterioration of the oil itself.

- 42 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
In many cases, once these contaminants are removed from the
oil, the oil can continue to be used.
Table 4 General examples of control reference for hydraulic
oil used in industrial machinery.
Testing Items Reference Value
Viscosity change ±10％
The increase in total acid 0.4 milligrams of potassium hydroxide per gram
value (after a decrease)
Water 0.1% or turbid
Insoluble components 0.05％
(n-pentane) (benzene)
Color (consistent) Considerable changes
Pollution level 7 milligrams per 100 milliliters

6.3.3 Operational controls

Here, we will discuss relevant items related to operation,
hydraulic equipment, as well as daily maintenance and
inspection measures. To prevent failures, these maintenance
inspections must be properly carried out.
(1)oil volume
Please ensure that the minimum oil level does not fall below
the midline of the oil level indicator. If the oil level is too
low, it will be difficult to separate small particles of
contaminants, water, foam, etc., thus accelerating the
deterioration of the oil. Therefore, please regularly check
whether hydraulic oil needs to be added to ensure an adequate
oil quantity in the tank.
(2) oil temperature
When the oil temperature is too low, please run the machine
idle before starting production to warm it up appropriately.
During normal operation, also please adjust the cooler to ensure
that the temperature of the hydraulic oil does not exceed 55℃ .
When the hydraulic oil overheats, the oil's lubricating film
no longer covers as it does under normal conditions, sealing
materials will be damaged, and the efficiency of the pump will
be adversely affected. Here, please take further cooling
measures for the oil, such as cleaning the cooler, increasing
the amount of cooling water, etc.
(3) oil pressure
- 43 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Please ensure that the pressure reading is normal. If the
pressure is abnormal, the filter outlet may be blocked and air
may be drawn into the oil. In such cases, the pump and pressure
gauge should be checked.

(4) Check the filter

Please monitor the pressure changes of the filter and clean
it regularly. If there are many impurities in the oil, please
inspect them and try to find out how they entered.
(5) The noise of the pump
The causes of abnormal noise include filter blockage, air
being drawn into the oil, high oil viscosity, or foreign objects
entering the pump, etc.
(6) Check for leaks
Check the joints, flanges, and hoses for leaks caused by seal
degradation.

6.3.4 Hydraulic equipment and maintenance

The work of inspecting and replacing hydraulic oil, as well
as flushing and other tasks, must be carried out carefully and
thoroughly.
(1)Fill oil into the fuel tank and top up oil
①Please fill oil through the air filter. When filling oil,
please remove the cover and cap, but do not place them on the
factory floor where dust and fibers may adhere to their inner
surfaces.
②Since the inner diameter of this filter is approximately
50 millimeters, the 1.5-inch pipe from the supply pump can be
easily inserted to top up the oil. There is a 100-mesh filter
on the air filter. If it becomes clogged, the oil will flow
backwards from the filter and spill onto the floor. Please note
this when using the supply pump. If this filter is not used,
when removing the fuel tank cover to add oil, ensure that the
oil is not contaminated by foreign objects.
③When first filling the fuel tank of large machines, etc.,
and not using a filter, please use a filter with a mesh size
of at least 100, and ensure that all devices used for filling
or pumping oil are completely clean. We recommend using a
flushing device when filling the fuel tank.

- 44 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
④Not only when first filling the fuel tank of the machine,
but also when topping up the supply with new oil, it is best
to consult the opinion of the oil supplier and seek their
assistance, as these companies are very willing to provide help.
⑤After changing the hydraulic oil, please let it stand for
3 - 5 hours so that the air bubbles can be removed and the
floating matter can settle before starting the pump motor.
(2)Regular testing of oil performance
If the oil is contaminated or deteriorates, the life of the
machine will be shortened and malfunctions may occur. Therefore,
it is absolutely necessary to regularly test the oil to detect
changes in its performance. Strictly speaking, such tests
should be carried out in the laboratory of the oil company.
However, users may still be able to understand the condition
of the oil through visual inspection methods. Please take a
sample from the hydraulic oil tank immediately after the machine
is shut down, as the oil is fully stirred at that time.
①Tests that users can perform
a)Visual inspection
Put the new oil sample and the in-use oil sample into their
respective test tubes, and compare their color, clarity, the
presence of floating matter, and water precipitation at the
bottom of the test tube, etc.
b)Drip test
The same test method is also adopted. By comparing it with
new oil, the condition of the oil can be understood. Drop one
drop of the in-use oil onto a filter paper (absorbent paper
available on the market can also be used) and observe it after
2 - 3 hours. If the oil is dirty or obviously deteriorated, the
contaminants will be easily observable.
②Qualitative and quantitative tests of oil products by oil
companies
If the two tests described above reveal abnormal oil
conditions, it will be necessary to conduct further tests in
the test laboratory of the oil supplier. Experienced service
technicians from oil companies can immediately determine, based
on the results of the above two tests, whether the oil should
be replaced with new oil or whether the sample should be taken
back to their laboratory for detailed testing to obtain the
- 45 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
final result.
⑧The period of regular testing
A day is designated for visual inspection or drip test every
month. If the oil company conducts qualitative and quantitative
tests one month, two months, and three months after replacing
the new oil, then the above tests should be carried out every
three months. When purchasing new oil, it is recommended that
users sign a special contract with the oil supplier regarding
oil inspection. Limits for the use of hydraulic oil: To
determine the limits for the use of hydraulic oil, when using
hydraulic equipment, please make an overall judgment mainly
based on the following listed items. Deterioration of the oil
itself: Based on the results of the qualitative and quantitative
tests mentioned above, the oil company will determine whether
the deterioration has reached the point where the oil must be
replaced. Pollution level: At this point, we should seek the
opinion of the oil company regarding the pollution level of the
oil. For hydraulic equipment, it is necessary to keep the oil
pollution level within the limits listed below. The maintenance
during the 1 - 3 months after the oil is purchased and put into
use is particularly important. It is no exaggeration to say that
during this period, the service life of the hydraulic device
will be determined. Please refer to the following table：

Gravimetric method, particle weight

Measuring method Statistical
/ 100 ml
method
The allowable degree
7 mg
of oil pollution NAS 11 Level

Note： Since the statistical method can only count particles of

5 microns or larger, and the reproducibility of the measured
values is poor, this method can only be used for reference.
(3)Flush
① Objectives and steps
First, it is to rinse away the metal particles, sand, and
dust that may have entered the oil tank and pipelines during
the manufacture, assembly, or installation of the machine. The
second reason for rinsing is to clean the hydraulic equipment

- 46 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
after it has been in use for a certain period of time. We believe
it would be best for you to invite the maintenance experts from
the oil company to carry out the rinsing in your factory using
their equipment.
② Rinse during oil change
No matter how good the hydraulic oil is, after it has been
used for a certain period of time, particles that wear the pump
and other moving parts of the hydraulic equipment will enter
the oil. Moreover, the deterioration of the oil will cause the
formation of sludge and dirt. Therefore, it is necessary to
change the oil. As already mentioned, even if the hydraulic oil
is used correctly, it is generally considered that its service
life is 2 to 3 years. Once it starts to deteriorate, the oil
will quickly become unusable. When this happens, not only should
the oil be changed, but also we recommend that you rinse the
equipment.
First, completely drain the oil. Then, after wiping the oil
tank with a sponge, rinse it with oil of the same viscosity as
the hydraulic oil. At this time, use a rinsing device and carry
out the rinsing at low pressure. After 4 to 8 hours of rinsing,
it is possible to remove all the metal particles that wear the
equipment, as well as various kinds of sludge and dirt. Of course,
after the rinsing, the rinsing oil should be drained as
thoroughly as possible, and the interior of the oil tank should
be wiped again carefully.
⑧ When the old oil is extremely contaminated by water,
chemicals, etc., carry out rinsing.
Based on the above, when deciding to use special-purpose
rinsing oil, the user should first consult the rinsing experts
of the oil company and the maintenance personnel of our company
to select the correct type of oil and determine how to carry
out the work of rinsing the equipment.
(4)Maintenance and Servicing - Summary
① Select the correct type of oil.
② Through regular testing, check the condition of the oil.
③ Maintain the oil temperature within an appropriate range,
i.e., 45± 5℃ (properly control the amount and temperature of
the cooling water).
④ When replacing with fresh oil, rinse the equipment as
- 47 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
required.
1.2.5 Lubricating oil and grease
(1)Select lubricating oil
In addition to hydraulic oil, the lubricants used include
gear oil and grease for sliding surfaces. When selecting such
oils, please refer to the recommended oil types and viscosity
data. It is important to limit the types of oils used as much
as possible.
Here, please follow the recommended use as described in
Chapter 2.
(2)Maintenance of lubricating oil
Hydraulic oil is readily available and can be used for oil
change almost immediately. However, lubricating oil is
different. Some lubricating oil must be stored for a long time.
In terms of the maintenance and storage of lubricating oil,
extra care must be taken.
① Oil drums must be stored on wooden floors.
② Seal the drum tightly. If possible, cover the can or drum
with waterproof paper or other suitable covers.
③ Ensure that the oil containers are protected from direct
sunlight.
④ Ensure that the temperature of the storage area for the oil
does not exceed 40℃ .
⑤ After a certain period of time, the grease used on bearings
and moving surfaces is no longer an effective lubricant. It
becomes contaminated by water, steam, and dust in the air and
deteriorates. Please do not forget to lubricate each part at
the recommended frequency. If the grease turns black or hardens,
it should be wiped off and the part should be relubricated to
ensure the normal rotation and sliding of these moving parts.

- 48 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter seven
Maintenance and upkeep
When inspecting, maintaining, and servicing the machine,
always keep safety in mind. Remember to turn off the main power
supply.
7.1 The installation and removal of plasticizing components
1. The connection between the front barrel and the barrel is
made using high-strength bolts of grade 12.9. After heating and
use, it should be rechecked and tightened to prevent the bolts
from loosening and material leakage due to thermal expansion
at high temperatures.
2. The connection between the screw head and the screw is made
using left-hand threads.
3. The barrel and the injection seat are positioned by
cylindrical pins and cannot rotate.
4. The installation and removal of screws and barrels
a. Heat and plasticize the barrel, empty the remaining plastic
in the barrel, and advance the screw to the bottom.
b. Retract the injection seat to the rear end position, and
remove the screws connecting the injection seat to the entire
advancing cylinder and the fixing screws of the front support
foot.
c. Rotate the barrel about 20 degrees to the rear of the machine
by hand until there is enough space to withdraw the screw.
Unscrew the tightening screws that connect the top shaft and
the screw, remove the half ring, and then unscrew the nozzle
and the front barrel in sequence.
Note：Do not rotate at too large an angle to prevent the injection
seat from falling off the machine body.
Note：The screw may be overheated. Do not grab it with bare hands.
d. Make the injection and anti dribble actions, and use a
spacer block to push the screw out of the barrel.
e. When installing a new screw into the barrel, it must be able
to rotate easily. After aligning the keyway at the tail with
the key in the top shaft, insert it so that the rear end face
of the screw is in contact with the bottom of the top shaft hole.

- 49 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Then put in the half ring and tighten the tightening screws.
When installing the screw head, apply wear-resistant
high-temperature lubricating grease to the threads to ensure
the convenience of disassembly and assembly of the screw head.
7.2 Care and maintenance
1. Maintenance of the electrical system
The control voltage of this injection molding machine is 24V
DC. The electrical components have a long service life, and the
maintenance and care are simple and safe. However, in order to
prevent accidents and extend the service life of the components,
the following preventive maintenance steps should be
implemented.
a. When inspecting the high-voltage components inside the
machine, the main power supply should not be turned on unless
necessary.
b. When changing the mold, do not allow the cooling water to
flow into the control box.
c. Check if the temperature in the control box is too high to
affect the normal operation of the circuit board. If it is
necessary to replace a relay, use a relay with the specified
voltage.

- 50 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
7.3 Maintenance of the hydraulic system
7.3.1.The influence of temperature on hydraulic oil：
When the oil temperature has not reached 20° C, avoid operating
the injection molding machine under load. The normal oil
temperature should be maintained between 30° C and 50° C.
If the machine is operated for a long time with the oil
temperature exceeding 50° C, the following problems may occur：
(1) The hydraulic oil deteriorates due to oxidation.
(2) The reduction in the viscosity of hydraulic oil leads to
the following situations:
(Ⅰ ) The oil pump is damaged.
( Ⅱ ) Oil leakage and pressure drop result in a simultaneous
decrease in injection pressure and clamping force.
(Ⅲ ) It reduces the working efficiency of the hydraulic valve,
causing the hydraulic valve to operate abnormally.
(Ⅳ ) Cause damage to hydraulic components.
(3) Accelerate the aging rate of oil seals.
Other phenomena, causes and treatment methods of hydraulic oil
deterioration.
7.3.2 Hydraulic oil foaming:
(1) If air enters the hydraulic system, all air leakage pipe
joints should be tightened and clean hydraulic oil should be
used.
(2) Check if the hydraulic oil is insufficient.
(3) The quality of hydraulic oil is too poor.
(4) The seepage pipe of the return oil tank is not immersed under
the hydraulic oil.
7.3.3 The hydraulic oil appears milky white:
(1) The air is humid and moisture enters the hydraulic oil. The
hydraulic oil should be checked every week during humid weather.
(2) Cooling water leaks into the oil tank. Special attention
should be paid to checking whether there is any water leakage
inside the oil cooler.
7.3.4 The oil cylinder is contaminated:
The paint on the bottom of the oil tank peels off or foreign
objects enter the oil tank. Be careful not to open the oil tank
cover casually to prevent impurities from falling into the oil
tank.
7.3.5 Change the hydraulic oil:
- 51 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
Hydraulic oil should be replaced every 3000 to 4000 working
hours. For a new machine, the first replacement of hydraulic
oil is generally around 2000 hours. Used hydraulic oil should
not be used as lubricating oil. The hydraulic oil can be drained
through the oil drain hole at the bottom of the oil tank. At
the same time, the sealing plate can also be removed, and then
the oil tank should be cleaned once with new hydraulic oil. Note
that new and old hydraulic oils should not be mixed.
7.3.6 Clean and replace the suction oil filter:
When changing the hydraulic oil, you can also screw out the
suction oil filter in the oil tank for cleaning.
7.3.7 Clean the oil cooler:
The oil cooler should be disassembled and cleaned about once
every six months to prevent internal corrosion damage or
reduction in cooling efficiency. The method is to remove the
outer covers at both ends of the cooler and use a fine brush
to clean the scale in the copper tubes.
7.3.8 Clean the hydraulic valve
If the hydraulic valve fails due to foreign matter blocking the
spool, the spool should be removed from the hydraulic valve to
clear the blockage. Clean it with diesel or kerosene (or soak
it in clean pressurized oil for cleaning), and then dry it with
compressed air.
Do not casually disassemble the hydraulic valve unless it is
determined that the injection molding machine has failed due
to foreign matter blocking the valve. In addition, when
reinstalling the hydraulic valve on the valve plate, use the
same and not excessive tightening force on each installation
screw to ensure even force on the screws.
7.4. Maintenance of the Clamping Unit
The hinge of the clamping unit has a very long service life,
but each moving part should be properly lubricated. The
preventive maintenance work for the machine hinge is as follows:
a. Regularly check the central lubrication system, its
lubrication distributors and lubricating pipelines. After
starting the machine, observe whether oil comes out at each
lubrication point.
- 52 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
b. Keep the four tie rods clean.
c. Keep the sliding feet and rails of the moving template clean
and lubricated.
d. Do not use the clamping unit beyond its working pressure.
e. When adjusting the mold, do not use the ultra-fast clamping
speed.
f. Control the stroke positions of the mold opening and closing
actions at the most appropriate positions to ensure smooth mold
opening and closing actions and reduce impacts.
g. Avoid using molds that are too large or too heavy.
7.5. Maintenance of the injection unit
The general preventive maintenance work is as follows:
a. Keep the two guide rods of the injection seat clean.
b. Keep the surface of the injection seat clean.
c. In addition to plastic, pigments and additives, do not allow
any other substances to fall into the hopper. If a large amount
of recycled material is used, a magnetic hopper should be added
to prevent metal fragments from entering the barrel.
d. Do not start the pre-plasticizing oil motor when the barrel
has not reached the pre-set temperature.
e. When using anti-salivation, make sure that the plastic in
the barrel is completely melted to avoid damaging the parts of
the transmission system when the screw retreats.
f. When using special plastics, you should consult the plastic
supplier about which type of screw is more suitable for this
type of plastic.
g. When changing the type of plastic, the barrel should be
cleaned.
h. Regularly check all parts of the injection unit, tighten
the relevant screws to ensure smooth injection movement.
i. Regularly check whether each part inside the thrust seat
operates normally, remove the old grease and replace it with
new lubricating grease.
j. When the temperature of the molten plastic is normal but
black spots or discoloration are constantly found in the molten
plastic, the check ring and check ring seat of the injection
screw should be checked for damage.
k. Only the nozzles, plasticizing components, heating rings

- 53 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
and fasteners specified by our company can be used.
l. The maximum heating temperature of the injection device
such as the screw barrel of this machine is 400℃ .
7.6. Toxic smoke protection
Due to insufficient pre-drying or the degradation of certain
materials, the molten material may be unexpectedly ejected from
the nozzle. In this case, operators should wear protective
equipment such as gloves and safety glasses when operating. The
injection mechanism is in a state of high temperature and high
pressure during operation. Generally, the maximum operating
temperature of the injection mechanism during the use of the
injection molding machine is 400℃ .
Some plastics will emit toxic smoke when overheated. Mainly
polytetrafluoroethylene (PTEE), polyformaldehyde (POM) and
polyvinyl chloride (PVC).
If these toxic smoke cannot be eliminated through an emergency
mechanical device, it is recommended to install an exhaust fan
to eliminate harmful smoke, and it is required that the switch
of the exhaust fan be interlocked with the power switch of the
injection molding machine. When processing toxic plastic raw
materials, an exhaust device must be added, and the operator
must wear protective devices.
Note: If the smoke exhaust device is directly installed on the
machine, we suggest installing it above the fixed template.

Schematic diagram of toxic raw material exhaust and

operator protective device

Note: If the smoke exhaust device is directly installed on the machine,

- 54 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
we suggest installing it above the fixed template.
7.7. Noise protection
Due to the noise of this machine model exceeding 70 db, it is
recommended that users take necessary protective measures to
prevent potential harm to the human body caused by excessive
noise.

7.8 Inspection items

7.8.1 Daily inspection items

(1) Ensure that the emergency stop switch can cut off the power
supply of the oil pump motor.
(2) Check the central lubrication system to ensure that there
is sufficient oil in the lubrication device's oil tank and that
each connecting rod is fully lubricated.
(3) Keep the injection molding machine and its surroundings
clean.
(4) Check if the temperature gauge and heating ring are normal.
(5) Check whether mold closing can be stopped or prevented when
the safety door is pulled open or half-open. Test the mold
closing respectively in manual, semi-automatic and fully
automatic modes. Check if the mechanical and electrical safety
devices are normal, if screws and nuts are loose, and if the
movement is flexible.
(6) Check if the oil pressure working pressure is too high.
(7) Whether the mold is firmly installed on the front template
and the movable template.
(8) If you need to change the plastic material, check the
plastic material used in the previous shift and confirm whether
the barrel has been cleaned.
(9) After the machine has been running for a while, check if
the oil temperature rises too quickly and exceeds 50 degrees
Celsius, and check if the cooling water flow supplied to the
- 55 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
cooler is sufficient and if the water temperature is low enough.
(10) Check if the doors, windows and sealing plates are complete
and in good condition. Do not start the machine until all parts
are complete.
7.8.2 Weekly inspection items:
(1) Repeat the above inspection items.
(2) Lubricate all moving parts that require lubrication.
(3) Check the contact position of the limit switch and the
connection screws and nuts of the electronic ruler. If there
is any looseness, it should be tightened.
(4) Check whether there is any oil leakage in all parts of the
hydraulic system. Tighten the leaking pipe joints, ferrules and
other parts, and replace the damaged oil seals.
(5) Check if all screws are loose and tighten them if necessary.
7.8.3Monthly inspection items:
(1) Repeat the inspection items in the previous section.
(2) Check if the control lever of the safety door is secure?
(3) Check if there are any loose electrical components or wiring
connections?
(4) Check if the hydraulic oil is contaminated or too moist?
Clean or replace the oil suction filter in the tank and change
to clean hydraulic oil.
(5) Check the linear proportion of pressure and flow rate, and
readjust if necessary.
(6) Remove the rear cover plate of the mold clamping part and
apply appropriate lubricating oil to the mold adjustment nut.
7.8.4 Annual inspection items:
(1) Repeat the inspection items in the previous section.
(2) Check if there are any signs of aging or hardening in the
wires, especially those that frequently come into contact with
lubricating oil or hydraulic oil.
(3) Check if there are any signs of wear on the injection screw.
(4) Check if the top shaft and bearing connected to the hydraulic
motor are normal, and re-inject grease.

- 56 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter eight
Die installation dimensions and simplified
outline drawing

- 57 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
8.1 Die installation dimension drawing

- 58 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
8.2 Machine outline dimension drawing

- 59 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
8.3 Foot installation dimension drawing

- 60 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
8.4 Hoisting drawing

- 61 -
 Suzhou Top Brand Machinery Technology Co., Ltd.

Chapter nine
Other various attached drawings
9.1 Mechanical attached drawings

- 62 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 63 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 64 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 65 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 66 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 67 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 68 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
9.2 Hydraulic attached drawings

- 69 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 70 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 71 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 72 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 73 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 74 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 75 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 76 -
 Suzhou Top Brand Machinery Technology Co., Ltd.
9.3 Electrical attached drawings

- 77 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 78 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 79 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 80 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 81 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 82 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 83 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 84 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 85 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 86 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 87 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 88 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 89 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 90 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 91 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 92 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 93 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 94 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 95 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 96 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 97 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 98 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 99 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 100 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 101 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 102 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 103 -
Suzhou Top Brand Machinery Technology Co., Ltd.

- 104 -