Machinecheckup
Customer
Address
Postal code
City
Machinetype
Machine Nr. Intern
Year Date
Service-engineer
Machinecondition
Machine has no deviations
Machine has deviations. This deviations have to be fixed, but are
not in such a way that they exceed certain safety- or functionality
demands. Machine is free to produce.
Machine has deviations. This deviations have to be fixed before the
machine goes back into production. This to prevent injuries or
damage to people or environment .
Signature Customer Signature Service Engineer
Page 1
.
Machinecheckup
Work to be done
Work performed
Demanded parts
Machine condition after checkup
Remarks during checkup are solved. Demanded parts are mounted,
work performed by Customer.
Remarks during checkup are solved. Demanded parts are mounted,
work performed by Stork IMM Service.
Hour counter Date
Signature Customer Signature Service Engineer
Page 2
1. Clamping unit mechanically
Levelling of the clamping unit is within the
tolerance of max 0,1mm/m. Levelling pads are Yes No NA
1.1 equally loaded and nuts are tightened
Sliding pads under back platen are in place and are Yes No NA
not damaged
1.2
Sliding strips from bed plate are straight, on
Yes No NA
correct tension and are not damaged(no deep
1.3 grooves or scratches)
Sliding pads under movable platen are in place and Yes
not damaged No NA
1.4
Rail guidance and carriage are tightened and not
Yes No NA
damaged
1.4
Play around tiebars on movable platen is Yes No NA
0,05mm equally divided
1.6
During production the machinebed is not getting hot Yes No NA
1.6
Parallellity of the platens is within tolerances Yes No NA
1.7
Play between the crosshead guidance and the
Yes No NA
bushings is max. 0.5mm
1.8
Toggle system is not damaged, keys are in place and
not bent. Play in toggle system between pin and Yes No NA
1.9 bushing is max. 0.5mm
All bolts/nuts from keys/pivots are in place and
tightened. (toggle system) Yes No NA
1.10
Crosshead coupling nuts are tightened, rod is not
Yes No NA
leaking and not damaged (no scratches/grooves)
1.11
Mould height adjustment : Clearance on the chain is Yes No NA
min. 1cm and max 3cm.
1.12
Seperation bolts and nuts between injection-/clamp unit
Yes No NA
are tightenend and distance bolts lay-on
1.13
Page 3
2. Injection unit (at working temperature)
Levelling of the injection unit is within the tolerance of max
0,2mm/m. Levelling pads are equally loaded and nuts are Yes No NA
2.1 tightened
Alignment of nozzle in fixed platen is within tolerance of
0.1mm. With mould still fixed alignment is less Yes No NA
2.2 accurate.
Play around screw is 0,05mm top- and bottomside. Yes No NA
Screw is not striking the cylinder.
2.3
Guiding bars are tightened and not damaged. Yes
Bearings from guide support are in place No NA
2.4
Guide supports are tightened and not damaged Yes No NA
2.5
3. 2K-Injection unit (at working temperature)
Levelling of the injection unit is within the tolerance of max
Yes No NA
0,2mm/m.
3.1
Alignment of nozzle in fixed platen is within tolerance of Yes No NA
0.1mm. With mould still fixed alignment is less accurate.
3.2
Play around screw is 0,05mm top- and bottomside.
Yes No NA
Screw is not striking the cylinder.
3.3
Guiding bars are tightened and not damaged.
Bearings from guide support are in place. Yes No NA
3.4
Guide supports are tightened and not damaged Yes No NA
3.5
Remarks
Page 4
4. Hydraulics leakages
Hydraulic hoses: NO blisters, leakages, damages,
hoses are dry. NO = Write down the hose number from Yes No NA
the schedule at remarks.
4.1
Hydraulic pipes: NO cracks, leakages or
damages. NO= Write down pipe number from schedule Yes No NA
at remarks
4.2
Hydraulicblock A (Pump / Accu) : NO leakages
from valves, stops, covers. NO = write downs the Yes No NA
4.3 Valves, stops and other pieces that are leaking
Hydraulicblock B (Clamp / Ejec): NO leakages
from valves, stops, covers. NO = write downs the Yes No NA
4.4 Valves, stops and other pieces that are leaking
Hydraulicblock C (Inj / Dos / Unit): NO leakages
from valves, stops, covers. NO = write downs the Yes No NA
4.5 Valves, stops and other pieces that are leaking
Hydraulic blocks (Cores / Mouldmaster.): NO
leakages from valves, stops, covers. NO = write downs Yes No NA
4.6 the Valves, stops and other pieces that are leaking
Ejector cylinder: NO leakages on rod- or Yes No NA
pistonside. Rod has not been damaged.
4.7
Clamping cylinder: NO leakages on rod- or Yes No NA
pistonside. Rod has not been damaged.
4.8
Injection cylinder: NO leakages on rod- or Yes
pistonside. Rod has not been damaged. No NA
4.9
Pulling cylinders: NO leakages on rod- or Yes No NA
pistonside. Rod has not been damaged.
4.10
Hydraulic dosing motor: NO leakages at the Yes No
cylinderheads, sealing flanges and spline seals. NA
4.11
Hydraulic mouldheight pump: NO Yes No NA
leakages
4.12
Remarks
Page 5
5. Hydraulic leakages
Hydraulic- PUMP 3 NO Leakages at connections and Yes No NA
5.1 between pump parts. shaft seal is not leaking.
Hydraulic- PUMP 2 NO Leakages at connections Yes No NA
5.2 and between pump parts. shaft seal is not leaking.
Hydraulic- PUMP 1 NO Leakages at connections Yes No NA
5.3 and between pump parts. shaft seal is not leaking.
Hydraulic filter/cooling pump NO leakages at Yes No NA
5.4 connections, by filter or at shaft seal.
6. Hydraulic leakages 2K-unit
Hydraulicblock C (Inj / Dos / Unit): NO leakages from
valves, stops, covers. NO = write downs the Valves, Yes No NA
6.1 stops and other pieces that are leaking
Injection cylinder: NO leakages on rod- Yes No NA
6.2 or pistonside. Rod has not been damaged.
Pulling cylinders: NO leakages on rod- or Yes No NA
pistonside. Rod has not been damaged.
6.3
Hydraulic dosing motor: NO leakages at
the cylinderheads, sealing flanges and spline Yes No NA
6.4 seals.
Remarks
Page 6
7. Hydraulic system
Calibrate PUMP 3 (RY30) All counts in the pressure
table are upfollowing, 200 bar is reached. At maximum Yes No NA
7.1 pressure there are no strange noises
Calibrate PUMP 2 (RY20) All counts in the pressure
table are upfollowing, 200 bar is reached. At maximum Yes No NA
7.2 pressure there are no strange noises
Calibrate PUMP 1 (RY10) All counts in the pressure
table are upfollowing, 200 bar is reached. At maximum Yes No NA
7.3 pressure there are no strange noises
Calibrate pressure transducers. All pressure
transducers indicate about 0 bar and a value for the Yes No NA
7.4 counts between 380-420.
Pump off, accumulators empty. Normal mode. Start
pump and charge accu's. No alarm accu charging Yes No NA
7.5 time exceeded (/acu/p/TMload_max )
Nitrogen pressure: measured pressure is according
the prescribed pressure(110 or 135bar) Yes No NA
7.6
Pressure in the system is reaching 200 bar Y400 + Yes No NA
Y275 =1 ; TR6.2 = 200bar
7.7
Remarks
Page 7
8. Lubrication machine
Oil lubrication system
Hoses, distributors and connections are not leaking and Yes No NA
8.1 are tightened.
Oil lubrication system
8.2 Customer uses the next type of oil
Oil lubrication pump Yes No NA
8.3 Connections are not leaking and are tightened.
Grease lubrication system
Hoses, distributors and connections are not leaking and Yes No NA
8.4 are tightened.
Grease lubrication system
Customer uses the next type of grease
8.5
Grease lubrication pump Yes No NA
8.6 Connections are not leaking and hoses aren't damaged
Lubrication control ( Oil/Grease) Yes
Sensors are adjusted (S7/S270) and are switching at the No NA
8.7 right pressures.
Parts to be lubricated by customer:
Yes No NA
-Sliding pads under back platen are lubricated
8.8 -Bearings in intermediate plate are lubricated
Leakoil: hoses and jerrycans are not leaking and are Yes No NA
8.9 mounted the right way
Remarks
Page 8
9. Hydraulic- and gearbox oil
Hydraulic oil (change once a year)
Oil level indicator is clear, oil is at the correct level, Yes No NA
9.1 indicator had not been short circuited.
Gearbox oil dosing (change every 2 years) Yes No NA
Oil level is visible and has the correct level, oil is clear.
9.2
Gearbox oil dosing 2K (change every 2 years) Yes No NA
Oil level is visible and has the correct level, oil is clear.
9.3
Gearbox oil clamping (PIV)(change every 2 years) Yes No NA
Oil level is visible and has the correct level, oil is clear.
9.4
10. Cooling water connections on machine
Cooling valves: are connected the right way,
couplings are tightened and valves are not Yes No NA
10.1 shortcircuited
Hoppercooling: is functioning, setpoint is Yes No NA
achieved.
10.2
Oil cooling: Oil temperature during Yes No NA
production is 45 °C
10.3
Frequency controllers / motors: (pages 141B,D,J)
Temperature motor 110°C max. Yes No NA
Temperature controller: 55°C max.
10.4
Remarks
Page 9
11. Electrical connections/parts
Main E-motor rotates normally without any strange
noises and overcurrent-safetyrelais is swichting off Yes No NA
11.1 when pushing test button.
Voltages are within a tolerance of Yes No NA
L1-L2-L3 = 400 V~ ±5% L1-N = 230 V~ ±5%
11.3
Supply voltage 24V is within a tolerance of 24 VDC ± 1V Yes No NA
11.4
Cables and plugs to valves, sensors and position
encoders are mounted correctly and are not damaged Yes No NA
11.5
Cylinder heating and thermocouples are
mounted correctly, are not damaged and free Yes No NA
11.6 from plastic
Filters cabinets are mounted and clean Yes No NA
11.7
Main switch locking is active when machine
is switched on, door can't be opened Yes No NA
11.8
All covers inside the cabinet are mounted to
prevent hazardous situations Yes No NA
11.9
Remarks
Page 10
12. Safety
Yes No NA
12.1 Emergency buttons: are working properly
Frontdoor OS: switches and doorlock are Yes No NA
12.2 working properly
Electrical frontdoor OS: Brake and safety strip Yes No NA
12.3 are working properly
Backdoor NOS: switches and doorlock are working Yes No NA
12.4 properly
Nozzle cover: switch is working properly, cover Yes No NA
12.5 is closing properly
Nozzle cover 2K: switch is working properly, cover Yes No NA
is closing properly
12.6
Unit swiffle out S250: Switch is mounted and Yes No NA
12.7 working properly
Switches mould height adj. S70 / S71: are Yes No
mounted correctly and working properly NA
12.8
Oil level switch S3: is connected the right Yes
way, has not been shortcircuited No NA
12.9
Underpressure switch S4: switch is working properly and Yes No NA
12.10 has not been shortcircuited
S03 / S027 / Y245 hydraulic safety: are Yes No NA
working properly
12.11
Safety fences and covers are mounted and Yes No NA
12.12 not damaged
Remarks
Page 11
13. Functions
''Dead band'' RY251 Yes No NA
13.1 Calibrate and note down values
Opening Closing
Decompression RY6 Calibrate at page 164C Yes No NA
13.2
Flmax Flmin
Calibrate mirror-plate variable pump NA
13.3
Bar
Nitrogen pressure accumulators NA
13.4
Slow (bar) Fast (bar)
Mouldheight adjustment (Hydraulic) NA
13.5 Note down pump pressure slow + fast
Slow A Fast A
Mould height adjustment (Electrical) Current NA
slow + fast (P88 in freq. controller)
13.6
Nozzle shutoff valve regulated at 90 bar, is working Yes No NA
13.7 properly and is not leaking
Remarks
Page 12
14. Maintenance
Yes No NA
Pull suction filter and clean the filter
14.1
Description of found particles
Replace high-pressure filter Yes No NA
14.2
Lubricate main E-motor (2 points) Check air inlets for Yes No NA
14.3 clogging
Check air filters main cabinet and replace if Yes
necessary No NA
14.4
Hydraulic oil (Visual indication) G=Good, G M B
14.5 M=Moderate, B=Bad
Check grounding connections Yes No NA
14.6
Klemaansluiting en borging van alle elektrokabels Yes No NA
14.7 controleren
Lubricate sliding pads under backplaten Yes No NA
14.8
Check wiring, fixation, heating and thermocouples Yes No NA
14.9 from transportcylinder
Check oil cooler for external leakage Yes No NA
14.10
Beluchtingsfilters sterkstroomkast vervangen Yes No NA
14.11
Check the support from the main E-motor Yes No NA
14.12
Lubricate the bearings from the intermediate plate Yes No NA
14.13
Check oil fill-filter if used Yes No NA
14.14
Page 13
15. Clamping force measurement before adjusting
Setpoint clamping force KN
Measured On mould
On testblock
OS NOS
top top
Tiebar 3 Tiebar 4
TLC3 Machine TLC4
KN Strain gauge KN
µ Strain gauge µ
OS NOS
bottom bottom
Tiebar 2 Tiebar 1
TLC2 Machine TLC1
KN Strain gauge KN
µ Strain gauge µ
Remarks
Page 14
16. Clamping force measurement after adjusting
Setpoint clamping force KN
Measured On mould
On testblock
OS NOS
top top
Tiebar 3 Tiebar 4
TLC3 Machine TLC4
KN Strain gauge KN
µ Strain gauge µ
OS NBZ
bottom bottom
Tiebar 2 Tiebar 1
TLC2 Machine TLC1
KN Strain gauge KN
µ Strain gauge µ
Remarks
Page 15
17. Remarks
Page 16
