Chapter 4 Machine installation

Chapter IV Machine installation

4-1 Machine pre-installation preparation

4-1-1 Environmental requirement
The machine must be installed indoors for avoiding wind and rain which can affect the product quality and
the machine life. The machine cannot be used in potentially explosive environments, but installed in the following
environment:
1. Ambient temperature: 0-40℃.
2. Relative humidity: 50% (40℃) -90% (20℃) (no condensate).
3. At least 200Lx illumination shall be kept at the operating position for ensuring the normal vision of the operator.
4. There are no additional dust, acid smell, corrosive gases and salts in the atmosphere.
5. The machine shall be prevented from directly exposing to sunshine or hot radial lines, since they can
change its accuracy and surface temperature.
6. Arrange exhaust equipment to pump out harmful gases generated by the plastic degradation if required. The
installation and use of the exhaust equipment must meet the requirements of local laws and regulations.
7. Adopt additional measures to ensure that the machine operates stably, if there is radiation (microwave, laser,
infrared ray, X- ray, etc.) around it.
8. The machine shall be stored in a -25℃-55℃ environment. The highest temperature can be increased to 70℃, in
case of short-term storage not exceeding 24 hours. Adopt proper moistureproof and shakeproof measures.
4-1-2 Installation space required
At least 1.5m shall be reserved between the machines for their easy installation, operation and maintenance
and avoiding the mutual effect between operators. Refer to the specification table and outside drawing of the
machine for details.
An ample space shall be allowed for installing the temperature controller, cooler, conveyor belt, drier, crown
block ,etc., and the spaces where some equipment will possibly be added shall be reserved if possible. The
auxiliary equipment shall never bring interference or loads to the operators nearby. Please refer to machine
foundation drawing for details.
4-1-3 Foundation requirement
1. Levelness: the parallelism of the machine mainly depends on whether the foundation is level.
2. Firmness: the product quality stability and machine life may be affected by the uneven foundation. The
foundation becomes uneven due to its geologic differences after the machine has run for a long time.
4-2 Machine lifting and handling
4-2-1 Considerations
1. During transport, confirm whether the movable machine or parts are firmly bound, and all fixed materials
must be cleared after the machine is placed on the predetermined foundation.
2. The hoisting position selected shall be proper, and the hoisted machine must be kept balanced. Adjust the
lifting sling if unbalance occurs in the initial lifting.
3. Add soft materials such as paper boards, cloth, rubber beds, etc. between the lifting sling and machine for
avoiding that the machine is damaged. Directly hook up the lifting ring if any.
4. Conduct hoisting movement slowly and stably, as paying attention to whether the housing point is moved.

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4-2-2 Hoist of the one-piece machine
See Figure 4-1, for the Hoist of the one-piece machine
Glass fiber canvas belts

Figure4-1

Figure 4-1

4-2-3 Hoist of the split machine

4-2-3-1 The method of the machine splitting and combination

Location of minimum Carriage

Mould clapping part mould thickness connecting seat Side dam Injection part

Bolt Locating pin Locking plate

Figure 4-2
Division of machine：
1. Platen status before division
a. MK6: adjust the mould clapping system to the minimum mould and the toggle to the mould clapping state
b. MK6(big machine) / MK6.6: adjust the mould clapping system to the maximum mould and the toggle
to the mould clapping state
2. Dismount the fixed screw on the carriage connecting seat from the stationary platen to make the screw
share with the platen.
3. Dismount the fixed screw of the side dam between the connection of the carriage machine base and the
mould clapping machine base, and dismount the side dam.
4. Split the connectors of wires between the front and rear machine base.
5. Split the oil pipes between the front and rear machine base and block it with the plug to avoid the outflow
of the hydraulic oil.
6. Do dismounting from top to bottom, loosen the connecting screw of the front and rear machine base and then dismount it.

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 Chapter 4 Machine installation
7. Dismount the cylindrical locating pin.
8. Tension the rope slightly according to the hoist schematic diagram of the carriage part, and pull it from the
horizontal direction until it splits from the mould clapping part.
Combination of machine：
1. Install the mould clapping in place, as required.
2. Hoist the carriage to the corresponding location. Slightly move it after alignment. Install the connecting
screw and locating pin to initially tighten the screw.
3. Preliminary leveling and completely tighten the connecting screw.
4. Connect the oil pipes between the front and rear machine base.
5. Connect the wire connectors between the front and rear machine base.
6. Install the side dam.
4-2-3-2 Hoist of the mould clapping and carriage part

Glass fiber canvas belts

Figure 4-3

Glass fiber canvas belts Location of the minimum mould

thickness

Figure 4-4
Note:
1. For 800T~1000T, machine can be divided into 4 parts for lifting and transportation if the factory space is not
big enough. For reference, see below figures of clamping unit, injection unit, clamping base, and injection
base.

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 Chapter 4 Machine installation

Figure 4-5
2. For 1200T or above, clamping unit can be divided into several parts as per request. See below figure the
lifting points of a clamping unit of 1200T or above.

Figure 4-6

4-2-4 Move the machine with cranes

1. Crane work can only be conducted per personnel checked to be qualified.
2. The machine or parts must be hoisted by the hoisting sling and crane of sufficient strength.
3. The machine or parts handling can be helped with steel pipe rollers, if no crane is provided in the factory.
4-2-5 Move the machine with forklifts
1. Forklift work can only be conducted by the personnel checked to be qualified.
2. Confirm that the forklift can indeed support the weight of the machine or parts.

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4-3 Installation way of machine
4-3-1 Post
Good stability and property of shock absorption, uneasy to be moved but cost a lot of time in installation.
Make the foundation plan and carry out together. Before the positioning of machine, install the horizontal
adjustment equipment firstly, such as fixed bolt and screw and so on. After the positioning of the positioned and
the horizontal adjustment, reinforce it with the concrete and wait for the solidification of the concrete.
4-3-2 Shock-proof rubber beds
The stability and property of shock absorption is as good as the first item. Being simple and time-saving are
its advantages. After the positioning of the machine, adjust level with the regulating screw. This accessory is
optional which can slightly reduce the shock and is adapted to small and medium size of machine (weight of
products + total weight of the sprue system).

Regulating
Flat gasket screw Screw Body

Rubber gasket

Figure 4-5
4-4 Power supply system
1. Only qualified personnel can carry out the wiring of the power system.
2. Before power supply connection, please turn off the power switch.
3. The machine must be grounded as recommended by national electrician laws and regulations. Use good earth
wires, which, moreover, cannot be connected to the water pipe and periodic inspection foundation.
4. Midway wiring is prohibited, and damaged wire appearance is not allowed for preventing electric leakage.
5. The electrical wiring shall be finished with the professional engineering company.
6. The power supply for different machine cannot be used in a linked line to avoid danger situation.
7. The power is three-phase four-wire system with voltage of 380V and frequency of 50HZ. The total power of
the machine can be seen in the technical data of different models (has been attached to the machine and been
sent to client with the instruction book).
8. Calculate the wire diameter specification according to the full-load current.
Notes:
If power supply is different, it shall be noted when ordering the goods.

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4-5 Cooling supply system
The cooling system of the injection moulding machine is divided into the hydraulic cycle cooling circuit,
mould cooling circuit and screw barrel cooling circuit
The cooling water source must be tap water, and its cooling water supply system shall be cleaned periodically
(the water carrying systems like water towers, water tanks, cycle water pipes, etc.) , so as to ensure the water
quality of the cooling water. It is recommended not to take the underground water as the water source, otherwise
the machine and the water pipe of the mould will be blocked by the calcium carbonate generated by the water that
cannot be easily cleaned. If there are too many impurities in the factory’s water, then the filter is suggested to be
additionally installed at the inlet position of the cooling water, and the filter mesh of the filter shall be cleaned
periodically to prevent blocking.
The temperature of the cooling water can be affected by the weather, climate and the season, so the pressure
shall conforms to the requirement on the cooling water label (0.5-1 kg/cm2), it is better to reach 1 kg/cm2.
For the model JM258-MK6 / JM268-MK6.6 and model under them, it is recommended that the maximum
mould cooling water flow is 20L/min and hydraulic oil cooling water flow is 30L/min. For the model
JM328-MK6 / JM328-MK6.6 and model higher than it, the suggested maximum mould cooling water flow is
40L/min and the suggested hydraulic oil cooling water flow is 60L/min. The cooling water flow is determined by
the moulding condition, water temperature, atmosphere temperature, the degree of cleaning of the cooler and other
factors. Therefore, the above data can only be used as reference.
4-5-1 Hydraulic cycle cooling circuit
When the machine rotates, the hydraulic oil temperature rises and the oil quality decreases, therefore, a
40-50℃ temperature constant state must be kept. The machine is equipped with a cooler and two inlet and outlet
to connect the cooling water. Customers should install a water valve to control the water volume. Usually, the
cooling water should be used instead of the freeze water to avoid the deterioration of hydraulic oil.
4-5-2 Mould cooling circuit
The cooling water discharge device is installed on the rear side of the machine, and its number can be
determined according to the number of the mould cooling water openings.
There are two cooling methods for general moulds, namely, the water cooling and oil cooling. The water
cooling is more appropriate, when the mould temperature is 15-95℃; and the oil cooling is usually used when the
mould temperature is 95-120℃. If the oil cooling is adopted, the oil products of a high ignition point shall be
selected and must be isolated. The output capability of the oil pump shall be considered, besides the selection of
the heat-conducting medium. Because for quickly taking away the heat effect, the heat-transfer medium must flow
rapidly, the output capability of the oil pump transporting the medium must be enough to achieve the effect. So,
the oil pump must be appropriately selected.
If the direct cooling mould temperature controller is used or the operating temperature is above 60℃, then
the temperature at the cooling water outlet will be very high, and the general plastic hose will be easily out of
shape and get loose, so the heatproof rubber cotton yarn pipe shall be equipped. The cooling water must be opened
first prior to opening the mould temperature controller, otherwise the pump shaft will be worn and even burned by
electric heating, after operating without water for a long time.
4-5-3 Screw barrel cooling circuit
There is a port of the screw barrel cooling circuit under the plasticizing barrel behind the carriage. Connect
the cooling water here to control the temperature of the feeding side of plasticizing barrel to avoid the difficult
feeding caused by high temperature. It is recommended that introduce a set of cooling water from the cooling
water discharge device to enter the screw barrel cooling circuit.

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4-6 Hydraulic oil and lubricating oil (grease)
4-6-1 Hydraulic oil
The actual efficacy of the hydraulic system is mostly decided by the quality of the hydraulic oil, so the
selection of the hydraulic oil is very important. At the same time, the hydraulic oil shall be prevented from
pollution during daily operation of the machine, in case the normal operation of the machine is affected. So the
following principles are suggested to be followed for the application of the hydraulic oil:
1. The hydraulic system adopts dust-free and anti-wear hydraulic oil, the toggle section adopts EP medium
load gear oil, and the lubricating grease adopts 2＃or 3＃lithium-based grease. It’s recommended to
select the hydraulic oil listed in the recommendation form. Please do not mix the hydraulic oil of
different trademarks, in case of the function failure of the hydraulic oil that can damage the machine.
2. Pay attention to the control of the operating temperature. The temperature range of the used oil is
15-55℃ and the best oil temperature range is 40-55℃ (No.46 pressure oil). The viscosity performance
of the oil is the best under this temperature, and the pollution degree of the oil is kept at ClassNSA9.
3. The oil mass injected shall reach more than two-thirds of the highest point of the oil level indicator and
check the oil mass again after running for a while, and supplement it if needed.
4. For the first time operation, the startup and stop of and air discharge from in the pump and the oil pipe
shall be repeated. No-load operation shall be conducted for at least 5 minutes after the gas discharge
from the pump has been confirmed as completed.
4-6-2 Lubricating oil (grease)
The lubricating oil is adopted for the toggle section of the MK6/MK6.6 series injection moulding machine
and is under the central automatic lubricating mode. The central lubricating oil pump is installed on the front end
of machine base, and the oiler shall be filled with lubricating oil prior to starting up. In normal condition, it is
recommended to set it to discharge oil for 5-8 sec per 100 injection periods.
Mould adjusting part, wear plate and the carriage part use lubricating grease. There is a series of manual oil
injection points in the mould clapping part and carriage part, please fill fully lubricating grease in these points
with oil gun prior to starting up.
Table 4-2 Recommendation of hydraulic oil and lubricating oil (grease)

Brand Anti-Wear Industrial Gear Oil Lubricating Lubricating

Hydraulic Oil (Toggle) Grease Grease
(Oil Tank) (Hand Pump, ( electric pump )
Manual Pump)

SHELL Tellus 46 Omala150 EP2,EP3 EP0,EP00

ESSO Nuto H 46 Spartan EP 150 EP2,EP3 EP0,EP00

MOBIL DTE 25 Mobilgear 629 EP2,EP3 EP0,EP00

BP HLP-HM 46 GR-XP 150 LS-EP2,LS-EP3 EP0,EP00

Sinopec L-HM46 L-CKD150 2#,3# 0#,00#

For lubricating grease, please choose the listed model and brand in the above form.
Notes:
Be sure not to use the recycled lubricating oil. Our company is not responsible for the damage to the
machine caused by the use of recycle lubricating oil.

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4-7 Machine cleaning
1. Clean up the antirust coating surface of the machine.
2. The machine must be cleaned, especially the tiebar surface and the mould platen and sliding feet, and only
cleaning cloth (not wool material) can be used for that.
3. Confirm that the tool, waste cloth or other materials are not left on the machine after the machine is cleaned up.
4-8 Testing for the motor running direction (variable pump)
1. Check the hydraulic oil level, and confirm whether it has been fully filled.
2. Power on the machine.
3. Press the pump startup key to start the pump motor, and the pump motor can only be started under the
manual mode.
4. Press the pump stop key to stop the oil pump motor after it has operated for 3-5 seconds. So, it will slow
down to stop.
5. Check whether the running direction of the pump motor is the same as the direction indicated by the arrow
mark on the machine body. The rotation direction of the oil pump is right, namely, seen from the rear cover
of the motor, the impeller is in the clockwise direction.
6. When the running direction of the oil pump motor is different from the indication, then any two power
supply cords on the input terminal of the starting contactor can be switched only after the general power
circuit breaker in the electric box and the power supply in the factory are turned off.
7. Turn on the factory power supply switch.
8. Repeat Steps 2-7 and confirm the running direction of the pump is the same as the direction indicated by the marks.
9. Start and stop the pump motor for multiple times (at least five times) alternately until the noise of the pump stops.
10. Stop the pump after it has run for about 20 seconds.
4-9 Running testing for the motor radiator fan (used for servo motor)
1. Power on the machine.
2. Dismantle the rear sheet metal, take a piece of paper and close it to the motor radiator fan. If the paper is sucked
towards the motor direction, then it indicates that the running direction of the motor radiator fan is correct.
3. When the running direction of the motor radiator fan is incorrect, the any two power supply cords of the
input terminal can be exchanged only after the general power circuit breaker in the electric box and the
power supply in the factory have been turned off.
4. Turn on the factory power supply switch.
5. Repeat Steps 1-4 and confirm the running direction of the pump is the same as the direction indicated by the marks.
6. Start and stop the oil pump motor for multiple times (at least five times) alternately until the noise of the oil
pump stops.
7. Stop the pump after it has operated for about 20 seconds.
4-10 Disassembly steps before machine packaging
4-10-1 Electricity
1. Turn off the general power switch in the power box.
2. Turn off the general circuit breaker in the factory.
3. Dismantle the power supply cords, cables and grounding wire.
4-10-2 Cooling water
1. Turn off the cooling water supply.
2. Put the drip tray under the connecting cooling water.
3. Dismantle the cooler, material pipe cooling ring and mould cooling water pipe, and collect the flowed-out water.
4. Dry the cooler, material pipe cooling ring and mould cooling water distributor pipeline.

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