OPERATION MANUAL

CHEN WAY MACHINERY CO., LTD.

 MODEL NO : CW/BL–100–S-20

–SCREW : 100 M/M, L/D = 30/1

MAIN MOTOR : 60HP * 6P + INVERTER

– DIE HEAD
TYPE：TORPEDO TYPE

–CLAMPING STROKE : 450–1000 M/M

2
CLAMPING PRESSURE : 210 KG/CM
(MAX)

– DEFLASHING UNIT
DRIVING：HYDRAULIC / PNEUMATIC

– POST COOLING
DRIVING：PNEUMATIC

–HYDRAULIC MOTOR : 25HP * 6P

2
PRESSURE : 210 KG/CM (MAX)

–100 POINTS PARISON CONTROL

MOTOR : 7.5HP x 6P

–ENTRY CODE
(FOR TIMER SETTING) : 300134

– ACCESSORIES .
A. ON-LINE LEAK TESTER
B. AUTO-DOSING UNIT
(VIRGIN / RECYCLE/ PIGMENT)

–MACHINE SERIES NO : 05-005

CHAPTER 2.

INITIAL ADJUSTMENT AND TRIAL OPERATION

2-1 PREPARATION FOR OPERATION

1. CLEANING THE VARIOUS SECTION OF THE MACHINE, CHECK FOR

LOOSE SCREWS AND DAMAGED PARTS.
2. FILL THE HYDRAULIC TANK WITH HYDRAULIC OIL THROUGH THE
OIL HOLE. FOR THE TYPE OF OIL TO BE USED, REFER TO ITEM 2-2
3. CLEAN THE GUIDE GROOVES, GUIDE WHEELS OF THE MOLD
MOVING SYSTEM WITH SPECIAL CARE AND THEN LUBRICATE.
4. TURN ON THE COOLING WATER AND CONFIRM THAT THE WATER
ON.
5. TURN ON THE COMPRESSED AIR AND CONFIRM THAT THE
COMPRESSED AIR HAS BEEN TURNED ON BY THE INDICATION OF
THE PRESSURE GAUGE ATTACHED TO THE REGULATOR.
6. CONFIRM THAT THE MOLD IS MOUNTED PROPERLY WITHOUT ANY
LOOSENESS.

OPERATION MANUAL １
2-2 OIL SUPPLY AND LUBRICATION

ASSEMBLY LUBRICATION KIND OF FREQUENCY METHOD OF

NAME POINT OIL OF OIL OIL SUPPLY
SUPPLY
MOLD BUSHING FOR A WEEKLY GREASE GUN
MOVING GUIDE RALLY
SYSTEM
MOULD A WEEKLY GREASE GUN
OPEN-CLOSE
PACK AND
PINION
GEAR BOX GEAR AND B EVERY 2000 OIL BATH
BEARING HOURS

HYDRAULIC HYDRAULIC C SUPPLIED

PIPING OIL THROUGH THE
SPECIFIED OIL
HOLE
EXTRUDER THRUST B WEEKLY OIL BATH
BEARING EVERY 2000
HOURS
LUBRICATOR LUBRICATOR D EVERY MOUTH CUP
OF
PNEUMATIC

OPERATION MANUAL ２
LUBRICATE A (GREASE) B (OIL) C (HYDRAULIC
BRAND OIL)
ISO GRADE #2 VG 220 VG 68

D
(PNEUMATIC)
TURBINE OIL
#90

OPERATION MANUAL ３
2-3 START

A: PROCESS
- HEAT ON THE HEATERS OF EVERY ZONE.
- INSPECT THE REVOLUTION DIRECTION OF HYDRAULIC MOTOR.
EXTRUDER MOTOR AND COMPRESSOR.

- MAKE SURE THE SET VALUE OF EVERY TEMPERATURE ZONE

REACHED (FOR 2-3 HOURS), AND THEN TURN ON THE POWER
EXTRUDER MOTOR.
Φ35 - 65 M/M BLOW M/C FOR 1 HOURS
Φ75 -125M/M BLOW M/C FOR 3 HOURS

- START THE EXTRUDER MOTOR AT LOW SPEED. (SAY 200-300 R.P.M.)

- TRY TO OPERATE THE MANUAL FUNCTIONS OF HYDRAULIC SYSTEM

(SAY MOLD CLOSE/OPEN, CARRIER UP/DOWN)

- TURN ON THE AUTO SELECTING SWITCH; MAKE SURE THE CORRECT

AUTO OPERATING.

- PUT ON THE CORRECT MOLD TOOLING BETWEEN THE VICE PLATE.

* PAY ATTENTION FOR THE HEATING FUNCTION, AVOID THE DAMAGE OF

OPERATION MANUAL ４
SCREW.

- RUN THE, MATERIAL AND THE MELTED MATERIAL UNTIL THE MELTED
MATERIAL IS EXTRUDED OUT FIRM THE DIE HEAD.
- TURN ON THE HEATING KNIFE, IF DEVISED WITH HOT HEATING KNIFE
UNIT.

- INSPECT IF THE MELTED MATERIAL IS EXTRUDED OUT EVENLY.

- START TO OPERATE.

B: FUNCTIONS FOR OPERATING BOX

- MOLD CLOSE:
THE CLAMPING PLATES WERE CLOSING AND DEVISED WITH HIGH AND
LOW SPEED. THE LOWER SPEEDS PROTECT THE MOLD IMPACTING.

MOLD OPEN LIMIT SWITCH

MOLD CLOSE SLOW SPEED LIMIT SWITCH
MOLD CLOSE END LIMIT SWITCH

CLAMPING PLATE

- CUTTER:

OPERATION MANUAL ５
FOR CUTTING PARISON FORWARD AND BACKWARD.

- STATION DOWNWARD:
THE CARRIER STATION MOVE DOWNWARD (RIGHT SIDE) FOR BLOWPIN
DOWN.
IN CASE OF THAT STATION DOWN END PHOTO-CELL (OR LIMIT SWITCH)
IS NOT EXECUTED, THE BLOW PIN CAN’T MOVE DOWN. IT SHALL
PROTECT THE BLOWPIN AND MOULD TOOLING.

- BLOWPIN DOWN:
MOVE DOWN THE BLOWPIN.

- BLOWING:
BLOWING THE COMPRESSED AIR TO FORM THE BOTTLES.

- MOULD OPEN:
OPENING THE CLAMPING PLATES.

- BLOWPIN UP:
MOVE UP THE BLOWPIN.
IF THE PHOTO-CELL OF BLOWPIN UP IS NOT EXCITED THAT CARRIER
STATION. CAN’T MOVE UP (LIFTING). IF AVOID THE DAMAGE OF
BLOWPIN AND MOULD TOOLING.

- STATION UPWARD:
THE CARRIER STATION MOVES UP (LIFTING)

OPERATION MANUAL ６
1. (MAN): FOR MANUAL OPERATION.
2. (STOP): STOPPING THE RUNNING.
3. (AUTO): AUTOMATICALLY RUNNING.

- SAFETY POSITION:
AT ANY TIME, WHEN PUSH THIS BUTTON THE STATION MOVE
DOWN/MOLD OPEN/BLOWPIN UP.

- EMERGENCE STOP:
THE MACHINE SHOULD BE STOPPED, WHEN PUSH THIS BUTTON.

- START:
WHEN THE SELECTING SWITCH IS PUTTED “3 (AUTO)” POSITION, AND
THEN PUSH “START”, IT SHALL START THE AUTOMATIC RUNNING.

C: TIMERS IN THE CONTROL CABINET

- BLOWING TR:
BLOWING TIME FOR BOTTLE.

- COOLING TR:
AFTER BLOWING TIME, IT STARTS TO EXCITE FOR PRODUCTION
COOLING AND AIR EXHAUSTING.

- BLANK PREBLOW TR:

DIE HEAD PRE-BLOWING TIME. WHEN THE PARISON CUTTING START,
THE TIME IS EXCITED FOR HARDING PARISON. IT MEANS THE AIR WILL

OPERATION MANUAL ７
HOLD THE PARISON FOR EASILY CUTTER TO AVOID THE PARISON
DEFORMATION (SAY 0.1~0.3 SECONDS)

- BLOW DELAY TR:

WHEN THE BLOWPIN IS MOVED DOWN, IT STARTS TO COUNT.

- BLOWPIN LIFTING STOPPING TEMPORARILY TR:

BLOWPIN TEMPORARILY LIFTING TIME, WHEN THE BOLWPIN LIFTING
STOPPING TEMPORARILY SWITCH IS USED.

- CLAMPING DELAY TR:

WHEN THE CARRIER STATION WAS MOVED UP, THIS TIMER STARTS TO
COUNT. THEN THE MOLD CLOSE.

- MOLD TIME:
IT MEANS PRODUCTION CYCLE TIME. FOR EXAMPLE, WHEN THE
PRODUCTION CYCLE TIME IS 10 SECONDS, THIS TIMER SHOULD BE
OVER 1O SECONDS (MAY BE 12 SECONDS).
WHEN ANY TROUBLE WAS HAPPENING THE MACHINE WAS STOPPED.
THE ALARM BUZZER WILL ALARM, WHEN THE TIME IS OVER 12
SECONDS.

- STATION DOWNWARD DELAY TR:

WHEN THE MOLD CLOSED, IT STARTS TO COUNT, AND THEN STATION
MOVE DOWN.

OPERATION MANUAL ８
- STATION UPWARD DELAY TR:
WHEN THE BLOWPIN MOVE UP, IT STARTS TO COUNT, AND THEN
STATION MOVE UP.

- BOTTOM SCRAP SWITCH:

THE SELECTING SWITCH IS AVAILABLE FOR BOTTLE BOTTOM SCRAP
DEFLASHING.

- BLOWPIN LIFTING STOPPING TEMPORARILY SWITCH:

SELECTING SWITCH FOR THIS FUNCTION. IT LIFTS THE BLOWPIN
TEMPORARILY AFTER THE BLOWING.

D: ADJUSTMENT
- HEATING KNIFE SET VALUE:
6~8 (TRANSFORMER SCALER)

- THICKNESS BLOW:
IT MEANS DIE HEAD BLOWING. ADJUST THE AIR FLOW CONTROL TO
MAKE THE QUALIFIED PRODUCTION.

- PARISON EMERGENCE BLOW:

IT CONTROLS THE BLANK PREBLOW AIR FLOWING OF DIE HEAD. WHEN
THE PARISON IS CUT THIS BLOWING WILL BE EXCITED.

- AIR PRESSURE: 3~6 KG/CM2

OPERATION MANUAL ９
- HYDRAULIC PRESSURE:
MOLD/CARRIER STATION MOVING PRESSURE 40~50 KG/CM2
BSG-03-2B-3B PRESSURE RELIEF VALVE.
MOLD CLOSED (HIGH PRESSURE): 70~120 KG/CM2 BSG-03-2P PRESSURE
RELIEF VALVE.

- MOLD CLOSING SLOW SPEED:

35~45 KG/CM2 BSG-03-2P PRESSURE RELIEF VALVE BLOWPIN MOVING
PRESSURE: 20~25 KG/CM2 RDM-02 PRESSURE REDUCING VALVE. IT CAN
PROTECT THE BLOWPIN, MOLD TOOLING FOR CALIBRATING.

- CUSHION FOR CARRIER STATION MOVING:

THE VALVE LDV-04W IS ADVISED ON THE BACK OF FRAME. WHICH CAN
MAKE SMOOTHLY CUSHION FOR CARRIER STATION MOVING.

- PARISON THICKNESS ADJUSTMENT:

WHEN THE PARISON RUN OUT FROM THE DIE HEAD, MAKE SURE THE
PARISON IS STRAIGHT.
DIE DIE

PARISON A B
STRAIGHT PARISON UNEVEN THICKNESS

B
A LOOSE THESE
BOLTS
TIGHEN THESE BOLTS

OPERATION MANUAL １０
- BLOWPIN STROKE:
ADJUST THE CORRECTLY STROKE OF BLOWPIN DOWN FOR PROTECT
THE MOLD TOOLING.

OPERATION MANUAL １１
 THE MOLD TOOLING
THE STOP NUT CAN BE
ADJUSTED FOR CORRECT
STROKE OF BLOWPIN

BLOWPIN OIL CYLINDER

MOLD TOOLING
THE BOTTOM ADJUSTMENT BOLTS CAN BE
ADJUSTED FOR MOLD TOOLING EVENLY XLOSE
IT CAN AVOID THE SMALL GAP ON THE
MOLD TOOLING WHEN HIGH PRESSURE MOLD
CLOSING IS BUILTED UP

BOTTOM ADJUSTMENT
BOLTS

- CLAMPING PLATE:
THE BOTTOM ADJUSTMENT BOLTS CAN BE ADJUSTED FOR MOLD
TOOLING EVENLY CLOSE IT CAN AVOID THE SMALL GAP ON THE MOLD
TOOLING WHEN HIGH PRESSURE MOL CLOSING IS BUILT UP.

E: STARTING
-MAKE SURE THE ”A PROCESS WAS EXECUTED.

-TURN ON THE HYDRAULIC MOTOR/COMPRESSOR/HEATING KNIFE

-PUT THE SELECTING SWITCH IN ”MAN” POSITION (IN THE OPERATING

OPERATION MANUAL １２
BOX)

-CARRIER STATION MOVE UP (WITH MANUAL OPERATION)

-CHILLING WATER FOR MOLD TOOLING/BLOWPIN, CIRCULATING WATER

FOR OIL COOLER AND HOPPER BLOCK.

-PUT THE SELECTING SWITCH IN ”AUTO” POSITION.

-INSPECT THE METED MATERIAL (PARISON) LENGTH AND THICKNESS

EVENLY.

-PRESS THE ”START” (IN THE OPERATING BOX) THE MACHINE

AUTOMATICALLY RUNNING.

-INSPECT THE EXTRUDER MOTOR REVOLUTION (R.P.M.) IS SUITED FOR

THE PRODUCTION CYCLE? PLEASE KINDLY ADJUST THE CORRECT
SPEED.

-ADJUST THE TIMERS FOR PRODUCING THE PRODUCTIONS.

-CLOSE THE SAFETY GATE.

F: STOP RUNNING
- PUT THE SELECTING SWITCH IN THE ”STOP” POSITION AND THEN
PRESS THE ”SAFETY POSITION” BUTTON. IT OPENS THE MOLD/CUTTER

OPERATION MANUAL １３
DOWN/BLOWPIN UP.

- REDUCING THE EXTRUDER SPEED (SAY 200~300 RPM)

- TURN OFF THE HYDRAULIC MOTOR/AIR COMPRESSOR/HEATING

KNIFE.

- STOP THE WATER SUPPLYING.

- TURN OFF THE EXTRUDER MOTOR.

- PUSH THE SHUTTLE STOP PLATE TO STOP THE MACHINE FEEDING

(UNDER THE HOPPER OF EXTRUDER).

- TURN OFF THE HEATERS.

- SWITCH OFF EACH BREAKER INSIDE OF THE CONTROL CABINET.

G: EMERGENCE STOP
WHEN ANY TROUBLE WAS HAPPEN – PLEASE PRESS THE ”EMERGENCE
STOP BUTTON” ON THE OPERATION BOX. THE MACHINE STOP
RUNNING.
AND THEN PRESS THE ”SAFETY POSITION” BUTTON, IT OPEN THE
MOLD/CARRIER STATION DOWN/BLOWPIN UP. TURN OFF THE
EXTRUDER!! DON’T PUT THE HAND TO TAKE THE PRODUCTION. WHEN
MACHINE RUNNING!!

OPERATION MANUAL １４
2-4 FOR RUNNING THE PVC MATERIAL

A: STARTING
- SET THE TEMPERATURE (SAY 150~165 ºC, DEPENDS ON THE
DIFFERENT MATERIAL GRADE.) THE DIE BUSHING TRANS FORM VALUE
WILL BE 100~180V.

- OPEN THE PVC MATERIAL SHUTTLE PLATE UNDER HOPPER AND STOP
THE PURGE (CLEANING) MATERIAL SHUTTLE PLATE.

- MAKE SURE THE TEMPERATURE WAS REACHED.

- STARTING AS THE PREVIOUS DESCRIPTION.

B: STOP RUNNING
- PUT THE PURGE MATERIAL (CLEANING MATERIAL) SURE AS HDPE /
LDPE / SPECIAL PVC FORMULATION FOR PURGE INSIDE OF SMALL
HOPPER.

- STOP THE PVC MATERIAL SHUTTLE PLATE AND OPEN PURGE

OPERATION MANUAL １５
MATERIAL SHUTTLE.

PVC HOPPER

SHUTTLE PLATE PURGE MATERIAL HOPPER

SHUTTLE PLATE
- REDUCING THE EXTRUDER MOTOR SPEED. (SAY 200~300 RPM)

- RUN THE PURGE MATERIAL COME OUT FOR CLEANING THE SCREW
AND DIE HEAD.

- BE CAREFUL THE SCREW AND DIE HEAD AVOID ANY BROKEN DUE TO
THE UNNORMAL SITUATION.

- STOP THE MACHINE RUNNING AS THE PREVIOUS DESCRIPTION.

NOTE: THESE PURGE MATERIALS SHOULD BE ALMOST THE SAME
MELTING TEMPERATURE WITH PVC MATERIAL.

** BE CAREFUL FOR THE STOP/RUN PROCESS TO AVOID THE PVC

MATERIAL BURNED.

C: MATERIAL BURNED (OVER HEATING)

WHEN THE DARK POINT OF PRODUCTION IS HAPPENING, IT MEANS THE
MATERIAL BURNED ALREADY.

OPERATION MANUAL １６
- STOP THE MATERIAL FEEDING. STOP THE SHUTTLE PLATE.

- EXTRUDER CONTINUOUSLY RUN TO CLEAN THE MATERIAL UNTIL THE

REMAINED MATERIAL.

- TURN OFF THE HEATERS OF DIE HEAD AND ADAPTER.

- TAKE OFF THE FOUR BOLTS OF ADAPTER, AND TAKE OUT THE
COMPLETE DIE HEAD.
NOTE: BE CAREFUL THE HAND. THE DIE HEAD IS HIGH TEMPERATURE.
SHOULD BE WITH GLOBES.

- TAKE OFF EACH PARTS AS THE DIE HEAD DRAWING.

- CLEANING THE REMAINED MATERIALS WITH COPPER PIECE

CAREFULLY. DON’T SCRATCH ANY PARTS. DON’T DAMAGE ANY PARTS.

- ASSEMBLY THE DIE HEAD AND TIGHTEN BOLTS EVENLY. BE CAREFUL

MATERIAL DUE TO UNEVENLY TIGHTEN.
NOTE: THE BOLTS OF DIE HEAD/ADAPTER/BARREL THAT NEED TO
BRUSH THE SPECIAL HIGH TEMPERATURE GREASE. WHEN
DISASSEMBLY/ASSEMBLY. IT AVOID THE THREAD DAMAGE IN SO HIGH
TEMPERATURE HIGH TEMPERATURE GREASE GRADE: 300ºC (S2MO
GRADE)
2-5 GENERAL MAINTENANCE

OPERATION MANUAL １７
THE BASEMENT MAINTENANCE IS VERY IMPORT FOR LONG TIME
SERVICE.
- OIL CHANGE PERIOD:
AS THE PREVIOUS DESCRIPTION.

- LUBRICATING:
AS THE PREVIOUS DESCRIPTION.

- WATER DRAIN O AIR:

THE BLOWING AIR SHOULD BE WITHOUT WATER FOR GOOD QUALITY
BOTTLE. IT NEED TO DRAIN EVERY FROM THE PNEUMATIC ELEMENTS.
(AIR FILTER)

- SHARPING FOR THE KNIFE OF PARISON CUTTING:

EVERY DAY SHARPING IT WITH OIL STONE. DON’T DAMAGE THIS KNIFE.

- CALIBRATING RING OF BLOWPIN:

OPERATION MANUAL １８
QUENCHING SECTION, HRC: 45℃~48℃

- CALIBRATING RING OF BLOWPIN:

QUENCHING SECTION, HRC:45-48°

- SLEEVE OF MOLD TOOLING:

SLEEVE, QUENCHING HRC:48-50°

MOLD TOOLING

- DIE PIN AND DIE BUSHING:

MAKE THE SMOOTH AND FINE SURFACE. DON’T SCRATCH ANY LINE
MARK AND DAMAGE.

- BOLT AND NUTS:

PAY ATTENTION FOR THESE ELEMENTS, AVOID ANY LOOSE AND
DAMAGE.

- MOLD TOOLING:
DON’T PUT ANY PARTS INSIDE OF THE MOLD TOOLING. KEEP CLEANING
AVOID ANY RUST.

- CLEANING THE COOLING CIRCULATING OF MOLD TOOLING:

AFTER LONG TIME RUNNING, IT EASILY TO CLOG THE PIPE/HOLE OF

OPERATION MANUAL １９
MOLD OF MOLD TOOLING. IT SHALL INFLUENCE THE EFFICIENCY OF
THE COOLING.
PUMP THE CLEAN AGENT INTO THE PIPING OF MOLD TOOLING. (CLEAN
AGENT: 100% WATER + 5% HYDROCHLORIC ACID.)
PAY ATTENTION FOR THE ACID

- SCREW:
IT’S THE HEART OF EXTRUDER.
DON’T MAKE ANY MISTAKE FOR THIS PART. HEATING WELL AND
ROTATING THE SCREW. DON’T ROTATE THE SCREW IS UNNORMAL
RUNNING TEMPERATURE. ABSOLUTE DON’T ROTATE THE SCREW,
WHEN ARE ”OFF”.

TURN OFF THE TEMPERATURE CONTROL OF BARRED/DIE. HOW TO

TAKE OFF THE SCREW?
1. TURN ON THE HEATERS OF ADAPTER AND BARRED (20~30 MINUTES).
2. TAKE-OFF THE COMPLETE DIE HEAD.
3. STOP THE MATERIAL FEEDING.
4. TURN ON THE EXTRUDER MOTOR IN LOW SPEED RANGE (SAY
200~300 RPM) CENTER THE REMAINED MELTED MATERIAL IS FORCED
OUT WELL.
5. STOP RUNNING THE EXTRUDER MOTOR.
6. TURN OFF THE HEATERS OF CYLINDER.
7. TAKE OUT THE COVER OF GEAR BOX. (PART 10, REF THE GEAR BOX
DRAWING.)
8. PUT THE PIPE STICK INSIDE OF OUTPUT SHAFT, AND FORCED IT

OPERATION MANUAL ２０
 COME OUT.
9. CLEAN THE SCREW WITH COPPER PIECE, DON’T SCRATCH ANY
SECTION-HEATERS: PAY ATTENTION THESE HEATING ELEMENTS
CAREFUL THE NORMAL AMPERE OF EACH HEATING ZONE.

WHEN THE AMPERAGE VALUE IS DOWN, IT MEANS THE HEATERS WAS

BROKEN.
KEEP SOME SPARE HEATERS FOR CHANGING AND KEEP RUNNING.

2-6 THE EXPERIENCE FORMULA

- THE DIE BUSHING DIMENSION.

D = P ×2÷π÷S
W = π( D2－d2 ) / 4 ×L ×DENSITY

D: DIA OF DIE BUSHING, cm

d: DIA OF DIE PIN, cm
π: 3.1416
S: SWELL RATIO, SAY: 1~1.3
DEPENDS ON MATERIAL PRESSURE AND PRODUCTION
W: WEIGHT OF PRODUCTION, gram
L: LENGTH OF PRODUCTION, cm
P: PINCH-OF WIDTH OF BOTTLE, cm
DENSITY: DENSITY OF MATERIAL g/cm3
HDPE: 0.92 g/cm3 PVC: 1.3~1.4 g/cm3 PP: 0.9 g/cm3

OPERATION MANUAL ２１
- THE DIE BUSHING DIMESSNSIONS.

- CALIBRATING DIMESIONS:
Dφ=dφ+(0.15-0..25), M/M
THAT IS FOR EASILY CALIBBATING AND TRIMMING.

BLOW PIN

OPERATION MANUAL ２２
 T R O U B LE
S HO O T ING IN
H Y D R A U LI C U N I T

TROUBLE SHOOTING IN HYDRAULIC UNIT １

PUMP

PHENOMENON: NO OIL OUTPUT

POSSIBLE CAUSES:
1. ROTATE DIRECTION OPPOSITE.
2. SHAFT NOT ROTATES.
3. INSIDE DAMAGED VANE NOT ROTATE.
4. SUCK PIPE CHOKE.
5. FILTER CHOKE.
6. FILTER CAPACITY NOT ENOUGH.
7. OIL VISCOSITY TOO HIGH.
8. R.P.M. NOT ENOUGH.
9. SEALING OF SUCK PIPE NO GOOD.
10. FILTER OVER THE OIL LEVEL
11. NO GAP BETWEEN VANES.
12. WORST SUCK ABILITY.

SUGGESTED SOLUTION:
1. CHANGE MOTOR ROTATE DIRECTION.
2. CHECK THE COUPLING.
3. REPAIR THE PUMP AND KEEP THE R.P.M. AND PRESSURE IN THE
NORMAL RANGE.
4. CHANGE OIL FILTER.
5. CLEAN FILTER.
6. INCREASE THE CAPACITY.
7. CHANGE OIL, IF OIL TEMP. TOO LOW, INCREASE HEATER.
8. KEEP IN NORMAL R.P.M.

TROUBLE SHOOTING IN HYDRAULIC UNIT ２

9. CHANGE OIL PIPE.
10. INCREASE OIL.
11. REPAIR PUMP.
12. REPAIR PUMP & CHECK CIRCUIT.

PHENOMENON: NOISY
POSSIBLE CAUSES:
1. DIE OF SUCK PIPE TOO SMALL.
2. FILTER CHOKE.
3. FILTER CAPACITY NOT ENOUGH.
4. OIL VISCOSITY TOO HIGH.
5. 2-STAGE PUMP SUCK PIPE FITTING NO GOOD.
6. AIR INTO THE SUCK PIPE.
7. PUMP SEALING LEAKAGE.
8. COVER SIDE SUCKING AIR.
9. BUBBLE IN THE OIL TANK.
10. OIL LEVEL TOO LOW.
11. VANE GAP NO GOOD.
12. NOISE OF COUPLING.
13. R.P.M. NOT IN THE NORMAL RANGE.
14. PRESSURE IS UNNORMAL.
15. SHAFT WEAR.
16. VANE WHEEL RING BREAKAGE.
17. COVER FITTING NO GOOD.
18. PUMP BREAKAGE.

TROUBLE SHOOTING IN HYDRAULIC UNIT ３

SUGGESTED SOLUTION.
1. VACUUM IN THE SUCKING SIDE KEEPS UNDER 127MM – HG.
2. CLEAN FILTER.
3. FILTER CAPACITY MUST OVER TWICE PUMP CAPACITY.
4. CHANGE OIL IF OIL TEMP TOO LOW SHOULD BE INCREASE HEATER
START OIL VISCOSITY MUST UNDER 4000 SSU.
5. KEEP PIPE STRAIGHT AS POSSIBLE.
6. COVER WITH GREASE AND TIGHTEN.
7. REPAIR PUMP.
8. COVER WITH GREASE AND REPAIR.
9. CHANGE RETURN PIPE POSITION.
10. INCREASE OIL.
11. REPAIR PUMP.
12. CHAIN BLOCKAGES OR NOT IN RIGHT POSITION.
13. CHECK WITH R.P.M. GAUGE.
14. CHECK WITH PRESSURE GAUGE.
15. REPAIR PUMP.
16. USE CLEAN OIL.
17. ASSEMBLE AGAIN.
18. REPAIR PUMP.

TROUBLE SHOOTING IN HYDRAULIC UNIT ４

PHENOMENON: FLOW QUANTITY LACK PRESSURE LACK
POSSIBLE CAUSES:
1. NO OIL OUTPUT.
2. VANE WHEEL WEAR AND LEAKAGE.
3. SHAFT BREAK.
4. PUMP COVER FITTING NOT IN CONNECT POSITION.
5. OIL VISCOSITY TOO LOW.
6. PRESSURE RELIEF VALVE UNNORMAL.

SUGGESTED SOLUTION:
1. DO AS LIST BEFORE.
2. REPAIR PUMP.
3. REPAIR PUMP.
4. ADJUST.
5. CHANGE OIL.
6. ADJUST.

PHENOMENON: PUMP WHEEL LEAKAGE

POSSIBLE CAUSES:
1. SEAL BREAKAGE.
2. SHAFT WEAR.
3. LEAKAGE SO GET HOLE RETURN OIL.
4. RETURN PIPE TOO SMALL.

TROUBLE SHOOTING IN HYDRAULIC UNIT ５

SUGGESTED SOLUTION:
1. CHANGE NEW ONE.
2. CHANGE NEW ONE.
3. REPAIR PUMP NOTES THE OIL VISCOSITY.
4. CHANGE PROPER PIPE.

PRESSURE RELIEF VALVE

PHENOMENON: HIGH PRESSURE DROPS SUDDENLY
POSSIBLE CAUSES:
1. SET PRESSURE NOT HIGH ENOUGH.
2. PRESSURE GAUGE NOT WORK.
3. NEEDLE VALVE NOT IN NORMAL POSITION.
4. PISTON MOTION NOT SMOOTH.
5. SPRING FORCE TOO SMALL.
6. SEAL CHOKE.

SUGGESTED SOLUTION:
1. SET AT NORMAL PRESSURE.
2. INSPECTION GAUGE.
3. ADJUST.
4. OPEN COVER CHECK IF CHOKE.
5. CHANGE SPRING.
6. ADJUST.

TROUBLE SHOOTING IN HYDRAULIC UNIT ６

PHENOMENON: PRESSURE UNSTEADY
POSSIBLE CAUSES:
1. PISTON MOTION NOT SMOOTH.
2. NEEDLE VALVE MOTION UNSTEADY.
3. NEEDLE VALVE WEAR.
4. AIR MIX WITH OIL.

SUGGESTED SOLUTION:
1. CLEAN PISTON HOLE.
2. ADJUST.
3. CHANGE NEEDLE VALVE AND OIL.
4. DO AS LIST BEFORE.

PHENOMENON: LIFT RAPIDLY VARIATION (SOME TIMES HAVE NOISE)

POSSIBLE CAUSES:
1. PISTON CHOKE.
2. NEEDLE VALVE OVER WEAR.
3. AIR INTO THE COVER SIDE.
4. VIBRATION WITH OTHER VALVE.
5. RETURN OIL PIPE IMPROPER.
6. FLOW RATE RAPIDLY.
7. HIGH BACK PRESSURE OF RETURN OIL PIPE.

TROUBLE SHOOTING IN HYDRAULIC UNIT ７

SUGGESTED SOLUTION:
1. ADJUST.
2. CHANG NEEDLE VALVE AND OIL.
3. INSPECTION IT.
4. CHANGE SET PRESSURE.
5. CHECK IF TOO LONG OR IMPROPER POSITION.
6. DECREASE IT.
7. CHANGE THE PIPE.

PRESSURE REDUCE VALVE

PHENOMENON: HIGH PRESSURE DROPS SUDDENLY
SUGGESTED SOLUTION: DO AS LIST BEFORE.
PHENOMENON: PRESSURE UNSTEADY
POSSIBLE CAUSES:
1. PISTON MOTION NO GOOD.
2. NEEDLE VALVE MOTION UNSTEADY.
3. NEEDLE VALVE WEAR.
4. AIR MIX INTO OIL.
5. BACK PRESSURE OF RETURN OIL VARIATION.

SUGGESTED SOLUTION:
1. CHECK RETURN OIL QUANTITY AND PISTON HOLE.
2. DO AS LIST BEFORE.
3. DO AS LIST BEFORE.
4. DO AS LIST BEFORE.
5. USE SINGLE RETURN OIL METHOD.

TROUBLE SHOOTING IN HYDRAULIC UNIT ８

FLOW CONTROL VALVE
PHENOMENON: PRESSURE COMPENSATED OUT OF ORDER
POSSIBLE CAUSES:
1. PISTON CHOKE.
2. BUSHING HOLE CHOKE.
3. SMALL PRESSURE DIFFERENCE BETWEEN INPUT AND OUTPUT PORT.

SUGGESTED SOLUTION:
1. TAKE IT APART AND CLEAN.
2. PRESSURE NOT LESS 10 KG/CM2.

PHENOMENON: DIAL INDICATOR STOP

POSSIBLE CAUSES:
1. ADJUST ROD CHOKE.
2. THE DIALER WAS BROKEN.

SUGGESTED SOLUTION:
1. TAKE IT APART AND CLEAN.
2. CHANGE IT.

TROUBLE SHOOTING IN HYDRAULIC UNIT ９

 T R O U B LE
S HO O T ING
IN
B LO W M O LD I N G

TROUBLE SHOOTING IN BLOW MOLDING １

TROUBLE SHOOTING IN BLOW MOLDING
(1) ROUGHNESS OF THE PARISON SURFACE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MELT TEMPERATURE TOO LOW 1.INCREASE TEMPERATURE.
NON-UNIFORM DIE TEMPERATURE 1.IMPROVE HEATING KEEP THE DIE TEMPERATURE
UNIFORM.
ROUGHNESS OF THE DIE SURFACE 1.POLISH THE DIE SURFACE.
ROUGH RESIN 1.INCREASE STOCK TEMPERATURE.
2.WITHIN LIMITED INCREASE OR DECREASE
SCREW SPEED.
3.INCREASE DIE LAND LENGTH.
4.MAINTAIN RESIN FLOW SMOOTHLY IN DIE LAND.
5.USE THE DIE OF LONG CORE.
CONTAMINATION 1.INCREASE STOCK TEMPERATURE
APPROXIMATELY 40℃ HIGHER THAN NORMAL, OR
CHANGE RESIN.
CORE TEMPERATURE TOO LOW 1.CHECK AIR LEAKAGE AT CORE ZONE AND REPAIR
IT.
DEAD SPOTS IN DIE 1.CHANGE THE FLOW PATTERN OF DIE,
STREAMLINE IT.
(2) BUBBLE IN PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
WET RESIN 1.DETERMINE THE WATER CONTENT OF RESIN. IF
RESIN IS WETTED, DRY IT.

TROUBLE SHOOTING IN BLOW MOLDING ２

AIR LEAKAGE 1.CHECK AIR LEAKAGE AT TORPEDO AND CORE,
AND REPAIR IT.
AIR BROUGHT IN BY RESIN 1.INCREASE BACK PRESSURE.
(3) NON-UNIFORM LENGTH, THICKNESS AND WEIGHT OF THE PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
UNSTEADY EXTRUSION AND 1.KEEP EXTRUSION AND MOLD-CLOSE SPEED
MOLD-CLOSE SPEED STEADY.
NON-UNIFORM EXTRUSION 1.USE HIGH SENSITIVE TEMPERATURE
TEMPERATURE CONTROLLER.
CHANGE OF CYCLE TIME 1.KEEP THE RIGHT CYCLE TIME.
RESIN SLIP IN SCREW 1.DECREASE THE USAGE OF PIGMENT AND
PIGMENT DISPERSION AGENT.
2.INCREASE BACK PRESSURE.
CHANGE OF CONTENT OF 1.FIX THE CONTENT OF REGROUND RESIN.
REGROUND RESIN
(4) MELT FRACTURE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
CORE TEMPERATURE TOO LOW 1.HEAT THE CORE SUFFICIENTLY BEFORE
BLOWING.
2.CHECK AIR LEAKAGE AT CORE, AND REPAIR IT.
CORE LONGER THAN DIE 1.ADJUST IT.
(5) CURLING OF THE PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM PARISON WALL 1.ADJUST THE CORE FOR THE ACCURATE
THICKNESS CENTERING.
NON-UNIFORM PARISON 1.CHECK THE HEATER.

TROUBLE SHOOTING IN BLOW MOLDING ３

TEMPERATURE
CORE SHIFTING 1.TIGHTEN CORE AND TORPEDO.
2.CHECK THE DIE OPENING AND ADJUST IT.
(6) DIE-LINE OR STREAKS IN THE PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
CONTAMINATION IN DIE 1.CLEAN IT.
OXIDIZED RESIN IN DIE AND CORE 1.CLEAN DIE AND CORE.
SCRATCH IN DIE AND CORE 1.POLISH IT.
DIFFERENT RESINS MIXED 1.PROPERLY ADJUST THE DIE TEMPERATURE TO
KEEP THE RESIN TEMPERATURE ADEQUATELY.
SPIDER MARK SLANT INCREASE THE LENGTH BETWEEN DIE HEAD AND
SPIDER.
2.ADJUST THE TORPEDO TO THE CENTER OF THE
CYLINDER.
3.DECREASE EXTRUSION RATE.
(7) PARISON CONTAMINATION
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MIXED WITH DEGRADED RESIN 1.AVOID DEGRADED RESIN.
RESIN PILED UP AT DEAD SPOTS 1.ELIMINATE DEAD SPOTS.
FACTORY ENVIRONMENT NOT 1.CLEAN IT TO AVOID RESIN CONTAMINATION.
SANITORY
(8) PARISON SAG
POSSIBLE CAUSES SUGGESTED SOLUTIONS
IMPROPER CHOICE OF RESIN 1.USE LOW MELT INDEX RESIN.
2.USE HIGH DENSITY RESIN.
MELT TEMPERATURE TOO HIGH 1.IF POSSIBLE LOWER MALT TEMPERATURE.

TROUBLE SHOOTING IN BLOW MOLDING ４

MOLDING CYCLE TIME TOO LONG 1.REDUCE THE MOLDING CYCLE TIME.
IMPROPER BLOW MOLDING MACHINE 1.USE WITH PARISON ADJUSTER OR
ACCUMULATOR.
(9) PARISON SWELL TOO LARGE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MELT TEMPERATURE TOO LOW 1.INCREASE MELT TEMPERATURE.
RESIN OVER KNEADING 1.REDUCE EXTRUSION SPEED.
IMPROPER CHOICE OF RESIN 1.USE HIGH MELT INDEX RESIN AND KEEP
OUTPUT STEADY.
IMPROPER DIE DESIGN 1.INCREASE DIE LAND LENGTH AND GAP.
(10) PARISON SWELL INSUFFICIENT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MELT TEMPERATURE TOO HIGH 1.DECREASE MELT TEMPERATURE.
RESIN UNDER KNEADING 1.INCREASE EXTRUSION SPEED.
PARISON SAG 1.CLOSE MOLD AS EARLY AS POSSIBLE.
IMPROPER DIE DESIGN 1.DECREASE DIE LAND LENGTH AND GAP.
(11) HORIZONTAL RING IN PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
OUTPUT FLUCTUANT 1.ADJUST EXTRUSION SPEED AND TEMPERATURE
PROPERLY.
EFFECT OF NO-RETURN VALVE 1.INCREASE THE GAP OF NO-RETURN VALVE.
(12) DEFORMATION OF PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM TEMPERATURE AT DIE 1.CHECK AIR LEAKAGE AT DIE AND REPAIR IT.
CORE SHIFTING 1.TIGHTEN THE TORPEDO AND CORE.
(13) SLOW OUTPUT

TROUBLE SHOOTING IN BLOW MOLDING ５

POSSIBLE CAUSES SUGGESTED SOLUTIONS
CORE TEMPERATURE TOO LOW 1.INCREASE CORE TEMPERATURE.
IMPROPER DIE DESIGN 1.INCREASE DIE LAND LENGTH,10 TIMES
OF GAP IS RECOMMENDED.
(14) BLACK WELD LINE IN PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
RESIN DEGRADATION 1.AVOID OVER HEATING AT NO-RETURN VALVE.
2.ELIMINATE DEAD SPOTS AT ACCUMULATOR AND
RAM.
3.AVOID DEAD SPOTS.
(15) NON-UNIFORM SWELL ALONG THE PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM HEATING 1.KEEP THE DIE HEATED UNIFORMLY.
2.STORE ONLY ON STROKE RESIN IN
ACCUMULATOR AT A TIME.
NON-UNIFORM EXTRUSION SPEED 1.KEEP THE PRESSURE OF RAM UNIFORM
2.AVOID SAGGING.
(16) NON-UNIFORM SWELL AROUND THE PARISON
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM HEATING 1.CHECK THE RIGHT POSITION AND FUNCTION
OF HEATING PLATE.
CORE SHIFTING 1.DECREASE BACK PRESSURE.
CORE OUT OF CENTER 1.TIGHTEN CORE.
2.ADJUST THE GAP.
(17) OBVIOUS WELD LINE
POSSIBLE CAUSES SUGGESTED SOLUTIONS

TROUBLE SHOOTING IN BLOW MOLDING ６

CORE SLANT 1.ADJUST THE CORE TO KEEP THE GAP UNIFORM.

RESIN DEGRADATION 1.CLEAN DIE AND CORE.

INSUFFICIENT BACK PRESSURE 1.INCREASE DIE LAND LENGTH.
(18) FISHEYE AT PRODUCT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
UN-MELTED GEL IN RESIN 1.INCREASE THE TEMPERATURE OF METERING
SECTION.
2.INCREASE BACK PRESSURE.
3.DECREASE EXTRUSION RATE (SCREW SPEED).
4.USE FINE SCREEN PACK.
WET RESIN 1.DRY IT BEFORE USE.
BUBBLE 1.USE HIGH COMPRESSION SCREW AND
DECREASE EXTRUSION TEMPERATURE.
(19) IMPERFECT PRODUCT SHAPE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
LOW BLOWING PRESSURE 1.INCREASE IT.
POOR AIR VENT 1.CHECK THE AIR VENT AT THE FIRST PART OF
MOLD. IF NECESSARY, ADJUST IT.
2.CHECK THE AIR VENT AT THE PARTING LINE. IF
NECESSARY, IMPROVE AIR VENT BY TAPPING A
SMALL TAPE AT PARTING LINE.
3.FINISH BLOWING IN TWO STAGES.
AIR LEAKAGE 1.CHECK AIR LEAKAGE AND REPAIR IT.
PARISON DAMAGED AT MOLD-CLOSE 1.INCREASE THE CUT-OFF WIDTH.
2.DECREASE THE MOLD CLOSE SPEED.
CUT-OFF TOO HOT 1.COOL IT.

TROUBLE SHOOTING IN BLOW MOLDING ７

NECK FLASHING 1.ADJUST THE BLOWING PIN LENGTH AND LOCATE
IT AT THE CENTER.
2.DECREASE BLOWING PRESSURE.
INCOMPLETE MOLD-CLOSE 1.BLOW AND CLOSE THE MOLD AT THE SAME TIME.

MOLD TEMPERATURE TOO LOW 1.INCREASE IT.

BLOW-UP RATIO TOO LARGE 1.USE LARGER DIE.
(20) PARTING LINE TOO THIN
POSSIBLE CAUSES SUGGESTED SOLUTIONS
POOR AIR VENT 1.INCREASE VENT ALONG PARTING LINE.
2.FINISH BLOWING IN TWO STAGES.
INCOMPLETE MOLD-CLOSE 1.CHECK IF THE GUIDE PIN AND PIN BUSH FIT WELL.
IF NECESSARY, ADJUST THEM.
INCOMPLETE MOLD-CLOSE 1.INCREASE MOLD-CLOSE PRESSURE OR
DECREASE BLOWING PRESSURE.
(21) PRODUCT DEFORMATION
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM WALL THICKNESS AND 1.FIX THE PRODUCT IN A FALSE MOLD AFTER IT IS
COOLING EJECTED TO AVOID DEFORMATION.
PRODUCT TAKEN OUT WHEN STILL 1.INCREASE COOLING TIME.
TOO HOT
(22) ROUGH SURFACE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MOLD TEMPERATURE TOO LOW 1.DECREASE COOLING WATER FLOW RATE OR
INCREASE COOLING WATER TEMPERATURE.
MELT TEMPERATURE TOO LOW 1.INCREASE IT.

TROUBLE SHOOTING IN BLOW MOLDING ８

POOR AIR VENT 1.INCREASE AIR VENT BY SAND BLASTING AT THE
SEPARATION LINE.
INADEQUATE BLOWING PRESSURE 1.INCREASE IT
MIXED WITH LOW MI RESIN 1.INCREASE MELT TEMPERATURE BY ABOUT 40℃
OR USE VIRGIN RESIN.
(23) STREAK AT PRODUCT SURFACE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
SCRATCH AT DIE OR CORE 1.CHECK AND REPAIR IT.
RESIN DEGRADATION 1.CLEAN DIE AND CORE.
CONTAMINATION 1.CLEAN DIE.
INSUFFICIENT BACK PRESSURE 1.INCREASE DIE LAND LENGTH OR EXTRUSION
RATE.
2.DECREASE DIE TEMPERATURE.
(24) PARTING LINE NOT SMOOTH
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MOLD TEMPERATURE TOO LOW 1.INCREASE IT.
INSUFFICIENT BACK PRESSURE 1.INCREASE IT.
POOR AIR VENT 1.INCREASE IT.
(25) WRAPAGE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
IMPROPER MOLD CONDITIONS 1.INCREASE MOLD TEMPERATURE.
2.INCREASE BLOWING PRESSURE.

TROUBLE SHOOTING IN BLOW MOLDING ９

PRODUCT EJECTED WHEN STILL HOT 1.DECREASE MOLD TEMPERATURE.
2.INCREASE COOLING TIME.
3.DECREASE MELT TEMPERATURE.
4.FIX THE PRODUCT IN A FALSE MOLD AFTER IT IS
EJECTED TO AVOID DEFORMATION.
POOR EJECTION MECHANISM 1.ADJUST THE MECHANISM TO EJECT THE
PRODUCT AFTER COMPLETE COOLING.
IMPROPER PRODUCT DESIGN 1.MODIFY RIB AND THICKER PART OF THE
PRODUCT.
INCOMPLETE COOLING 1.MODIFY COOLING WATER CHANNEL TO LET THE
COOLEST WATER PASS THE THICKEST PART OF
THE PRODUCT TEST
(26) WELD LINE NOT SMOOTH
POSSIBLE CAUSES SUGGESTED SOLUTIONS
IMPROPER MOLD DESIGN 1.THE ANGLE OUTWARD FROM THE PINCH-OFF
SHOULD BE MODIFIED.
PRODUCT EJECTED WHEN STILL HOT 1.DECREASE MOLD TEMPERATURE.
2.INCREASE COOLING TIME.
PRODUCT AFFECTED BY PRESSURE 1.BEFORE MOLD OPENED WITHDRAW COMPLETELY
WHEN MOLD OPENED THE BLOW-PIN.
(27) INSUFFICIENT CORNER THICKNESS
POSSIBLE CAUSES SUGGESTED SOLUTIONS
ANGLE AT CORNER TOO SHARP 1.AVOID IT.
IMPROPER MOLD DESIGN 1.COOLING THE CORNER AS FAST AS POSSIBLE.
2.IMPROVE THE AIR VENT AT CORNER.
NON-UNIFORM PARISON THICKNESS 1.KEEP IT UNIFORM.

TROUBLE SHOOTING IN BLOW MOLDING １０

(28) RESIN TAIL ON THE PRODUCT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
PARISON TOO LONG 1.DECREASE PARISON LENGTH.
IMPROPER MOLD DESIGN 1.ADJUST TAIL LENGTH.
2.COOL THE TAIL.
(29) PINHOLE ON THE PRODUCT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
WET RESIN 1.DRY IT BEFORE USING.
CONTAMINATION 1.AVOID IT.
AIR BROUGHT IN BY RESIN 1.DECREASE EXTRUSION SPEED.
2.USE HIGH COMPRESSION SCREW.
(30) POOR GLOSS
POSSIBLE CAUSES SUGGESTED SOLUTIONS
IMPROPER CHOICE OF RESIN 1.USE HIGHER FLOW RESIN.
MELT TEMPERATURE TOO LOW 1.INCREASE MELT TEMPERATURE AND INSTALL A
HEATING PLATE ON THE DIE.
MOLD TEMPERATURE TOO LOW 1.INCREASE IT.
BLOW TOO LATE 1.BLOW EARLIER.
ROUGH SURFACE 1.SMOOTH IT.
(31) SHRINKAGE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
PRODUCT EJECTED WHEN STILL HOT 1.DECREASE MOLD TEMPERATURE.
2.DECREASE MELT TEMPERATURE.
IMPROPER MELDING CONDITION 1.INCREASE MELT TEMPERATURE.
BLOWING PRESSURE TOO LOW 1.INCREASE BLOWING PRESSURE AND BLOWING
TIME.

TROUBLE SHOOTING IN BLOW MOLDING １１

IMPROPER CHOICE OF RESIN 1.USE LOWER DENSITY AND HIGHER MI RESIN.
IMPROPER PRODUCT DESIGN 1.DECREASE THE WALL THICKNESS.
IMPROPER MOLD DESIGN 1.MODIFY THE COOLING-WATER CHANNEL.
(32) POOR WELD LINE
POSSIBLE CAUSES SUGGESTED SOLUTIONS
IMPROPER CUT-OFF 1.INCREASE THICKNESS OF BLADE OF CUT-OFF.
2.CHANGE THE WORN-OUT BLADE OF CUT-OFF.
CUT-OFF TOO HOT 1.COOL COMPLETELY.
MELT TEMPERATURE TOO HIGH 1.DECREASE IT.
MELT TEMPERATURE TOO LOW 1.INCREASE IT.
CONTAMINATION 1.AVOID CONTAMINATION.
2.USE VIRGIN RESIN TO PURGE.
MIXED WITH OXIDIZED RESIN 1.DECREASE THE USAGE OF REGROUND RESIN.
MOLD CLOSE TOO EARLY 1.DELAY IT.
TAIL TOO LONG 1.ADJUST THE TAIL LENGTH APPROXIMATELY
40-45% OF THE WIDTH OF PARISON.
(33) WELD LINE WEAKNESS
POSSIBLE CAUSES SUGGESTED SOLUTIONS
CONTAMINATION 1.CLEAN DIE AND DIE HEAD.
BACK PRESSURE TOO LOW 1.INCREASE THE DIE LAND LENGTH.
2.DECREASE THE DIE TEMPERATURE.
RESIN OVER KNEADING 1.TIGHTEN THE BACK PRESSURE CONTROL VALVE,
DECREASE THE GAP WHERE RESIN PASSES.
2.INCREASE BACK PRESSURE.
3.INCREASE EXTRUSION TEMPERATURE OR THE
TIME THAT RESIN REMAINS IN THE EXTRUDER.

TROUBLE SHOOTING IN BLOW MOLDING １２

(34) INSUFFICIENT CORNER THICKNESS OF RECTANGULAR PRODUCT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
NON-UNIFORM BLOW-UP RATIO 1.MODLFY THE SHAPE OR THICKNESS O PARISON
TO AVOID THE RESULTS BROUGHT BY
NON-UNIFORM BLOW-UP RATIO. FOR EXAMPLE,
CHANGE OF PARISON TO RECTANGULAR OR
INCREASE THE THICKNESS OF CORNER.
(35) DELIMITATION
POSSIBLE CAUSES SUGGESTED SOLUTIONS
CONTAMINATION 1.AVOID IT.
MELT TEMPERATURE TOO LOW 1.INCREASE MELT TEMPERATURE AND KEEP
THE CORE TEMPERATURE THE SAME AS IT.
(36) NON-UNIFORM WALL THICKNESS
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MELT TEMPERATURE TOO HIGH 1.DECREASE IT.
BACK PRESSURE TOO LOW 1.INCREASE DIE LAND LENGTH.
BLOW TOO LATE 1.BLOW EARLIER.
BLOW TOO EARLY 1.BLOW LATER.
MOLD AND CENTER TO DIE NOT 1.ADJUST THEM.
ADJUSTED
(37) INADEQUATE PRODUCT WEIGHT
POSSIBLE CAUSES SUGGESTED SOLUTIONS

IMPROPER MOLDING CONDITION 1.INCREASE MELT TEMPERATURE.

2.INCREASE EXTRUSION RATE.
3.CLOSE MOLD EARLIER.
IMPROPER CHOICE OF RESIN 1.USE LOWER MI RESIN.

TROUBLE SHOOTING IN BLOW MOLDING １３

GAP TOO NARROW 1.ENLARGE IT.
(38) BURNED SPOTS ON PRODUCT
POSSIBLE CAUSES SUGGESTED SOLUTIONS
MIXED WITH DEGRADED RESIN 1.ADJUST THE HEATING PLATE TO AVOID PARTLY
OVERHEATING
2.AVOID DEAD SPOTS IN DIE.
3.DECREASE THE USAGE OF REGROUND RESIN.
RESIN OXIDIZED 1.AVOID EXTRUDING WITHOUT RESIN.
2.AVOID MELTED RESIN TO CONTACT WITH AIR.
CONTAMINATION 1.AVOID IT.
(39) FLASH
POSSIBLE CAUSES SUGGESTED SOLUTIONS
PINCH-OFF TOO WIDE 1.DECREASE PARISON DIAMETER OR LIMIT THE
SWELL OF PARISON.
INCOMPLETE MOLD-CLOSE 1.INCREASE MOLD-CLOSE PRESSURE.
2.MODIFY MOLD EDGE.
3.DECREASE BLOWING PRESSURE.
MOLD AND CENTER OF DIE NOT 1.ADJUST THEM.
ADJUSTED

TROUBLE SHOOTING IN BLOW MOLDING １４

MOOG 30 POINTS
CONTROLLER
/J141-212B

MOOG 30 POINTS CONTROLLER /J141-212B １

 MOOG 30 POINTS CONTROLLER /J141-212B
1.WIRING (AS THE WIRE DRAWING)

2.KEY IN THE BATTERY (THE BLACK WIRE IS IN BOTTOM DIRECTION)

3.DIP SWITCH (IN SIDE OF CONTROL PANEL) SETTING (1、4、7 "ON", - FOR ENGLISH
AND ACCUMULATOR TYPE) ON : , OFF :

4.TURN ON THE BREAKER (INSIDE OF CONTROL PANEL) / TURN ON THE POWER SOURCE.

5.PRESS "SET" KEY.

6.PRESS "SET" / "F2" TOGETHER AT THE SAME TIME. AND THEN SET THE CURRENT TIME.

7.PRESS "F1" (PROFILE)

8.PRESS "SET" / "F1" TOGETHER AT THE SAME TIME. FOR SETTING THE CORE TYPE.

* SERVO HYDRAULIC PRESSURE: 20 - 30 KG/CM 2 *

DIVERGE: ,CONERGE:

-PRESS "SET" → CORE DIVERGE CONVERGE , TURN THE ENTRY KNOB TO

CHOICE AND THEN PRESS " SET "

ENTRY KNOB

-THE MONITOR SHOW AS DCOT ZERO SPAN , "SET" FLASHING.

NOTE: ZERO → THE MIN. DIE GAP.

SPAN → THE MAX. DIE GAP.
WE SET THE " ZERO" FIRST.

MOOG 30 POINTS CONTROLLER /J141-212B ２

 TURN THE ENTRY KNOB COUNTER CLOCK WISE DIRECTION, MAKE
THE CURRENT IN THE RANGE OF ZERO, AND THE
- VOLTAGE IN THE RANGE OF +2 - +5.

┌───┬───┐ ┌─────┬──┐
└───┴───┘ └─────┴──┘
-20MA 0 20MA -10V 0 10V
(CURRENT) (VOLTAGE)

-AT THIS MOMENT, THE MONITOR SHOW ZERO , PLEASE TURN THE ENTRY
ZERO

KNOB CLOCKWISE DIRECTION. MAKE THE CURRENT IN THE RANGE OF ZERO,

AND THE VOLTAGE IN THE RANGE OF-2~ -5 .

┌───┬───┐ ┌───┬─────┐
└───┴───┘ └───┴─────┘
-20MA 0 20MA -10V 0 10V
(CURRENT) (VOLTAGE)

AND THEN PRESS "SET" .YOU SET THE " SPAN" ALREADY.

┌──────┐
-PRESS THE CURSOR ( ▽ OR △ ) TO CORE STROKE , PUSH "SET" AND THEN TURN
└──────┘
THE ENTRY KNOB TO DECIDE THE STROKE (MAX : 25M/M), PRESS "SET". IT MEANS

THAT YOU SET THE CORE STROKE ALREADY.

-THE MONITOR SHOW UNIT % M/M PLEASE TURN THE ENTRY KNOB TO CHOICE

THE UNIT OF CORE STROKE (% OR M/M), AND PRESS "SET".

-PUSH THE CURSOR ( ▽ OR △) TO ACCUM (ACCUMULATOR),AND PRESS "SET".

THE MONITOR INDICATE EMPTY FULL , EMPTY : MATERIAL PURGE END

FULL : MATERIAL STORAGE END

PLEASE SWITCH ON THE HYDRAULIC PUMP OF MATERIAL PURGE. PRESS THE " MANUAL

MOOG 30 POINTS CONTROLLER /J141-212B ３

 PURGE " OF PLC, MAKE SURE THAT IS THE END OF PURGE. AND THEN PRESS "SET", AND

THE "END OF EXTRUSION" LAMP LIGHT. IT MEANS THE "EMPTY" WAS SET ALREADY.

THE MONITOR SHOWS EMPTY FULL , PRESS THE MANUAL "MATERIAL RETURN"

AND MAKE SURE THAT IS THE END OF MATERIAL STORAGE. AND THEM PUSH THE "SET",

"THE END OF FILLING" LAMP LIGHT. IT MEANS THE "FULL" WAS SET ALREADY.

NOTE: PAY ATTENTION FOR THE DIE HEAD SAFETY LIMIT SWITCH. 90% OF MAX
STORAGE STROKE.

-PUSH THE CURSOR ( ▽ △ ) TO ”GAIN” ,” PRESS ” SET ” (GAIN - IT MEANS THE

RESPONSE OF SERVO VALVE FOR PARISON CONTROLLING)

THE MONITOR INDICATE AS:

GAIN TIMES
MOVE
END
PLEASE TURN THE ENTRY KNOB TO DECIDE THE TIMES RANGE (SAY 2 - 3), PRESS

"SET". AND THEN PRESS THE CURSOR ( ▽ △) TO "MOVE" .AT THIS MOMENT TURN THE

ENTRY KNOB TO TEST AND HEAR THE RESPONSE OF DIE PIN MOVING. PRESS THE

CURSOR TO "END", AND PRESS THE "SET".

NOTE : PLEASE REPEAT THE PROCESS OF ZERO SPAN / % MM / EMPTY FULL

/ GAIN, WHEN CHANGE THE NEW DIE PIN AND DIE BUSHING !

9. F3 FILE FOR LOADING AND SAVE (MEMORY) APPLICATION. PRESS "F3" LOAD SAVE

FOR L0ADING THE PREVIOUS PROFILE. TURN THE ENTRY KNOB TO LOAD ,AND PRESS

"SET". AND THEN TURN THE ENTRY KNOB TO THE REQUIRED NUMBER, PRESS THE "SET".

IT SHALL SHOW "LOAD A FILE ? YES NO ". TURN THE ENTRY KNOB TO YES ,

MOOG 30 POINTS CONTROLLER /J141-212B ４

 PRESS "SET". THE MONITOR SHOWS THE DESIRED PROFILE.

-FOR SAVING THE NEW PROFILE. TURN THE ENTRY KNOB TO SAVE , PRESS "SET"

THE MONITOR INDICATE "CHANGE FILE NO ?" YES NO . IF YOU WANT TO CHANGE

TO FILE NUMBER TURN THE ENTRY KNOB TO YES AND PRESS "SET". TURN THE

ENTRY KNOB TO CHOICE THE NUMBER, AND PRESS "SET". FINALLY, TURN THE ENTRY

KNOB TO "END", AND PRESS "SET". THE MONITOR INDICATE "SAVE? YES NO ",

YOU HAVE TO TURN THE ENTRY KNOB FOR YES , AND PRESS "SET".

NOTE : IT HAS "100" PROFILE FOR SAVING MEMORY.

10.EXPLAINING OF CONTROLLER

START : STARTING TO PROCESS

DIE GAP : IT MEANS THE DIE PIN CLOSING

ACCUMULATOR : FOR ACCUMULATOR TYPE BLOW MOULDING M/C

CONTINUOUS : FOR CONTINUOUS TYPE BLOW MOULDING M/C

DIVERGE: DIE PIN

CONERGE: DIE PIN

-END OF FILLING : IT MEANS THE END OF MATERIAL STORAGE.

POINT OUT : IT INDICATE THE POINT OF PARISON PROFILE WHEN MATERIAL IS

PURGING.

END OF EXTRUSION : IT MEANS THE END OF MATERIAL PURGE.

MOOG 30 POINTS CONTROLLER /J141-212B ５

11.PRESS "F1 (PROFILE)" TO SET THE DESIRED PROFILE.

SHOT SIZE: THE STORAGE CAPACITY SETTING FOR REQUIRED PRODUCTION. (%

PERCENTAGE)

DIE GAP : IT MEANS THE DIE PIN CLOSING WHEN THE MATERIAL IS STOCKED. SET THE
VALUE OF 0.5 - 1 M/M, TO AVOID THE DAMAGE BETWEEN THE DIE PIN AND
DIE BUSHING.

DELAY : DELAY THE % FOR THE PROFILE SETTING WHEN PURGE THE MATERIAL.
(SAY 0 - 0.5% )

*CUSHION : IT MEANS THAT END SIGNAL OF MATERIAL PURGE. SET THE VALUE 0.5 - 0.7
%. IT WILL AVOID THE ERROR SIGNAL FOR AUTOMATICALLY RUNNING DON'T
SET 0 % VALUE, IT EASILY HAVE THE ERROR SIGNAL DUE TO THE
MECHANICAL SHOCK.
WEIGHT : THE BASEMENT WEIGHT OF PROFILE
RANGE H : THE HIGHEST PROFILE RANGE
RANGE L : THE LOWEST PROFILE RANGE
30

RANGE L

RANGE H
0

WEIGHT

CURSOR ▽ △ :FOR MOVING DOWN / UP

MOOG 30 POINTS CONTROLLER /J141-212B ６

X10
:TEN TIMES SETTING

:ENTRY KNOB, FOR INCREASE OR CREASE THE SETTING VALUE

SET :SET FOR INPUT

12.INCREASE THE PRESSURE OF SERVO HYDRAULIC TO THE RANGE OF 50 - 120 KG/CM2

13.OTHERS

-KEEP THE WATER CIRCULATION IN THE IE HEAD ALL THE TIME. OTHERWISE, THE
PACKING OF DIE HEAD WILL BROKEN AND OIL LEAKAGE.

-MANUALLY OPERATE THE MATERIAL PURGE AND RETURN WEEKLY TO CLEAN THE
REMAINED RESIN.

-REPEAT THE ITEM "8" WHEN CHANGE THE NEW DIE PIN AND DIE BUSHING.

-BE CAREFUL THE LVDT OF DIE HEAD WHEN CHANGE THE NEW DIE PIN AND DIE
BUSHING

*LOOSE THIS NUT AVOID THE DAMAGE OF LVDT. *FIX THE SHAFT WITH BIG
SPANNER

LVDT

TOP of DIE HEAD

MOOG 30 POINTS CONTROLLER /J141-212B ７