Quick Answer

Injection molding machine overheating is usually caused by problems in the hydraulic system, cooling system, servo motor, or improper machine operation.

Common causes include:

• Dirty oil coolers
• High hydraulic oil temperature
• Insufficient cooling water flow
• Worn hydraulic pumps
• Servo motor overheating
• Blocked ventilation systems
• Excessive machine loading

Ignoring overheating can lead to component failure, increased maintenance costs, and unplanned production downtime.

Why Overheating Is a Serious Problem

Every injection molding machine generates heat during operation.

However, excessive heat can damage critical components such as:

• Hydraulic pumps
• Hydraulic valves
• Servo motors
• Seals
• Hydraulic oil
• Electrical components

Overheating often reduces machine efficiency long before a major failure occurs.

What Is Considered Overheating?

Most hydraulic injection molding machines operate best when hydraulic oil temperature remains between:

35°C and 55°C (95°F–131°F)

Temperatures consistently above recommended levels may indicate an underlying problem.

Always refer to the machine manufacturer’s specifications.

Cause #1: Dirty or Blocked Oil Cooler

One of the most common causes of overheating is reduced cooling efficiency.

Oil coolers gradually accumulate:

• Dust
• Dirt
• Scale
• Debris

This reduces heat transfer and causes hydraulic oil temperature to rise.

Signs

• Gradually increasing oil temperature
• Stable production load but rising heat
• Reduced cooling performance

Solution

✓ Clean the oil cooler regularly

✓ Inspect cooling passages

✓ Follow preventive maintenance schedules

Cause #2: Insufficient Cooling Water Flow

Many injection molding machines rely on water-cooled heat exchangers.

Poor cooling water flow can dramatically reduce cooling performance.

Possible Causes

• Blocked pipes
• Closed valves
• Low water pressure
• Scale buildup

Solution

✓ Verify water flow rate

✓ Inspect valves and piping

✓ Clean cooling circuits

Cause #3: Worn Hydraulic Pump

Hydraulic pumps naturally wear over time.

As wear increases:

• Internal leakage increases
• Efficiency decreases
• Heat generation rises

Warning Signs

• High oil temperature
• Pressure instability
• Increased noise
• Reduced machine responsiveness

Solution

Inspect pump performance and replace worn components when necessary.

Cause #4: Contaminated Hydraulic Oil

Dirty or degraded oil increases friction throughout the hydraulic system.

Common contaminants include:

• Water
• Dust
• Metal particles
• Oxidized oil

Contaminated oil often causes higher operating temperatures.

Solution

✓ Inspect oil condition

✓ Replace filters

✓ Perform oil analysis when appropriate

Cause #5: Hydraulic Oil Viscosity Problems

Using the wrong oil grade can create overheating issues.

Oil that is too thick:

• Creates excessive resistance
• Increases energy consumption

Oil that is too thin:

• Reduces lubrication efficiency

Solution

Always use the hydraulic oil grade recommended for the machine and operating environment.

Cause #6: Servo Motor Overheating

Servo-driven injection molding machines may generate temperature alarms when cooling becomes inadequate.

Common Causes

• Blocked air passages
• Cooling fan failure
• High ambient temperature
• Excessive machine load

Signs

• Servo temperature alarms
• Reduced performance
• Unexpected shutdowns

Solution

Inspect cooling fans, ventilation systems, and motor operating conditions.

Cause #7: Excessive Machine Loading

Machines operating continuously near maximum capacity generate more heat.

Examples include:

• High injection pressures
• Fast cycle times
• Heavy molds
• Continuous 24/7 production

Solution

Review process settings and confirm the machine is properly sized for the application.

Cause #8: Cooling Fan Failure

Electrical cabinets, servo motors, and control systems often rely on cooling fans.

A failed fan can quickly increase component temperatures.

Signs

• Hot electrical cabinets
• Control system alarms
• Servo overheating

Solution

Inspect fans during preventive maintenance and replace failed units promptly.

Cause #9: Poor Factory Ventilation

The surrounding environment also affects machine temperature.

Factories with:

• High ambient temperatures
• Poor airflow
• Inadequate ventilation

often experience more overheating problems.

Solution

Improve air circulation and maintain acceptable room temperatures whenever possible.

Cause #10: Clogged Hydraulic Filters

Restricted filters can increase system resistance.

This may cause:

• Increased pump load
• Reduced flow
• Additional heat generation

Solution

Replace filters according to maintenance schedules.

Monitor filter indicators regularly.

Common Signs of Injection Molding Machine Overheating

Watch for the following symptoms:

Rising Hydraulic Oil Temperature

One of the earliest warning signs.

Servo Motor Temperature Alarms

Often indicate cooling or loading issues.

Slower Machine Performance

Heat can affect system efficiency.

Frequent Machine Alarms

Temperature-related alarms should never be ignored.

Increased Energy Consumption

Overheated systems generally operate less efficiently.

How to Prevent Overheating

Preventive maintenance is the best defense against overheating.

Recommended practices include:

Daily

✓ Monitor oil temperature

✓ Check cooling water flow

✓ Inspect for leaks

Weekly

✓ Inspect filters

✓ Check cooling systems

✓ Verify fan operation

Monthly

✓ Clean cooling equipment

✓ Review alarm history

✓ Inspect hydraulic oil condition

Annually

✓ Perform hydraulic system evaluation

✓ Inspect pumps

✓ Review cooling system performance

What Happens If Overheating Is Ignored?

Persistent overheating can lead to:

• Hydraulic pump failure
• Oil degradation
• Seal damage
• Servo motor damage
• Increased downtime
• Higher repair costs

Small temperature problems often become major failures if left unresolved.

Which Component Causes Overheating Most Often?

In many factories, the most common causes are:

1. Dirty oil coolers
2. Insufficient cooling water flow
3. Contaminated hydraulic oil
4. Worn hydraulic pumps
5. Cooling fan failures

These issues are often preventable through regular maintenance.

How DAYAMAC Supports Overheating Troubleshooting

DAYAMAC, the injection molding machine division of DAYA MACHINERY, supports customers worldwide with maintenance and spare parts solutions.

We provide:

• Hydraulic pumps
• Hydraulic valves
• Oil coolers
• Cooling system components
• Servo motor parts
• Hydraulic filters
• Technical consultation

Our team helps manufacturers diagnose overheating problems and improve machine reliability.

Common Questions

What temperature is too high for an injection molding machine?

Most hydraulic systems operate best between 35°C and 55°C, although exact limits vary by manufacturer.

Can dirty hydraulic oil cause overheating?

Yes. Contaminated oil increases friction and reduces hydraulic system efficiency.

Why does my servo motor keep overheating?

Common causes include blocked airflow, cooling fan failure, excessive load, and high ambient temperature.

Can a hydraulic pump cause overheating?

Yes. Worn pumps often generate excess heat due to internal leakage and reduced efficiency.

How can I reduce machine overheating?

Regular maintenance, clean hydraulic oil, proper cooling system operation, and timely filter replacement are among the most effective solutions.

Contact DAYAMAC

Need help sourcing cooling system components, hydraulic parts, or maintenance supplies?

DAYAMAC provides:

• Hydraulic pumps
• Oil coolers
• Hydraulic filters
• Servo system components
• Spare parts sourcing
• Industrial Sourcing & Supply Solutions

Contact our team for support with injection molding machine maintenance and troubleshooting.

Quick Answer

Servo motor alarms are designed to protect the machine from damage and indicate problems such as overheating, encoder faults, overload conditions, communication errors, or power supply issues.

Most servo alarms can be resolved by identifying the root cause rather than simply resetting the machine.

Common causes include:

• Motor overheating
• Encoder failures
• Servo drive faults
• Loose electrical connections
• Excessive machine load
• Cooling system problems

A systematic troubleshooting process helps minimize downtime and prevent repeated failures.

Why Do Servo Motor Alarms Occur?

Modern injection molding machines use servo systems to improve:

• Energy efficiency
• Response speed
• Pressure control
• Production consistency

The servo drive continuously monitors motor performance.

When abnormal conditions are detected, the system generates an alarm to protect both the motor and the machine.

Ignoring alarms can lead to costly component damage.

Common Servo Motor Alarms

While alarm codes vary by manufacturer, most alarms fall into several categories.

Alarm Type #1: Overload Alarm

Typical Symptoms

• Machine stops suddenly
• Servo overload warning appears
• Reduced machine performance

Possible Causes

• Excessive hydraulic pressure demand
• Mechanical resistance
• Pump issues
• Incorrect machine settings

Troubleshooting Steps

✓ Check machine load

✓ Verify hydraulic system condition

✓ Inspect pump operation

✓ Review recent process changes

Repeated overload alarms should never be ignored.

Alarm Type #2: Overheating Alarm

Typical Symptoms

• Servo temperature alarm
• Machine shutdown during operation

Possible Causes

• Blocked cooling airflow
• Failed cooling fan
• High ambient temperature
• Continuous heavy operation

Troubleshooting Steps

✓ Clean cooling vents

✓ Inspect cooling fans

✓ Check room temperature

✓ Verify motor temperature

Overheating is one of the most common servo system problems.

Alarm Type #3: Encoder Alarm

Typical Symptoms

• Position error alarms
• Machine movement abnormalities
• Servo startup failure

Possible Causes

• Damaged encoder
• Loose encoder cable
• Electrical interference
• Encoder contamination

Troubleshooting Steps

✓ Inspect encoder wiring

✓ Check cable connections

✓ Verify encoder condition

✓ Review alarm history

Encoder-related alarms often require careful inspection rather than immediate component replacement.

Alarm Type #4: Communication Error

Typical Symptoms

• Servo drive communication fault
• Intermittent machine operation

Possible Causes

• Damaged communication cable
• Loose connectors
• Control system issues
• Electrical noise

Troubleshooting Steps

✓ Inspect communication cables

✓ Verify connector integrity

✓ Check grounding system

✓ Restart control systems according to manufacturer procedures

Alarm Type #5: Low Voltage Alarm

Typical Symptoms

• Servo startup problems
• Random shutdowns
• Drive fault messages

Possible Causes

• Unstable power supply
• Voltage drop
• Electrical distribution problems

Troubleshooting Steps

✓ Measure incoming voltage

✓ Inspect power connections

✓ Check electrical panels

✓ Consult qualified electrical personnel if necessary

Stable power quality is essential for servo system reliability.

Alarm Type #6: Overvoltage Alarm

Typical Symptoms

• Immediate servo shutdown
• Drive protection activation

Possible Causes

• Power supply fluctuations
• Regenerative energy issues
• Drive configuration problems

Troubleshooting Steps

✓ Verify incoming power quality

✓ Check drive parameters

✓ Inspect braking systems if applicable

Alarm Type #7: Motor Feedback Error

Typical Symptoms

• Position instability
• Machine movement errors

Possible Causes

• Encoder failure
• Feedback cable damage
• Signal interference

Troubleshooting Steps

✓ Inspect feedback wiring

✓ Check cable routing

✓ Verify encoder performance

First Steps When a Servo Alarm Appears

When a servo alarm occurs:

Step 1: Record the Alarm Code

Always record the exact alarm code before resetting the machine.

The code provides critical diagnostic information.

Step 2: Check the Machine Manual

Different manufacturers use different alarm numbering systems.

The machine documentation should always be the first reference.

Step 3: Inspect for Obvious Problems

Look for:

• Loose wiring
• Damaged cables
• Cooling issues
• Hydraulic abnormalities

Many alarms are caused by simple issues.

Step 4: Review Recent Changes

Ask:

• Was maintenance recently performed?
• Were machine settings changed?
• Was new material introduced?

Recent changes often provide clues.

Common Servo Alarm Troubleshooting Mistakes

Resetting Without Investigation

Repeated resets may hide developing problems.

Ignoring Overheating

Heat-related alarms often indicate serious maintenance issues.

Replacing Components Too Quickly

Accurate diagnosis should come before expensive replacements.

Ignoring Alarm History

Previous alarms often reveal patterns that help identify root causes.

Preventive Maintenance for Servo Systems

Preventive maintenance significantly reduces alarm frequency.

Recommended practices include:

Monthly

✓ Inspect cooling fans

✓ Check cable connections

✓ Clean ventilation paths

Quarterly

✓ Inspect electrical terminals

✓ Check servo drive status

✓ Verify grounding

Annually

✓ Review alarm history

✓ Inspect encoder condition

✓ Evaluate motor performance

Preventive maintenance is often the most cost-effective way to avoid servo-related downtime.

When Should a Servo Motor Be Replaced?

Replacement may be necessary when:

• Internal damage is confirmed
• Repeated failures occur
• Repair costs become excessive
• Critical components are no longer available

Many servo motor issues can be repaired without replacing the entire motor.

A proper inspection should always be performed first.

How DAYAMAC Supports Servo System Troubleshooting

DAYAMAC, the injection molding machine division of DAYA MACHINERY, helps manufacturers diagnose and source replacement components for servo systems.

We support customers with:

• Servo motors
• Servo drives
• Encoders
• Cooling fans
• Electrical components
• Spare parts sourcing
• Technical consultation

Our team assists factories in reducing downtime and restoring reliable machine operation.

Common Questions

What is the most common servo motor alarm?

Overheating, overload, encoder, and communication alarms are among the most frequently encountered servo system faults.

Can I reset a servo alarm and continue production?

You can reset the alarm, but the root cause should always be investigated to prevent recurring failures.

Can low voltage cause servo alarms?

Yes. Unstable power supply is a common cause of servo system faults.

Does a servo alarm always mean the motor is damaged?

No. Many alarms are caused by wiring, cooling, sensors, or external system issues rather than motor failure.

How can I reduce servo motor alarms?

Regular maintenance, proper cooling, electrical inspections, and prompt troubleshooting are the most effective preventive measures.

Contact DAYAMAC

Need help sourcing servo motors, servo drives, encoders, or injection molding machine spare parts?

DAYAMAC provides:

• Servo motor solutions
• Servo drive components
• Encoder replacements
• Electrical spare parts
• Technical support
• Industrial Sourcing & Supply Solutions

Contact our team for assistance with servo system troubleshooting and spare parts sourcing.

Quick Answer

Oil leakage in an injection molding machine is usually caused by worn seals, damaged hydraulic hoses, loose fittings, excessive system pressure, or aging hydraulic components.

While small leaks may appear harmless, they can lead to:

• Hydraulic pressure loss
• Increased oil consumption
• Machine contamination
• Higher maintenance costs
• Unexpected downtime

Identifying and repairing leaks early can prevent more serious hydraulic system failures.

Is Oil Leakage a Serious Problem?

Yes.

Many machine operators ignore small oil leaks because the machine continues running normally. However, even minor leakage can indicate developing problems within the hydraulic system.

Over time, oil leakage may cause:

• Reduced hydraulic efficiency
• Pump damage
• Pressure instability
• Safety hazards
• Increased operating costs

A leaking machine should always be inspected as soon as possible.

What Are the Most Common Causes of Oil Leaks?

Several hydraulic components can develop leaks during normal operation.

The most common causes include:

• Worn seals
• Aging hydraulic hoses
• Loose fittings
• Damaged cylinders
• Excessive hydraulic pressure
• Hydraulic oil contamination

Proper maintenance can prevent many of these issues.

Cause #1: Worn Hydraulic Seals

Hydraulic seals naturally wear over time.

Continuous exposure to:

• Pressure
• Heat
• Oil flow
• Mechanical movement

gradually reduces seal effectiveness.

Common leak locations include:

• Hydraulic cylinders
• Pumps
• Valves
• Hydraulic motors

Solution

✓ Inspect leaking components

✓ Replace worn seals

✓ Verify proper installation procedures

Seal replacement is often one of the simplest and most cost-effective repairs.

Cause #2: Damaged Hydraulic Hoses

Hydraulic hoses operate under high pressure and can deteriorate with age.

Common signs include:

• Surface cracking
• Abrasion damage
• Bulging sections
• Oil seepage

Hoses located near moving machine parts are particularly vulnerable.

Solution

✓ Inspect hoses regularly

✓ Replace damaged hoses immediately

✓ Secure hoses properly to reduce vibration wear

Preventive replacement is usually less expensive than emergency repairs.

Cause #3: Loose Hydraulic Fittings

Machine vibration can gradually loosen hydraulic connections.

Leaks often occur around:

• Hose fittings
• Adapters
• Manifolds
• Valve blocks

Solution

✓ Inspect hydraulic connections

✓ Tighten fittings according to manufacturer specifications

✓ Replace damaged fittings if necessary

Overtightening should be avoided because it can damage threads and sealing surfaces.

Cause #4: Excessive Hydraulic Pressure

Operating above recommended pressure levels places additional stress on:

• Seals
• Hoses
• Valves
• Hydraulic cylinders

High pressure can accelerate wear and increase leakage risk.

Solution

✓ Verify pressure settings

✓ Inspect pressure relief valves

✓ Confirm machine parameters are correctly configured

Pressure should always remain within the manufacturer’s recommended limits.

Cause #5: Hydraulic Cylinder Wear

Hydraulic cylinders experience constant movement during machine operation.

Over time, wear may develop on:

• Cylinder rods
• Internal seals
• Cylinder bores

Common symptoms include:

• Oil around cylinder rods
• Reduced clamping force
• Pressure instability

Solution

✓ Inspect cylinder condition

✓ Replace worn seals

✓ Repair or rebuild damaged cylinders

Early intervention often prevents more costly repairs.

Cause #6: Hydraulic Pump Leakage

Hydraulic pumps may leak externally or internally.

Potential causes include:

• Seal wear
• Shaft wear
• Excessive operating temperature
• Oil contamination

Solution

✓ Inspect pump housing

✓ Check pump seals

✓ Evaluate pump performance

✓ Replace worn components when necessary

Pump maintenance is critical for overall hydraulic system reliability.

Cause #7: Contaminated Hydraulic Oil

Contaminated oil accelerates wear throughout the hydraulic system.

Common contaminants include:

• Dust
• Water
• Metal particles
• Degraded oil additives

Contamination can damage:

• Seals
• Pumps
• Valves
• Hydraulic cylinders

Solution

✓ Monitor oil condition

✓ Replace filters regularly

✓ Perform oil analysis when appropriate

✓ Maintain proper reservoir cleanliness

Clean oil helps extend the life of hydraulic components.

Cause #8: High Hydraulic Oil Temperature

Excessive heat can damage hydraulic seals and reduce oil performance.

High oil temperatures may result from:

• Cooling system problems
• Dirty heat exchangers
• Excessive machine load
• Hydraulic inefficiency

Solution

✓ Inspect cooling systems

✓ Clean heat exchangers

✓ Verify proper water flow

✓ Monitor operating temperatures

Maintaining correct oil temperature helps prevent premature seal failure.

How Can You Identify the Source of an Oil Leak?

The first step is determining exactly where the leak originates.

Inspect:

Hydraulic Hoses

Look for:

• Cracks
• Wet surfaces
• Damaged fittings

Hydraulic Cylinders

Check:

• Rod seals
• Cylinder bodies
• End caps

Hydraulic Pump

Inspect:

• Pump housing
• Shaft seals
• Connections

Valve Blocks

Check for oil accumulation around valves and fittings.

Cleaning the area before inspection often makes leak detection easier.

Can Oil Leaks Cause Machine Performance Problems?

Yes.

Oil leaks may contribute to:

• Pressure fluctuations
• Slower machine response
• Reduced clamping force
• Increased cycle times
• Higher energy consumption

In severe cases, production quality may also be affected.

How Can Oil Leaks Be Prevented?

Most hydraulic leaks can be prevented through proper maintenance.

Recommended practices include:

Daily Inspection

• Check for visible leaks
• Monitor oil levels
• Inspect hoses

Preventive Maintenance

• Replace worn seals
• Inspect fittings
• Service hydraulic components

Hydraulic Oil Management

• Maintain oil cleanliness
• Replace filters regularly
• Monitor oil condition

Temperature Control

• Maintain cooling systems
• Prevent overheating

Preventive maintenance is usually the most effective way to reduce leakage problems.

When Should a Leak Be Repaired Immediately?

Immediate repair is recommended when:

• Oil is actively dripping
• Hydraulic pressure becomes unstable
• Oil levels drop rapidly
• Safety hazards develop
• Production performance is affected

Delaying repairs often increases maintenance costs.

How DAYAMAC Supports Hydraulic System Maintenance

DAYAMAC, the injection molding machine division of DAYA MACHINERY, supports manufacturers worldwide with:

• Hydraulic system spare parts
• Hydraulic hoses and fittings
• Seals and repair components
• Hydraulic pumps
• Maintenance consultation
• Technical support

Our team helps customers reduce downtime, improve hydraulic system reliability, and extend machine service life.

Common Questions

Is a small hydraulic oil leak a problem?

Yes. Even small leaks may indicate developing hydraulic system issues and should be inspected promptly.

What is the most common cause of oil leakage?

Worn seals and aging hydraulic hoses are among the most common causes.

Can hydraulic oil leaks reduce machine performance?

Yes. Leaks can cause pressure loss, slower response, and reduced efficiency.

How often should hydraulic hoses be inspected?

Hoses should be visually inspected during routine maintenance and daily machine inspections.

Can preventive maintenance prevent most oil leaks?

Yes. Regular inspections, seal replacement, and hydraulic system maintenance can prevent many leakage problems.

Contact DAYAMAC

Looking for hydraulic system spare parts or maintenance support?

DAYAMAC provides:

• Hydraulic hoses and fittings
• Seals and repair kits
• Hydraulic components
• Technical consultation
• Spare parts sourcing
• Injection molding machine maintenance support

Contact our team to keep your injection molding machines operating efficiently and leak-free.

Communication is key. **Immediately stop installation and contact us with photos/videos.** If the issue is verified as a supplier quality or specification error on our end, we will arrange and cover the cost of a replacement part as quickly as possible. Our goal is to minimize your downtime. Clear and prompt communication from your side helps us resolve any issue efficiently.

question: oil pump sound too big after period production

daya machinery:  possible reason as below:

1. filter net has dirty.   solution: clean filter and change the hydraulic oil.
2. quality of sutionoil pipe is poor.  solution: check and change the suction oil pipe, filter net, hydraulic oil.
3. oil pump worn out .   solution: check and change if need

Question: temperature control failure

daya injection molding machine:  below possible reasons:

1. temperature control gauge is wrong.   solution: measure it by multimeter, change it if need
2. thermocouple is wrong.  solution: check the thermocouple of each heating section.  and change it if damaged
3. during charging, the screw and barrel are too hot to make the heating band broken.    solution:  meansing the heating band, change it if damaged

Question: machine work without force

daya injection machine: below possible reasons:

1. The relief valve blocked and often release oil .    solution: Check relief valve and Clean the valve
2. oil seal ring wear out .  solution:Check each oil cylinder, piston and oil seal ring or change
3. oil pump wear out.   solution: remove oil pump, check and change if need
4. preportion valve wear out.   solution: Check and Change proportion valve

question: no movement of machine

daya machine: below possible reasons:

1.  Amplificatory board no output.  solution: Measure output voltage of amplificatory board, and if no voltage, change the board.
2. fuse burn out.  solution: Check or change connecting fuse
3. oil pump’s motor rotation reversion.  solution: Exchange two phase
4. join device between oil pump and motor.   solution:After switch off change it
5. pressure valve blocked no pressure.  solution:Clear pressure valve, and change hydraulic oil and filter
6. 24V power wire broken.  solution:Measure and reconnect them
7. oil pump motor burn out and not start.   solution: Measure motor winding by multimeter and Change motor
8.  Oil pump is wrong, not retraction oil and increase pressure.   solution:remove oil pump, check and change it if need
9. Be wanting one phase at three-phase of electricity power.   solution:  check the main electric supply.

question: the action of machine too slow

daya injection machine: below possible reasons:

1. current set fail.   solution: Check current of flow and pressure and reset it
2. flow valve blocked.  solution:Clean flow valve
3. system pressure too low.  solution:  adjust system pressure

question: the injection machine shakes greatly

daya injection molding machine: below possible reasons:

1. fixed bolt of main motor loose.   solution: Tighten the bolts
2. body and guide of machine not leveling.    solution: Adjust the parallelism and horizontal.

question: Flow and pressure do not proportion

daya injection machine: possible reason as below:

1. voltage transformer connected bad.    solution: Measure transformer output by multimeter or reconnect it
2. wiring wrong.   solution: Measure connecting wire point by multimeter and reconnect it
3. number control grid weld fails .  solution: Measure connecting wire point by multimeter and weld it again.

Question: pressure and oil temperature too high

DAYA injection machine: there may be below possible reasons:

1. the hydraulic oil leveling inside the oil tank is too low.  solution:  filling enough hydraulic oil
2. the pressure is too high at no load condition.  solution： set pressure at 1.5Mpa at no load
3. water temperature is too high.  solution: Clean water scale and add water flow capacity or clean water

Question: full automatic operation failure

daya injection molding machine:  possible reasons as below

1. sensor is failure or fixed bolts loosen.    solution：Fix the sensor’s bolt well or change it
2. time relay failure or damaged.  solution： Check time relay and change it
3. thermocouple connect poor or damage .  solution ： Change or reconnect it
4. Heating ring damaged   solution: Change it
5. temperature gauge damaged.   solution: Check and change it

Question: semi automatic operation failure

daya molding machine:

electricity switch or time relay no working .  solution: Find fault according to action diagram or change electricity part

question: the machine can only do injection only at semi-auto operation

daya injection machine: Injection time relay is wrong. solution: Check the time relay and change one

question: barrel temperature exceed setting value

daya injection molding machine:   there may be low possible reasons:

1. screw rotation speed too fast.  solution: Adjust the screw speed
2. backpressure too high.  solution: decrease the backpressure
3. screw and barrel worn.   solution ： check and change
4. temperature setting improper.  solution: check and reset
5. the temperature at plastic cutting too high (specially ABS).   solution: Adjustment screw rotation peed and backpressure lower

Question: no injection at semi automatic operation

Daya injection machine ：  there are possible reasons:

1. The platen do not clamp to end at the carriage forward end.  solution：check the limit switch and connect the wire
2. wire broken.  solution: reconnect it
3. relay inserted wrong.  solution:   the relay insert correctly
4. no zero on the PLC.  solution:  reset the 0 position on the panel.
5. time relay is damaged.  solution: change it.

question: screw can’t mix color well

daya injection machine:  possible reasons as below:

1. material has problem.  solution: change it.
2. temperature too low.  solution: increase the heating temperature
3. back pressure too low.   solution: increase it
4. screw rotating speed twoo low.   solution: add the speed
5. diffuse quanity of oil is too small.  solution:  add them

Question: black points on the product

Daya machinery:  there may be below reasons:

1. There are old material left over on the screw.   solution: Clean and polishing screw
2. There are some old material left over on the barrel, or accessory hasn’t clean.  solution: Clean accessory and polishing barrel
3. Some parts are dirty and rust such as suck off ring, thrust ring screw tip, material cylinder.   solution：Clean, polish and change them
4. Have old material left over on the flange and nozzle.  solution: Clean, polish and change them
5. Temperature is too high, backpressure of charging is too high.   solution: Check each section temperature, and fall down, decrease backpressure.
6. raw material are dirt.  solution: check and change them

question: back-pressure not set at plasticizing

daya machinery:

Bad back-pressure valve.  solution: Clean back pressure valve or change it

Question: The noise of beginning plasticizing is loudly

daya machinery:

1. Exchange fast/low speed over fast.   solution: Raise backpressure or increase injection section step  or Raise holding pressure, add plasticizing time

Question: The noise of injection loudly at beginning injection

daya machinery:    there may be below reasons:

1. beginning speed of injection too quick.  solution： Adjustment setting value on the menus
2. backpressure too high.   solution: decrease the back pressure
3. there is air inside the oil circuit.   solution:  exhaust the air.

question: injection machine’s carriage do not moves

DAYA MACHINEY: there may be below reasons:

1. .piston bar broken.   solution: Remove locking nut and change piston bar
2. direction valve of carriage moving is no working.   solution: Check and clean it if blocked
3. Electricity wire disconnected.   solution: change the coil of solenoid valve or connect wire

Question: injection machine no charge

DAYA MACHINEY:  there may be below reasons:

1. back-pressure valve damaged or back-pressure too high.  solution: Change backpressure valve or adjust pressure lower
2. the cooling water of barrel are not enough, temperature of hopper is too high.   solution:Clear plastic block feel in the hopper, in the barrel, increase cooling water capacity.
3. no material in the hopper.   solution: Check and charge the material
4. screw and barrel wore out.   solution: Check and change it

Question: machine can’t inject

DAYA MACHINERY:

1. Coil of solenoid valve is burned.  solution:  check and change it.
2. valve core blocked by dirty thing.  solution:  clean it or change the solenoid valve
3. pressure of injection is too low.    solution: set injection pressure
4. the temperature of material barrel is too low.    solution: check, change fuse and reset temperature of material barrel
5. piston seal of injection cylinder is damaged.   solution: check seal ring and change it
6. shut off ring broken .   solution:  check and change the ring
7. nozzle blocked.   solution: clean nozzle or change it

Question: The hydraulic motor oscillating at plasticizing

DAYA MACHINERY: there may be below reasons:

1. gearing damaged.  solution: change gearing
2. setting clearance between gearing improper.  solution：Check transmission shaft shaking or not at plasticizing, reset the clearance.
3. screw distortion。 solution:If screw bend change screw
4. copper bushing of carriage wear out heavily.  solution: Check copper bushing and leader and change them

Question: the sound is too high when opening mold

DAYA MACHINERY:  there may be below possible reasons:

1. Lubricates of clamping structure are worse.  solution: Check steel sleeve and shaft with locking, if wear out, change it.
2. clamping force is too large.   solution: Adjust suitable clamping force.
3. Parallel between fixed mold platen and moving platen platen is bad. Set moving platen and improve mold parallelism
4. exchange time is too short from low  speed to quick speed. Solution: add Propriety opening mold time

Question: can’t adjust mold height

DAYA MACHINERY: there may be below reasons:

1. The clearance between pressing lid of adjusting nut and nut is too small. solution: Adjustment the clearance between lid and nut
2. screw thread of mold-adjust nut gnaws dead.   solution: Change nut, or repair the screw
3. the slider of moving platen moves too heavy.  solution: Adjustment moving slider  again
4. The motor used for adjusting mould does not work.  solution: Check the valve of  mold adjustment, if bad change or repair it
5. proximity switch, relay and contactor are burned.   solution: Check 3-phase voltage, and change these parts
6. the wire interrupt or connect bad.  solution: Check control wire and each contact, then reconnect

Question:Can’t control to open mould fastly or slowly

DAYA MACHINERY:The Relay on program plate is wrong.  Solution: Change relay

Question: mold clamping blocked

DAYA MACHINERY: there may be air in the oil circuit.  solution:  exhaust the air

Question:only have speed and no pressure at clamping

DAYA MACHINERY: High pressure stroke switch does not work.   solution: Check the switch and repair or change it

Question: high pressure mold clamping not work

DAYA MACHINERY: it is because the set of mold height improper.  solution: Adjustment moving platen forward

Question: the moving mold platen don’t close during mold closing

DAYA MACHINERY: Wire connecting error.   solution:Check and reconnect them

Question: the mold auto open slowly at other operation after clamping

DAYA MACHINERY: Opening mold valve is leakage.  Solution: Change opening mold valve

Question: big oil pump do not unload

DAYA MACHINERY:  there may be below possible reason:

1. hydraulic valve blocked.  solution: Clean pressure valve or reconnect
2. unloading time too short.  solution: Extend unloading time
3. Speed and pressure of unload too small or nothing.    solution:Raise speed and pressure of discharge

Question: Fault of adjustment mould counter

DAYA MACHINERY: there are possible below situation:

1. proximity switch is bad.  solution: Change switch, setting position
2. adjusting mold travel time too short.   solution: Adjusting molds stroke time.
3. adjustment nut blocked.  solution: Change burned parts and set clearance of adjustment mold nut

Question: creeping of opening and closing mold

DAYA MACHINERY:  there may be 3 possible reasons.

1, Leader supported moving platen and tie bars wear out heavily. solution: Change wears out parts and often lubricate machine.

2, Level and vertical between two platens.   solution:  Setting leader levelly.  or Adjust slide of moving platen to make tie bar straight.

3.the opening mold speed and pressure setting data are wrong.  Solution: Exhaust air gas. or Adjust flow and pressure proportional.  or Set current data of proportion valve.

Question：how many kinds of injection molding machine

DAYA MACHIENRY:

According to the shape; vertical, horizontal, “the two most commonly used” are divided into: ultra-small injection molding machine, small injection molding machine, medium-sized injection molding machine, large injection molding machine, super large injection molding machine. That is, the injection volume ranges from a few milligrams to several tens of kilograms, and is divided into several parts to several thousand tons according to the clamping force.

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Question: How to avoid sink mark when molding plastic products?

DAYA MACHIENRY: Instead it is part thickness distribution with respect to injection point (gate) towards the extreme point on the melt flow path i.e, last fill point. A good injection molding part thickness should always decrease (not uniform) along the flow path and that thickness decrease magnitude is the prime factor responsible for sink marks.

Basically injection (processing) pressure and temperature are primarily polymer and then mold and machine dependent. i.e., injection melt state variables., So part form / features have very less to do with setting injection melt state.However a good control to prevent sinks can be achieved by increasing packing intensification rate, this technique can considerably compensate thickness distribution variance also, which is quite often.

Question:How to make plastic parts look like metal?

DAYA MACHINERY: Like most processes, making plastic parts look like metal can be done poorly or well, and can be appropriate or not. If you want to look at some really beautiful metal coated parts, check out some of the bathroom and kitchen fixtures at your local Home Depot, Lowe’s, etc. This requires specific material and design skill, but these parts are durable, wear reasonably well and look just like, particularly, chromed metal, in part because those items are chrome-plated.

As with any project, the hard part is to define as closely as possible what it is you want: Does it have to “sort of look like metal,” does it have to look like a mirror, does it need to look like brushed stainless, etc., and how much abrasion, temperature resistance (e.g. will it sit on the top of a car dashboard where it could get to 180F), does the metal in the metallic look have to contribute anything other than aesthetics (e.g. conductivity)? The more time you spend closely defining the parameters, the better chance you have for success.

Question: machine can’t make the good product stably

DAYA MACHINERY:

In a stable production cycle, if the quality of the finished product is unstable, which may be caused by wear or improper adjustment of the mechanical parts.

1. Wear of screw, check ring and barrel.
2. The inner seal of the injection cylinder is damaged and internal leakage occurs.
3. The temperature control of the heating cylinder is unstable.
4. The pressure and speed control are partially abnormal.

Abnormal noise occuring indicating that parts are damaged or improperly adjusted. The cause should be repaired according to the location of the noise.

1. The hydraulic oil in the fuel tank is insufficient. The suction of the oil pump or the dirt of the oil filter will cause the oil pump to be short of oil, causing the air bubbles in the oil to leak and hit the blade to generate noise. The solution is to check the oil quantity and prevent the air from being inhaled. Clean the oil filter.

2. The viscosity of the hydraulic oil is high, and the flow resistance is increased. It is necessary to replace the suitable hydraulic oil.

3. Due to the damage of the bearing or blade of the oil pump or motor, the concentricity deviation of the coupling causes noise, and the concentricity or replacement parts must be adjusted.

4, the directional valve reaction is not effective but the function is still, such as valve core wear, internal leakage, burr blocking, movement is not flexible, solenoid valve failure due to insufficient current will also produce noise. The solution is to clean the valve core, the valve core must be replaced with new parts, and the current must be stable and sufficient.

5. The hydraulic components are damaged or the oil pipelines are blocked, causing noise when the hydraulic oil flows at high speed.

6. If the mechanical part is faulty, the bearing is worn or the machinery lacks lubricating oil or the parts are loose, the reason should be found to tighten or replace the parts to ensure sufficient lubricating oil.

An abnormal rise in oil temperature may be caused by an abnormality in the cooling system or high heat generated by the hydraulic components during operation.

1, the cooling system is not normal

1) Insufficient supply of cooling system, such as insufficient water opening, insufficient water pressure or pump flow does not meet the needs.
2) Blockage of pipes, such as filters, cooling towers or water pipes.
3) The cooling water temperature is too high, such as the cooling tower cooling capacity is insufficient, or the damage or the temperature is too high.

2, the hydraulic system produces high heat

1) The oil pump is damaged, and internal parts are worn at high speed to generate high heat.
2) The pressure regulation is not proper, and the hydraulic system is in a high pressure state for a long time and is overheated.
3) Internal leakage of the hydraulic components, such as damage to the directional valve or damage to the seal ring, causes heat to be generated when the high pressure oil flows through the small space.

(1) According to different load requirements, always check and adjust the pressure of the relief valve to make it just right.

(2) Reasonable selection of hydraulic oil, especially oil viscosity, when conditions permit, try to use a lower viscosity to reduce viscosity friction loss.

(3) Improve the lubrication condition of moving parts to reduce friction loss, which is beneficial to reduce working load and reduce heat generation.

(4) Improve the assembly quality and accuracy of the hydraulic components and hydraulic system, strictly control the matching clearance of the fittings and improve the lubrication conditions. The sealing material with low friction coefficient and the improved sealing structure are used to reduce the starting force of the hydraulic cylinder as much as possible to reduce the heat generated by the mechanical friction loss.

Question: why machine alarm – high hydraulic oil temperature

1.  The fuel tank volume is too small, the heat dissipation area is insufficient, and the cooling device has a small capacity.
2. The dosing pump oil supply system that selects the pump capacity according to the fast-forward speed, during operation, most of the excess flow will overflow from the overflow valve under high pressure and generate heat.
3. The unloading circuit in the system is faulty or the unloading circuit is not set. When the pump stops working, the oil pump cannot be unloaded. The entire flow of the pump overflows under high pressure, causing overflow loss and heating, resulting in temperature rise.
4. The system piping is too long and too long, too much bending, partial pressure loss and large pressure loss along the path.
5. The component accuracy is insufficient and the assembly quality is poor, and the mechanical friction loss between the relative movements is large.
6.  The matching clearance of the fittings is too small, or the wear is too large, resulting in excessive clearance, and the internal and external leakage is large, resulting in volume loss, such as the volumetric efficiency of the pump is reduced, and the temperature rise is fast.
7. The hydraulic system working pressure is adjusted much higher than the actual needs. Sometimes it is necessary to increase the pressure to work because the seal is too tight, or because the seal is damaged or the leak is increased.
8. The temperature of the gas and working environment is high, causing the oil temperature to rise.
9. Selecting the viscosity of the oil is improper, the viscosity is large, the viscous resistance is large, and the viscosity is too small, the leakage is increased, and both cases can cause the heat rise.

Quesiton: Injection moulding machine can’t close the mold

DAYA MACHINERY:

1.  check the front travel switch of safety door and repair it.
2. check the 24V5A power in the electric box, replace the insurance and the power box.
3.  check whether the spool is stuck, clean the spool.
4. check the I/O board has output or not,weather the magnetic valve is open or not.
5. check whether the hydraulic safety switch is closed, whether the mechanical lock rod is opened or not.

solution:

 1): starting speed is slow, check the screw damping ,wheher it is too big, adjust to use  screw with small damping hole.

2): damping screw middle hole too big, check the Y screw hole damping is too large or not,change for damping nail with smaller center hole  .

Handling method:

1)check whether the lubricating oil pipe is cut off , if so, reconnect the tubing pipe.

2): small amount of lubricating oil, increase lubricating oil amount , add once at 50 mold open-close circle,or manually add lubricating oil.

3): clamping force over large, check whether the mold needs large clamping force, lower the clamping force.

4): the current fluctuation of the amplifier board, check whether the current parameters meet the acceptance criteria, re adjust the current value.

5): parallelism error,use  indicator to check head board parallelism to make sure it’s  greater than the acceptance criteria or not; adjust the parallelism.

Processing method:

1): increase the speed of the mold open-close, the pressure and flow is too small, not adjusted, check the speed of the mold open-close, the pressure is appropriate or not, increase the pressure and speed of the mold open-close.

2): The electronic ruler in clamping unite is zero change, check the ruler,whether it is stop in the zero position or not, re adjust the electronic ruler into zero position.

3) check whether it is anti- hinge.