Maintenance Troubleshooting

For your convenience, we offer quick troubleshooting guides below to assist with
common maintenance problems that may arise with a press.

For any problems not listed here, please contact the service department
at service@usmolding.com or call (440) 918-1701

  • Reset light curtain (If installed)
  • Check that the three Emergency Stop switches are released
  • Check that the control power is on (120 VAC ON Lamp), on newer presses this lamp is blue, press the blue lens to turn on control power
  • Check overload relay on hydraulic motor starter and reset if require

  • Hydraulic pump must be running
  • Gates & guards must be closed and switches activated
  • Light Curtain (If installed) must be reset, and not blocked, indicated by green light on
  • If no light curtain is installed or is Bypassed; two cycle start buttons or Top Cycle Start and an applicable function button must be pressed
  • Output enable switch must be on (If installed)
  • Top platen must be locked
  • Hydraulic oil must be full and not over temperature (Fault light on steady) unless in Set-up mode

  • General
    • See items 1 & 2 above
    • Pressure column must be out and proximity switch made
    • Check the clamp open position on the Clamp Setup Screen, Clamp must be above (less than) the open position to move down
    • Must use Inch Open and Top Cycle Start pushbuttons without light curtain
  • Semi-Auto Mode
    • If the machine has Light Curtains and they are manually disabled, you must use the Top Cycle Start and Inch Open pushbuttons to open the clamp
    • If Cycle Stop switch is on (Illuminated at the end of the cycle) you must use the Inch Open (and Top Cycle Start, if Light Curtain is not installed or active) pushbutton(s)

  • General
    • See items 1 & 2 above
    • Pressure column must be out and proximity switch made
    • Pressure column "In", proximity switch must not be made
    • If equipped, mold core shuttle must be in and proximity switch must be made
    • If equipped, top ejectors must be at or above the "Up" position as set
    • If using the Top and Bottom Cycle Start Pushbuttons, they must be pressed simultaneously
    • Check the Clamp Set-Up screen and check the Clamp Pressure and flow values
  • Semi-Auto Mode
    • Mold must be fully open, see clamp setup screen
    • If equipped with light curtains, the parts must be removed, or the light curtains broken between cycles
    • If purge limit is greater than zero, you must first purge the inject to close the clamp

  • See items 1 & 2 above
  • Hydralock Selector switch must be on
  • Hold the Cycle Start Switch(es) until the pressure column move in
  • Hydralock must be collapsed and collapsed proximity switch must be on
  • Clamp must be at or above "Closed" position as set on Clamp Set-Up Screen
  • In Semi-Auto Mode the inject barrel must be full to the preset volume to enter the cycle

  • See items 1 & 2 above
  • Hold the Cycle Start Switch(es) until the pressure column move in
  • Hydralock must be collapsed and collapsed proximity switch must be on
  • Clamp must be at or above "Closed" position as set on Clamp Set-Up Screen
  • In Semi-Auto Mode the inject barrel must be full to the preset volume to enter the cycle
  • If Cycle Stop switch is on (Illuminated at the end of the cycle) you must use Inch Open and, (If light curtain option is not installed), the Top Cycle Start pushbuttons
  • On older presses: If the light curtain is disabled, then on the first cycle after selecting Semi-Auto Mode you must manually open the press as if the Cycle Stop were engaged (see above)

  • After changing a mold always turn the Hydralock Selector "off"
  • Check and adjust the "Mold Closed Position" on the Clamp Set-Up Screen
  • Visually check the adjustment of the Hydralock spacers and/or the Hydralock adjustment screw, adjust as applicable
  • Disconnect the Pressure Column In proximity switch
  • Turn the Hydralock Selector "On"
  • Raise the clamp, and observe that the pressure column comes in when the clamp reaches the closed position
  • Check that the gap does not exceed 1/4", adjust as required
  • Retract the pressure column
  • Re-connect the Pressure Column in proximity switch
  • WARNING: Do not allow the Hydralock to extend more than 5/8" or damage will result

  • Check that the guards and light curtain (if equipped) are closed and made
  • Check that the Output Enable switch (if equipped) is on
  • Check to see if the Cycle Stop Switch is on and illuminated

  • Hydralock speed or pressure set too low on Clamp Set-Up screen
  • If Inject Transfer Mode is on, Hydralock will not expand until Inject and Dwell are done
  • Hydralock pressure switch is already on, or analog pressure sensor is indicating set pressure
  • The pressure column must be in and both proximity switches must be made
  • Hold the Cycle Start Pushbutton(s) until the Hydralock expands

  • Hydralock speed or pressure set too low on Clamp Set-Up Screen
  • In Inject Transfer Mode the Hydralock will continue to expand until the "Transfer Time" set on the Auxiliary Options Screen has expired
  • The Hydralock pressure as set on the Clamp Set-Up Screen is below the set point of the Hydralock Pressure Switch or the Hydralock Pressure Transducer, raise the Hydralock pressure

  • The Screw Lifting Arm must be down and the Screw Arm Down Proximity switch must be on
  • Screw motor must be off and/or Inject volume must be full before auto injecting
  • Mold is not in the "closed" position
  • Inject set volume must be more than zero
  • Hydralock collapsed proximity switch must be off
  • Hydralock Safety proximity switch must be off
  • The Pressure column must be in and the two proximity switches must be made
  • The Hydralock pressure as set on the Clamp Set-Up Screen is below the set point of the Hydralock Pressure Switch or the Hydralock Pressure Transducer, raise the Hydralock pressure
  • The Hydralock pressure as set on the Clamp Set-Up Screen is above the set point of the Hydralock Pressure Switch or the Hydralock Pressure Transducer, raise the Hydralock pressure or correct the overpressure condition, check for double-inject
  • For Automatic injection the Semi-Auto mode must be selected
  • If the press is not in Inject Transfer Mode the Hydralock Pressure set point must be satisfied before injection will start
  • Check the 1st stage inject pressure and speed
  • If the 2nd stage inject volume is not zero, then check the 2nd stage inject pressure and speed
  • If no light curtain is installed or it is manually disabled, the Bottom Cycle Start and the Manual Inject pushbuttons must be used
  • If a vacuum time has been set on the Auxiliary Options Screen, injection will not start until the vacuum time has expired
  • The Purge Inject (Manual Inject) pushbutton will only work when the Clamp is in the Open position
  • If the Purge Limit on the Main Operation Screen is not zero, the Purge Inject Pushbutton will be disabled after the preset volume is purged and will not be enabled until the next cycle or the mode is changed to Setup

  • Mode selector must be in Setup mode
  • The Screw Lifting Arm must be down and the Screw Arm Down Proximity switch must be on
  • Pressure and flow may be too low to move the plunger, try adjusting the manual System Pressure and System Flow controls while holding the Plunger Retract Pushbutton

  • Inject volume is above the set point
  • Inject volume is above the maximum volume
  • Feed port alarm is active, no stock in feeder (Screw motor will run for 10 sec. each time the Jog Screw is pressed in Semi-Auto)
  • With the Screw in the normal position, the Screw Arm Down and the Jog Safety Proximity switches must be made
  • With the Screw in the clean-out (or lifted) position, the Screw Arm Down and the Jog Safety Proximity switches must not be made
  • Screw set speed too slow
  • Screw temperature too cold for rubber compound
  • In Semi-Auto with the Screw Reload switch on and with the screw start option on the Auxiliary Options Screen set to "Screw Start After Inject", the screw should start after the Dwell Timer finishes, the Screw Delay Timer Finishes and the Cure Timer Starts

  • With the Screw in the normal position, the Screw Arm Down and the Jog Safety Proximity switches must be made

  • Gates & guards must be closed and switches activated
  • Light Curtain (If installed) must be reset, and not blocked, indicated by green light on
  • Press must be in Set-Up Mode
  • Select the Top Platen Up, if Light Curtain is not installed, also press the Bottom Cycle Start Pushbutton

  • Gates & guards must be closed and switches activated
  • Light Curtain (If installed) must be reset, and not blocked, indicated by green light on
  • Press must be in Set-Up Mode
  • If equipped with Hydraulic Top Platen Locks, select Unlock Top Platen, light should blink when locks have retracted
  • Check the Top Platen Unlocked proximity switch
  • With manual Top Platen Locks, pull locking bar completely out
  • Select the Top Platen Down, if Light Curtain is not installed, also press the Bottom Cycle Start Pushbutton