Assembly Manual Hylectric Machines

Chapter 1 Machine Leveling (Mono Base)

NOTE: All parts of the MACHINE must be installed onto the BASE reference
the Assembly Instructional Procedures.

Leveling Pads

NOTE: Check the area for cleanliness where

the leveling mounts are positioned.
Clean all oil, grease, and wax buildup.
2 Heavily coated areas should be
scraped or sanded back to bare
concrete.
1 1. Ensure that the LEVELING PADS are in the
proper orientation.
NOTE: Labels must face outwards and the
PADS are in the direction of the mold
stroke column movement.
3
2. Loosen off the locknuts.
3. Preload all of the LEVELING PADS.
NOTE: The mount pads should protrude
3mm (0.125 in) from the bottom of the
MOUNT HOUSING. However, due to
floor irregularities, this condition may
only be set at the highest floor level.

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 Hylectric Machines

Moving Platen Position

1. Position the MOVING PLATEN to maximum

shut height.
2. The table below indicates the distance
between the STATIONARY PLATEN and the
MOVING PLATEN.

Maximum Shut Height Chart

Machine Max. Shut Machine Max. Shut

Sizes Height Sizes Height

H90 500mm HL90 700mm

H120 550mm HL120 750mm

H160 HL160

H225 660mm HL225 900mm

H300 750mm HL300 1000mm

H400 850mm HL400 1100mm

H500 950mm HL500 1200mm

H650 1100mm HL650 1400mm

H800 1200mm HL800 1500mm

H1000 1300mm HL1000 1600mm

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Assembly Manual Hylectric Machines

Level Positioning
6
1. Position the V-blocks on the RAILS or the
BASE at the STATIONARY PLATEN end.
NOTE: The location of the “V-Blocks”
depends upon the space between the
STATIONARY PLATEN and the
RAILS.
2. Position the “Straight Edge” across the “V-
4 Blocks”.
3. Place the “Precision Level” across the BASE
on the “Straight Edge”.
4. Place the “Precision Level” length ways on the
4 RAILS or BASE.
5. Center the “Precision Level” between the
MOVING and the STATIONARY PLATENS.
1 Also between the MOVING and the CLAMP
PLATENS.
3
6. Place a “Precision Level” on the machined
pad on the INJECTION end.

Level Adjustment (Length

Ways)

1. Adjust one side of the BASE, along it’s length,

from the CLAMP end to the INJECTION end.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
3. Turn the bolt of the PADS to raise and lower
the machine as needed.
NOTE: The use of a PANCAKE JACK may be
required for heavier machines.
4. Check the level of the machine and ensure
that the level is within tolerance 0.10mm /
meter (0.001in/ 10") at the CLAMP end and
0.8mm / meter (0.008 in/10") at the
INJECTION end.
5. Level the other side of the BASE then check
and readjust the first side.
3 NOTE: Make sure that both sides are level
first before continuing to level cross
ways.

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 Hylectric Machines

Level Adjustment (Cross

Ways)

1. Check the level on the “Straight Edge” with the

“Precision Level”.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
3. Adjust all PADS on one side evenly to achieve
the proper level within a tolerance of 0.10mm /
meter (0.001in / 10").
NOTE: The use of a PANCAKE JACK may be
required for heavier machines.
4. Recheck the level length ways and adjust as
required.
NOTE: Both length ways and cross ways
must be level before leveling is
achieved.

Level Achieved

NOTE: When Length ways and Cross ways are

within tolerance, level is achieved.
1. Once level is achieved, tighten all locknuts.
2. Check the “Precision Level” to determine the
1 level is still within tolerance.
3. Return all Precision Levels back to the
appropriate locations.

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Assembly Manual Hylectric Machines

Chapter 2 Machine Leveling for Assembly (Split

Base)
NOTE: All parts of the MACHINE must be installed onto the BASE reference
the Assembly Instructional Procedures.

Leveling Pads

NOTE: Check the area for cleanliness where

the leveling mounts are positioned.
Clean all oil, grease, and wax buildup.
Heavily coated areas should be
scraped or sanded back to bare
concrete.
1. Make sure that the LEVELING PADS are in
the proper orientation.
NOTE: Labels must face outwards and the
PADS are in the direction of the mold
stroke column movement.
2. Loosen off the locknuts.
3. Preload all of the LEVELING PADS.
NOTE: The mount pads should protrude
3mm (0.125 in) from the bottom of the
MOUNT HOUSING. However, due to
floor irregularities, this condition may
only be set at the highest floor level.

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 Hylectric Machines

Moving Platen Position

1. Position the MOVING PLATEN to maximum

shut height.
2. The table below indicates the distance
between the STATIONARY PLATEN and the
MOVING PLATEN.

Maximum Shut Height Chart

Size of Max. Shut Size of Max. Shut

Machines Height Machines Height

H90 500mm HL90 700mm

H120 HL120
550mm 750mm
H160 HL160

H225 660mm HL225 900mm

H300 750mm HL300 1000mm

H400 850mm HL400 1100mm

H500 950mm HL500 1200mm

H650 1100mm HL650 1400mm

H800 1200mm HL800 1500mm

H1000 1300mm HL1000 1600mm

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Assembly Manual Hylectric Machines

Level Positioning (Clamp End)

4 1. Position the “V-Blocks” on the Rails or the
BASE at the STATIONARY PLATEN end.
2. Position the “Straight Edge” across the “V-
Blocks”.
3. Place the “Precision Level” across the BASE
on the “Straight Edge”.
4. Place the “Precision Level” length ways on the
RAILS or BASE.
4
5. Center the “Precision Level” between the
MOVING and the STATIONARY PLATENS.
Also between the MOVING and the CLAMP
PLATENS.
1 3

Level Adjustment (Length

Ways)

1. Adjust one side of the BASE, along it’s length,

from CLAMP end to the STATIONARY end.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
3. Turn the bolt of the PADS to raise and lower
the machine as needed.
4. Check the level of the machine and make sure
that the level is within a tolerance of 0.10mm /
meter (0.001in/ 10").
3 5. Level the other side then check and readjust
the first side.
NOTE: Make sure that both sides are level
first before continuing to level cross
ways.

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 Hylectric Machines

Level Adjustment (Cross

Ways)

1. Check the level on the “Straight Edge” with the

“Precision Level”.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
NOTE: Adjust all PADS on one side evenly to
achieve the proper level within a
tolerance of 0.10mm / meter (0.001in /
10").
3. Recheck the level length ways and adjust as
required.
4. Both length ways and cross ways must be
level before leveling is achieved.

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Assembly Manual Hylectric Machines

Chapter 3 Machine Leveling for Integration (Split

Base)
NOTE: Make sure that the Electrical cabinet and the Power pack are
disconnected from the Injection Base prior to leveling the BASE for
integration.

Integration Assembly

1. Loosen off the bolts that attach the

INJECTION BASE to the CLAMP BASE.
2. Measure the GAP between the INJECTION
6 BASE and the CLAMP BASE.
3. If the GAP is not equal proceed to the next
step. If they are equal proceed to LEVELING
PADS.
4. Torque the bolts and lift the CLAMP at the
STATIONARY PLATEN end slightly.
5. Lower the Machine and loosen the bolts.
6. Measure the GAP between the INJECTION
BASE and the CLAMP BASE.
7. Make sure that the GAPS are equal.
NOTE: The difference between both sides
should not be greater than 0.05 mm.
8. If the GAPS are not equal repeat steps 4 to 6.

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 Hylectric Machines

Leveling Pads

NOTE: Check the area for cleanliness where

the leveling mounts are positioned.
Clean all oil, grease, and wax buildup.
Heavily coated areas should be
scraped or sanded back to bare
concrete.
1. Make sure that the LEVELING PADS are in
the proper orientation.
NOTE: Labels must face outwards and the
PADS are in the direction of the mold
stroke column movement.
2. Loosen off the locknuts.
3. Preload all of the LEVELING PADS.
NOTE: The mount pads should protrude
3mm (0.125 in) from the bottom of the
MOUNT HOUSING. However, due to
floor irregularities, this condition may
only be set at the highest floor level.

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Assembly Manual Hylectric Machines

Moving Platen Position

1. Position the MOVING PLATEN to maximum

shut height.
2. The table below indicates the distance
between the STATIONARY PLATEN and the
MOVING PLATEN.

Maximum Shut Height Chart

Size of Max. Shut Size of Max. Shut

Machines Height Machines Height

H90 500mm HL90 700mm

H120 HL120
550mm 750mm
H160 HL160

H225 660mm HL225 900mm

H300 750mm HL300 1000mm

H400 850mm HL400 1100mm

H500 950mm HL500 1200mm

H650 1100mm HL650 1400mm

H800 1200mm HL800 1500mm

H1000 1300mm HL1000 1600mm

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 Hylectric Machines

Level Positioning (Clamp End)

4 1. Position the “V-Blocks” on the Rails or the
BASE at the STATIONARY PLATEN end.
2. Position the “Straight Edge” across the “V-
Blocks”.
3. Place the “Precision Level” across the BASE
on the “Straight Edge”.
4. Place the “Precision Level” length ways on the
RAILS or BASE.
4
5. Center the “Precision Level” between the
MOVING and the STATIONARY PLATENS.
Also between the MOVING and the CLAMP
PLATENS.
1 3

Level Adjustment (Length

Ways)

1. Adjust one side of the BASE, along it’s length,

from CLAMP end to the STATIONARY end.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
3. Turn the bolt of the PADS to raise and lower
the machine as needed.
NOTE: The use of a PANCAKE JACK may be
required for heavier machines.
4. Check the level of the machine and make sure
that the level is within a tolerance of 0.10mm /
meter (0.001in/ 10").
5. Level the other side then check and readjust
the first side.
3 NOTE: Make sure that both sides are level
first before continuing to level cross
ways.
6. Check the interconnection bolts while levelling
to ensure that they are loose.

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Assembly Manual Hylectric Machines

Level Adjustment (Cross

Ways)

1. Check the level on the “Straight Edge” with the

“Precision Level”.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
NOTE: Adjust all PADS on one side evenly to
achieve the proper level within a
tolerance of 0.10mm / meter (0.001in /
10").
3. Check the interconnection bolts from time to
time while levelling and ensure that they are
loose.
4. Recheck the level length ways and adjust as
required.
NOTE: Both length ways and cross ways
must be level before leveling is
achieved.
5. Make sure that the bolts that attach the
INJECTION BASE to the CLAMP BASE are
able to move freely.

Level Positioning (Injection

2
End)

1. Position the “Precision Level” on the RAILS.

2. Position the large “Precision Level” across the
RAILS.
1 NOTE: Make sure that the levels are
positioned at the end closest to the
STATIONARY PLATEN.

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 Hylectric Machines

Injection Leveling (Length

Wise)

1. Adjust one side of the BASE, along it’s length,

from GEAR BOX end to the STATIONARY
PLATEN end.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
3. Turn the bolt of the PADS to raise and lower
the machine as needed.
NOTE: The use of a PANCAKE JACK may be
required for heavier machines.
4. Check the level of the machine and ensure
that the level is within a tolerance of 0.8mm /
meter (0.008in/ 10").
5. Check the interconnection bolts while levelling
to ensure that they are loose.
6. Level the other side then check and re-adjust
the first side if necessary.
NOTE: Make sure that both sides are leveled
before continuing to level cross ways.

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Assembly Manual Hylectric Machines

Injection Leveling (Across the

Rails)

1. Check the reading on the “Precision Level”

across the RAILS.
2. Adjust the level of the machine at the end
where the “Precision Level” indicates the
maximum deviation.
NOTE: Adjust all PADS on one side evenly to
achieve the proper level within a
tolerance of 0.8mm / meter (0.008in /
10").
3. Check the interconnection bolts while levelling
to ensure that they are loose.
4. Recheck the level length ways and adjust as
required.
5. Both length ways and cross ways must be
level before leveling is achieved.
6. Upon completion of leveling ensure that the
connection bolts are able to move freely.
7. Ensure that the positioning of the bolt that
joins the INJECTION BASE is as close to the
centre of the slot as possible.

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Assembly Manual Hylectric Machines

Chapter 4 Parallelism for Assembly

NOTE: Make sure that the Base is leveled as per Leveling procedures.
]-

Tie Bar Nuts

NOTE: The TIE BAR NUTS procedure must

be completed in Assembly.
1. Ensure that the correct GAP between TIE
BAR NUTS and the RETAINING PLATES are
set at the CLAMP end.
2. The table below indicates the GAP
dimensions.

Size of Machines Gap Dimensions

H/HL90 2mm
H/HL160 2mm
H/HL 225 2mm
H/HL 300 3mm
H/HL 400 3mm
H/HL 500 3mm
H/HL 650 5 mm
H/HL 800 5 mm
H/HL 1000 5 mm

3. Ensure that the TIE BAR NUTS are loosened

at the STATIONARY PLATEN end.

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 Hylectric Machines

Moving Platen Position

1. Position the MOVING PLATEN to maximum

shut height.
2. The table below indicates the distance
between the STATIONARY PLATEN and the
MOVING PLATEN.

Maximum Shut Height Chart

Machines Max. Shut Machines Max. Shut

sizes Height sizes Height

H90 500mm HL90 700mm

H120 HL120
550mm 750mm
H160 HL160

H225 660mm HL225 900mm

H300 750mm HL300 1000mm

H400 850mm HL400 1100mm

H500 950mm HL500 1200mm

H650 1100mm HL650 1400mm

H800 1200mm HL800 1500mm

H1000 1300mm HL1000 1600mm

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Assembly Manual Hylectric Machines

Stationary Platen

1. Place the “Box Level” onto the RAILS, close to

the PLATEN, to verify it’s accuracy.
2. Position the “Box Level” on the operator and
non-operator side of the STATIONARY
PLATEN.
3. Determine that the STATIONARY PLATEN is
perpendicular to the BASE on the operator
and non-operator sides.
NOTE: The tolerance, without TEST
BLOCKS or MOLDS, must be within
0.15 mm / m (0.0015 in / 10in) leaning
away from the MOVING PLATEN and
0.1mm / m (0.001in / 10 in) leaning
towards the MOVING PLATEN
relative to the “Precision Level” on the
BASE.
4. If unable to reach tolerance call Q.A.

Moving Platen

1. Place the “Box Level” onto the RAILS, close to

the PLATEN, to verify it’s accuracy.
2. Place the “Box Level” on the operator and
non-operator side of the MOVING PLATEN.
3. Determine that the MOVING PLATEN is
perpendicular to the BASE on the operator
and non-operator sides.
NOTE: The tolerance, without TEST
BLOCKS or MOLDS, must be within
0.15 mm / m (0.0015 in / 10") leaning
away from the STATIONARY PLATEN
and 0.1 mm / m (0.001in / 10 in)
leaning towards the STATIONARY
PLATEN relative to the “Precision
Level” on the BASE.
4. If unable to reach tolerance call Q.A.

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 Hylectric Machines

Clamp Cylinder

1. Place the “Box Level” onto the RAILS, close to

the CYLINDER, to verify it’s accuracy.
2. Place the “Box Level” onto the CLAMP
CYLINDER.
3. Determine that the CLAMP CYLINDER is
perpendicular to the BASE.
NOTE: The tolerance is within +0.15 mm /
meter (0.0015 in / 10") relative to the
“Precision Level” on the BASE.
4. If unable to reach tolerance call Q.A.

Clamp Spacer Blocks

2
1. Remove the “Clamp locating pins” from the
CLAMP.
2. Insert the SPACER BLOCKS between the
CLAMP and the DOWEL PINS on both sides.
3. At the STATIONARY PLATEN adjust the
UPPER and LOWER TIE BAR NUTS equally,
Operator side or Non-Operator side, until both
sides reached the required measurement.
NOTE: Ensure that the Clamp spacer blocks
are able to move freely and a 0.1mm
(0.004") feeler gauge cannot be
inserted.
4. Loosen off the STATIONARY PLATEN TIE
BAR NUTS.
5. Turn all the TIE BAR NUTS until they contact
the STATIONARY PLATEN. Tighten the
RETAINING PLATES.
6. Torque the RETAINING PLATE bolts to the
required specification.

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Assembly Manual Hylectric Machines

Parallelism Check

1. Take measurements from the four corners

between the STATIONARY and the MOVING
PLATENS MOLD FACES with an “Inside
Micrometer”.
NOTE: Take the measurements from just
above and below the TIE BARS.
2. Check that the measurements are within the
tolerances according to the Table 4-1
"Machine Parallelism Specifications".
3. If unable to obtain the tolerances from top to
bottom loosen the STATIONARY RETAINING
PLATES and verify the perpendicularity of the
PLATENS with a “Box Level”.
4. If unable to obtain the tolerances from side to
side loosen the RETAINING PLATES at the
STATIONARY PLATEN and the mounting bolts
that attach the MOVING PLATEN to the
LINEAR GUIDE RAILS.
5. Adjust the UPPER and LOWER TIE BAR
NUTS equally, Operator side or Non-Operator
side, until the tolerances are reached.
Table 4-1 Machine Parallelism Specifications 6. Loosen off all the STATIONARY PLATEN TIE
BAR NUTS. Turn all the TIE BAR NUTS until
Size of Machines Tolerances they contact the STATIONARY PLATEN.
7. Torque the MOVING PLATEN bolts that attach
H/HL 90 0.12 mm the PLATEN the LINEAR RAILS GUIDES to
the required specification and then torque the
H/HL 160 0.13 mm RETAINING PLATE bolts to the required
specification.
H/HL 225 0.15 mm
8. Retake the measurement with the “Inside
H/HL 300 0.17 mm Micrometer”.
NOTE: Make sure that the gap between the
H/HL 400 0.20 mm
SPACER BLOCKS and the DOWEL
H/HL 500 0.23 mm PINS are not greater than 0.1mm
(0.004 in.).
H/HL 650 0.25 mm 9. If unable to obtain the tolerances from side to
side repeat steps 4 to 8. If tolerances are
H/HL 800 0.28 mm
obtained witness mark the RETAINING
H/HL 1000 0.30 mm
PLATE BOLTS.

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 Hylectric Machines

Transportation bolts

1. Ensure that the Transportation bolts can be

installed by hand.
2. If unable to insert the Transportation bolts
reposition the CLAMP CYLINDER and
preform the PARALLELISM FOR ASSEMBLY
procedure from the start.

Checking Column Guide

Bushings

1. Position the MOVING PLATEN to maximum

day light less the stroke required for access to
the CLAMP COLUMN BUSHINGS.
2. For machines H/HL 500 and smaller proceed
to step 3. For machines H/HL 650 and larger
proceed to step 4.
3. Use a 0.05 mm (0.002 in) feeler gauge to
check for a GAP between all the COLUMN
GUIDE BUSHINGS and the COLUMN.
4. Use a 0.05 mm (0.002 in) feeler gauge to
check for GAP between the VERY BOTTOM
COLUMN GUIDE BUSHING and the
COLUMN.
5. If unable to insert the feeler gauge repeat the
LEVELING & PARALLELISM procedure.

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