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573\ri0\sl-213\slmult0 \fs18\cf0\f0\charscalex100 {About Us}\par\pard\li520\ri0\
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n\pard\li0\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-493\slmult0 \fs44\cf
0\f0\charscalex100 {Procedure Title:}\fs26\cf0\f0\charscalex100 { MOLD MAINTENAN
CE}\par\pard\li0\ri0\sl-506\slmult0 \fs44\cf0\f0\charscalex100 {Procedure Number
: }\fs26\cf0\f0\charscalex100 {WIT-031}\par\pard\li0\ri0\sl-213\slmult0 \fs18\cf
0\par\pard\li0\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {1.0 Purpose}\par\p
ard\li533\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li533\ri0\sl-186\slmult0 \fs18\c
f0\f0\charscalex100 {To provide a systematic approach to the maint
enance}\par\pard\li533\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {requiremen

ts of molds.}\par\pard\li0\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-186\
slmult0 \fs18\cf0\f0\charscalex100 {2.0 Scope}\par\pard\li533\ri0\sl-213\slmult0
\fs18\cf0\par\pard\li533\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {In ord
er to maintain quality parts, they must be produced in}\par\pard\li5
33\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {quality molds. The best
quality parts are produced from}\par\pard\li533\ri0\sl-240\slmult0 \fs
16\cf0\f0\charscalex100 {precision molds. Molds, quite like cars, begin to wear
with use}\par\pard\li533\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {and main
taining a tool is an investment in precision.}\par\pard\li533\ri0\sl-213\slmult0
\fs18\cf0\par\pard\li533\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {Proper
tool maintenance is a matter of attention to detail. As}\par\pard\li53
3\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {things begin to wear, they must
be noted and attended to. This}\par\pard\li533\ri0\sl-240\slmult0 \fs16\cf0\f0\
charscalex100 {is a simple matter of keeping a molding log for maintenance as}\p
ar\pard\li533\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {little things come
up and performing periodic maintenance as}\par\pard\li533\ri0\sl-253\slmult0
\fs18\cf0\f0\charscalex100 {the tool is run in production.}\par\pard\li0\ri0\sl213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100
{3.0 Responsibility}\par\pard\li533\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li533
\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {This maintenance procedure
is a guideline provided to our}\par\pard\li533\ri0\sl-240\slmult0 \fs
16\cf0\f0\charscalex100 {customers for the proper maintenance of mol
ds. It is the}\par\pard\li533\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex10
0 {customer's responsibility to determine a maintenance schedule}\par\pard\li533
\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {and follow it, Western I
ndustrial is not responsible for}\par\pard\li533\ri0\sl-240\slmult0 \fs1
8\cf0\f0\charscalex100 {specifying or performing maintenance.}\par\pard\li0\ri0\
sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex
100 {4.0 Definitions}\par\pard\li0\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0
\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.0 Procedure}\par\pard\li0\ri0\sl-2
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{5.1 The degree and frequency of maintenance are determined by
four}\par\pard\li0\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {factors.}\p
ar\pard\li0\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-186\slmult0 \fs18\c
f0\f0\charscalex100 {5.1.1 Material: Aluminum or soft tools will suffer wear and
tear in a shorter}\par\pard\li0\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {
period of time than tools made of conventional tool steel. Molds mad
e of}\par\pard\li0\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {hardened stee
l will last longer than those made of conventional mold steel.}\par\pard\li0\ri0
\sl-213\slmult0 \fs18\cf0\par\pard\li0\ri0\sl-186\slmult0 \fs18\cf0\f0\charscale
x100 {5.1.2 Complexity: Molds with intricate mechanisms or parts
requiring}\par\pard\li0\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {unreason
ably high precision will require more maintenance than a simple}\par\pa
rd\li0\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {two plate tool making
a low precision part. Slides, lifters, internal cores,}\par\pard\li0\
ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {hydraulic and mechanical syste
ms, hot runners, complex ejector systems}\par\pard\li0\ri0\sl-240\slmult0
\fs18\cf0\f0\charscalex100 {or mechanisms with small, therefore weak,
components all add to the}\par\pard\li0\ri0\sl-240\slmult0 \fs18\cf0\
f0\charscalex100 {maintenance schedule.}\par\pard\li0\ri0\sl-213\slmult0 \fs18\c
f0\par\pard\li0\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex100 {5.1.3 Molding m
aterial: Materials with high melt temperatures wear molds}\par\pard\li0
\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {out quicker than those with low
temperatures. Higher melt temperatures will}\par\pard\sect\sectd\sbknone\pard\se
ct\sectd\sbkpage\pgwsxn12240\pghsxn15840\marglsxn666\margrsxn133\margtsxn666\mar
gbsxn186\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slm
ult0 \fs18\cf0\f0\charscalex100 {expose the metals to more heat and enhance mate
rial wear. Filled materials}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\cha
rscalex100 {are abrasive because the fillers are not liquid. Fib
erglass, mineral fillers}\par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\cha

rscalex100 {(Usually Mica), etc. are very abrasive to metal, they wil
l tend to wash the}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscale
x100 {mold steel away after thousands of cycles.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.
1.4 Abuse: Excessive clamp pressures, high injection pressures, jerking
}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {the mold op
en and closed, not lubricating the appropriate components,}\par\pa
rd\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {multiple ejection, cras
hing the mold closed or closing up on partially ejected}\par\pard\li3906\ri0\sl240\slmult0 \fs18\cf0\f0\charscalex100 {parts are a sure road to increased maint
enance.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186
\slmult0 \fs16\cf0\f0\charscalex100 {Abuse can also be defined at the work place
. A shop that is dirty, open to}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0
\charscalex100 {the outside dust and dirt, machines with grease and absorbent on
the floor}\par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {all
create an atmosphere that will cause the molds to wear out
quicker.}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {Areas
exposed to acid vapors, such as a molding area located near
a}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {plating ope
ration will corrode the steel. Areas of high uncontrolled humidity}\par\pard\li3
906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {or salt water will also enhan
ce corrosion. Dry areas with constant wind and}\par\pard\li3906\ri0\sl-253\slmul
t0 \fs18\cf0\f0\charscalex100 {dust will cause premature wear on the mold.}\par\
pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs1
6\cf0\f0\charscalex100 {Abuse can be incipient: Using untreated coolan
t in the tool can cause a}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\
f0\charscalex100 {scale build up in the water lines. Build up can be noticed by
an increase in}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {t
he differential of temperatures and pressures from the inlet and outlet of}\par\
pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {the cooling circu
it. This scaling dramatically decreases the heat transfer}\par\pard
\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {ability of the tool
and therefore affects the process capability and}\par\pard\li3906
\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {dimensional stability of the par
ts. While the tool steel may seem in perfect}\par\pard\li3906\ri0\sl-240\slmult0
\fs16\cf0\f0\charscalex100 {working order, clogged or constricted cooling circu
its can seriously affect}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charsc
alex100 {part quality. Solutions to environmental abuse:}\par\pard\li3906\ri0\sl
-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscale
x100 {5.1.4.1 Have a clean operation using well maintained tools and equipment.}
\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0
\fs18\cf0\f0\charscalex100 {5.1.4.2 Use soft or treated water in cooling system
s.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmu
lt0 \fs18\cf0\f0\charscalex100 {5.1.4.3 Blow out or drain the tool when it is pu
lled from the machine.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li
3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.1.4.4 Seal the work area a
nd mold storage area from outside environment.}\par\pard\li3906\ri0\sl-213\slmul
t0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.1.
4.5 Have outside, filtered, positively pressurized air circulated in.}\par\pard\
li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs18\cf0
\f0\charscalex100 {5.2 Maintenance Frequency.}\par\pard\li3906\ri0\sl-213\slmult
0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.2.1
Level 1: Every time the mold is pulled from production or put back into}\par\pa
rd\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {production, Routine Mai
ntenance.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-2
00\slmult0 \fs16\cf0\f0\charscalex100 {5.2.2 Level 2: 20,000 cycles or
nine production shifts for Inspection}\par\pard\li3906\ri0\sl-240\slm
ult0 \fs18\cf0\f0\charscalex100 {Maintenance.}\par\pard\li3906\ri0\sl-213\slmult
0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.2.3
Level 3: 100,000 cycles or every 10 production runs for G

eneral}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {Maintenan

ce.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slm
ult0 \fs16\cf0\f0\charscalex100 {5.2.4 Level 4: 250,000 cycles or ha
lf the anticipated life time volume,}\par\pard\li3906\ri0\sl-240\slmul
t0 \fs18\cf0\f0\charscalex100 {whichever comes first for Major Maintenance.}\par
\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs
16\cf0\f0\charscalex100 {5.3 Level 1 A, Simple Preventive Maintenance,
to be done each time the}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf
0\f0\charscalex100 {mold is removed from production:}\par\pard\li3906\ri0\sl-213
\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100
{5.3.1 Before the mold is removed from the press, it is to be heated (if the}\p
ar\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {mold is chilled)
so that all surface condensation is evaporated. With the}\par\pa
rd\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {mold still warm, intern
al mold surfaces should be gently cleaned with shop}\par\pard\li3906\ri0\sl-240\
slmult0 \fs16\cf0\f0\charscalex100 {safety solvent to remove any residual
dirt and grime, the ejector system}\par\pard\li3906\ri0\sl-240\slmult0
\fs16\cf0\f0\charscalex100 {moved fully forward, then sprayed with approved rust
preventive before the}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscal
ex100 {ejector system is retracted and the mold closed. Lenses and highly polish
ed}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {surfaces shou
ld be protected following specific instructions.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.
3.2 All water lines should be drained and blown free of all residual water to}\p
ar\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {avoid build up of
rust due to standing water. It is imperative that no water}\par\pard\sect\sectd\
sbkpage\pgwsxn12240\pghsxn15840\marglsxn666\margrsxn133\margtsxn666\margbsxn200\
pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs1
8\cf0\f0\charscalex100 {be trapped inside mold.}\par\pard\li3906\ri0\sl-213\slmu
lt0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex100 {5.3
.3 Check and assure all bolts, plates, clamps etc. are in place and tight.}\par\
pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs1
8\cf0\f0\charscalex100 {5.3.4 Bag the last shot as an example of the typical qua
lity of this run. Store}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charsca
lex100 {these parts with the mold.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0
\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.4 Level 1B, Si
mple Preventive Maintenance, to be done when removing a}\par\pard\li3906\ri0\sl240\slmult0 \fs18\cf0\f0\charscalex100 {tool from storage:}\par\pard\li3906\ri0\
sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charsca
lex100 {5.4.1 Open the mold. Using properly approved safety shop solvent, remove
}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {the mold preser
vative with a lint free pad. It is bad practice to immediately}\par\pard\li3906\
ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {run parts on the assumpti
on that the first shots will scrape away the}\par\pard\li3906\ri
0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {protective coating and will
therefore be used to clean out the mold}\par\pard\li3906\ri0\sl-2
40\slmult0 \fs18\cf0\f0\charscalex100 {preservative.}\par\pard\li3906\ri0\sl-213
\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100
{5.5 Level 2, Inspection Maintenance:}\par\pard\li3906\ri0\sl-213\slmult0 \fs18
\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.5.1 This m
aintenance is performed by the lead operator or a tool maker at}\par\pard\li3906
\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {the end of a production
run. Using the check list and visual inspection}\par\pard\li3906\
ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {techniques, the mold is l
ooked over and any minor repairs that are}\par\pard\li3906\ri0\sl240\slmult0 \fs16\cf0\f0\charscalex100 {necessary are noted for the co
nvenience of the General Maintenance}\par\pard\li3906\ri0\sl-253\slmult0
\fs16\cf0\f0\charscalex100 {procedure. If not, needed repairs or future require
d touch-up notations are}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charsc
alex100 {kept with the mold history log for future evaluation.}\par\pard\li3906\

ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\cha

rscalex100 {5.5.2 Any components missing or cavity blocked off should be
noted and}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {atte
nded to. A sample from the blocked cavity should be retained for th
e}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {mold maker to
make repairs.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\
sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.5.3 The mold should be washed with
safety solvent to remove the varnish}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\c
f0\f0\charscalex100 {and build up from the molding process.}\par\pard\li3906\ri0
\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charsc
alex100 {5.5.4 The vents should be checked for depth in a mi
nimum of four}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100
{clock-face places around the cavity face.}\par\pard\li3906\ri0\sl-213\slmult0
\fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.5.5
Notations for work to be done during the General Maintenance}
\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {procedure should
be noted on the form for future work.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18
\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.5.6 Bent,
worn or broken ejector pins should be noted. The mold should}\par\pard\li3906\ri
0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {be removed from production and the
pins replaced.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0
\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.6 Level 3, General Maintenance:}\p
ar\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \
fs16\cf0\f0\charscalex100 {5.6.1 Only competently trained tool room techni
cians should perform this}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\ch
arscalex100 {maintenance.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard
\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.6.2 All plates ar
e separated and their faces cleaned. Caution: Highly}\par\pard\li3
906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {polished surfaces should n
ot be cleaned with brushes or rags. Use only}\par\pard\li3906\ri0\sl
-240\slmult0 \fs16\cf0\f0\charscalex100 {uncontaminated facial tissues or
cotton balls. Loosen dirt by spraying}\par\pard\li3906\ri0\sl-240\sl
mult0 \fs16\cf0\f0\charscalex100 {cleaning fluid into cavity and wipe
clean with clean cotton balls. Do not}\par\pard\li3906\ri0\sl-240\
slmult0 \fs16\cf0\f0\charscalex100 {touch with fingers, dust on fingertips may
scratch a polished surface. Be}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\
f0\charscalex100 {careful when blowing a cavity out, there may be dust or rust i
n the air lines}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {
which may damage the polished cavity.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\
cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.6.3 All c
omponents are checked for wear. Any excessive wear is noted}\par\pard
\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {and a determination is ma
de to repair, replace or continue to use.}\par\pard\li3906\ri0\sl-213\slmult0 \f
s18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.6.4 Al
l rough areas outside the cavity detail area are to be worked out.}\
par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {Any area inside
the cavity detail area with dings, dents or other signs of}\par\par
d\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {wear or abuse shou
ld be considered critical and should be carefully}\par\pard\li3906
\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {analyzed before replacements or
repairs are commenced.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li
3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.6.5 All moving parts
are to be lubricated if required. Use lubricant}\par\pard\li390
6\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {sparingly on all moving parts w
hich make contact with plastic parts.}\par\pard\sect\sectd\sbkpage\pgwsxn12240\p
ghsxn15840\marglsxn666\margrsxn133\margtsxn666\margbsxn200\pard\li3906\ri0\sl-21
3\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-360\slmult0 \fs18\cf0\f0\charscalex10
0 {5.6.6 Vents should be checked for depth, width and land as compare
d to}\par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {the tool d
rawing specifications. This data should be recorded on the check}\par\pard\li390

6\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {list and a determination

made to repair if required. They should also be}\par\pard\li3906
\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {checked for corrosion and vent b
urns (Better venting may be required).}\par\pard\li3906\ri0\sl-213\slmult0 \fs18
\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.6.7 "O" ri
ngs, seals and gaskets should be checked for integrity.}\par\pard\li3906\ri0\sl213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex
100 {5.6.8 All water lines are to be pressure tested for leaks and re-certified
for}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {flow capacit
y. Water lines that have built up scale and are restricted should}\par\pard\li39
06\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {be pressure cleaned with a des
caling agent.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\
sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.6.9 The ejector system is
to be examined for proper alignment. If the}\par\pard\li3906\ri0\s
l-240\slmult0 \fs16\cf0\f0\charscalex100 {ejector pin holes have become egg
shaped it must be determined if they}\par\pard\li3906\ri0\sl-240\slmult
0 \fs16\cf0\f0\charscalex100 {should be re-drilled and bored to a
larger size and the existing pins}\par\pard\li3906\ri0\sl-240\slmult0
\fs18\cf0\f0\charscalex100 {replaced with over size pins.}\par\pard\li3906\ri0\s
l-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscal
ex100 {5.6.10 Broken return springs, re-plating or re-texturing as a
result of the}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100
{material eroding the mold surface, replacement of gates or ga
te inserts,}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {ne
w runner blocks etc. must be analyzed and determined. Replace
all}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {springs af
ter 50,000 cycles.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906
\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex100 {5.7 Level 4, Major Maintenance:}
\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0
\fs16\cf0\f0\charscalex100 {5.7.1 This maintenance should be performe
d by skilled tool and die}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf
0\f0\charscalex100 {personnel. It should be done when triggered either by the ml
d fulfilling the}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100
{required number of cycles for maintenance, excessive wear or damage to}\
par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {the tool. Rec
ord keeping here is quite important. Before maintenance}\par\pard\
li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {begins, there should b
e four complete shots (Parts, sprues and runners)}\par\pard\li3906\ri0\s
l-240\slmult0 \fs16\cf0\f0\charscalex100 {delivered with the tooling for st
udy. Two shots should be from the initial}\par\pard\li3906\ri0\sl-240\sl
mult0 \fs16\cf0\f0\charscalex100 {mold qualification. This gives a visual record
of what was acceptable when}\par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\ch
arscalex100 {the mold was new and fully functioning. The second two shots should
be}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {the most rec
ent parts produced before the tool was pulled for maintenance.}\par\pard\li3906\
ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {Comparison of the before and afte
r shots will give an excellent indication of}\par\pard\li3906\ri0\sl-240\slmult0
\fs18\cf0\f0\charscalex100 {wear and abuse the tool has suffered.}\par\pard\li3
906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0
\charscalex100 {5.7.2 All components determined and authorized to be replaced sh
ould be}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {removed
and new components constructed and installed in accordance to}\par\pard\li3906\r
i0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {the original designs if pr
eviously certified spare components are not}\par\pard\li3906\ri0\sl-24
0\slmult0 \fs18\cf0\f0\charscalex100 {available.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.
7.3 Worn leader pins, bushings and all bearing moving surfaces should be}\par\pa
rd\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {checked for wear and re
placed/repaired as required.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\p
ard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.7.4 Plates and mo

ld cavity surfaces should be checked for parallelness}\par\pard\li3906\ri

0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {and ground flat if required.}\par\p
ard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16
\cf0\f0\charscalex100 {5.7.5 Mold cavity surface should be cleaned and polished
as required to the}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex10
0 {original surface requirements. Galling, dings and dents should be wo
rked}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {out until
the surface is fully in compliance to the original print}\p
ar\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {specifications.}\p
ar\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \
fs16\cf0\f0\charscalex100 {5.7.6 All components not meeting the part
print's original specifications}\par\pard\li3906\ri0\sl-240\slmult0 \fs18
\cf0\f0\charscalex100 {should be repaired, replaced and re-qualified as required
.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmul
t0 \fs16\cf0\f0\charscalex100 {5.7.7 All components that have been p
lated should be stripped and}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\c
f0\f0\charscalex100 {re-plated where required. All components that h
ave had special surface}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\c
harscalex100 {treatments for corrosion resistance, lubricity, hardness and the l
ike should}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {be re
-treated to insure the original intent of the tool.}\par\pard\li3906\ri0\sl-213\
slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100
{5.7.8 All moving components should be checked for ease of mo
vement.}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {Adjustme
nts should be made as required. All return springs in the ejector}\par\pard\li
3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {plate should be replaced wit
h new springs to avoid fatigue.}\par\pard\sect\sectd\sbkpage\pgwsxn12240\pghsxn1
5840\marglsxn666\margrsxn133\margtsxn666\margbsxn226\pard\li3906\ri0\sl-213\slmu
lt0 \fs18\cf0\par\pard\li3906\ri0\sl-360\slmult0 \fs18\cf0\f0\charscalex100 {5.7
.9 All water lines should be flushed with descaling agent to remove scale}\par\p
ard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex100 {build up. All "O" ring
s, internal plugs, seals and gaskets should be replaced.}\par\pard\li3906\ri0\sl
-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscale
x100 {5.7.10 For tools requiring high production, the cavities should be removed
}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {and stress reli
eved to remove work hardening and material embrittlement.}\par\pard\li3906\ri0\s
l-240\slmult0 \fs16\cf0\f0\charscalex100 {The entire mold/cavity set must be reinspected and re-qualified as though}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\c
f0\f0\charscalex100 {it was a new cavity.}\par\pard\li3906\ri0\sl-213\slmult0 \f
s18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.7.11
The mold base is to be inspected for cracks, work hardening,
}\par\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {corrosion, et
c. If the mold base was plated or painted for corrosion}\par
\pard\li3906\ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {resistance, the coat
ing is to be stripped, the base cleaned and the coating}\par\pard\li3906\ri0\sl253\slmult0 \fs18\cf0\f0\charscalex100 {reapplied. The mold's ID is to be re-don
e indicating the tool was rebuilt.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0
\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.7.12 The cavit
y surface is to be inspected for wear or erosion of plating or}\par\pard\li3906\
ri0\sl-240\slmult0 \fs16\cf0\f0\charscalex100 {texturing. When determined
necessary, the cavity surfaces are to be}\par\pard\li3906\ri0\sl-240
\slmult0 \fs16\cf0\f0\charscalex100 {stripped and re-plated, or the textur
e is to be polished off and then new}\par\pard\li3906\ri0\sl-253\slmult0
\fs18\cf0\f0\charscalex100 {texture applied.}\par\pard\li3906\ri0\sl-213\slmult
0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.8 S
uggested tools available for proper tool maintenance:}\par\pard\li3906\ri0\sl-21
3\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex10
0 {5.8.1 Assembly table: 3' x 3' x 6' (90cm x 90cm x 180cm) should be able to}\p
ar\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {handle a minimum o
f 1 ton or 1000kg.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906

\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.8.2 Good lighting: A high dens

ity portable lamp with a magnetic base is}\par\pard\li3906\ri0\sl-240\slmult0
\fs18\cf0\f0\charscalex100 {desirable.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18
\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.8.3 (2) He
at-treated rails: 36" x 1" x 1" (90cm x 2.5 cm x 2.5 cm) for molds}\par\pard\li3
906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {to slide on.}\par\pard\li3906
\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\ch
arscalex100 {5.8.4 (2) Pry bars: 7075 Aluminum.}\par\pard\li3906\ri0\sl-213\slmu
lt0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs16\cf0\f0\charscalex100 {5.8
.5 (3) Hammers: Heavy-duty plastic head, light duty plastic head, l
ight}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {weight (13
oz) machinists hammer (Ball Peen).}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0
\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.8.6 (2) Hex wr
enches: (1) Set metric, (1) set inch and extension pipe.}\par\pard\li3906\ri0\sl
-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscale
x100 {5.8.7 (1) Ruby polishing stone (fine): To remove burrs or scratches on mol
d}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0\charscalex100 {inserts.}\par\
pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs1
6\cf0\f0\charscalex100 {5.8.8 (1) Medium bench stone: To remove bu
rrs or scratches on mold}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f
0\charscalex100 {plates.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\
li3906\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex100 {5.8.9 (1) File: To remover
burrs or hobbed corners and edges on mold base.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.
8.10 (1) Cleaning tank: With clean cleaning solvent.}\par\pard\li3906\ri0\sl-213
\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-200\slmult0 \fs18\cf0\f0\charscalex100
{5.8.11 Towels: Clean shop rags or paper towels.}\par\pard\li3906\ri0\sl-213\sl
mult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5
.8.12 Air hose: With standard shop air pressure.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.
8.13 Flashlight.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\r
i0\sl-200\slmult0 \fs18\cf0\f0\charscalex100 {5.8.14 Grease: All-purpose type, m
inimum temperature 500 degree F.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\p
ar\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.8.15 Cleaning br
ushes.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\
slmult0 \fs16\cf0\f0\charscalex100 {5.8.16 (1) Set knock out pins: For removing
pins in ejector housing (Do not}\par\pard\li3906\ri0\sl-253\slmult0 \fs18\cf0\f0
\charscalex100 {use these knock out pins in cavity or core area).}\par\pard\li39
06\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\
charscalex100 {5.8.17 Soft brass pins: For removing plastic material left in spr
ue bushing.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl
-186\slmult0 \fs16\cf0\f0\charscalex100 {5.8.18 (1) Ratchet wrench: With 7/
16 and 9/16 deep sockets for removing}\par\pard\li3906\ri0\sl-253\slmult0
\fs18\cf0\f0\charscalex100 {water line fittings.}\par\pard\li3906\ri0\sl-213\slm
ult0 \fs18\cf0\par\pard\li3906\ri0\sl-186\slmult0 \fs18\cf0\f0\charscalex100 {5.
8.19 Containers: For storing all loose parts.}\par\pard\sect\sectd\sbkpage{\shp
{\*\shpinst
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\shpfhdr0\shpwr3\shpwrk0\shpfblwtxt1\shplid2033\shpz0\shpbxpage\shpbypage
\absh15840\absw12240{\sp{\sn shapeType}{\sv 75}}
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}}}}\pgwsxn12240\pghsxn15840\marglsxn666\margrsxn133\margtsxn666\margbsxn666\par
d\li3906\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3906\ri0\sl-360\slmult0 \fs18\c
f0\f0\charscalex100 {5.8.20 Masking tape: To protect all critical corners on eje
ctor pins, ejector}\par\pard\li3906\ri0\sl-253\slmult0 \fs16\cf0\f0\charscalex10
0 {sleeves and lift cores. To protect cavity and core and wherever there is a}\p
ar\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100 {sensitive area on
tool which can be easily damaged.}\par\pard\li3906\ri0\sl-213\slmult0 \fs18\cf0\
par\pard\li3906\ri0\sl-186\slmult0 \fs16\cf0\f0\charscalex100 {5.9 Always protec
t exposed cavity and core areas by covering with a rigid}\par\pard\li3906\ri0\sl
-253\slmult0 \fs16\cf0\f0\charscalex100 {impact resistant material, such as a sh
eet of plywood or rigid plastic. Tools}\par\pard\li3906\ri0\sl-253\slmult0 \fs16
\cf0\f0\charscalex100 {or parts may be accidentally dropped and can end up on to
p of a cavity or}\par\pard\li3906\ri0\sl-240\slmult0 \fs18\cf0\f0\charscalex100
{core insert causing extensive damage.}\par\pard\li3786\ri0\sl-213\slmult0 \fs18
\cf0\par\pard\li3786\ri0\sl-213\slmult0 \fs18\cf0\par\pard\li3786\ri0\sl-320\slm
ult0 \fs16\cf0\f0\charscalex100 {Western Industrial Tooling 1996 - 2009}\par\pa
rd\li1933\ri0\sl-306\slmult0 \fs16\cf1\f0\charscalex100 {Home}\fs16\cf0\f0\chars
calex100 { \uc1\u8226X }\fs16\cf1\f0\charscalex100 {Molds}\fs16\cf0\f0\charscale
x100 { \uc1\u8226X }\fs16\cf1\f0\charscalex100 {Design}\fs16\cf0\f0\charscalex10
0 { \uc1\u8226X }\fs16\cf1\f0\charscalex100 {Contact}\fs16\cf0\f0\charscalex100
{ \uc1\u8226X }\fs16\cf1\f0\charscalex100 {About Us}\fs16\cf0\f0\charscalex100 {
\uc1\u8226X }\fs16\cf1\f0\charscalex100 {Procedures}\fs16\cf0\f0\charscalex100
{ \uc1\u8226X }\fs16\cf1\f0\charscalex100 {Jig Grinding}\fs16\cf0\f0\charscalex1
00 { \uc1\u8226X }\fs16\cf1\f0\charscalex100 {Privacy Policy}\par}