MAXIMATOR RM350 Setup guide

RM350
Maintenance Information
Safety 2
GCM Internal Parts 3
400 & 700 Bar GCM Valve Calibration 5
400 & 700 Bar GCM Valve Service 5
GCM Valve Service 6
RM350 General Maintenance 10
HPP General Maintenance 12

Safety
Please read the following information carefully before installing and using the
equipment.
Compressed air and gases can be EXTREMELY dangerous and MUST be treated
with extreme care.This equipment works at pressures up to 620 Bar (8990 psi) and
uses single and 3 phase electrical power.
REMEMBER: Nitrogen gas is an asphixiant Never breathe in gas escaping from the
system. Nitrogen gas is not poisonous, but can overcome a person in a confined
space.Always stay alert when venting Nitrogen gas.
REMEMBER: Don’t be fooled by the size of the high-pressure receiver. A 50 litre
receiver charged to 350 Bar contains the equivalent of 7500 liters of gas at
atmospheric pressure.
REMEMBER: Unlike hydraulic oil, gas is compressible, and will continue to expand
until the
pressures inside and outside the system equalize.
NEVER commence any maintenance or servicing work on the equipment without
ensuring that the system is depressurized.
NEVER adjust a pipefitting that is under pressure.
NEVER adjust a safety valve to achieve a lifting pressure higher than that set at the
Maximator factory. A safety valve is provided to prevent over pressurisation of the
system and
overloading of the compressor. Tampering with a safety valve can cause serious
damage or injury.
NEVER run the equipment without the guards it was supplied with.
NEVER re-use damaged fittings, especially if they rely on threads for security (i.e.
pipe fittings,
nuts, bolts etc).
NEVER attempt to straighten badly bent pipes
NEVER allow any part of your body or any person to be in front of an opening that is
venting gas.Particles from inside the system can become embedded in the skin and
cause serious injury or death.
ALWAYS take care when opening valves or venting the system, and open the valve
slowly.
ALWAYS isolate the electric power supply before commencing work on the system.
ALWAYS entrust electrical work to a qualified electrician.
ALWAYS comply with local, regional and national legislation
HAZARD
HP/HLP Mould Pipes are a trip hazard.
Always place away from routes where traffic is likely to damage them.
REMEMBER:
COMPRESSED GAS AND ELECTRICITY CAN KILL.
TREAT THEM WITH RESPECT.

GCM Internal Parts

400 & 700 Bar GCM Valve Calibration
GCM valves should be calibrated monthly. Refer to the model’s Operating Manual
for further information.
400 & 700 Bar GCM Valve Service
GCM Valve Filter Service
The GCM valve incorporates two sintered metal filters. These filters remove particles
from the HP inlet gas and from gas vented from the mould. Particles in the gas can
cause the valve to leak and so it is important that these filter are in place. The inlet
filter has a 7 micron particle size; the outlet filter has a 60 micron particle size.
Note:
Generally, it is advised to check and clean the filter at least every three months.
However, for situation where contaminants can be returned in the pipe from the
mould, it is recommended that more frequent cleaned in carried out.
Generally, due to contamination in the gas returned from molding, the outlet filter will
become dirty quicker than the inlet filter.

GCM Valve Service
GCM Vale Servicing should be carried out at least every year. The valve will require
more frequent servicing if the inlet and outlet filter are not kept clean, or if gas
returned from the molding contains large quantities of contamination or aggressive
substances. To service the valve, a valve service kit (part number 4112 see page 22
for a list of parts included) is required. To service the valve, proceed as follows:

RM350 General Maintenance
Maximator recommend that all customers should carry out the following maintenance
schedule.
INTERVAL
COMMENTS
Daily
All gas fittings should be checked for leaks and leak rectified where
necessary.
All connecting hoses should be checked for damage/wear and
replaced if found faulty.
Power cable to be checked for damage/wear and replaced if found
faulty.
Monthly
Valves to be calibrated and checked for accuracy.
Fan filter element to be cleaned using compressed air.
6 Monthly
Fan filter element to be replaced.
Annually
All GCM valves to be fully serviced.

HPP General Maintenance
Maximator recommend that customer should carry out the following maintenance
schedule.
INTERVAL
COMMENTS
Daily
Oil level should be checked and topped up if required. Oil grade
recommended ISO32 (4493).
Unit should be checked for oil leaks and repaired where necessary.
All hoses used to connect to mould must be checked for damage
and wear.
Filter to be checked for blockages (this can be confirmed by
checking the filter condition indicator).
Monthly
Quality of the oil should be checked and oil replaced if necessary.
All fitting should be checked for tightness.
6 Monthly
Oil should be changed in the tank and all hoses flushed clean.
Filter should be replaced and filter cradle cleaned.
Oil sight glass should be removed and cleaned.
Annually
Oil pump & coupling should be inspected for excessive wear and
damage (to gain access to pump & coupling the tank lid will need to
be removed).
All hydraulic cores need to be checked for correct operation.
Level switch to be checked for correct operation.
Overload to be checked for correct operation.