Section 5 - Assembly .......................................................5-1
5.1 Cutaway of a Cast-in System .............................................................................5-1
5.2 Cutaway of a Bolt-in System ..............................................................................5-2
5.3 Cutaway of a MasterSHIELD System ................................................................. 5-3
5.4 Gate Seal Finishing ............................................................................................5-3
5.5 Hot Valve / Hot Sprue / F Type ...........................................................................5-4
5.6 Water-Cooled Gate Insert Installation (Optional) ................................................5-5
5.7 Thermocouple Installation ..................................................................................5-6
5.8 Thermocouple Removal For Non-Front Mounted Thermocouples .....................5-8
5.9 Dura Line Thermocouple Installation ..................................................................5-9
5.10 Nozzle Insertion ..............................................................................................5-12
5.10.1 Nozzle Insertion for Master-Series and Dura Lines ...............................5-12
5.10.2 Step Installation .....................................................................................5-13
5.10.3 Nozzle Insertion—ThinPAK Centi and Deci ...........................................5-14
5.10.4 Nozzle Insertion—MasterSHIELD Centi, Deci, and Pico ....................... 5-16
5.10.5 Nozzle Insertion—MasterSHIELD Femto ..............................................5-19
5.11 Nozzle Wire Layout ......................................................................................... 5-23
5.11.1 Back Mounted Thermocouples ..............................................................5-23
5.11.2 Front Mounted Thermocouples ..............................................................5-23
5.12 Emergency Heater Sleeve .............................................................................. 5-24
5.12.1 Installation of Emergency Heater Sleeve...............................................5-24
5.12.2 Removal of Emergency Heater Sleeve..................................................5-27
5.13 Valve Bushings ...............................................................................................5-28
5.13.1 Types of Valve Bushings ........................................................................ 5-28
5.13.2 Valve Bushing Installation ......................................................................5-28
5.14 Mount the Manifold .........................................................................................5-30
5.14.1 Manifold Locator ....................................................................................5-31
5.14.2 Manifold Locating Dowel Pin .................................................................5-32
5.14.3 Manifold and Slot Locator ......................................................................5-32
5.15 Manifold Thermocouple Installation ................................................................5-33
5.16 Main Manifolds ...............................................................................................5-34
5.16.1 Inlet Seal Installation - Without Step ..................................................... 5-34
5.16.2 Inlet Seal Installation - With Step ........................................................... 5-35
5.17 Pressure Disk / Valve Disk Installation ...........................................................5-35
5.17.1 Pressure Disk: Final Grinding Required ................................................5-36
5.17.2 Pressure Disk Installation ......................................................................5-38
5.17.3 Pressure Disk: Final Grinding Not Required .......................................... 5-38
5.17.4 EcoDisk Installation ...............................................................................5-39
5.17.5 Valve Disk - Final Grinding Required .....................................................5-40
5.18 Support Bushing Installation for Systems with MasterSHIELD ......................5-42
5.19 Valve Disk Installation for Systems with MasterSHIELD ................................5-43
5.20 Heater Plates Installation ................................................................................ 5-44
5.21 Inlet Components Installation .........................................................................5-46
5.21.1 Back Plate Installation ...........................................................................5-46
5.21.2 Center Heater Installation ......................................................................5-47
5.21.3 Three Piece Center Heater Installation ..................................................5-47
5.21.4 Inlet Extension Installation .....................................................................5-48
ii
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Hot Runner User Manual
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