With the injection molding machine's hydraulic system operating under high pressure, pilot-operated relief valves are commonly used in the control circuits of such systems. In practice, to ensure optimal performance and protect the control system, it is essential to accurately diagnose and promptly troubleshoot any issues with the pilot valve. A malfunctioning pilot relief valve can cause the injection molding machine to become inoperable. Based on observed symptoms, common causes include a broken pilot spool spring, a blocked or damaged pilot orifice, poor sealing at the pilot valve port, or a jammed main spool. To address these issues, several corrective actions can be taken. For a broken spring, it may be temporarily flattened or replaced for emergency use. The orifice should be cleaned thoroughly, and if necessary, the oil passage can be cleared or even broken open in an emergency. Additionally, grinding or cleaning the affected areas can help restore normal function. Another common issue is pressure-limiting instability, which can manifest as either low or high pressure in the hydraulic system, leading to weak actuation, pipe leakage, pump failure, or even structural damage. This instability is often caused by incorrect pressure settings, a bent or weakened pilot spool spring, or contaminated oil that restricts proper fluid flow. To resolve this, the pressure should be readjusted, the spring replaced if necessary, and the system cleaned to remove contaminants. It's important to note that pressure-limiting instability is typically a progressive failure, while a complete pilot relief valve failure tends to occur suddenly. After resolving the fault, it is crucial to recheck and adjust the pressure limit on the pilot-operated relief valve to ensure the system operates safely and efficiently. Regular maintenance and timely inspections are also recommended to prevent future failures and maintain the reliability of the hydraulic system.

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