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Instron 300DX, Operating Instructions Manual

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Instron 300DX Operating Instructions Manual Download Page 87

87

Hydraulic power supply (HPS)

Product Support: 

www.instron.com

Socket head cap screw, 
M10 x 1.5p x 25 mm

Compression test space - secure 
bumper plate to bottom of adjustable 
crosshead

300DX-G8

300-8821-9309

4

Socket head cap screw, 
M16 x 2p x 35 mm

300DX-G1
300DX-G7
600DX-G1
600DX-G8

300-8821-9511

2

Setscrew, 
M8 x 1.25p x 50 mm

Compression test space - secure 
holding button to bumper plate

300DX-G8

300-8822-9540

1

Setscrew, 
M8 x 1.25p x 25 mm

300DX-G1
300DX-G7
600DX-G1
600DX-G8

300-8822-9550

1

Setscrew, 
M8 x 1.25p x 40 mm

600DX-G7

300-8822-9452

1

Holding button

Compression test space - for use with 
bumper plate to mount compression 
fixtures to the adjustable crosshead

All

226724-1

1

Setscrew, 
1/2-13 x 1.5 in

Compression test space - mount the 
holding button to a fixture

All

300-8822-4478

1

Fixture holding screw

Compression test space - secure 
fixtures to bottom of adjustable 
crosshead (must remove bumper 
plate)

300DX-G8

210150-1A

1

600DX-G8

193418-1C

1

Hex key, T-handle, 
10 mm, 6 in blade

Tighten and loosen fixture holding 
screw in adjustable crosshead

300DX-G8

300-8875-9344

1

Hex key, T-handle, 
3/8 in, 6 in blade

600DX-G8

300-8875-9234

1

Hex key, T-handle, 4 mm, 
6 in  blade

Tighten and loosen M5 cap screws

All

300-8875-9369

1

Hex key, 14 mm, L-shape ball

Tighten and loosen M16 cap screws

600DX-G1
600DX-G7

300-8875-9350

1

Screwdriver, 3/8 in slot

Assist in removal of grip jaws from 
grip pocket

300DX-G7
600DX-G7

300-8899-10699

1

Lubricant, Molykote GN metal 
paste, 1 lbs can

Lubricate grip assemblies

300DX-G1
600DX-G1

300-8894-9035

1

Grease gun

Lubricate grip assemblies

300DX-G7
600DX-G7

300-8899-10682

1

Lubricant, Molykote GN metal 
paste, 14 oz cartridge

Lubricate grip assemblies

300DX-G7
600DX-G7

300-8894-9059

2

Adhesive, Loctite 246 
Threadlocker high temperature/
medium strength, 10 mL 
(0.34 oz)

Maintain grip assemblies

300DX-G7
600DX-G7

300-8899-10741

1

Table 17.    Ancillary parts list. (Continued)

Description

Location or Purpose

Frame Model

Part Number

1

Quantity

Summary of Contents for 300DX

Page 1: ...www instron com Industrial Products Group Model DX Static Hydraulic Universal Testing System Operating Instructions M47 17027 EN Revision C The difference is measurable ...

Page 2: ...ormation contained therein may be acquired only by written permission signed by a duly authorized officer of ITW Trademarks Instron is a registered trademark of Illinois Tool Works Inc ITW Other names logos icons and marks identifying Instron products and services referenced herein are trade marks of ITW and may not be used without the prior written permission of ITW Other product and company name...

Page 3: ...de range of applications with which our instruments are used and over which we have no control additional protection devices and operating procedures may be necessary due to specific accident prevention regulations safety regulations further EEA directives or locally valid regulations The extent of our delivery regarding protective devices is defined in your initial sales quotation We are thus fre...

Page 4: ...east the amount recommended in your grip documentation This amount can vary between 66 to 100 insertion depth refer to supplied instructions for your specific grips Use any centering and alignment devices provided Hazard Protect electrical cables from damage and inadvertent disconnection The loss of controlling and feedback signals that can result from a disconnected or damaged cable causes an ope...

Page 5: ...shead movement cannot occur Robotic Motion Hazard Keep clear of the operating envelope of a robotic device unless the device is de activated The robot in an automated testing system presents a hazard because its movements are hard to predict The robot can go instantly from a waiting state to high speed operation in several axes of motion During system operation keep away from the operating envelop...

Page 6: ...e gas connections without first disconnecting the gas supply and discharging any residual pressure to zero Explosion Hazard Wear eye protection and use protective shields or screens whenever any possibility exists of a hazard from the failure of a specimen assembly or structure under test Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers...

Page 7: ...2 Specifications 21 Use limits 21 Frame 22 59 Series control unit 25 Environmental conditions 26 Heat load 26 Noise level 27 Chapter 3 Operation 29 Operation of controls 29 Operation of HPS 33 Isolation of HPS from the load frame 33 Procedure for 300DX frames 33 Procedure for 600DX frames 34 Mount fixtures 34 Mount tension fixtures 35 Mount compression fixtures 35 Start the system 37 Change height...

Page 8: ...61 Preventative maintenance schedule 61 Make daily checks of system 63 Remove and install base covers 64 Electronics 66 Clean the fans 66 Fuses 66 Inspect the cables 66 Frame 66 Check non painted surfaces 66 Adjustable crosshead 67 Inspect the hydraulic cylinder 70 Grip assemblies G1 style and G7 style crossheads 72 Clean external surfaces and check operation of grip assemblies 72 Lubricate the gr...

Page 9: ...9 Preliminary Pages Product Support www instron com Spare and replacement parts 90 Appendix A CE Certificate 91 Appendix B Grip Jaws 93 ...

Page 10: ...Preliminary Pages 10 M47 17027 EN ...

Page 11: ...ation Manual Your system consists of a frame a hydraulic power supply a control unit a computer system with an Instron materials testing software package and any testing accessories necessary to secure the specimen in the test space Software test methods that are appropriate for your testing requirements are available These instructions do not include the development of test methods within the mat...

Page 12: ... test spaces so that users can quickly change between tension and compression testing without having to remove heavy fixtures This flexible design helps to ensure safety reduce operator fatigue and improve productivity System components Model DX systems consist of Frame Hydraulic Power Supply HPS 59 Series control unit and other system controls and electronics Instron approved computer system with...

Page 13: ...rossheads 1 G1 style crossheads Closed front crossheads with manually operated in head wedge grips for tension testing 2 G7 style crossheads Open front crossheads with hydraulically operated in head wedge grips for tension testing 3 G8 style crosshead Compression only frame with bolt pattern to accept compression fixtures 4 HPS and electronics located in base of frame 5 Optional operator dashboard...

Page 14: ... in whole or in part is used throughout this manual to identify specifications and procedures appropriate for your frame configuration Knowing the complete model number of your frame is critical To determine the complete model number and thus configuration of your frame refer to one of the following The frame serial tag see System identification on page 14 The Instron quote Testing accessories Tes...

Page 15: ...me For proper operation of the system it is important to be able to identify and to understand the basic function of these components Figure 2 DX frame components for legend see Table 1 1 2a 1 8 6 9 4a 5 2b 3a 1 1 3b 4b View B Fixed Unit Frame with G8 style crossheads Frame with G1 style or G7 style crossheads View A Loading Unit 7 ...

Page 16: ...ening of the tension test space Refer to Adjust the position of the tension crosshead on page 38 for more information 4 Adjustable crosshead a G7 style b G1 style c G8 style not shown For tension testing provides lower grip for tension specimen Also provides mounting surface for external tension fixtures Refer to Mount fixtures on page 34 for more information For compression testing the bottom of ...

Page 17: ...page 29 for more information 59 Series control unit The 59 Series control unit houses control components that receive and process data from the various system transducers communicate with the system s controlling software and provide feedback to the system s servo valve to operate the frame as set up in the controlling software Refer to Table 9 on page 29 for more information User control panel Th...

Page 18: ...e protection or use protective shields or screens Be sure to read and understand the operator s manual before using the system Read the manual Read and understand the operator s manual before using the system Guard removal hazard Indicates that a hazard exists do not operate the system with covers removed Be sure to read and understand the operator s manual before using the system Only authorized ...

Page 19: ...view Product Support www instron com Grease location Indicates the location of grease fitting to apply appropriate lubricant Table 3 Descriptions of safety and information labeling Continued Label Meaning and Purpose ...

Page 20: ...n any aspect of the product documentation Please email info_dev instron com with your comments System verification Caution System verification is vital to ensure the accuracy of your calibration Current standards recommend that you do not exceed 18 months between verifications Instron provides a fully traceable verification service including UKAS NVLAP certification where appropriate Contact your ...

Page 21: ...st not be used as a press The system should not be operated by anyone who does not fit the criteria specified in the Operator characteristics and Operator training experience sections of this table Intervention procedures The system is equipped with Emergency Stop and software reset frame enable controls see Table 2 on page 17 and separately supplied Software documentation Use type Industrial Oper...

Page 22: ...echnical specifications Specification1 300DX 600DX Maximum Capacity2 300 kN 30 000 kgf 67 500 lbf 600 kN 60 000 kgf 135 000 lbf Design Capacity3 240 kN 24 000 kgf 54 000 lbf 480 kN 48 000 kgf 108 000 lbf A Tension Test Opening per crosshead style and tension crosshead position 4 G1 First notch 0 508 mm 0 20 in 44 508 mm 1 75 20 in Second notch 203 711 mm 8 28 in 178 711 mm 7 28 in Third notch 406 ...

Page 23: ...l Equipment 7 Tension Specimen Size Flat Maximum8 thickness x width G1 25 x 50 mm 1 x 2 in 45 x 70 mm 1 75 x 2 75 in G7 50 x 70 mm 2 x 2 75 in 60 x 100 mm 2 36 x 4 in Tension Specimen Size Round Minimum and Maximum8 diameter G1 5 to 32 mm 0 2 to 1 25 in 7 to 57 mm 0 25 to 2 25 in G7 3 to 40 mm 0 118 to 1 57 in 3 to 57 mm 0 118 to 2 25 in Tension Specimen Length minimum Refer to the appropriate Gen...

Page 24: ...isplayed reading whichever is greater Resolution11 C4A 1 27 µm 0 00005 in Cyclic Test and Frequency Limits Capable of tension tension or compression compression cyclic testing only Cyclic tests are limited to ramp type waveforms as defined within the materials testing software package being used with the system Frequency limits are defined by the compliance of the specimen and the dynamic control ...

Page 25: ... crosshead interference can occur 6 Minimum compression test opening measured with the hydraulic cylinder fully extended and adjustable crosshead in lowest position Maximum compression test opening measured with the hydraulic cylinder fully retracted and adjustable crosshead in highest position Values do not include specimen fixtures 7 The General Assembly drawing is located in the separately supp...

Page 26: ...uracy 0 5 of reading down to 1 500 of load cell capacity Linearity 0 25 of reading over a range of 0 2 to 100 of capacity Repeatability 0 25 of reading over a range of 0 2 to 100 of capacity Strain Measurement Accuracy 0 5 of reading down to 1 50 of full range with ASTM E 83 class B 1 or B 2 or ISO 9513 class 0 5 extensometer Certifications Conform to all relevant European standards 1 Software dat...

Page 27: ... pressure value does not exceed 63 Pa Since many variables such as room layout affect noise levels it can not be assumed that these readings will be equal to those in the field The noise level readings were taken at a location in front of the system as shown in Figure 4 This is the typical location for an operator to stand when operating the system Figure 4 Location of noise level reading Frame Op...

Page 28: ...Chapter 2 Specifications 28 M47 17027 EN ...

Page 29: ...clude but is not limited to eye protection and head protection Other types of personal protective equipment may also be needed You must perform your own risk assessment and take appropriate measures to protect yourself from harm Table 9 Control functions Control Location Description Emergency stop HPS control box When it is necessary to stop motion of the frame immediately press the Emergency Stop...

Page 30: ... in the controlling software If the display is showing live displays you must toggle back to show the soft key functions if you want to use a soft key button on the control panel For information on setting up the display and numbered buttons refer to the controlling software s On line Help Jog Controls User control panel Figure 5 These buttons actuate the piston of the hydraulic cylinder in the di...

Page 31: ...it can be turned on see software manual or on line help for information on setting this feature Also it can only be turned on when the frame HPS is enabled START TEST User control panel Figure 5 Press this button to begin the test once all test parameters are set Up and Down Arrow indicators show the type of test selected Up indicates tension and Down indicates compression STOP TEST User control p...

Page 32: ...Chapter 3 Operation 32 M47 17027 EN Figure 5 User control panel ...

Page 33: ... Examples would be applications where the testing is sensitive to vibration The following procedures isolate the HPS the HPS rests directly on the floor and is no longer attached to the load frame Procedure for 300DX frames 1 Power off the machine and disconnect the power cord 2 Remove the rear and side panels from the base 3 Using a 6 mm hex wrench remove the mounting hardware four black socket h...

Page 34: ...re 7 so that the HPS is supported on the leveling feet 5 Check clearances all around the base of the HPS If any part of it is in contact with the frame base use the leveling feet to make adjustments to avoid contact 6 Reinstall the rear and side panels Reconnect the power supply and power on the machine Check for leaks and proper machine operation Mount fixtures Warning Figure 7 Location of screws...

Page 35: ...ion of the grip assemblies refer to Operate grip assemblies G1 style and G7 style crossheads on page 42 Mount compression fixtures Compression fixtures purchased separately must be mounted to the bumper plate that is on the bottom of the adjustable crosshead and the compression table Neither the bumper plate nor the compression table can be used to apply force directly to a specimen Upper compress...

Page 36: ...Chapter 3 Operation 36 M47 17027 EN Figure 8 Example of bumper plate 1 Bumper plate typical 2 Setscrew M8 3 Button hole 25 mm 1 in diameter 4 Mounting button 5 Compression fixture 1 2 3 4 5 ...

Page 37: ...Open or create the desired test procedure in the controlling software 7 Check that the lights on the front of the 59 Series control unit are illuminated as follows T indicator of the SERVICE display is green A indicator of the SERVICE display is blinking red 8 Check that the lights on the user control panel are illuminated as follows POWER is green FRAME STANDBY is red TEST STOPPED is red 9 Calibr...

Page 38: ... platform must be of sufficient height so that the operator can reach the tension crosshead Blocks of lumber to support the tension crosshead A hex key refer to Table 10 on page 39 for size needed supplied No lifting equipment is necessary the adjustable crosshead can be used as an elevator Recommended procedure 1 Start the system see page 37 Start the HPS 2 Adjust the adjustable crosshead so that...

Page 39: ... Lower the tension crosshead so that it rests on the lower retaining rings Tighten the socket head cap screws until seated plus one quarter turn b For frames that use the hinged clam style or two piece style of lower retaining rings place the lower retaining rings 4 into the notches and tighten the socket head cap screws until seated plus one quarter turn Lower the tension crosshead so that it res...

Page 40: ... piece style two 3 8 24 SHCS use 5 16 in hex key Not used when crosshead in highest notch position2 No Two piece style two 3 8 24 SHCS use 5 16 in hex key 1 SHCS socket head cap screw 2 For 600DX frame models the upper retaining rings are not used when the tension crosshead is in the highest notch position The crosshead is secured in place by the column caps Table 10 Retaining ring use style and f...

Page 41: ...the adjustable crosshead For procedure on moving the adjustable crosshead see Adjustable crosshead control switch in Table 9 on page 29 Always wear appropriate personal protective equipment when preparing operating and maintaining this equipment Personal protective equipment should include but is not limited to eye protection and head protection Other types of personal protective equipment may als...

Page 42: ...n be chosen for your specific application See Grip jaw selection on page 43 for some tips on selecting the appropriate grip jaws for your application Use of Molykote type GN metal paste high pressure lubricant is necessary for proper operation of the grips Instron recommends only this brand and type of high pressure lubricant Use of any other lubricant risks damage to the grip components This dama...

Page 43: ...s like those for cable type specimens are designed for a single size of specimen It is very important that the size of specimen to be tested falls within the specimen range of the grip jaws If the specimen is larger than the maximum or smaller than the minimum designed specimen range of the grip jaws do not use those grip jaws Also once the specimen is installed in the grip jaws the jaws should no...

Page 44: ...nt on the grip components is always moist and is not dry clumped or dirty Caution Use of Molykote type GN metal paste high pressure lubricant is necessary for proper operation of the grips Instron recommends only this brand and type of high pressure lubricant Use of any other lubricant risks damage to the grip components This damage would not be covered under warranty Make sure the specimen is cen...

Page 45: ...he tension crosshead and adjustable crosshead Be sure enough filler plates are installed so that the narrow end of the grip jaws does not protrude beyond the crosshead when the specimen is gripped Failure to keep the narrow end of the grip jaws inside the pocket during a test will cause serious damage to the grip jaws and lead to grip pocket deformation Use enough filler plates so that at least th...

Page 46: ...OT apply lubricant to the specimen gripping surface All equipment must be supplied by the customer unless noted as supplied For a list of equipment that was supplied with the system refer to Ancillary parts on page 87 Be careful not to injure fingers or hands when installing or removing grip jaws Grip jaws typically weigh at least 3 2 kgs 7 lbs Grip jaws come as matched pairs It is important that ...

Page 47: ... pocket See the NOTE above regarding matched grip jaw pairs Be sure to insert the jaws properly 5 Insert appropriate filler plates shoulders will rest on top of crosshead into the grip pockets from the top of the crosshead so that they sit between the sloped sides of the grip pocket and the sloped side of the grip jaw See the Filler plate guidelines G1 style crossheads only on page 45 for importan...

Page 48: ...sshead 4 Grip pocket 5 Grip stop plate 6 Socket head cap screw see Table 11 for size and quantity 7 Jaw retainer 8 Button head cap screw see Table 11 for size and quantity 9 Filler plate 10 Grip jaw 11 Bumper plate View A Tension Crosshead Exploded View Assembled View View B Adjustable Crosshead Exploded View Assembled View 6 5 8 7 9 10 4 2 9 5 9 3 2 1 2 11 9 10 4 2 ...

Page 49: ...can be inserted into the crosshead through the top of the grip pocket When step 4 is reached the grip jaws must be inserted one at a time into the pocket Also remember that the grip jaws must be inserted with the narrow end up 9 The grip jaws are now ready to clamp a test specimen See Insert specimen on page 56 for recommended procedures on inserting a specimen into the grip jaws When performing r...

Page 50: ...ler plates from the grip pocket b Rotate the crank handle to close the grip jaws until the grip jaws clear the pinion grip jaws will not extend any further This will raise the upper portion of the grip jaws out of the grip pocket c Hold the grip jaws in place with the crank handle and grasp one of the grip jaws d Continue to hold the grip jaw and rotate the crank handle to lower the remaining jaw ...

Page 51: ...e 11 use 4 mm hex key Warning 6 Repeat for each grip jaw Factory clamping speed is set to 4 mm sec 0 16 in sec closure rate or less A hazard to operators may be created if the clamping speed is adjusted faster than 4 mm sec 0 16 in sec Use caution if adjusting the clamping speed of the jaws The jaws can be adjusted to move very quickly Keep fingers and hands free of jaws Be careful not to injure f...

Page 52: ...90 ft lbs 10 mm M16 x 25 mm 4 10 mm Table 12 Specifications for cap screws Frame Model Guide Plate SHCS item 7 Figure 11 Grip Dust Cover BHCS item 10 Figure 11 Size Quantity per crosshead Torque Size of Hex Key Needed Size Quantity per crosshead Size of Hex Key Needed ...

Page 53: ...te front and rear 7 Socket head cap screw and washer see Table 12 for size quantity and torque 8 Piston dust cover 9 Grip dust cover 10 Button head cap screw see Table 12 for size and quantity 11 Wear plate 12 Guide pin one on each side of jaw carrier 13 Retainer setscrew M8 600DX only 14 Access hole for retainer setscrew 600DX only 15 Grip pocket 16 Guide slot for guide pin 17 Push plate and pist...

Page 54: ...ose position but will be put into Neutral mode i e will not function When power is restored to the frame the grips and the grip controls will remain in this hold neutral condition until the switch is reset The switch must be reset to restore grip function To reset the switch move it to the Neutral position and then operate as desired For conditions that result in loss of main power to the frame se...

Page 55: ...ls to fully open the grip jaws The grip jaws must be fully open 2 For 300DX frames pry a grip jaw and release it from the magnet in the jaw carrier use screwdriver For 600DX frames loosen the retainer setscrew 9 through the access hole on the front guide plate 6 Figure 11 use 4 mm hex key Only loosen the setscrew enough to release the grip jaw 3 Remove the grip jaw from the grip pocket 4 Repeat fo...

Page 56: ... guidelines on page 43 4 Clamp the grip jaws firmly in contact with the specimen 5 For frames with G1 style crossheads Remove the crank handle from both the upper and lower pinions If the crank handle is not removed damage to the pinion and the rack teeth of the grip jaws can occur 6 The specimen is now ready for testing Warning These grips are designed to grip specimens for testing Therefore an u...

Page 57: ...ration of 6 mm 0 25 in is sufficient 6 Determine the required test opening and stroke needed to complete the desired test Be sure to take into consideration the effective length of the fixtures that will be used the length or height of the specimen and the expected change in length or height that the specimen will undergo during the test Always wear appropriate personal protective equipment when p...

Page 58: ...ted for graphing and results Also the user may be prompted to perform some operation such as remove an extensometer When the operation has been performed click the appropriate button to continue the test 15 When the test is complete the system will automatically stop the test as determined by the test procedure 16 Remove the specimen and prepare the system for another test as applicable The test c...

Page 59: ...on 4 Exit the controlling software and any other software that is running Shut down the Windows Operating System 5 Turn off all peripheral equipment 6 Turn the system disconnect switch to OFF O If the frame will sit idle between tests press the DISABLE FRAME button in the controlling software to shut down the HPS For added precaution engage the Emergency Stop button to ensure that the HPS can not ...

Page 60: ...accessories mounted in the test space and personal injury is still possible Also any equipment in the tension test space may be damaged If possible remove any specimens from the frame If power can not be restored to the frame and it is necessary to retract the piston into the hydraulic cylinder contact your local Instron Services department as directed on page 20 for a solution Warning Caution On ...

Page 61: ...l only Preventative maintenance schedule Table 14 outlines a recommended preventative maintenance schedule for system components Always wear appropriate personal protective equipment when preparing operating and maintaining this equipment Personal protective equipment should include but is not limited to eye protection and head protection Other types of personal protective equipment may also be ne...

Page 62: ...is continuously between 60 and 80 deg C 140 and 176 deg F Change the oil see page 83 Frame Lubricate the adjustable crosshead see page 67 Biennially or once every 4000 hrs of operation 2 HPS For normal operating conditions where oil temperature is continuously below 60 deg C 140 deg F Change the oil see page 83 Every 5 years System Replace high pressure hydraulic hoses see page 86 Every 7 years Sy...

Page 63: ... in the retaining rings that support the tension crosshead on the columns Check that power is adequately supplied to the electronics Start up the system and check all indicator lights on the user control panel HPS controls and 59 Series control unit Check that the lights are not too bright or too dim and that they don t flicker If any of these conditions exist this could indicate a problem with th...

Page 64: ...ull the front cover 1 forward to remove it To install the covers perform the above procedures in reverse Tighten all cap screws until fully seated plus one quarter turn To remove one or both side covers 1 Loosen the two button head cap screws 4 Figure 14 from the appropriate side of the front cover It is not necessary to remove the cap screws just loosen them enough to remove the cover 2 Slide the...

Page 65: ...65 Preventative maintenance schedule Product Support www instron com Figure 14 Base covers 1 Front cover 2 Left side cover 3 Rear cover 4 Front side screws 5 Rear screws 1 3 5 4 2 ...

Page 66: ...ransducer cable connections at the frame and at the HPS Tighten any loose connections that you may find Inspect all cables for deterioration Check for abrasions cuts etc Replace cables as necessary If you notice any problems resulting from this inspection contact your local Instron Services department as directed on page 20 for immediate assistance Frame Warning Check non painted surfaces All non ...

Page 67: ...frame The backlash eliminator assemblies have nipple style grease fittings for easy lubrication All threads of the screw columns must have a coating of grease at all times The drive chain is located in the base of the frame Equipment and supplies required A nipple style grease gun Either a hand operated or pneumatic grease gun can be used For frames with G7 style crossheads DO NOT use the grease g...

Page 68: ... dried to a paste the old grease should be removed using solvent or diesel fuel before applying new grease Use caution to prevent solvent from contacting painted surfaces or skin Also use cautionary measures such as placing towels around the top of the backlash eliminator assembly to minimize the amount of solvent that gets into the backlash eliminator assembly For 600DX frames clean both screw co...

Page 69: ...Top plate 7 Grease fitting for backlash eliminator 8 Backlash eliminator assembly 9 Chain cover 10 M6 button head cap screw Rear view of 300DX with rear cover removed HPS also removed for clarity Side view of 600DX with side cover removed some internal parts also removed for clarity Rear view of 600DX with rear cover removed HPS also removed for clarity 1 2 3 4 5 7 8 2 8 6 7 3 4 9 10 ...

Page 70: ...nd any equipment from the frame In particular remove any towels from around the screw columns Warning d Start the system see page 37 e Raise or lower the adjustable crosshead until a new section of drive chain is exposed f Shut down the system see page 59 g Repeat steps b through f until all sections of the drive chain have been lubricated h For 600DX frames install the cover that was removed in s...

Page 71: ...airly constant as the piston moves Increases and decreases in the load reading could indicate that the piston is binding If you notice any problems resulting from this inspection contact your local Instron Services department as directed on page 20 for immediate assistance Inspect the hydraulic cylinder for signs of oil leakage as discussed in Make daily checks of system on page 63 If oil leakage ...

Page 72: ...cimen sized hole cut out in the middle For a really simple cover use a paper or Styrofoam plate Just make sure that the cover does not interfere with testing or operation of the grip assemblies Once the grip assemblies have been cleaned check the operation of the grip assemblies with a set of grip jaws installed Open and close the grip jaws several times and check for binding and abnormal noise Th...

Page 73: ...You will need a soft cloth and the grease gun loaded with a grease cartridge 1 Use the grip controls to fully open the grip jaws 2 Remove the grease fitting plug 13 Figure 17 from the dust cover to access the grease fitting 3 Using the soft cloth wipe away any dirt or specimen debris from the grease fitting of the jaw carrier that you want to lubricate 4 Attach the grease gun nozzle to the grease ...

Page 74: ...e locating boss the edge can be filed smooth Check the gripping teeth If more than 50 of the gripping teeth are broken or damaged the grip jaw should be replaced Check the entire grip jaw for cracks If any cracks are found the grip jaw should be replaced 2 For frames with G1 style crossheads Clean and inspect filler plates a Remove filler plates from each grip pocket b Clean lubricant from all fil...

Page 75: ...es gouged or worn surfaces bent edges and warping see Figure 16 for an example of a damaged wear plate If a wear plate has ANY damage replace it It is very important that the wear plates be free from damage If damaged wear plates are used damage to other grip components will occur d It is highly recommended that the wear plates are replaced anytime the jaw carriers are replaced see step 6 6 For fr...

Page 76: ...t b Inspect each grip pocket for damage For frames with G1 style crossheads use a flashlight to illuminate the surfaces of the grip pocket Check for signs of wear galling scoring or other damage Light scoring should be smoothed with a file or pneumatic sander If deformation of the pocket or severe scoring is noticed contact your local Instron Services department as directed on page 20 It may be po...

Page 77: ...on page 51 for size quantity and torque 3 Wear plate 4 Jaw carrier 5 Guide pin one on each side of jaw carrier 6 Grip jaw 7 Grip pocket 8 Guide slot for guide pin 9 Push plate and piston 10 Piston dust cover 11 Grip dust cover 12 Button head cap screw see Table 12 on page 51 for size and quantity 13 Grease fitting plug 14 Grease fitting 2 13 14 1 3 4 6 5 10 9 7 8 11 12 13 1 ...

Page 78: ...n teeth Some amount of broken teeth are acceptable but if it is affecting operation of the jaws then the pinion will need to be replaced Equipment required An 5 mm hex key supplied Recommended procedure To install a new pinion perform the following procedure 1 Remove the crank handle from the pinion 2 Loosen but do not remove the setscrew that holds the pinion in the crosshead use hex key The sets...

Page 79: ...ght gauge on the HPS The oil should be to the top of the sight gauge when the frame s hydraulic cylinder is fully retracted When it is necessary to add oil perform the following procedure Equipment and supplies required A 4 mm hex key supplied A clean funnel with a mesh filter Clean towels rags or similar Hydraulic fluid amount required depends on how much is needed to sufficiently fill reservoir ...

Page 80: ...ight gauge This will reset the temperature level switch c Remove the funnel d Install the air breather filter onto the reservoir fill hole 4 Start the HPS and fully retract the hydraulic cylinder 5 Press the DISABLE FRAME button in the controlling software to shut down the HPS 6 Remove the air breather filter from the reservoir fill hole push down and turn counterclockwise 7 Insert a clean funnel ...

Page 81: ...ron com Figure 20 Components of the HPS Rear and side covers removed 1 Motor 2 Air breather filter 3 Fill hole 4 Sight gauge 5 Oil filter 6 Heat exchanger and fan 7 System pressure gauge 8 Relief valve RV1 9 Servo manifold 10 Reservoir 1 2 4 10 9 7 6 5 3 8 ...

Page 82: ...l type and quantity on page 86 New oil filter element for Instron part number see Table 18 on page 90 New air breather filter for Instron part number see Table 18 on page 90 Recommended procedure Refer to Figure 20 on page 82 for identification of components 1 Remove the right side cover from the frame base Refer to Remove and install base covers on page 64 2 Start the HPS and fully retract the hy...

Page 83: ...down b Put towels around the base of the oil filter to absorb leaking oil c Start the HPS and monitor the flow of oil from the vent plug Watch for air bubbles in the oil Run the HPS until there are no more air bubbles Clean up any leaking oil d Press the DISABLE FRAME button in the controlling software to shut down the HPS e Tighten the vent plug use 9 16 in socket and torque wrench to a torque of...

Page 84: ... breather filter from the reservoir fill hole push down and turn counterclockwise Properly dispose of the air breather filter 4 Install the new air breather filter onto the reservoir fill hole 5 Install the cover that was removed in step 1 Inspect the hydraulic hoses Hydraulic hoses should be inspected at the frequency stated in the Preventative maintenance schedule on page 61 Check the following ...

Page 85: ...tuators Oil type and quantity The International Standards Organization ISO viscosity designation for oil appropriate to use in the reservoir is ISO VG 32 An ISO VG 32 grade oil was used to fill the hydraulic reservoir before the equipment left the factory As it becomes necessary to add to or replace the oil in the reservoir use an ISO VG 32 grade oil Many brand names contain this number In general...

Page 86: ...lies secure jaw retainer 300DX G1 300 8826 1020 8 Button head cap screw 3 8 16 x 0 75 in 600DX G1 300 8826 1027 8 Socket head cap screw M10 x 1 5p x 35 mm Grip assemblies secure grip stop plate to tension crosshead 300DX G1 300 8821 9310 2 Socket head cap screw M16 x 2p x 35 mm 600DX G1 300 8821 9511 2 Filler plate 3 16 in thick Grip assemblies 300DX G1 109797 1 1 12 600DX G1 126509 1B 16 Pinion G...

Page 87: ...shead must remove bumper plate 300DX G8 210150 1A 1 600DX G8 193418 1C 1 Hex key T handle 10 mm 6 in blade Tighten and loosen fixture holding screw in adjustable crosshead 300DX G8 300 8875 9344 1 Hex key T handle 3 8 in 6 in blade 600DX G8 300 8875 9234 1 Hex key T handle 4 mm 6 in blade Tighten and loosen M5 cap screws All 300 8875 9369 1 Hex key 14 mm L shape ball Tighten and loosen M16 cap scr...

Page 88: ...50 3 8 in ball end Tighten and loosen various fasteners All 300 8875 1958 1 Hex key set 9 piece 1 5 10 mm ball end Tighten and loosen various fasteners All 300 8875 9290 1 1 Part numbers are listed for reference only Some parts can not be ordered using these numbers contact your local Instron Services department as directed on page 20 to order parts Table 17 Ancillary parts list Continued Descript...

Page 89: ...ote GN metal paste 0 45 kgs 1 lbs can Lubricate grip assemblies 300DX G1 600DX G1 300 8894 9035 Lubricant Molykote GN metal paste 0 4 kgs 14 oz cartridge Lubricate grip assemblies 300DX G7 600DX G7 300 8894 9059 Adhesive Loctite 246 Threadlocker high temperature medium strength 10 mL 0 34 oz Maintain grip assemblies 300DX G7 600DX G7 300 8899 10741 Cleaner and degreaser Loctite 7070 ODC FREE 475 m...

Page 90: ...Chapter 4 Maintenance 90 M47 17027 EN ...

Page 91: ...n EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design BS EN 61326 1 2006 Electrical Equipment for Measurement Control and Laboratory Use EMC Requirements Low Voltage Directive 2014 35 EU EMC Directive 2014 30 EU Instron a division of Illinois Tool Works Inc Industrial Products Group Manufacturer Address Address Name and address of th...

Page 92: ...Appendix CE Certificate 92 This page is intentionally blank ...

Page 93: ...ge to the grips Table 19 Available grip jaws and their specifications Frame Model Grip Jaw Catalog Number Jaw Type1 Specimen Range2 Tooth Profile Jaw Face Size W x H Minimum Engagement 300DX G1 W 1214 Flat face 0 25 mm 0 1 in 16 tpi horizontal 65 deg 50 x 76 mm 2 x 3 in 60 mm 2 4 in W 1215 Vee face 12 32 mm 0 5 1 25 in 16 tpi horizontal 65 deg W 1215 A 5 13 mm 0 2 0 5 in 600DX G1 W 1408 Flat face ...

Page 94: ...al 65 deg 100 x 100 mm 4 x 4 in 80 mm 3 2 in W 5197 B 30 60 mm 1 18 2 36 in W 5198 A Vee face 3 10 mm 0 12 0 39 in 20 tpi horizontal 65 deg W 5198 B 10 35 mm 0 39 1 38 in W 5198 C 35 57 mm 1 38 2 25 in 10 tpi horizontal 65 deg 1 Flat face grip jaws are for testing square or rectangular specimens Vee face grip jaws are for testing round specimens 2 For flat face grip jaws this is the specimen thick...

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Page 96: ...Product Support www instron com ...

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