Industrial Products Group

Model DX Static Hydraulic

Universal Testing System

Operating Instructions
M47-17027-EN Revision C

www.instron.com

The difference is measurable ®

 Electromagnetic Compatibility

Where applicable, this equipment is designed to comply with International Electromagnetic

Compatibility (EMC) standards.

To ensure reproduction of this EMC performance, connect this equipment to a low imped-
ance ground connection. Typical suitable connections are a ground spike or the steel frame
of a building.

Proprietary Rights Notice

This document and the information that it contains are the property of Illinois Tool Works
Inc. (ITW). Rights to duplicate or otherwise copy this document and rights to disclose the
document and the information that it contains to others and the right to use the information
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 names listed are trademarks or trade names of their respec-
tive companies.

Original Instructions

Copyright © 2018 Illinois Tool Works Inc. All rights reserved. All of the specifications
shown in this document are subject to change without notice.

Corporate Headquarters European Headquarters

Instron Instron
825 University Avenue Coronation Road
Norwood, MA 02062-2643 High Wycombe, Bucks HP12 3SY
United States of America United Kingdom
 Preliminary Pages

General Safety Precautions

Materials testing systems are potentially hazardous.

Materials testing involves inherent hazards from high forces, rapid motions, and
stored energy. You must be aware of all moving and operating components in
the testing system that are potentially hazardous, particularly force actuators or
a moving crosshead.

Carefully read all relevant manuals and observe all Warnings and Cautions. The
term Warning is used where a hazard may lead to injury or death. The term
Caution is used where a hazard may lead to damage to equipment or to loss of
data.

Instron products, to the best of its knowledge, comply with various national and
international safety standards, in as much as they apply to materials and
structural testing. We certify that our products comply with all relevant EU
directives (CE mark).

Because of the wide 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 free of liability in this respect.

At your request, we will gladly provide advice and quotations for additional
safety devices such as protective shielding, warning signs or methods of
restricting access to the equipment.

The following pages detail various general warnings that you must heed at all
times while using materials testing equipment. You will find more specific
Warnings and Cautions in the text whenever a potential hazard exists.

Your best safety precautions are to gain a thorough understanding of the

equipment by reading your instruction manuals and to always use good
judgment.

It is our strong recommendation that you should carry out your own product
safety risk assessment.

Product Support: www.instron.com 3

Preliminary Pages

Warnings

Hazard - Press the Emergency Stop button whenever you consider that an unsafe
condition exists.
The Emergency Stop button removes hydraulic power or electrical drive from the testing
system and brings the hazardous elements of the system to a stop as quickly as
possible. It does not isolate the system from electrical power, other means are provided
to disconnect the electrical supply. Whenever you consider that safety may be
compromised, stop the test using the Emergency Stop button. Investigate and resolve
the situation that caused the use of the Emergency Stop button before you reset it.

Flying Debris Hazard - Make sure that test specimens are installed correctly in grips
or fixtures in order to eliminate stresses that can cause breakage of grip jaws or
fixture components.
Incorrect installation of test specimens creates stresses in grip jaws or fixture
components that can result in breakage of these components. The high energies
involved can cause the broken parts to be projected forcefully some distance from the
test area. Install specimens in the center of the grip jaws in line with the load path.
Insert specimens into the jaws by at least 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 open loop condition that may drive the actuator or crosshead
rapidly to its extremes of motion. Protect all electrical cables, particularly transducer
cables, from damage. Never route cables across the floor without protection, nor
suspend cables overhead under excessive strain. Use padding to avoid chafing where
cables are routed around corners or through wall openings.

High/Low Temperature Hazard - Wear protective clothing when handling equipment

at extremes of temperature.
Materials testing is often carried out at non-ambient temperatures using ovens,
furnaces or cryogenic chambers. Extreme temperature means an operating
temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F). You must use protective
clothing, such as gloves, when handling equipment at these temperatures. Display a
warning notice concerning low or high temperature operation whenever temperature
control equipment is in use. You should note that the hazard from extreme temperature
can extend beyond the immediate area of the test.

4 M47-17027-EN
 Preliminary Pages

Warnings

Crush Hazard - Take care when installing or removing a specimen, assembly,

structure, or load string component.
Installation or removal of a specimen, assembly, structure, or load string component
involves working inside the hazard area between the grips or fixtures. When working in
this area, ensure that other personnel cannot operate any of the system controls. Keep
clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between
the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or
crosshead movements necessary for installation or removal are slow and, where
possible, at a low force setting.

Hazard - Do not place a testing system off-line from computer control without first
ensuring that no actuator or crosshead movement will occur upon transfer to
manual control.
The actuator or crosshead will immediately respond to manual control settings when
the system is placed off-line from computer control. Before transferring to manual
control, make sure that the control settings are such that unexpected actuator or
crosshead 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 envelope of the robot. De-activate the robot before entering the envelope for
any purpose, such as reloading the specimen magazine.

Hazard - Set the appropriate limits before performing loop tuning or running
waveforms or tests.
Operational limits are included within your testing system to suspend motion or shut off
the system when upper and/or lower bounds of actuator or crosshead travel, or force or
strain, are reached during testing. Correct setting of operational limits by the operator,
prior to testing, will reduce the risk of damage to test article and system and associated
hazard to the operator.

Electrical Hazard - Disconnect the electrical power supply before removing the
covers to electrical equipment.
Disconnect equipment from the electrical power supply before removing any electrical
safety covers or replacing fuses. Do not reconnect the power source while the covers
are removed. Refit covers as soon as possible.

Product Support: www.instron.com 5

Preliminary Pages

Warnings

Rotating Machinery Hazard - Disconnect power supplies before removing the

covers to rotating machinery.
Disconnect equipment from all power supplies before removing any cover which gives
access to rotating machinery. Do not reconnect any power supply while the covers are
removed unless you are specifically instructed to do so in the manual. If the equipment
needs to be operated to perform maintenance tasks with the covers removed, ensure
that all loose clothing, long hair, etc. is tied back. Refit covers as soon as possible.

Hazard - Shut down the hydraulic power supply and discharge hydraulic pressure
before disconnection of any hydraulic fluid coupling.
Do not disconnect any hydraulic coupling without first shutting down the hydraulic
power supply and discharging stored pressure to zero. Tie down or otherwise secure all
pressurized hoses to prevent movement during system operation and to prevent the
hose from whipping about in the event of a rupture.

Hazard - Shut off the supply of compressed gas and discharge residual gas pressure
before you disconnect any compressed gas coupling.
Do not release 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 exists from the failure of a test specimen, assembly or
structure, particularly where explosive disintegration may occur. Due to the wide range
of specimen materials, assemblies or structures that may be tested, any hazard
resulting from the failure of a test specimen, assembly or structure is entirely the
responsibility of the owner and the user of the equipment.

Hazard - Ensure components of the load string are correctly pre-loaded to minimize
the risk of fatigue failure.
Dynamic systems, especially where load reversals through zero are occurring, are at risk
of fatigue cracks developing if components of the load string are not correctly pre-
loaded to one another. Apply the specified torque to all load string fasteners and the
correct setting to wedge washers or spiral washers. Visually inspect highly stressed
components such as grips and threaded adapters prior to every fatigue test for signs of
wear or fatigue damage.

6 M47-17027-EN
 Preliminary Pages

Table of Contents

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame configuration options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Testing accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Frame components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System safety and information labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Product support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 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 of tension test opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust the position of the adjustable crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust the position of the tension crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Change height of compression test opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjust the position of the adjustable crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Product Support: www.instron.com 7

Preliminary Pages

Operate grip assemblies - G1-style and G7-style crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Grip jaw selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Specimen guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General use guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Filler plate guidelines (G1-style crossheads only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install grip jaws - G1-style crossheads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Remove grip jaws - G1-style crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install grip jaws - G7-style crossheads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Remove grip jaws - G7-style crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Insert specimen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Run a test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 grip assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Clean and inspect grip components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Hydraulic power supply (HPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Check the oil cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Add oil to reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Change the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Change the air breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Inspect the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Replace the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Oil type and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Consumable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8 M47-17027-EN
 Preliminary Pages

Spare and replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Appendix A CE Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Appendix B Grip Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Product Support: www.instron.com 9

Preliminary Pages

10 M47-17027-EN
 Chapter 1
Introduction
• About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
• System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
• Frame components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• System control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• System safety and information labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• Product support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• System verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

About these instructions

These instructions describe the function, operation and maintenance for various models of the DX testing
systems. If unsure of your specific model, refer to “System identification” on page 14.

These instructions assume the following:

• You are an operator familiar with the operation of materials testing systems in general.
• Your system has been installed in its final location according to the requirements outlined in the
system’s Pre-Installation 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 materials testing software.
This is covered in more advanced training that can be provided by Instron Service and Training
departments.

Throughout your documentation are NOTE, CAUTION and WARNING statements that alert you to important
information. They appear as follows:

Notes provide further clarification on particular issues.

Caution
Cautions alert the user to situations that may cause equipment damage.

Warning
Warnings alert the user to situations that may cause serious personal injury or death.

11
Chapter 1: Introduction

Please read these instructions, and any other documents provided, thoroughly and carefully. Be sure to
understand all Warnings and Cautions before attempting to operate any of the system in whole or in part.

System overview
Purpose

Warning
If the equipment is used in a manner not specified by Instron, the protection provided by the
equipment may be impaired. Injury to personnel or damage to the system may result. Be
sure to read and understand the material presented in these instructions and in any other
accompanying instructions.

The Instron Model DX Static Hydraulic Universal Testing Systems are available in a variety of capacities.
They have been developed for high-capacity testing to provide the forces necessary for static tension,
compression, bend and shear testing. They are suited for tests on specimen samples such as bar, rebar,
plate, tube, pipe, sheet, wire, and concrete. These frames feature two 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 Instron materials testing software

Figure 1 identifies the system components and various frame configurations (see “Frame
configuration options” on page 14).

12 M47-17027-EN
 1. G1-style crossheads - Closed-front crossheads with
manually operated in-head wedge grips for tension
testing
2 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
1 pattern to accept compression fixtures
4. HPS and electronics located in base of frame
5. Optional operator dashboard/touch monitor

Figure 1.

Product Support: www.instron.com

5
3

4 4
4

DX testing systems - various configurations shown.

600DX Frame 300DX Frame 300DX Frame
shown with shown with shown with
G1-Style Crossheads G7-Style Crossheads G8-Style Crossheads
System overview

13
Chapter 1: Introduction

Frame configuration options

Frames can be configured with a variety of options. These options include:

• Crosshead variations:
• G1-style crossheads - Closed-front crossheads with manually operated grip assemblies for
tension testing
• G7-style crossheads - Open-front crossheads with hydraulically operated grip assemblies for
tension testing
• G8-style crosshead - Compression only frame with bolt pattern to accept compression fixtures
• Test opening variations:
• E1 - Standard tension opening
• E2 - Increase tension test space by: 610 mm (24 in) for 300DX frames, 406.4 mm (16 in) for
600DX frames

The configuration options selected for your frame are identified in the complete model number of the
frame. The complete model number is defined as:

{Capacity (in kN)}{Model family}-{Controller}{Crosshead style option}{Test opening option}

Some examples would be:

300DX-V1-G1-E1, 300DX-V1-G7-E1, 600DX-V1-G1-E1, 600DX-V1-G8

It is very important to be aware of and understand the configuration of your frame as you perform various
operations and procedures so that they can be performed correctly - the complete model number (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
Testing accessories are purchased separately from the frame. Testing accessories either provide a
means to secure the specimen in the test space or provide additional functionality to the frame.
Instructions on the installation, use and maintenance of Instron testing accessories are provided
separately with each testing accessory. A variety of testing accessories are available. Contact your
Instron Sales Representative for more information.

System identification
Your system has been given a unique serial number for system identification. This serial number can be
found on the serial tag located on the rear of the frame (i.e. the frame serial tag).

The frame serial tag includes other important system information, including information on your frame’s
configuration. Frame configuration information can also be found on your Instron quote. Refer to “Frame
configuration options” on page 14 for explanation of frame configuration.

14 M47-17027-EN
 System overview

Frame components
Refer to Figure 2 and Table 1 to identify components of the frame. For proper operation of the system,
it is important to be able to identify and to understand the basic function of these components.

1
3a

3b
1

2a

7
1

4a
1
4b

2b
8

5 View A
Loading Unit
6

9
View B
Fixed Unit

Frame with Frame with

G8-style G1-style or
crossheads G7-style
crossheads

Figure 2. DX frame components - for legend see Table 1.

Product Support: www.instron.com 15

Chapter 1: Introduction

Table 1. Frame component descriptions, see Figure 2.

Component Description

View A: Loading unit Applies load to the specimen during the test. Consists of: a tension crosshead1,
two notched columns1, a compression table, and the hydraulic cylinder.

View B: Fixed unit Remains fixed during the test. Consists of: an adjustable crosshead, two screw
columns, and the base.

1. Grip assemblies1 Secure a specimen for tensile testing. Grip assemblies are operated either
manually (G1-style crossheads) or hydraulically (G7-style crossheads). Refer to
“Operate grip assemblies - G1-style and G7-style crossheads” on page 42
for more information.

2. Test space Area where tests are performed. The DX is a dual test space frame. The tension
a. Tension1 test space is between the tension crosshead and adjustable crosshead. The
b. Compression compression test space is between the adjustable crosshead and compression
table.
The vertical opening of each test space can be adjusted. Refer to “Change
height of tension test opening” on page 38 and “Change height of
compression test opening” on page 41 for more information.

3. Tension crosshead1 Provides upper grip for tension specimen. Also provides mounting surface for
a. G7-style external tension fixtures, refer to “Mount fixtures” on page 34 for more
b. G1-style information.
The position of the tension crosshead can be adjusted to change the vertical
opening of the tension test space. Refer to “Adjust the position of the tension
crosshead” on page 38 for more information.

4. Adjustable crosshead For tension testing, provides lower grip for tension specimen. Also provides
a. G7-style mounting surface for external tension fixtures. Refer to “Mount fixtures” on
b. G1-style page 34 for more information.
c. G8-style (not shown) For compression testing, the bottom of the crosshead provides mounting surface
for upper compression fixtures - do not test directly against the bottom of the
adjustable crosshead. Refer to “Mount fixtures” on page 34 for more
information.
The position of the adjustable crosshead can be adjusted to change the vertical
opening of either test space. Refer to “Operation of controls” on page 29 for
more information.

5. Compression table Provides mounting surface for lower compression fixtures - do not test directly
against the compression table. Refer to “Mount fixtures” on page 34 for more
information.

6. Load cell Measures the force applied to the specimen.

7. Notched columns1 Connect the tension crosshead to the compression table. Notches allow position
of tension crosshead to be adjusted. Refer to “Adjust the position of the
tension crosshead” on page 38 for more information.

8. Screw columns Connect the adjustable crosshead to the base. Threaded portion of columns
allows position of adjustable crosshead to be adjusted. Refer to “Operation of
controls” on page 29 for more information.

9. Base Provides mounting for hydraulic cylinder. Houses the hydraulic power supply
(HPS).

1. These items provided on frames with G1-style or G7-style crossheads only.

16 M47-17027-EN
 System overview

System control components

Refer to Table 2 to identify control components of the system. For proper operation of the system, it is
important to be able to identify and to understand the basic function of these components.

Table 2. System control descriptions.

Component Description

Emergency stop Press this button to immediately stop motion of the frame. This stops
all frame motion and disables the frame. This button will take
precedence over all other system controls. Refer to Table 9 on
page 29 for more information.

Main power disconnect switch Provides control of main power to the system. When the switch is off,
all power to the frame, HPS and all system controls are shut off.
Power to the computer system is unaffected as it has its own power
supply.

Pump start Press this button to start the HPS. Refer to Table 9 on 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 The controls on this panel allow the operator to manually adjust the
hydraulic cylinder, to start and stop tests, to reset and return to the
zero extension point and other testing controls/functions. Refer to
Table 9 on page 29 for more information.

Adjustable crosshead control Allows the operator to jog the adjustable crosshead. This changes the
switch height of both the tension test opening and the compression test
opening.

Grip controls Allows the operator to open and close the grip jaws. Operated either
manually (G1-style crossheads) or hydraulically (G7-style crossheads).
Refer to “Operate grip assemblies - G1-style and G7-style
crossheads” on page 42 for more information.

Product Support: www.instron.com 17

Chapter 1: Introduction

System safety and information labeling

Table 3 explains the meanings of any safety and information labels that may be attached to any part of
the testing system.

Table 3. Descriptions of safety and information labeling.

Label Meaning and Purpose

Crush hazard - Indicates that a pinching or crush hazard exists from two objects coming together
and instructs the user to read and understand the operator’s manual before using the machine.

Electrical hazard - Indicates that a hazard exists from high voltage or electrical current.

Electrical hazard - Indicates that a hazard exists from leakage current and that the equipment must
be connected to a mains ground point.

High pressure hazard - Indicates that a hazard exists from high pressure. Do not adjust or reset any
pressure settings until you have read and understood the operator’s manual. Personal injury or
damage to equipment may result. Most pressure settings should only be adjusted by an Instron
service engineer.

Eye protection - Indicates that a flying debris hazard exists either from specimen failure or improper
use of system components. Wear eye 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 personnel should service the equipment.

Guard removal hazard - chain drive inside - Indicates that a hazard exists from a chain drive - do not
operate the system with covers removed. Be sure to read and understand the operator’s manual
before using the system. Only authorized personnel should service the equipment.

Hand crush hazard - Indicates that a pinching or crush hazard exists from two objects coming
together - movement from the sides.

Pinching hazard - Indicates that an increased risk of pinching hazard exists if the grip closing speed
is adjusted to be faster than 4 mm/sec (0.16 in/sec).

Ground stud - Indicates a ground stud. Connect to an appropriate ground/earth system.

Protective earth - Indicates the protective earth terminal for the main power supply.

Three-phase power supply - Indicates that the equipment requires a three-phase power supply.

Grip engagement - Indicates the proper amount of grip engagement to avoid damage to equipment.

18 M47-17027-EN
 System overview

Table 3. Descriptions of safety and information labeling. (Continued)

Label Meaning and Purpose

Grease location - Indicates the location of grease fitting to apply appropriate lubricant.

Product Support: www.instron.com 19

Chapter 1: Introduction

Product support
Instron provides documentation, including manuals and online help, that can answer many of the
questions you may have. It is recommended that you review the documentation sent with the system you
purchased for possible solutions to your questions.

If you cannot find answers in these sources, contact Instron’s Services department directly. A list of
Instron offices is available on our website at www.instron.com. You may email your questions to
service_support@instron.com (if your system is still in warranty, please include “IPG Warranty” in the
subject line). In the US and Canada, you can call directly at 1-800-473-7838.

Product documentation
Instron offers a comprehensive range of documentation to help you get the most out of your Instron
products. Depending on what you have purchased, your documentation may include some or all of the
following:

Pre-Installation Manual Information about preparing your site for installation of the system,
receiving the system, and lifting and handling of the system.

Operating Instructions How to use your system components and controls, and other frequently
performed operating tasks.

System Concepts Additional information about your system.

Online Help Software products come complete with context sensitive help, which
provides detailed information on how to use all software features.

Accessory Equipment How to set up and use any accessories you have purchased, for example
Reference grips, fixtures, extensometers, transducers, hydraulic power units, non-
standard actuators, and environmental chambers.

We welcome your feedback on 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 local Instron Representative for details.

20 M47-17027-EN
 Chapter 2
Specifications
• Use limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
• Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
• 59 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
• Environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
• Heat load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
• Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Use limits
Table 4 gives information on the use limits of the testing system, as determined in accordance with
ISO 12100, section 5.3.2.

Table 4. Use limits of the testing system.

Intended use When fit with appropriate fixtures, the system is intended to conduct static tension, compression, bend, flexure
and and shear tests on a variety of specimen shapes and material types. The material types must be limited to those
foreseeable that break into no more than two pieces that will be retained in the fixtures or whose failure does not result in
misuse: hazardous projectiles. The system can operate in servo control mode only through an Instron Materials Testing
Software package. The system must never be left unattended while in operation.
The system should not be used for any purpose other than static testing of the material types specified above. It
must not be used to test specimens of material types that result in hazardous projectiles unless an interlocked
guard with an appropriate performance level is added. You must conduct your own risk assessment and take
appropriate measures to prevent operator injury and guard the equipment. Instron offers safety rated guards for
this purpose. Please contact your local Instron representative for more information.
The system must 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 The system is equipped with Emergency Stop and software reset (frame enable) controls (see Table 2 on
procedures: page 17 and separately supplied Software documentation).

Use type: Industrial

Operator Typical adult in good health with no disabilities that prevent safe operation of the testing system.
characteristics:

Operator Operators should be familiar with the operation of materials testing systems in general and with the inherent
training/ hazards of such testing in particular. Operators should gain a thorough understanding of this equipment by
experience: reading these instructions and all other documents provided. Initial basic safety and operational training is
provided by Instron Service personnel during installation of the system.
Maintenance personnel or technicians should have sufficient training and skills so that they can safely perform
all procedures outlined in Chapter 4 beginning on page 61.
Trainees and apprentices should only operate or maintain the system under direct supervision of a qualified
operator or maintenance personnel.
The general public should not have access to the system.

Exposure of Exposure to hazards is greatly reduced by the knowledge of qualified operators. Anyone who does not fit the
other persons criteria specified in the “Operator characteristics:” and “Operator training/experience:” sections of this
to hazards: table should not have access to the system.

21
Chapter 2: Specifications

Frame
The technical specifications for the various standard DX frames can be found in Table 5. If unsure of the
options included with your frame, check the model number listed on the frame’s serial number tag; it
includes option designations.

E For legend, refer to Table 5.

A B
H
F

C
G

Figure 3. DX specification measurements.

Table 5. DX frame technical specifications.

Specification1 300DX 600DX

Maximum Capacity2 300 kN 600 kN

30,000 kgf 60,000 kgf
67,500 lbf 135,000 lbf
Design Capacity3 240 kN 480 kN
24,000 kgf 48,000 kgf
54,000 lbf 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 - 914 mm (16 - 36 in) 381 - 914 mm (15 - 36 in)

Fourth notch 610 - 1118 mm (24 - 44 in) 584 - 1118 mm (23 - 44 in)

Fifth notch 813 - 1321 mm (32 - 52 in) 787 - 1321 mm (31 - 52 in)

Sixth notch 1016 - 1524 mm (40 - 60 in) N/A

22 M47-17027-EN
 Frame

Table 5. DX frame technical specifications. (Continued)

Specification1 300DX 600DX

G7 First notch 0 - 305 mm (0 - 12 in) N/A5

Second notch 0 - 508 mm (0 - 20 in) 0 - 356 mm (0 - 14 in)

Third notch 203 - 711 mm (8 - 28 in) 25 - 559 mm (1 - 22 in)

Fourth notch 406 - 914 mm (16 - 36 in) 229 - 762 mm (9 - 30 in)

Fifth notch 610 - 1118 mm (24 - 44 in) 432 - 965 mm (17 - 38 in)

Sixth notch 813 - 1321 mm (32 - 52 in) 635 - 1168 mm (25 - 46 in)

Seventh notch N/A 838 - 1372 mm (33 - 54 in)

Total Tension Crosshead Notch Positions (per crosshead style and frame height option)

G1-E1 3 3

G1-E2 6 5

G7-E1 3 N/A

G7-E2 6 55

(B) Compression Test Opening6 Refer to the appropriate General Assembly drawing provided in the “Reference
Manual-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 General Assembly drawing provided in the “Reference
Manual-Equipment”7
(C) Horizontal Test Width

G1, G7 381 mm (15 in) 526 mm (20.688 in)

G8 395 mm (15.563 in) 526 mm (20.688 in)

Horizontal Test Depth

G1, G7 356 mm (14 in) 279 mm (11 in)

G8 356 mm (14 in) 559 mm (22 in)

Stroke 152 mm (6 in) 152 mm (6 in)

Adjustable Crosshead Travel 356 mm (14 in) 381 mm (15 in)

Product Support: www.instron.com 23

Chapter 2: Specifications

Table 5. DX frame technical specifications. (Continued)

Specification1 300DX 600DX

(D) Crosshead Thickness

G1 98 mm (3.875 in) 178 mm (7 in)

Tension crosshead:
356 mm (14 in)
G7 267 mm (10.5 in)
Adjustable crosshead:
381 mm (15 in)

G8 98 mm (3.875 in) 178 mm (7 in)

(E) Column Diameter

G1, G7 64 mm (2.5 in) 89 mm (3.5 in)

G8 51 mm (2 in) 64 mm (2.5 in)

(F) Maximum Overall Height Refer to the appropriate General Assembly drawing provided in the “Reference
Manual-Equipment”7
Overall Frame Area 786 x 943 mm 974 x 1205 mm
(width (G) x depth (H)) (30.94 x 39.13 in) (38.31 x 47.44 in)

Weight Refer to the appropriate General Assembly drawing provided in the “Reference
Manual-Equipment”7

Speed Information

Testing Speed Range

0.1 to 150 mm/min (0.004 to 6 in/min)
(at full load)

Jog (Adjusting) Speed

150 mm/min (6 in/min)
(Maximum)

Adjustable Crosshead Speed9

380 mm/min (15 in/min)
(Maximum)

Position Information

Accuracy10

Equal to or less than +/-0.13 mm (0.005 in) or +/-0.5% of displayed reading,

C4A
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 limit of the system. The frame
uses a single acting ram to apply load and is not capable of forced unloading
through hydraulics and relies solely on specimen compliance and/or gravity to return
the ram. Therefore, cycling performance is completely dependent on specimen
characteristics. In all cases, the frequency for cyclic testing is limited to 1 Hz or less.

Grip Wedge Pocket Alignment12

G1 Within +/-1.27 mm (0.050 in) left to right and front to rear

G7 Within +/-0.64 mm (0.025 in) left to right and front to rear

Compression Test Space Parallelism13 Within +/-0.001 mm/mm (0.001 in/in) left to right and front to rear

24 M47-17027-EN
 59 Series control unit

Table 5. DX frame technical specifications. (Continued)

Specification1 300DX 600DX

Power Requirements 200-250 VAC, 3Phase, 50/60 Hz, 15 Amp

380-415 VAC, 3Phase, 50/60 Hz, 10 Amp
440-480 VAC, 3Phase, 50/60 Hz, 10 Amp

Certifications Conform to all relevant European standards and carry a CE mark

1. G1 = Dual test space with open-front crossheads and manual crank and pinion grip actuation
G7 = Dual test space with open-front crossheads and hydraulic grip actuation
G8 = Compression only test space with open-front adjustable crosshead
E1 = Standard tension opening
E2 = Extended tension opening by:
- 610 mm (24 in) for 300DX frames
- 406.4 mm (16 in) for 600DX frames
2. Long term static tests should be limited to 30 minutes or less when the test is performed at or near maximum capacity. Time
varies inversely with test load. 50% maximum capacity tests should be limited to 60 minutes or less. An oil temperature
switch limits test duration based on safe reservoir temperature. Assumes ambient temperature of 25 deg C (77 deg F).
3. The design capacity is the peak load at which the frame should be used for no more than 80% of the time. In other words, at
least 80% of specimen testing should be conducted at peak loads that are at or below the design capacity. The frame should
only be used at loads between the design capacity and the maximum capacity less than 20% of the time.
4. Minimum and maximum tension test opening is provided for each crosshead style and each notch position of the tension
crosshead. First notch position is with the tension crosshead in the lowest notch on the columns. Number of notch positions
provided depends on frame height option purchased; not all frames have all notch positions listed. Minimum opening is with
the hydraulic cylinder fully retracted and the adjustable crosshead in highest position. Maximum opening is with the hydraulic
cylinder fully extended and the adjustable crosshead in lowest position. Values do not include crosshead thickness or any
specimen fixtures.
5. First notch should not be used; 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 supplied “Reference Manual-Equipment”. General Assembly
drawings are model specific; please be sure to refer to the appropriate drawing for your model and its configuration.
8. Several sets of grip jaws may be required to cover the range.
9. Adjustable crosshead speed is approximate and provided for reference only. Adjustment speed may vary depending on
crosshead type and fixtures attached to adjustable crosshead.
10.Under no load conditions. Accuracy is affected under load. The encoder cannot compensate for frame deflection (axial
stiffness) or the load cell and load string deflections. Over short travels and higher loads, the error could be over 100%.
Conversely, over longer travels and lower loads, the error may be insignificant. The axial frame stiffness and load cell stiffness
values published may be used to assess this affect. The load string also needs to be considered. In general, the extension
(position) readout should not be used as the primary strain measuring device where an extensometer on the specimen is
clearly warranted. Frame compliance can be accounted for to some extent by Instron software.
11.At speeds below approximately 0.1 mm/min (0.004 in/min) the hydraulic cylinder moves in increments approximately equal to
these values and can be seen as load steps depending on the specimen stiffness and load range.
12.Alignment of the grip wedge pockets is measured with approximately 200 mm (8 in) between crossheads in the tension test
space.
13.Parallelism is measured under no load conditions between the table and underside of the adjustable crosshead.

59 Series control unit

Table 6. 59 Series control unit technical specifications.

Data Sampling 40 kHz

Data Capture Selectable up to 1000 Hz1

Intelligent data capture
Synchronous on all channels

Product Support: www.instron.com 25

Chapter 2: Specifications

Table 6. 59 Series control unit technical specifications.

Digital Signal Processor 32-bit floating point

Self-test diagnostics
Real-time closed-loop control
Real-time data acquisition

Data Transfer to Computer 1000 Hz

Transducer Inputs Standard Instron rationalized transducers

Any 0-10 V analog DC input

Transducer Resolution 1 part in 500,000 of +/- full scale (19 bits)

Load Measurement Accuracy +/- 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 data capture rate may vary.

Environmental conditions
Table 7 lists the recommended environmental conditions in which the system should be operated and
stored.

Table 7. Recommended environmental conditions.

Operating Temperature: +10 to +38 deg C (+50 to +100 deg F)

Storage Temperature: -40 to +66 deg C (-40 to +150 deg F)

Humidity: 10% to 90% (non-condensing)

Atmosphere: Designed for use under normal laboratory conditions. Protective measures may
be required if excessive dust, corrosive fumes, electromagnetic fields, or
hazardous conditions are encountered.

Heat load
The HPS generates a certain amount of heat during operation. Refer to Table 8 for the approximate heat
output of the HPS operating at both a 10% duty cycle and 50% duty cycle. The duty cycle is defined as the
amount of time that the HPS operates under full load conditions. For example, operating at a 10% duty
cycle would mean performing approximately one 6-minute test at full load per hour.

Table 8. Approximate heat output of various frame models.

Approximate Heat Output at 10% Approximate Heat Output at 50%

Frame Model Duty Cycle Duty Cycle

300DX 232 W (792 BTU/hour) 459 W (1569 BTU/hour)

600DX 286 W (976 BTU/hour) 496 W (1694 BTU/hour)

26 M47-17027-EN
 Noise level

Noise level
The A-weighted emission sound pressure level generated by the testing system under normal operating
conditions does not exceed 70 dBA. The peak C-weighted instantaneous sound 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.

Frame

Approximately 500 mm (18 in)

Operator

Figure 4. Location of noise level reading.

Product Support: www.instron.com 27

Chapter 2: Specifications

28 M47-17027-EN
 Chapter 3
Operation
• Operation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
• Operation of HPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
• Mount fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• Start the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
• Change height of tension test opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• Change height of compression test opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• Operate grip assemblies - G1-style and G7-style crossheads . . . . . . . . . . . . . . . . . . . . . . 42
• Run a test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• Shut down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

Operation of controls
Table 9 provides details on the function and operation of various system controls. The controls supplied
with the system depend on options purchased - not all controls listed in Table 9 are supplied with every
system.

Table 9. Control functions.

Control Location Description

Emergency stop HPS control When it is necessary to stop motion of the frame immediately, press the
box Emergency Stop button. This shuts down the HPS and disables the
frame. To resume operation:
1. Release the Emergency Stop button by turning it clockwise as
depicted by the arrows on the knob face.
2. Enable the frame in the controlling software.
3. Press the Pump Start button. The green indicator light should
illuminate and the HPS should start.

Pump start HPS control Turns on the HPS. The frame must be enabled through the controlling
box software before the HPS can be started. The button will illuminate when
the HPS is on.

29
Chapter 3: Operation

Table 9. Control functions. (Continued)

Control Location Description

Adjustable crosshead HPS control Adjust the position of the adjustable crosshead either before or after a
control switch box test. This changes the height of both the tension test opening and the
compression test opening. Do not apply a load to the specimen using this
switch. If this control will not function, be sure the Emergency Stop
button is released. Move the adjustable crosshead as follows:
1. Start the system; see page 37. Start the HPS.
2. Rotate the switch in the required direction - Up and Down arrows
indicate resulting crosshead direction.
3. Hold the switch until the crosshead is at the required height.
4. Release the switch. The switch automatically returns to its neutral
position and crosshead motion stops.

Display and User control The display and its associated buttons operate together with the
associated buttons panel controlling software. The numbered buttons, labeled 1, 2, 3 and 4,
(Figure 5) operate as either “soft keys” or “live display keys” and the button to the
left of the display is the toggle button that switches the numbered buttons
between those two operations.
As soft keys, you can assign up to four functions that you use frequently,
such as Balance Load. Any soft key functions that you have assigned in
the controlling software are shown in the display next to the appropriate
button. Pressing a button performs the action displayed next to it.
As live display keys, you can assign up to four live displays. The live
displays are copies of any live displays that you have set up 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 These buttons actuate the piston of the hydraulic cylinder in the direction
panel indicated. When the JOG DOWN button is held longer than three
(Figure 5) seconds, the dump valve will open to allow oil to return directly to the
reservoir, thus providing for a faster unload rate. The dump valve actually
cycles to maintain the error signal within prescribed limits. This can cause
a pulsing sound from the frame while it is unloading. This is considered
normal and is not a cause for concern.
If you hold the button in, the adjustment speed increases linearly, up to a
preset maximum, until you release the button.

FINE JOG User control Turn this thumbwheel for slow but accurate positioning of the piston
(or FINE POSITION) panel within the hydraulic cylinder. FINE JOG allows you to set an accurate
(Figure 5) zero extension point, or to set a precise grip position for loading
specimens. It can also be used to apply a controlled preload to
specimens.

ZERO EXTENSION User control Press this button to set the current position of the piston as the zero
(or RESET GL) panel extension point (or gauge length) position. After setting the zero extension
(Figure 5) point, the piston returns to this position when:
• The piston encounters a pre-set limit or event that instructs the piston
to return to zero extension point
• You press the RETURN button (with Bluehill software only)

30 M47-17027-EN
 Operation of controls

Table 9. Control functions. (Continued)

Control Location Description

AT ZERO Indicator User control This indicator illuminates when the piston is at the preset zero extension
(or AT GL Indicator) panel point. It will also illuminate when you press the ZERO EXTENSION
(Figure 5) button, which indicates that the current position of the piston is now the
new zero extension point.

POWER Indicators User control This POWER indicator illuminates when power to the 59 Series control
panel unit is on.
(Figure 5) Associated with this are FRAME STANDBY and FRAME READY
indicators. Certain subsystems, such as the load cell and its conditioner
board, require a somewhat lengthy warm-up time. In FRAME STANDBY,
power is supplied to these subsystems but not to the HPS (frame is
disabled). In FRAME READY, the system supplies power to all
subsystems including the HPS (frame is enabled). The system is ready for
operation.

SPECIMEN PROTECT User control SPECIMEN PROTECT is an electronic function that protects test
and Indicator panel specimens and load cells from overload during test setup. Press this
(Figure 5) button to toggle this function on and off. The ON indicator shows when
SPECIMEN PROTECT is on and off. The indicator blinks when
SPECIMEN PROTECT is on. SPECIMEN PROTECT must be set up in
the controlling software before 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 Press this button to begin the test once all test parameters are set. Up
panel and Down Arrow indicators show the type of test selected (Up indicates
(Figure 5) tension and Down indicates compression).
STOP TEST User control Press this button to stop motion of the piston at the end of the test, if it
panel has not already been programmed at the computer.
(Figure 5)

RETURN User control This function is dependent on the controlling software; refer to the
panel controlling software’s On-line Help.
(Figure 5)

LOAD 59 Series A female 25-pin interface that connects the system’s load cell to the
control unit transducer conditioning card.

STRAIN 1 59 Series A female 25-pin interface that connects an extensometer to an optional

control unit transducer conditioning card.

STRAIN 2 59 Series A female 25-pin interface that connects an extensometer to an optional

control unit transducer conditioning card. (Typically only required for transverse strain
or other dual extensometer setups.)

SERVICE Display 59 Series Provides an indication of self-tests that are performed by the controls
control unit when the system is powered up and is also an indicator of system status.
System status is normal when the T indicator is green and the A indicator
is blinking red.

Product Support: www.instron.com 31

Chapter 3: Operation

Figure 5. User control panel.

32 M47-17027-EN
 Isolation of HPS from the load frame

Operation of HPS
The HPS is operated by controls on the front panel of frame base and the user control panel, and by
functions within the controlling software. Methods to start and stop the HPS are provided in Table 9 on
page 29, “Run a test” on page 57 and “Shut down the system” on page 59.

When the HPS is on, the hydraulic cylinder should be positioned so that the piston is neither fully
retracted nor fully extended. When the hydraulic cylinder is in either of these conditions, it is difficult for
the 59 Series controls to maintain the position and the servo loop control could build up enough error to
shut down the HPS.

Isolation of HPS from the load frame

There may be some testing applications where it is desirable to isolate the Hydraulic Power Supply from
the load frame. 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

Figure 6. Location of screws on 300DX

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 head cap screws from
the left and right of the machine (No. 1 in Figure 6).
4. Loosen the lock nuts around the 4 set screws (No. 2 in Figure 6) to allow the set screws to turn.
5. Using a 6 mm hex wrench, rotate the 4 set screws (No. 2 in Figure 6) to raise the HPS so that it is
clear of the frame mounting.
6. Using a 10 mm hex wrench, lower the leveling feet on the base of the HPS (No. 3 in Figure 6) so that
the HPS is supported on the leveling feet.
7. Check clearances all around the base of the HPS. If any part of it is in contact with the frame base,
use the set screws and leveling feet to make adjustments to avoid contact.

Product Support: www.instron.com 33

Chapter 3: Operation

8. Remove the 4 set screws and lock nuts (No. 2 in Figure 6).
9. Reinstall the rear and side panels. Reconnect the power supply and power on the machine. Check for
leaks and proper machine operation.

Procedure for 600DX frames

Figure 7. Location of screws on 600DX

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 (six black socket head cap screws from
the left and right of the machine (No. 1 in Figure 7).
4. Using a 10 mm hex wrench, lower the leveling feet on the base of the HPS (No. 2 in Figure 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
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

34 M47-17027-EN
 Mount fixtures

Use of lifting or handling equipment (i.e. overhead crane, hoist, etc.) may be necessary to lift and install
testing accessories. Many testing accessories weigh in excess of 15 kgs (30 lbs) and may be difficult for
operators to install and remove from the frame. All of these considerations are the responsibility of the
customer.

The frame is supplied with multiple bolt patterns for the mounting of specimen load trains and testing
accessories. Some bolt patterns are designed for the mounting of specific standard Instron accessories
or fixtures, while others are more general for the mounting of a wide range of standard Instron
accessories or fixtures. Any bolt pattern can be used for the mounting of customer fixtures; appropriate
adaptation may be necessary. The capacity of any load train or accessory may be limited by the capacity
of the bolt pattern being used. Most bolt patterns can accommodate testing at full frame capacity. Refer
to the Note below.

Details of the bolt patterns provided on your frame can be found on the General Assembly drawing that is
located in the separately supplied “Reference Manual-Equipment”. General Assembly drawings are
model specific; please be sure to refer to the appropriate drawing for your model and its configuration.

Any bolt pattern that is six M10 x 1.5p tapped holes equally spaced on a 100 mm (3.937 in) bolt circle
diameter can only accommodate low range tension testing up to 100 kN (22,500 lbs).

Mount tension fixtures

When it is desired to use other tension fixtures instead of the grip assemblies to grip a specimen, external
tension fixtures (purchased separately) can be mounted to the tension crosshead and adjustable
crosshead with proper adapters. Adapters can either be clamped in the grip assemblies or bolted to the
crossheads using the bolt pattern provided on the top or bottom of each crosshead. For operation 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 compression fixtures can be mounted to the bumper plate by one of two methods:
• Bolt the fixture directly to the bumper plate using the bolt pattern provided in the bumper plate.
• Use the setscrew and button hole provided in the bumper plate, see Figure 8. The compression
fixture must be equipped with a mounting button that fits into the button hole, as shown in
Figure 8. The setscrew is tightened against a recess in the holding button.
• Lower compression fixtures can be mounted to the compression table using the bolt pattern provided
in the compression table. Depending on the compression fixture, it may not be necessary to secure
the fixture to the table, refer to any instructions provided with your fixture.

Product Support: www.instron.com 35

Chapter 3: Operation

1 1. Bumper plate (typical)

2. Setscrew, M8
2 3. Button hole, 25 mm (1 in) diameter
4. Mounting button
3 5. Compression fixture

Figure 8. Example of bumper plate.

36 M47-17027-EN
 Mount fixtures

Start the system

This document presumes that customer training (by Instron service personnel) has been completed and
that at least one procedure has been created in the controlling software.

Before operating the system:

• Familiarize yourself with the operating features and controls described in these instructions and in all
other accompanying documentation for the controlling software.
• Verify that your system voltage is compatible with your power supply.
Following is the recommended procedure for system startup:

1. Be sure that the proper rating of main power is supplied to all system components and that all
electrical cables are plugged in.
2. If the system includes an expansion channel module, turn the power switch on the rear of the module
to ON ( | ).
3. Turn the system disconnect switch to ON ( | ).
4. Turn on power to all peripheral equipment that interfaces with the computer system. This includes
the monitor, printer, any digital calipers, etc. Turn on power to the computer’s CPU (central
processing unit).
5. Check the display on the user control panel. The display shows an hour glass while the controls
perform self-tests. Once the hour glass goes away, start the controlling software.

While the controlling software and control electronics are booting up, do not press any control buttons.
This could cause a failure during some of the self-test routines.

6. 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

If the SERVICE display flashes the letter “F” during startup, it indicates that an error has occurred. Refer
to “Troubleshooting” in the System Concepts Manual (supplied separately) for more information.

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. Calibrate the load cell and let the system warm-up for at least 15 minutes to assure system stability,
then re-calibrate.

A fifteen minute warm-up period is also necessary whenever a load cell is changed, or after the initial
connection of a strain gauge. After the warm-up period, the load cell or strain gauge must be calibrated.

Product Support: www.instron.com 37

Chapter 3: Operation

Change height of tension test opening

Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

Frames with G8-style crossheads do not have a tension test space and do not have a tension crosshead
or notched columns.

The height of the tension test opening can be changed. To change the height, adjust the position of the
adjustable crosshead, the tension crosshead, or both. Adjustment can only be done between tests, never
during a test.

Adjust the position of the adjustable crosshead

For procedure on moving the adjustable crosshead, see “Adjustable crosshead control switch” in
Table 9 on page 29.

Adjust the position of the tension crosshead

The crosshead can be placed at any of the available notches in the notched columns (see Table 5 on
page 22 for available notch information). The tension crosshead is supported and secured by retaining
rings that fit into the notches. The number and style of retaining rings used depends on the frame model,
see Table 10 on page 39. However, all frame models have lower retaining rings that are installed in the
notches that are directly below the crosshead.

Equipment required
• A suitable stable platform such as a man-lift, stairs, or ladder. The 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 blocks of lumber can be placed between the tension
crosshead and the adjustable crosshead. Adjust the crosshead as follows:
a. To lower the tension crosshead, raise the adjustable crosshead so that it has enough travel to
move downward.
b. To raise the tension crosshead, lower the adjustable crosshead so that it has enough travel to
move upward.

38 M47-17027-EN
 Mount fixtures

3. Place the lumber between the adjustable crosshead and tension crosshead. Ensure that the tension
crosshead is securely supported and level. If the tension crosshead does not remain level during
adjustment, it can bind on the columns and become stuck.
4. Loosen the socket head cap screws that secure each retaining ring (1 and 4, Figure 9) (use hex key).
Remove the retaining rings from each column. If spacers (2) are present do not remove them; they
will simply slide along the column as the crosshead is moved, just make sure that they slide smoothly
over any notch.
5. Adjust the adjustable crosshead until the lower surface of the tension crosshead is above the desired
notch.
6. Reinstall the lower retaining rings according to the style of retaining rings used for your frame (see
Table 10 on page 39):
a. For frames that use the bolt-on style of lower retaining rings, place the lower retaining rings (4)
into the notches and start the socket head cap screws into the bottom of the tension crosshead.
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 rests on the lower retaining rings.
Place the upper retaining rings (1) into the notches and tighten the socket head cap screws until
seated plus one-quarter turn.

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.

7. Lower the adjustable crosshead and remove the lumber.

8. Normal operation can now resume.

6
1
1. Upper retaining ring
2 2. Spacer (not used on all models)
3. Tension crosshead
3 4. Lower retaining ring
5. Notch
4 6. Column cap or bolt

Figure 9. Tension crosshead and retaining rings.

Table 10. Retaining ring use, style and fastener information.

Frame
Model Upper Retaining Ring Spacer Lower Retaining Ring

Hinged clam style, one M8 SHCS1 Hinged clam style, one M8 SHCS
300DX-G1 Yes
(use 6 mm hex key) (use 6 mm hex key)

Product Support: www.instron.com 39

Chapter 3: Operation

Table 10. Retaining ring use, style and fastener information. (Continued)

Frame
Model Upper Retaining Ring Spacer Lower Retaining Ring

Split bolt-on style, four M10 x 35 mm SHCS

300DX-G7 No No
(use 8 mm hex key)

Two-piece style, two 3/8-24 SHCS

Two-piece style, two 3/8-24 SHCS
600DX-G1 (use 5/16 in hex key) No
(use 5/16 in hex key)
Not used when crosshead in highest notch position

Two-piece style, two 3/8-24 SHCS

Two-piece style, two 3/8-24 SHCS
600DX-G7 (use 5/16 in hex key) No
(use 5/16 in hex key)
Not used when crosshead in highest notch position2

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.

40 M47-17027-EN
 Mount fixtures

Change height of compression test opening

Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

The height of the compression test opening can be changed. To change the height, adjust the position of
the adjustable crosshead. Adjustment can only be done between tests, never during a test.

Adjust the position of the adjustable crosshead

For procedure on moving the adjustable crosshead, see “Adjustable crosshead control switch” in
Table 9 on page 29.

Product Support: www.instron.com 41

Chapter 3: Operation

Operate grip assemblies - G1-style and G7-style

crossheads
Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

Warning
These grips are designed to grip specimens for testing. Therefore, an unavoidable pinching
hazard exists. Make sure to read and understand all installation, removal and operating
instructions before using the grips!

Caution
Improper alignment of grip jaws and specimen will cause grip jaw damage and lead to grip
pocket deformation. Be sure to read and obey the guidelines outlined on page 43 through
page 44.

Grip assemblies are provided on frames with either G1-style or G7-style crossheads. Both the tension
and adjustable crossheads are equipped with grip assemblies that are designed to grip specimens for
tensile testing. Frames can be purchased with either manual grip actuation (G1-style crossheads) or
hydraulic grip actuation (G7-style crossheads).

Regardless of which type of grip actuation your frame is equipped with, the basic method of grip operation
is the same. Each crosshead has a grip pocket with sloped sides (see Figure 10 on page 48 and
Figure 11 on page 53). A matching pair of grip jaws fits into each grip pocket. The initial clamping force
on the specimen is applied manually or hydraulically (as per crosshead style - G1 or G7), and then as load
is applied to the specimen, the sloped sides of the grip pockets cause the grip jaws to tighten further on
the specimen.

The grip jaws are purchased separately from the frame so that the appropriate jaw type can 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 damage would not be covered under warranty. A
small amount of Molykote type GN metal paste is supplied with the frame, additional quantities can be
purchased from Instron, contact your local Instron Services department as directed on page 20. Be sure
to apply the lubricant as specified in these instructions.

The following sections provide more details on grip jaw selection, grip jaw installation, and grip use. Refer
to the appropriate section for your frame’s crosshead style.

42 M47-17027-EN
 Mount fixtures

Grip jaw selection

A specimen’s size, shape and hardness must be considered when selecting the correct set of grip jaws to
test that specimen. Improper selection of grip jaws can allow specimen slippage. Specimen slippage will
cause excessive and premature wear of the grip jaw’s teeth and further reduce the grip jaw’s gripping
ability.

In general, there are three criteria to consider when selecting a set of grip jaws:

• Face profile: The grip jaw’s gripping face is made with a certain profile to fit the cross section of the
specimen. The two most common face profiles are flat and vee. Flat-face grip jaws are used to test
rectangular, or flat, specimens. Vee-face grip jaws are used to test round specimens, including rebar
specimens. There are also grip jaws that have a semi-circular profile for testing cable-type
specimens.
• Tooth profile: The surface of the gripping face is cut with a specific tooth profile to provide gripping
ability. The tooth profile is defined by the cut of the teeth and the spacing of the teeth. The tooth cut
is typically diamond or horizontal (also known as serrated). The tooth cut may affect the gripping
effectiveness on some specimen types. The spacing of the teeth can be reported in either a pitch
measurement (distance between rows of teeth) or the number of teeth per inch (TPI). A finer tooth
(i.e. smaller pitch or larger TPI) typically works best for softer materials and smaller specimens. A
coarse tooth (i.e. larger pitch or smaller TPI) typically works best for harder materials and larger
specimens.
• Specimen range: Grip jaws are typically designed to test a specific range of specimen sizes.
However, certain types of grip jaws, 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 not extend out of the grip body. This includes the position
of the grip jaws at the end of the test. If the grip jaws do extend more than 7 mm (0.25 in) at the end
of the test, this would indicate the wrong size jaws are being used.

Instron offers a wide selection of grip jaws. For further information about the sizes and types of jaws
available, see Appendix B. You can also contact your regional Instron office or check our web site at
www.instron.com for assistance.

Specimen guidelines
It is important to obey proper guidelines when preparing and testing a specimen:

• Do not attempt to test specimens that are of incorrect length:

• For typical flat grip jaws and vee grip jaws, the specimen must be long enough to allow it to be
gripped by at least 80 percent of the gripping face of each grip jaw. When less than 80 percent
of the grip jaw’s gripping face is used to clamp the specimen, the grip jaw will tip and cause
damage to the grip pocket and internal grip components. Often the specimen may slip and
cause damage to the face of the grip jaws.
• For cable jaw inserts, the specimen must be long enough to allow it to be gripped by 100 percent
of the gripping face of each grip jaw.
• Set the jaws firmly in contact with the specimen but do not hammer on the grip jaws or any other
component of the grip assemblies to tighten the grip jaws.
• Watch for signs of specimen slippage and stop the test if slippage occurs.
• Be sure that the tooth pattern of the grip jaws is sufficient for the specimen’s material type.

Product Support: www.instron.com 43

Chapter 3: Operation

General use guidelines

It is important to obey the following guidelines when using the grip assemblies:

• For frames with G1-style crossheads: Use sufficient filler plates.

• Be sure to properly maintain the grip assemblies as outlined in “Grip assemblies - G1-style and
G7-style crossheads” on page 72.
• Keep grip components well lubricated as instructed in grip jaw installation procedures and in “Grip
assemblies - G1-style and G7-style crossheads” on page 72. It is important that the lubricant
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 centered in the grip jaws.
• For frames with G1-style crossheads: Keep the grip jaws centered in the grip pocket by using an
equal number of filler plates behind each grip jaw.
• Keep the ends of each pair of grip jaws even.
• Use the proper type of grip jaws for your specimen.
• DO NOT lubricate the gripping face of the grip jaws.

44 M47-17027-EN
 Mount fixtures

Filler plate guidelines (G1-style crossheads only)

Filler plates are used for G1-style crossheads only.

Filler plates are an important part of the specimen gripping assembly. They assure the alignment of the
specimen with the centerline of the grip pocket as well as axial alignment of the specimen. They also
assure that the grip jaws do not extend beyond the crosshead (into the test space) when the specimen is
gripped. Tests that are performed with the grip jaws extended beyond the crosshead will cause serious
damage to the grip jaws and lead to grip pocket deformation. Grip jaw damage and grip pocket
deformation caused by this type of use is NOT covered under warranty, see “Specimen guidelines” on
page 43 for more information.

When installing filler plates, it is imperative to remember the following:

• Insert the filler plates into the grip pocket from the top of the crosshead so that they sit between the
grip pocket and the sloped side of the grip jaw. The shoulders of the filler plate rest on the top of the
crosshead and prevent the filler plate from falling through the crosshead.
• Install filler plates of the same total thickness behind each grip jaw. This assures alignment of the
specimen with the centerline of the pocket as well as axial alignment of the specimen between the
tension crosshead and adjustable crosshead.

This does not apply to grip jaws that are made to test non-uniform specimens, such as angle grip jaws. In
these cases, it is typically necessary to use filler plates of different thickness for each grip jaw so that
proper specimen alignment can be achieved. The goal is to achieve alignment of the specimen with the
centerline of the pocket as well as axial alignment of the specimen between the 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 the minimum gripping requirements are met; see “Specimen
guidelines” on page 43. When the minimum gripping requirements are NOT met, the grip jaw will
tip and cause damage to the grip pocket and other grip components. Often the specimen may slip
and cause damage to the face of the grip jaws.

Caution
Tests that are performed with the grip jaws extended beyond the crosshead will cause
serious damage to the grip jaws and lead to grip pocket deformation. Use as many filler
plates as required so that the narrow end of the grip jaws does not protrude beyond the
crosshead when the specimen is gripped.

Product Support: www.instron.com 45

Chapter 3: Operation

Install grip jaws - G1-style crossheads

Equipment and supplies required

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.

• A suitable stable platform such as a man-lift, stairs, or ladder. The platform must be of sufficient
height so that the operator can reach the tension crosshead.
• Hex keys, see Table 11 on page 49 for sizes
• Molykote type GN metal paste

Recommended procedure

Warning
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 grip jaws are installed into the grip pockets as a
matched pair. If they are not installed as matched pairs, the grips will not function. Matched pairs can
be determined by placing the gripping teeth faces together as depicted below. Place each matched pair
into the appropriate crosshead so that the rack teeth meet with the pinion.
For grip jaws with horizontal rack teeth:
Top view
Place the gripping teeth faces of the
grip jaws together so that a “V” is formed.
Front view When a “V” is formed, the rack teeth faces of each grip jaw
should be on the same side.

For grip jaws with angled rack teeth:

Upper left Upper right

Gripping teeth faces

Lower left Lower right

1. Remove the grip stop plate (5, Figure 10) from the top of the tension crosshead by removing the two
socket head cap screws (6) that hold the plate to the crosshead (use hex key stated in Table 11).
2. Be sure a jaw retainer (7) is installed on each grip jaw as shown in Figure 10 (use hex key stated in
Table 11).
3. Lubricate the rear and sides (the smooth surfaces that come into contact with the grip pocket or filler
plate) of each jaw with Molykote type GN metal paste. Apply lubricant liberally. DO NOT apply
lubricant to the specimen gripping surface.

46 M47-17027-EN
 Mount fixtures

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.

It is important that the lubricant on the grip jaws, grip pocket and filler plates is always moist and is not
dry, clumped or dirty.

4. Insert the grip jaws into the grip 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
important information on selecting and inserting filler plates.

Product Support: www.instron.com 47

Chapter 3: Operation

7
View A
Tension Crosshead

10

Exploded View Assembled View

9 5
1. Tension crosshead
2. Crank handle and pinion
3. Adjustable crosshead
1
4. Grip pocket
5. Grip stop plate
6. Socket head cap screw
2
(see Table 11 for size and quantity)
7. Jaw retainer
9 8. Button head cap screw
(see Table 11 for size and quantity)
9. Filler plate
3 10. Grip jaw
11. Bumper plate
2

11

10
View B
Adjustable Crosshead

Exploded View Assembled View

Figure 10. Components of the grip assemblies for G1-style crossheads.

48 M47-17027-EN
 Mount fixtures

Warning
Be careful not to injure fingers when inserting heavy filler plates.

Caution
Grip jaws that extend beyond the crosshead during a test will cause serious damage to the
grip jaws and lead to grip pocket deformation. Use as many filler plates as required so that
the narrow end of the grip jaw does not protrude through the crosshead when the specimen
is gripped.

6. Open and close the grip jaws several times using the crank handle to check grip jaw action and
ensure freedom of movement. If the grip jaws stick, remove them and apply more lubricant until the
problem is resolved.
7. Install the grip stop plate on the tension crosshead and secure with the socket head cap screws (use
hex key stated in Table 11).
8. Repeat steps 3 through 6 to install the remaining set of grip jaws into the adjustable crosshead. It is
not necessary to remove the bumper plate from the bottom of the crosshead because the grip jaws
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 repeated
tests with the same set of grip jaws, it will be necessary to apply fresh lubricant to the grip jaws and
filler plates as described in “Lubricate the grip assemblies” on page 72.

Filler plates can be inserted or removed from the tension crosshead with the grip stop plate in place.

Table 11. Specifications for grip stop plate and jaw retainer cap screws.

Grip Stop Plate SHCS Jaw Retainer BHCS

(item 6, Figure 10) (item 8, Figure 10)

Size of Hex Key Size of Hex Key

Frame Model Size Quantity Needed Size Quantity Needed

300DX-G1 M10 x 30 mm 2 8 mm 3/8-16 x 0.75 in 4 7/32 in

600DX-G1 M16 x 35 mm 2 14 mm 3/8-16 x 0.75 in 4 7/32 in

Product Support: www.instron.com 49

Chapter 3: Operation

Remove grip jaws - G1-style crossheads

Equipment required

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.

• A suitable stable platform such as a man-lift, stairs, or ladder. The platform must be of sufficient
height so that the operator can reach the tension crosshead.
• Hex keys (supplied), see Table 11 on page 49 for sizes

Recommended procedure
1. Remove the grip jaws from the tension crosshead:
a. Filler plates can be removed although this is not necessary.
b. Remove the grip stop plate (5, Figure 10) from the top of the tension crosshead by removing the
two socket head cap screws (6) that hold the plate to the crosshead (use hex key stated in
Table 11).
c. Turn the crank handle to place the grip jaws in the fully opened position.
d. Hold the crank handle and lift each grip jaw out of the grip pocket.
2. Remove the grip jaws from the adjustable crosshead (it is not necessary to remove the bumper
plate (11) from the bottom of the crosshead; the grip jaws can be removed one at a time from the top
of the grip pocket):
a. Remove all filler 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; this
provides clearance for removal of the first grip jaw.
e. Lift the first grip jaw out of the grip pocket.
f. Rotate the crank handle to raise the remaining grip jaw.
g. Grasp the grip jaw and remove it from the grip pocket.

Install grip jaws - G7-style crossheads

Equipment and supplies required

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.

• A suitable stable platform such as a man-lift, stairs, or ladder. The platform must be of sufficient
height so that the operator can reach the tension crosshead.
• 4 mm hex key (supplied)

50 M47-17027-EN
 Mount fixtures

• Molykote type GN metal paste

Recommended procedure

Warning
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.

Warning
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) each.

Each grip jaw has an alignment hole to assure proper orientation in the grip pocket and proper teeth
alignment. Left and right grip jaws are typically interchangeable.

1. Start the system; see page 37. Start the HPS.

2. Use the grip controls to fully open the jaw carriers (see Table 13 on page 54 for operation of grip
controls). The jaw carriers must be fully open.
3. Lift a grip jaw into the grip pocket and align the alignment hole (3, Figure 12) in the grip jaw to the
alignment pin (4) in the jaw carrier.
4. Place the locating boss (2) into the jaw carrier recess (5).
5. For 300DX frames, the magnet (7) will hold the grip jaw in place. For 600DX frames, tighten the
retainer setscrew (9) against the retainer button (8) through the access hole on the front guide
plate (6, Figure 11) (use 4 mm hex key).

Warning
For 600DX frames: The tightness of the retainer setscrew (13, Figure 11 on page 53) should
be checked after 50 consecutive tests are performed with the same set of grip jaws. The
retainer setscrews can vibrate loose and allow the grip jaws to fall out of the jaw carriers.

6. Repeat for each grip jaw.

Table 12. Specifications for cap screws.

Guide Plate SHCS Grip Dust Cover BHCS

(item 7, Figure 11) (item 10, Figure 11)

Quantity Size of Quantity Size of

Frame (per Hex Key (per Hex Key
Model Size crosshead) Torque Needed Size crosshead) Needed

34 N-m
300DX-G7 M8 x 25 mm 4 6 mm M12 x 20 mm 4 8 mm
(25 ft-lbs)

Product Support: www.instron.com 51

Chapter 3: Operation

Table 12. Specifications for cap screws.

Guide Plate SHCS Grip Dust Cover BHCS

(item 7, Figure 11) (item 10, Figure 11)

Quantity Size of Quantity Size of

Frame (per Hex Key (per Hex Key
Model Size crosshead) Torque Needed Size crosshead) Needed
122 N-m
600DX-G7 M12 x 25 mm 6 10 mm M16 x 25 mm 4 10 mm
(90 ft-lbs)

52 M47-17027-EN
 Mount fixtures

1. Tension crosshead
2. Adjustable crosshead
3. Bumper plate
4. Grip jaw
1 a. Locating boss
b. Retainer button (600DX only)
5. Jaw carrier
a. Jaw carrier recess
6. Guide plate (front and rear)
7. Socket head cap screw and washer
(see Table 12 for size, quantity and torque)
8. Piston dust cover
2 9. Grip dust cover
10. Button head cap screw
(see Table 12 for size and quantity)
11. Wear plate
3
12. Guide pin (one on each side of jaw carrier)
13. Retainer setscrew (M8) (600DX only)
5a 14. Access hole for retainer setscrew (600DX only)
5
15. Grip pocket
View A 16. Guide slot for guide pin
17. Push plate and piston

10

6 6
4 4a 4b 16 7
15

4
5
11

8 View B

17
12 13 View C
14

Figure 11. Components of the grip assemblies for G7-style crossheads.

Product Support: www.instron.com 53

Chapter 3: Operation

300DX Frames 600DX Frames

1 2 3 4 5 6 1 2 3 8 4 5 9 6

1. Grip jaw 6. Jaw carrier

2. Locating boss 7. Magnet (300DX only)
3. Alignment hole 8. Retainer button (600DX only)
4. Alignment pin 9. Retainer setscrew (M8) (600DX only)
5. Jaw carrier recess

Figure 12. Details of grip jaw and jaw carrier.

Table 13. Function of grip controls (see Figure 13 on page 54.

Function Switch Type Use

Open Momentary - returns to Neutral when released Unclamp grip jaws

Close1 Latch - remains at Close when released Clamp grip jaws, test in progress

Neutral N/A (no switch activated) No test in progress, system idle

1. If a switch is in the Close position and main power is lost to the frame*, the grips will stop and hold their current
position; also the switch will remain latched in the Close 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, see “Loss of power” on page 60.

Upper open

Upper close

Lower close

Lower open

Figure 13. Hydraulic grip control handset.

54 M47-17027-EN
 Mount fixtures

Remove grip jaws - G7-style crossheads

Equipment and supplies required

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.

• A suitable stable platform such as a man-lift, stairs, or ladder. The platform must be of sufficient
height so that the operator can reach the tension crosshead.
• 4 mm hex key (supplied)
• Screw driver (supplied) - for 300DX only

Recommended procedure
1. Use the grip controls 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 for each grip jaw.

Product Support: www.instron.com 55

Chapter 3: Operation

Insert specimen

Warning
These grips are designed to grip specimens for testing. Therefore, an unavoidable pinching
hazard exists. Make sure to read and understand all installation, removal and operating
instructions before using the grips!

Be sure to use a specimen of sufficient length to meet the minimum gripping requirements; see
“Specimen guidelines” on page 43. With this in mind, take the following steps to insert a specimen
into the grips:

1. Make sure both upper and lower grip jaws are open (unclamped).
2. Insert and center the specimen into the grip jaws of the upper grip assembly and clamp the grip jaws
firmly in contact with the specimen. Be sure that the specimen is inserted according to the minimum
gripping requirements outlined in “Specimen guidelines” on page 43. Let go of the specimen and
remove your hand from the frame.
3. Raise or lower the adjustable crosshead as necessary so that the specimen extends the proper
distance into the grip pocket of the adjustable crosshead. Be sure that the specimen is inserted
according to the minimum gripping requirements outlined in “Specimen guidelines” on page 43.
4. Clamp the grip jaws firmly in contact with the specimen.

For frames with G7-style crossheads: When a specimen is gripped hydraulically, the gripping force at
each end often causes a compression load in the specimen. This load may be noticeable on the
indicator. If this is objectionable, we suggest either setting up and using the specimen protect feature in
the controlling software or using the JOG UP control button on the user control panel to move the
loading unit in the load direction as the grip jaws are closed on 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
Be sure to keep fingers out of the frame while the crosshead is moving or a test is in
progress.

56 M47-17027-EN
 Mount fixtures

Run a test
Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

This information is NOT test specific, it is only intended to assist you in the general aspects of running a
test. If you are testing to a specific standard or society specification (ASTM, ISO, EN, BS, etc.), those
specifications should be obeyed with regard to number of tests run, specimen specifications, fixturing,
inserting specimens and all other aspects of materials testing.

This document presumes that customer training (by Instron Service Engineer) has been completed and
that at least one procedure has been created in the controlling software.

Refer to the supplied software manual for specific information about the controlling software. The
following is only a general description of the necessary steps to run a test.

Ensure that the following conditions are met before a test is run:

• The LOAD channel is calibrated.

• The STRAIN channel is calibrated if you are using an extensometer.
• You have reviewed the manuals for the controlling software and are familiar with the on-line help
system that accompanies the software.
• Know the specific procedures to set up and run a test.
• The load transducer, grips and fixtures are appropriate for your test.
Following is the recommended procedure to run a test on a specimen:

1. If the system is not currently turned on, complete “Start the system” on page 37.
2. Verify that the setup and test parameters are reasonable and correct for your test.
3. Ensure that the displays on the user control panel illuminate.
4. Check that the frame is enabled.
5. Start the HPS. The FRAME READY indicator will illuminate. Immediately check the position of the
piston within the hydraulic cylinder; the piston should be positioned so that it is neither fully retracted
nor fully extended. If the piston is in either of these conditions, the servo loop control could build up
enough error to shut down the HPS. Use the jog controls to move the piston if necessary - typically a
separation 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.

Product Support: www.instron.com 57

Chapter 3: Operation

7. Determine if it is necessary to make any adjustments to the frame configuration to attain the
required test opening that was determined in step 6:
a. For tension tests: Raise or lower the tension crosshead as necessary - see “Adjust the position
of the tension crosshead” on page 38. Also, raise or lower the adjustable crosshead as
necessary using the adjustable crosshead control switch.
b. For compression tests: Raise or lower the adjustable crosshead as necessary using the
adjustable crosshead control switch.
8. Install the desired specimen fixtures into the test space using adapters and alignment couplings as
necessary. If using the grip assemblies to perform a tension test, install the grip jaws - see “Operate
grip assemblies - G1-style and G7-style crossheads” on page 42.
9. Balance the load, if necessary.
10. Install the specimen into the fixtures as specified by your test method.
11. Install extensometry, strain gauges, etc. (if applicable).
12. Reset the zero extension point, if necessary.
13. Start the test.

The test can be stopped at any time by using either the STOP TEST button on the user control panel or
the END TEST button in the controlling software. This does not shut down the HPS unless the end test
action in the software is set up to perform that task.

If it is necessary at any time to shut down the HPS, press the DISABLE FRAME button in the controlling
software.

14. As the test is running, the controlling software dynamically displays the data that is being collected or
calculated 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).

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 be inadvertently started. Release the Emergency Stop button when ready to run the
next test. Once the HPS is running, immediately check the position of the piston within the hydraulic
cylinder; the piston should be positioned so that it is neither fully retracted nor fully extended. Use the
jog controls to move the piston if necessary - typically a separation of 6 mm (0.25 in) is sufficient.

58 M47-17027-EN
 Mount fixtures

Shut down the system

It is recommended that the system as a whole (frame, control unit, HPS, computer system, peripherals,
etc.) be shut down at the end of each working day or anytime it will sit idle for long periods of time. The
procedure to shut down the system is as follows:

1. Remove any specimen from the fixtures and jog the hydraulic cylinder so that the piston is fully
retracted. Also, refer to “Loss of power” on page 60.
2. Press the DISABLE FRAME button in the controlling software to shut down the HPS.
3. Engage the Emergency Stop button.
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 be inadvertently started. Release the Emergency Stop button when ready to run the
next test. Once the HPS is running, immediately check the position of the piston within the hydraulic
cylinder; the piston should be positioned so that it is neither fully retracted nor fully extended. Use the jog
controls to move the piston if necessary - typically a separation of 6 mm (0.25 in) is sufficient.

Product Support: www.instron.com 59

Chapter 3: Operation

Loss of power
If at any time main power is lost to the frame (due to the disconnect switch being turned off,
Emergency Stop being engaged, power loss at the customer power supply, or complete power loss to
facility), gravity will cause the frame to go to its natural resting state, i.e. the piston will retract into the
hydraulic cylinder. To impede this process, the system is equipped with a valve that closes at loss of
system power and prohibits oil leakage from the hydraulic cylinder. However, it can not stop 100% of oil
leakage and thus the hydraulic cylinder will drift very slowly. Drift is slow enough that a noticeable
amount of drift may be seen if system power remains off over an extended period (i.e. several days). Even
with this very slow drift rate, multiple pinching hazards may exist on the frame (depending on 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
On loss of power, immediately remove hands and arms from the frame to avoid personal
injury.

Caution
On loss of power, any equipment in the test space may be damaged, particularly
extensometers. It is always good practice to keep equipment that is not currently in use out
of the test space.

It can be verified that the piston is fully settled to the bottom of the cylinder by the following:

• Measure the distance between the bottom of the compression table and the top of the base plate.
This distance should be less than the following:
• 300DX: 64 mm (2.5 in)
• 600DX: 105 mm (4.125 in)
• If power has been off for at least 5 minutes.
• Visually observe the loading unit for movement.

60 M47-17027-EN
 Chapter 4
Maintenance
• General maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• Make daily checks of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• Remove and install base covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• Grip assemblies - G1-style and G7-style crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
• Hydraulic power supply (HPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
• Ancillary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• Consumable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
• Spare and replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

General maintenance recommendations

Only the maintenance procedures outlined in these instructions should be performed by the customer or
their representative. All other maintenance and repairs should be performed by Instron Service
personnel only.

Preventative maintenance schedule

Table 14 outlines a recommended preventative maintenance schedule for system components.

Table 14. Recommended preventative maintenance schedule.

Frequency Component Maintenance Task

Daily: System • Make daily checks of system; see page 63.

• For frames with G1-style or G7-style crossheads - Clean external
Grip assemblies
surfaces and check operation of grip assemblies; see page 72. 1

61
Chapter 4: Maintenance

Table 14. Recommended preventative maintenance schedule. (Continued)

Frequency Component Maintenance Task

Daily or after every 50 • For 600DX frames: The tightness of the retainer setscrew should be
consecutive tests: Grip assemblies checked daily or after 50 consecutive tests are performed with the same
of G7-style set of grip jaws. The retainer setscrews can vibrate loose and allow the
crossheads grip jaws to fall out of the jaw carriers. See “Install grip jaws - G7-style
crossheads” on page 50.

Weekly or after every • Lubricate the grip assemblies; see page 72. 1
Grip assemblies
150-300 tests2:
Monthly or after every • Clean and inspect grip components; see page 73. 1
Grip assemblies
2000 tests2:

Monthly: • Visually inspect all hoses (exposed and hidden) and around the base of
System the frame for signs of oil leakage. Investigate any abnormal or excessive
leakage and correct appropriately.

Frame • Check non-painted surfaces; see page 66.

• Check level of oil in reservoir and add oil as necessary. Refer to “Add oil
HPS
to reservoir” on page 80.

Biannually • Inspect the hydraulic hoses; see page 85.

System
(or once every 1000 hrs. • Inspect the cables; see page 66.
of operation)2:
• Inspect the adjustable crosshead; see page 67.
Frame
• Inspect the hydraulic cylinder; see page 70.
HPS • Check the oil cleanliness; see page 80.
3
•
Electronics • Clean the fans; see page 66. 3:
Annually System • Verify/Calibrate system.
(or once every 2000 hrs.
of operation)2: • Change the air breather filter; see page 85.
• For special operating conditions where oil temperature is continuously
HPS
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 • For normal operating conditions where oil temperature is continuously
(or once every 4000 hrs. HPS below 60 deg. C (140 deg. F) - Change the oil; see page 83.
of operation)2:

Every 5 years: System • Replace high pressure hydraulic hoses; see page 86.
Every 7 years: System • Replace low pressure hydraulic hoses; see page 86.
1. The frequency listed here for maintenance of the grip assemblies is only a recommendation. The correct frequency for your
grips is heavily dependent on how often the grips are used, the environmental conditions in which the grips are used, and
the type of specimens that are tested. Frequent use or dirty environments may require more frequent maintenance, while
less frequent use or clean laboratory conditions could require less. We recommend beginning with the frequency listed
here and then adjusting this frequency as experience dictates. Also, the lower grip may require more frequent cleaning
than the upper grip, simply because it will tend to collect more dirt and debris.
2. Whichever is soonest.
3. The frequency listed here is only a recommendation. The correct frequency for your system is heavily dependent on the
environmental conditions in which your system is used. Dirty environments may require a more frequent interval, while
clean laboratory conditions could require less. We recommend beginning with the frequency listed here and then adjusting
this frequency as experience dictates.

62 M47-17027-EN
 Preventative maintenance schedule

Make daily checks of system

Before operating the system each day, a general check of the system is highly recommended. Performing
a good general check on a daily basis is an important part of preventative maintenance. It also allows the
operator to become familiar with the system, and with what is considered normal behavior and normal
appearance. Once familiar with the system, operators will be more likely to notice any abnormalities that
could indicate problems, or potential problems, with the system. Before operating the system each day:

• Check that the frame is square and not out of alignment. This can be a simple visual check. Stand
away from the frame and check that all horizontal components (i.e. the compression table,
adjustable crosshead and tension crosshead) are parallel with each other and aligned vertically. Also
check that all vertical components (i.e. all columns) are parallel with each other and aligned
horizontally. Misalignment indicates that a larger problem exists.
• Check that all testing fixtures (compression plates, bend fixtures, external tension accessories,
adapters, etc.) are free of dirt, damage and deformation. Any fixture with damage or deformation
should be corrected before use!
• Check the tightness of the socket head cap screws 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 the power supply in the 59 Series control unit or with system main
power (customer supply).
• Visually inspect the following for signs of oil leakage. Investigate any leakage and correct
appropriately. It is not necessary to remove any covers from equipment unless an oil leak is found.
• Any exposed hydraulic hoses - this may indicate leakage from loose connections or from
damaged hoses.
• Around the base of the frame - this may indicate leakage from internal hydraulic connections,
from the HPS, or from the hydraulic cylinder.
Remove covers as necessary to investigate any oil leakage; see “Remove and install base
covers” on page 64. If an oil leak is suspected from the hydraulic cylinder, see “Inspect the
hydraulic cylinder” on page 70 for guidance.
• Check that all cables are free of wear and chafing, have adequate slack to prevent excessive strain
on connectors, and have tight connections.

If any of these checks reveal a potential problem, the problem should be investigated and corrected
before the system is operated. For assistance in troubleshooting the system, contact your local Instron
Services department as directed on page 20.

Product Support: www.instron.com 63

Chapter 4: Maintenance

Remove and install base covers

To perform any maintenance on the electrical panel or HPS it is necessary to remove one or more of the
base covers. Refer to the following procedures to remove covers as needed for a given maintenance task.
The only equipment required is a 4 mm hex key (supplied).

To remove the front cover:

1. Be sure all cables are disconnected from the 59 Series control unit on the right side of the base.
2. Loosen the two button head cap screws (4, Figure 14) on each side of the front cover. It is not
necessary to remove the cap screws, just loosen them enough to remove the cover.
3. Carefully pull 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 side cover (2) toward the rear 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 the rear cover:

1. Loosen and remove the six button head cap screws (5, Figure 14) from the rear cover.
2. Remove the rear cover (3) from the base.

To install the covers, perform the above procedures in reverse. Tighten all cap screws until fully seated
plus one-quarter turn.

64 M47-17027-EN
 Preventative maintenance schedule

1 3

1. Front cover
2. Left side cover
3. Rear cover
4. Front/side screws
5. Rear screws

Figure 14. Base covers.

Product Support: www.instron.com 65

Chapter 4: Maintenance

Electronics
To access any of the electronics, it is necessary to remove the front cover of the base. Refer to “Remove
and install base covers” on page 64.

Clean the fans

The fan opening of the computer system’s CPU should be cleaned at the frequency stated in the
“Preventative maintenance schedule” on page 61. Use a vacuum to remove dust and dirt from the
grill of the fan and the fan filter.

Fuses
The system is equipped with one or more fuses. These fuses should only need replaced when they are
blown. Refer to Chapter 4 of the System Concepts Manual (supplied separately) for more information on
troubleshooting for a blown fuse.

Inspect the cables

Cables should be inspected at the frequency stated in the “Preventative maintenance schedule” on
page 61. Check the following:

• Inspect all cables for loose connections. This includes power cable and transducer 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
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

Check non-painted surfaces

All non-painted frame surfaces (i.e. compression table, crosshead surfaces, etc.) should be checked for
signs of dryness or corrosion and kept covered with a thin film of light machine oil to prevent corrosion.
The oil should be applied at the frequency stated in the “Preventative maintenance schedule” on
page 61.

66 M47-17027-EN
 Frame

Adjustable crosshead

Inspect the adjustable crosshead

Operation of the adjustable crosshead should be checked at the frequency stated in the “Preventative
maintenance schedule” on page 61. To check operation, use the adjustable crosshead controls to
operate the adjustable crosshead through its entire range of motion. Check for binding and abnormal
noise. The crosshead should move smoothly. If you notice any problems resulting from this inspection,
contact your local Instron Services department as directed on page 20 for immediate assistance.

Lubricate the adjustable crosshead

The backlash eliminator assemblies, screw columns and adjustable crosshead drive chain must be
lubricated at the frequency stated in the “Preventative maintenance schedule” on page 61. Proper
lubrication prevents wear and promotes good operation of these components. Each frame is equipped
with one or more backlash eliminator assemblies and screw columns. 300DX frames have one backlash
eliminator assembly and one screw column. 600DX frames have two backlash eliminator assemblies
and two screw columns. The assemblies are located in the base of the 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

All equipment and supplies 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.

• 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 gun that is supplied for lubrication of the grip
assemblies.
• A 5 mm hex key (supplied)
• Solvent or diesel fuel - Only needed to clean the grease from the screw columns if the existing grease
on the screw columns has dried to a paste
• A paint brush
• Clean towels, rags, or similar
• Appropriate lubricants - refer to Table 15 for recommended greases - equivalent greases can be
substituted

Table 15. Recommended lubricants for adjustable crosshead components.

Location Recommended Lubricant

Backlash Eliminators (grease • Dow Corning, Molykote BR2 Plus1

fittings) • Chevron, Delo Heavy Duty Moly 3% EP2
Screw Columns • Allegheny Petroleum, Altra LCM EP#2
Note: Other suitable greases can be used. A suitable grease is any multipurpose
extreme pressure NLGI grade #2 lithium complex grease with 3% Molybdenum
Disulfide.

Product Support: www.instron.com 67

Chapter 4: Maintenance

Table 15. Recommended lubricants for adjustable crosshead components.

Location Recommended Lubricant

Crosshead Drive Chain • Petroleum based oil (motor oil) SAE30

• Roller Chain Lubricant
Note: Use only petroleum based oils, such as good quality motor oil, with a viscosity
equivalent to SAE30 or specifically petroleum based roller chain lubricants. Do not
use penetrating lubricants, such as WD-40, to lubricate or clean the chain.

1. Can be purchased from Instron. See Table 18 on page 90 for part numbers.

Recommended procedure
1. For 600DX frames: Start the system; see page 37. Completely lower the adjustable crosshead.
2. Be sure the system is shut down.
3. Remove covers from the base of the frame to expose the components, see the following:
• For 300DX frames: Remove the rear cover (see “Remove and install base covers” on
page 64). See Figure 15 for location of components.
• For 600DX frames: Remove the rear cover and then remove both side covers (see “Remove
and install base covers” on page 64). See Figure 15 for location of components.
4. Lubricate the backlash eliminator assemblies:

For 300DX frames, it will be easier to reach the grease fitting of the backlash eliminator if the adjustable
crosshead is at the top of its travel.

a. Clean the grease fitting of each backlash eliminator assembly of any dust or debris.
b. Connect the fitting of the grease gun to one of the grease fittings.
c. Apply grease until grease is forced out around the backlash eliminator assembly.
d. Remove the grease gun fitting.
e. Remove any excess grease.
f. Repeat steps b through e as necessary for remaining backlash eliminator assembly.
5. Lubricate the screw columns:
a. Clean any dust, dirt or debris that may be present on the exposed threads. If the grease has
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 columns.
b. Use a paint brush to paint the grease onto all exposed screw column threads. Be sure to grease
thoroughly. For 600DX frames, grease both screw columns.
c. Remove yourself and any equipment from the frame. In particular, remove any towels from
around the screw columns.

68 M47-17027-EN
 Frame

Rear view of 300DX with rear cover removed

1 (HPS also removed for clarity).

3 1. Adjusting column
2. Screw column
4 3. Drive motor
4. Drive chain
5 5. Lower crosshead
6. Top plate
7 7. Grease fitting for backlash
eliminator
8 8. Backlash eliminator assembly
9. Chain cover
10. M6 button head cap screw

3 4 9 10

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).

Figure 15. Lubrication of components for adjustable crosshead.

Product Support: www.instron.com 69

Chapter 4: Maintenance

Warning
Entanglement hazard exists. It is necessary to start up the system in order to complete
lubrication. Remove all body parts from the frame before starting the system. Be sure that
all equipment is removed from the frame.

d. Start the system; see page 37.

e. Raise or lower the adjustable crosshead to allow access to the unexposed section of the screw
columns. For 300DX frames, this would be the portion that is covered by the lower crosshead.
For 600DX frames, this would be portions of the screw columns that are below the top plate.
f. Shut down the system; see page 59.
g. Repeat steps a and b on this newly exposed area of each screw column.
h. For 600DX frames, repeat steps c through g. Continue to repeat these steps until the entire
length of both screw columns have been cleaned and greased.
i. Remove any equipment from the frame. In particular remove any towels from around the screw
columns and any towels that were used during the cleanup process.
6. Lubricate the drive chain:

For 300DX frames, it will be easier to reach the drive chain if the adjustable crosshead is at the top of its
travel.

a. For 600DX frames, remove the chain cover (9, Figure 15) from the top plate (use 5 mm hex
key).
b. Lubricate the exposed section of the drive chain (4) (use paint brush).
c. Remove yourself and any equipment from the frame. In particular, remove any towels from
around the screw columns.

Warning
Entanglement hazard exists. It is necessary to start up the system in order to complete
lubrication. Remove all body parts from the frame before starting the system. Be sure that
all equipment is removed from the frame.

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 step a.
7. Install any covers that were removed in step 3.

Inspect the hydraulic cylinder

The hydraulic cylinder should be inspected at the frequency stated in the “Preventative maintenance
schedule” on page 61. Perform the following:

70 M47-17027-EN
 Frame

• Check movement of the piston in the hydraulic cylinder. Use the jog controls to operate the hydraulic
cylinder through its entire range of motion. Check for binding and abnormal noise. The piston should
move smoothly. Also, watch the load display in the controlling software. The load reading should
remain fairly 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 is discovered and traced to the hydraulic cylinder, contact your
local Instron Services department as directed on page 20 for immediate assistance.

Product Support: www.instron.com 71

Chapter 4: Maintenance

Grip assemblies - G1-style and G7-style crossheads

Warning
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 needed. You must perform your own risk assessment and take
appropriate measures to protect yourself from harm.

The grip assemblies must receive regular care to prevent damage to grip pockets and grip components.
In general, the frequency guidelines stated in the “Preventative maintenance schedule” on page 61
will give you a good indication of when and how to care for your grips. However, if your system is used in a
very dirty environment or to test specimens that create debris at fracture, then those frequencies may
need increased.

Clean external surfaces and check operation of grip assemblies

The external surfaces of the grip assemblies should be cleaned of dirt and debris at the frequency stated
in the “Preventative maintenance schedule” on page 61. The external surfaces include the exposed
portions of the grip pockets and the face of the grip jaws. This cleaning is particularly important for the
lower grip body because it will tend to collect more dirt and debris.

Open and close the grip jaws as necessary to make it easier to reach all surfaces. For frames with G1-
style crossheads (closed pockets), it may be easier to remove the grip jaws from the crosshead. Various
methods can be used to remove the dirt and debris: a rag or cloth, a brush (medium sized, with medium-
stiff bristles is recommended), or a vacuum.

For specimens that create a lot of debris at fracture (such as rebar), it will probably be necessary to
increase the cleaning frequency to every few tests instead of only once a day. Also, it can be very helpful
to use some type of protective cover around the specimen and over the grip pocket to reduce the amount
of debris that falls into the grip pocket. This cover can be made of paper or cardboard with a specimen-
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.
The grip jaws should move smoothly. For frames with G1-style crossheads, be sure that the grip jaws stay
aligned with each other as they are opened and closed. If they do not, this indicates a damaged pinion
that probably needs to be replaced. Refer to “Inspect and replace the pinion - G1-style crossheads”
on page 79.

Lubricate the grip assemblies

The grip assemblies must be properly and sufficiently lubricated to operate properly. Grip components
should be lubricated at the frequency stated in the “Preventative maintenance schedule” on page 61
- be sure to read Footnote 1 in this section. 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. A small amount of Molykote type GN metal paste is supplied with
the frame, additional quantities can be purchased from Instron, contact your local Instron Services
department as directed on page 20. Lubrication procedures are different depending on whether the

72 M47-17027-EN
 Frame

frame is equipped with G1-style crossheads or G7-style crossheads. Be sure to apply the lubricant as
specified in these instructions.

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.

It is important that the lubricant on the grip components is always moist and is not dry, clumped or dirty.

For frames with G1-style crossheads: Remove the grip jaws from the crossheads as outlined in “Remove
grip jaws - G1-style crossheads” on page 50. Add fresh lubricant to the grip jaws and reinstall them
as outlined in “Install grip jaws - G1-style crossheads” on page 46. It is not necessary to remove
existing grease before applying fresh grease.

For frames with G7-style crossheads: The jaw carriers are lubricated through grease fittings located in
the crosshead next to each jaw (see Figure 17 on page 77); a grease gun and two grease cartridges are
supplied with the grips and additional quantities can be purchased from Instron. The grease fittings apply
grease to the rear and sides of the jaw carriers. Use the following procedure to lubricate each jaw carrier.
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 fitting.
5. Pump the gun an appropriate amount of times until grease seeps out between the grip body and jaw
carrier. Begin with five pumps of the gun and increase or decrease the amount as experience
dictates.
6. Detach the grease gun nozzle from the fitting.

New grease guns may be difficult to detach from the fitting. If this occurs, simply loosen the nozzle from
the grease gun hose to release the spring in the nozzle. It may be necessary to pry nozzle from fitting;
use care not to damage nozzle or grips. This condition should decrease as the grease gun is broken in.

7. Repeat as necessary to lubricate the remaining jaw carriers.

8. Re-install all grease fitting plugs.

Clean and inspect grip components

The grip pockets and all grip components should be cleaned and inspected at the frequency stated in the
“Preventative maintenance schedule” on page 61, or more frequently if needed - be sure to read
Footnote 1 of this table.

Product Support: www.instron.com 73

Chapter 4: Maintenance

Equipment and supplies required

All equipment and supplies 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.

• A suitable stable platform such as a man-lift, stairs, or ladder. The platform must be of sufficient
height so that the operator can reach the tension crosshead.
• 4 mm hex key (supplied)
• For 300DX -G1 frames: 14 mm hex key
• For frames with G1-style crossheads: Hex keys, see Table 11 on page 49 for sizes
• Molykote type GN metal paste

Recommended procedure
1. Clean and inspect grip jaws, this includes all sets of grip jaws, not just the ones in use:
a. Remove grip jaws from each grip pocket, refer to either “Remove grip jaws - G1-style
crossheads” on page 50 or “Remove grip jaws - G7-style crossheads” on page 55
depending on the crosshead style of your frame.
b. Clean lubricant from all sets of grip jaws.
c. Inspect each grip jaw for damage:
• For frames with G1-style crossheads: Check the rack teeth. If the rack teeth are broken such
that smooth operation of the pinion is prevented, the grip jaw should be replaced.
• For frames with G7-style crossheads: The locating boss on the rear of the grip jaw fits into
the recess of the jaw carrier with tight tolerance. Dirt or damage in either area may cause
them to be press-fit together during testing. If damage is found along the edge of the
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 filler plates.
c. Inspect filler plates for damage. Check for bent corners, nicked or galled surfaces, and warping.
If a damaged filler plate can be repaired so that it is flat and the shoulders will still support the
filler plate in the crosshead, then the filler plate may be repaired and re-used. If damage is
severe enough to prohibit repair, then the filler plate must be replaced.
3. For frames with G1-style crossheads: Clean and inspect grip stop plate and bumper plate:
a. Remove grip stop plate from the top of the tension crosshead (refer to step 1 of “Install grip
jaws - G1-style crossheads” on page 46.
b. Remove bumper plate from bottom of adjustable crosshead (use 14 mm hex key).
c. Clean any lubricant from all plates.
d. Inspect all plates for cracks. If cracks are found, replace the component.
4. For frames with G7-style crossheads: Clean and inspect guide plates:

74 M47-17027-EN
 Frame

a. Remove the guide plates from the front of each grip pocket (use 6 mm hex key for 300DX frames,
or 10 mm hex key for 600DX frames).
b. Clean lubricant from all guide plates. This includes the guide plates on the rear of the grip
pocket; it is not necessary to remove them.
c. Inspect all guide plates for damage. Check for sharp edges, deformed corners and warping. Also
check all guide slots for damage - this could indicate a bent or broken guide pin (see step 6).
Sharp edges and deformed corners can typically be filed smooth. If damage is severe or inhibits
motion of the jaw carriers, the guide plates should be replaced.
5. For frames with G7-style crossheads: Clean and inspect wear plates:
a. Remove wear plates from each grip pocket.
b. Clean lubricant from the wear plates.
c. Inspect wear plates for damage. Check for broken plates, 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).

Figure 16. Wear plate damaged by improper lubrication.

6. For frames with G7-style crossheads: Clean and inspect jaw carriers:
a. Remove jaw carriers from each grip pocket.
b. Clean lubricant from the jaw carriers.
c. Inspect jaw carriers for damage:
• Check the recess of each jaw carrier for dirt or damage. The locating boss of the grip jaw fits
into the recess with tight tolerance. Dirt or damage in either area may cause them to be
press-fit together during testing. If damage is found along the edge of the recess, the edge
can be filed smooth.
• Check for any cracks, particularly around the upper portion of the recess. If any cracks are
found, the jaw carrier must be replaced.

Product Support: www.instron.com 75

Chapter 4: Maintenance

• Check for excessively shiny or worn surfaces (blackening is worn off of surface). This could
indicate a poor fit or presence of debris. Investigate the cause of the wear and correct any
problems. Some wear is expected with normal use.
• Check for gouged surfaces. This could indicate that there is or has been debris between
surfaces and that the interval for cleaning should be more frequent, see Footnote 1 of
Table 14 on page 61. This could also indicate that the grip dust covers (11, Figure 17) are
not installed correctly. (Continued use with debris between surfaces may cause binding of
the jaw carriers and lead to further damage or wear. If gouge is not severe, the area can be
filed smooth. If gouge can not be smoothed, the jaw carriers should be replaced.
• Check for bent or broken front and rear guide pins (5, Figure 17). Bent or broken pins
indicate misuse; check for proper specimen engagement and proper jaw face sizing for the
specimen being tested. If damage is not severe, a pin can be straightened. If straightening
is not possible or if a pin is broken, the pin should be replaced.
• Check for sharp edges or deformed corners that could inhibit motion of the jaw carriers or
cause damage to wear plates. If damage is not severe, the edges and corners can be filed
smooth. If damage can not be repaired, the jaw carriers should be replaced.
• It is highly recommended that the wear plates are replaced anytime the jaw carriers are
replaced (see step 5).
7. Clean and inspect grip pockets:
a. Clean all dirt, debris and lubricant from each grip pocket.
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 possible to correct problems by machining.
8. For frames with G1-style crossheads: Reassemble components:
a. Install grip stop plate to top of tension crosshead and bumper plate to bottom of adjustable
crosshead.
b. Reassemble and lubricate components according to the instructions outlined in “Install grip
jaws - G1-style crossheads” on page 46.
9. For frames with G7-style crossheads: Reassemble components:
a. Install jaw carriers into grip pocket. Place the groove in the bottom of the jaw carrier over the
edge of the push plate and slide jaw carrier into the grip pocket. Be sure that the guide pin in the
rear of the jaw carrier enters the slot in the rear guide plate.
b. Install a wear plate between each jaw carrier and the side of the grip pocket. Be sure to orient
the wear plates properly as shown in Figure 17.
c. Clean the threads of the guide plate cap screws (removed in step 4) with Loctite® ODC-FREE
Cleaner and Degreaser 7070.
d. Apply a small amount of Loctite 246® Threadlocker High Temperature/Medium Strength to the
threads of the cap screws.
e. Install guide plates to front of each crosshead and secure in place with the prepared cap screws.
Torque each cap screw to the torque listed in Table 12 on page 51 for your model.
f. Lubricate the grip assemblies as outlined in “Lubricate the grip assemblies” on page 72.
10. The grip assemblies are now ready for normal operation.

76 M47-17027-EN
 Frame

12 13
13
11
14

8 1
7

3 4 6

1
10
2 9

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

Figure 17. Components of the grip assemblies for G7-style crossheads.

Product Support: www.instron.com 77

Chapter 4: Maintenance

Inspect and replace the pinion - G1-style crossheads

For frames with G1-style crossheads, a pinion should be replaced if it no longer operates the grip jaws
correctly. For correct operation, the ends of the grip jaws should always be aligned with each other as
they are opened or closed (see Figure 18). To check operation, install a set of grip jaws in the grip
pocket and then operate the crank handle to open and close the grip jaws. Watch the grip jaws as they
open and close, they should maintain correct alignment throughout the motion. If they do not, then
perform the following check to determine why alignment is not being maintained:

1. Remove each grip jaw from the grip pocket and check its rack teeth. If rack teeth are broken, then
this could be the cause for incorrect alignment or operation. Grip jaw may need to be replaced.
2. Visually inspect the pinion. Turn the crank handle and watch the pinion inside the grip pocket (if
necessary use a flashlight to illuminate the pinion). Watch for broken 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.

Correct alignment Incorrect alignment

Figure 18. Identifying correct alignment of grip jaws - G1-style crossheads.

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
setscrew is accessed through a hole in the crosshead. For the tension crosshead, the access hole is
located on the top of the crosshead, toward the front and just above the crank handle. For the
adjustable crosshead, the access hole is located on the bottom of the crosshead, also toward the
front and just below the crank handle.
3. Remove the pinion from the crosshead.
4. Insert the new pinion into the crosshead; be sure to insert the rounded end of the pinion first. The
square end of the pinion (that accepts the crank handle) should be protruding from the crosshead,
see Figure 19.
5. Install the crank handle onto the end of the pinion.
6. Tighten the setscrew against the pinion just until seated. Back off the setscrew one-half turn.

78 M47-17027-EN
 Hydraulic power supply (HPS)

Pinion for 300DX Pinion for 600DX

2
1

1. Groove for setscrew

2. Square end for crank handle

Figure 19. Pinion.

Hydraulic power supply (HPS)

The HPS should be maintained according to the “Preventative maintenance schedule” on page 61.

Check the oil cleanliness

The cleanliness of the oil in the reservoir should be checked at the frequency stated in the “Preventative
maintenance schedule” on page 61. Check the appearance of the oil through the sight gauge; it
should be a clear amber color. If the oil appears dirty, it should be changed (see “Change the oil” on
page 83).

In the United States and Canada, an oil sample test kit is available for purchase from Instron Services;
contact your local Instron Services department as directed on page 20 for more information about the
test kit.

Add oil to reservoir

It should only be necessary to add oil to the reservoir if an oil leak is evident. However, the oil level
should be checked at the frequency stated in the “Preventative maintenance schedule” on page 61.
Check the oil level through the sight 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

All equipment and supplies 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.

• 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), for
fluid specifications see “Oil type and quantity” on page 86

Product Support: www.instron.com 79

Chapter 4: Maintenance

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. Clean the area around the fill hole and air breather filter (3 and 2) to remove all dust, dirt and grime.
3. If the oil temperature/level switch has tripped and it is determined that the trip was caused by a low
oil level, perform steps b through d of this procedure only. Otherwise, skip this step and continue
with step 4.
a. Remove the air breather filter from the reservoir fill hole - push down and turn counterclockwise.
b. Insert the clean funnel with a mesh filter into the fill hole and add enough of the recommended
hydraulic fluid to the reservoir until the oil is visible at the bottom of the sight 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 with a mesh filter into the fill hole and fill the reservoir with the recommended
hydraulic fluid. Fill the reservoir to the top of the sight gauge.
8. Install the air breather filter onto the reservoir fill hole.
9. Start the HPS and cycle the hydraulic cylinder through its full stroke a few times. Fully retract the
hydraulic cylinder. Press the DISABLE FRAME button in the controlling software to shut down the
HPS. Check the oil level. If the oil is not to the top of the sight gauge, repeat steps 6 through 9. If
the oil is to the top of the sight gauge, continue with next step.
10. Install the cover that was removed in step 1.

80 M47-17027-EN
 Hydraulic power supply (HPS)

8
1

Rear and side covers removed.

6

1. Motor 5
2. Air breather filter
3. Fill hole
4. Sight gauge
5. Oil filter 7
6. Heat exchanger and fan
7. System pressure gauge
8. Relief valve RV1
9. Servo manifold 9
10. Reservoir 10

Figure 20. Components of the HPS.

Product Support: www.instron.com 81

Chapter 4: Maintenance

Change the oil

The oil in the reservoir should be changed at the frequency stated in the “Preventative maintenance
schedule” on page 61, or if the oil is determined to be dirty during a visual inspection (see “Check the
oil cleanliness” on page 80). The oil filter should be changed every time that the oil is changed. The
following procedure includes steps to change the oil filter.

Equipment and supplies required

• A 3 mm hex key
• A 4 mm hex key
• A 9/16 in socket
• A 7/8 in socket
• A 1 in deep socket
• A ratchet wrench (for the sockets that are listed above - may also need a socket adapter depending
on what the drive size requirements are)
• A torque wrench with range of at least 20 to 68 N-M (15 to 50 lbf-ft) (for the sockets that are listed
above - may also need a socket adapter depending on what the drive size requirements are)
• A hand pump or similar to remove oil from reservoir
• A clean funnel with a mesh filter
• An oil container for collection of used oil
• Clean towels, rags, or similar
• Hydraulic fluid, for fluid specifications and amount required see “Oil 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 hydraulic cylinder.
3. Press the DISABLE FRAME button in the controlling software to shut down the HPS.
4. Change the oil filter:
a. Clean the outside surfaces of the filter and manifold (5 and 9) with a cleaning solvent to remove
all dust, dirt and grime. Wipe dry with a clean towel.
b. Remove the vent plug from the top of the filter housing (use 9/16 in socket and ratchet wrench).
c. Locate relief valve “RV1” on the servo manifold (8). Loosen the relief valve (use 1 in deep socket
and ratchet wrench). By hand, continue to loosen and slowly remove the relief valve. This allows
oil to drain from the filter.
d. Wrap the relief valve in a clean towel to keep it clean, and set it aside.
e. Carefully loosen the filter housing (use 7/8 in socket and ratchet wrench. By hand, continue to
loosen and slowly remove the filter housing.
f. Wrap the filter housing in a clean towel to keep it clean, and set it aside.

82 M47-17027-EN
 Hydraulic power supply (HPS)

g. Very gently remove the filter element. Oil from the inner part of the filter element will drain out
and return to tank. Be careful not to shake any dirt off of the element and into the oil. Properly
dispose of the filter element.
h. Inspect the filter cavity for damage. Wipe the filter cavity with a clean towel to remove all debris.
i. Install the new filter element. Carefully slide it over the bushing at the bottom of the filter cavity.
j. Inspect the filter housing and seals for damage. Wipe them with a clean towel to remove all
debris.
k. Apply clean hydraulic oil to the threads of the filter housing (as a lubricant).
l. Install the filter housing over the filter element. Tighten the filter element by hand until you feel
resistance from the seals. Change to the 7/8 in socket and ratchet wrench and continue to
tighten the filter element until fully seated. Change to the torque wrench and tighten the filter
housing to a torque of 61 N-m (45 lbf-ft).
m. Wipe the area around the port for the relief valve with a clean towel to remove all debris.
n. Carefully install the relief valve in the port. Tighten the valve by hand until it is seated in the port
and you feel resistance from the seal. Continue to tighten the relief valve (use 1 in deep socket
and torque wrench) to a torque of 34 N-m (25 lbf-ft).
o. Install the vent plug into the top of the filter housing (use 9/16 in socket and ratchet wrench)
until snug and then back it out one full turn.
5. Purge air from the oil filter:
a. Make sure the HPS is shut 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 20 N-m (15 lbf-ft).
Clean up any leaking oil.
f. Start the HPS and let it run for approximately ten minutes. While the HPS is running watch the oil
filter and vent plug for oil leakage. If there is oil leakage, check and tighten the appropriate
component.
g. When there is no oil leakage, cycle the hydraulic cylinder through its full stroke several times to
ensure proper operation and to completely purge air from the system.
h. Press the DISABLE FRAME button in the controlling software to shut down the HPS.
6. Clean the HPS of all spilled and leaked oil. Clean the area around the fill hole and air breather
filter (3 and 2) to remove all dust, dirt and grime.
7. Remove the air breather filter from the reservoir fill hole - push down and turn counterclockwise.
8. Remove the screws from the air breather fitting (use 3 mm hex key) on the reservoir. Remove the
fitting and plastic screen from the reservoir fill hole.
9. Insert the hand pump hose into the reservoir.
10. Pump the oil out of the reservoir and into the oil container.
11. Install the air breather fitting and plastic screen into the reservoir fill hole. Secure the air breather
fitting to the reservoir with the screws that were removed in step 8.
12. Insert a clean funnel with a mesh filter into the fill hole and fill the reservoir with the recommended
hydraulic fluid. Fill the reservoir to the top of the sight gauge.

Product Support: www.instron.com 83

Chapter 4: Maintenance

13. Install the air breather filter onto the reservoir fill hole.
14. Start the HPS and cycle the hydraulic cylinder through its full stroke a few times. Fully retract the
hydraulic cylinder. Press the DISABLE FRAME button in the controlling software to shut down the
HPS. Check the oil level. If the oil is not to the top of the sight gauge, repeat step 7 and then
steps 12 through 14. If the oil is to the top of the sight gauge, continue with next step.
15. Install the cover that was removed in step 1.

Change the air breather filter

The air breather filter should be changed at the frequency stated in the “Preventative maintenance
schedule” on page 61.

Equipment and supplies required

• New air breather filter - for Instron part number see Table 18 on page 90

When ordered from Instron, the air breather filter includes a new air breather fitting and plastic screen.
The only part needed is the air breather filter. However, you can replace the existing air breather fitting
and plastic screen with the new parts if desired or necessary (due to damage, etc.).

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. Clean the area around the fill hole and air breather filter (3 and 2) to remove all dust, dirt and grime.
3. Remove the air 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:

• Inspect all hose fittings for loose connections. This includes connections at the frame and at the
HPS. Also be sure to check all hose fittings for any hydraulic accessories that are part of the testing
system. Tighten any loose fittings that you may find.
• Inspect all hydraulic hoses for deterioration. Check for abrasions, cuts, etc. Replace hoses as
necessary.

Replace the hydraulic hoses

Hydraulic hoses should be replaced at the frequency stated in the “Preventative maintenance
schedule” on page 61. The service life of any hydraulic hose depends on the pressure that it is
subjected to during its normal use.

84 M47-17027-EN
 Hydraulic power supply (HPS)

Replace low pressure hydraulic hoses

Low pressure hoses are hoses that are normally subjected to pressures less than 20 bar (300 psi). Low
pressure hoses would be:

• Drain hoses
• Return hoses between system components and the reservoir

Replace high pressure hydraulic hoses

High pressure hoses are hoses that are normally subjected to pressures 20 bar (300 psi) and greater.
High pressure hoses would be:

• Supply hose between the HPS and hydraulic cylinder

• For frames with G7-style crossheads, any supply hose between the HPS and hydraulic grip actuators

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 look for oils with the following
properties: good demulsibility; low air entrainment; low pour point; and additives that protect against rust,
corrosion, accelerated pump wear, foaming, and oxidation.

Approximate reservoir capacities for the various models of DX frames can be found in Table 16.

Table 16. Approximate capacity of HPS reservoir.

Frame Model Reservoir Capacity

300DX 34 L (9 gal)

600DX 34 L (9 gal)

Product Support: www.instron.com 85

Chapter 4: Maintenance

Ancillary parts
DX systems are provided with operating tools and other accessories that are either: required to complete
installation of the frame; required for use or maintenance of frame; or required for set up of accessories
on the frame. These ancillary parts are included with the frame upon delivery. Ancillary parts for the
various DX systems are listed in Table 17. Be sure to keep these ancillary parts in a safe place so they
do not get misplaced.

Table 17. Ancillary parts list.

Description Location or Purpose Frame Model Part Number1 Quantity

Grip stop plate Grip assemblies - tension crosshead 300DX-G1 228133-1 1

600DX-G1 225769-1 1

Jaw retainer Grip assemblies - tension crosshead 300DX-G1 228134-2 4

600DX-G1 225768-2 4

Button head cap screw, Grip assemblies - secure jaw retainer

300DX-G1 300-8826-1020 8
5/16-18 x 0.5 in
Button head cap screw,
600DX-G1 300-8826-1027 8
3/8-16 x 0.75 in

Socket head cap screw, Grip assemblies - secure grip stop

300DX-G1 300-8821-9310 2
M10 x 1.5p x 35 mm plate to tension crosshead

Socket head cap screw,

600DX-G1 300-8821-9511 2
M16 x 2p x 35 mm

Filler plate, 3/16 in thick Grip assemblies 300DX-G1 109797-1-1 12

600DX-G1 126509-1B 16

Pinion Grip assemblies 300DX-G1 228377-2 2

600DX-G1 228143-2 2

Setscrew, Grip assemblies - secure pinion in 300DX-G1

300-8822-9522 2
M10 x 1.5p x 25 mm crosshead 600DX-G1

Crank handle Grip assemblies 300DX-G1

300-8876-1006 2
600DX-G1
Wear plate Extra set for grip assemblies 300DX-G7 221722-1 4

600DX-G7 225566-1 4

Grip dust cover, rubber Extra set for grip assemblies 300DX-G7 227831-1 4

600DX-G7 225752-1 4

Piston dust cover Grip assemblies 300DX-G7 221174-1 2

600DX-G7 225751-1 2

Bumper plate Compression test space - mount to 300DX-G8 217481-2 1

bottom of adjustable crosshead
300DX-G1
300DX-G7
226722-3 1
600DX-G1
600DX-G8

86 M47-17027-EN
 Hydraulic power supply (HPS)

Table 17. Ancillary parts list. (Continued)

Description Location or Purpose Frame Model Part Number1 Quantity

Socket head cap screw, Compression test space - secure

300DX-G8 300-8821-9309 4
M10 x 1.5p x 25 mm bumper plate to bottom of adjustable
crosshead
Socket head cap screw, 300DX-G1
M16 x 2p x 35 mm 300DX-G7
300-8821-9511 2
600DX-G1
600DX-G8

Setscrew, Compression test space - secure

300DX-G8 300-8822-9540 1
M8 x 1.25p x 50 mm holding button to bumper plate

Setscrew, 300DX-G1
M8 x 1.25p x 25 mm 300DX-G7
300-8822-9550 1
600DX-G1
600DX-G8

Setscrew,
600DX-G7 300-8822-9452 1
M8 x 1.25p x 40 mm

Holding button Compression test space - for use with

bumper plate to mount compression All 226724-1 1
fixtures to the adjustable crosshead

Setscrew, Compression test space - mount the

All 300-8822-4478 1
1/2-13 x 1.5 in holding button to a fixture

Fixture holding screw Compression test space - secure 300DX-G8 210150-1A 1

fixtures to bottom of adjustable
crosshead (must remove bumper 600DX-G8 193418-1C 1
plate)
Hex key, T-handle, Tighten and loosen fixture holding
300DX-G8 300-8875-9344 1
10 mm, 6 in blade screw in adjustable crosshead

Hex key, T-handle,

600DX-G8 300-8875-9234 1
3/8 in, 6 in blade

Hex key, T-handle, 4 mm, Tighten and loosen M5 cap screws

All 300-8875-9369 1
6 in blade

Hex key, 14 mm, L-shape ball Tighten and loosen M16 cap screws 600DX-G1
300-8875-9350 1
600DX-G7

Screwdriver, 3/8 in slot Assist in removal of grip jaws from 300DX-G7

300-8899-10699 1
grip pocket 600DX-G7

Lubricant, Molykote GN metal Lubricate grip assemblies 300DX-G1

300-8894-9035 1
paste, 1 lbs can 600DX-G1
Grease gun Lubricate grip assemblies 300DX-G7
300-8899-10682 1
600DX-G7
Lubricant, Molykote GN metal Lubricate grip assemblies 300DX-G7
300-8894-9059 2
paste, 14 oz cartridge 600DX-G7

Adhesive, Loctite 246 Maintain grip assemblies

Threadlocker high temperature/ 300DX-G7
300-8899-10741 1
medium strength, 10 mL 600DX-G7
(0.34 oz)

Product Support: www.instron.com 87

 Chapter 4: Maintenance

Table 17. Ancillary parts list. (Continued)

Description Location or Purpose Frame Model Part Number1 Quantity

Cleaner and degreaser, Loctite Maintain grip assemblies

300DX-G7
7070 ODC-FREE, 300-8899-10742 1
600DX-G7
475 mL (16 oz) spray

Isolation pad set, 4 in square Frame installation All 300-8899-10650 1

Hex key set, 13 piece, Tighten and loosen various fasteners

All 300-8875-1958 1
0.050 - 3/8 in ball end
Hex key set, 9 piece, Tighten and loosen various fasteners
All 300-8875-9290 1
1.5 - 10 mm ball end
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.

88 M47-17027-EN
 Spare and replacement parts

Consumable parts
DX systems are designed to require very few parts to be replaced during their lifetime. These consumable
parts are listed in Table 18. The replacement frequency of each part, or the condition that indicates that
replacement is necessary, is discussed throughout this chapter.

Table 18. Consumable parts list.

Description Location or Purpose Frame Model Part Number1

Lubricant, Molykote GN metal paste, Lubricate grip 300DX-G1

300-8894-9035
0.45 kgs (1 lbs) can assemblies 600DX-G1

Lubricant, Molykote GN metal paste, Lubricate grip 300DX-G7

300-8894-9059
0.4 kgs (14 oz) cartridge assemblies 600DX-G7

Adhesive, Loctite 246 Threadlocker high Maintain grip 300DX-G7

300-8899-10741
temperature/medium strength, 10 mL (0.34 oz) assemblies 600DX-G7
Cleaner and degreaser, Loctite 7070 ODC-FREE, Maintain grip 300DX-G7
300-8899-10742
475 mL (16 oz) spray assemblies 600DX-G7

Lubricant, Molykote BR2 Plus, Lubricate backlash

All 105-1-60
0.4 kgs (14 oz) cartridge eliminators

Lubricant, Molykote BR2 Plus, Lubricate screw

All 300-8894-9064
16 kgs (35 lbs) can columns

Oil filter element (3 micron) HPS - oil filter All 300-8873-9150

Air breather filter HPS - reservoir All 300-8868-9091

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.

Spare and replacement parts

The Instron Services department can supply parts for your system. In the event that your system requires
replacement parts, or if you choose to keep spare parts in stock, please contact your local Instron
Services department as directed on page 20 for the proper part.

Product Support: www.instron.com 89

Chapter 4: Maintenance

90 M47-17027-EN
 Appendix A
CE Certificate

EC Declaration of conformity for machinery

(Machinery Directive 2006/42/EC, Annex II., sub. A)

Manufacturer: Instron, a division of Illinois Tool Works, Inc. - Industrial Products Group
Address: 900 Liberty Street, Grove City, PA, 16127, USA

Name and address of the person authorised to compile the technical file:
Name: Jonathan Snell
Address: Instron - Division of ITW Limited, Coronation Road, High Wycombe, Buckinghamshire, HP12 3SY,
United Kingdom

Herewith we declare that

Model Number:
Serial Number:

z is in conformity with the relevant provisions of the Machinery Directive (2006/42/EC)

z is in conformity with the provisions of the following other EC-Directives

Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU

And furthermore, we declare that

z the following (parts/clauses of) European harmonised standards published in the Official Journal have been used
BS EN 60204-1: 2006 Safety of Machinery, Electrical Equipment of Machines
EN ISO 12100: 2010 Safety of machinery - General principles for design - Risk assessment and risk
reduction
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

z the following (parts/clauses of) other European harmonised standards, technical standards and specifications have
been used

Place of Issue: Grove City, PA USA Signature:

Date of Issue:
Stephen A. Somple
R&D Engineering Manager

Supplier’s declaration of conformity (in accordance with ISO/IEC 17050-1)

91
Appendix : CE Certificate

This page is intentionally blank.

92
 Appendix B
Grip Jaws
A range of grip jaws are available for use with the frame’s grip assemblies. Table 19 lists the catalog
numbers and specifications of grip jaws that are available. In addition, other grip jaws can be ordered
and made to customer specifications; contact your regional Instron office or check our web site at
www.instron.com for assistance.

Caution
Always use grip jaws that are designed for the size of the specimen that you are testing.
Using undersized specimens for your grip jaws can cause damage to the grips.

Table 19. Available grip jaws and their specifications.

Grip Jaw
Catalog Jaw Specimen Tooth Jaw Face Size Minimum
Frame Model Number Type1 Range2 Profile (W x H) Engagement

16 tpi,
W-1214 Flat-face 0-25 mm (0-1 in) horizontal,
65 deg. 50 x 76 mm 60 mm
300DX-G1
W-1215 12-32 mm (0.5-1.25 in) 16 tpi, (2 x 3 in) (2.4 in)
Vee-face horizontal,
W-1215-A 5-13 mm (0.2-0.5 in) 65 deg.

8 tpi,
W-1408 horizontal,
65 deg.

8 tpi,
W-1408-A diamond,
65 deg.
Flat-face 0-45 mm (0-1.75 in)
16 tpi,
W-1409 horizontal,
65 deg. 70 x 125 mm 100 mm
600DX-G1
16 tpi, (2.75 x 5 in) (4 in)
W-1409-A diamond,
65 deg.

10 tpi,
W-1410 12.7-57 mm (0.5-2.25 in) horizontal,
65 deg.
Vee-face
W-1410-A 7-25 mm (0.25-1 in) 16 tpi,
horizontal,
W-1411 12.7-57 mm (0.5-2.25 in) 65 deg.

93
Appendix : Grip Jaws

Table 19. Available grip jaws and their specifications. (Continued)

Grip Jaw
Catalog Jaw Specimen Tooth Jaw Face Size Minimum
Frame Model Number Type1 Range2 Profile (W x H) Engagement
W-5246-A 0-16 mm (0-0.63 in)
20 tpi,
W-5246-B Flat-face 16-32 mm (0.63-1.26 in) horizontal,
65 deg.
W-5246-C 32-50 mm (1.26-1.97 in)

W-5247-A 3-10 mm (0.12-0.39 in) 20 tpi, 70 x 76 mm 60 mm

300DX-G7
horizontal, (2.75 x 3 in) (2.4 in)
W-5247-B 10-20 mm (0.39-0.79 in) 65 deg.
Vee-face
W-5247-C 20-30 mm (0.79-1.18 in) 10 tpi,
horizontal,
W-5247-D 30-40 mm (1.18-1.57 in) 65 deg.
W-5197-A 0-30 mm (0-1.18 in) 20 tpi,
Flat-face horizontal,
W-5197-B 30-60 mm (1.18-2.36 in) 65 deg.

W-5198-A 3-10 mm (0.12-0.39 in) 20 tpi,

100 x 100 mm 80 mm
600DX-G7 horizontal,
W-5198-B 10-35 mm (0.39-1.38 in) (4 x 4 in) (3.2 in)
65 deg.
Vee-face
10 tpi,
W-5198-C 35-57 mm (1.38-2.25 in) 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 thickness.
For vee-face grip jaws this is the specimen diameter.

94
Product Support: www.instron.com