Shimadzu AG-IC 100 KN and 300 KN Instruction Manual - 349-05554B

349-05554B
INSTRUCTION MANUAL
FOR
SHIMADZU AUTOGRAPH
AG-100kNIC
And
AG-300kNIC
To ensure proper use of this equipment, read

this manual thoroughly.
Keep this manual carefully for your reference.
Before Using the System
Introduction
Read this instruction manual prior to operating the product.
Thank you for purchasing the AG-IC series AutoGraph testing machine.
This instruction manual includes guidelines for installing the system, precautions that should be
followed when using the system, and a description of relevant accessories and optional parts.
Please read the instruction manual carefully before using the testing machine.
Keep it stored safely in an accessible location for easy reference.
IMPORTANT · Read this manual thoroughly before using the product and operate the product in
accordance with the instructions in this manual.
· If the user or usage location changes, ensure that this Instruction Manual is always
kept together with the product.
· If this manual or a product warning label is lost or damaged, immediately contact
your Shimadzu representative to request a replacement.
· To ensure safe operation, read all Safety Instructions before using this product.
· To ensure safe operation, contact your Shimadzu representative if product
installation, adjustment, or re-installation (after the product is moved) is required.
· Contact your Shimadzu representative if product or peripheral disposal is required.
NOTICE · All rights are reserved, including those to reproduce this manual or parts
thereof in any form without permission in writing from Shimadzu
Corporation.
ã 2009 Shimadzu Corporation. All rights reserved.
· Information in this manual is subject to change without notice and does not
represent a commitment on the part of the vendor.
· Any errors or omissions which may have occurred in this manual despite
the utmost care taken in its production will be corrected as soon as
possible, although not necessarily immediately after detection.
Microsoft and Windows are registered trademarks of Microsoft Corporation

in the United States and/or other countries.
i
Inscription of this manual
This operation manual defines warnings, cautions and other information as follows:
Inscription Meaning
Failure to avoid the described condition may result in serious injury or

WARNING death.
Failure to avoid the described condition may result in slight or middle

CAUTION injury, or damage to the equipment.
NOTE Includes information necessary for correct use of the equipment.
ii
The warnings on safe for SHIMADZU AUTOGRAPH
The AUTOGRAPH is the measuring equipment intended to measure mechanical strength or other
properties of various materials and products, and big power is generated.
Depending on a handling situation, there is a danger of causing serious obstacles (an injury, death
accident, etc.) to a human body, and material damage.
Therefore, you observe the following warning after an understanding enough, and I ask you to use
it safely.
WARNING
Using this equipment carelessly may result in serious injury or death.
While the crosshead is operated, be sure not to put a part of your body
(hand, head, etc.) in the testing space.
WARNING
The dangerous power according to capacity arises in a part of operation.
Surely, an operator needs to read an instruction manual carefully and needs
to use it correctly. Moreover, please manage so that only the person who
received education about the operation method uses it.
WARNING
To avoid electric shock, do not touch the inside of equipment with a hand
by any means.
WARNING
Except for lubricating work, do not open the ball screw protection cover.
Do not test when the ball screw protection cover is opened.
During lubricating work, be careful that your hairs will not be caught in the
machine.
iii
WARNING
Please bring neither a face nor the body close to a specimen during a test.
In such case, the specimen breaks and a fragment disperses, causing injury to
an eye or the body. Please cope with installation of a testing space safety
door etc. for the specimen to crush.
WARNING
To avoid electric shock, an injury, and a fire, people with special
knowledge need to do the work of wiring, maintenance, and check.
WARNING
To avoid electric shock, be sure to ground the grounding terminal of a
power supply cable (100Ω or less).
WARNING
Do not apply force to the crosshead when the load cell is dismounted, or
when force cannot be transmitted to the load cell. In such a case, the
AUTOGRAPH cannot detect overload conditions, causing damage to the
frame or jig.
WARNING
Before operating the crosshead, be sure to set the crosshead stroke limit
switch to avoid the destruction of a frame, jig, and load cell by the collision
of the jig.
iv
WARNING
“Safety function” is attached in this equipment. It detect the force shift
applied to the load cell while crosshead moves under jog operation or return
function. If the force shift value becomes over a determined value, it makes
stop the crosshead immediately.
Although this function is one of the safety device, the equipment can not
exclude danger by overshoot at the high-speed operation.
When the crosshead is operated in the direction of reducing force, the
crosshead does not stop in order to remove force at overload and the
convenience of operation.
Note that this function is not intended to ensure that preventing the objects
from running into the others in the test space and overload.
Moreover, please do not use this function for control, such as positioning.
v
Note on Shimadzu AUTOGRAPH AG-IC Handling
When the load cell and extensometer are installed and exchanged, be sure to
turn off the power supply according to the under mentioned notes
NOTE
Before connecting the CAL cable to the connector (disconnecting the CAL cable
from the connector), be sure to turn OFF the power supply.
If the cable is connected or disconnected while the power supply is turning ON,
the capacity of the load cell and calibration data might break.
Moreover, new information on the load cell (extensometer) is not valid and force
(elongation) value becomes incorrect without resetting the power.
Load cell
CAL. cable
POWER SUPPLY
ON
Sensor Amplifier Panel for the

AG-IC Series (Floor-type)
vi
WARNING LABELS ON THE EQUIPMENT
(FLOOR-TYPE TESTING MACHINE)
WARNING
HAZARDOUS VOLTAGE
To avoid electric shock, do not disassemble.
Warning label
(Backside of testing machine)
WARNING
HAZARDOUS VOLTAGE
To avoid electric shock, turn off the power supply before removing the power cable.
Warning label
(Backside of testing machine)
vii
WARNING LABELS ON THE EQUIPMENT
(FLOOR-TYPE TESTING MACHINE)
RISK OF INJURY
Keep hands clear while the crosshead is operating.
Warning label
viii
Countermeasures in Emergency
If the crosshead does not stop or you smell something burning, carry out the following
countermeasures:
To restart operation, check the equipment, and contact our service representative if required.
 Procedure for stopping the equipment in emergency

 1) Stop the emergency stop button.
 2) Turn OFF the power switch of the tester.
 3) Turn OFF the circuit breaker on the rear right side of the tester.
(Floor-type only)
 4）Disconnect the power supply cable from the rear of the tester.
Emergency stop
switch
Smart controller
Circuit breaker (Rear right side of the tester)
Power switch
AG-IC series (floor-type) tester
Emergency stop switch and power switch
ix
Warranty
Thank you for purchasing the AG-IC series AutoGraph testing machine.
Shimadzu provides the following warranty for this product.
1. Period Please contact your Shimadzu representative for information about the period of
this warranty.
2. Description If a product/part failure occurs for reasons attributable to Shimadzu during the
warranty period, Shimadzu will repair or replace the product/part free of charge.
However, in the case of products which are usually available on the market only
for a short time, such as personal computers and their peripherals/parts, Shimadzu
may not be able to provide identical replacement products.
3. Exceptions: Failures caused by the following are excluded from the warranty, even if they
occur during the warranty period.
1) Improper product handling

2) Repairs or modifications performed by parties other than Shimadzu or Shimadzu designated
companies
3) Product use in combination with hardware or software other than that designated by Shimadzu
4) Computer viruses leading to device failures and damage to data and software, including the
product's basic software
5) Power failures, including power outages and sudden voltage drops, leading to device failures
and damage to data and software, including the product's basic software
6) Turning OFF the product without following the proper shutdown procedure leading to device
failures and damage to data and software, including the product's basic software
7) Reasons unrelated to the product itself
8) Product use in harsh environments, such as those subject to high temperatures or humidity
levels, corrosive gases, or strong vibrations
9) Fires, earthquakes, or any other act of nature, contamination by radioactive or hazardous
substances, or any other force majeure event, including wars, riots, and crimes
10) Product movement or transportation after installation
11) Consumable items
Note: Recording media such as floppy disks and CD-ROMs are considered consumable
items.
If there is a document such as a warranty provided with the product, or there is a separate contract
agreed upon that includes warranty conditions, the provisions of those documents shall apply.
Separate warranty periods shall be stipulated for custom specification parts and system.
x
After-Sales Service and Availability of Replacement Parts
After-Services If any problem occurs with this product, perform an inspection and take
appropriate corrective action as described in this manual's troubleshooting
section.
If the problem persists, or the symptoms are not covered in the
troubleshooting section, contact your Shimadzu representative.
Replacement Parts Replacement parts for this product will be available for a period of seven
Availability (7) years after the product is discontinued. Thereafter, such parts may
cease to be available.
Note, however, that the availability of parts not manufactured by
Shimadzu shall be determined by the relevant manufacturers.
Installation
To ensure safe operation, contact your Shimadzu representative if product installation, adjustment,
or re-installation (after the product is moved) is required.
Action for Environment (WEEE)
To all users of Shimadzu equipment in the

European Union:
WEEE Mark
Equipment marked with this symbol indicates that it was sold on or after 13th
August 2005, which means it should not be disposed of with general household
waste. Please note that our equipment is for industrial/professional use only.
Contact your Shimadzu service representative when the equipment has

reached the end of its life. They will advise you regarding the equipment
take-back.
With your co-operation we are aiming to reduce contamination from waste

electronic and electrical equipment and preserve natural resource through re-use and recycling.
Please do not hesitate to ask your Shimadzu office or Shimadzu distributor, if you require further
information.
xi
EMC Directive
This instrument is a class A product, designed not for use in residential environment. Accordingly,
if using the instrument in residential environment, the user may be required to take adequate
measures.
Regulatory Information
For Europe:
The product complies with the requirement of the
Low Voltage Directive 2006/95/EC and EMC Directive 2004/108/EC
Product Name : Universal Testing Instruments
Model Name : Autograph AG-IC Series

AG-100kNIC
AG-300kNIC
Manufacturer : SHIMADZU CORPORATION

Analytical & Measuring Instruments Division
Address : 1,NISHINOKYO-KUWABARACHO,
NAKAGYO-KU,KYOTO,604-8511, JAPAN
Authorized Representative : SHIMADZU EUROPA GmbH

in EU
Address : Albert-Hahn-Strasse 6-10, 47269
Duisburg, F.R. Germany
xii
CONTENTS
CONTENTS
CHAPTER 1 OUTLINE.......................................................................................................1-1
1.1Outline .............................................................................................................................1-2
1.2 Precautions ....................................................................................................................1-2
1. Handling the load cell............................................................................................................. 1-2
2. Handling the grips .................................................................................................................. 1-3
3. Cycle test ................................................................................................................................. 1-3
4. Setting the crosshead limit switch......................................................................................... 1-3
1.3 Specifications................................................................................................................1-4
1. Outline .................................................................................................................................... 1-4
2. Detailed specifications ............................................................................................................ 1-5
1.4 Individual Specifications for Testing machine <Standard type/Lead screw
extension type> .....................................................................................................1-9
CHAPTER 2 PARTS IDENTIFICATION .........................................................................2-1
2.1 Main frame....................................................................................................................2-2
2.2 Accessories ..................................................................................................................2-3
2.3 Peripheral Equipment ...................................................................................................2-5
1. Set of load cells........................................................................................................................ 2-5
2. Test jigs .................................................................................................................................... 2-6
3. Recorder/Data processor....................................................................................................... 2-10
4. Maintenance parts ................................................................................................................ 2-11
CHAPTER 3 FEATURES AND FUNCTIONS OF EACH SUBASSEMBLY................3-1
3.1 Main frame .....................................................................................................................3-2
1. AG-ICseries (Floor-type) ......................................................................................................... 3-2
3. Description on the main parts................................................................................................ 3-4
3.2 Smart controller ..............................................................................................................3-6
1. External views and names of the main parts........................................................................ 3-6
2. Description on the main parts................................................................................................ 3-7
3.3 Load Cell (Option), Tension force jig (Option) ................................................................3-9
1. External view and names of the main parts (Floor-type)..................................................... 3-9
2. External view and names of the main parts (Table-type) .................................................. 3-10
3. Part names ............................................................................................................................ 3-11
CHAPTER 4 BASIC OPERATIONS..................................................................................4-1
4.1 Introduction...................................................................................................................4-2
4.2 Precautions for Installation ...........................................................................................4-3
1. Installation environment....................................................................................................... 4-3
2. Conditions for Installation location ...................................................................................... 4-3
3. Delivery/Installation.............................................................................................................. 4-3
4. Main frame level adjustment ................................................................................................ 4-4
5. Conditions for the power supply ........................................................................................... 4-5
4.3 Fixing Smart controller ...................................................................................................4-6
1. Mount the smart controller in installation .......................................................................... 4-6
4.4 Cable Connections .........................................................................................................4-7
1. AG-IC series testing machine (Floor-type) ............................................................................ 4-7
2. Connection with a personal computer ................................................................................... 4-8
4.Connecting the analog recorder .............................................................................................. 4-9
4.5 Safety Devices............................................................................................................4-10
1. Emergency stop switch ......................................................................................................... 4-10
xiii
CONTENTS
2. Crosshead stroke limit switch.............................................................................................. 4-10

3. Turnover prevention brackets (Optional) ............................................................................ 4-12
4. Testing space safety door (Optional).................................................................................... 4-12
4.6 Turning ON/OFF Power Supply..................................................................................4-13
1. Introduction........................................................................................................................... 4-13
2. Turning ON the power .......................................................................................................... 4-13
3. Warm-up ................................................................................................................................ 4-14
4. Calibration for Force Amplifier ............................................................................................ 4-15
5 Turning OFF the power ......................................................................................................... 4-15
4.7 How to Use Smart controller.......................................................................................4-16
1. LED display........................................................................................................................... 4-16
4.8 Moving Crosshead Up/Down ......................................................................................4-17
1. Starting a test ....................................................................................................................... 4-17
2. Returning the crosshead (High-speed return to the origin)............................................... 4-18
3. Stopping a test....................................................................................................................... 4-18
4. Manual operation .................................................................................................................. 4-19
5. Safety function ...................................................................................................................... 4-20
6. Setting the crosshead origin................................................................................................. 4-21
4.9 Testing machine Setup ...............................................................................................4-21
1. Mounting the load cell .......................................................................................................... 4-21
2. Mounting the tensile test jig (Optionally available, except for the load cell)
4-24
3. Removing the tensile test jig ..................................................................................... 4-32
CHAPTER 5 PERFORMING A TEST ..............................................................................5-1
5.1 Procedure for Tensile Test (Example) ..........................................................................5-2
1. Preparations for Test .............................................................................................................. 5-2
2. Procedure for Tensile Test ...................................................................................................... 5-2
5.2 Procedure for Compression/Bending Test (Example) ....................................................5-5
1. Preparations for Test .............................................................................................................. 5-5
2. Procedure for Compression/Bending Test.............................................................................. 5-6
CHAPTER 6 PERFORMANCE INSPECTION/MAINTENANCE .............................6-1
6.1 Periodic Inspection .........................................................................................................6-2
6.2 Inspection of the Safety Devices ....................................................................................6-2
1. Emergency stop switch ........................................................................................................... 6-2
2. Crosshead stroke limit switches ............................................................................................ 6-2
6.3 Force Inspection.............................................................................................................6-4
1. Force inspection ...................................................................................................................... 6-4
2. Force Calibration (F-CAL)...................................................................................................... 6-6
6.4 Maintenance (Lubrication and Cleaning)........................................................................6-7
1. Maintenance of the ball screw................................................................................................ 6-7
2. Maintenance of the fan filter( Floor type) ............................................................................. 6-8
3. Maintenance of the smart controller ..................................................................................... 6-8
4. Maintenance of the testing machine body............................................................................. 6-8
CHAPTER 7 TRANSPORT/STORAGE ............................................................................7-1
7.1 Precautions for Transport .............................................................................................7-2
1. Installation space .................................................................................................................... 7-2
2. Installation environment........................................................................................................ 7-2
3. Power supply ........................................................................................................................... 7-2
4. Precautions .............................................................................................................................. 7-2
5. Level adjustment (Table-type testing machine).................................................................... 7-3
6. Cable connections.................................................................................................................... 7-3
7.2 Precautions for Storage..................................................................................................7-4
xiv
CONTENTS
1. Precautions for storage ........................................................................................................... 7-4

2. Storing environment ............................................................................................................... 7-4
3. Provisions for storage ............................................................................................................. 7-4
CHAPTER 8 TROUBLESHOOTING ................................................................................8-1
8.1 Introduction.....................................................................................................................8-2
8.2 Alarm Messages and Resetting Alarms..........................................................................8-2
8.3 Other Troubles................................................................................................................8-6
1. Troubles related to key input ................................................................................................. 8-6
2. Other troubles ......................................................................................................................... 8-7
8.4 C-RAM Clear ..................................................................................................................8-8
8.5 Checking the Circuit Breaker (AG-IC Series Floor-type) ................................................8-9
CHAPTER 9 MAINTENANCE PARTS LIST ..................................................................9-1
9.1 Consumable Parts..........................................................................................................9-2
9.2 Maintenance Parts .........................................................................................................9-2
xv
CONTENTS
(Blank sheet)
xvi
CHAPTER 1 Outline
CONTENTS
1.1 Outline..................................................................... 1-2
1.2 Precautions ............................................................ 1-2
1.3 Common Specifications .......................................... 1-4
1.4 Individual Specifications......................................... 1-9
1-1
1. Outline
1.1 Outline
We at Shimadzu appreciate it very much that you have purchased a

Shimadzu AUTOGRAPH AG-IC series testing machine.
The AG-IC series AUTOGRAPH is a universal testing machine

indispensable to quality control and researches of various materials such
as metal, ceramic, plastic and rubber, and various products such as
screws, electronic components, foods, medical supplies and films, as
well as to research and development of new materials.
To perform material strength measurement, the universal testing

machine must provide extremely-high body rigidity and loading speed,
and reliability in force measurements.
The AG-IC series AUTOGRAPH is the precision universal testing

machine that provides excellent basic performance and enables you to
operate various functions easily. We are sure that this product can be
used for a long period.
The AG-IC series AUTOGRAPH can be used for various tests such as
compression and bending tests, in addition to tensile tests. However,
this operation manual mainly describes the commonly-performed
tensile tests.
1.2 Precautions
1. Handling the load cell

Since the load cell is a high-precision equipment for detecting a force, handle
the load cell with thorough attention to the following points. To handle the
small-capacity load cell, special attention is required.
1 ) Make sure that the force applied to the load cell does not exceed 150% of the
rated load capacity. (The force includes the jig mass applied to the load cell.)
2 ) Do not apply eccentric force or impact to the load cell.
3 ) Avoid using the load cell in a place where an extreme temperature change
may occur. The operating temperate range is +5 °C to +40 °C. During a test,
make sure that temperature fluctuations does not exceed +/－2 °C.
1-2
1. Outline
NOTE
The AG-IC series AUTOGRAPH provides an over force detecting function. However, if an
overshoot occurs before the crosshead stops, the load cell may be damaged. If the force reaches
the load cell capacity within approx. 2 seconds or the maximum force is unknown, perform a
preliminary test to make sure that the force does not exceed 90% of the load cell capacity.
To perform a preliminary test, set the test speed so that the maximum force will be reached in 5
or more seconds. If the maximum force is unknown, select the tester's lowest speed to perform a
trial operation.
2. Handling the grips

1 ) Be sure not to use the grips under any conditions other than those specified.
2 ) Grip a specimen by 80 to 100% length of the grip tooth length. Do not grip a
specimen by a shorter length. Otherwise, the specimen man slip from the
grips, and the grip teeth or grip body may be damaged.
3 ) After completion of a test, or during replacement of the grip teeth, be sure to
clean the grip teeth and the sliding part of the grip body. Apply molybdenum
grease to these parts so that the grip can work smoothly.
3. Cycle test
To maintain the performance of the SHIMADZU AUTOGRAPH for a long
period, the following conditions are provided for a cycle test. Use the
AUTOGRAPH under the specified conditions.
1 ) Cycle test conditions:

a) Cycle frequency: 3 cycles/min or less
b) Continuous operation time and number of continuous cycles: 10 hours
or less, 1000 cycles or less
NOTE
The above cycle test conditions are is the limit of the performance of the
testing machine. Please examine below on this condition in principle.
2 ) Lubrication
Apply the specified lubrication oil to the ball screw periodically. Be careful
to prevent oil lacking.
4. Setting the crosshead limit switch

Be sure to set the crosshead upper/lower limit switch to the position where the
crosshead safely stops. In particular, after switching the test mode
(tensile/compression/bending test), make sure that the crosshead limit switch
has been properly set.
For the crosshead limit switch setting procedure, see Section 4.5 2. .
1-3
1. Outline
1.3 Specifications
1. Outline
(1) Loading method High-precision, constant-speed strain control using two ball screws
(2) Force capacity 100 kN (10 tf) and 300 kN (30tf)
(3) Force measurement accuracy
･ Tensile Within +/-1% of an indicated value:
measurement Acceptable in JIS B7721
accuracy
(Within 1/1 to 1/250 range of the rated load
cell capacity)
Standard accuracy type cell capacity is optional)
･ Compression Within +/-1% of an indicated value:
accuracy
cell capacity)
cell capacity is optional)
･ Tensile Within +/-0.5% of an indicated value:
accuracy
cell capacity)
High accuracy type
･ Compression Within +/-0.5% of an indicated value:
accuracy
cell capacity)
(4) Crosshead speed Within +/-1% (At a constant crosshead speed of 0.5 to 500 mm/min.
accuracy Based on the crosshead movement within a specified period)
(5) Installation 1) Temperature 5 to 40 ºC
environments (Temperature fluctuations during test: within
+/-2 ºC )
2) Relative humidity 20 to 80% (no condensation)
1-4
1. Outline
2. Detailed specifications
(1) Crosshead speed setting

Test speed is set up as a part of conditions by the exclusive data-processing software.
The number of digits for the speed setting (preset resolution) is different from
the control resolution. Although the crosshead speed can be set higher than the
control resolution, the actual operation speed is limited to the control
resolution.
Example) When the crosshead speed is set to 500.5 m/min, the actual
operation speed is 500 mm/min for 100kN.
In the case of 100kN capacity testing machine
Speed (mm/min) 0.0005～0.001 0.001～1 1～40 40～100 100～1000
Resolution (mm/min) 0.0001 0.001 0.2 0.5 1.0
In the case of 300kN capacity testing machine
Speed (mm/min) 0.0005～0.001 0.001～0.5 0.5～20 20～50 50～500
Resolution (mm/min) 0.0001 0.001 0.1 0.25 0.5

When using inch/min unit for speed, the set speed is calculated to mm/min
speed value. There will be some error within above resolution maximum.
Example: In the case of the crosshead speed is set to 1 inch/min

In Unit Conversion of Inch = 25.4mm,
“1 inch/min → 25.4mm/min” is “1 inch/min → 25.25mm/min”
(2) Crosshead control START/STOP/RETURN

JOG UP/JOG DOWN
(3) Crosshead position Manual Dial
fine-adjustment
(4) Force measuring device (Force amplifier)
1) Measurement Selected from 7 levels (´1, ´2, ´5, ´10, ´20, ´50, ´100)
magnification
2) Measurement Approx. 1/16000 of the full scale of each range
resolution
3) Automatic force range switching function
1-5
1. Outline
When the force exceeds 95% When the force falls below
･ Details on the of FS during increasing 30% of FS during decreasing
switching function force force
Switching to a lower Switching to a higher
amplitude amplitude
Automatic force range switching function cannot be used at the following condition.
・ When controlling by force speed and strain rate (ALSC).
・ When you use ultra high-speed sampling.
4) Force calibration It performs by exclusive data-processing software.

(Electric calibration)
5) Force to be Tensile/Compression force
calibrated
6) Zero-point It performs by smart controller or exclusive data-processing
adjustment software.
7) Force signal output Analog (0 to 5 VDC)
Resolution : 1/2048 (Approx. 2.5 mV)
Output rate : 10 ms
(5) Force value display device

1) Display device
・Display module Digital display on the smart controller and exclusive
data-processing software.
・Display unit SI unit system : mN, N, kN
[KGF unit system : gf, kgf, tf]
[Pound unit system : lbf, kip]
※A unit is not displayed on a Smart controller.
2) Display resolution 1/5000 of the full scale of each range(smart controller)
1/16000 of the full scale of each range(exclusive
data-processing software)
(6) Crosshead stroke measuring device

1) Measuring method Measurement using an optical encoder
2) Measurement resolution 0.001 mm
3) Measurement origin setting The origin is set to a desired position by pressing the
position zero key
4) Stroke signal output Analog (0 to 5 VDC)
Resolution : 1/2048 (Approx. 2.5 mV)
Output rate : 10 ms
(7) Crosshead stroke display device (Switched over between (11) the extension value display function)
1) Display device
・Display type Digital display on the smart controller and exclusive
data-processing software
・Display resolution 0.001 mm
・Display unit Selected from mm, cm, in
※A unit is not displayed on a Smart controller.
(8) Test control mode
1-6
1. Outline
1) Single test control mode(TRAPEZIUM2 SINGLE, TRAPEZIUM Lite)

Stroke test control, stress test control, force control, and strain test control are possible by
the exclusive data-processing software. Please refer to the user guide of exclusive
data-processing software for details.
2) Cycle test control mode(TRAPEZIUM2 CYCLE)

Stroke test control, stress test control, force control, and strain test control are possible by
the exclusive data-processing software(Max 1000 cycle). Please refer to the user guide of
exclusive data-processing software for details.
NOTE
Cycle test conditions
To perform a cycle test with the AUTOGRAPH, observe the following conditions:
1) Cycle frequency 3 cycles/min or less
2) Continuous operation time 10 hours or less
3) Number of continuous cycles 1000 cycles or less
3) Control mode(TRAPEZIUM2 CONTROL)

The arbitrary control which combined stroke test control, stress test control, force control,
and strain test control are possible by the exclusive data-processing software. Please refer to
the user guide of exclusive data-processing software for details.
(9) Specimen breakage detecting function(set up by the exclusive data-processing software)

1) Types of detecting functions Desired two values (sensitivity level and breaking level)
can be set.
2) Detecting/setting method
・Sensitivity Breakage is detected when the force is reduced at a speed
of "A% of the force full scale per second" or a higher
speed. (0 £ A £ 1000)
・Breaking level Breakage is detected when the force is reduced to "B% of
the force full scale" after exceeding "3% of the force full
scale". (0 £ B £ 5)
3) Crosshead action after Stop or return to the origin. (Either action can be
detection selected.)
4) Turning ON/OFF the When the testing machine repeats loading and unloading
specimen breakage detecting operations during a test such as a cycle test or peel test,
function this function can be turned OFF.
(10) Extension value display function (Switched over between (7) the crosshead stroke display function)
1) Input voltage range 0 to 10 V (5 V full scale is recommended)
(Rated absolute maximum input: -15 to +15 V)
2) Display mode mm, cm, in: Actual extension value
3) Display type It displays by exclusive data-processing software.
4) Display resolution 1/16000 (= Approx. 2.5 mV)
1-7
1. Outline
(11) The exclusive data-processing software Windows version (TRAPEZIUM2)

※Please refer to the user guide of exclusive software "TRAPEZIUM2" about specification.
Please prepare the computer hardware for control and data processing.
(12) Safety/Protection devices

1) Stroke limiter The photoelectric sensor detects preset two points (upper
and lower limits).
2) Overload limiter The testing machine automatically stops when "102% of
the force full scale" is detected.
3) Emergency stop switch Provided on the smart controller
4) Driving motor overcurrent Provided
protection
5) Driving motor overheat Provided
protection
6) Driving motor amplifier Provided
protection
7) Main power supply Provided
overcurrent protection
8) Ball screw protection cover Provided
9) Automatic control stop The feedback control mode automatically stops when the
function control parameter error exceeds +/-10% of the full scale.
1-8
1. Outline
1.4 Individual Specifications for Testing machine

<Standard type/Lead screw extension type>
Table 1.1 Individual Specifications for the AG-IC Series (Floor type)
SI unit AG-100kNIC AG-300kNIC
Model name
Gravity unit AG-10TIC AG-30TIC
Force capacity 100kN/10tf 300kN/30tf
Crosshead speed and allowable
Full speed 100kN/10tf Full speed 300kN/30tf
force
Test speed 0.0005～1000mm/min 0.0005～500mm/min
Return speed 1100mm/min 550mm/min
Standard 1250 1440
Crosshead-to-ta +250 1495 1690
Extension
quantity
ble distance +500 1735 1930

(mm) +750 1970 2165
+1000 2200 2395
Effective test space width (mm) 575
Up to 2000 mm Up to 2000 mm
Crosshead-to-table distance (mm) 100kN/10tf 300kN/30tf
and allowable force 2000 mm or longer distance 2000 mm or longer distance
50kN/5tf 150kN/15tf
Testing machine dimensions
1170 × 750
Width ´ Depth (mm)
Standard 2162 / 800 2412 / 900
Testing machine
+250 2412 / 850 2662 / 950
Extension
height (mm) /
quantity
+500 2662 / 900 2912 / 1000

Mass (Approx.
Kg) +750 2912 / 950 3162 / 1050
+1000 3162 / 1000 3412 / 1100
Driving motor type AC servo motor
Maximum power consumption 1.6 kW 2.0 kW
Maximum leak current 10 mA
Required power supply capacity
6.0 kVA 7.5 kVA
(3-phase, 200-230 V)
NOTE
The above power supply capacity indicates the value required for the steady state. When
the power switch is turned ON, or the crosshead returns, a rush current flows through the
circuit. Use a circuit breaker that provides sufficiently large capacity and pass surge
current without trip.
1-9
1. Outline
(Blank sheet)
1-10
CHAPTER 2
Parts Identification
CONTENTS
2.1 Main frame.................................................... 2-2
2.2 Accessories.................................................... 2-3
2.3 Peripheral Equipment.................................... 2-5
2-1
2. Parts Identification
2.1 Main frame
Fig. 2.1 shows the external view of the testing machine main frame. The
testing machine includes the accessories listed in Table 2.1,2.2.
Model name P/N
AG-100ｋNIC S346-53423
AG-300kNIC S346-53424
Fig. 2.1a Main frame (Floor-type)
P/N
S346-53162-02
Fig. 2.1c Smart controller
2-2
2.2 Accessories
The accessories listed in Table 2.1 and Table 2.2 are included in the
testing machine with each capacity. Make sure that all the listed items
are included in your testing machine.
Table 2.1 Accessories of the AG-IC Series Floor-type Testing machine

AG-100kNIC AG-300kNIC
Connection cables
Cable assembly, 200 VAC 345-03758-03
Cable assembly, Ground 345-28183-01
Smart controller fixture This fixture has clung to the testing machine.
Holder smart controller 347-54783
Screw, SUS TRUSSHEAD 7.5Y M4X8 020-37013-01(2pieces)
Standard tools
Tool box
038-03005
Rotation bar
344-21855
Hexagon bar wrench set
340-48001-10
Screwdriver set
340-48002
Screwdriver for adjustment
086-10504-10
Hexagon bar wrench H ´ 17 086-03813
Operation manual (This document) 349-05554
Limit guide sticker 347-50051(Caution) 347-50052-02(Tens.) 347-50052-04(Comp.)
Safety Precautionｓ sheet 347-02670
2-3
Fig. 2.2 Cable Assembly (200 V)
Fig. 2.3 Cable Assembly (Ground)
Fig. 2.4 Cable Assembly (100 V)
Tool box
Rotation bar Hxagon bar wrench set
Adjustable wrench 250 Screwdriver for adjustment Hexagon bar wrench H×17
Fig2.5 Standard tools
2-4
2.3 Peripheral Equipment
In addition to the main frame, peripheral equipment is required to

perform a test.
The main items of the peripheral equipment are listed below:
1. Set of load cells
The set of load cells are classified into various types in terms of the force
capacity, calibration unit, and guaranteed accuracy.
The part number table lists the load cells of JIS Class 1 (Standard type: See
Table 2.3a,b) and those of JIS Class 0.5 (High-precision type; See Table
2.4a,b).
The set of load cells for the AG-IC series are provided with the special CAL
(calibration) cables. Since the load cell capacity and other characteristic data
on the load cell are stored in the calibration cable, one CAL cable is always
required for one load cell. If a load cell is combined with a different type of
calibration cable, the accuracy of the force measurement data cannot be
guaranteed. Be sure to store the calibration cable and the load cell as a pair by
checking the cell number indicated on the label of the calibration cable.
SFL type load cell (including CAL cable)
Table 2.3 Set of the Load Cells
P/N P/N
Load cell type
(Force capacity) JIS Class 1(Tensile and compression JIS Class 0.5(Tensile and compression
load calibration) load calibration)
SI unit system Metric unit system SI unit system Metric unit system
Reference calibration (N) Reference calibration Reference calibration (N) Reference calibration
(kgf) (kgf)
SPL-10kN/1tf 346-52114-11 346-52115-11 346-52116-51 346-52117-51

SFL-20kN/2tf 346-52114-12 346-52115-12 346-52116-52 346-52117-52
SFL-50kN/5tf 346-52114-13 346-52115-13 346-52116-53 346-52117-53
SFL-100kN/10tf 346-52114-14 346-52115-14 346-52116-54 346-52117-54
SFL-300kN/30tf 346-52114-16 346-52115-16 346-52116-56 346-52117-56
2-5
2. Test jigs
(1) Tensile test jig

To perform a tensile test, the grips and the attachments for mounting the grips
(universal joint and lower joint) are required. The typical jigs used for a tensile
test are described below.
1) Wedge-type constant-position grips (Set of upper and lower grips)
Table 2.4 Wedge-type Constant-position Grips(300kN)

Force
Part No. Tooth gap Tooth size
capacity Tooth type
300kN
343-05840 file for flat plate 0～8.5 mm 50(W)×75(L) mm
(30tf)
Table 2.5 Wedge-type Constant-position Grips(100kN,50kN)

Force
Part No. Tooth type Tooth gap Tooth size
capacity
100kN
346-52791-02
(10tf) 0～7
file for flat plate 40(W)×55(L) mm
50kN mm
346-52791-01
(5tf)
Table 2.6 Small wedge-type Constant-position Grips(20kN, 5kN)

Force
capacity
20kN
346-52653-03
(2tf) 0～7
file for flat plate 25(W)×55(L) mm
5kN mm
346-52653-01
(500kgf)
2-6
2) Screw-type flat grips (Set of upper and lower grips)
Table 2.7 Screw-type Flat Grips

Force
capacity
5kN File for 0～16 60(W)×50(L)
(500kgf) 346-52326-04 flat plate mm
mm
1kN File for 0～15 50(W)×30(L)

346-52327-04 flat plate mm
(100kg) mm
50N 0～14 35(W)×25(L)
346-52328-04 Plane
(5kgf) mm mm
3) Joint parts for tensile test jig (Set of upper and lower jigs)
Table 2.8 Joint Parts for the Tensile Test Jig

Load cell
Frame type capacity Part No.
AG-300kNIC 300kN（30tf） 343-08798-01

AG-100kNIC 100kN（10tf） 344-11101-11
The part numbers in the above table indicate the standard
combinations. When the load cell capacity is different from
the frame capacity, other joint jigs may be required. For
further information, contact SHIMADZU CORPORATION.
2-7
(2) Compression/bending test jigs
1) Joint jig for compression/bending test

This joint jig can be used for both compression and bending tests.
Table 2.9 Joint Jig for Compression Test

Part No.
Applicable load
Frame type (For standard-type
cell capacity
testing machine)
AG-300kNIC 300kN（30tf） 346-51530-04
AG-100kNIC 100kN（10tf） 346-51530-03
2) Compression plate for compression test
Table 2.10 Compression Plate for Compression Test

Type Plate diameter Allowable force Part No.
Fixed 343-08095
φ100 300kN
Ball-seated 346-50639-03
2-8
3) Bending test jig
a b
c d
Table 2. 11 Bending Test Jig

Applicable Support point Maximum Application
Applicable specimen Punch radius Part No. Drawing
standards radius capacity joint jig
JIS K6911, 346-52697-01/
Plastic K7171,ISO 178 R5 R2 10/100ｋN
(Thickness:3mm 343-08171-03 a
or less)
ASTM D790 346-52697-02/ a
Plastic R5 R5 10/100ｋN
343-08171-01
See
JIS K7055,
Composite material Table 2.9
(3/4-point bending)
K7074,K6911 b
R3,R5 R3,R2 5kN 343-05934-10
K7203
Metal R5 R15 100kN 343-08096-01 d
Ceramics R1601 c
(3/4-point bending)
R2.5 R2.5 5kN 343-08892-08
2-9
3. Recorder/Data processor
(1) Data processing software TRAPEZIUM2 *1

TRAPEZIUM2 SINGLE is attached for AG-IC series. Optional software is listed below.
Product name Part No.

TRAPEZIUM2 SET *2 345-47307
TRAPEZIUM2 SINGLE 345-47307-01
TRAPEZIUM2 CYCLE 345-47307-02
TRAPEZIUM2 CONTROL 345-47307-03
Note1) Provide a personal computer separately
Note 2) TRAPEZIUM2 SET include SINGLE, CYCLE and CONTROL.
(2) XT-P recorder (AR-5422)
P／N 345-05842
(3) XTY-P recorder (AR-6422)
P／N 345-05843
2-10
4. Maintenance parts
(1) Force inspection jig

1) Force inspection jig to be attached to the tensile test jig
Table 2.12 Composition of the forcer and weight

in the force inspection
Force to be
Weight Part No.
inspected
50 N 50 N (´ 1) 346-51040-31
100 N 100 N (´ 1) 346-51040-17
500 N 100 N (´ 5) 346-51040-32
5 kgf 5 kgf (´ 1) 346-51040-21
10 kgf 10 kgf (´ 1) 346-51040-07
50 kgf 10 kgf (´ 5) 346-51040-22
2-11
(Blank sheet)
2-12
CHAPTER 3 Features and
Functions of Each Subassembly
CONTENTS
3.1 Main frame............................................................ 3- 2
3.2 Smart controller .................................................... 3- 8
3.3 Load Cell (Option),

Tension force jig (Option)....................3-11
3-1
3. Features and Functions of Each Subassembly
3.1 Main frame
1. AG-ICseries (Floor-type)
Fig. 3.1a to Fig. 3.1e show the external views of the main frame and the names of the main parts.
9 Crossyoke
1 Post
2 Upper limit switch knob 10 Load cell
11 Crosshead
3 Ball screw protection cover
6 Rear cover
１2 Smart controller
4 Lower limit switch knob
31 Emergency stop switch 31 Emergency stop switch

5 Ball screw(inside the post)
13 Control box
7 Table
14 Power switch
8 Front cover
15 Loadcellconnector Fig 3.1a Main Parts of the AG-IC

Series(Floor-type)Main frame
16 Sensor amplifier connector

（EXT1，EXT2）（option）
17 Analog output 1(Force)connector
18 Analogoutput2connector
19 Analoginput 1connector
Fig 3.1b Sensor Amplifier Panel for the
20 Analoginput 2connector AG-IC series(Floor-type)
3-2
3.Features and Functions of Each Subassembly
21 Fan (inside the cover)
22 Power circuit breaker
Fig. 3.1c Rear View of the AG-IC Series

(Floor-type) Main frame
29 Power supply input
connector (3-phase, 200 V
input)
23 Smart controller connector
24 RS-232C connector
25 Analog recorder
connector
26 ACC 1
27 ACC 2
30 Ground terminal
28 ACC 3 If the ground terminal of the power
supply cable cannot be grounded,
ground this terminal via the supplied
ground cable.
Fig. 3.1e Power Supply Panel for the

Fig. 3.1d I/O Connector Panel for the AG-IC AG-IC Series (Floor-type)
Series (Floor-type)
3-3
3. Description on the main parts
1) Power circuit breaker 22 (for the floor-type only)

Power circuit breaker for the whole equipment
2) Power switch 14 (See Figs. 3.1a and 3.2b)

Handy switch used to turn ON/OFF the power supply during normal operation.
3) Emergency Stop Switch 31 (See Fig.3.1a and 3.2a)

Used to stops the crosshead forcefully. Pressing these switches cut off the power to
the servo motor. (See Section 4.5 1.)
4) I/O connector panel (See Figs. 3.1d and 3.2d)

The I/O connector panel connects the cables from the optional external units
such as the smart controller and the analog recorder.
① Smart controller connector 23
Connects the smart controller cable.
②RS-232C connector 24
This is a connector for personal computer cable connection.
③Analog recorder connector 25
Outputs a signal to the optional analog recorder.
④ACC1 26 to ACC3 28
Extension connector used to connect the optional equipment.
5) Sensor amplifier panel (See Figs. 3.1b and 3.2c)

①Load cell connector 15
The load cell connector is connected with the internal force amplifier.
②Sensor amplifier connector（EXT1，EXT2）（Option） 16

Outputs an analog signal (force, stroke, etc).
The full-scale of the analog output is +5 V.
③ Analog output 1/Analog output 2 connectors 17 18 (with standard stereo jack)

Outputs an analog signal (force, stroke, etc).
The full-scale of the analog output is +5 V.
④Analog input 1/Analog input 2 connectors 19 20 (with standard stereo jack)
Inputs an analog signal from an external device such as an extensometer amplifier.
The input level is 0 to 5 V.
3-4
6) Limit switch knobs 2 4

Used to set the upper and lower limits of the crosshead moving range.
Be sure to set the limit switch before starting a test.
（See Section 4.5 2. ）
7) Fan 21 (for the floor-type only)

The filter is fixed with the retainer. The filter can be easily cleaned and
replaced.
(See Section 6.4.2)
Fan fixing bracket
Filter
Retainer
Fig. 3.3 Fan
3-5
3.2 Smart controller
1. External views and names of the main parts
7 Manual lamp
1 LED display for Force

8 Up lamp
2 LED display for Position
9 Down lamp
3 Jog up key lamp
10 Force zero key
4 Jog down key
11 Position zero key
5 Start key
12 Manual dial
6 Return key
13 Manual key
14 Stop key
A lid is shifted downward.
Press waveform area and

shift downward.
Open in case of optional
accessories are attached.
Such as a pneumatic grip
controller and an automatic
extensometer.
ａ. Smart controller(Front View)
15 Extension meter
open／close key
16 Upper arm key
17 GL set key
20 Close upper/lower grip key
18 Lower arm key
1st Upper , 2nd Lower
19 Arm park／set key
21 Open upper & lower
grips key
ｂ. Smart controller option key

（opened the lid）
Fig3.4 External views of Smart controller
3-6
2. Description on the main parts
1） LED display for Force 1

Force is displayed in usual.
2） LED display for position. 2
Position is displayed in usual.
3） Jog up key 3
Used to move the crosshead upward when the MANUAL mode is ON.
Only when this key is being pressed, the crosshead moves upward.
4） Jog down key 4

Used to move the crosshead downward when the MANUAL mode is ON.
Only when this key is being pressed, the crosshead moves downward.
5） Start key 5
Used to start a test.
6） Return key 6
Used to return the crosshead to the origin.
If it continues pushing the key 3 seconds or more, the crosshead moves.
It does not operate, when manual mode is ON.
7） Manual Lamp 7
The Lamp is switched on the light/put out by Manual mode ON/OFF.
8） Up Lamp 8
The Lamp is switched on the light, blinked and put out by the operation method of a
crosshead. It is 4.7 for details. Please refer to how to use a Smart controller.
9） Down Lamp 9
The Lamp is switched on the light, blinked and put out by the operation method of a
crosshead. It is 4.7 for details. Please refer to how to use a Smart controller.
10） Force zero key 10
Zero balance of force is performed.
11） Position zero key 11

Position display makes zero.
12） Manual dial 12

Used to move the crosshead upward or downward when the MANUAL mode
is ON.
Turning this dial clockwise moves the crosshead upward, and turning this dial
counterclockwise moves it downward.
13） Manual key 13

Used to turn ON/OFF the crosshead manual control operation.
14） STOP key 14

Used to stop a test.
3-7
15） Extension meter open／close key 15 (Optional operation)

Used to open／close individual extension meter’s arms.
16） Upper arm key 16 (Optional operation)

Used to move upper arm of individual extensometer.
17） GL set key 17 (Optional operation)

Used to move upper and lower arms of individual extensometer to original GL position.
18） Lower arm key 18 (Optional operation)

Used to move lower arm of individual extensometer.
19） Arm park／set key 19 (Optional operation)

Used to keep arms to parking position or measuring position.
20） Close up→down key 20 (Optional operation)

Used to close grip teeth, interlocked with pneumatic controlled grips.
21） Open up & down key 21 (Optional operation)

Used to open grip teeth, interlocked with pneumatic controlled grips.
For the operating procedure of the optional key 15 －21 , ｐlease refer to
each instruction manual for optional units.
3-8
3.3 Load Cell (Option), Tension force jig (Option)
1. External view and names of the main parts (Floor-type)
1 Lock nut （UJ）

2 Load cell mounting volt
3 Load cell （SFL type）
4 Crosshead
5 Universal joint
6 Fixing pin
7 Upper grip
8 Lower grip
9 Lock nut（Grip）
10 Fixing pin
11 Lower joint
12 Table
13 Center pin
Fig. 3.5a External View of the Tensile Test Jig for AG-IC Series (Floor-type)
The above figure shows the tensile
test jig for the AG-100kNIC type.
With other types, the size of the parts
is different.
3-9
2. External view and names of the main parts (Table-type)
2 Load cell mounting volt
14 Auxiliary plate
4 Crosshead
3 Load cell
1 Lock nut（UJ）
5 Universal joint
6 Fixing pin
7 Upper grip
8 Lower grip
9 Lock nut（Grip）
10 Fixing pin
11 Lower joint
12 Table
13 Center pin
Fig. 3.5b External View of the Tensile Test Jig for AG-IC Series (Table-type)
The above figure shows the screw-type
plane grips. With other types, the shape
of the parts is different.
3-10
3. Part names
1) Load cell 3
The load cell converts force (tensile or compression force) into an electric
output through a strain gauge. The force detecting unit in the load cell is
equipped with a strain gauge that develops elastic deformation when force is
applied. The load cell converts the magnitude of the applied force into a
change in the resistance of the strain gauge, and outputs the converted value
as an electric signal.
Various load cells with different capacity are provided for both tensile and
compression tests. Users can select desired force capacity depending on the
test purpose and the force to be applied.
NOTE
The allowable force applied to the load cell is within 150% of the rated load
capacity, for both tensile and compression tests. In particular, when using a
load cell with small capacity, make sure that the force does not exceed the
load cell capacity. Be careful not to touch the detecting unit or drop the load
cell.
The load cell and the CAL cable have been calibrated as a pair before shipment.
Be sure to use the CAL cable compatible with the load cell, because the CAL
cable and load cell are combined as a pair. If an incompatible CAL cable is
connected to the load cell, force measurement becomes abnormal, disabling
proper overforce detection.
2) Universal joint 5 (Option)

The universal joint for tensile test is mounted between the load cell and the
upper grip. Only the vertical component of the force applied to the upper grip
is transmitted to the load cell through the universal joint. The type of the
universal joint depends on the load cell capacity.
3) Grips (Upper grip 7 , Lower grip 8 )(Option)
The AG-IC series provides optional grips applicable to various specimens. Fig.
3.5a shows the wedge-type constant-position grips suitable for metal and
plastic, plate and rod specimens.
The lower grip is equipped with the lock nut 9 to eliminate the clearance
around the pin 10 at the lower joint 11 connecting part.
During a test, be sure to tighten the lock nut slightly to eliminates the
clearance around the pin.
Other types of grips and grip teeth are also available, in addition to those
shown in Fig. 3.5a. Prepare various grips suitable for your specimens.
4) Lower joint 11 (Option)
The lower joint connects the lower grip by using a pin.
3-11
(Blank Sheet)
3-12
CHAPTER 4
Basic Operations
CONTENTS
4.1 Introduction...................................................... 4-2
4.2 Precautions for Installation .............................. 4-3
4.3 Fixing the Smart controller .............................. 4-8
4.4 Cable Connections ........................................... 4-9
4.5 Safety Devices ............................................... 4-13
4.6 Turning ON/OFF Power Supply.................... 4-16
4.7 How to Use Smart controller ......................... 4-19
4.8 Moving Crosshead Up/Down ........................ 4-20
4.9 Testing machine Setup................................... 4-23
4-1
4. Basic Operations
4.1 Introduction
The AG-IC series operating procedures are described in Chapter 4

through Chapter5. The outline of each chapter is as follows:
Chapter 4 To operate the AG-IC series for the first time, be sure
to read this chapter before turning ON the power
supply. This chapter describes how to use the smart
controller, outline of the menu structure, how to
mount the load cell and test jig to the main frame, and
basic procedures for operating the crosshead.
Chapter 5 Describes the basic test procedures.
This chapter describes the following preparations for starting a test.

■ Installation environment
■ Smart controller fixing procedure
■ Cable connections
■ Functions of the safety devices
■ Turning ON/OFF the power supply
■ Basic procedure for using the smart controller
■ Crosshead operating procedure
■ Mounting the test jigs
4-2
4. Basic Operations
4.2 Precautions for Installation
1. Installation environment
1) Operating temperature 5 to 40 °C
(Temperature fluctuations must be within +/-2 °C during a test.)
2) Humidity 20 to 80% (No condensation)
3) Vibration Frequency : less than 10Hz
Amplitude : less than 0.005mm
4) Electro-magnetic wave influence
Avoid Electro-magnetic wave. Measurement value might
be shifted and error will occur.
2. Conditions for Installation location

Before installing the AG-IC series testing machine, check the conditions of the
installation location.
1) Make sure that the floor provides sufficient force capacity that can withstand
the testing machine mass.
With the table-type testing machine, use a table with sufficient force capacity
that can withstand the testing machine mass and the jig mass. Never mount
the testing machine on a table whose withstand force capacity is unknown.
For the mass of each type of frame, refer to the table1.4 and 1.5 in Section
1.4.
2) Provide a clearance between the top of the testing machine and the ceiling.
For delivery and installation, a clearance of at least 30 cm is recommended.
3) Make sure that the testing machine can be easily accessed during
maintenance.
3. Delivery/Installation
The AG-IC series testing machine must be delivered and installed by the staff
of SHIMADZU CORPORATION and an authorized service company. For
transport of the testing machine, some prohibitions are prescribed. If any
persons other than our staff transport this equipment after installation, be sure
to read the instructions described in Chapter 10 "Transport/Storage" carefully
beforehand.
1) To lift the main frame, use a belt and lifting device with withstand load
capacity two times or larger than the main frame mass. For the mass of each
type of main frame, refer to the table in Section 1.4.
2) To lift the main frame, be careful that the main frame body is not largely
tilted. If the belt slips, the main frame may shake, resulting in injury to the
working personnel.
4-3
4. Basic Operations
3) With both the floor-type and table-type, do not lift the main frame by the
crossyoke (top plate). Otherwise, the crossyoke may break, or the main frame
may drops, resulting in injury to the working personnel.
4. Main frame level adjustment

After installing the testing machine, perform main frame level adjustment.
With the floor-type main frame, adjust the front, rear, right and left level
adjusting bolts on the mounting base. With the table-type main machine,
adjust the level adjusting feet located at 4 corners bottom. The optional table
for the table-type machine is also equipped with the level adjusting feet.
1) Level adjustment for floor-type testing machine
<Tools>
･ Level meter
・ Hexagon wrench H ´ 17 (Accessory)
<Procedure>
(a) Place a level meter on the main frame table laterally.
(b) While reading the indication on the level meter, adjust the level
adjusting bolts at the four corners by using the hexagon wrench.
(c) Re-place the level meter on the main frame table in the front-rear
direction, and adjust the bolts in the same way.
(d) Repeat the above steps several times until the main frame is
correctly leveled.
2) Level adjustment for the table-type testing machine.
<Tool>
・ Level meter
<Procedure>
(a) Place a level meter on the testing machine table laterally.
(b) While reading the indication on the level meter, turn the level
adjusting feet at the four corners bottom of the machine manually.
(c) Re-place the level meter on the testing machine table in the
front-rear direction, and adjust the feet in the same way.
(d) Repeat the above steps several times until the testing machine is
correctly leveled.
4-4
4. Basic Operations
5. Conditions for the power supply

Before connecting the power supply, check the power supply ratings.
1) With the floor-type testing machine, use a power supply rated for 200 to 230
V (3-phase). For the power supply capacity for each type of testing machine,
refer to the table 1.4 in Section 1.4.
2) Allowable voltage fluctuation Within +/－10% of the rated voltage
3) Grounding condition Class D or higher level grounding

condition is required. (Ground
resistance:100 ohm or less)
NOTE
When power supply voltage becomes +10% or more of rating, and －10% or less,
incorrect operation is carried out or there is a possibility that parts may damage parts.
When change of power supply voltage is large, please install a stabilization power supply.
4-5
4. Basic Operations
4.3 Fixing Smart controller
1. Mount the smart controller in installation

The hook on the back of a smart controller is hooked on the holder attached on
the right post, and the same time, the magnet of the back lower part attaché to
the holder, too.
Smart controller （Backside）
Hook
Magnet Holder smart controller
4-6
4. Basic Operations
4.4 Cable Connections
1. AG-IC series testing machine (Floor-type)
Load cell Load cell

Main frame
Load cell cable
Smart controller
CAL cable
Controller unit
Ground cable
Power supply cable

Smart controller cable
Note) For the location of each connector,

see Figs 3.1b through 3.1e.
Fig. 4.5a Cable Connections for the AG-IC Series Floor-type Testing machine
4-7
4. Basic Operations
2. Connection with a personal computer

AUTOGRAPH AG-IC series must be connected with a personal
computer. So, the AUTOGRAPH enables data processing using the
special data processing software. Prepare a personal computer of the
model/specifications recommended by the data processing software.
This section describes how to connect a personal computer to the

AUTOGRAPH. For the software installation procedure and operating
procedure, read the operation manual included in the data processing
software. The parameters operated through the personal computer are
described in the operating procedure in CHAPTER 5.
RS-232C connector
Fig 4.6b I/O connector panel of the AG-IC series (Floor-type)
Connect the RS-232C connector (round connector with 5 pins) on the I/O
connector panel of the main frame with the RS-232C connector (D-sub square
connector with 9 pins) of the personal computer through the special cable
followed.
5pins D-sub
DIN 9pins
4-8
4. Basic Operations
4.Connecting the analog recorder
The speed of the optional analog recorder can be set on the data
processing software TRAPEZIUM2’s window. Analog recorder's other
operations (turning ON/OFF the power supply, switching the chart feed
mode, moving the pen up/down, turning ON/OFF the chart feed
function, zero/span adjustment, etc.) should be performed on the
recorder.
Before using the analog recorder for the first time, the "Recorder Connected"
status must be registered.
Please refer to the user guide of TRAPEZIUM2 for details.
To use the X-Y record mode, the

Y-axis (extension) input must be
connected.
Analog recorder connector
Fig4.7b I/O connector panel of the AG-IC series (Floor-type)
Connect the above analog recorder connector (D-sub square connector with 9
pins) of the AUTOGRAPH with the CONTROL connector (square connector
with 36 pins) of the analog recorder through the special cable followed.
D-sub IDC
9pins 36pins
4-9
4. Basic Operations
4.5 Safety Devices

The AG-IC series testing machine provides the following two types of safety
devices:
1) Emergency stop switch
2) Crosshead stroke limit switch
The following safety/protection equipment are optionally available.

1) Overturn prevention bracket
2) Safety door for the testing area
1. Emergency stop switch

The emergency stop switches are provided at the both left and right side of the
posts for floor-type machine. And at the both left and right side of front cover for
table-type machine. If the crosshead unintentionally moves, press one of this
switch immediately. Pressing this switch cuts off the power to the motor circuit
and stops the crosshead forcefully in any condition (even in a machine trouble).
To reset the emergency stop switch, turn OFF the main power at once, and turn it
in the direction indicated on the switch surface. Then, the switch is reset by spring
force.
2. Crosshead stroke limit switch

The crosshead stroke limit switch is used to set mechanical limits of the
crosshead. If the crosshead is improperly operated, this function prevents the
crosshead or crosshead jig from hitting against the crossyoke jig or testing
machine table jig.
Upper limit switch knob
Actuator
MAX
Lower limit switch knob Tensile stroke
Zero position
Gauge length (GL)
Table
Fig. 4.7 Setting the limit switch (example)
4-10
4. Basic Operations
During a tensile test, the lower limit is usually set to the test start position, and
the upper limit is set to the expected maximum tensile stroke (maximum
extension).
1) Setting the upper limit

Loosen the upper limit switch knob, and fix it to the upper limit position of the
crosshead moving range. The limit switch is activated when the crosshead moves
upward by approx. 2 mm from this position. Set the upper limit in consideration of
this margin.
2) Setting the lower limit
Loosen the lower limit switch knob, and fix it to the lower limit position of the
crosshead moving range. The limit switch is activated when the crosshead moves
downward by approx. 2 mm from this position. Set the lower limit in consideration
of this margin.
3) When the actuator fixed to the top of the crosshead reaches either the upper
or lower limit switch knob, alarm is displayed on the display of a personal
computer.and the limit switch is activated to stop the crosshead forcefully.
CAUTION
The crosshead upper and lower limits expected during a test must be set
to proper values. If setting these limits is difficult, determine the setting
range so that the gap between the crosshead top jig and the crossyoke
and the gap between the crosshead bottom jig and the table jig are 20
mm or more.
NOTE
If alarm screen does not appear even when the crosshead stops during limit switch
activate, turn OFF the main power at once before resetting the limit switch.
<Resetting the limit switch>

a) Loosen the (upper or lower) limit switch knob, and slide it upward or downward
to reset the limit switch.
b) When the personal computer has connected with the main frame, please cancel
according to the message displayed on a display. When the personal computer is
not connected with the main frame, please push and cancel the stop key of a
smart controller.
c) After resetting the limit switch, set the upper and lower limit switch knobs to the
proper positions again.
4-11
4. Basic Operations
3. Turnover prevention brackets (Optional)

The SHIMADZU AUTOGRAPH AG-IC series a floor-type tester with
100kN and 300kN load capacity.
To use the floor-type tester, you must fix the tester to a floor by using
dry pit.
Note that these turnover prevention brackets are not intended to ensure
turnover prevention in occurrence of a natural disaster such as an
earthquake.
The part numbers of the turnover prevention brackets are listed below:
Type Part No. Remark
AG-100kNIC and 300kNIC
Floor-type A 346-50278-08
(Capacity: 100kN and 300kN)
Effective testing width of tester:
575 mm
Floor-type B AG-100kNIC and 300kNIC
346-50278-09
(For the extended (Capacity: 100kN and 300kN)
special width tester) Effective testing width of tester:
975 mm
4. Testing space safety door (Optional)

When a specimen may scatter during a test, it is recommended to use
the testing space safety door. The specifications of the testing space
safety door vary depending on the tester's capacity and the type of the
specimen being used. Contact SHIMADZU for further information.
4-12
4. Basic Operations
4.6 Turning ON/OFF Power Supply
1. Introduction
The AG-IC series floor-type testing machine needs a power supply rated for
200 to 230 V AC (3-phase). The power is supplied through the power supply
input connector (socket) at the rear of the testing machine. Before turning ON
the power, check the following points:
1) Make sure that the primary power supply capacity is proper.

AG-IC series floor-type AG-300kNIC : 7.5 kVA
AG-100kNIC : 6 kVA
2) Make sure that the testing machine is properly grounded. (Required class D ground
condition)
3) Make sure that the power supply cable is properly connected to the connector.
Note that most of the accessories such as the recorder and data processor needs a single-phase
100 VAC power supply. Provide a power supply for such equipment separately, in addition to
the power supply for the testing machine.
Fan
Power supply input

Fig. 4.6ａ Power supply input connector connector
（Floor-type）
2. Turning ON the power

1) Supply power to the primary side.
2) Turn ON the power supply circuit breaker of the testing machine. (Floor-type only)
Power supply circuit

breaker
4-13
4. Basic Operations
Fig. 4.8a Power Circuit Breaker (AG-IC Series Floor-type)
3) Turn ON the power switch.
Power switch
Fig. 4.8b Power Switch

(AG-IC Series Floor-type)
4) The LED part of a smart controller becomes the following displays.
Load cell capacity display Force Position display

ROM version display
(In the case of 500N) (The present value is displayed.)
(In the case of version1.0)
Fig4.9 Initial display of the LED part
5) If the emergency stop switch on the main frame is locked, turn this switch to unlock it.
When the emergency stop switch is locked, power cannot be supplied to the servo amplifier.
3. Warm-up
To stabilize the measurement system of the AG-IC series testing machine, take a warm-up time
of approx. 15 minutes after turning ON the power. (The testing machine can be warmed up
even when the emergency stop switch is being pressed.)
4-14
4. Basic Operations
4. Calibration for Force Amplifier
To calibrate the force amplifier, the AG-IC series provides the electric calibration (E-CAL)
function that sends a calibration signal corresponding to each load cell to perform automatic
span adjustment for the force amplifier.
Perform this calibration once a day before starting a test.

Every time the force polarity (tension/compression) is switched or the load cell is replaced, be
sure to perform this calibration.
NOTE
To perform the force calibration, warm up the testing machine for at least 15 minutes
after turning ON the power supply.
Electric force calibration (E-CAL) is performed by data-processing software

"TRAPEZIUM2."
Please choose the "test | sensor | calibration" of the menu of TRAPEZIUM2, or carry out a right
click in a sensor display part, and choose a calibration from a pop-up menu.
5 Turning OFF the power
1) Turn OFF the power switch.

(If you do not turn ON the power supply for one or more days, turn OFF the circuit breaker as
follows.)
2) Turn OFF the power supply circuit breaker. (Floor-type only)
3) Turn OFF the circuit breaker of the primary power supply (at the user's site).
NOTE
Do not turn OFF the power supply while the crosshead is being operated. Otherwise, the
service life of this equipment may be shortened.
4-15
4. Basic Operations
4.7 How to Use Smart controller
1. LED display
.
There are a LED display part and a crosshead operation switch part in a smart controller. The LED
display part displays by the following specifications in order to make the action of a crosshead links
clearly.
 The operation mode is divided in the color of LED.

LED COLOR OPERATION MODE
Green Program（Test） control
Red High Speed Return control
Orange Manual & Jog control
 The motion is expressed with the method of lighting.

Lighting of LED OPERATION MODE
Test condition is not set by PC and
Putting out lights START key is not available.
Keep stopping under Manual ON
Test condition is already set by PC and
Putting on(Green) START key is available. The test start
direction is shown.
While pressing RETURN key, return
Putting on(Red)
direction is shown until starting return.
Blink(Green, Red, Orange) Crosshed is moving.
Example1． When the test condition is not set from the PC
（LED is putting out）

Putting out
Example2. When a crosshead is going up

In the case of testing
（Blinking by Green）
In the case of returning
Putting on （Blinking by Red）
In the case of manual and jog running
Putting out （Blinking by Orange）
Example3. When a crosshead is stopping (Test is ready)
In the case of UP Start

“UP” LED is putting on Green.
In the case of DOWN Start
“DOWN”LED is Putting on Green.
4-16
4. Basic Operations
Example4. At the time of a hold (experimental stop, Force hold / Force zero hold
under test) state
UP and DOWN LED blink Green
4.8 Moving Crosshead Up/Down
The AG-IC series provides the test start switch, high-speed return switch (to
return the crosshead to the origin), and test stop switch for test. And the
MANUAL (manual operation) mode is provided to move the crosshead to a
desired position (test start position) while preparing a test.
To operate the crosshead, use the above crosshead control switches on the
smart controller.
Jog up key
Manual dial
Jog down key
Start key Manual On/Off key
Return key
Stop key
Fig4.10 Crosshead operation switch
1. Starting a test
Either UP/DOWN LED lights on to green when the testing condition is set from the
PC, and the crosshead start moving in the direction when the start key is pressed.
LED is blinking while moving.
When LED of UP/DOWN light off, the operation by the start key is invalid.
Moreover, the START key operation is disabled while manual control function is
ON.( See 4.8 4.)
Example 1. Testing upward
“UP” LED is Blinking to green.
4-17
4. Basic Operations
2. Returning the crosshead (High-speed return to the origin)

If Return key is pressed, the LED of the returning direction lights up red. Keep
pressing 3 seconds or more, crosshead start returning and the LED of the
returning direction blinks red.
It is not available when the manual mode is ON.
The return speed is 1100 mm/min (AGIC-300KN type: 550 mm/min,

Table-type: 1000 mm/min). When the crosshead reaches the origin, the testing
machine reduces the return speed, allowing the crosshead to stop at the origin
without overshooting. If the return switch is executed when the crosshead is
near the origin, the testing machine moves the crosshead at a reduced speed,
and may take a long time to return the crosshead to the origin.
The system watches the force change while returning the crosshead from the
start of the operation. If the force change more than constant value is applied
to the load cell, the crosshead is stopped by alarm (Safety function)
Example1. Under returning upward
Beep sound sounds and

“UP”LED blinks in red.
3. Stopping a test
Pressing the STOP key stops the crosshead at the current position, and
finish the current test.
Example1. When a stop button is pushed during test operation
“UP” or ”DOWN” LEDs light green.

(When batch test is continued, the
direction of a test start is displayed. When
batch test is finished, both LEDs light
off.)
4-18
4. Basic Operations
4. Manual operation
1) Jog operation using the UP/DOWN key

a) Press the Manual On/Off key
As for the manual mode, Manual LED lights up on a smart controller. Manual ON/OFF
is repeated whenever pushing a key.
b) Only while pushing the Jog up key, a crosshead goes up and “UP”LED blinks it in orange.
c) Only while pushing the Jog down key, a crosshead goes down and “DOWN”LED blinks it in
orange.
Please refer to the user manual of the software "TRAPEZIUM2" of exclusive use about change of
speed.
The system watches the force change while the crosshead is operating by jog
operation from the start of the operation. If the force change more than constant
value is applied to the load cell, the crosshead is stopped by alarm. (Safety function)
2) Operation using the manual dial
Users can move the crosshead within a minute range by using the
manual dial to perform fine adjustment on the crosshead position
and to eliminate the initial force.
a) Press the Manual On/Off key to turn ON the Manual mode.

b) Turning the manual dial ⑧ moves the crosshead upward or downward
depending on the direction of rotation. The crosshead moving distance
depends on the number of turns and turn speed.
Turning the dial Turning the dial

counterclockwise moves clockwise moves the
the crosshead crosshead upward.
downward.
Fig. 4.11 Manual dial
Example1. When continuing pushing a Jog up key in manual mode
“UP” LED is Blinking to orange.
4-19
4. Basic Operations
5. Safety function
Safety function detect the force shift applied to the load cell while crosshead moves under jog
operation or return function. If the force shift value becomes over a determined value, it makes
stop the crosshead immediately.
The functions are to stop the crosshead as early as possible at unexpected emergency
accident---the jigs hit against the others--- and to improve safety.
Because the following limitations exist, note that this function is not intended to ensure that
preventing the objects from running into the others in the test space and overload.
<Note1> The amount of the detected force is decided depending on the capacity of the load cell.
<Note2> The response of detection is 0.5-1 seconds. Danger by the overshoot can not be
excluded.
<Note3> When the crosshead is operated in the direction of reducing force, the crosshead
does not stop in order to remove force at overload and the convenience of operation.
The discernment of a direction is decided by setting UP START/DOWN START of
the testing condition.
<Note4> This function does not work from beginning of operation for about one second.
Therefore, it is invalid when the crosshead is operated by the jog operation as little by
little as inching.
Moreover, the crosshead moves only for one second even when the load is applied to
the load cell beforehand.
<Release of the safety function>
In the case of applying the load intentionally by the jog operation, the safety function can be
released.
Keep pushing the stop key for about two seconds when manual mode OFF.
The beep "pee!" sound continues sounding and the safety function changes in the state of OFF.
The beep "pee!" sound continues sounding until the safety function returns to turning ON for
the attention rousing. The safety function does not work when the manual mode is turned on
and the crosshead is operated by jog operation in this condition.
When the manual mode is returned OFF, or the stop key is pushed after the manual mode is
turned on, the safety function returns to turning ON and the beep sound "pee!" stops.
4-20
4. Basic Operations
6. Setting the crosshead origin
Press the Position zero key on

the smart controller to reset the
position display to zero. The UP
MANUAL
crosshead origin is set to the
DOWN
current position. FORCE ZEROL
POSITION ZEROL Position Zero

key
4.9 Testing machine Setup
1. Mounting the load cell
CAUTION
The load cell and the CAL cable have been calibrated as a pair before
shipment.
Be sure to use the CAL cable compatible with the load cell, because the
CAL cable and load cell are combined as a pair. If an incompatible CAL
cable is connected to the load cell, force measurement becomes
abnormal, disabling proper over force detection.
NOTE
When you insert a CAL cable in a connector (it extracts), please be sure to turn OFF
a power supply. There is a possibility that a CAL value may turn into an unusual
value.
NOTE
When mounting the load cell to the crosshead, fix the load cell tightly with the
supplied bolts. If the load cell is mounted loosely, accurate measurement results
may not be obtained.
NOTE
After mounting the load cell, be sure to perform force calibration. (See 4.6 4).
4-21
4. Basic Operations
a) load cell can be read in the normal direction. Then, fix the load cell to the
crosshead with the mounting bolt.
Fig. 4.12 Load Cell Cable Connection (Floor-type)
b) Connect the load cell terminal of the load cell cable to the load cell connector
securely, and fix the connector.
(With the load cell with 10 kN or less capacity, this cable connection is not
necessary, since the load cell incorporates the load cell cable.)
c) Fix the load cell cable to a position where it does not block the crosshead
movement, as shown in Fig. 4.12.
d) Connect the CAL cable and load cell cable to the connector.
CAL cable Load cell cable Load cell
Load cell with 20 kN or more capacity
Fig4.13 Load Cell Cable/CAL cable
4-22
4. Basic Operations
e) Connect the D-SUB connector of the CAL cable to the testing machine's
connector. (The connector positions on the floor-type testing machine and the
table-type testing machine are shown in Fig. 4.14a and Fig. 4.14b, respectively.)
Then, fix the connector with the screw included in the connector.
Connect the
CAL cable.
Fig. 4.14a CAL Cable Connection

(for Floor-type)
4-23
4. Basic Operations
2. Mounting the tensile test jig (Optionally available, except for the load cell)
Fig. 4.15a and Fig. 4.15b show the external views of the testing
machine with the tensile test jig attached. Table 4.2 shows the mass of
each unit of the test jig for the testing machines with 5 kN (500 kgf) or
more capacity.
To mount each unit of the test jig, perform the procedure described in
steps 1) to 3).
CAUTION
Some test jig components mass 10 kg or more. During transport of a heavy
component, be careful not to drop it. When transporting such a heavy
component, exercise through attention not to drop it. The jig weighting
20 kg or more must be handled by a person trained for transporting heavy
objects. To transport a heavy component, use an appropriate device such as a
crane, as required.
Lock nut
Load cell mounting bolt
Load cell (SFL type)
Crosshead
Universal joint
Fixing pin
Upper grip
Lower grip
Lock nut
Fixing pin
Lower joint
Table
Center pin
Fig. 4.15a Mounting the Tensile Test Jig to the AG-IC Series (Floor-type) (AG-100
kNIC)
4-24
4. Basic Operations
Load cell mounting bolt

Auxiliary plate
Crosshead
Load cell
Lock nut
Universal joint
Fixing pin
Upper grip
Lower grip
Lock nut
Lower joint
Fixing pin
Center pin
Fig. 4.15b Mounting the Tensile Test Jig to the AG-IC Series (Table-type)
Table 4.2 Mass of the Tensile Test Jig

For AG-100kNIC For AG-300kNIC
Lower joint 2.5 10.5
Universal joint 8.5 26
Grips 10 33
Load cell 3.9 16
(Unit: kg)
4-25
4. Basic Operations
1) Mounting the lower joint

a) Insert the center boss into the center hole (f 20) at the top of the table to center the lower joint.
b) Fit the center boss into the lower joint , and position the pin hole of the lower joint in the
front-rear direction.
c) Fix the lower joint with the lower joint mounting bolt.
2) Mounting the universal joint to the floor-type testing machine

a) In case of 100 kN or less capacity (See Fig. 4.15a)
Insert the universal joint from the bottom of the crosshead, and insert the external thread of the
universal joint into the hole of the load cell. Position the pin hole of the universal joint in the
front-rear direction, and insert the universal joint stopper pin into the groove of the load cell.
Then, fix the universal joint with the lock nut (UJ).
b) In case of 300 kN capacity (See Fig. 4.16)

① Align the periphery of the universal joint with that of the lower joint , and place the
universal joint on the lower joint so that the pin hole of the universal joint is positioned in
the front-rear direction.
② Lower the crosshead, and pass the external thread of the universal joint through the hole of
the load cell . (See Figs 4.16a and 4.16b.)
NOTE
To insert the universal joint into the hole of the load cell , lower the crosshead while
watching the universal joint from the top of the crosshead to center the universal joint in the
hole of the load cell, in order to prevent the universal joint from hitting against the load
cell . Lower the crosshead at a low speed of approx. 1 mm/min.
4-26
4. Basic Operations
Load cell
Crosshead
Universal joint
Lower joint
Fig. 4.16a Mounting the Universal Joint
Make sure that the driving

hole faces up.
Detailed drawing
Fig. 4.16b Mounting the Universal Joint
Table
Fig. 4.16b Mounting the Universal Joint
4-27
4. Basic Operations
③ Stop the crosshead at the position where the shaft of the universal joint protrudes from the
top of the load cell by approx. 40 mm. Then, mount the lock nut (UJ) . (See Fig. 4.16b)
④ Turn the lock nut (UJ) by using the driving rod to pull down the universal joint . Give
several turns to the lock nut until the universal joint is raised. Then, turn the universal joint
113 , and make sure that the universal joint stopper pin is inserted in the groove.
⑤ If the stopper pin is not set in the groove, give more turns to the lock nut (UJ). Then, make
sure that the stopper pin is set in the groove. After the stopper pin is set in the groove,
tighten the lock nut (UJ) completely.
After tightening the lock nut (UJ) completely, move the crosshead upward.
(See Figs. 4.16c and 4.16d)
Lock nut (UJ)

Driving rod
Load cell
Crosshead
Lower joint Cover

Table
Fig 4.16c Mounting the Universal Joint

Universal joint
Table
Fig 4.16d Mounting the Universal Joint
4-28
4. Basic Operations
3) Mounting the grips (Wedge-type constant-position grips/Standard screw-type plane grips)

a) Mounting the wedge-type constant-position grips with 5 to 100 kN capacity (See Fig.
4.15a)/standard screw-type flat grips (See Fig. 4.15b)
① Insert the boss of the upper grip into the hole at the bottom of the universal joint . Align the
pin holes with each other, and insert the fixing pin into the pin holes.
② Insert the boss of the lower grip into the hole of the lower joint . Turn the lock nut (grip) by
using the supplied hook wrench so that the pin holes are aligned with each other. Then,
insert the fixing pin into the pin holes.
b) Mounting the grips with the capacity of 300 kN

① To mount the grips with the capacity of 300 kN, remove the handle attached to the lower
grip before mounting the lower grip. Mount the handle to the threaded hole at the side of the
grip body so that you can transport the grip by holding this handle. (See Fig. 4.18a)
(Perform this step with the grip laid.)
② Before mounting the grips, turn the open/close handle of the upper and lower grips in the
direction to open the grip teeth, so that the grip teeth do not protrude from the grips.(See
Fig.4.18a)
Make sure that the grip teeth does not protrude from the grips.
Lower grip
Grip handle
Lock nut (grip)

図 5.1１a つかみ具の
Fig. 4.18a Mounting the grips
4-29
4. Basic Operations
③ Insert the boss of the lower

grip into the hole of the Crosshead
lower joint . Turn the lock
nut (grip) by using the hook
wrench so that the pin holes
are aligned with each other, Lower grip
and insert the fixing pin
into the pin holes. (See Figs.
4.18b)
Lower joint
Fig. 4.18b Mounting the grips
④ After inserting the fixing pin ,

tighten the lock nut (grip) by
using the hook wrench to
prevent the fixing pin from
being loosened. Universal joint
(See Figs. 4.18c)
Lower grip
Hook wrench
Fixing pin
Fig. 4.18c Mounting the grips
4-30
4. Basic Operations
⑤ Put the upper grip on

the lower grip . (See
Universal joint
Fig. 4.18d)
Upper grip
Lower grip
Fig. 4.18d Mounting the grips
Crosshead
⑥ Lower the crosshead . Universal joint
Insert the boss of the
grip into the hole of Fixing pin
the universal joint .
Align the pin holes Upper grip
with each other, and
insert the fixing pin Lower grip
into the pin holes.
(See Fig. 4.18e) Lower joint
Fig. 4.18e Mounting the grips
NOTE
To insert the upper grip into the hole of the universal joint , lower the crosshead while
centering the boss of the upper grip in the hole of the universal joint , in order to prevent the
boss of the upper grip from hitting against the universal joint .Lower the crosshead at a low
speed of approx. 1 mm/min.
4-31
4. Basic Operations
⑦ Move the crosshead upward. (See Fig. 4.18f)

Remove the handle of the lower grip from the grip body, and re-mount it to the original
position (rotating part).
Fig. 4.18f Mounting the Grips
3. Removing the tensile test jig
To remove the tensile test jig, reverse the test jig mounting procedure described in 4.10
Section 2. Before removing the test jig, turn the open/close handle in the direction to open the
grip teeth, so that the grip teeth do not protrude from the grips. (See Fig. 4.18a)
When removing the test jig from the testing machine, handle heavy components with thorough
attention.
4-32
CHAPTER 5
Performing a Test
CONTENTS
5.1 Procedure for Tensile Test ............................ 5-2
5.2 Procedure for Compression/Bending Test .... 5-6
5-1
5. Performing a Test
5.1 Procedure for Tensile Test (Example)
Normally, the test procedure should be repeated several times in the

CYCLE mode. This section describes the operating procedure for
routine work (e.g. tensile test using the analog recorder).
For the specific procedure for each step, see the section corresponding
to each step.
For compression and bending tests, see Section 7.2
1. Preparations for Test
1 ) Turning the power ON (AUTOGRAPH, Recorder) ®4.6

2 ) Force amplifier calibration
Electric force calibration (E-CAL) ®4.6 4
3 ) Mounting the tensile test jig ®4.9 2
2. Procedure for Tensile Test
In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can
operate parts by personal computer.
(1) Setting the limit switch knob Set the limit switch knob to the position where it does
not block the crosshead when the crosshead is moved
to the test start origin. ®4.5
(2) Moving the crosshead to the test start Move the crosshead in the JOG or MANUAL mode
origin to the test start origin according to the GL (the
distance between grips suitable for a specimen).
®4.8
(3) Setting the crosshead zero position Please choose zero reset of a position from the test
(origin) menu of "TRAPEZIUM2." This position becomes the
starting point of a crosshead.
(The Position zero key of a Smart controller can be
pushed and zero reset can also be carried out.)
(4) Setting the limit switch knob To move the crosshead up/down safely, set the limit
switch knob within the range of "Tensile stroke +α".
®4.5
(5) Setting the test type and test mode Excepting a special case, select the TENSILE - UP
START test type, and the SINGLE or CYCLE test
mode.
(6) Setting the test speed Set the test speed.
5-2
(7) Setting the test load range Set the test load range.
(8) Setting the MAX/MIN values For the SINGLE mode, enter the MAX limit value.
For the CYCLE mode, enter the MAX/MIN setting
values.
(9) Setting MAX/MIN ACT For the SINGLE mode, set MAX ACT. For the
CYCLE mode, set MAX/MIN ACT.
(10) Setting breakage detection Set the breakage detecting function to ON/OFF, and
set the conditions for breakage detection.
(11) Setting up the recorder Set the chart mode, chart speed and chart ratio of the
recorder.
In the case of using the exclusive
data-processing software “TRAPEZIUM2”,
you can set chart speed by personal
computer.
(12) Chucking a specimen in the upper grip
(13) Test load amplifier zero adjustment Please choose zero reset of an Force sensor from the
test menu of "TRAPEZIUM2." Zero balance of
examination power is performed.
(The Force zero key of a Smart controller can be
pushed, and zero balance can also be performed.)
(14) Chucking a specimen in the lower grip
(15) Removing the initial test load Move the crosshead to the position where the test
load becomes zero using the manual dial.
After finishing the manual operation, be sure to turn
OFF the manual control function.
®4.8 4.
(16) Starting the recorder Turn ON the chart drive, and lower the pen.
® Recorder Operation Manual (separate sheets)
(17) Starting a test Press the START key of the crosshead control switch
on the smart controller to start a test.
®4.8 4.
(18) Ending the test Depending on the preset test conditions, the
AUTOGRAPH stops or returns the crosshead to the
origin to end the test.
(19) Stopping the recorder Turn OFF the chart drive, and raise the pen.
(20) Removing the specimen ① Loosen the lower grip, and remove the lower end
of the specimen from the grip.
② Loosen the upper grip, and remove the upper end
of the specimen from the grip.
(21) Returning the crosshead to the origin

(Press the Return key of the Smart controller to return
the crosshead to the origin. ®4.8 )
This operation is not necessary if "MAX RETURN"
has been selected for the test mode, since the
crosshead will automatically return to the origin when
specimen breakage is detected.
5-3
・ To repeat the same test, return to Step (12). To test a specimen with a different GL or to
execute a different test mode, perform the above procedure from Step (1).
CAUTION
A broken surface of a hard specimen may be a sharp edge. To touch such a
specimen, be careful not to be injured. It is recommend to wear gloves.
CAUTION
If the crosshead improperly moves during a test due to a setting error, press
the emergency stop switch.
To stop the AUTOGRAPH normally during a test, press the Stop key.
CAUTION
While the crosshead returns to the origin, it is moving at a high speed. Please
do not put a hand into an operation part. Moreover, be careful for a jig not to
be equivalent to a surrounding vessel. When an examination machine carries
out unusual operation, please push an emergency stop key immediately.
NOTE
If the breakage detecting function has not been properly set, the breakage cannot be
detected, and the crosshead continues to move in the tensile direction and does not stop
until the limit switch is activated, even when specimen breakage occurs in the CYCLE
mode. Set the limit switch with sufficient margin so that the jig mounted to the crosshead
upper surface will not hit the yoke.
5-4
5.2 Procedure for Compression/Bending Test (Example)
For the specific procedure for each step, see the section corresponding
to each step.
1. Preparations for Test

To perform a compression/bending test, adjustment work such as jig
replacement is required. This section describes the procedure for changing the
AUTOGRAPH setup conditions from the tensile test mode to the
compression/bending test mode. To change the compression/bending test to
the tensile test condition , follow the same procedure.
(1) Turning the power ON (AUTOGRAPH, Recorder) ®4.6

(2) Force amplifier calibration
Electric force calibration (E-CAL) ®4.6 4
(3) Mounting the compression test jig
Remove the tensile test equipment (universal joint, lower joint and grips)
(® Section 4.9 3), and mount the compression/bending test equipment.
Tensile Compression Bending
5-5
2. Procedure for Compression/Bending Test
In the case of using the exclusive data-processing software “TRAPEZIUM2”, you can operate
parts by personal computer.
(1) Setting the limit switch knob Set the limit switch knob to the position where it does
not block the crosshead when the crosshead is moved
to the test start origin. ®4.5
(2) Moving the crosshead to the test start Move the crosshead in the JOG or MANUAL mode
origin to the test start origin until the upper jig nearly
touches the specimen. ®4.8
(3) Setting the crosshead zero position Please choose zero reset of a position from the test
(origin) menu of "TRAPEZIUM2." This position becomes the
starting point of a crosshead.
(The Position zero key of a Smart controller can be
pushed and zero reset can also be carried out.)
(4) Setting the limit switch knob To move the crosshead up/down safely, set the limit
switch knob within the range where it does not touch
the upper or lower jig such as compression plate.
®4.5
(5) Setting the test type and test mode Excepting a special case, select the COMPRESSION
- DOWN START test type, and the SINGLE or
CYCLE test mode.
(6) Setting the test speed Set the test speed.
(7) Setting the force range Set the force range.
(8) Setting the MAX/MIN values For the SINGLE mode, enter the MAX limit value.
For the CYCLE mode, enter the MAX/MIN setting
values.
(9) Setting MAX/MIN ACT For the SINGLE mode, set MAX ACT. For the
CYCLE mode, set MAX/MIN ACT.
(10) Setting NUM (number of cycles) For the CYCLE mode, set the number of cycles. If
you do not intend to set this parameter, select OFF.
(11) Setting breakage detection Set the breakage detecting function to ON/OFF, and
set the conditions for breakage detection.
(12) Setting up the recorder Set the chart mode, chart speed and range of the
recorder.
In the case of using the exclusive
data-processing software “TRAPEZIUM2”,
you can set chart speed by personal
computer.
(13) Mounting a specimen
(14) Force amplifier zero adjustment Please choose zero reset of an Force sensor from the
test menu of "TRAPEZIUM2." Zero balance of
examination power is performed.
(The Force zero key of a Smart controller can be
pushed, and zero balance can also be performed.)
(15) MANUAL operation to move the Through MANUAL operation, move the crosshead
crosshead to the point where the initial until it touches the specimen. After finishing the
force is applied manual operation, be sure to turn OFF the manual
control function. ®4.8 4..
5-6
(16) Starting the recorder Turn ON the chart drive, and lower the pen.
(17) Starting a test Press the START key of the crosshead

control switch on the smart controller to
start a test. ®4.8
(18) Ending the test Depending on the preset test conditions, the
AUTOGRAPH stops or returns the
crosshead to the origin to end the test.
(19) Stopping the recorder Turn OFF the chart drive, and raise the pen.
(20) Removing the specimen Remove the specimen from the lower jig.
(21) Returning the crosshead to the origin (Press the Return key of the Smart controller to return
the crosshead to the origin. ®4.8 )
This operation is not necessary if "MAX RETURN"

has been selected for the test mode, since the
crosshead will automatically return to the origin when
specimen breakage is detected.
・ To repeat the same test, return to Step (13). To test a specimen with a different thickness
or to execute a different test mode, perform the above procedure from Step (1).
CAUTION
If the crosshead improperly moves during a test due to a setting error, press
the emergency stop switch.
To stop the AUTOGRAPH normally during a test, press the Stop key.
CAUTION
While the crosshead returns to the origin, it is moving at a high speed. Please
do not put a hand into an operation part. Moreover, be careful for a jig not to
be equivalent to a surrounding vessel. When an examination machine carries
out unusual operation, please push an emergency stop switch immediately.
5-7
(Blank Sheet)
5-8
CHAPTER 6 Performance
Inspection/Maintenance
CONTENTS
6.1 Periodic Inspection.................................................. 6-2
6.2 Inspection of the Safety Devices............................. 6-2
6.3 Force Inspection...................................................... 6-4
6.4 Lubrication and Cleaning........................................ 6-8
6-1
6.Performance Inspection/Maintenance
6.1 Periodic Inspection
This system incorporates the highly-stabilized electric force calibration

function. To enhance the stability of this function, it is recommended that this
system should undergo an annual force inspection using actual force.
This force inspection will be conducted based on the documents supplied from
SHIMADZU by the service company that received the education and training in our
company.
They also perform inspection and maintenance of each part of the driving
system.
To ensure traceability and long-term safe operation of this system, ask
SHIMADZU service representatives for the periodic inspection.
Furthermore, in case of repair and adjustment made by any person other than
SHIMADZU or our authorized service company, I am afraid that
SHIMADZU CORPORATION cannot warrant the product.
6.2 Inspection of the Safety Devices
If any of the safety devices does not operate during the following
inspections, contact SHIMADZU CORPORATION or our authorized
service company.
In case of repair and adjustment made by any person other than SHIMADZU
or our authorized service company, I am afraid that SHIMADZU
CORPORATION cannot warrant the product.
1. Emergency stop switch
(1) While pressing the [Jog] key to move the crosshead, press the emergency
stop switch.
(2) If the crosshead stops and it will not be moved again by pressing the [Jog]
key, the emergency stop switch is judged to be normal.
(3) Turn the emergency stop switch in the direction indicated by arrow to reset
it.
2. Crosshead stroke limit switches
(1) While pressing the [Jog] key to move the crosshead, push up the upper limit
collar and hold it.
key, the upper limit switch is judged to be normal.
(3) Stop pushing up the upper limit collar, and make the limit rod free.
(4) The Stop key of a Smart controller is pushed.
(5) In this status, press the [Jog] key, and make sure that the crosshead can be
moved.
6-2
(6) While pressing the [Jog] key to move the crosshead, push down the lower
limit collar and hold it.
key, the lower limit switch is judged to be normal.
(8) Stop pushing down the lower limit collar, and make the limit rod free. In this
status, press the [Jog] key, and make sure that the crosshead can be moved.
This completes the inspection procedure. The working points of the limit
switches are shown below.
A Upper limit point

Free position
B Lower limit point
A + B is approx. 4 mm. Since the free position includes

a return error of approx. 1 mm, A and B are 1 mm to 3
mm.
If A or B is too small, the limit switch may be improperly
activated by vibration during a test.
If such a problem occurs, hold the limit collar with your hand,
and push it toward A or B , smaller one.
If the above adjustment does not work, contact our authorized

service company.
6-3
6.3 Force Inspection
When force data seem to be doubtful, or during monthly inspection,

check the force according to the procedure described in "1. Force
Inspection". If the force accuracy falls below the allowable range,
contact our authorized service company or SHIMADU corporation.
1. Force inspection
This method allows users to check whether a force value is
approximately normal or not, simply by using light
weights.
(The following values are examples.)
Check whether the displayed force value is normal UJ
by using the following weights:
For the load cell with 1 kN to 300 kN capacity: Use Ring joint
a single weight corresponding to 100 N.
For the load cell with 100 N to 500 N capacity: Use
Plate to hang
a single weight corresponding to 50 N. weight
<Inspection of tensile force> Weight
(1) Mount the ring joint for the weight hanging
plate to the universal joint with a pin.
(2) Hang the weight hanging plate on the ring
joint.
(3) Set the force range to the minimum range within the prepared weight force.
(4) Set the force polarity (test type) to "Tension".
(5) Perform the electric force calibration (See Section 4.6 4.).
(6) Push the weight hanging plate by hand to make sure that the displayed force
value is increased.
(7) Place a weight gently.
(8) Make sure that the displayed force value is equal to the weight load.
(9) The tolerance range is +/-1% of the indicated value (for the standard type),
or +/-0.5% of the indicated value (for the high-precision type).
<Inspection of compression force>
NOTE
Inspection of compression Force cannot be performed in a SFL type
(20kN-250kN) Load cell. When you inspect, please inspect using a loop
detection machine (Option).
(1) Remove the load cell from the crosshead, and place it on a hard level table
upside down.
(2) Screw the weight plate into the load cell.
(3) Set the force range to the minimum range within the prepared weight load.
(4) Set the force polarity (test type) to "Compression".
(5) Perform the electric force calibration (See Section 4.6 4.).
6-4
Weight
Plate to hang
weight
Load cell
Table
(6) Push the weight hanging plate by hand to make sure that the displayed force
value is increased.
(7) Place a weight gently.
(8) Make sure that the displayed force value is equal to the weight load.
(9) The tolerance range is +/-1% of the indicated value (for the standard type),
or +/-0.5% of the indicated value (for the high-precision type).
6-5
2. Force Calibration (F-CAL)
If a significant force error is found in the inspection described above, or

during periodic inspection, force calibration by applying actual load
(named F-CAL in followed) must be performed. This force calibration
identify electrical calibration value.
In principle, the F-CAL should be performed by our service

representatives. If the user has calibration weights or a loop force meter,
the F-CAL can be performed by the user. In this case, however, it must
be conducted by a person trained for the calibration procedure.
Improper calibration may cause significant errors in measurement
results. Note that, if a user conducts the F-CAL, SHIMADZU cannot
guarantee the force accuracy.
To perform the F-CAL, the operation of applying actual load is required.

This operation varies depending on whether tensile force or
compression force is applied, and also varies depending on whether the
hanging weights or loop force meter is used to apply each force.
These operating procedures are described in the separate manual.
Contact our sales representatives to request this manual, as required.
This manual also includes the description on necessary components.
Force calibration (F-CAL) is performed by control and data-processing software

"TRAPEZIUM2."
Please choose the "Tool | Adjustment of testing machine amplifier | FCAL" of the menu
of TRAPEZIUM2.
Please refer to the user guide chapter 5 of software "TRAPEZIUM2" for details.
6-6
6.4 Maintenance (Lubrication and Cleaning)
1. Maintenance of the ball screw
Lubricate the ball screw periodically to prevent oil lack.

While rotating the ball screw at a middle speed (50 to 100 mm/min)
(moving the crosshead up/down), apply grease throughout the ball
screw by using a soft brush.
<Grease name>
Universal grease NLGI No. 2 (Shell Albania Grease No. 2)
<Lubrication interval>
Monthly
Fig. 6.1 Cleaning the Ball screw
CAUTION
To lubricate the ball screw, open only one of the ball screw protection covers.
(The protection covers are located at the top left, bottom left, top right and
bottom right.) Do not open two or more covers simultaneously.
During lubricating work, be careful that your fingers, hairs or a part of your
clothes will not be caught in the machine. After completion of the lubricating
work, be sure to mount the ball screw protection cover.
6-7
2. Maintenance of the fan filter( Floor type)
A filter is attached to the rear panel fan

of the floor-type AG-IC series.
Although the filter cleaning interval Fan
varies depending on the operating
frequency or surrounding conditions, Retainer
the filter should be cleaned
approximately once a month.
This filter is attached between the fan
and the retainer. Remove the retainer by
pulling the both sides in the directions
indicated by arrows.
If the filter is extremely dirty or
damaged, replace it with a new filter. Filter
Fan filter 9325-M
Part No. 042-60934-19
Fig. 6.2 Maintenance of the Fan
3. Maintenance of the smart controller

[Control keys]
Wipe the control key by using soft cloth damped with a little water.
[LED display part]

Wipe the LED display part gently by using dry soft cloth or soft cloth damped
with a little ethanol.
[Case]
Wipe the case by using dry soft cloth or soft cloth damped with a little neutral
detergent.
4. Maintenance of the testing machine body

[Table surface]
The table surface is grind-finished. To prevent the table from rusting, wipe
dust off, and apply grease to the parts with no jig.
[Other casing]
Wipe other casing by using dry soft cloth or soft cloth damped with a little
neutral detergent.
NOTE
Keep water off the internal components of the tester, smart controller and controller unit.
6-8
CHAPTER 7
Transport/Storage
CONTENTS
7.1 Precautions for Transport ........................................ 7-2
7.2 Precautions for Storage ........................................... 7-4
7-1
7.Transport/ Storage
7.1 Precautions for Transport

If you intend to transport this equipment, it is recommended to ask our
authorized service company. But if you need to transport this equipment by
yourself, observe the following instructions.
If your testing machine has undergone the official certification, the
certification may become ineffective after the testing machine is transported.
It is recommended that you should take the certification's effective period into
consideration and transport the testing machine before it undergoes the next
certification.
Moreover, in case of repair and adjustment made by any person other than
SHIMADZU or our authorized service company, I am afraid that
SHIMADZU CORPORATION cannot warrant the product.
1. Installation space
Ensure the installation place conditions described in Section 4.2

"Precautions for Installation".
2. Installation environment
Ensure the installation environment described in Section 4.2

3. Power supply
Ensure the power supply conditions described in Section 4.2

4. Precautions
NOTE
To lift the testing machine, use a belt or lifting machine apply with load capacity twice or
more than the testing machine mass. For the testing machine mass, refer to the table given in
Section 1.3.2.
7-2
1) When lifting the testing machine by forklift,

put wood attachment to lower surface of
crosshead. Make sure to keep balance and
lift testing machine carefully.
2) When lifting the testing machine by belt, make sure

that the testing machine body is not tilted. If the testing Fig.7.1AG-IC（table-type）
Lift by forklift.
machine body is tilted, the belt may slip, causing the testing
machine to shake and injure working personnel.
3) Do not lift the testing machine by the crossyoke (top plate).
Lifting the testing machine by the crossyoke may break the
crossyoke, causing the testing machine to fall and injure
working personnel.
4) Do not lift the testing machine by any part other

than the crosshead.
Fig.7.2 AG-IC（table-type）Lift by belt.
5. Level adjustment (Table-type testing machine)
For level adjustment, refer to the testing machine level adjustment

described in Section 4.2 "Precautions for Installation".
6. Cable connections
For cable connections, refer to Section 4.4 "Cable Connections (AG-IC series
Table-type)".
7-3
7.2 Precautions for Storage
1. Precautions for storage
If the testing machine is stored for a long period, the battery for the
memory that stores test conditions will be exhausted in approx. six months,
and the system becomes the C-RAM clear status. To use the testing
machine again, test conditions must be registered.
2. Storing environment
Store the testing machine in the following environment:

1) Temperature: –10 to 60 °C
2) Humidity: 20 to 80% (no condensation)
3) In a place with little dust
4) In a place free from corrosive gas or vapor
5) In a place where the testing machine is not exposed to direct sunlight
3. Provisions for storage
The table-type testing machine's table surface has been ground. When the testing
machine is stored for a long period, this part may become rusty. Before storing the
testing machine, apply a rust-preventive agent or spindle oil to this part.
The floor-type testing machine's table surface and crosshead upper and lower surfaces
have been ground. When the testing machine is stored for a long period, these parts
may become rusty. Before storing the testing machine, apply a rust-preventive agent
or spindle oil to these parts.
7-4
CHAPTER 8
Troubleshooting
CONTENTS
8.1 Introduction............................................................. 8-2
8.2 Alarm Messages and Resetting Alarms................... 8-2
8.3 Other Troubles......................................................... 8-5
8.4 C-RAM Clear.......................................................... 8-7
8.5 Checking the Circuit Breaker

(AG-IC Series Floor-type) ...................................... 8-9
8-1
8. Troubleshooting
8.1 Introduction
Generally, troubles cannot be predicted. However, in many cases, some

troubles are found to be only operation errors. This chapter includes examples
of such troubles. Before judging this equipment to be defective, find a similar
condition in this chapter.
If an abnormal condition or system error which is not described in this chapter
occurs, contact SHIMADZU plant, or our authorized service company or
distributor.
In case of repair and adjustment made by any person other than SHIMADZU
or our authorized service company, I am afraid that SHIMADZU
CORPORATION cannot warrant the product.
8.2 Alarm Messages and Resetting Alarms
When the AUTOGRAPH detects an abnormal condition, an alarm message

will be displayed on the smart controller and display of the personal computer.
An example of the alarm display on the smart controller is shown in below,
and the alarm messages and the corresponding troubleshooting procedures are
listed in Table from next page. While an alarm message is displayed, the
crosshead is not in operation, and the display cannot be switched. After
reading the displayed alarm message, take an appropriate countermeasure, and
then reset the alarm display.
Example. In the case of Alarm code 0000
NOTE
When an emergency stop switch or a limit switch operates, a crosshead carries out an
emergency stop and the above-mentioned alarm indication is not given, please turn
OFF a power supply immediately. Please cancel each switch after rebooting.
8-2
8. Troubleshooting
Table 8.1 Alarm messages and the corresponding troubleshooting procedures.

Alarm
Alarm name Alarm condition and countermeasure
code
Data cannot be retained due to deterioration of the backup battery
on the CPU board.
0000 BATTERY ERROR
® The CPU board must be replaced. Contact our authorized
service company.
The emergency stop switch is pressed when the SET signal is ON.
0010 EMERGENCY SWITCH ON ® Examine the cause of the emergency stop. After making sure
that the dangerous conditions are avoided, turn the
emergency stop switch to reset it.
The limit switch is activated when the SET signal is ON.
0020 CROSS-HEAD LIMIT ® Examine the cause that the limit switch has been activated.
After making sure that the dangerous conditions are
avoided, release the limit collar to reset the limit switch.
A user attempted to move the crosshead when the SET signal is
OFF.
SERVO OFF ® Make sure that the emergency stop switch or the limit
0030 switch is not ON. If either switch is ON, check the safety,
and reset this switch.
Force exceeding 102% of the load cell capacity is applied to the

load cell.
0040 OVER LOAD ® Reduce the force by using the manual dial.
If the force has already been removed, execute the force
auto-zero function.
The Start key of a smart controller was pushed without setting up
test conditions.
0043 TEST READY ERROR ® LED of a rise and descent blinks and a test machine does
not operate. Please push a start key again after setting up
examination conditions.
Force exceeding -102% of the load cell capacity is applied to the
load cell.
0045 UNDER FORCE ® Reduce the force by using the manual dial.
If the force has already been removed, execute the
force auto-zero function.
During automatic control, the deviation exceeds 10% of the full
scale, resulting in a control error.
0050 OUT OF CONTROL ® Change the gain for the automatic control.
If the response speed is too slow, increase the gain.
If hunting occurs, lower the gain.
The test condition setting is improper. (Example: The MAX setting
PARAMETER ERROR is lower than MIN setting for the CYCLE test mode.)
0060
® Check the preset test conditions.
The maximum point setting is improper. (Example: The MAX
point is larger than the full scale.)
® <When the force/extension parameter is selected>
0062 MAX PARAMETER ERROR Set a proper range for the force/extension amplifier, or turn
ON the automatic range switching function.
® <When the position parameter is selected>
The preset value is too high.
8-3
8. Troubleshooting
Alarm
Alarm name Alarm condition and countermeasure
code
The minimum point setting is improper. (Example: The MIN point
is lower than the negative full scale.)
® <When the force/extension parameter is selected>
0064 MIN PARAMETER ERROR Set a proper range for the force/extension amplifier, or turn
ON the automatic range switching function.
® <When the position parameter is selected>
The preset value (negative value) is too low.
The speed setting is improper.
0066 SPEED PARAME. ERROR ® The preset speed is beyond the rated speed range.
Set a proper speed.
The servo amplifier alarm is activated.
® Turn OFF the main switch, and then turn it ON again.
0070 SERVO ERROR ®<If it turn ON again, when alarm does not disappear. >
Request service to SHIMADZU. In table-type, the motor
brush must be checked.
The servo amplifier cannot be started.
0075 SERVO READY ERROR ® Turn OFF the main switch, and then turn it ON again.
The system failed in the AUX input calibration.
0080 CALIBRATION ERROR ® Make sure that the AUX input voltage is between 4 V and
10 V during span adjustment.
Auto zero error
AUTO ZERO ERROR ® Repeat the auto-zero procedure two or three times. If the
0082 zero adjustment does not work, a load cell failure or system
error may be considered.
Actual force calibration error
® Make sure that the force is applied in the preset forcing
0084 F-CAL ERROR direction.
® Make sure that the amplifier range setting is suitable for the
applied force.
E-CAL signal generation error
0086 E-CAL MAKE ERROR ® System error
E-CAL error
0088 E-CAL ERROR ® System error
Touch detection error by Safety function
® If the force is applied to the load cell during returning
TOUCH LOAD operation or jog operation, the crosshead is stopped by
0100 alarm (Safety function). For the explanation of a safety
function and release, refer to item 5 of section 4.8.
RS-232C communication error (Example: Buffer error)

00b0 RS-232C ERROR ® System error
I/O board memory error
00d0 I/O EEP-ROM ERROR ® System error
CAL cable memory error
00d5 SENS. EEP-ROM ERROR ® System error
CAL cable memory error
00e0 CAL. CONNECTOR ERROR ® Sensor amplifier type and CAL. cable is not matched.
(Force / SG / DTF)
8-4
8. Troubleshooting
<Methods for reset Alarm display>
1. In case of Alarm dialog is displayed on PC
Click “ALARM RESET” in alarm dialog box and click ”YES” of next dialog box.
2. In case of Alarm dialog is not displayed on PC
Press STOP key on the smart controller.
8-5
8. Troubleshooting
8.3 Other Troubles
This section describes example of troubles except being shown in Table 8.1
and its countermeasure.
1. Troubles related to key input
If the following key inputs are disabled, the causes listed in the
right column may be considered.
Disabled key Cause

1) This key can be operated after PC works, test condition is
selected and show the test screen (PC). Confirm the test
ready status.
Start key 2) Operation of this key is disabled when the manual control
function is turned ON. Before operating this key, press the
MANUAL key, and make sure that the manual control
function is OFF.
1) To ensure safety, the Return key input is enabled only by
keep pressing this key for at least two seconds. After
confirming the safety in the testing area, keep pressing the
Return key.
Return key
2) Operation of this key is disabled when the manual control
function is turned ON. Before operating this key, press the
MANUAL key, and make sure that the manual control
function is OFF.
1) These operations are disabled unless the manual control
Jog key function is turned ON by pressing the manual on /off key.
Manual dial Before operating the Jog keys or manual control dial, make
sure that the manual control function is ON.
1) All keys are disabled while an alarm message is displayed
both on the PC and smart controller..
All keys
2) All keys other than the STOP key are disabled while an
alarm message is displayed only on the smart controller.
8-6
8. Troubleshooting
2. Other troubles
Problem Countermeasure
Numerical LED are not 1) Connect the smart controller cable correctly.
displayed. 2) Make sure that the power supply is connected. Make sure that the
distribution panel is ON.
3) Turn OFF the power supply, and then turn it ON again.
4) Check the fuse for blowout (with the AG-IC series table-type).
® See Section 8.6.
5) Check the circuit breaker for tripping (with the AG-IC series
floor-type). ® See Section 8.5
6) Execute the C-RAM clear. ® See Section 8.4.
[----] appears on the force 1) Connect the load cell correctly.

display. 2) Execute the C-RAM clear. ® See Section 8.4.
The force display blinks. 1) Check the load cell for over-force.
2) Set the force range to “´ 1”.
3) Connect the load cell correctly.
4) Execute the force auto-zero function.
The SET signal cannot be 1) Check if the emergency stop switch is not activated.
turned ON. 2) Check if the crosshead limit switch is not activated.
The beep "pee!" sound The safety function is OFF mode.
continues sounding. Press the STOP key after manual mode is turned ON, so that the
safety function returns to ON.
Crosshead is running Press emergency stop switch and turn OFF the main power at once.
without control. Turn ON the power again.
8-7
8. Troubleshooting
8.4 C-RAM Clear
The internal parameters of this equipment will be reset to the factory

settings.
This equipment provides two kinds of the procedure to clear the C-RAM
as follows.
NOTE
When the C-RAM clear is executed, the crosshead position will be reset
and the zero point of the force and the extension shifts to the initial value.
It is necessary to readjust about each item.
Moreover, the testing condition is initialized and the force range changes
one time.
<Method A>
C-RAM Clear is performed by control and data-processing software "TRAPEZIUM2."
Please choose the "tool | adjust of force amplifier | other" of the menu of TRAPEZIUM2.
Please refer to the user guide Chapter5 of software "TRAPEZIUM2" for details.
<Method B>
Keep pressing the STOP key, turn ON the power supply.
8-8
8. Troubleshooting
8.5 Checking the Circuit Breaker (AG-IC Series Floor-type)
The power supply circuit breaker is located at the rear right side of the
testing machine. When the lever is not at the uppermost position, the
circuit breaker has been tripped due to overcurrent, or turned OFF.
To turn ON the circuit breaker again, turn it OFF (lower the lever to the
lowermost position) once, and then turn it ON.
(Rear of the floor-type )
Power supply
circuit breaker
8-9
8. Troubleshooting
（Blank Sheet）
8-10
CHAPTER 9
Maintenance Parts List
CONTENTS
9.1 Consumable Parts.................................................... 9-2
9.2 Maintenance Parts ................................................... 9-2
9-1
9. Maintenance Parts List
9.1 Consumable Parts
For daily maintenance, use the consumable parts listed below:
Part No. Part name Floor-type

042-60934-19 Filter, 9325-M ○
017-30308-03 Grease (Albania EP2) EP2 ○
9.2 Maintenance Parts
The maintenance parts listed here are used to repair exhausted/deteriorated parts.
Replacement of these parts should be conducted by SHIMADZU service
representatives. The supply period for each part is 7 years after stop of the production
of this product. However, supply of PCBs, electric components and components made
of special materials may not be stopped exceptionally even within 7 years from the
production stop, for the component manufacturer’s reasons. Moreover, the term of a
guarantee of maintenance parts has become someday or and the direction which
reached early of 18 months after use 6 months or, and our company factory shipments.
However, as for the parts that are not pure products of SHIMADZU, I would like to fix
it for the supply period that the maker where the part was manufactured determined.
Moreover, in case of repair and adjustment made by person other than SHIMADZU or
our authorized service company, I am afraid that SHIMADZU CORPORATION
cannot warrant the project.
Part No. Part name Floor-type

345-08127-70 PCB ASSY,CPU/AG-I ○
345-08130-71 PCB ASSY,I/O ○
345-09800 PCB ASSY,MOTHER ○
346-52110-01 FORCE AMP /I ○
074-80382-02 Power supply LWT30H-5FF ○
074-80383-27 Power supply ZWS30-24 ○
347-50211 Fan ASSY(ASF80171) ＊ ○
042-60934-03 Filter unit (9325-F) ＊ ○ ＊1 ＊3
346-53162-01 Smart controller ○ ＊1
Note 1 Theses parts can be replaced by users
Note 2 Four motor brushes per testing machine are required.
Note 3 The filter unit (9325-F) includes the filter (9325-M) and retainer as a set.
See Fig. 6.2 in CHAPTER 6.
9-2
9.Maintenance Parts List
<Separate Table 1>

Part No.
Part name
AG-100kNIC AG-300kNIC
Servo amplifier 339-87089-01 339-87090-01
Servo motor 339-87089-11 339-87090-11
■ For the part numbers of the standard accessories (such as cables) and peripheral equipment
(such as the load cell), refer to CHAPTER 2.
■ For components other than the above, ask SHIMADZU plant, or our authorized service
company/distributor.
9-3
9. Maintenance Parts List
（Blank Sheet）
9-4

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349-05554B

To ensure proper use of this equipment, read

Microsoft and Windows are registered trademarks of Microsoft Corporation

Failure to avoid the described condition may result in serious injury or

Failure to avoid the described condition may result in slight or middle

NOTE Includes information necessary for correct use of the equipment.

Sensor Amplifier Panel for the

(Backside of testing machine)

(Backside of testing machine)

 Procedure for stopping the equipment in emergency

Circuit breaker (Rear right side of the tester)

AG-IC series (floor-type) tester

Emergency stop switch and power switch

1) Improper product handling

Action for Environment (WEEE)

To all users of Shimadzu equipment in the

Contact your Shimadzu service representative when the equipment has

With your co-operation we are aiming to reduce contamination from waste

Product Name : Universal Testing Instruments

Model Name : Autograph AG-IC Series

Manufacturer : SHIMADZU CORPORATION

Authorized Representative : SHIMADZU EUROPA GmbH

2. Crosshead stroke limit switch.............................................................................................. 4-10

1. Precautions for storage ........................................................................................................... 7-4

1.1 Outline..................................................................... 1-2

1.2 Precautions ............................................................ 1-2

1.3 Common Specifications .......................................... 1-4

1.4 Individual Specifications......................................... 1-9

We at Shimadzu appreciate it very much that you have purchased a

The AG-IC series AUTOGRAPH is a universal testing machine

To perform material strength measurement, the universal testing

The AG-IC series AUTOGRAPH is the precision universal testing

1. Handling the load cell

2. Handling the grips

1 ) Cycle test conditions:

4. Setting the crosshead limit switch

(1) Crosshead speed setting

In the case of 100kN capacity testing machine

Speed (mm/min) 0.0005～0.001 0.001～1 1～40 40～100 100～1000

Resolution (mm/min) 0.0001 0.001 0.2 0.5 1.0

In the case of 300kN capacity testing machine

Speed (mm/min) 0.0005～0.001 0.001～0.5 0.5～20 20～50 50～500

Resolution (mm/min) 0.0001 0.001 0.1 0.25 0.5

Example: In the case of the crosshead speed is set to 1 inch/min

(2) Crosshead control START/STOP/RETURN

3) Automatic force range switching function

4) Force calibration It performs by exclusive data-processing software.

(5) Force value display device

(6) Crosshead stroke measuring device

(8) Test control mode

1) Single test control mode(TRAPEZIUM2 SINGLE, TRAPEZIUM Lite)

2) Cycle test control mode(TRAPEZIUM2 CYCLE)

3) Control mode(TRAPEZIUM2 CONTROL)

(9) Specimen breakage detecting function(set up by the exclusive data-processing software)

(11) The exclusive data-processing software Windows version (TRAPEZIUM2)

(12) Safety/Protection devices

1.4 Individual Specifications for Testing machine

ble distance +500 1735 1930

+500 2662 / 900 2912 / 1000