- Caterpillar Products: All
Introduction
European Union Compliant, CE Marked
Important Safety Information
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Think Safety | |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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Personal Protection/Important Information | |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.
General Information Section
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Current for Software Version 7.1 | |
The Digital Valve Spring Tester is a high precision machine designed for compression spring testing of force and length.
Standard Features
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- Force capacity of 680.39 kg (1500 lb)
- 5 in stroke travel and range measurement
- Compression testing of force and length
- Deflection compensation for accurate testing
- Mechanical and software overload protection
- Digital calibration and linearization
- Backlit digital LCD display of force and length
- Rack and pinion drive for convenient hand operation
- Wipe-clean embossed key face plate
- Push-button force and length zeroing
- Push-button English or Metric unit selection
- NIST traceable calibration
- High-resolution force and length
- RS 232 to USB output to PC or printer
- Cast aluminum and steel frame housing for durability
- 2 3/8 in diameter load platforms
- Built in shunt calibration verification
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RS 232 Connection and Power Connection (Back View) | |
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RS to USB | |
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Adapter Cable | |
Force and Length Specifications
| Force Specifications |
Length Specifications | |
| Capacity | Force Resolution | High Resolution Length |
680.39 kg (1500 lb) |
0.45 kg (1 lb) |
0.025 mm (0.001 inch) |
| Accuracy =±Resolution x 2 | ||
Operation Section
Quick Start Guide
- Warm up the tester for 30 minutes before using.
- Initialize (zero) the tester to zero length and zero force.
- Place a spring on the lower platform.
- Use the handle to compress the spring to the specified length and read the force.
| NOTICE |
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Warning: A compressed or extended spring has stored potential energy proportional to the spring constant. To avoid injury release this energy in a controlled manner when testing and wear appropriate eye protection. Also, use approved fixtures to prevent springs from flying out due to buckling under load. (Fixtures include extension hooks, larger platforms, buttons, etc.) Do not apply more force than the tester can handle. Although equipped with software and hardware overload stops, damage to the tester can occur. Release the force quickly and safely if MAXIMUM FORCE is reached. |
Installation
A dry, non-humid, non-condensing environment kept at room temperature 20° C ± 5° C (68° F ± 9° F) is suggested when choosing a workstation for operating the tester. This location should offer protection from debris or falling objects or anything that may damage or interfere with the operation of the tester. Keep in mind accessibility to a printer and power outlet depending on the capabilities of the tester. Be sure that the operating location is clean and dry and all parts to be tested are free of oil and contaminants.
Once a workstation location is selected: Place the tester on a level and stable work area where the operator can perform compression testing in a comfortable manner. We recommend that you secure the tester to the work surface. Insert the end of the Handle through the hole to the left of the Handle Release Lever. Tighten the Handle Release Lever when in position. The Handle moves the Upper Platform and is also used to apply force. Remove and reinstall at the next 90-degree slot for convenience in testing.
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The Stroke (or Length) Lock on the left side holds the upper platform at a desired length under load up to 300 lbs. This feature simplifies setting length stops. The Overload Stop Screws on top of the tester base near the Lower Platform are set and sealed at the factory. The Overload Stop Screws should not be changed.
General Startup
Commands using the keypad buttons will refer to the button in CAPITALIZED BOLD LETTERS in brackets throughout the manual.
Next the display will read,"tester starting".
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The display will then read, "V1500# v7.1 LENGTH RES .0010
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The fist line in the example above shows the model description (VXXX), force capacity (1500#), and the software version (v7.1) used to configure the tester. The second line indicates the tester length resolution (.0010). In the next display that appears, the first line displays "ZERO LENGTH" indicating that the ZERO LENGTH button should be pressed to activate the length reading function on that line. The force display on the second line should show zero or a small reading. Press (ZERO LENGTH) to activate the length reading function, if available.
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The display defaults to the manual testing mode and the last unit of measurement used on the tester before the tester was turned off. Learn about the control panel in the next section.
The Control Panel
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(UNITS) Choose unit of measurement (lb, N, oz, or kg) for force and (in or mm) for length.
(MODE) Select the test mode that applies. The test modes available are Manual and Peak. A mode for Shunt calibration verification is included.
(ZERO FORCE) Zero out the current force reading displayed.
(ZERO LENGTH) Zero out the current length reading displayed.
(SEND) Send displayed reading the PC or printer.
(ON/CLEAR) Turns on the tester and resets Peak mode.
(OFF) Turns off the tester. Turn the tester off when not in use to save the battery life.
Test Modes
Either Manual or Peak mode may be used for testing. A third mode, Shunt Calibration Verification is not used for testing.
When the machine is first turned on, the machine defaults to Manual mode. Press (MODE) to enter Peak mode, and again to enter Shunt calibration mode.
Each of the modes is described in the following sections:
Manual Mode
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The Manual (tracking) Mode displays the current force and length during testing and dynamically adjusts as the force recedes or increases. The length lock may be tightened at a desired measuring point to hold the upper platform in place and fix the reading on the display for recording. Press(SEND) to record the data in a printable format and continue testing.
Peak Mode
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The Peak Mode is indicated by pk in the lower left of the display as shown in the illustration above. This testing mode is standard on all models. When testing in this mode, the display dynamically adjusts to reflect the force and length measurement as the force applied increases. When the force applied recedes, the display locks in at and displays the highest force reading that occurred, along with corresponding length, if applicable. If a greater force is later applied, the display will continue to adjust to a force that exceeds the previous reading but will not adjust to a lesser reading.
To reset the display reading, press (ON/CLEAR). If the display does not return to zero or near zero, press (MODE) to exit Peak mode. press (MODE) again to enter the Manual mode. Press (ZERO FORCE) with no force applied while in the Manual mode to zero the display. Return to peak mode to proceed.
Shunt Calibration
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The Shunt mode is indicated by shn in the lower left of the display, as shown in the illustration above. This mode does not apply to testing but to the calibration of the testing unit and is used to verify the accuracy of force readings.
The tester should be warmed up and the force display zeroed in the Manual mode before entering the shunt calibration mode for verification. Make sure that the unit of measurement is the same as the Shunt Value recorded on the Calibration Report from the factory. When the shunt calibration mode is activated, a load is electrically simulated and generates a force reading on the display. Compare the force value displayed in the underlined field shown in the example below with the Shunt Value recorded on the Calibration Report shipped with the tester. The two numbers should match or be relatively close. Contact Larson Systems if there is a notable discrepancy.
Force and Length Initialization
The force and length displayed must be initialized (zeroed) at a reference point to achieve consistent results. This should be done prior to testing.
The normal reference point for force is with the platforms apart and no load (spring) on the lower platform. Force initialization may need to be done after the normal initialization with the sample spring resting on the lower platform. This ensures that the weight of the test spring is not included in the force measurement. The test procedure includes this step.
The normal reference point for length is with the upper and lower platforms together (compression), with force applied.
If stop rods are part of the tester assembly, make sure that the rods are set to permit free travel of the upper platform before initializing.
- Turn on the tester and move the upper platform all the way upward.
- There should be no force applied and nothing resting on the lower platform.
- Press (ZERO FORCE). The force display should read zero.
- Bring the upper platform down to meet the lower platform.
- With the platforms together and applying 10% to 30% full-scale force, press (ZERO LENGTH).
Testing Procedure
Preparation
- Turn on the tester and allow the tester to warm up for at least 30 minutes prior to testing.
- Check out the operating condition of the tester. Make sure the upper assembly moves freely and all parts are in working order.
- Exercise the machine in the way that testing will be done to facilitate the most accurate readings.
- Leave the tester in Manual mode to begin.
Compression
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- Choose the unit of measurement to be used for testing by pressing UNITS.
- Initialize both force and length for compression per instructions.
- Place head in contact with spring and remove handle. Then press (ZERO FORCE). This deducts the weight of the spring from the force measurement.
- To test in Peak mode, press (MODE). The lower left of the display reads, pk. Otherwise, remain in Manual mode and begin testing with the next step.
- Perform test by applying compressive force to sample using the handle on the upper rack assembly. Use the standards you previously determined appropriate for desired results to complete the test.
- The resulting data may be sent to a printer at the measurement point by pressing (SEND). If preferred, manually record the data. If the sample passes or fails the test, remove from platform and sort as needed.
- Press (ON/CLEAR) to reset the display. If you are testing in the Peak mode, and the display will not zero, you will need to zero it in the Manual mode. Then return to Peak mode to continue testing.
- Repeat procedure from step 3, making sure that the force display reads zero with the sample on the platform with no force applied as instructed.
When length is initially zeroed, it should not be necessary to initialize length again before testing additional samples, unless (ZERO LENGTH) is pressed when platforms are apart.
Parallelism Check
The upper platform must be parallel with the load cell (lower platform) to achieve reliable readings. Parallelism directly affects length accuracy and should be verified prior to verifying the length calibration. This procedure requires using a dial indicator for parallelism measurement. If a dial indicator is not available or length data is not required, this procedure may be omitted.
Deflection Compensation Check
- With no force applied, press (ZERO FORCE).
- Bring the upper platform down to meet the lower platform. While applying about 5% full-scale force, press (ZERO LENGTH) to initialize.
- Place a 0.1 in gauge block between the upper and lower platform.
- Apply 5% and 95% full-scale force and record the deflection length for compression. The length displayed should read the same at 5% and 95% within .001 of an inch.
Length Calibration Check
- Bring platforms together and press (ZERO FORCE) while applying a known force near 50% full scale to initialize. Remove force.
- Place a 0.1 inch gauge block between the load cell and upper platform.
- Apply the same known force used to initialize the tester in step 1 and record the gauge block length and displayed length.
- Repeat step 3, inserting gauge blocks increasing length to 1,2,3,4,5, and 6 inches.
Force Calibration Verification
- Move the upper platform to the maximum height.
- Press (ZERO FORCE) to zero the display.
- Apply known loads in ascending order in ten equal increments up to full scale and record the results.
- Reapply the loads at least three times to establish repeatability.
- Evaluate the results. The results should be within the accuracy specifications found in the corresponding force specification table for the tester in section 1.
Maintenance
General Maintenance
The Digital Valve Spring tester is a low maintenance tester. Caterpillar recommends that oils and other liquids be kept away from and off the electronics portion of the tester. If liquid or oil should contact the device, wipe it off with a soft cloth or paper towel. Never apply any cleaner or solvent directly to the electronics faceplate. A mild plastic cleaner applied to a wipe may be used. Take measures to protect the tester from debris or falling objects. The load cell contains sensitive electronics and can be severely damaged by such forces.
Calibration
Caterpillar recommends that you have your tester calibrated for NIST traceable certification on an annual basis. Frequency of calibration can be based on how often and for what purpose the tester is used.