Part Number XC-129

Revision A

INSTALLATION, CALIBRATION, AND OPERATION

Line Tension Transducer

P/N LTT-100K-E6855-01

Manufacturers of Precision Instruments

Printed in U.S.A. July 02, 1998

 Manual XC-129 contains 16 pages, divided as follows:

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 1998

iii through iv . . . . . . . . . . . . . . . . . . . . . . . June 1998
1 through 10 . . . . . . . . . . . . . . . . . . . . . . . June 1998

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.

Information in this manual is subject to change without notice.

 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

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M/D Totco
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

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 Table of Contents

Table of Contents
1. Introduction ...................................................................................................................... 1
2. Description........................................................................................................................ 2
3. System Components........................................................................................................ 3
4. Principle of Operation...................................................................................................... 4
5. Installation ........................................................................................................................ 5
5-1 General............................................................................................................................... 5
5-2 Installation Procedure......................................................................................................... 5
6. Periodic Inspection .......................................................................................................... 7
6-1 General............................................................................................................................... 7
6-2 Periodic Inspection Procedure ........................................................................................... 7
7. Field Maintenance ............................................................................................................ 7
7-1 General............................................................................................................................... 7
7-2 Deflecting Block Removal and Replacement Procedure.................................................... 7
7-3 Clamping Mechanism Removal and Replacement Procedure........................................... 8
8. Shop Maintenance............................................................................................................ 8
9. Recommended Spares Parts........................................................................................... 8
10. Part Number and Description Reference ..................................................................... 10

July 02, 1998 Table of Contents - 1

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Table of Contents LTT-100K-E6855-01
Manual XC-129

Table of Contents - 2 July 02, 1998

M/D Totco
 LTT-100K LINE-TENSION TRANSDUCER
Installation, Operation, and Maintenance

1. Introduction
This manual contains installation and operation instructions relative to the M/D Totco
LTT-100K-E6855-01 Line-Tension Transducer (Figure 1). Read the appropriate section of
this manual before installing or operating this equipment. Make sure that personnel oper-
ating the wire rope system and transducer are familiar with the procedures in this manual.

Yoke Crank
Wire
Rope Top

Wire
Rope Deflection
Block Yoke Crank

Side

Figure 1. LTT-100K-E6855-01 Line-Tension Transducer, Top and Side Views

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 LTT-100K-E6855-01
Installation, Operation, and Maintenance Manual XC-129

2. Description
The LTT-100K-E6855-01 Line-Tension Transducer provides a 0-2 mV/V electrical signal
output proportional to a wire rope’s single-line load up to 100,000 lbs. (45360 kg), maxi-
mum. The system consists of:
• An aluminum block with internally sealed strain gages
• Deflection plates
• A center clamping mechanism

Features of the LTT-100K-E6855-01 are:

• Accepts wire-rope diameters from 7/8 to 2 inches (22.2 to 50.8 mm) without
requiring modification.
• Light weight: 17 pounds (7.7 kg)
• Low maintenance
• High accuracy with better than 2% repeatability

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LTT-100K-E6855-01
Manual XC-129 Installation, Operation, and Maintenance

3. System Components
The LTT-100K-E6855-01 system consists of a transducer body that measures 2 x 4 x 12
inches(50.8 x 101.6 x 304.8 mm), machined from a solid aluminum billet (Figure 2). The
body is hard-anodized and painted to provide environmental protection even under the
most extreme conditions.

4.00

12.00

6.00

3.00

Figure 2. LTT-100K-E6855-01 Transducer Body

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 LTT-100K-E6855-01
Installation, Operation, and Maintenance Manual XC-129

Inside the transducer body are load-sensing strain gages that provide a 2mV/V, full scale,
signal output representing 0 to 100,000 lb of line pull. The LTT-100K-E6855-01 requires
5VDC (± 0.1) of excitation voltage. Attached to the transducer body are the following:

Deflection Blocks Replaceable stainless-steel deflection blocks are at both ends of

the transducer body. These blocks provide an offset for the wire
rope away from the transducer body. When the clamping mech-
anism is installed and clamping pressure is applied, the clamp-
ing blocks force the wire rope to deflect 1/4 inch (6.35 mm).
They also maintain alignment of the wire rope along the center
of the transducer body.
Clamping Mechanism Bolted to the center of the transducer body, the clamping mech-
anism forces the wire rope to its initial position; the clamping
mechanism then transfers the force exerted by the wire rope to
the transducer body.
The clamping mechanism includes a crank lever that makes
additional tools during installation unnecessary. For increased
safety, the clamping mechanism is captivated so that no parts
may become detached during installation.
Connector A military-style 6-pin connector eases field installation with
mating cable connectors. PIN A is (+) EXC, PIN B is (-) EXC,
PIN C is (+) SIG, PIN D is (-) SIG, PIN E and PIN F are not
connected..

4. Principle of Operation
When the LTT-100K-E6855-01 is installed, the transducer is clamped to the anchored
wire rope (deadline). Because of the transducer’s geometry, the wire line is bent or
deflected by 1/4 inch (6.35 mm) at the center of the transducer body when properly
installed.
When additional load is applied to the wire rope, the wire rope tends to straighten at the
deflection point; it therefore exerts an outward force on the yoke. This force is transmitted
through the clamping mechanism, with reaction forces at the deflection blocks to the
transducer body.
These combined forces create a strain on the transducer body, which the strain gages
detect. The strain-gage bridge produces a 0-2mV/V output signal proportional to the
tension in the wire rope.

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LTT-100K-E6855-01
Manual XC-129 Installation, Operation, and Maintenance

5. Installation
5-1 General

This section contains procedures for installing the LTT-100K-E6855-01 sensor.

The sensor is factory calibrated to output 0-2mV/V, representing 0 to 100,000 lbs
(0 to 45360 kg) line tension when powered by 5 Volts DC.
No special tools are required for installation. The only special part necessary for
installation is the mating signal cable of suitable length for the particular
application.
Each LTT-100K-E6855-01 Line Tension Transducer is delivered fully operational
for the wire line load range of 0 to 100,000 lbs (0 to 45360 kg).

CAUTION
The LTT-100K-E6855-01 directly measures single-line load only.
Be sure the equipment displaying the load value accommodates the
correct number of lines strung.

CAUTION
The LTT-100K-E6855-01 is often installed where high vibration is
present. While vibration does not damage the LTT-100K-E6855-01,
be sure to route the signal wire so vibration does not cut or damage
the wire.

5-2 Installation Procedure

Install the LTT-100K-E6855-01 Line Tension Transducer as follows:

1. Find an acceptable site to install the LTT-100K-E6855-01, keeping in
mind the following:
a. The best place to install the device is close to the anchor; this reduces cable
sway and vibration.The shortest distance from the anchor to the
LTT-100K-E6855-01 is 3 feet (0.914 m).
b. Reduce cable-routing effort by considering the location of the data-acquisi-
tion unit to which the LTT-100K-E6855-01 is attached.
c. Because it is not a hydraulic device, the elevation of the LTT-100K-E6855-
01 relative to other devices is not important.

NOTE
To simplify installation, perform these steps when the wire line is not
under load.

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 LTT-100K-E6855-01
Installation, Operation, and Maintenance Manual XC-129

2. Make sure that the crank retaining screw (Figure 3) is in place and
tight.
3. Loosen the yoke (Figure 3) by rotating the crank counterclockwise.
Rotate the crank until there is enough gap to allow installation.
4. Open the clamp by lowering the clamping mechanism and rotating it
180 degrees.
This allows the installation of the wire rope.
5. Close the clamp by rotating 180 degrees.
Make sure that the holes in the clamping block line up with the guide posts.
6. Tighten the clamp by rotating the crank clockwise one full turn after the
wire rope contacts the transducer body.
7. When installing signal cable, PIN A is (+) EXC, PIN B is (-) EXC, PIN
C is (+) SIG, PIN D is (-) SIG, PIN E and PIN F are not connected. .
Secure the cable near the sensor, providing strain relief and preventing
accelerated cable wear.

4.56

Crank

Retaining Wire
Screw Rope
Yoke

Clamping
Shoe

End
Deflector

3.20

Signal Output
Body
Connector

4.00

Figure 3. LTT-100K-E6855-01 System Assembly

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LTT-100K-E6855-01
Manual XC-129 Installation, Operation, and Maintenance

6. Periodic Inspection
6-1 General

This section contains procedures for periodic inspection and field maintenance.
Periodic inspection includes preventative maintenance and service for equipment
safety, security, and cleanliness.
6-2 Periodic Inspection Procedure

Perform the following steps every two weeks:

1. Wipe off and inspect equipment for excessive wear, gouging, and cable
fraying.
2. Replace defective parts or assemblies to reduce downtime.
3. Return defective item to the nearest M/D Totco facility for shop main-
tenance or repair.

7. Field Maintenance
7-1 General

Field maintenance is limited to removal and replacement of system components or

the assembly itself. Detailed shop maintenance includes component disassembly,
cleaning, inspection, and reassembly.
Field-repairable components include:
• Deflecting blocks
• Clamping mechanism assembly
7-2 Deflecting Block Removal and Replacement Procedure

If deflecting blocks become worn, output from the device will decrease. If signal
output loss can be attributed to deflecting block wear, replacement is necessary.
Remove and replace deflecting blocks as follows:
1. Perform the installation procedure in Section 5-2 in reverse order.
When a step instructs to tighten by rotating clockwise, perform the opposite to
loosen (rotate counterclockwise), etc.
2. Using a 5/32-inch hex wrench, remove the two screws holding the
deflecting block in place (Figure 3).
3. Apply Loctite thread-locking adhesive to each of the screws removed
in Step 2 above.
4. Install new deflecting block using the Loctite-treated screws.
5. Perform the installation procedure in Section 5-2.

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 LTT-100K-E6855-01
Installation, Operation, and Maintenance Manual XC-129
7-3 Clamping Mechanism Removal and Replacement Procedure

If the clamping shoe of the clamping mechanism becomes worn, output from the
transducer will decrease. If signal output loss can be attributed to clamping shoe
wear, replacement is necessary.
Remove and replace the clamping shoe as follows:
1. Perform the installation procedure in Section 5-2 in reverse order.
When a step instructs to tighten by rotating clockwise, perform the opposite to
loosen (rotate counterclockwise), etc.
2. Remove the retaining screw and lock washer from the clamping shoe.
(Figure 3).
3. Rotate the clamping shoe 90 degrees and slide the shoe off.
4. Install a new clamping shoe and lock by installing the retaining screw
and washer removed in Step 2 above.
5. Perform the installation procedure in Section 5-2.

8. Shop Maintenance
Detailed shop maintenance of the sensor assembly includes:
• Disassembly
• Cleaning
• Inspection
• Reassembly
Do not separate permanently bonded parts such as the expansion plug; instead, replace the
next higher assembly. Lubricate crank screw threads.If the sensor does not operate or does
not hold calibration, return the transducer body to the M/D Totco manufacturing facility
for repairs.

9. Recommended Spare Parts

PART NUMBER DESCRIPTION QTY

TCL-100K-102 SHOE 1

TCL-100K-103 END DEFLECTOR 2

TCL-100K-104 POST 2

TCL-100K-107 YOKE 1

2100-06301 CONN, BOX M, 3-PIN, 1

2170-10000 GASKET, CONN, SQ FLG, MS TYP #14 1

J811-14XS SCREW, 1/4-20X1.75, CSK, SKT 4

261028 CRANK, SHOE 1

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LTT-100K-E6855-01
Manual XC-129 Installation, Operation, and Maintenance

Figure 4. LTT-100K-E6855-01 Parts Diagram

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 LTT-100K-E6855-01
Installation, Operation, and Maintenance Manual XC-129

10. Part Number and Description Reference

Units
Figure &
Part Number Description per
Index No.
Assy

Fig 4 LTT-100K-E6855- Line Tension Transducer Assembly 1

01

1 LTT-100K-E6855- Body 1
10

2 TCL-100K-103 Deflection Block 1

3 TCL-100K-107 Yoke 1

4 999449-670 Screw, 10-32 X .50 1

6 2100-06301 Connector, MS BX 1

7 2800-44060 Screw, SHCS, SS 4-40 X 3/8 4

8 999291-006 Washer, Flat, #4 4

9 2802-14000 Lockwasher, Split, #4, SST 4

10 2170-10000 Gasket 1

11 J811-14XS Screw, 1/4-20 X 1.75 4

12 261028 Crank Shoe 1

13 999268-009 Washer, Lock, Hel, .190 1

14 991702-007 Lubricant 1

15 991201-012 Loctite #242 AR

16 TCL-100K-102 Shoe 1
17 TCL-100K-104 Post 2

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