I Part Number TW524

1\11oTotco-

1A Varco Company

INSTALLATION, OPERATION, AND MAINTENANCE

SUM-MASTER TOTALIZER LOAD CELL SYSTEM

COMPRESSION TYPE

Manufacturers of Precision Instruments

Printed in U.S.A. April 1976

 Manual TW524 contains 18 pages as follows:

Cover .............................. March 1998

ii thru vi. ............................ March 1998
1 thru 14 ............................. .Aprill976

All product, brand, or trade names used in this publication are the trademarks or registered trade-
marks 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.

. ..
April 1976 III
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.

iv April 1976
M/D TOTCO
 TW524
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IIECKE
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CONTENTS
Section No. Title Page No.
I INTRODUCTION AND DESCRIPTION ..................... 2
l-l. Introduction ................................ 2
l-3. Description ................................ 2
II INSTALLATION AND OPERATION ....................... 5
2-l. Pre-Installation ............................. 5
2-3. System Installation ........................... 5
2-4. Load Cell Installation .......................... 5
2-5. Indicator Installation .......................... 5
2-6. Hydraulic Hose Installation ... i .................. 5,‘7
2-7. Post Installation Checkout ....................... 7
2-9. System Operation ............................ 7
2-13. System Accuracy ............................ 7
2-15. System Weight Test .......................... 8
III MAINTENANCE AND TROUBLESHOOTING ................. 10
3-l. Maintenance ............................... 10
3-4. Troubleshooting ............................. 10
IV REPAIR ........................................ 11
4-l. Repair .................................... 11
4-3. Component Repair ........................... 11
4-5. Load Cell Gap .............................. 11
4-6. Charging and Bleeding System ................... 12
LIST OF TABLES
Table No. Title Page No.
3-l. Malfunction Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10111
4-l. Nominal Cell Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIST OF ILLUSTRATIONS

Figure No. Title Page No.

l-l. Typical Sum-Master Totalizer Load Cell Systems ............. 3
2-l. Overall Dimensions for 8-l/2, 12 and 18 inch
Indicator Installation .............................. 6
2-2. Sample Load Data Worksheet .......................... 9
4-l. 0 Ring Replacement ................................ 12
4-2. Load Cell Gap and Plug Location ........................ 13

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MARTIN

SECTION I
INTRODUCTION AND DESCRIPTION
l-l. INTRODUC TION
l-2. This manual provides installation, operation and maintenance instructions for the Sum-
Master Totalizer Load Cell Systems manufactured by the MARTIN-DECKER COMPANY,
Santa Ana, California.

l-3. DESCRIPTION.
l-4. The Sum-Master Totalizer Load Cell Systems (hereinafter referred to as the load cell
systems) are hydraulically operated, require no external power source, and are fully
assembled and loaded with MARTIN- DECKER hydraulic fluid prior to shipment. They
are available in two, three, and four sensater load cell models and with 8-l/2, 12 or
18 inch dial indicators. They are designed to operate in the temperature range of -50°F
(-45.5”C) to 150” F (65.5”C) with hydraulic hose lengths up to 100 feet for some models.
Accuracy of the load cell systems when shipped from the factory l 0.2 of 1% of full scale
capacity. For a complete listing of the systems and characteristics refer to PLlOGST.
Specifications concerning part number breakdown are given in the example below:
SWTS183-1000-36
1000 = 100,000 lb

l-5. The load cell systems consist of three basic components: an indicator, two or more
hydraulic hose assemblies and two or more sensater load cells.
1-6. SYSTEM COMPONENTS. The load cell system consists of the following basic
components and attaching hardware:
Indicator
it: Sensater Load Cells (hereinafter referred to as load cells)
Hydraulic Hose
2 Tubing (Optional)
Disconnects (Optional)
I: Attaching and Support Hardware
1-7. Indicator. Th& indicator provides a dial faceplate, calibrated in pounds, tons or
kilograms, as specified. The indicator has a damper for each load cell input to the
indicator to smooth pointer sensitivity and to adjust the pointers response to the
operator’s preference. Also included on each indicator is a dial adjust gear, which
rotates the dial to make necessary tare adjustments.
l-8. Load Cell. The load cell transmits a no-lag, linear load indication signal to the
indicator by transforming the applied load to a hydraulic signal. This is accomplished
by a sensater diaphragm sensing element held in place by the load cell housing.

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SWTS 82 SERIES

123 OR
183 SERIES

SWTS 124 OR
SWTS 184 SERIES

Figure l-l. Typical Sum-Master Totalizer Load Cell Systems

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OECKER
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l-9. Hydraulic Hose. Two types of hydraulic hose are used,depending upon the capacity
of the system. The hydraulic hose comes standard with l/4 NPT hose connections.
Disconnect couplings are available for most capacities where installation or dis-
connecting of the hose from the load cell or indicator is required. The hydraulic
hose will come in maximum lengths of 50 feet in a single unit, and couplings (P/N 5103)
will be used where extended lengths are needed to meet the job’s requirements. Where
permitted, tubing is recommended for long distances,
a. The 3/16 inch diameter hose is of single wire braid construction and rubber
covered. MARTIN-DECKER recommends use of this hose with all systems
using 4.0 to 16.1 square inch load cells.
b. The l/4 inch diameter hose is of double wire braid construction and rubber
covered. MARTIN-DECKER recommends use of this hose with all systems
using 25.0 to 100.0 square inch load cells.
l-10. 5900 Series Disconnects. Disconnects are available for most capacities where
disconnection of the hose from the load cell or indicator is required. Usually the
female half of the disconnect is installed on the hose while the male half is installed
at the indicator to facilitate connection. Disconnects may be used in-line to separate
two hoses. Disconnect halves are supplied with protective covers to preclude entry
of contaminants into system when assemblies are disconnected.

l-11. Tubing. Copper or stainless steel tubing may be used to supplement the hydraulic hose
for fixed applications or where the indicator is mounted at extreme distances from the
load cell. It can also be used for rigidity and transmission line protection.

1-12. Attaching and Support Hardware. The system is furnished with all necessary attaching
and support hardware to facilitate installation and maintenance:
a. Check Valves - Usually installed on the load cells and are used to replenish
the hydraulic fluid in the system. In some cases the check valve may be
located elsewhere in the system.
b. YA2 Hand Pump - Used for field loading the system with hydraulic fluid.
Connects to the check valve.
C. Hydraulic Fluid - Supplied in quart and gallon containers. W 15 (quart)
W16 (gallon) hydraulic fluid is to be used in the event it becomes necessary
to charge the system in the field.

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. . 0 A. MARTIN
OECKE
SECTION II
INSTALLATION AND OPERATION

2-l. PRE -INSTALLATION

2-2. The pre-installation procedure consists primarily of insuring that the Totalizer Load
Cell System is the correct system to be installed.
Items to be checked:
a. Indicator dial is calibrated in the units of measurement (pounds, tons, or
kilograms) compatible with what will be measured.
b. Disconnect 0 rings are not damaged (Refer to paragraph 4-4 for replace-
merit).
Load Cell capacity suitable for load to be weighed.
:: Determine that the load cell and hydraulic hose is located in a position to
move freely, taking into account any obstructions that may interfere with
the load to be measured. Also, determine that hydraulic hose is of sufficient
length for routing from the indicator to the load cell.
e. Verify condition of hose disconnects and fittings to ensure that they will
not leak hydraulic fluid when mated.
2-3. SYSTEM INSTALLATION

2-4 LOAD CELL INSTALLATION. The load cell can be mounted in any position, dependent
upon the application. The load plates of the cell may be tilted a maximum of 2” from
their parallel position to facilitate installation without causing a measurement error.
Misalignment (lateral displacement) of the load plates is tolerable: however if mis-
alignment exceeds .06-inches, it will produce a slight error in indication, and increased
wear to the diaphragm will result.
CAUTION
The load cells are incapable of supporting torsional loads
of any significance. Torsional loads will cause the diaphragm
to rotate over the pressure plate, resulting in early failure.
In applications where twisting is encountered, a swiveling
device must be used to relieve the load cell from torsional loads.

2-5. INDICATOR INSTALLATION. Select a location for the indicator that will provide
convenient visual access to the operator. Figure 2-l shows overall bracket dimensions
Drill four mounting holes for bracket
ii: Install indicator/bracket using screws and washers as required.
2-6. HYDRAULIC HOSE INSTALLATION
Route hose so that it will not be crushed, cut, or otherwise damaged.
;: Tie hose to structures where permitted.

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DECKER

WTS122 12 INCH INDICATOR

WTS123 12 INCH INDICATOR 6TS82 8l/, INCH IN‘DICATOR
WTS124 12 INCH INDICATOR

it \
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1 (4) M/32 DU
Y0uNTING HOLEa

WTS182 18 INCH INDICATOR

WTS183 18 INCH INDICATOR
WTSl84 18 INCH INDICATOR
Figure 2-l. Overall Dimensions for 8-l/2, 12 and 18 Inch Indicator Installation
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2-6. cont.
CAUTION
Allow sufficient slack in the hose to avoid pulling hose
taut. Excess tension could cause fitting or connector failure.

C. Connect disconnects in accordance with the following procedures:

1. Carefully align male and female coupling halves before mating
2. Push two halves together firmly.
3. Thread nut onto male half of coupling and tighten.
NOTE
If the 0 ring becomes damaged during mating, replace as
perparagraph4-4.
2-7. POST-INSTALLATION CHECKOUT

2-8. After system installation, check to insure that it is operating properly.

a. Exercise the system, using a known weight of at least 25 percent of full scale
capacity several times. This is to flex the sensater diaphragm in the load
cells.
b. Remove weight from sensater load cell.
C. Turn tare adjust knob to rotate dial indicator to zero.
d. Check load cell to see that it is free of all encumbrances .

2-9.. SYSTEM

2-10. The load indicating system is automatic, but two adjustments of the load cell system
indicator are necessary prior to initial use of the system.

2- 11. LOAD POINTER ZERO (‘I’ARK) ADJUSTMENT

Apply a load to the system.
it: Remove load.
C. Adjust tare adjust knob until indicator pointer reads zero with all tare loads
acting on load cells.
NOTE
When reading the indicator, maintain a direct and perpen-
dicular line of sight between the eye and pointer in order
to eliminate the possibility of parallax error.

2-12. POINTER DAMPING ADJUSTMENT. The adjustment is designed to adjust pointer

sensitivity to the operator’s preference, however, the adjustment can affect indicator
response if too much damping is applied. The following procedure is recommended
to achieve desired sensitivity. Access to the dampers can be obtained by inserting
a screw driver through the openings in the front panel of the 12 in. and 18 in models.
Dampers on 8-l/2 in. model are exposed tee handle stems.
a. Fully engage all dampers, by pushing stem into insure thread engagement,
and turn stems clockwise to closed position.
b. Open all dampers by turning stems counterclockwise two complete revolutions.
C. If pointer is too sensitive, turn all damper stems clockwise l/4 to l/2
revolution.
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2-12 cont.
d. If pointer is sluggish, turn all damper stems counterclockwise l/4 to l/2
revolution.
e. Recheck Sensitivity and repeat appropriate step -c or -d until desired
sensitivity is reached.

2-13. WTEM ACCURACY

2-14. System accuracy is such that the indicated load should not differ from actual load
more than a.2 of one percent of full scale. Use a series of known loads to check
the system’s accuracy. (Refer to paragraph 2-15)

2-15. SYSTEM WEIGHT TEST

2-16. To insure accuracy of the load indicator system, load tests should be performed
at 6-month intervals and at initial test at system installation. A sample load
test data worksheet is provided in figure 2-2 and the weight test procedure is
as follows:
Note
Test weight accuracy should be equal to or better
than the accuracy of the gage being tested.
a. Assemble necessary equipment to perform test:
1. Test weights on the order of 25, 50, 75 and 100 percent of the total
capacity of the system.
2. Rigging or equipment required to hoist test weights. If weight of
rigging is to be included in test, its weight must be known.
b. Apply test weights in sequence and write indicator reading in the space
provided on the worksheet.
Repeat step b to insure repeatability.
:: If system does not meet specified tolerances, refer to paragraph 3-4.

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MARTIN

DECKE
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OWNER DATE

MFG. MARTIN-DECKER CO. MODEL SERIAL

,SANTA ANA, CALIF. I
SYSTEM CAPACITY
I I

CONFIGURATION AT TIME OF TEST

LOCATION OF LOAD SENSORS

TEST LOAD DATA: PERCENT OF TOTAL SYSTEM CAPACITY

WEIGHT OF TEST LOAD TO INCLUDE ALL EQUIPMENT
25% 50% 1 75% I 100%
1st INDICATOR 25% TEST 50% TEST 75% TEST 100 % TEST
READING WEIGHT WEIGHT WEIGHT WEIGHT

ERROR*
2nd INDICATOR
READING

ERROR*
A
CONDITION OF TOTALIZER SYSTEM:

INSPECTOR ORGANIZATION DATE

* A plus error denotes an indicated load greater than actual load.

A minus error denotes an indicated load less than actual load.

Figure 2-2. Sample Load Data Worksheet

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DECKER
0 SECTION III
MAINTENANCE AND TROUBLESHOOTING
3-l. MAINTE NANC E
3-2. GENERAL. The system as described in this manual requires no maintenance. However,
general operating practices should include:
a. Cleaning indicator glass on an “as necessary” basis. This can be accomplished
by using any commercially available glass cleaning solution and a clean, soft-
lint-free cloth.
b. Visual inspection of the system prior to use; pay particular attention to the
integrity of fittings and connections (no fluid leakage) and that the load cells
are free of obstructions. Should any leakage and/or malfunction be observed,
refer to paragraph 4-2.
Note
The maintenance/repair procedures contained in this
section and Section IV are the only procedures to be
performed in the field. In situations involving a faulty
component, the component should be returned to
MARTIN-DECKER COMPANY, 1928 South Grand,
Santa Ana, California, or authorized service facility
for repair and recalibration.
3-4. TROUBLESHOOTING
3-5. If during operation, indication of system malfunction is observed (no load indication and/
or sluggish, erratic or erroneous indications) see table 3-1 for tabulation of probable
causes and their corrective actions.
TABLE 3-l. MALFUNCTION ISOLATION

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

Load Indication Improper zero (tare) Adjust zero set (tare)
Too High setting paragraph 2-11
System charge Reduce (bleed system)
over load hydraulic charge
paragraph 4-6
Load Indication Improper zero (tare) Adjust zero set (tare)
Too Low setting paragraph 2-11
Insufficient system Charge system
charge paragraph 4-6
Loose and leaking Tighten hose
hose connection connection
Leaking disconnect Replace 0 ring in female
assembly (in-line or at half of disconnect
indicator) paragraph 4-4
Obstruction in hydraulic Replace
hose or clean hose
Hydraulic hose crimped Straighten hydraulic hose and
eliminate tight bends, etc
Load cell under tension Remove tension

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DECKER
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TABLE 3-l. MALFUNCTION ISOLATION (Cont)
a- D
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Erratic or Sluggish Insufficient system Charge system
Indication charge paragraph 4-6

Incorrect damper Correct damper setting

charge paragraph 2-12

Obstruction in hose Replace or clean hose

Hydraulic Hose crimped Straighten hydraulic hose,
eliminate tight bends, etc
Load cell under tension Remove tension

No Indication Dampers closed Correct damper setting

paragraph 2-12
Load cell/cells dry Check load cell gap and
(No hydraulic fluid) charge system paragraph 4-6
Hydraulic Hose crimped Straighten hydraulic hose,
eliminate tight bends, etc
Obstruction in hose Replace or clean hose
SECTION IV
REPAIR
4-l. SYSTEM REPAIR
4-2. System repair is limited to removing a faulty component and replacing it with one in
servicable condition. This section of the manual covers repairs that may be readily
performed in the field and does not include detailed disassembly/assembly procedures
of the indicator and load cell. Field repairs consist of charging or bleeding the hydraulic
system, removing and replacing the indicator, load cell and/or hydraulic hose.
4-3. COMPONENT REPAIR
4-4. DISCONNECT 0 RING REPLACEMENT. If the 0 ring in the female half of the disconnect
becomes damaged during mating or other cause, it must be replaced to preserve the integ-
rity of the system (Refer to figure 2-l).
Remove damaged 0 ring from the female half of the disconnect.
Clean 0 ring groove thoroughly.
Lubricate (using silicone, or equivalent) and install new 0 ring (PN B651-1lA).
Disconnect is ready to be returned to service.
4-5. LOAD CELL GAP. (Refer to Figure 4-2) The load cell gap is the distance measured
between the load plate and the load cell retaining ring. The nominal gap is the proper
gap for a load cell, as specified in table 4-l. The nominal gap may vary up to &l/a-inch
to achieve system accuracy.

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m
DECKER

Figure 4-l. 0 Ring Replacement

4-6. CHARGING AND BLEEDING SYSTEM
4-7. HYDRAULIC FLUID ADDITION. The system must be kept charged with fluid at all times
to achieve proper system accuracy. A quick check for adequate fluid in the system is the
gap between load cell load plate and retainer ring. Hydraulic fluid addition is as follows:
Remove all weight from load cell.
Insure that hose is free of kinks and sharp bends.
Remove cap from F53 check valve.
Close dampers.
Attach YA2 hand pump to check valve. Do not tighten.
Fill hand pump reservoir with W15/W16 fluid.
Note
Keep hand pump reservoir at least half full at
all times to avoid introduction of air into
system.
g* Operate hand pump plunger slowly to bleed air from pump at check valve
connection.
h. When air bubbles cease, tighten hand pump to check valve connection.
i. Loosen load cell plug.
j. Pump fluid through system and bleed at load cell plug until air bubbles cease
to appear.
k. Tighten load cell plug.

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4-7. cont.
1. Pump enough fluid into the system to slightly overcharge the load cell.
m. On completion of fluid addition the load cell may need to be bleed to achieve
system accuracy. Perform system weight test paragraph 2-15.
4-8. HYDRAULIC FLUID REDUCTION. Occasionally it may be necessary to reduce the
quantity of hydraulic fluid in the system to achieve accuracy.
Remove all weight from load cells.
Zero pointer (paragraph 2-11).
Apply full scale weight to system.
If readings are fast, the load cells must be bled. If the indicated reading at
full scale is 1,000 pounds fast on a 100,000 pound system, consisting of four
load cells. Then you must determine how much to bleed each load cell. To
determine this, you must divide the number of load cells into the error.
Example:
Pounds Error 1000
Number of load cells = 4 -- 250 pounds
The error for each load cell is 250 pounds. When bleeding the system, you
must bleed twice that of the error. Therefore, each cell will be bled
500 pounds. Then the indicated reading at full scale will be 99,000 pounds.
e. On completion of step d. remove weight from load cells, then apply weight.
Repeat several times to exercise the diaphragm to the reduction of fluid in
the system.
f. Remove weight and zero pointer.
g. Apply full scale load,if indicated reading is still fast repeat steps a thru e.
If indicated reading is within tolerance, perform system weight tegt (paragraph
2-15) to insure accuracy of 25, 50, 75 and 100 percent of full scale.
TABLE 4-l. NOMINAL CELL GAP

Figure 4-2. Load Cell Gap and Plug Location

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