Hydro-Weight Master Indicator System: Service Manual

Hydro-Weight Master Indicator
System
Service Manual
REFERENCE REFERENCE DESCRIPTION
This document contains proprietary and confidential information which National Oilwell Varco
belongs to National Oilwell Varco, hereafter referred to as NOV. It is
loaned for limited purposes only and remains the property of NOV. No 1200 Cypress Creek Road
part of this document may be reproduced or copied in any form, or by any Cedar Park, Texas 78613
means, including electronic, mechanical, photocopying, recording, or
otherwise without the express written consent of NOV. This document is
USA
to be returned to NOV upon request and in any event upon completion of Phone 512-340-5000
the use for which it was loaned. All copyrights pertaining to this document Fax 512-340-5219
and the information contained and represented are the property of and
retained by NOV. Product, brand, or trade names used within this
publication are the trademarks of their respective owners.
© Copyright 2019 National Oilwell Varco. All Rights Reserved.

DOCUMENT NUMBER REV
26-70-MAN P
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Document number 26-70-MAN
Revision P
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Revision History
P 15 Jan 2019 New manual format per EN#: 1824962 GN MO VW
A-N - Revision history no extant - - -
Rev Date Reason for issue Prepared Checked Approved
Change Description
Revision Change Description

A-N Revision history no extant
P New manual format
Suggested Content Improvements
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subject and location in the document to CPTechPubs@nov.com.
Or, simply mark your suggested changes on the specific pages, scan, and email them as attachments.
Alternatively, marked-up pages can be mailed to the following address:
National Oilwell Varco
ATTN: Technical Publications
1200 Cypress Creek Road
Cedar Park, TX 78613
USA
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Table of Contents

Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2: Overview
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Weight Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Weight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 3: Installation and Functional Test

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Load Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Weight Gauge Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Functional Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 4: Periodic Inspection and Maintenance

Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Field Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Fluid Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Weight Gauge Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Hose Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Load Cell Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Weight Gauge Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shop Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load Cell Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load Cell Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Table of Contents
Weight Gauge Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Weight Gauge Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Damper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Damper Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Short Linkage Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Short Linkage Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Weight Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Related Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Approved Expendable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 5: Troubleshooting
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fault Isolation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1: General Information
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This manual contains installation, operation, maintenance and parts information. Information in this
manual should enable qualified personnel to install, operate and troubleshoot this system. Every
effort has been made to ensure the accuracy of the information contained herein. National Oilwell
Varco (NOV) will not be held liable for errors in this material, or for consequences arising from
misuse of this material.
Conventions
Notes, Cautions, and War nings
Notes, cautions, and warnings provide additional information to advise readers to take specific
action to protect personnel from potential injury or lethal conditions. They may also inform the
reader of actions needed to prevent equipment damage. Pay close attention to the advisories.
Note: The note symbol indicates that additional information is provided about the
current topics.
Caution: The caution symbol indicates that potential damage to equipment or injury to
personnel exists. Follow instructions explicitly. Extreme care should be taken
when performing operations or procedures preceded by this caution symbol.
Warning: The warning symbol indicates a definite risk of equipment damage or
danger to personnel. Failure to observe and follow proper procedures
could result in serious or fatal injury to personnel, significant property
loss, or significant equipment damage.
ESD The ESD (Electrostatic Discharge) warning symbol indicates the
Warning: potential for static electrical discharge exists, which can damage or
destroy electronic components, and can set off explosions or fires in
flammable environments. Static control precautions are needed when
encountering this symbol.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your application, see the technical drawings included with
your NOV documentation.
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Safety Requirements
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in NOV manuals are the recommended methods of performing operations
and maintenance.
To avoid injury to personnel or equipment damage, carefully observe requirements

outlined in this section.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation,
and maintenance to ensure their safety.
Personnel should wear protective gear during installation, maintenance, and certain
operations.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
NOV recommends that only those tools specified be used when stated. Ensure that personnel and
equipment safety are not jeopardized when following service procedures or using tools not
specifically recommended by NOV.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.
Read and follow the guidelines below before installing equipment or performing
maintenance to avoid endangering exposed persons or damaging equipment.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installment.
 Replace failed or damaged components with genuine NOV parts. Failure to do so could
result in equipment damage or injury to personnel.
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Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
Failure to conduct routine maintenance could result in equipment damage or injury to

personnel.
Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.
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2: Overview
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2: Overview
This manual covers the overview of the Hydro-Weight Master Indicator System.
Description
The Hydro-Weight Master System allows the operator to function more safely and efficiently by
continuously displaying the total load weight on the hook. System applications include many sizes
of oil and gas rigs including workover and service rigs. System requirements include a single drum
hoisting, and deadline configuration with the hoisting deadline anchored at a fixed point.
Weight Indicator System

The Hydro-Weight Master System (See Figure 2.1) includes a weight gauge and load cell
interconnected by a hydraulic hose assembly. The weight gauge is calibrated for the number of
lines strung to the traveling block. The load cell transforms the load weight into a hydraulic
pressure which is then transmitted through the hydraulic hose to the weight gauge. The system is
loaded, scaled, and calibrated at the factory. A hydraulic fluid hand pump, supplied with the
system, enables adding fluid as needed. Refer to Table 2.1 for leading particulars.
Weight Gauge
The box-mounted weight gauge is a 6-in. pressure gauge which uses a standard Bourdon tube
movement to drive the gauge pointer. The steel box has a removable cover for gauge protection
and welded coupling for pipe mounting. The gauge is fluid filled to reduce the effects of vibration,
to lubricate and protect working parts, and to eliminate glass frosting. The gauge is calibrated for
the number of lines strung in the traveling block and features an adjustable target pointer and an
adjustable damper. The target pointer is set for the maximum target load and the damper is set for
dial pointer sensitivity. Refer to Table 2.1 for gauge weight capacities versus the number of lines
strung.
Load Cell
The tension-type load cell assembly includes a heavy duty aluminum bronze cylinder, a hard
chrome-plated piston rod, and two shackles. The 6.53 in.2 area load cell is used with the 25,000 lb
(approximately 11,000 daN) system. The 10.8 in.2 area load cell is used with the 30,000 lb
(approximately 14,000 daN) system. The load cell piston rod is secured with dowel pins to prevent
it from turning inside the cylinder body.
Note: Non-spinning load cells prevent the O-rings from wearing out prematurely and the
deadline from unraveling.
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Figure 2.1 - Hydro-Weight Master System (Typical) Component Details
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2: Overview
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Table 2.1 Leading Particulars
System Characteristics
-50° to +150°F
Operating Temperature
-45° to + 65°C
Hydraulic Fluid W15:58P (10136015-001)
Weight 60 lb (approx.)
Weight Gauge
Size 6-in. dial
Pointer Travel 360°
Accuracy 0.5% Full Scale
Damper Adjustable
Target Pointer Adjustable
Movement Bourdon Tube
Dial Fixed
Load Cell
Types Tension Type, Cylindrical, with Steel Non-Spin Piston
0-25,000 lb (11,000 daN) (11,340 kg) 6.53 in.2

Ranges, Single Line Load
0-30,000 lb (14,000 daN) (13,608 kg) 10.8 in.2
Hydraulic Hose
Description Flexible, 1/4-in. ID, Double-Wire Braid, Rubber-Covered
Bending Radius 4 in. (min)
Working Pressure 5000 psig
Burst Pressure 20,000 psig (min)
Couplings Self-Sealing, Quick-Disconnect
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Table 2.2 Gauge Weight Capacities
SINGLE LINE PULL CAPACITIES
(pounds) (decanewtons) (kilograms) Number of lines strung
25,000 11,000 11,340 2/4, 4/6, 6/8
30,000 14,000 13,608 2/3, 2/4, 4/6, 6/8
Hydraulic Hose Assembly

The hydraulic hose is 1/4 in. ID, double-wired braid, rubber covered. It has a working pressure
rating of 5000 psig and a minimum burst pressure rating of 20,000 psig. The end connections are
1/4 in. NPT. The gauge end coupling is a brass, self-sealing, quick-disconnect fitting.
Principles of Operation
When the load cell is installed between the floor, substructure or crown, and the end of the load
deadline (Figure 3.1) the load cell senses a proportional share of the hook load. The piston in the
load cell transforms line pull (load) into a hydraulic pressure signal. This signal is transmitted
through the fluid in the hose to the Bourdon tube in the weight gauge. The Bourdon tube
movement drives the weight gauge pointer to indicate the load in pounds (daN) single line pull
times the number of lines strung. The weight gauge dial is calibrated for the number of lines strung
to the traveling block to indicate the total weight on the hook.
Related Documents
Publication Number Title
26-69-MAN Illustrated Parts Breakdown, Hydro-Weight Master Indicator System
Installation, Operation, and Maintenance Instructions, Hydraulic Gauge

29-03-MAN
Test Bench Assembly
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3: Installation and Functional Test
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This secton contains procedures for installing and adjusting the Hydro-Weight Master system
components. The system is calibrated and filled with fluid when shipped from M/D Totco (See .
"System Fluid Loading" on page 17). No special tools or electric power are required for installation.
Typical system installation details are shown in Figure 3-1.
Caution: Load rating of the mounting hardware must be heavier than the maximum load
rating of the Hydro-Weight Master Indicator System.
Installation
Load Cell Installation
The load cell must be installed in the deadline at its anchor point. To ensure correct operation, the
load cell must hang freely in all operating positions, and in proper alignment with the deadline. For
best results the pair of shackles supplied should be used in hanging the load cell.
1. See Figure 3.1, View A, for typical installations on the rig floor or substructure. Remove
shackle pins and install load cell as shown.
2. Secure load cell with shackles and pins as applicable.
Note: Load cell 6.53 is secured with 1-1/8 in. pins (16.0 tons). Load cell 10.8 is
secured with 1-1/4 in. pins (17.5 tons).
Weight Gauge Assembly Installation

The weight gauge assembly may be installed anywhere on the rig floor, so long as it is always
visible to the operator. The gauge box is equipped with a 2-in. half-coupling welded to its base to
permit installation on a 2-in. line pipe riser support.
1. See Figure 3.1, View B, for typical installation on a 2-in. pipe riser support.
2. Weld or bolt a pipe support to the rig floor or mounting plate so that the box-mounted gauge
will always be visible to the rig personnel and about eye-level height.
3. Twist the welded-on coupling at the bottom of the gauge box on to the top of the pipe riser
support.
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Figure 3.1: Hydro-Weight Master System Installation Details
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Hydraulic Hose Installation

The hydraulic hose is normally supplied already connected to the load cell. The end of the hose
which connects to the gauge is equipped with a self-sealing, quick-disconnect coupling. The hose
should be routed between the load cell and the gauge in such a manner that it is protected from
chafing or other damage. The hose should be clamped in this position, and then connected to the
gauge.
Note: The load cell/hydraulic hose assembly is factory filled with hydraulic instrument
fluid, W15:58P (10136015-001), red. If the hose is disconnected from the load cell,
the hydraulic fluid will be lost and the system will require reloading before use (Refer
to "System Fluid Loading" on page 17).
1. Remove the dust cap from the vertical (lower) hose coupling behind the gauge box.
2. Connect the hose quick-disconnect fitting to the hose coupling.
3. Reload the system with fluid (Refer to "System Fluid Loading" on page 17).
Functional Test
For functional test and startup, the rig traveling blocks and rigging should be in normal operating
positions. (Refer to "System Fluid Loading" on page 17). The gauge dial shows the weight of the
rigging as part of the total weight of the hook load. As a starting point for pointer sensitivity, the
damper T handle should be turned clockwise to fully closed and then turned counterclockwise one
full turn open. The system is now ready for operation.
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4: Periodic Inspection and Maintenance
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This section contains procedures for periodic inspection and maintenance. The periodic inspection
includes preventive maintenance and service for equipment safety, security, and cleanliness. Field
maintenance is limited to removal and replacement of the system components or major
assemblies. Detailed shop maintenance includes component disassembly, cleaning, inspection,
reassembly, and calibration (See Figure 4.1)
Periodic Inspection
The equipment should be wiped off and inspected for oil leaks, scratched or cracked glass, or
frayed hydraulic hoses. If inspection reveals any of these, the defective assembly should be
replaced to minimize down time and the faulty item returned to the nearest M/D Totco store for
more detailed shop maintenance. Hydraulic instrument fluid should be added to the system as
required for proper operation.
Field Maintenance
Field maintenance is generally limited to the removal and replacement of system components or
other easy to reach major assemblies. However, items such as leaky connector or cracked gauge
glass could be replaced and the system or gauge reloaded with fluid under field maintenance if
minimum down time does not affect overall operations.
System Fluid Loading

M/D Totco W15:58P (10136015-001) hydraulic instrument fluid (See "Approved Expendable Items
List" on page 34) should be added to the system after initial installation, during periodic inspection,
and any time the gauge, hose, or load cell is replaced.
Note: Any air entrained in the hoses, lines, or components will result in a sluggish and
possibly a low indication on the gauge.
The weight gauge (11, Figure 4.1) is fitted with a dust-protected, self-sealing, quick-disconnect
fitting (6,7,8) horizontally mounted behind the box into the gauge damper. The fitting is tee-
connected to the hose connection from the load cell. (The gauge, hose, and load cell make up the
system). To load the system with hydraulic fluid, perform the following steps:
1. Fill the hand pump bowl with instrument fluid.
2. Open the damper stem to allow fluid to circulate between the gauge (11) and the load cell (5)
through the hose (3).
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Figure 4.1: Hydro-Weight Master System (Typical)
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Legend for Figure 4.1
Item No. Description Item No. Description
1 Dust Cap 9 Elbow
2 Hose Coupling 10 Tee
3 Hydraulic Hose Assembly 11 Weight Gauge Assembly
4 Shackle 12 Bolt
5 Load Cell Assembly 13 Lock Washer
6 Dust Cap 14 Box Assembly
7 Connector Coupling 15 Hydraulic Fluid Hand Pump
8 Nipple 16 One Quart Instrument Fluid
3. Uncap the dust cap (6) from the top filling connector (7), and connect the hand pump (15) to
the connector (7). Pump in as much fluid as the system will accept from the hand pump until
the back pressure on the pump handle is felt. The gauge pointer will indicate some pre-load
value. Another field technician may observe that the load cell piston rod extends not more
than 1/4 in. from the cylinder body.
Note: During filling and purging operations the fluid level in the hand pump must be at
least half full at all times. This lessens the possibility of air being pumped into the
system with the fluid.
4. Unscrew the bleed plug at the top of the damper just enough to allow a small amount of fluid to
flow out during purging. This action will allow air entrained in the gauge or hose to escape.
Fluid flow will stop with gravity holding the fluid in the gauge. Observe that the gauge pointer
returns to zero.
5. Remove the bleed plug; wipe clean; apply pipe sealant (see "Approved Expendable Items
List" on page 34) to the first two threads. Reinstall the bleed plug hand tight. Tighten with a
wrench an additional one full turn.
6. Disconnect the hand pump (15); reinstall the dust cap (6) on the filling connector (7). The
system is now fully charged with fluid and ready for operation.
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Weight Gauge Filling

To add fluid to the gauge, perform the following steps:
1. With the gauge in an upright position, remove the screw, and seal at the top right (1 o'clock)
position on the gauge case.
2. Pour in M/D Totco W8 (10136036-001) gauge instrument fluid (clear) (Refer to "Approved
Expendable Items List" on page 34) to within 1/4 in. of the top of the gauge glass.
3. Reinstall the seal, and screw at the top of the gauge.
Note: The gauge fluid may be added while the gauge is still in the box by using an
offset screw driver and a length of flexible plastic tubing to inject the fluid.
Hydraulic Hose Removal and Replacement

If hydraulic hose is to be replaced in the field, perform the following steps:
1. With no load on the hook, remove clamps or tie-wraps securing hose to structure.
2. Clean and disconnect hose coupling (2, Figure 4.1) behind the box at the gauge coupling (7).
3. Remove hose (3) from load cell (5) cylinder body.
4. Connect new hose (3) at load cell (5) cylinder body.
5. Route new hose through structure and secure with tie-wraps or clamps.
6. Connect hose coupling (2) to gauge coupling (7).
7. Bleed and recharge system as described in "System Fluid Loading" on page 17.
Load Cell Removal and Replacement

If load cell assembly is to be replaced in the field, perform the following steps:
1. With no load on the hook, uncouple the hose connector (2, Figure 4.1) at the gauge coupling
(7). Remove hydraulic hose (3) load cell end from the load cell (5) cylinder body.
2. Remove shackle pins and remove load cell (5) from shackles (4).
3. Inspect shackles (4) and pins for wear or cracks and replace if necessary.
4. Install identical load cell (5); secure in shackles (4) with shackle pins.
5. Reconnect hydraulic hose (3) at the load cell (5) elbow.
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Weight Gauge Assembly Removal and

Replacement
If the weight gauge is to be replaced in the field, perform the following steps:
1. With no load on the hook, disconnect the hydraulic hose coupling (2, Figure 4.1) at the back
of the gauge coupling (7).
2. Remove tee (10) with all connecting hardware (6 through 9) intact.
3. Remove gauge mounting screws (12) and lock washers (13). Lift out gauge assembly (11).
4. Install replacement gauge assembly (11) in the box. Install lock washers (13) and mounting
screws (12).
5. Apply Loctite pipe sealant with Teflon (Refer to "Approved Expendable Items List" on page 34)
to threads of tee (10) and install tee into damper block in back of gauge (11).
Shop Maintenance
Detailed shop maintenance includes disassembly, cleaning, inspection, reassembly, and
calibration of the system equipment. Permanently bonded parts (welded, soldered, riveted) should
not be separated; the next higher subassembly should be replaced. All gaskets, O-rings, and seals
must be replaced. Figure 4.2 through Figure 4.5 show maintenance details in disassembly order.
Note: Good maintenance practices suggest disassembling equipment only to the level
necessary to determine whether parts subject to wear and failure are still serviceable.
Load Cell Disassembly

To disassemble the load cell (See Figure 4.2) perform the following steps:
1. Remove the elbow (3) and setscrew (4). Drain off fluid.
2. Secure load cell cylinder head (5) in a vise; unscrew load cell body (16) with a cylinder head
spanner wrench (Refer to "Related Tools and Test Equipment" on page 34). Remove gasket
(6).
3. Secure piston rod (11) in the vise. Remove setscrew (9) from piston (10). Unscrew piston (10)
from piston rod (11) with a piston spanner wrench (See "Related Tools and Test Equipment"
on page 34). Remove piston rod (11).
4. Remove and discard all O-rings and seals (8, 12 through 15).
5. Clean, degrease, and inspect parts carefully.
Caution: Do not sandblast wearing surfaces including cylinder bore, piston, and piston
rod.
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Figure 4.2: Load Cell Assembly, Non-Spin (Typical)
1 Identification Plate 9 Setscrew
2 Drive Screw 10 Piston
3 Street Elbow 11 Piston Rod
4 Setscrew 12 O-ring
5 Cylinder Head 13 O-ring
6 Flange Gasket 14 O-ring
7 Screw 15 Oil Seal
8 Oil Seal 16 Cylinder Body
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Load Cell Reassembly

To reassemble the load cell (See Figure 4.2) perform the following steps:
Note: Lubricate and reinstall new gaskets, O-rings, and seals.
1. Secure piston rod (11) in the vise. Place the cylinder body (16) over the piston rod (11).
2. Install the piston (10) on the piston rod (11), and twist on with a piston spanner wrench (Refer
to "Related Tools and Test Equipment" on page 34). Install setscrew (9).
3. Remove piston rod (11) from the vise and secure cylinder head (5) in the vise. Install gasket
(6).
4. Use cylinder head spanner wrench (Refer to "Related Tools and Test Equipment" on page 34)
to twist cylinder body (16) on the cylinder head (5). Install setscrew (4).
5. Screw a male quick-disconnect fitting in to the elbow (3); loosen screw (7), and seal (8).
6. Connect the hand pump to the male fitting; purge the load cell with hydraulic instrument fluid.
Tighten screw (7), and seal (8). Disconnect hand pump.
7. Pressurize the load cell to maximum pressure (Refer to Table 3-1. Weight Gauge Single
Line Pull Details) and check for leaks. Observe that piston rod (11) extends not more than 1/
4 in. from cylinder body (5).
8. Remove male quick-disconnect fitting and reconnect hose to elbow (3).
9. Refer to "Load Cell Removal and Replacement" on page 20 to install shackles.
Weight Gauge Disassembly

To disassemble the gauge (See Figure 4.3) remove it from the box as described in "Weight Gauge
Assembly Removal and Replacement" on page 21. Place it face up on a clean workbench and
perform the following steps:
1. Unscrew the case ring screws (2), and remove the case ring (1).
2. Lift out the gauge glass assembly (3 through 7).
3. Pour off the gauge fluid for disposal.
4. Remove and discard gauge glass O-ring (8) from case.
5. Use pointer pullers (Refer to "Related Tools and Test Equipment" on page 34) to lift off the
pointer (9) carefully.
6. Remove screws (11), lock washers (12), and dial (10).
7. Disconnect the male connector (29) from Bourdon tube (13). Remove tube mounting screws
(14), and O-rings (15); lift out the Bourdon tube assembly (13) with the linkage (19) and the
movement (23) attached.
8. Remove screw (17), and lock washer (18); lift off the movement stop (16).
9. Remove nuts (20), screws (21), linkage (19), and lock washers (22).
10. Remove screw (24), and lift off movement (23).
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11. Remove screws (26), lock washers (27); lift damper assembly (25); remove connector (29)
from bottom of damper. Remove damper (25) and tubing (28). Refer to "Damper
Disassembly" on page 27, and "Damper Reassembly" on page 28 for damper disassembly
and reassembly.
12. Loosen or remove screw (31), lock washer (32), and tube stop (30) as desired.
13. Remove screw (33) and seal (34) from top of case (35).
14. Clean, degrease, and inspect parts carefully. Lubricate and replace all gaskets, O-rings and
seals. Replace any worn or damaged parts.
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Figure 4.3: Weight Gauge Assembly (Typical)
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1 Case Ring 19 Short Linkage Assembly
2 Screw 20 Slotted Nut
3 Knurled Knob 21 Screw
4 Setscrew 22 Washer
5 O-ring 23 Movement Assembly
6 Target Pointer (Red) 24 Screw
7 Plexiglass Cover 25 Damper Assembly
8 Gauge Glass O-Ring 26 Screw
9 Pointer (Black) 27 Lock Washer
10 Dial 28 Tubing
11 Screw 29 Connector
12 Lock Washer 30 Tube Stop
13 Bourdon Tube Assembly 31 Screw
14 Tube Mount Screw 32 Lock Washer
15 O-ring 33 Screw
16 Movement Stop 34 Oil Seal
17 Screw 35 Gauge Case
18 Lock Washer
Weight Gauge Reassembly

To reassemble the gauge, place gauge case (35) face up on a clean workbench and perform the
following steps:
Note: The damper gasket, all seals and O-rings, and any worn or damaged metal
parts must be replaced with identical new parts.
Note: The filler screw (33) and seal (34) may be installed now to enable filling with
gauge fluid before glass is installed.
1. If the tube stop (30) was removed or loosened, replace and/or secure with screw (31), and
lock washer (32). Do not tighten screw (31) until after calibration (Refer to "Weight Gauge
Calibration" on page 29).
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2. Place the damper gasket over the hole pattern on top tubing (28) to the bottom of the damper
(25) with the male connector (29).
3. Install the damper (25), and secure with screws (26), and lock washers (27).
4. Secure the movement (23) to the Bourdon tube (13) with the screw (24).
5. Secure the linkage assembly (19) to the Bourdon tube (13) and the movement (23) with the
screws (21), washers (22), and nuts (20).
6. Secure the movement stop (16) to the movement (23) with the screw (17), and lock washer
(18). Do not tighten screw (17) until after calibration. (Refer to "Weight Gauge Calibration" on
page 29.)
7. Install the Bourdon tube with the movement and linkage attached into the case. Secure the
Bourdon tube (13) with the screws (14), and O-rings (15).Connect tubing (27) to the Bourdon
tube (13) with the male connector (29).
8. Calibrate the gauge movement as described in "Weight Gauge Calibration" on page 29.
9. Set the dial (10) in place with the zero at the 6 o'clock position. Secure dial (10) on the pointer
pinion. Install the pointer (9) carefully with an automatic center punch (Refer to "Related Tools
and Test Equipment" on page 34). Pointer hub should be flush with pinion end and pointer
should not touch dial.
10. Place the gauge glass O-ring (8) in its groove around the front of the case (34).
Note: Approximately 24 ounces of gauge fluid may now be poured into the gauge
case if filler screw (32) and seal (33) are installed.
11. Place the gauge glass assembly in place making sure that red target pointer does not touch
either the black pointer or the gauge glass.
12. Place case ring (1) over screw holes in case and secure with four screws (2). Tighten screws
evenly around the ring.
13. Stand gauge upright. Remove filler screw (33), oil seal (34), and add gauge instrument fluid to
within 1/4-in. of the top of the gauge glass. Replace filler screw (33), and oil seal (34).
Damper Disassembly
To disassemble the damper (See Figure 4.4) perform the following steps:
1. If the damper is screwed to the gauge case, remove screws (1) and lock washers (2);
otherwise start by removing gasket (3) and hex plug (4).
2. Male connector (5) may have been removed with tubing from the Bourdon tube, otherwise
remove it.
3. Unscrew retainer nut (10) and remove high pressure stem assembly (6 through 11).
4. Remove O-ring (6), back-up seal (7), roll pin (8), stem cap and nut (10) from stem assembly
(11).
5. Clean, degrease, and inspect parts carefully. Replace gasket, O-ring, back-up seal, and any
worn, damaged, or defective parts.
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Figure 4.4: Damper Assembly, High Pressure, Gauge Mount
1 Screw 7 Back Up Seal
2 Lock Washer 8 Roll Pin
3 Damper Gasket 9 Stem Cap
4 Plug 10 High Pressure Nut
5 Male Connector 11 High Pressure Stern
6 O-ring 12 Gauge Mount Damper Body
Damper Reassembly
To reassemble the damper (See Figure 4.4) perform the following steps:
1. Assemble parts for stem assembly (6 through 11).
2. Insert stem assembly into damper body (12) and secure with retainer nut (10).
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3. Screw in hex (bleed) plug (4) hand-tight.
Note: After weight gauge is purged and recharged with instrument fluid, apply Loctite
with Teflon pipe sealant (Refer to "Approved Expendable Items List" on page 34) to
first two threads of hex bleed plug before tightening the plug in place.
Shor t Linkage Disassembly

To disassemble the linkage assembly (See Figure 4.5) perform the following steps:
1. Remove slotted nuts (1), lock washers (2), and shoulder screws (3,4) from Bourdon tube and
movement.
2. Lift out the linkage assembly.
3. Pencil mark positions and remove nuts (5), washers (6), and slide bar (7).
4. Clean, degrease, and inspect parts carefully. Replace any worn, damaged, or defective parts.
Shor t Linkage Reassembly

To reassemble the linkage assembly (See Figure 4.5) perform the following steps:
1. Place slide bar (7) on top of linkage bar (8) with slotted end over adjusting screws (9).
2. Secure with washers (6) and elastic stop nuts (5).
3. When ready to attach to Bourdon tube tip and movement, hold slotted nut (1) behind tube tip
or movement quadrant. Insert screw (3,4) through bar and place washer (2) behind bar before
mating with slotted nut (See 15 through 18, Figure 4.3).
Note: All mounting hardware should be positioned approximately at the same

locations in the slide bar as before disassembly.
Calibration
Equipment should be calibrated before installation, or any time it is suspected of being out of
tolerance. The calibration procedures described below apply to a box-mounted weight gauge
assembly with male fittings installed for female, quick-disconnect, hose and pump connections.
Weight Gauge Calibration

To calibrate the weight gauge, perform the following steps:
Note: Be sure the Bourdon tube mechanism is loaded with hydraulic instrument fluid,
entrained air is bled off, and the damper is open. Be sure the movement assembly is
centered for proper dial alignment.
1. Drain and disassemble the gauge down to the movement as described in "Weight Gauge
Disassembly" on page 23, steps 1 through 6.
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Figure 4.5: Short Linkage Assembly
1 Slotted Nut 6 Washer
2 Washer 7 Linkage Bar Slide
3 Shoulder Screw 8 Linkage Bar
4 Shoulder Screw 9 Screw
5 Stop Nut
2. If the gauge was just repaired for parts replacement, center the linkage in the movement
quadrant slot (11, Figure 4.6) and in the Bourdon tube tip slot (9). Adjust the linkage so that
the quadrant arm (7) is parallel with the top plate of the movement (6).
3. Connect the gauge to a hydraulic pressure test bench (Refer to "Related Tools and Test
Equipment" on page 34).
4. Install the 360° calibration dial (Refer to "Related Tools and Test Equipment" on page 34) with
0° marker at the six o'clock position.
5. Set the gauge pointer (3) on its pinion (5) and pointing at about 2° to the right of zero (358°).
Note: After any linkage adjustments, turn the calibration dial so the pointer remains
about 2° to the right of zero. Do not reset the pointer during calibration.
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Figure 4.6: 6-in. Gauge Calibration Flow Diagram
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A Movement Stop 6 Movement Assembly
B Maximum Stop 7 Movement Quadrant Arm
1 Dial Face Center 8 Linkage Slide Nuts
2 Dial 9 Bourdon Tube Tip
3 Pointer 10 Linkage Assembly
4 Movement Mounting Screws 11 Slotted End of Movement Quadrant
5 Pointer Pinion Shaft 12 Linkage Attaching Screws
6. Refer to Table 3-1. Weight Gauge Single Line Pull Details for the proper calibration
pressure to apply to the test stand gauge for full scale deflection.
7. Pressurize the test bench gauge for quarter-scale indication (90°) on the calibration dial;
increase the pressure to half-scale indication (180°). Note the pointer position on the weight
gauge calibration dial. If the pointer indicates less than 88° (quarter-scale) and 176° (half-
scale) loosen screw and raise the left side of the linkage (10) in the quadrant slot (11).
Conversely, if the pointer indicates more than 92° and 184° respectively, lower the left side of
the linkage (10) in the quadrant slot (11). Tighten screw snugly.
8. Depressurize and adjust the left side linkage, and repressurize as needed until quarter-scale
and half-scale indications are within tolerance. Tighten linkage screw snugly.
9. Pressurize the test bench gauge for three-quarters scale indication (270°); increase the
pressure to full-scale indication (360°). Note the pointer (3) position on the weight gauge
calibration dial. If the pointer indicates less than 265° (three-quarters-scale) and 352° (full-
scale) loosen the linkage slide nuts (8) and shorten the linkage between the quadrant (11) and
the tube tip (9). Tighten linkage slide nuts (8) snugly. Conversely, if the pointer indicates more
than 275° and 5° (360 or zero plus 5) respectively, lengthen the linkage (10) between the
quadrant (11) and the tube tip (9).
10. Depressurize and adjust the right side linkage; and repressurize as needed until three-
quarters-scale and full-scale indications are within tolerance.
11. Tighten linkage slide nuts (8) and screws securely. Check for binding.
12. Pressure to move the quadrant to drive the pointer one full revolution around to zero. Tighten
screw (31, Figure 4.3) against the Bourdon tube stop (30) to limit pointer travel.
13. Remove pointer and calibration dial. Disconnect weight gauge from test bench.
14. Replace production dial, reinstall pointer with automatic center punch (Refer to "Related Tools
and Test Equipment" on page 34).
15. Complete reassembly as described in "Weight Gauge Reassembly" on page 26, steps 9
through 13.
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16. Tighten stem on damper (25, Figure 4.3).
Note: In the calibration flow diagram, Figure 4.6 the diamond decision blocks form an
outline for calibration procedures. The rectangles form an outline for actions to
perform based on previous decision points.
Note: To determine calibration pressure required, the full scale range of the dial face
(capacity) is divided by the size of the load cell cylinder.
Example: Full scale range 30,000 lb 2778 psig
10.8
Table 3-1. Weight Gauge Single Line Pull Details
30,000 lb
25,000 lb std single line pull
single line pull
Style
Piston Cylinder Tension Piston Cylinder Tension
Non-Spin Non-Spin
Sealing Method O-Rings O-Rings
Effective Piston Area 6.53 in.2 10.8 in.2
25,000 lb 30,000 lb
Maximum Work Load 11,000 daN 14,000 daN
11,340 kg 13,604 kg
Calibration Pressure 3828 psig 2778 psig
1/4 in. Hose with Quick- 1/4 in. Hose with Quick-Disconnect
Fittings
Disconnect
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Related Tools and Test Equipment

Part Number Description
T847-1 (10135703-002) Pointer Puller Tool
999776 (10125191-001) Automatic Center Punch (Starrett)
211075 (10034775-001) Calibration Dial, 6 in. Gauge, 360°
210986:58P High Pressure Test Bench Assembly
212818:58P Vacuum Pump Assembly
J996:58P (10130627-003) Nipple, Pipe, Hex
970621-005 (10122703-001) Quick-Disconnect Fitting
211457-101 (10035017-001) Spanner Wrench, 4.0 and 6.53 Piston
211457-103 (16616213-001) Spanner Wrench, 10.8 Piston
212331-102 (10035695-002) Spanner Wrench, 4.0 and 6.53 Cylinder Head
212331-101 (10035695-001) Spanner Wrench, 10.8 Cylinder Head
968601-003 (10122452-001) Elbow
Approved Expendable Items List

Part Number Description
W8 (10136036-001) Instrument Fluid, M-8, Clear, 1-qt Can
W15:58P (10136015-001) Instrument Fluid, M-15, Red, 1-qt Can
991201-023 (10123699-001) Pipe Sealant with Teflon (Loctite)
992405-001 (10123792-001) Silicon Lubricant
992417-001 (10123807-001) Trichloroethylene Solvent or Equivalent
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5: Troubleshooting
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5: Troubleshooting
This section contains information for isolating and correcting troubles which may arise during
operation, calibration or test of the weight indicator. Refer to Table 5-1. Troubleshooting Table,
for help in isolating troubles and for suggested remedies. After service or repair, adjust and
calibrate the unit before returning it to service.
Troubleshooting Table
Table 5-1. Troubleshooting Table
TROUBLE PROBABLE CAUSE REMEDY
Obstruction in hose. Purge or replace hose.
Loss of hydraulic fluid. Reload with hydraulic fluid.

No indication on gauge. Gauge internal mechanism
Replace gauge.
damaged.
Worn quick-disconnect fitting. Replace fitting.
Load cell improperly positioned. Reposition load cell.
Incorrect zero dial setting. Adjust or calibrate as required.

Gauge indication too high. Excessive hydraulic fluid. Bleed off hydraulic fluid.
Gauge internal mechanism

Replace gauge.
damaged.
Load cell improperly positioned. Reposition load cell.
Incorrect zero dial setting. Adjust or calibrate as required.

Gauge indication too low. Insufficient hydraulic fluid. Pump in additional hydraulic fluid.

Replace gauge.
damaged.
Improper pointer damper Open or close damper stem as

adjustment. required.
Remove glass and straighten

Pointer rubbing glass or dial.
pointer.
Erratic or sluggish gauge
indication. Insufficient hydraulic fluid. Pump in additional hydraulic fluid.
Sticky gauge movement. Replace gauge.

Replace gauge.
damaged.
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Page 36 of 37
TROUBLE PROBABLE CAUSE REMEDY
Excessive fluid preload. Bleed off fluid.
Faulty movement. Recalibrate or replace movement.

Gauge pointer does not
return to zero. Pointer bent, dragging. Straighten pointer.
Worn quick-disconnect fitting. Replace fitting.
Gauge pointer tracks to a

Low fluid. Recharge gauge or system.
given point, then stops.
Fault Isolation Diagram

The Fault Isolation Diagram, Figure 5.1 is a graphic illustration to help the technician in isolating
and correcting faults in the Hydro-Weight Master System. The diamond decision blocks form an
outline for troubleshooting procedures. The rectangles form an outline of actions to perform based
on the previous decision points.
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5: Troubleshooting
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IF AFTER INSPECTING THE SYSTEM

AND DSCUSSING SYMPTOMS WITH
CONNECT HOSE TO DISCONNECT HOSE FROM START RIG PERSONNEL. THE PROBLEM IS
HYDRAULIC TEST SYSTEM INDICATOR ASSEMBLY NOT EVIDENT. FOLLOW THE
PROCEDURES OUTLINED IN THIS
CHART.
PRESSURE PRESSURE NO INSPECT LOAD

SYSTEM TO 100 PSI HOLD CELL FOR LEAKS
YES
NO LOAD CELL REMOVE LOAD

RESTRICTION CELL
LEAK
PRESENT YES
YES NO
INSTALL NEW LOAD
REMOVE CELL
RESTRICTIONS
LOAD CELL NO
CHARGED REMOVE HOSE
HOSE
YES
DAMAGED
YES
RECHARGE
DISCONNECT INSTALL NEW HOSE AND
NO HOSE
HOSE FROM LOAD CELL
TEST SYSTEM
INSPECT HANSEN DETERMINE GAUGE REPLACE STEM

COUPLERS FOR CALIBRATION O-RING
WEAR PRESSURE
COUPLERS NO
WORN
PRESSURE SYSTEM TO RECHARGE GAUGE

YES CALIBRATE PRESSURE ASSEMBLY
REPLACE WORN
COUPLERS
PRESSURE REMOVE INSTALL NEW

HOLD GAUGE GAUGE
NO
YES
GAUGE FULL
SCALE
NO
YES
TERMINATE RESTORE SYSTEM TO

OPERATIONAL STATUS GAUGE
ASSEMBLY
Figure 5.1: Hydro-Weight Master System Fault Isolation Diagram
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Hydro-Weight Master Indicator System: Service Manual

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Hydro-Weight Master Indicator

REFERENCE REFERENCE DESCRIPTION

© Copyright 2019 National Oilwell Varco. All Rights Reserved.

Revision Change Description

Suggested Content Improvements

Chapter 3: Installation and Functional Test

Chapter 4: Periodic Inspection and Maintenance

To avoid injury to personnel or equipment damage, carefully observe requirements

General System Safety Practices

 Isolate energy sources before beginning work.

Failure to conduct routine maintenance could result in equipment damage or injury to

Proper Use of Equipment

Weight Indicator System

Figure 2.1 - Hydro-Weight Master System (Typical) Component Details

Table 2.1 Leading Particulars

Hydraulic Fluid W15:58P (10136015-001)

Size 6-in. dial

Pointer Travel 360°

Accuracy 0.5% Full Scale

Target Pointer Adjustable

Movement Bourdon Tube

Types Tension Type, Cylindrical, with Steel Non-Spin Piston

0-25,000 lb (11,000 daN) (11,340 kg) 6.53 in.2

Description Flexible, 1/4-in. ID, Double-Wire Braid, Rubber-Covered

Bending Radius 4 in. (min)

Working Pressure 5000 psig

Burst Pressure 20,000 psig (min)

Couplings Self-Sealing, Quick-Disconnect

Table 2.2 Gauge Weight Capacities

SINGLE LINE PULL CAPACITIES

(pounds) (decanewtons) (kilograms) Number of lines strung

25,000 11,000 11,340 2/4, 4/6, 6/8

30,000 14,000 13,608 2/3, 2/4, 4/6, 6/8

Hydraulic Hose Assembly

26-69-MAN Illustrated Parts Breakdown, Hydro-Weight Master Indicator System

Installation, Operation, and Maintenance Instructions, Hydraulic Gauge

3: Installation and Functional Test

Weight Gauge Assembly Installation

Figure 3.1: Hydro-Weight Master System Installation Details

Hydraulic Hose Installation

4: Periodic Inspection and Maintenance

System Fluid Loading

Figure 4.1: Hydro-Weight Master System (Typical)

Legend for Figure 4.1

Item No. Description Item No. Description

1 Dust Cap 9 Elbow

2 Hose Coupling 10 Tee

3 Hydraulic Hose Assembly 11 Weight Gauge Assembly

5 Load Cell Assembly 13 Lock Washer

6 Dust Cap 14 Box Assembly

7 Connector Coupling 15 Hydraulic Fluid Hand Pump

8 Nipple 16 One Quart Instrument Fluid

Weight Gauge Filling

Hydraulic Hose Removal and Replacement

Load Cell Removal and Replacement

Weight Gauge Assembly Removal and

Load Cell Disassembly

Figure 4.2: Load Cell Assembly, Non-Spin (Typical)

Legend for Figure 4.2

Item No. Description Item No. Description

1 Identification Plate 9 Setscrew

2 Drive Screw 10 Piston

3 Street Elbow 11 Piston Rod