Hydro-Mast Weight

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 part of this 1200 Cypress Creek Road
document may be reproduced or copied in any form, or by any means, Cedar Park, Texas 78613
including electronic, mechanical, photocopying, recording, or otherwise
without the express written consent of NOV. This document is to be returned
USA
to NOV upon request and in any event upon completion of the use for which Phone 512-340-5000
it was loaned. All copyrights pertaining to this document and the Fax 512-340-5219
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

26-72-MAN (P/N 18016105-001) 02

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Revision History

Rev Date Reason for issue Prepared Checked Approved

01 - Initial Release - - -
02 22 July 2019 New manual format per EN#: 1884938 GN MO SS

Change Description

Revision Change Description

01 Initial Release
02 New manual format

Suggested Content Improvements

We welcome your suggestions to improve the content of this document. Please email them along with their
subject and location in the document to WB-USA-MDTTechPubs@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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 2: Overview
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Weight Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Weight Gauge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hook Load Weight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mast Load Weight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Integrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Load Cell Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Principles Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
One Pad System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Two Pad System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 3: Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dual Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Table of Contents
Chapter 4: Periodic Inspection and Maintenance
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Field Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Gauge and Damper Fluid Loading Single-Pad System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Gauge and Integrator Fluid Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Load Cell Pad And Hose Fluid Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Load Cell/Hose Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Weight Gauge Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Shop Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Load Cell Pad Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Load Cell Pad Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Back-Mounted, 6-in. Gauge Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Back-Mounted, 6-in. Gauge Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Damper Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Damper Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Short Linkage Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Short Linkage Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Panel-Mounted, 6-in. Gauge Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Panel-Mounted, 6-in. Gauge Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Panel-Mounted, 8-1/2 in. Gauge Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Panel-Mounted, 8-1/2 in. Gauge Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure Integrator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure Integrator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Weight Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Related Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Approved Expendable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Chapter 5: Troubleshooting
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fault Isolation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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1: General Information

This manual contains installation, operation, troubleshooting, and parts information,

which should enable qualified personnel to install, operate, maintain, 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 manual or for consequences arising from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information and advise
them 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.
The note symbol indicates that additional information is provided about
Note: the current topics.

The caution symbol indicates that potential damage to equipment or injury

to personnel exists. Follow instructions explicitly. Extreme care should be
Caution:
taken when performing operations or procedures preceded by this caution
symbol.
The warning symbol indicates a definite risk of equipment damage or
danger to personnel. Failure to observe and follow proper procedures
Warning:
could result in serious or fatal injury to personnel, significant property
loss, or significant equipment damage.
ESD The ESD (Electrostatic Discharge) warning symbol indicates that static
Warning: control precautions are needed.

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.
Caution: 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.
Caution: 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.
Caution: 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.
Caution: 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.

Related Documents
Publication No. Title

26-71 Illustrated Parts Breakdown, Hydro-Mast Weight Indicator System

Installation, Operation and Maintenance Instructions, Hydraulic

29-03
Gauge Test Bench Assembly

29-04 Illustrated Parts Breakdown, Hydraulic Gauge Test Bench Assembly

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2: Overview

This manual contains installation, operation, and maintenance instructions for the
Hydro-Mast weight indicator system manufactured by M/D Totco. Information in this
manual is intended for the skilled technician to install, operate, and service the system
with standard hand tools.
Note: Unless otherwise specified, the instructions contained in this manual apply to
both the 6-in. gauge and the 8-1/2 in. gauge weight indicator systems (English, SI Units,
and Metric). When ordering parts or requesting service, be sure to state which type
weight indicator system is to be serviced.

Purpose
The Hydro-Mast weight indicator is a rugged, hydraulically operated instrument
system, constructed for rigs with a hook load capacity of up to approximately
300,000 lbs. Typical applications include truck-mounted and workover rigs. The gauge
assembly displays total hook load and relative mast load (except for single pad
systems) whether the deadline is fastened to the anchor, traveling block, or crown,
running double fast line or swabbing with sand line.

Description
Weight Indicator System
Each weight indicator system (See Figure 2.1 through Figure 2.3) includes:
 A weight indicator gauge assembly.
 One or two pad type compression load cells.
 Interconnecting hydraulic hoses with quick disconnect fittings at the gauge end.
 Hydraulic instrument fluid and a hand pump.
Figure 2.1 on page 12 shows a 6-in. gauge system with one load cell pad (HM-6-1).
Figure 2.2 on page 13 shows a 6-in. gauge system with two load cell pads (HM-6-2).
Figure 2.3 on page 14 shows an 8-1/2 in. gauge system with two load cell pads (HM-8-2).
Refer to "Leading Particulars" on page 15 for leading particulars. The weight gauge
assembly is housed in a protective steel box. A coupling welded to the box bottom
enables mounting the gauge assembly on a pipe stand. The load cell pad is set under
the mast leg(s) to sense the weight of the mast and the hook load. The weight gauge
assembly is connected to the load cell(s) with a 1/4-in. ID, flexible, hydraulic hose line.
These system components are described in detail in the following paragraphs.

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Figure 2.1: Hydro-Mast (HM) Weight Indicator System, 6-in. Gauge and One Load Cell Pad
(Typical)

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Figure 2.2: Hydro-Mast (HM) Weight Indicator System, 6-in. Gauge and Two Load Cell Pads
(Typical)

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Figure 2.3: Hydro-Mast (HM) Weight Indicator System, 8-1/2 in. Gauge and Two Load Cell
Pads (Typical)

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Leading Particulars
System Characteristics

Operating Temperature -50° to +150°F

-45° to +65°C

Hydraulic Fluid W15:58P (10136015-001) instrument fluid (red)

Hook Load Weight Gauge

Size 6-in. or 8-1/2 in. dial

Pointer Travel 360°
Accuracy 0.5% Full Scale
Damper Adjustable
Target Pointer Adjustable
Movement Bourdon Tube
Dial Zero Adjustable

Mast Load Relative Weight Gauge

0-110 relative
0-160 relative

Pad Type Load Cell

Type Compression type, piston, and cylinder body

150,000 lb (max)
Working load
50 in.2 effective area

Hydraulic Hose

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

Covered
Bending Radius 4 in. (min)
Working Pressure 5000 psig (max)
Burst Pressure 20,000 psig (min)
Couplings Self-Sealing, Quick-Disconnect

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Weight Gauge Assembly

A typical weight gauge assembly (Figure 2.4) includes:
 A protective steel box with door(s).
 A hook-load weight gauge.
 Two mast-load relative weight gauges (two load cell systems).
 An integrator (two load cell systems).
These parts are described in detail in the following paragraphs.
Steel Box
1. The size of the steel box (three options available) depends on the diameter of the
weight gauge and the space requirement for mast load gauges and an integrator.
2. A 2 in. diameter coupling is welded to the bottom of the box to enable pipe stand
mounting on the rig.
3. Removable front and back doors protect the gauges during shipment,
installation, and removal.

Figure 2.4: Weight Gauge Assembly (Typical) Details

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Hook Load Weight Gauge

1. The hook load weight gauge (Figure 2.5) is a direct reading hydraulic pressure
gauge with a pointer driven by a Bourdon tube movement.
2. The gauge may be either 6-in. or 8-1/2 in. diameter depending on the system
selected for the weight range to be monitored.
3. Both size gauges have zero adjustable dials calibrated to display total hook load
weights in pounds, decanewtons, or kilograms. The 6-in. gauge has a standard
(simple) movement and pointer.
4. The 8-1/2 in. gauge has a 4:1 ratio geared (compound) movement and two
pointers, one for a vernier calibrated dial.
5. The gauge is fluid-filled to lubricate the movement and to eliminate the
possibility of glass frosting.

Figure 2.5: Hook Load Weight Gauge (Typical) Details

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Mast Load Weight Gauge

1. The mast load weight gauges (Figure 2.6) below the hook load gauge on the steel
box panel indicate relative weight.
2. Weight of the mast legs is sensed by the pad type load cell and is transmitted to
the mast load weight gauges as a hydraulic pressure signal. As the mast legs are
leveled on the pads (Figure 3.1) the weights of the mast legs may be balanced by
observing the mast load gauges.
3. The gauges are available in 0-50, 0-110, and 0-160 dial ranges depending on the
weight ranges to be monitored.

Figure 2.6: Mast Load Relative Weight Gauge (Typical)

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Pressure Integrator
The hydraulic pressure integrator (Figure 2.7) is essentially two piston and cylinder
devices mechanically coupled. When hydraulic pressure is applied to these pistons, the
combined resultant force is applied to a third piston surface which compresses the
hydraulic fluid, transmitting a pressure signal to the hook load weight gauge. Stated
another way, the integrator receives two signals which are summed algebraically and
displayed on the hook load weight gauge.

Figure 2.7: Pressure Integrator Top View Details

Load Cell Pad Assembly

The pad type compression load cell (Figure 2.8) consists of a heavy duty hydraulic
piston and cylinder body with rubber O-ring seals. Maximum load for the load cell is
150,000 lbs. As the load cell is positioned under a mast leg, the weight exerted on the
load cell pad compresses the fluid in the chamber. Fluid compression transmits a signal
from the fluid chamber to the weight gauge through the hydraulic hose. Either one or
two load cells are used depending on the type of mast. The number of lines strung
makes no difference.
Considered part of the load cell pad assembly, the hydraulic hose is 1/4-in. I.D., double
wired braid, rubber covered. It has a working pressure rating of 5,000 psig and a
minimum burst pressure rating of 20,000 psig. The end connections are 1/4-in. NPT
steel. The gauge end coupling is a self-sealing, quick-disconnect fitting.

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Figure 2.8: Pad-Type Compression Load Cell With Hose Assembly, Details

Principles Of Operation
One Pad System
1. When the system components are properly installed and checked (see
"Installation" on page 23) the load cell senses the total weight of the mast and
hook load.
2. The weight gauge is set for zero with the hook empty and the target pointer (red)
is set for the maximum weight desired by the user.
3. When the hook is loaded, the piston in the load cell transforms the line pull (load)
into a hydraulic pressure signal. The signal is transmitted through the fluid in the
hose to the Bourdon tube in the gauge.
4. Action of the Bourdon tube on the movement drives the gauge pointer (black) to
indicate the hook load weight.

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Two Pad System

1. When the system components are properly installed and checked (see
"Installation" on page 23) each load cell senses about half the total of the mast
and hook load. The weight gauge is set to zero with the hook empty.
2. The target pointer (red) on the 6-in. gauge is set for the maximum target weight
capacity of the system. (The 8-1/2 in. gauge has no target pointer.)
3. When the hook is loaded, the piston in each load cell transforms the line pull
(load) into a hydraulic pressure signal. The signal from each cell is transmitted to
both the mast load relative weight gauges and to the pressure integrator.
4. The outputs from each half of the integrator are summed and channeled to the
Bourdon tube in the hook load weight gauge.
5. Action of the Bourdon tube on the movement (compound, geared) drives the
black pointer to indicate a coarse hook load weight. The movement drives the red
pointer (a 4:1 ratio vernier) to indicate a vernier hook load weight.

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3: Installation

This section contains procedures for installing and adjusting the Hydro-Mast system.

Installation
The system is calibrated and filled with instrument fluid when shipped from M/D Totco.
Refer to "Gauge and Damper Fluid Loading Single-Pad System" on page 27 for system
fluid loading. No special tools or electric power are required for installation. Typical
system outline and dimensions are shown in Figure 3.1.
Each hydro-mast weight indicator system is delivered fully operational for the hook
load weight range selected. The only special parts required for installation are a length
of 2-in. pipe and hardware for pipe stand mounting suitable for the individual rig.
"Leading Particulars" on page 15 lists the leading particulars for both the 6-in. and the
8-1/2 in. gauge weight indicator systems.
Caution: Make sure the dial range is correct for the hook load weight
range of the rig.

To install typical hydro-mast system components (Figure 3.2), perform the following
steps:
Caution: The base for the load cell pad must be made with non-yielding
materials such as timbers or reinforced slab or steel I-beams.

Note: Make sure all weight indicator system components are fully
charged with instrument fluid and the system has been calibrated.

1. Weld or bolt a length of 2-in. pipe to the rig floor or mounting plate. Pipe should
be long enough so that the box mounted gauge is at about eye level for the driller.
2. Install the box mounted gauge on the pipe riser support. A hammer union
connection is typical.
3. Place the load cell pad(s) under the mast leg adjusting screw(s).
4. Route the hose(s) through protected area and connect to the back of the gauge.
Hoses must be slack.
5. Lower the mast leg adjusting screw(s) to contact the centering guide(s) in the top
of the load cell pad(s).
6. Using mast leg adjustment, preload weight gauge to recommended value. Refer
to Note above.
7. Set the target pointer for maximum target load.

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Figure 3.1: Hydro-Mast System Outline and Dimensions

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Figure 3.2: Hydro-Mast Weight Indicator Installation (Typical)

Note: In a single mast system, the mast load is indicated as a preload on

the weight gauge. In a dual mast system, the mast loads are equalized as
the screws are lowered and observed on the relative weight gauges. Typical
weight on each mast leg is 3,000 to 5,000 lbs.

Functional Test
Single Mast System
For functional test and startup, the traveling block and rigging should be in normal
operating position. The hook load weight gauge dial should be zeroed to cancel out the
weight of the rigging, and thereby display only the hook load. The target pointer is set
to maximum target 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.
Dual Mast System
For functional test and startup, the traveling block and rigging should be in normal
operating position. The hook load gauge dial should be zeroed to cancel out the weight
of the rigging. This action sets the gauge to indicate only the hook load. Dual mast load
weight (3,000 to 5,000 lbs, typical each leg) is indicated on the relative weight gauges.

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4: Periodic Inspection and Maintenance

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 (Figure 4.1
through Figure 4.3).

Periodic Inspection
The equipment should be wiped off and inspected for fluid 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. System fluid
loading is described in "Gauge and Damper Fluid Loading Single-Pad System" on page
27 through "Load Cell Pad And Hose Fluid Loading" on page 33.

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 a 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.
Gauge and Damper Fluid Loading Single-Pad System
M/D Totco W15:58P (10136015-001) hydraulic instrument fluid (refer to "Approved
Expendable Items List" on page 60) should be added to the gauge and damper before
initial installation, during periodic inspection, and any time the gauge, hose, or load
cell is replaced. To load the gauge and damper, perform the following steps:
Warning: All weight must be removed from the load cell pad before removing or
disconnecting system components.

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Figure 4.1: Hydro-Mast (HM) Weight Indicator System, 6-in. Gauge and One Load
Cell Pad (Typical)

Item No. Description Item No. Description

1 Load Cell Pad Assy with Hose 7 Elbow

2 Hand Pump Assy 8 Tee
3 Instrument Fluid 9 Weight Gauge
4 Dust Cap 10 Screw
5 Connector 11 Lock Washer
6 Nipple 12 Box
13 Door
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To load the gauge and damper, perform the following steps:

1. Fill the hand pump bowl with instrument fluid.
2. Set the gauge dial to zero with the zero adjusting knob. Open the damper stem to
allow fluid to circulate between the gauge (9) and the load cell (1) through the
hose.
3. Remove the dust cap (4) from the upper filling connector (5); connect the hand
pump (2) to the connector (5). Pump in as much fluid as the system will accept
from the hand pump until you feel the back pressure on the pump handle. The
gauge pointer will indicate some pre load value.
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 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 (refer to "Approved
Expendable Items List" on page 60) to the first two threads. Reinstall the bleed
plug.
6. Disconnect the hand pump (2); reinstall the dust cap (4) on the filling connector
(5). The gauge and damper are now fully charged with fluid and ready for
operation.

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Gauge and Integrator Fluid Loading

M/D Totco W15:58P (10136015-001) hydraulic instrument fluid (refer to "Approved
Expendable Items List" on page 60) should be added to the gauge and integrator before
initial installation, during periodic inspection, and any time the gauge, hose, or load
cell is replaced.
Warning: All weight must be removed from the load cell pad before removing
or disconnecting system components.

Note: Any air entrained in the hoses, lines, or components will result in a sluggish
and possibly low indication on the gauge.

To load the gauge and integrator, follow the steps below:

1. Remove the top dust caps (5, Figure 4.2 and Figure 4.3) and install open female
disconnect fittings on the male connectors (6).
2. Loosen the tube fitting on the back of the damper junction block at the top of the
gauge.
3. Remove the pipe plug from the tee in the end of the integrator; install male
connector; connect the hand pump.
4. Fill the hand pump bowl with M/D Totco W15:58P (10136015-001) instrument fluid
(refer to "Approved Expendable Items List" on page 60).
5. Pump fluid into the integrator and gauge lines until the piston rod opposite the
tee is fully extended and bubble-free fluid is flowing from the gauge tubing.
6. Tighten the fitting at the damper junction block hand tight plus three-eighths
turn.
7. Remove female disconnect fittings. Disconnect the pump.
8. Place the weight gauge assembly on its back.
9. Remove the male connector from the tee.
10. Apply pipe sealant (refer to "Approved Expendable Items List" on page 60) to
bleed plug and reinstall.

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Figure 4.2: Hydro-Mast (HM) Weight Indicator System, 6-in. Gauge and Two Load Cell Pads
(Typical)

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Legend for Figure 4.2

Item No. Description Item No. Description

1 Load Cell Pad Assy with Hose 14 Coupling

2 Hand Pump Assy 15 Mast Load Gauge
3 Instrument Fluid 16 Nut
4 Box Door 17 Integrator
5 Dust Cap 18 Screw
6 Connector 19 Lock Washer
7 Nipple 20 Hook Load Gauge
8 Elbow 21 Bolt
9 Elbow 22 Nut
10 Connector 23 Identification Plate
11 Junction Block 24 Screw
12 Bolt 25 Box
13 Nut 26 Tubing

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Load Cell Pad And Hose Fluid Loading

To load fluid in the load cell pad and hose, perform the following steps:
Warning: All weight must be removed from the load cell pad before
removing or disconnecting system components.

1. Install two male couplings into a hose coupling (refer to "Related Tools and Test
Equipment" on page 60). Connect the hose assembly coupling (5, Figure 4.4) to
one of the male couplings.
2. Loosen bleed plug (3, Figure 4.4) in load cell cylinder.
3. Connect hand pump to the other male coupling; fill the pump bowl with
instrument fluid (refer to "Approved Expendable Items List" on page 60).
4. Pump fluid through the hose into the load cell until any entrained air is purged
from the hose and load cell. Continue until the bottom of the slots in the piston
ears are within 1/16-in. of the cap screws.
5. Upend the load cell; remove the bleed plug; wipe clean and add pipe sealant
(refer to "Approved Expendable Items List" on page 60). Reinstall bleed plug.
6. Disconnect the hand pump and double male coupler from the end of the hose.
7. Reconnect the hose to the weight gauge assembly before returning the mast load
weight to the load cell pad.
Caution: Handle the load cell pad with the handles provided; do not lift or drag
load cell by the hose.

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Figure 4.3: Hydro-Mast (HM) Weight Indicator System, 8-1/2 in. Gauge and Two Load Cell
Pads (Typical)

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Legend for Figure 4.3

Item No. Description Item No. Description

1 Load Cell Pad Assy with Hose 14 Coupling

2 Hand Pump Assy 15 Mast Load Gauge
3 Instrument Fluid 16 Nut
4 Box Door 17 Integrator
5 Dust Cap 18 Screw
6 Connector 19 Lock Washer
7 Nipple 20 Hook Load Gauge
8 Elbow 21 Bolt
9 Elbow 22 Nut
10 Connector 23 Identification Plate
11 Junction Block 24 Screw
12 Bolt 25 Box
13 Nut 26 Tubing

Load Cell/Hose Removal and Replacement

If either or both the load cell and hose are to be replaced, perform the following steps:
Warning: All weight must be removed from the load cell pad before removing or
disconnecting system components.

1. Raise the mast leg adjusting screw (Figure 3.2) up off the load cell pad.
2. Disconnect hose from gauge assembly connector (Figure 2.2). Replace dust caps
on hose and gauge assembly connectors.
3. Unscrew hose from load cell pad (Figure 2.8) if load cell pad or hose is to be
replaced.
4. Replace load cell pad, hose, or both, as required.
5. Recharge load cell pad and hose as described in "Load Cell Pad And Hose Fluid
Loading" on page 33.
6. Connect the hose to the gauge assembly.
7. Lower the mast leg adjusting screw to contact the load cell centering guide.
8. Balance the mast loads as observed on the relative weight gauges (5,000 lbs mast
load will be shown as about 5 on the gauge).
9. Turn the hook load weight gauge dial to zero.

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Weight Gauge Assembly Removal and Replacement

To replace the weight gauge assembly in the field, perform the following steps:
Warning: All weight must be removed from the load cell pad before removing or
disconnecting system components.

1. Raise the mast leg adjusting screw (Figure 3.2) up off the load cell pad.
2. Disconnect hose from gauge assembly connector (Figure 4.1, Figure 4.2, and
Figure 4.3). Replace dust caps on hose and gauge assembly connectors.
3. Disconnect the boxed weight gauge assembly from its mounting.
4. Install an identical operational boxed weight gauge assembly as the one
removed.
5. Reconnect hose at gauge assembly connector.
6. Recharge system as needed (refer to "Gauge and Damper Fluid Loading Single-
Pad System" on page 27 through "Load Cell Pad And Hose Fluid Loading" on page
33).

Shop Maintenance
Detailed shop maintenance includes disassembly, cleaning, inspection, reassembly,
and calibration of the system equipment.
Note: Good maintenance practices suggest disassembling equipment only to the
level necessary to determine whether parts subject to wear and failure are still
serviceable.
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 4.4 through Figure 4.10 show maintenance details.
Load Cell Pad Disassembly
Disassemble the load cell pad assembly (Figure 4.4) as follows steps:
Caution: Handle the load cell pad with the handles provided; do not lift or drag load
cell by the hose. Loosen bleed plug (3, Figure 4.4) to bleed off fluid and to
depressurize load cell.
1. Remove identification plate (1) and drive screws (2) if required.
2. Remove bleed plug (3); pour off and dispose of fluid.
3. Remove handle (11) and screws (12) as needed.
4. Remove dust cap (4), coupling (5), and hose (6).
5. Remove socket head screws (8) from inside piston (7) openings.

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6. Insert a low pressure (under 15 psi) air line into the hose opening in the cylinder
(13). Turn on the air to separate the piston (7) from the cylinder (13).
7. Remove the piston O-ring (9) and the cylinder O-ring (10) and discard.
8. Clean and degrease all parts.

Figure 4.4: Load Cell Pad Assembly, Hydro-Mast System

Legend for Figure 4.4

Item No. Description Item No. Description

1 Identification Plate 7 Piston

2 Drive Screw 8 Setscrew
3 Bleed Plug 9 Piston O-ring
4 Dust Cap 10 Cylinder O-ring
5 Coupling 11 Handle
6 Hose Assy 12 Screw
13 Cylinder

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Load Cell Pad Reassembly

Reassemble the load cell pad (Figure 4.4) as follows steps:
Note: Make sure new piston O-ring (9) and cylinder O-ring (10) have been installed and
lubricated.

1. Place cylinder (13) on a clean work bench.

2. Place the piston (7) on the cylinder (13).
3. Align piston openings with screw holes in the cylinder. Insert screws (8) and
tighten evenly.
4. Install hose (6) with coupling (5) and chain for dust cap (4).
5. Install handle (11) with screws (12) as needed.
6. Install bleed plug (3).
7. Install identification plate (1) with drive screws (2) as needed.
8. Purge and charge load cell and hose as described in "Load Cell Pad And Hose
Fluid Loading" on page 33.
Back-Mounted, 6-in. Gauge Disassembly
To disassemble the back-mounted gauge (Figure 4.5) remove box-mounting hardware,
place the gauge face up on a clean work bench, 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 puller (refer to "Related Tools and Test Equipment" on page 60) to
carefully lift off the pointer (9).
6. Remove snap ring (10) and dial (11).
7. Disconnect the male connector (28) from Bourdon tube (12). Remove tube
mounting screws (13), and O-rings (14); lift out the Bourdon tube assembly (12)
with the linkage (18) and the movement (22) attached.
8. Remove screws (16) and lock washers (17); lift off the dial mount (15).
9. Remove nuts (19), screws (20), linkage (18), and lock washers (21).
10. Remove screws (23) and lift off movement (22).

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11. Remove screws (25), lock washers (26); lift damper assembly (24); disconnect
connector (28) from bottom of damper. Remove damper (24) and tubing (27).
(Refer to "Damper Disassembly" on page 42 and "Damper Reassembly" on page
44 for damper disassembly and reassembly.)
12. Loosen or remove screw (30), lock washer (31) and tube stop (29) as desired.
13. Remove setscrew (32); remove zero adjust drive (33), O-ring (34), housing nut (35),
O-ring (36), and zero adjust gear (37).
14. Remove screw (38) and seal (39) from top of case (40).
15. 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 4.5: 6-in. Gauge Assembly, Back Mount, Back Zero Adjust (Typical)

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Legend for Figure 4.5

Item No. Description Item No. Description

1 Case Ring 21 Washer

2 Screw 22 Movement Assy
3 Knurled Knob 23 Screw
4 Setscrew 24 Damper Assy
5 O-ring 25 Damper Mounting Screw
6 Target Pointer (Red) 26 Lock Washer
7 Plexiglass Cover 27 Tubing
8 Gauge Glass O-ring 28 Connector
9 Pointer (Black) 29 Tube Stop
10 Snap ring 30 Screw
11 Dial 31 Lock Washer
12 Bourdon Tube Assy 32 Setscrew
13 Tube Mounting Screw 33 Zero Adjust Drive Assy
14 O-ring 34 O-ring
15 Dial Mount 35 Housing Nut
16 Screw 36 O-ring
17 Lock Washer 37 Zero Adjust Gear
18 Short Linkage Assy 38 Screw
19 Slotted Nut 39 Seal
20 Screw 40 Gauge Case

Back-Mounted, 6-in. Gauge Reassembly

To reassemble the gauge, place gauge case (40) face up on a clean workbench and
perform the following steps:
Note: The damper gasket, all seals, O-rings, and any worn or damaged metal parts
must be replaced with identical new parts.

1. Assemble the zero adjust assembly (33 through 37, Figure 4.5) and install through
the back of the gauge case (40). Replace setscrew (32) in zero adjust gear (37).
2. If tube stop (29) was removed or loosened, replace and/or secure with screw (30)
and washer (31). Do not tighten screw (30) until after calibration (refer to
"Calibration" on page 56).

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3. Place the damper gasket over the hole pattern on top of the gauge case (40).
Secure the damper end of the tubing (27) to the bottom of the damper (24) with
the male connector (28).
4. Install damper (24) and secure with screws (25), and lock washers (26).
5. Secure the movement (22) to the Bourdon tube assembly (12) with the screws
(23).
6. Secure the linkage assembly (18) to the Bourdon tube (12) and the movement (22)
with the screws (20), washers (21), and nuts (19).
7. Secure the dial mount (15) to the movement (22) with the screw (16) and lock
washer (17).
8. Install the Bourdon tube with movement and linkage attached into the case.
Secure the Bourdon tube (12) with the screws (13), and O-rings (14). Connect
other end of tubing (27) to the Bourdon tube (12) with the male connector (28).
9. Calibrate the gauge movement as described in "Calibration" on page 56.
10. Set the dial (11) in place with the zero at the 6 o'clock position. Secure dial (11) in
the dial mount (15) with snap ring (10). Install the pointer (9) carefully with an
automatic center punch (refer to "Related Tools and Test Equipment" on page
60). Pointer hub should be flush with pinion end and pointer should not touch
dial.
11. Place the gauge glass O-ring (8) in its groove in the case (40).
Note: Approximately 24 oz of gauge instrument fluid may now be poured into the
gauge case if filler screw (38) and seal (39) are installed.

12. Place the gauge glass assembly in place making sure that red target pointer does
not touch either the black pointer or the gauge glass.
13. Place case ring (1) over screw holes in case and secure with four screws (2).
Tighten screws evenly around the ring.
14. Stand gauge upright. Remove filler screw (38) and oil seal (39) and add gauge
instrument fluid to within 1/4-in. of the top of the gauge glass. Replace filler screw
(38), and oil seal (39), if not installed earlier.
Damper Disassembly
To disassemble the damper (Figure 4.6) perform the following steps:
Note: High pressure and low pressure damper disassembly procedures are identical.
Some stern parts differ.

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).

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2. Male connector (5) may have been removed with tubing from the Bourdon tube,
otherwise remove it.
3. Unscrew retainer nut (10) and remove stem assembly (6 through 11).
4. Remove O-ring (6), back-up seal (7), roll pin (8), stem cap (9), 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.

Figure 4.6: Damper Assembly, High Pressure, Gauge Mount

Legend for Figure 4.6

Item No. Description Item No. Description

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 Stem
6 O-ring 12 Gauge Mount Damper Body

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Damper Reassembly
To reassemble the damper (Figure 4.6) perform the following steps:
Note: High pressure and low pressure damper reassembly procedures are identical.
Some stem parts differ.

1. Assemble parts for stem assembly (6 through 11).

2. Insert stem assembly into damper body (12) and secure with retainer nut (10).
3. Screw in hex (bleed) plug (4) hand tight.
Note: After weight gauge is purged and recharged with instrument fluid, apply pipe
sealant (refer to "Approved Expendable Items List" on page 60) to first two threads of
hex bleed plug before tightening the plug in place.

Short Linkage Disassembly

To disassemble the linkage assembly (Figure 4.7) 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.
Short Linkage Reassembly
To reassemble the linkage assembly (Figure 4.7) 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 (18 through 21, Figure 4.5).
Note: All mounting hardware should be positioned at approximately the same
locations in the slide bar as before disassembly.

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Figure 4.7: Short Linkage Assembly

Legend for Figure 4.7

Item No. Description Item No. Description

1 Slotted Nut 6 Washer

2 Washer 7 Linkage Slide Bar
3 Shoulder Screw 8 Linkage Bar
4 Shoulder Screw 9 Screw
5 Stop Nut

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Panel-Mounted, 6-in. Gauge Disassembly

To disassemble the panel-mounted gauge (Figure 4.8) remove box-mounting
hardware, place the gauge face up on a clean workbench, and perform the following
steps:
1. Remove the setscrew (2) and the knurled knob (1) on the front zero adjust
assembly.
2. Remove the zero adjust drive (3) and the sleeve bearing (4).
3. Remove the setscrew (5); remove the zero adjust idler shaft (6), O-ring (7),
housing nut (8), O-ring (9), and zero adjust gear (10).
4. Unscrew the case ring screws (12) and remove the case ring (11).
5. Lift out the gauge glass assembly (13 through 17).
6. Pour off the gauge fluid for disposal.
7. Remove and discard gauge glass O-ring (18) from case.
8. Use pointer pullers (refer to "Related Tools and Test Equipment" on page 60) to
lift off the pointer (19) carefully.
9. Remove snap ring (20) and dial (21).
10. Disconnect the male connector (39) from Bourdon tube (22). Remove tube mount
screws (23) and O-rings (24); lift out the Bourdon tube assembly (22) with the
linkage (28) and the movement (32) attached.
11. Remove screws (26) and lock washers (27); lift off the dial mount (25).
12. Remove nuts (29), screws (30), linkage (28), and lock washers (31).
13. Remove screws (33) and lift off movement (32).
14. Remove screws (36), lock washers (37); lift damper block (34); disconnect
connector (39) from bottom of damper block. Remove damper block (34), gasket
(35) and tubing (38).
15. Loosen or remove screw (41), lock washer (42) and tube stop (40) as desired.
16. Remove screw (43) and seal (44) from top of case (45).
17. 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 4.8: 6-in. Gauge Assembly, Panel Mount, Front Zero Adjust (Typical)

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Legend for Figure 4.8

Item No. Description Item No. Description

1 Zero Adjust Knob 24 O-ring

2 Setscrew 25 Dial Mount
3 Zero Adjust Drive Assy 26 Screw
4 Sleeve Bearing 27 Lock Washer
5 Setscrew 28 Short Linkage Assy
6 Idler Shaft Gear 29 Slotted Nut
7 O-ring 30 Screw
8 Housing Nut 31 Washer
9 O-ring 32 Movement Assy
10 Zero Adjust Gear 33 Screw
11 Case Ring 34 Junction Block
12 Screw 35 Damper Gasket
13 Knurled Knob 36 Block Mounting Screw
14 Setscrew 37 Lock Washer
15 O-ring 38 Tubing
16 Target Pointer (Red) 39 Male Connector
17 Gauge Glass 40 Tube Stop
18 Case O-ring 41 Screw
19 Gauge Pointer (Black) 42 Lock Washer
20 Snap ring 43 Screw
21 Dial 44 Seal
22 Bourdon Tube Assy 45 Gauge Case
23 Tube Mounting Screw

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Panel-Mounted, 6-in. Gauge Reassembly

To reassemble the gauge (Figure 4.8), place gauge case (45) face up on a clean
workbench and perform the following steps:
Note: The damper block gasket, all seals and O-rings, and any worn or damaged metal
parts must be replaced with identical new parts.

1. If tube stop (40) was removed or loosened, replace and/or secure with screw (41)
until after calibration (refer to "Calibration" on page 56).
2. Place the damper block gasket (35) over the hole pattern on top of the gauge case
(45). Secure the damper end of the tubing (38) to the bottom of the damper (34)
with the male connector (39).
3. Install damper (34) and secure with screws (36) and lock washers (37).
4. Secure the movement (32) to the Bourdon tube assembly (22) with the screws
(33).
5. Secure the linkage assembly (28) to the Bourdon tube (22) and the movement (32)
with the screws (30), washers (31), and nuts (29).
6. Secure the dial mount (25) to the movement (32) with the screw (26) and lock
washer (27).
7. Install the Bourdon tube with movement and linkage attached into the case.
Secure the Bourdon tube (22) with the screws (23), and O-rings (24). Connect
other end of tubing (38) to the Bourdon tube (22) with the male connector (39).
8. Assemble the zero adjust assembly (6 through 10) and install through the back of
the gauge case (45). Replace setscrew (5).
9. Install sleeve bearing (4) and zero adjust drive (3).
10. Calibrate the gauge movement as described in "Calibration" on page 56.
11. Set the dial (21) in place with the zero at the 6 o'clock position. Secure dial (21) in
the dial mount (25) with snap ring (20). Install the pointer (19) carefully with an
automatic center punch (refer to "Related Tools and Test Equipment" on page
60). Pointer hub should be flush with pinion end and pointer should not touch
dial.
12. Place the gauge glass O-ring (18) in its groove in the case (45).
13. Place the gauge glass assembly in place making sure that red target pointer does
not touch either the black pointer or the gauge glass.
14. Place case ring (11) over screw holes in case and secure with four screws (12).
Tighten screws evenly around the ring.
15. Stand gauge upright. Remove filler screw (43) and oil seal (44) and add gauge
fluid to within 1/4-in. of the top of the gauge glass. Replace filler screw (43) and oil
seal (44), if not installed earlier.

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Panel-Mounted, 8-1/2 in. Gauge Disassembly

To disassemble the panel mounted gauge (Figure 4.9) remove box-mounting
hardware, place the gauge face up on a clean workbench, and perform the following
steps:
1. Remove the setscrew (2) and the knurled knob (1) on the front zero adjust
assembly.
2. Remove the zero adjust drive (3) and the sleeve bearing (4).
3. Remove the setscrew (5); remove the zero adjust idler shaft (6), O-ring (7),
housing nut (8), O-ring (9), and zero adjust gear (10).
4. Unscrew the case ring screws (13) and remove the case ring (11).
5. Lift out the gauge glass (14).
6. Pour off the gauge fluid for disposal.
7. Remove and discard gauge glass O-ring (15) from case.
8. Use pointer puller (refer to "Related Tools and Test Equipment" on page 60) to lift
off the pointers (16,17) carefully.
9. Remove screws (18), dial center (19), bearing posts (20), and dial (21).
10. Disconnect the male connector (37) from Bourdon tube (22). Remove tube mount
screws (23), and O-rings (24); lift out the Bourdon tube assembly (22) with the
linkage (25) and the movement (29) attached.
11. Remove nuts (26), screws (27), linkage (25), and lock washers (28).
12. Remove screws (30) and lift off movement (29).
13. Remove plugs (31,32), screws (35), lock washers (36); lower junction block (33);
disconnect connector (37) from bottom of block. Remove block (33), gasket (34)
and tubing (38).
14. Loosen or remove screw (40), lock washer (41) and movement stop (39) as
desired.
15. Remove dial posts (42).
16. Remove screw (43) and seal (44) from top of case (45).
17. 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 4.9: 8-1/2 in. Gauge Assembly, Panel Mount, Front Zero Adjust (Typical)

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Legend for Figure 4.9

Item No. Description Item No. Description

1 Zero Adjust Knob 24 O-ring

2 Setscrew 25 Short Linkage Assy
3 Zero Adjust Drive Assy 26 Slotted Nut
4 Sleeve Bearing 27 Screw
5 Setscrew 28 Washer
6 Idler Shaft Gear Assy 29 Movement Assy
7 O-ring 30 Screw
8 Housing Nut 31 Plug
9 O-ring 32 Plug
10 Zero Adjust Gear 33 Junction Block
11 Case Ring 34 Damper Gasket
12 Screw 35 Block Mounting Screw
13 Screw 36 Lock Washer
14 Gauge Glass 37 Male Connector
15 Case O-ring 38 Tubing
16 Pointer, Weight (Black) 39 Movement Stop
17 Pointer, Vernier (Red) 40 Screw
18 Dial Center 41 Lock Washer
19 Screw 42 Dial Post
20 Bearing Post 43 Screw
21 Outer Dial 44 Seal
22 Bourdon Tube Assy 45 Gauge Case
23 Tube Mounting Screw

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Panel-Mounted, 8-1/2 in. Gauge Reassembly

To reassemble the gauge (Figure 4.9), place gauge case (45) face up on a clean
workbench and perform the following steps:
Note: The junction block gasket, all seals and O-rings and any worn or
damaged metal parts must be replaced with identical new parts.

1. If movement stop (39) was removed or loosened, replace and/or secure with
screw (40) and washer (41). Do not tighten screw (40) until after calibration (see
"Calibration" on page 56).
2. Install dial posts (42).
3. Place the junction block gasket over the hole pattern on bottom of the gauge case
(45). Secure the block end of the tubing (38) to the top of the block (33) with the
male connector (37).
4. Install block (33) and secure with screws (35) and lock washers (36). Install plugs
(32, 31).
5. Secure the movement (29) to the Bourdon tube assembly (22) with the screws
(30).
6. Secure the linkage assembly (25) to the Bourdon tube (22) and the movement (29)
with the screws (27), washers (28), and nuts (26).
7. Install the Bourdon tube with movement and linkage attached into the case.
Secure the Bourdon tube (22) with the screws (23), and O-rings (24). Connect
other end of tubing (38) to the Bourdon tube (22) with the male connector.
8. Calibrate the gauge movement as described in "Calibration" on page 56.
9. Set the dial (21) in place with the zero at the 6 o'clock position. Secure dial (21)
with bearing posts (20). Install dial center (18) with screws (19). Install the
pointers (17,16) carefully with an automatic center punch (see "Related Tools and
Test Equipment" on page 60). Pointer hub should be flush with pinion end and
pointer should not touch dial.
10. Place the gauge glass O-ring (15) in its groove in the case (45).
Note: Approximately 40 ounces of gauge fluid may now be poured into the
gauge case if filler screw (43) and seal (44) are installed.

11. Place the gauge glass (14) in place making sure that vernier pointer does not
touch either the black pointer or the dial.
12. Place case ring (11) over screw holes in case and secure with four screws (13).
Tighten screws evenly around the ring.
13. Assemble the zero adjust assembly (6 through 10) and install through the back of
the gauge case (45). Replace setscrew (5) in zero adjust gear (10).

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14. Install the sleeve bearing (4) and the zero adjust drive (3).
15. Install the knurled knob (1) and secure with the setscrew (2).
16. Stand gauge upright. Remove filler screw (43) and oil seal (44) and add gauge
fluid to within 1/4-in. of the top of the gauge glass.
17. Replace filler screw (43) and oil seal (44), if not installed earlier.
Pressure Integrator Disassembly
To disassemble the integrator (Figure 4.10) place the device on a clean workbench and
perform the following steps:
1. Remove elbow (1), plug (2), and tee (3).
2. To remove the single chamber cylinder head (4), unscrew screws (5).
3. Remove and discard seal (6), O-ring (7), and O-ring (8).
4. Remove double shaft piston (9) and O-ring (10)
5. Remove the single chamber cylinder (11).
6. To remove the double chamber cylinder head (12) remove screws (13).
7. Remove and discard O-ring (14).
8. Remove the single shaft piston (15).
9. Remove and discard O-ring (16) and O-ring (17).
10. Remove the double chamber (18) from the main body (20).
11. Clean, degrease, and inspect all parts carefully. Lubricate and replace seals and
O-rings. Replace any worn or damaged parts.

Figure 4.10: Pressure Integrator Assembly, Hydro-Mast System

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Legend for Figure 4.10

Item No. Description Item No. Description

1 Elbow 11 Single Chamber Cylinder

2 Plug 12 Double Chamber Cylinder Head
3 Tee 13 Screw
4 Single Chamber Cylinder Head 14 O-ring
5 Screw 15 Single Shaft Piston
6 Seal 16 O-ring
7 O-ring 17 O-ring
8 O-ring 18 Double Chamber Cylinder
9 Double Shaft Piston 19 Window
10 O-ring 20 Integrator Body

Pressure Integrator Reassembly

To reassemble the integrator (Figure 4.10) perform the following steps:
Note: All seals and O-rings and any worn or damaged parts, must be
replaced with identical new parts.

1. Make sure the plexiglass window (19) in the body (20) is not cracked or dirty.
2. Install the double chamber cylinder (18) in the body (20).
3. Make sure the O-ring (17) in the chamber and O-ring (16) on the piston (15) are
lubricated when inserting the piston.
4. Make sure the O-ring (14) is lubricated when installing the cylinder head (12).
Secure with screws (13).
5. In a similar sequence, install the single chamber cylinder (11), the double shaft
piston (9), seal (6), and cylinder head (4). Secure with screws (5).
6. Install tee (3), plug (2), and elbows (1).
7. Install in box, connect tubing, and charge as described in "Gauge and Integrator
Fluid Loading" on page 30.

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Calibration
Equipment should be calibrated before installation or any time it is suspected of being
out of tolerance. The calibration procedures described in the following paragraphs are
for 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 "Back-
Mounted, 6-in. Gauge Disassembly" on page 38 through "Pressure Integrator
Disassembly" on page 54.
2. If the gauge was just repaired for parts replacement, center the linkage in the
movement quadrant slot (11, Figure 4.11) and in the Bourdon tube tip slot (9).
Adjust the linkage (10) 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 60).
4. Install the 360° calibration dial (refer to "Related Tools and Test Equipment" on
page 60) with 0° marker at the 6 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.
6. Refer to Figure 4.11 and "Related Tools and Test Equipment" on page 60 for the
proper calibration pressure to apply to the test stand gauge for full scale pointer
rotation.
7. Pressurize the test bench gauge for quarter-scale indication (90°); 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.

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8. Depressurize; adjust the left side linkage; and repressurize as needed until
quarter-scale and half-scale indications are within tolerance. Tighten linkage
screws snugly.
9. Pressurize the test bench gauge for three-quarters scale (270°); increase the
pressure to full-scale (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; 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. Repressurize to move the quadrant to drive the pointer one full revolution around
to zero. Tighten screw against the tube stop (8) to limit pointer travel.
Depressurize and repressurize to check pointer travel for full scale.
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 60).
15. Complete reassembly as described in "Back-Mounted, 6-in. Gauge Reassembly"
on page 41 through "Pressure Integrator Reassembly" on page 55.
16. Tighten stem on damper (24, Figure 4.5).
Note: In the calibration flow diagram, Figure 4.11, the diamond decision
blocks form an outline for calibration procedures. The rectangles form an
outline for actions to perform based on previous decision points.

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Figure 4.11: Weight Gauge Calibration Flow Diagram

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Legend for Figure 4.11

Item No. Description Item No. Description

A Movement Stop 6 Movement Assy

B Tube Stop
1 Dial Face Center
2 Dial
3 Pointer
4 Movement Mounting Screws
5 Pointer Pinion Shaft
7 Movement Quadrant Arm
8 Linkage Slide Nuts
9 Bourdon Tube Tip
10 Linkage
11 Slotted End of Movement Quadrant
12 Linkage Attaching Screws

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Related Tools and Test Equipment

Part Number Description

T847-1 Pointer Puller Tool

10135703-002
999776 Automatic Center Punch (Starrett)
10125191-001
211075 Calibration Dial, 6-in. Gauge
10034775-001
210986:58P High Pressure Test Bench Assembly
212828:58P Vacuum Pump Assembly
HYD-1065 Nipple, Pipe, Hex
970621-009 Quick-Disconnect Fitting
10122707-001
211230 Damper Stem Wrench, Low Pressure
10199654-001
999728-001 Nut Driver, Linkage, 5/32 in.
10125159-001
968601-003 Elbow
10122452-001
970621-005 Male Coupling, 2 each
10122703-001
970617-002 Elbow

Approved Expendable Items List

Part Number Description

W8 Instrument Fluid, 1 qt can (gauge fluid)

10136036-001
10136015-001 Instrument Fluid, 1 qt can (hydraulic fluid)
991201-023 Pipe Sealant with Teflon (Loctite)
10123699-001
992405-001 Silicon Lubricant
10123792-001
Coml Trichloroethylene Solvent or Equivalent

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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 Hydro-Mast Indicator. Refer to the
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

Trouble Probable Cause Remedy

Obstruction in hose. Purge or replace hose.

Loss of hydraulic fluid. Reload with hydraulic fluid.

No indication on Gauge internal mechanism Replace gauge.
gauge. damaged.

Worn quick-disconnect hose Replace fitting(s).

fitting(s).

Incorrect zero dial setting. Adjust or calibrate as

required.
Gauge indication too
Excessive hydraulic fluid. Bleed off hydraulic fluid.
high.
Gauge internal mechanism Replace gauge.
damaged.

Entrained air in the system, Purge and recharge system

integrator not loaded. components.

Incorrect zero dial setting. Adjust or calibrate as

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

Gauge internal mechanism Replace gauge.

damaged.

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Trouble Probable Cause Remedy

Air in the system. Bleed entrained air off.

Improper pointer damper Open or close damper stem as

adjustment. required.

Pointer rubbing glass or dial. Remove glass and straighten

Erratic or sluggish pointer.
gauge indication. Insufficient hydraulic fluid or Purge and pump in additional
entrained air in components. hydraulic fluid.

Sticky gauge movement. Replace gauge.

Gauge internal mechanism Replace gauge.

damaged.

Excessive fluid pre load. Bleed off fluid.

Faulty movement. Recalibrate or replace

Gauge pointer does movement.
not return to zero.
Pointer bent, dragging. Straighten pointer.

Worn quick-disconnect fitting. Replace fitting.

Gauge pointer tracks Low fluid. Recharge gauge or system.

to a given point, then
stops.

Fault Isolation Diagram

The Fault Isolation Diagram, Figure 5.1, is a graphic illustration to help isolate and
correct faults in the Hydro-Mast indicator 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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WARNING
CONNECT HOSE DISCONNECT ALL WEIGHT MUST BE REMOVED
LOWER MAST LEGS TO START FROM LOAD CELL PAD.
TO HYDRAULIC HOSE (S) FROM
CONTACT LOAD CELL
TEST SYSTEM INDICATOR

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
IF AFTER INSPECTING THE SYSTEM NO
AND DSCUSSING SYMPTOMS WITH
RIG PERSONNEL. THE PROBLEM IS
NOT EVIDENT. FOLLOW THE
YES
PROCEDURES OUTLINED IN THIS
CHART. TERMINATE RESTORE SYSTEM TO
OPERATIONAL STATUS GAUGE
ASSEMBLY

Figure 5.1: Hydro-Mast Weight Indicator Fault Isolation Flow Diagram

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This manual is 26-72 and can also be referenced as 18016105-001.

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