part number tw522 revision a - pslcolombia martib decker.pdfthe service procedures recommended by...

INSTALLATION, OPERATION, AND MAINTENANCE

Printed in U.S.A.

SD AND SW SERIES LOAD CELL SYSTEMS

Part Number TW522 Revision A

Manufacturers of Precision Instruments

April 01,1998

Manual TW522 contains 22 pages, divided as follows:

Cover. ........................... April 1998 i through iii ....................... April 1998 Introduction/Description ............ April 1998 Installation/Operation ............... April 1998 MaintenanceLI’roubleshooting ........ April 1998 Repair ........................... April 1998

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

Information in this manual is subject to change without notice.

IMPORTANT SAFETY NOTICE

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

April 17,1996 M/D TOTCO

Page 1

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

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and workmanship defects, subject to the following exceptions:

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

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

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

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

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

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

The warranty periods for various products are:

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

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

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

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

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

Page 2 April 17,1996 M/D TOTCO

MAATIN-DECKER/TECHNICAL MANUAL I


CONTENTS Sect ion No.

I

II

III

IV

Table No. 3-l.

Title INTRODUCTION AND DESCRIPTION .................... l-l. Introduction ................................ l-4. Description ................................ 1-6. System Components ...........................

INSTALLATION AND OPERATION ...................... 2-l. Installation ................................. 2-2. Pre-Installation ............................. 2-4. System Installation ........................... 2-10. Post-Installation Checkout ...................... 2-12. System Operation ............................ 2-16. System Accuracy Check ........................ 2-18. System Weight Test ...........................

MAINTENANCE AND TROUBLESHOOTING ................ 3-l. Maintenance ................................ 3-3. Troubleshooting .............................

REPAIR.. ...................................... 4-l. System Repair .............................. 4-3. Component Repair ............................

LIST OF TABLES Title

Malfunction Isolation ...............................

LIST OF ILLUSTRATIONS Figure No.

l-l. 2-l. 2-2. 2-3.

2-4.

2-5. 2-6.

Title Compression and Tension Load Cell Systems ............... Application of Lever Ratio ........................... Overall Dimensions for 6 Inch Indicator and Bracket Installation . . Overall Dimensions for 8-l/2 and 12 Inch Indicator and Bracket

InstalIation ..................................... Overall Dimensions for 18 and 24 Inch Indicator and Bracket

Installation ..................................... Volume Chamber Calibration .......................... Sample Load Data Worksheet ..........................

Page No. 4 4 4 4

7 7 7 7

12 12 12 13

15 15 15

15 15 15

Page No. 16

Page No. 5 8 9

10

:i 14

4-l. Load Ceil Gap and Plug Location , . . . . . . . . . . . . . . . . . . . . . . 18

lo/81 Page 3

II SD AND SW SERIES LOAD CELL SYSTEMS I MART~~~;OE~~CER/TECHN~~*L MANUAL - I II I I. I

l-l.

l-2.

l-3.

1-4.

l-5.

l-6.

1-7.

l-8.

SECTION I INTRODUCTION AND DESCRIPTION

INTRODUCTION

This manual contains installation, operation and maintenance instructions for the MARTIN-DECKER SD Series (Tension) and SW Series (Compression) Load Cell Systems.

Read the appropriate section of this manual before performing the indicated installation, operatien or maintenance procedures. Insure that all personnel who will be performing these procedures have read the Important Safety Notice located on the inside front cover of this book.

DESCRIPTION

TENSION AND COMPRESSION LOAD CELL SYSTEMS. (See figure I-I) Both the tension and compression load cell systems are hydraulically operated, require no external power source, are assembled and fully loaded with MARTIN-DECKER hydraulic fluid prior to shipment. They are designed to operate within the ambient temper&re range of -290 to 49°C (-20” to 120°F). Accuracy of the systems, when shipped from the factory, is &. 2% of full Scale capacity at an ambient range of 16” to 27°C (66’ to 86°F). Hose lengths should be limited to values compatible with the load celI effective area, consult MARTIN- DECKER for these limits and methods to add tubing where required.

SYSTEM COMPONENTS. The system consists of the following basic components and attaching hardware:

E:

2 e.

Indicator Sensater Load Cell (hereinafter referred to as load cell) Hydraulic Hose Disconnect Coupling(s) (Optional) Tubing (Optional)

Indicator. The indicator provides a dial faceplate, calibrated in Pounds, tons or kilograms, as specified. The indicator has a damper to smooth pointer sensitivity and adjust pointer response to the operators preference. Also included on each indicator is a dial adjust gear, which rotates the dial to make necessary tare adjustments.

Load Cell. The load cell transmits a hydraulic pressure signal to the indicator by trans- forming the applied load into the respective pressure. This is accomplished by a diaphragm sensing element held in place by a load cell housing. All load cells are compression measurement devices. With the addition of auxiliary hardware it has the additional capability of measuring tension loads with extreme accuracy. (Refer to figure l-1).

Page 4 3/83

MARTIN-DECKER/ TECHNICAL MANUAL SD AND SW SERIES LOAD CELL SYSTEMS

u TYPICAL SW SERIES COMPRESSION LOAD CELL SYSTEM

TYPICAL SD SERIES TENSION LOAD CELL SYSTEM

Figure l-l. Compression and Tension Load Cell Systems

Page 5

SD AND SW SERIES LOAD CELL SYSTEMS II RMRTIN-OECKEW TECHNICAL MANUAL I

1-9.

l-10.

l-11.

1-12.

Hydraulic Hose. of the system.

Two types of hydraulic hose are used, depending upon the capacity The hydraulic hose with l/4 NPT hose connections is standard.

Disconnect couplings are available for most capacities where installation or frequent disconnecting of the hose from the load cell or indicator is required. The hydraulic hose will come in maximum lengths of 50 feet in a single unit and couplings (P/N J103) will be used where extended lengths are needed to meet job requirements.

a. The 3/16 inch diameter hose is of single wire braid construction and rubber covered. MARTIN-DECKER recommends use of this hose with all systems, using 4.0 to 16.1 square inch load cells.

b. The l/4 inch diameter hose is of double wire braid construction and rubber covered. MARTIN-DECKER recommends use of this hose with all systems, using 25.0 to 100.0 square inch load cells.

JlOQOOA s&s Discomeck Disconnects are available for most capacities where dis- connection of the hose from the load cell or indicator is required. The female half of the disconnect is usually installed on the hose while the male half is installed on the damping chamber to facilitate connection. Additionally, disconnects may be used in-line to separate two hoses. Disconnect halves are supplied with protective covers to preclude entry of contaminants into system when components are disconnected.

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

Attaching and Support Hardware. The system is furnished with all necessary attaching and support hardware to facilitate installation and maintenance:

a. Check Valve - Usually installed on the load cell and is used to replenish the hydraulic fluid in the system. In some cas-?s, the check valve may be located elsewhere in the system.

b. YA2 Hand Pump - Used for field loading the system with hydraulic fluid. Connects to the check valve.

C. Hydraulic Fluid - Supplied in quart and gallon containers., W 15 (quart) W16 (gallon) hydraulic fluid is to be used in the event it becomes necessary to charge the system in the field.

d. Indicator Bracket - Used for mounting the indicator.

Page 6 lo/al

MARTIN-OECICER /TECHNICAL MANUAL SD AND SW SERIES LOAD CELL SYSTEMS

SECTION II

INSTALLATION AND OPERATION

2-l. INSTALLATION

2-2. PRE -INSTALLATION

2-3. The pre-installation procedure consists primarily of insuring that either the Tension or Compression System is the correct system to be installed. The following is to be checked:

a. Determine that indicator dial is calibrated in the units of measurement (pounds, tons, or kilograms) compatible with what will be measured.

b. Determine that disconnect O-rings (if supplied with system) are not damaged (Refer to paragraph 4-4 for replacement).

:: Determine that load cell capacity is suitable for the intended application. Determine that the load cell and hydraulic hose is located in a position to move freely, taking into account any obstructions that may interfere with the load to be measured. Also, determine that hydraulic hose is of sufficient length for routing from the indicator to the load cell.

e. Verify condition of hose disconnects and fittings to insure that they will not leak hydraulic fluid when mated.

2-4. SYSTEM INSTALLATION

2-5. LOAD CELL INSTALLATION. The load cell may be mounted in any attitude, depending on application requirement. The SD Series Tension Cell should be installed in such a manner that when a load is applied, the components mating with the eye nuts, hooks, pad- eyes, etc. bear at the center of these attachments. The SW Series Compression Cells should be installed in such a manner that the mating surfaces are within 1” to 2” of parallel. The load plate (piston) and retainer ring (cylinder) should not be eccentric greater than l/16 inch. Eccentricity or excessive out of parallel loading may produce an indication error and induce premature failure of the diaphragm.

1 CAUTION] The load cell does not support torsional loading of any significance. Torsional loads will cause the diaphragm to rotate over the pressure plate, resulting in premature failure. In applications where twisting is encountered, a swiveling device must be used to relieve the load cell from torsional loads. Some versions of the SD tension load cell are available with anti-rotation configuration.

2-6. Compression Load Cell in Lever Applications. When an SW Compression System has been ordered to be used with a lever (i.e. specified as 3:1, 2:l or other lever ratio), the lever length and position of the weight must be precisely measured to maintain accuracy. If, for example, a 2:l ratio system has been ordered, the weight must be applied to the lever at the midpoint between the load cell and the lever pivot point (fulcrum). Any devia- tion from this arrangement will result in faulty weight indication (figure 2-l). Figure 2-l shows a 2:l ratio lever arrangement; note that while the load cell receives half of the applied weight, the indicator shows all of it. Changing the position of the weight along the

2/80 Page 7

SD AND SW SERIES LOAD CELL SYSTEMS MARTIN-OEEKER/lECHN#AL MANUAL

2-6. cont. lever will change the indication: closer to the load cell will increase the error in a plus direction (reads fast) while farther from the load cell will increase the error in a minus direction (reads slow). For final span adjustment, change the length of the lever slightly by moving the load cell closer to, or farther from, the pivot point. When the span has been adjusted, bolt the lever to the load cell to prevent accidental shifting.

2-7. Requirements for a successful lever installation include: a. Lever secured to pivot point (free to rotate vertically) and load cell to prevent

accidentalshifting. Distance (L, figure 2-l) to be precisely measured. b. Load center of gravity positioned directly over predetermined location on

lever to maintain ratio of system. C. Lever must be sufficiently sturdy to prevent introduction of a bending moment

with attendant indication error. d. System must be level within l/4 bubble on a carpenters level, or equivalent.

2-8. INDICATOR INSTALLATION. Select location for the indicator that provides convenient visual access to the operator.

-1 The indicator is a precision instrument and must be handled with extreme care.

a. Locate indicator mounting bracket. Figures 2-2, 2-3 and 2-4 give mounting dimensions for the 6, 8-l/2, 12, 18 and 24 inch indicators.

b. After locating bracket, refer to the proper figure for mounting dimensions.

:: Drill holes. Install bracket on indicator.

e. Install indicator/bracket using screws and washers.

I ~--------------+-------------+ ‘m------+-----q I I $--- IB---y I

I I I

k --l&-w/ 1 I I I I I

2:l RATIO IA = l/21, F = 1/2W 3:l RATIO II = l/31, F = 1/3W 4:l RATIO IC = l/41, F = 1/4W

VAllATlOl II IA, ID OR IC WILL CAUSE IllCORRECT WElEllT IllDICATIOI II DIRECT PROPORTlOl TO VARIANCE.

Figure 2-1. Application of Lever Ratio Page 8

MARTIN-DECKER/TECHNICAL MANUAL SD AND SW SERIES LOAD CELL SYSTEMS 11 TW522 1

I 2.44 (62mm) t-

It-

1 .18 (30mm)

‘h-18 NPT

t-

7.50 4 (191mm)

I /- (4) .;;gm)

120" SPACMC

NOTE: Indicator furnished with damper at bottom unless otherwise specified.

Figure 2-2. Dimensions for 6-Inch Indicator and Al232 Bracket

2/80 Page 9

SD AND SW SERIES LOAD CELL SYSTEMS II MARTIN-DECKER /TECHNICAL MANUAL

.62 (16mm

8-l/2 INCH INDICATOR

14.00 (356mm)

-

-

(86mf-f

/- BRACKET (TYPICAL)

- .62 (16mm)

12 INCH INDICATOR

--

- .62 (16mm)

(4) .31 DIA (8mm)

. BRACKET

Figure 2-3. Overall Dimensions for 8-l/2 and 12 Inch Indicator and A1063A Bracket Installation

Page 10 2180

MARTIN-DECKER /TECHNICAL MANUAL I SD AND SW SERIES LOAD CELL SYSTEMS Ir

4.03 ( 1 fpFm I

18 INCH LNDICATOR

(4) MOUNTING HOLES FOR 18 INCH

4.28 ( 1 O;FFm

-

+- (2i%im) J 1.25 (32mm) -5.00

(127mm) I - 12.00 (305mm)

b-1 1.25 (286mm)

26.12 (663mm

INDICATOR .44 DIA I (102mm)

-f-l- -l 5.cp

1 I

t

q-f ‘. 4.00

I l-

A I ’ 8

I

(4) MOUNTING HOLES FOR 24 INCH INDICATOR .44 DIAL

I.OO(203mm)

I I I

I 1 1 1 1 10.00 (254mm)

lb .62 (143mm) r-6.00 (152mm l-4

(4) 38 DIA (10mm) INDICATOR BRACKET

Figure 2-4. Overall Dimensions for 18 and 24 Inch Indicator and A1049 Bracket Installation

2/80 Page 11

l--&a SD AND SW SERIES LOAD CELL SYSTEMS II MARTIN-DLCKER/rrCHMCAL MANUAL I II I 1~ J

2-9. HYDRAULIC HOSE INSTALLATION

ii: Route hose so that it will not be crushed, cut or otherwise damaged. Tie hose to structures where permitted.

pGEGq Allow sufficient slack in the hose to avoid pulling hose taut. Excess tension could cause fitting or connector failure.

2-10.

2-11.

C. Connect disconnects. POST-INSTALLATION CHECKOUT

After system installation check to insure that it is operating properly. a. Exercise the system several times, using a known weight of at least 25 percent

of full scale capacity. This is to flex the Sensater diaphragm in the load cell. b. Remove weight from Sensater load cell.

2 Turn tare adjust knob to rotate dial indicator to zero. Check load cell to see that it is free of all encumbrances.

2-12.

2-13.

SYSTEM OPERATION

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

2-14. LOAD POINTER ZERO ADJUSTMENT. Apply a load not exceeding 75% of full scale capacity. Remove load.

NOTE When reading the indicator, maintain a direct and perpendicular line of sight between the eye and pointer in order to eliminate the possibility of parallax error.

C. Adjust zero adjust knob until indicator pointer reads zero with $1 tare loads acting on load cell.

2-15.

2-16. 2-17.

POINTER DAMPING ADJUSTMENT. The damper is located on the top, bottom or side of the indicator case and has a tee handle or slotted stem projecting from the damper block.

a. Fully engage damper, push stem in and turn clockwise to closed position. b. Open damper by turning stem counterclockwise two complete revolutions. C. If pointer is too sensitive, turn stem clockwise l/4 to l/2 revolution. d. If pointer is sluggish, turn damper stem counterclockwise l/4 to l/2

revolution . e. Recheck sensitivity and repeat step 2 or d

sensitivity is reached. -,, as applicable, until desired

SYSTEM ACCURACY CHECK System accuracy is such that the indicated load should not differ from actual load more than *to. 2% of full scale over an ambient temperature range of 16” to 27°C (SO’ to 80°F). Adjustments to the system fluid volume may be required for ambient temperatures outside of the quoted range. Extra hose should not be added to systems as they are received from MARTIN-DECKER. See paragraphs l-9 & l-11. Use a series of known loads to check the systems accuracy. (Refer to paragraph 2-18). I~-

Page 12 3183

I MARTIN-OECKER/tECHNICM MANUAL I


2-18. SYSTEM WEIGHT TEST

2-19. To insure accuracy of the load indicator system, a load test should be performed at g-month intervals and at initial test or system installation. A sample load test data worksheet is provided in figure 2-6 and the weight test procedure is contained in paragraph 2-20.

2-20. WEIGHT TEST NOTE

Test weights should have a minimum accuracy of io. 01%.

a. Assemble necessary equipment to perform test: 1. Test weights on the order of 15, 35 and 75 percent of the total capacity

of the system, accurate to *O. 01%. 2. Rigging or equipment required to hoist test weights. If weight of

rigging or lift equipment is to be included in test, its weight must also be known to *to. 01%.

b. Apply test weights and write indicator reading in the space provided on the worksheet.

C. Repeat step b to ensure repeatability. d. If system does not meet specified tolerances refer to paragraph 3-3.

2-21. VOLUME CHAMBER

2-22. Some models of the SW and SD series Load Cell systems include a calibration volume chamber. On systems so equipped the following procedures should be followed to make minor corrections to the fluid load for system accuracy correction (figure 2-5).

STEM

1.

Figure 2-5. Volume Chamber Adjustment

If scale reading is too high:

t : Loosen lock nut (1). Apply a full scale capacity load or as near full scale capacity load as is available.

C. Turn volume chamber adjust stem (2) counterclockwise until scale reads correct weight being applied to scale.

d. Remove test weight being.applied to scale.

f’: Re-zero scale at tare load. Apply test weight to scale.

g. If the scale still reads high, repeat step b thru e until scale checks at zero and the test weight &ing u&d.

h. Tighten lock nut. If scale reading is too low: a. Loosen lock nut (1). b. Apply a full scale capacity load or as near full scale

capacity load as is available. C. Turn volume chamber adjust stem (2) clockwise until

, scale reads correct weight being applied to scale. d. Remove test weight being applied to scale.

4: Re-zero scale at tare load. Apply test weight to scale.

g. If the scale sti$l reads low, repeat step 2 thru 5 until scale checks at zero and the test weight being used.

h. Tighten lock nut.

10181 Page 13

SD AND SW SERIES LOAD CELL SYSTEMS I MARTIN-DECKER/ TECHNICAL MANUAL

OWNER

MFG. MARTIN-DECKER MODEL SERIAL SANTA ANA, CALIFORNIA

SYSTEM CAPACITY

CONFIGURATION AT TIME OF TEST

LOCATION OF LOAD SENSOR

TEST LOAD DATA: PERCENT OF TOTAL SYSTEM CAPACITY WEIGHT OF TEST LOAD TO INCLUDE ALL EQUIPMENT (To + 0.1%)

I 75% I

15% TEST 35% TEST 75% TEST WEIGHT WEIGHT WEIGHT

1st INDICATOR READING

ERROR *

2nd INDICATOR READING

ERROR * I I I

CONDITION OF LOAD INDICATING DEVICE:

INSPECTOR ORGANIZATION DATE

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

Figure 2-6. Sample Load Data Worksheet

Page 14 2/80

I MARTIN-DECKER/TECHNICAL MANUAL SD AND SW SERIES LOAD CELL SYSTEMS

3-1. 3-2.

3-3. 3-4.

3-5.

4-l. 4-2.

4-3.

lo/81

SECTION IlI - MAINTENANCE AND TROUBLESHOOTING MAINTENANCE GENERAL. The system, as described in this manual, requires no maintenance. However,general operating practices should include:

a. Cleaning indicator glass on an “

as

necessary

”

basis. This can be accomplished by using any commercially available glass cleaning solution and a clean, soft, lint-free cloth.

b. Visual inspection of the system prior to use. Pay particular attenMon to the integrity of fittings and connections (no fluid leakage). Check load cell gap and ascertain that the load cell is free of obstructions. Should any leakage and/or malfuncMon be observed, refer to paragraph 4-2.

NOTE The maintenance/repair procedures contained in this section and Section lV are the only procedures practical to be performed in the field. In situations involving a faulty component, the faulty component should be returned to MARTIN-DECKER, 1928 South Grand, Santa Ana, California, or authorized service facility for repair and recalibration.

TROUBLESHOOTING B during operation an indication of system malfunction is observed (no load indication and/or sluggish, erratic or erroneous indication), see Figure 4-l and check load cell gap (Paragraph 3-5) in conjunction with Table 3-l for tabulation of probable causes and their corrective actions. LOAD CELL GAP, (Figure 4-l). The load cell gap is the distance measured between the load plate and the load cell retaining ring. The gap will vary from one load cell to another due to configurational makeup. The nominal gap is stamped on the load cell pipe plug at the completion of system calibration at MARTIN-DECKER. This information can be used as a quick reference when a malfunction is suspected in the system, or when hydraulic fluid is added or reduced (Paragraphs 4-4 and 4-5), and as a com- parative check against actual weight calibration. The load cell must be exercised several times before this measurement is made. (Paragraph 2-17).

SECTION IV - REPAIR SYSTEM REPAIR System repair is limited to removing a faulty component and replacing it with one in serviceable condition. This section of the manual covers repairs that may be readily performed in the field and does not include detailed disassembly/assembly procedures of the indicator and load cell. Field repairs consist of charging or bleeding the hydraulic system, removing and replacing the indicator, load cell and/or hydraulic hose or replacing the O-Ring (Part No. 100796-113110) in the J900 or J901 series Hydraulic hose disconnects. COMPONENT REPAIR - HYDRAULIC HOSE DISCONNECT. The J10900A series hydraulic hose quick disconnect half couplings. (Part Nos. J10900A-02 and JlOgOOA-20) have replaced the J900 and J901 series disconnects. The J109OOA series disconnects do not contain an O-Ring: however, the 5900 and J901 Series disconnect contains an O-Ring which if damaged must be replaced, as follows, to preserve the integrity of the system.

b

”

.

Be sure that system is not under load. Remove damaged O-Ring from the female-half of the disconnect.

C. Clean O-ring groove. d. Lubricate (using silicon, or equivalent) and install new O-Ring (Part No.

100796-113AO).

[cAunoNl

e.

Be careful not to damage O-Ring during mating. A damaged o-ping could result in hydraulic fluid lealdng during operation.

Carefully align male and female coupling halves and plsh firmly together. Thread nut onto male half of coupling and tighten.

Page 15

SD AND SW SERIES LOAD CELL SYSTEMS I MIIRTIN-DECKER/TECHNlCIIL MANUAL

MALFUNCTION Load Indication Too High

Load Indication Too Low

TABLE 3-l. MALFUNCTION ISOLATIOX

PROBABLE CAUSE CORRECTIVE ACTION Improper zero (tare) Adjust zero set (tare) setting (para 2-14) System charge overload

Improper zero (tare) setting Insufficient system charge

Reduce (bleed system) hydraulic charge (para 4-6) Adjust zero set (tare) (para 2-14) Charge system

! (para 4-5) Loose and leaking hose connection I

Tighten hose connection

Obstruction in hydraulic hose

Replace or clean hose

Hydraulic hose crimped Straighten hydraulic hose and eliminate tight bends, etc.

Erratic or Sluggish Indication

Insufficient system charge Incorrect damper setting Obstruction in hose

Charge system (para 4-5) Correct damper setting (para 2-15) Replace or clean hose

Hydraulic hose crimped Straighten hydraulic hose, eliminate tight bends, etc.

No Indication Dampers closed Correct damper setting (Para 2-15) I

Load cell/cells dry Check load cell gap and (No hydraulic fluid) charge system (para 4-5) L Hydraulic hose crimped Straighten hydraulic hose,

eliminate tight bends Obstruction in hose Replace or clean hose

Page 16 lo/81


4-4. CHARGING AND BLEEDING SYSTEM

4-5. HYDRAULIC FLUID ADDITION, LOAD SYSTEM. The system must be kept full of hydraulic fluid at all times to accurately indicated hoisted weight or load. A quick check for adequate fluid in system is the gap between the load cell load plate and retainer ring. Refer to figure 4-l for gap location, proper gap will be stamped on load cell plug or nameplate.

ba: 2 e. f. Et*

h. . i

.

1. m.

n. 0.

P.

-Remove all weight from load cell. Insure that weight hose is free of kinks and sharp bends. Remove cap from F350-1 check valve. Close dam

Ai! er.

Attach Y hand pump to check valve. Do not tighten. Fill hand pump reservoir with W/15/ W16 (red) hydraulic fluid. Operate hand pump plunger slowly to bleed air from pump at check valve.

NOTE Keep hand pump reservoir at least half full at all times to avoid introducing air into system. When air bubbles cease (step g) tighten hand pump to check valve connection. Raise load cell to a position slightly higher than indicator. Loosen load cell plug (figure 4-l). pump fluid into system and bleed at load cell plug until air bubbles cease to appear. Tighten load cell Pump enough flui x

lug. into system to slight1 overcharge system, loosen pipe

plug and bleed to proper gap (figure 4-1 . Tighten pipe plug. Disengage hand pump from check valve.

r Replace and tighten check valve cap. Adjust LOAD damper as necessary (paragraph 2-15).

4-6. HYDRAULIC FLUID REDUCTION. Occasionally it may be necessary to reduce the quantity of hydraulic fluid in the system to achieve accuracy.

a. Remove all weight from load cell.

NOTE - Use rag or other type of container to trap escaping fluid.

4-7.

b. Loosen plug on damper until fluid begins to escape from fitting. Bleed fluid until cell gap is at required dimension. Tighten pipe plug.

INDICATOR DAMPER SEAL REPLACEMENT. If the 0 - ring in the damper block should become scarred and hydraulic fluid leaks from around damper stem:

a. Remove damper stem by turning stem nut counterclockwise. b. Remove damaged 0- ring. C. Lubricate new 0- ring with silicone d. Install new 0 - ring by slipping over

shoulder into recessed groove.

[ CAUTION 1 Use extreme care when insertrng the damper stem into the damper body to prevent damaging 0 -ring.

grease or equivalent. end of stem working it up over

f : g.

Insert damper stem into damper block. Install damper stem nut by turning clockwise. Recharge of system will be necessary, refer to paragraph 4-5.

10181 Page 17

I II II I 1 ‘

Iw522

11 SD AND SW SERIES LOAD CELL SYSTEMS 1 I ~

‘

*~~I-OECK-E~*~

MANUAL. I

SD SERIES LOAD CELL

SW SERIES

t COMPRESSION LOAD CELL

EFFECTIVE 1 1

SW SERIES LOAD CELL

AREA NOMINAL GAP SQ. IN. IN 1 mm

Figure 4-1. Load Cell Gap and Plug Location


REPLACEMENT PARTS LIST

DIAL SIZE 6

”

a-1./2

”

12

”

18

”

INDICATOR SERIES GA87 D8 :D2:

WA12 WM18

Glass, Indicator B60 B915-1 B624-2 B1053-2

Gasket, Indicator Glass B63 B916-1 B62OA-1 B620A-18

Pointer, Indicator K357-1 K404-1 K306-2 K5W O-Ring, Damper B-651-6A

I Fluid, Indicator (Quart) I

W8 (Gallon) W8-I I

I Hose, Hydraulic 3116 Ma I

5392-2 l/4 Dia J398-

•

I

Fluid, Instrument (Quart) (Gallon)

Check Valve

Diaphragm (Sensater)

w15 W16

F350-1

see Parts Lists

l Include dash no for hose length required,eg 5392-5 indicates 5 foot length

Page 18 lo/81


m -~ERIES(TENSION)LOAD~ELLSYSTEM REPLACEMENTDIAPHRAGM

PARTSLIST CAPACITY

(LBS) 500

1,000 2,000

3,000 4,000

5,000 6,000 10,000

15,000 16,000 20,000 16,000 20,000 25,000 50,000 60,000

80,000 120,000 150,000 200,000 300,000

LOADCELL PART NO. E403 -lxx

E137A-lxx

E137A-2xx

E135B-2xx

E135B-3xx

E135B-4xx

E286-lxx E286-2xx

E282-lxx E282-3xx E282 -4xx E250-2xx E421-2xx

EFFECTIVE DIAPHRAGM AREA (SQ. INS) PART NO.

4.02 E401A-2

6.44 E97-21

6.44 E97 -22

16.10 E83-20

16.10 E83-30

36.767 E257-36

50.00 E273 -40

60.00 E251A-50 . E390-45

SD - SERIES PADEYE (TENSION) LoADcELL SYSTEM REPLACEMENT DIAPHRAGM

PARTS LIST

lo/81 Page 19

I SD AND SW SERIES TAOAD CELL SYSTEMS I I MARTIN-DECKEWlECHNtCAL MANUAL

SW - SERIES (COMPRESSION) LOAD CELL SYSTEM REPLACEMENT DIAPHRAGM

PARTS LIST

APACITY WS)

500 1,000

1,000 2,000

3,000 4,000

3,000 4,000 5,000 6,000 5,000 6,000

10,000 5,000 6,000 10,000

15,000 16,000 20,000 25,000 25,000 30,000 40,000 30,000 40,000 50,000 60,000 60,000 80,000

LOO, 000 125,000 150,000 100,000 125,000 160,000 zoo, 000 200,000 250,000 300,000 400,000 500,000

LOAD CELL PART NO.

E3?4-21/22

3136-11/12

E136-21/22

E360-214

E373-l/3

E92-11112

E92-21/22

E369-l/2

E266-2/6

E328-l/2

E384-l/2

E523-l/2

E523-314

EFFECTIVE DIAPHRAGM AREA (SQ. INS) PART NO.

4.02 E324-15

6.44 E97-21/22

6.44 E97-22

8.00 E358-20

12.00 E323 -24

16.10 E83 -20

16.10 E83-30

25.00 E325-30

36.767 E257-36

50.00 E273-40

60.00 E251A-50

100.00 E390-45

Page 20 lo/81

part number tw522 revision a - pslcolombia martib decker.pdfthe service procedures recommended by...

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