Part Number TW-538

Revision A

INSTALLATION, CALIBRATION, AND OPERATION

CRANE LOAD INDICATOR SYSTEM

MODELS
SC6B, SC6C, SC6D, SC10, SC10A, SC10B

Manufacturers of Precision Instruments

Printed in U.S.A. July 27, 1992

 Manual TW538 contains 22 pages, divided as follows:

Cover ........................... March1996

i through iii ...................... March 1996
TOC-5 through TOC-6 ............. March 1996
l-l ............................ March1996
2- 1 through 2-3 ................... March 1996
3-l through 3-4. .................. March 1996
4-l through 4-5 ................... March 1996
5-l ............................ March1996
6-l ............................ March1996
7-l ............................ March1996

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.
 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 ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

ii March 27,1996
M/D TOTCO
LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,

WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITA-
TION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PUR-
POSE.

M/D TOTCO warrants to Buyer (“Purchaser”) of new products manufactured or supplied by M/D
TOTCO that such products are, at the time of delivery to the Purchaser, free of material and work-
manship defects, subject to the following exceptions: (a) Any product that has been repaired or
altered in such a way, in M/D TOTCO’s judgment, as to affect the product adversely, including any
repairs, rebuilding, welding or heat treating outside of an M/D TOTCO-authorized facility, (b) Any
product that has, in M/D TOTCO’s judgment, been subject to negligence, accident or improper
storage, (c) Any product that has not been installed, operated and maintained in accordance with
normal practices and within the recommendations of M/D TOTCO, (d) For all items of special
order by Purchaser that are not manufactured by M/D TOTCO, Purchaser should submit warranty
claims directly to the manufacturer thereof.

M/D TOTCO’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 and of repaired or
replacement products to or from authorized M/D TOTCO service facility shall be borne by Pur-
chaser. M/D TOTCO may, at its sole option, elect to refund the purchase price of the products,
and M/D TOTCO shall have no further obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Purchaser.
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) Hydraulics and Mechanical Equipment: one (1)
year from date of installation or fifteen (15) months from date of shipment from M/D TOTCO,
whichever occurs first, b) All Elastomer Diaphragms: six (6) months from date of shipment from
M/D TOTCO, c) Electronic Equipment: six (6) months from date of shipment from M/D TOTCO.

. ..
March 27,1996 III
M/D TOTCO
 TABLE OF CONTENTS
Paragraph/Title Page
CHAPTER 1
GENERAL INFORMATION
1 .o GENERAL INFORMATION ..................................................... .1-1
1.1 General......................................................................l- 1
1.4 Personnel Qualifications ........................................................ .I-1
1.5 Unpackingandlnspection........................................................1- 1
1.7 Precautionary Information ....................................................... .1-l
1.8 Related Publications ........................................................... .1-l

CHAPTER 2
DESCRIPTION
2.0 DESCRIPTION .............................................................. ..2- 1
2.1 GeneralDescription.............................................................2- 1
2.2 Parameters.. ............................................................... ..2- 1
2.3 SystemComponents ......................................................... ..2- 1
2.4 HydraulicCylinder..............................................................2- 1
2.5 lndicator......................................................................2- 1
2.6 MUDWATCH Specifications ..................................................... .2-l
2.7 J10900ADisconnects.. ....................................................... ..2- 1
2.8 Attaching and Support Hardware. ................................................. .2-l
2.9 TheoryofOperation.............................................................2- 2

CHAPTER 3
INSTALLATION
3.0 lNSTALLATlON................................................................3- 1
3.1 Pre-Installation. ............................................................... .3-l
3.2 System Installation ............................................................ .3-l

CHAPTER 4
CALIBRATION/OPERATION
4.0 CALIBRATION/OPERATION. .................................................... .4-l
4.1 Factors Affecting Calibration/Operation. ............................................ .4-l
4.2 System Weight Test. ........................................................... .4-l
4.3 SystemOperation ............................................................ ..4- 2

CHAPTER 5
MAINTENANCE
5.0 MAINTENANCE................................................................5- 1
5.1 General......................................................................5- 1
5.2 Periodic Maintenance .......................................................... .5-l
5.3 Indicator Maintenance .......................................................... .5-l

CHAPTER 6
TROUBLESHOOTING
6.0 TROUBLESHOOTING. ......................................................... .6-l
6.1 General......................................................................6- 1

March 27,1996 TOG5

M/D TOTCO
Crane Load Indicator Systems
Manual TW538 Table of Contents

CHAPTER 7
REPAIR
7.0 REPAlR......................................................................7-1
7.1 RepairProcedures..............................................................7-1
7.2 Recharging the Load System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-l
7.3 Bleeding the Load System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-l

ILLUSTRATIONS

Figure 2-1 Typical Crane Weight Indicator Systems. ..................................... .2-2

Figure 2-2 J10900A Disconnect Assembly. ............................................ .2-3
Figure 3-l Counting Parts Line. ..................................................... .3-2
Figure 3-2 Typical Load Cell Installation Configurations. .................................. .3-2
Figure 3-3 Overall Dimensions for 6-inch Indicator and Bracket. ............................ .3-4
Figure 3-4 Overall Dimensions for 8 l/2-inch Indicator and Bracket. ......................... .3-4
Figure 4-1 System Weight Test Worksheet (Sample). .................................... .4-3
Figure 4-2 Hydraulic Cylinder Charge/Recharge Dimensions .............................. .4-4
Figure 7-l YA2Hand Pump ....................................................... ..7- 1

TABLES

Table 6-l Malfunction Isolation Chart ................................................ .6-l

TOG6 March 27,1996

M/D TOTCO
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

JANUARY1988

SECTIONl.0

GENERALINFORMATION

1.1 GENERAL. This manual provides in- applicable, in Martin-Decker technical

structions for the installation, operation and manuals. Locations of these precautionary
maintenance for Martin-Decker’s Crane Load notices are listed at the top of Page i.
Indicator Systems: SCGB, SCGC, SCGD, SClO,
SClOA and SClOB Cylinder Type models. The application of each type is as follows:

NOTES: WARNING: Used where a possibility of

damage to equipment or serious injury or
1. Models SCGC and SClOA replaced death to personnel exists.
Models SC6 and SC10 in production
in December 1980.
2. Models SCGD and SClOB replaced CAUTION: Used where a possibility of
Models SCGA and SClOA in pro- interruption of service exists.
duction in June, 1988 .
1.8 RELATED PUBLICATIONS.
1.2 Read the appropriate section of this
manual before attempting to perform any PUBLICATION SUBJECT:
installation, operation or maintenance NO.
procedures described herein.
TW517 SC28 h SC38 Series
1.3 Ensure that all personnel who will be Crane Load Indicator
performing any of the procedures described Systems, Sensator Type
in this manual, have read the Important TW 519 SB Series Crane Load
Safety Notice on Page i. and Radius Indicator
System, Sensator Type
1.4 PERSONNEL QUALIFICATIONS. En- TW523 SR Series Crane Radius
sure that personnel who will install and Indicator Systems
operate the equipment are qualified by TW 597 CLM2 Crane Load
training or experience to work with the Moment Indicator
equipment. System
TW610 CLM3 Crane Load
1.5 UNPACKING AND INSPECTION. The Moment Indicator
SC Series Crane Load Indicator Systems are System
shipped in containers designed to protect TW660 Crane Load Indicator
them from the normal hazards encountered (Compression Load
in transit. Carefully open the containers and Cell)
inspect for damage or missing parts. Check TW 593 P325E Hydraulic
the contents against the packing list. If any Cylinder
external damage or missing parts are ap- TW673 P10012A Hydraulic
parent, immediately notify Martin-Decker Cylinder
and the shipping agency. TW 1021 P10130A Hydraulic
Cylinder
1.6 Martin-Decker reserves the right to
change specifications at any time without NOTE: The P10012A and
prior notice. P10017A replaced the P325E
and P265D cylinders respect-
1.7 PRECAUTIONARY INFORMATION. ively in production in Novem-
Two types of precautionary notices, ber 1980. P10130A replaced the
WARNING and CAUTION, are found where P10012A in June, 1988.

l-l
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

SECTION 2.0

DESCRIPTION

2.1 GENERAL DESCRIPTION. The Cylinder necessary tare adjustments. The indicator is
Tw Series SC Crane Weight Indicator filled with Martin-Decker W8 Gauge Fluid
Systems (Fig. 2-11, when installed and oper- before operation for lubrication and protection
ated in accordance with the instructions against corrosion.
contained in this manual, are designed to
prevent crane overloading. ‘Ihe systems 2.6 HYDRAULIC HOSE. The hydraulic hose
provide constant monitoring of load para- (5234) connects the indicator gauge to the
meters of the crane on which they are in- cylinder. The l/4-inch high pressure hose is
stalled. The systems are 100% hydraulically double wire braided and rubber covered. It is
operated and require no external power supplied in lengths to satisfy individual system
source. requirements. Hose lengths greater than 50
feet are coupled with J10900A series dis-
2.2 PARAMETERS. These Systems are de- connects.
signed to operate within an ambient temp-
erature range of -20’ and +120° F f-29’ and 2.7 J10900A DISCONNECTS. The system is
+49O C). The system is accurate to plus or normally supplied with a J10900A-02 female
minus one percent of its rated full scale ca- half disconnect (Fig. 2-21 installed on one end
pacity when shipped from the factory. of the hose, and a J10900A-20 male half dis-
connect (Fig. 2-21 installed at the indicator
2.3 SYSTEM COMPONENTS. The SC series damping chamber. When mated, these compo-
systems are designed to individual crane re- nents constitute a J10900A Disconnect
quirements. The basic system consists of one Assembly. Additional disconnects for con-
hydraulic cylinder, (usually installed in the necting lengths of hose are supplied upon
crane main fall rigging), and an indicator. A 6- request.
inch indicator (GA1041 is supplied with SCGB,
SCGC and SCGD series systems. An 8-l/2-inch 2.8 ATTACHING AND SUPPORT HARD-
indicator (GD31) is supplied with SClO, SClOA WARE. The system is furnished with all
and SClOB series systems. Listed below are necessary attaching hardware to facilitate
the basic components of each system and at- installation and maintenance.
taching hardware:
a. Check Valve. Normally installed on
a. Hydraulic Cylinder the damper and used to replenish or
b. Indicator to reduce hydraulic fluid in the
C. Hydraulic Hose system. May be located elsewhere if
d. Disconnect Couplings desired.
e. Recharging Equipment b. Indicator Bracket. For mounting the
f. Attaching and Supporting Hardware indicator inside the crane cab.
ET. Tubing (optional) C. Hydraulic Fluid. Supplied in quart
1Wl5) or gallon (W16) containers and
2.4 HYDRAULIC CYLINDER. The hydraulic is used with the YA2 hand pump to
cylinder transmits a linear load signal to the charge the system in the field.
indicator by transforming the applied load into d. YA2 Hand Pump. For field loading
a hydraulic pressure signal. the system with hydraulic fluid. The
pump swivel nut connects to the
2.5 INDICATOR. The indicator has a scale check valve on the indicator.
calibrated in pounds, tons or kilograms as e. C71 Tie Straps. For fastening the
required by the user. It has a damper to hose or tubing to the boom. One
smooth pointer sensitivity and adjust response strap for every 10 feet of hose or
to operator preference. Included on each tubing is normally supplied with each
indicator is a dial adjust gear to make system.

2-l
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

f. Tubing (Optional). Copper tubing is may cause the indicated load to be

normally used to supplement the hy- outside the original calibration ac-
draulic hose for fixed boom appli- curacy. A crane-installed system ac-
cations where boom lengths exceed curacy of +2.0% of capacity, how-
100 feet. Its PVC covering protects ever, may be considered acceptable.
the tubing from chafing. C. Determining Hook Load. Factors af-
fecting the accuracy of a dead end
hydraulic cylinder application in-
2.9 THEORY OF OPERATION. cludes the number of lines reeved
between the boom point sheaves and
the block hook, the boom length and
a. Load Indicator System. When a load the boom angle. While hoisting, the
is applied to the cylinder, a linear friction of the sheaves causes the
hydraulic pressure signal is gener- crane load indicator to indicate a
ated by a diaphragm sensing ele- load which is lighter than it actually
ment. This signal is transmitted is. This friction can be from 0.5% to
through a high pressure hose to a’ 2% for each sheave in wire rope
bourdon tube type gauge assembly service. Conversely, sheave friction
which indicates the amount of force also causes the indicator to read high
on a weight dial (available in pounds, during lowering operations. To get an
kilograms or decaNewt0n.s). accurate indication of load weight,
b. Load System Accuracy. The load take the average of the indication
indicating system is factory cal- obtained during hoisting and lowering
ibrated to within +l% of full scale operations. Refer to Section 4.0 for
capacity. When the system is instal- details in calculating ‘Hoisting’ and
led on a crane, several influencing ‘Lowering’ readings, ‘Mean Load
factors, sheave friction in particular, Indicator Readings’ and % Error.

MODEL SCGD

MODEL SClOB

Figure 2-l. Typical Crane Weight Indicator Systems.

2-2
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

BM)RAuLIC HOSE
(REF)

JlOKioA-02
P,t?iiOlA DISCONNECT
BODY

Figure 2-2. J10900A Disconnect Assemb 1ly.

2-3
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

SECTION 3.0

INSTALLATION

3.1 PRE-INSTALLATION CHECKS. Pre- the indicator location to the

installation procedure consists of verifying cylinder, including extensions used
that the load indicating system is correct for when operating the crane with
the crane on which it is to be installed. Items additional boom sections. Check
to check: the size and condition of all hose
disconnects and collars to ensure
a. Ensure the indicator dial is they will not leak hydraulic fluid.
calibrated in the units of meas-
urement (pounds, tons, kilograms, 3.2 SYSTEM INSTALLATION.
etc.) compatible with the capacity
of the crane as dictated by its
configuration. CAUTION
b. Ensure the indicator dial is marked
with parts of line to be used with The crane load system is
crane configuration. If more than hydraulically charged at
one reeving is to be used, there Martin-Decker. Do not open
should be a separate scale on the the system except at dis-
dial (or a separate dial) for each of connect couplings.
the reevings. See Fig. 3-l for parts
line determination. a. Hydraulic Cylinder Installation.
c. Cylinder capacity must be adequate Select the method of installing the
for full crane capacity. To deter- hydraulic cylinder, taking into
mine cylinder capacity, use either account any obstructions and crane
one of the following methods: configuration. See Fig. 3-2 showing
typical load cell installations.
1. For even parts line dead-ended
at the boom, divide the system
capacity by parts of line to CAUTION
determine cell load as follows:

To ensure proper cylinder

Crane Load
Cell Load = operation, verify that the
Parts Line
cylinder hangs free and com-
pletely clear of all obstruc-
2. For odd parts line with su- tions at all operating angles
spended upper load block and of the boom. The cylinder
line dead-ended at the Iower must be free to align itself
block (hook), multiply the ca- with the deadline or hanger
pacity by the ratio of parts to ensure that it does not
line. This ratio is ‘parts line at bind.
upper block’ divided by ‘parts
line at the hook’ as follows: b. Hydraulic Hose and Tubing Instal-
lation.
Cell Load = (Parts Line at Upper Block) x Crane Load
(Parts Line at Hook)
CAUTION

During hydraulic hose and/or

d. Ensure hose or tubing is of tubing layout and instal-
adequate length for routing from lation, (can’t on page 3-3)

3-l
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

3 tMTS b tMTS 5 ?llTS c tms 1 tAlTS

Figure 3-I. Counting Parts Line.

Figure 3-2. Typical Load Cell Installation Configurations.

3-2
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

allow sufficient slack in CAUTION

the hose to avoid pulling
it taut during crane op- Do not remove the plug
eration. Excess tension from the damper as-
can cause connector fail- sembly as hydraulic fluid
ure. may be lost.
Install hose and tubing as follows:
d. Post-Installation Checkout. After
1. Route hose or tubing from system installation is complete,
hydraulic cylinder to indicator. check the following to ensure
Select the best layout to pro- proper system operation:
tect hoses and tubing from
damage during crane operation.
If tubing is being used, ensure 1. Check all mounting hardware
that junction blocks are firmly for secure installation.
secured to prevent tubing 2. Lower boom. Check all fittings
fittings from rotating and and connections for leaks;
becoming loose. tighten if necessary to preserve
2. Connect the hose disconnects. the integrity of the Load
3. Use C71 Tie Straps approxi- Indicator System.
mately every 10 feet to secure- 3. Check that cylinder piston rod
ly fasten hoses or tubing to the extension (gap) is within
boom to prevent chafing, cut- specifications shown in Fig. 4-
ting, crushing or other damage 2. If the gap is not within
during crane operation. range, recharge the system.
Refer to paragraph 7.3.
4. Exercise the system through
C. Indicator Installation. Select a several cycles. Hoist a known
location for the indicator that weight of at least 25 percent of
provides a good visual access for full crane capacity to approx-
the operator. Installation may be imately a foot off the ground,
either inside or outside the crane then lower it to remove weight
cab. from the rigging. Repeat
several times to exercise the
1. Using Fig. 3-3 for the 6-inch cylinder.
indicator or Fig. 3-4 for the 8- 5. On completion of step 4,
l/a-inch indicator, locate and remove weight from the hoist.
drill holes for the indicator Turn the tare adjust knob
mounting bracket. (knurled knob on back of the
2. Install the bracket and indi- indicator) to rotate load dial to
cator gauge. zero.

3-3
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

l
9.75
(244mm)

frij
1

Figure 3-3. Overall Dimensions for 6-Inch Indicator and Bracket.

10.31
(262mm)
0. 56
(14mm)

q-7
+f
1

!!A.. 0.62
(16mm) c
3.12
- (107mm)

BRACKET 8-l/2 INCH INDICATOF(

Figure 3-4. 9verall Dimensions for 8-l/2-Inch Indicator and Bracket.

3-4
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

SECTIONCO

CALIBRATION/OPERATION

4.1 FACTORS AFFECTING CALIBRA- a. Test weights used for calibration

TION/OPERATION. Factors affecting ac- should be approximately 15, 35 and
curacy of a dead end load cell application 75 percent of System capacity and
include the number of lines reeved between must be accurate to within &l%.
the boom point sheaves and the hook block, The weight of the rigging used for
the boom length and boom angle. While hoist- lifting test weights must also be
ing, the friction of the sheaves causes the known (to within *l%).
crane weight indicator to indicate that load b. Check that the cylinder gap (Fig. 4-
is lighter than it actually is. This friction can 2) is within specifications. If the
range from .5 to 2 percent for each sheave gap is not within specifications,
in wire rope service and also causes the recharge or bleed the system aa
indicator to read high during lowering required. Refer to Section 7.0.
operations. ‘l’b get an accurate indication of C. Perform Zero set tare adjustment
load weight, take the average of the in- (paragraph 4.3).
dication obtained during hoisting and lower- d. Record data as follows:
ing operations. For example:
1. Enter the weight of the test
weights in the table labeled
a. A crane is rigged with 4 parts line; ‘Weight Test Specifications’.
load indication system capacity is
80,000 pounds. NOT& If lifting rigging
b. Load to be lifted is 65,000 pounds. is to be used, add the
C. Load cell is at dead end. lifting rigging weight to
d. Sheave friction equals 314 of one the test weight. Enter
percent per sheave. total on the worksheet
in the box indicated.
When the load is raised, the load in-
dicator reads 63,000 pounds; when the load is 2. Determine “Mean Loadn aa
lowered, the load indicator reads 67,000 follows:
pounds. Mean or average value of the -two
readings is 65,000 pounds. A. Hoist the 15% weight ap-
In addition, raising and lowering the proximately 10 feet. In the
boom will cause the indicator to show an table labeled “Mean Load
increase, then a decrease in the indicated Computationstf, record “In-
weight. This apparent discrepancy is cause by dicator Reading (Hoisting)fl
hydrostatic pressure and may be ignored once in the box indicated.
the weight of the load has been hoisted. The B. Lower the weight two feet.
indication change due to the change in the Enter the “Indicator Read-
hydrostatic head can be used as a quick test. ing (LoweringP in the box
Once during each operating day, cycle the indicated.
boom from full stop to full stop and back C. Add the readings (Indicator
again, noting the load indicator movement. It Reading, Hoisting) and (In-
should rise and fall with the boom action. If dicator Reading , Lower-
the indication does not change, perform the ing) and enter the sum in
weight test detailed below. the box indicated “Sum of
Readings”.
4.2 SYSTEM WEIGHT TEST. Use weight D. Divide the ?surn” (step C)
test worksheet (sample on page 4-3) to by 2 and enter the result in
record and calculate data. The following the box labeled “Mean Indi-
equipment is needed to perform the test: ca tor Reading”.

4-l
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

E. Repeat steps A, R, C and D enter the “2nd Hoist Mean

for the 35% and 75% test Indicator Reading” and the “4th
weights. Hoist Mean Indicator Reading”
F. Repeat steps A, R, C and n in the table labeled “Repeat-
for the 35% test weight for ability Test”.
the repeatability test.
A. Calculate % error as follows:
3. On the worksheet, perform the %prorI
“Percent of Error Computa- 2nd Rolst Mwn 4th AoM Mean
tions” as follows: Icator Rudfnq H- hdlcrtor Rudlng
rL 0 f 100
(2nd Hobt Yun hdiutar Rudlnq)
-4. In the table noted “Percent
of Error Computations”, B. Calculated repeatability %
enter the “Actual Load” Error should be less than or
(Total Weight of Test equal to 1%.
Weight Plus Rigging), enter
the “Mean Indicator Read- 4.3 SYSTEM OPERATION.
ing” and enter the “Total
Indicator System Capa-
city”. From these numbers,
- WARNING -
compute the % error as
follows:
Before proceeding with the
c
(Actual LadI - hfenn Indicator Rendin a = loo operation adjustments, make
%Ehor=
Indicator System Capacity the _ following checks to
avoid damage to the
B. If percent of error for all equipment or serious injury
test loads is f l-1/2%, the or death to personnel.
system is within the speci- Ensure that:
fications. If percent of
error is greater that f l- 1. Parts line shown on the
l/2%, check and repair the indicator dial match the
hydraulic system. See Sec- crane rigging.
tion 6.0 for Troubleshoot- 2. Capacities shown on the
ing. indicator dials match
the load rating chart
4. To determine repeatability, located in the crane cab.

4-2
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

SYSTEM WEIGHT TEST WORK SHEET

OWNER DATE
CRANE MFR: MODEL: SERIAL NO.

MODEL SERIAL NO.

DEVlCE MFR: MARTlN-DECKER
SYSTEM CAPACIM:
CRANE CONFIGURATION AT TlME OF TEST:

LOCATlON OF LOAD SENSOR:

WEIGHT TEST SPEClFlCATlONS
LOW WEIGHT INTERMEDIATE WEIGHT HIGH WEIGHT
(APPROX. i 5~) (APPROX 35x) (APPRo~. 75x)
TOTAL WEIGHT OF TEST
1 WEIGHT PLUS RIGGING (&1X)1
MEAN LOAD COMPUTATlONS
1st HOIST 2nd HOIST 3rd HOIST 4th HOIST
15x 35x 75x 35%
INDICATOR READING
(HOISTING 1 )
INDICATOR READING
(LOWERING 1)
SUM OF READINGS
(HOISTING & LOWERING)
MEAN INDICATOR READING
UEANINDICATCRREADlNG-y
PERCENT OF ERROR COMPUTATlONS
MINUS MEAN INDICATOR DlVlDED INDICATORSYSTEM MULTIPLIEDBY X ERROR
tlOlST READING > BY CAPACIM 100
1st HOIST I x 100
2nd HOIST L. x 100
.
3rd HOIST T x 100
REPEATABIUN TEST
2nd HOIST 2nd HOIST
MlNUS DlVlDED MULllPUED BY X ERROR
38X 3sx 100
WANWDlCAlcR *’ MAN
(YZF p;““” (!i%ilFiywc
.
-T x 100
4th HOIST SHOULD EQUAL SECOND HOIST MTHIN fl%
CONDITION OF LOAD INDlCATlNG DEVICE:
1 INSPECTOR: IORGANIZATION:
Figure 4-l. System Weight Test Worksheet (Sample).

4-3
 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

W.16

A.

P10130A Hydraulic Cylinder (production effective 6/l/88)

B. RPzPLRi l.18 OSmmlDtA

mcNDs
\

,DIhI A B
FULL 1.00 (25mm) 11.64 (296mm)
RECHARGE 1.75 (44mm) 12.39 (315mm)
.

P10012A-00003 Hydraulic Cylinder (production discontinued 6/l/88).

C.

DIM A B
‘FULL 0.25 ( 6mm) 7.81 (199mm)
RECHARGE 0.75 (19mm) 6.31 (223mm)

P325E-2 Hydraulic Cylinder (production discontinued 12/14/80)

Figure 4-2. Hydraulic Cylinder Charge/Recharge Dimensions.

 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD- SClO- SClOA-SClOB

a. Indicator Test. At the beginning of crane load system is to be used for

each operating day, cycle the boom weight indication:
from full stop to full stop and back
again, noting the indicator move- 1. Position the boom at the radius
ment. It should rise and fall with the where the lift is to be made.
boom action. If the indication has 2. Remove any lifting rigging from
not changed, perform the system the hook.
weight test described in Paragraph 3. Turn the indicator zero adjust
4.2. knob until the pointer is at zero
on the dial.
b. Load Pointer Zero Set (Tare Adjust- 4. Hook up the lifting rigging and
ment). Due to the effect of hydro- pick it off the ground. Note the
static head (indicator variations weight of this rigging.
because of changes in the height of 5. Turn the indicator zero adjust
the cylinder above the indicator), knob until the pointer is at zero
make a tare setting prior to hoisting on the dial
each time the boom angle or load 6. The crane is now ready to weigh-
radius is changed: lift.

1. Position the boom at the radius

(boom at the angle) at which lift
- WARNING -
is to be made.
2. Remove any lifting rigging from
the hook. Weight of lifting rigging
_. _ .
3. Turn the indicator dial zero must be added to dial in-
adjustment knob (knurled knob dication to ensure that
on the back of the indicator the crane capacity is not
case) and rotate the dial until exceeded.
the pointer is at zero.
d. Pointer Damper Adjustments. The
damper is located on top of the 6-
NOTE: When reading the inch indicator or on the bottom of
indicator, maintain a the 8-l/2-inch indicator case and has
direct and perpendicular a tee handle for adjustment.
line of sight between the
eye and the pointer in 1. If the pointer is too sensitive,
order to eliminate the push damper tee handle in and
possibility of parallax turn it clockwise to decrease
error. pointer action.
2. If the pointer is sluggish, turn
the tee handle counterclockwise
c. Tare Setting When Weighing. If the to increase pointer sensitivity.

4-5
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD-SClO-SClOA-SClOB

SECTIONS.0

MAINTENANCE

5.1 GENERAL. The systems described in 5.2 PERIODIC MAINTENANCE. The Load
this manual require little maintenance, Indicator System is designed for long, trouble
however, general operating practices should free service involving little maintenance.
include: Perform weekly inspections on the hoses to
ensure they are not cut, crushed or otherwise
damaged.

a. Cleaning the indicator glass on an 5.3 INDICATOR MAINTENANCE. If the

“as necessary ” basis by using any movement should become sluggish or other-
good commercially available glass wise malfunction, inspection and repair
cleaning solution and a clean, soft, should be performed only by qualified
lint free cloth. instrument personnel, otherwise, the
instrument should be returned to Martin-
b. Visual inspection of the system Decker or an authorized repair facility. If
prior to use, with special attention replacement or repair of any parts is
paid to the integrity of fittings and required, order them from Martin-Decker or
connections, ensuring no leakage any authorized representative. It is likely
and that the load cell is free of any that re-calibration will be required if any
obstructions. Should any leakage or repairs are performed on the indicator gauge.
and other malfunction be observed, Ensure the indicator is repaired and
refer to Section 6.0. calibrated only by qualified personnel.

5-l
 TW538
CRANELOADINDICATORSYSTEM-CYLINDERTYPE
MODELSSCGB-SCGC-SCGD- SClO- SClOA-SClOB

SECTION6.0

TROUBLESHOOTING

6.1 GENERAL. Most common system malfunctions can be remedied using Table 6-l in
conjunction with the repair procedures in the following paragraphs.

TABLE6l.MALFUNCTIONISOLAT'IONCHART

MALFUNCTION PROBABLECAUSE CORRECTIVEACTION

No reading on No fluid in system Recharge system (para 7.3)

indicator dial
Obstruction in hose Clear or replace hose
l

Damper closed Correct damper setting

Inaccurate load Hydraulic system Check hose connection for
indication undercharged leakage; recharge system
Worn indicator Repair or replace indicator;
internal mechanism contact Martin-Decker for
service

Improper zero (tare) Adjust zero-set (tare);

setting recharge system

Erratic or sluggish Improper damper Correct damper setting

indicator reading setting

Air in hydraulic Purge system of air by pumping

system W15 fluid through check valve
on indicator and bleed through
bleed plug on the cylinder
Worn indicator Repair or replace indicator;
internal mechanism contact Martin-Decker for
service

Continued loss of Worn cylinder seals Contact Martin-Decker for

fluid at cylinder and/or piston service

6-l

-- -.- _--.- -.-

 TW538
CRANE LOAD INDICATOR SYSTEM - CYLINDER TYPE
MODELS SCGB - SCGC - SCGD - SC10 - SClOA - SClOB

SECTION 7.0

REPAIR

7.1 REPAIR PROCEDURES. The following to slightly overcharge.

procedures cover repairs that may be per- k. Loosen cylinder screw (or plug) and
formed in the field and do not include bleed until correct gap is obtained.
detailed disassembly/assembly procedures for 1. Tighten cylinder screw (or plug).
the indicator gauge, hydraulic cylinder or m. Disengage the hand pump swivel
related equipment. nut from the check valve.
n. Replace and tighten check valve
7.2 Field repairs consist of recharging or cap.
bleeding the hydraulic system and replacing 0. Adjust damper as necessary.
faulty components, i.e., the indicator gauge,
hydraulic cylinder or hoses. 7.4 BLEEDING THE LOAD SYSTEM.

7.3 RECHARGING THE LOAD SYSTEM. a. Remove all weight from the
cylinder.
a. Assemble the hand pump and swivel
as shown in Fig. 7-1. NOTE: Use a rag or con-
b. Remove the cap from the check tainer to trap escaping fluid.
valve on the damper.
C. Attach the hand pump swivel nut to b. Using a 5/8-inch wrench, loosen the
the check valve. check valve on the indicator until
fluid begins to escape from the
NOTE: Do not tighten the fitting.
swivel nut at this time. It
will be used to purge air CAUTION
from the system.
Avoid backing the check valve
d. Fill pump bowl with Martin-Decker all the way out or fluid may
WlS/W16 (red) fluid. be lost from the system.
e. Stroke the pump until air is purged
at the loose swivel nut, then c. While bleeding fluid, constantly
tighten the nut. check the cylinder gap {Fig. 4-2,
dim. ‘A9 for proper reading.
NOTE: Keep pump reservoir d. When cylinder gap is correct,
at least one-half full at all retighten the check valve.
times to prevent introduc- e. Perform the Weight Test. See
ing air into the system. Section 4.0. -

f. Raise the cylinder to a position

slightly higher than the indicator
gauge.
Loosen truss head bleed screw at
the base of P325E cylinder; or plug
at the top of P10012A and P10130A
cylinders.
h. Pump fluid into the system and
bleed at the cylinder screw (or
plug) until air bubbles cease to
appear.
i. Tighten the cylinder bleed screw
(or pipe plug).
j. Pump enough fluid into the system Figure 7-l. YA2 Hand Pump Assembly.

7-l