Lift Truck Weight Indicator

Technical Manual
GA1035A Series

REFERENCE REFERENCE DESCRIPTION

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

© Copyright 2011 National Oilwell Varco, All Rights Reserved.

DOCUMENT NUMBER REV

TW693 B

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Revision History

B 06.09.2011 Template Conversion

A 05.26.2011 Released per EC#: 79668-0
Rev Date Reason for issue Prepared Checked Approved

Change Description

Revision Change Description

A First Issue
B Template Conversion

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Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 2: Overview
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shut-Off Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 3: Installation
Pre-Installation Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Weight Indicator Installation Without Optional Gauge Isolation Valve. . . . . . . . . . . . . 11
Weight Indicator Installation with Optional Gauge Isolation Valve. . . . . . . . . . . . . . . . 13
Bleeding the Weight Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chapter 4: Calibration and Operation

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Weighing Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Initial Lift Test to a Known Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustable Item Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 5: Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hoist Mechanism Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 6: Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Table of Contents
Chapter 7: Factory Repair
Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Reinstalling the Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 8: Drawings and Parts Lists

GA1035A Weight Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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1: General Information

This manual contains installation, operation, maintenance, and parts information, which should
enable qualified personnel to install, operate and troubleshoot this system. Every effort has been
made to ensure the accuracy of the information contained herein. National Oilwell Varco (NOV) will
not be held liable for errors in this manual or for consequences arising from misuse of this material.

Conventions
Notes, Cautions, and War nings
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.

Note: The note symbol indicates that additional information is provided about the
current topics.

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

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 installations,
operations, and maintenance.

Caution: To avoid injury to personnel or equipment damage, carefully observe

requirements outlined in this section.

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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 installation.
 Replace failed or damaged components with genuine NOV parts. Failure to do so could
result in equipment damage or injury to personnel.
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.

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2: Overview

Physical Description
The NOV Lift Truck Weight Indicator System provides the lift truck operator with a ready indication
of the load lifted by the lift truck during normal operations. The system operates off the existing lift
truck hydraulic system instead of using a load cell for weight measurement.
The Model GA1035A Weight Indicator System has a 6 in. gauge with an adjustable Item that
permits field calibration in minutes without removal of the gauge. The gauge contains a manual
tare adjustment for zeroing out the weight of the trucks forks and pallets or containers the operator
does not want included in the weight measurement. A pulsation damper controls excessive pointer
oscillations and protects the gauge during shock loading.

Weighing
Weighing should be done with the forks one foot off the ground, receiving pressure from only the
primary lift cylinder(s). (Refer to the section on "Installation" on page 11, and "Calibration and
Operation" on page 17).

Shut-Off Valves
Caution: Pressure to the gauge should be shut off when weight is taken to heights where
another ram begins to extrude or when the load is taken to the trucks maximum height,
or when carrying a heavy load over a rough road surface. This can be accomplished by
closing an optional shutoff valve. Failure to do this may over-pressure the gauge and
damage it, voiding the calibration and warranty.

It is recommended that a gauge isolation device be installed on trucks with multiple lift cylinders.
The gauge is calibrated for use in the lower cylinder range and may be damaged by the higher
pressures incurred when lifting loads in the upper cylinder ranges.
It is also recommended that a gauge isolation device be installed on trucks used in installations
with multiple operators who do not properly adjust or close the damper as description in the
Caution note above.
NOV offers a gauge isolation push-to-read valve which may be installed in the pressure line to the
gauge to protect the gauge from over pressure or shock loading. This optional valve kit, KT1105A,
is supplied with all necessary hardware for installation. The gauge isolator valve has a push-to-
read knob that delivers instant pressure to the gauge, but totally isolates the gauge from the fluid
pressure line until the knob is pressed. When the knob is released, a spring-loaded spool closes
instantly and drains all fluid pressure from the gauge back into the reservoir. Partial snubbing
action in the valve protects the gauge from surge damage when the actuating knob is pushed. The
spring-loaded spool is custom fitted to the all steel body and minimizes maintenance and leakage.

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The basic model number for the Lift Truck Weight Indicator System is GA1035A. The various
options are specified by dash numbers or letters following their basic model number as follows:

Part No. Designator GA1035A XXX X X X

Basic Part Number

Note: Add K for
Kilograms (GA1035AK)
Add D for decaNewtons
(GA1035D)
Dial Designator - Table 2-1.
Tube Designator - Table 2-2.
Fitting Designator - Table 2-3.
Hose Designator - Table 2-4.

Note: The gauge isolation valve described in "Shut-Off Valves" on page 7 may be
purchased as an optional kit, P/N KT1105A with all necessary installation hardware
and fittings. Refer to Figure 8.4 on page 32 for more information.

Figure 2.1: GA1035 Gauge Dimension Drawing

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Table 2-1. Dial Designators

DIAL UNITS DIAL NUMBER
Designator Pounds Kilograms decaNewtons Pounds Kilograms decaNewtons
4SS 200 200 ---- B1151-0002 B1151-0002K ----
6SS ---- ---- 250 ---- --- B1576-00025
7SS 300 300 ---- B1151-0003 B1151-0003K ----
9SS 500 500 ---- B1151-0005 B1151-0005K ----
CSS 1,000 1,000 1,000 B1151-0010 B1151-0010K B1576-0010
ESS 1,500 1,500 1,500 B1151-0015 B1151-0015K B1576-0015
FSS 2,000 2,000 2,000 B1151-0020 B1151-0020K B1576-0020
HSS 2,500 2,500 2,500 B1151-0025 B1151-0025K B1576-0025
JSS 3,000 3,000 3,000 B1151-0030 B1151-0030K B1576-0030
KSS 4,000 4,000 4,000 B1151-0040 B1151-0040K B1576-0040
LSS 5,000 5,000 5,000 B1151-0050 B1151-0050K B1576-0050
MSS 6,000 6,000 6,000 B1151-0060 B1151-0060K B1576-0060
NSS 7,500 7,500 ---- B1151-0075 B1151-0075K B1576-0075
PSS 8,000 8,000 8,000 B1151-0081 B1151-0081K B1576-0081
RSS 10,000 10,000 10,000 B1151-0100 B1151-0100K B1576-0100
TSS 12,000 12,000 12,000 B1151-0120 B1151-0120K B1576-0120
USS 15,000 15,000 15,000 B1151-0150 B1151-0150K B1576-0150
VSS 16,000 16,000 ---- B1151-0160 B1151-0169K B1576-0160
WSS 18,000 18,000 ---- B1151-0181 B1151-0181K ----
XSS 20,000 20,000 20,000 B1151-0200 B1151-0200K B1576-0200
SWS 25,000 25,000 25,000 B1151-0250 B1151-0250K B1576-0250
S1S 30,000 30,000 30,000 B1151-0300 B1151-0300K B1576-0300
S2S 40,000 40,000 40,000 B1151-0400 B1151-0400K B1576-0400
S3S 50,000 50,000 50,000 B1151-0500 B1151-0500K B1576-0500
S4S 60,000 ---- ---- B1151-0600 ---- ----
S5S 75,000 ---- ---- B1151-0750 ---- ----
S6S 80,000 ---- ---- B1151-0800 ---- ----
S7S 90,000 ---- ---- B1151-0900 ---- ----
S8S 100,000 ---- ---- B1151-1000 ---- ----
S9S 120,000 ---- ---- B1151-1200 ---- ----
S0S 150,000 ---- ---- B1151-1501 ---- ----
SBS 180,000 ---- ---- B1151-1800 ---- ----
SES 250,000 ---- ---- B1151-2500 ---- ----
SFS 300,000 ---- ---- B1151-3000 ---- ----
SGS 400,000 ---- ---- B1151-4000 ---- ----
SHS 500,000 ---- ---- B1151-5000 ---- ----
SJS 600,000 ---- ---- B1151-6000 ---- ----
SMS 1,000,000 ---- ---- B1151-10000 ---- ----
STS ---- 3,500 ---- --- B1151-0035K ----

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Table 2-2. Tube Designators

DESIGNATOR TUBE NUMBER PSI RANGE @ 360 WITH RETARD

G 0221A-08 394-710

H 0221A-09 500-900

J 0221A-10 724-1284

K 0221A-11 960-1700

L 0221A-12 1350-2220

M 0221A-13 1585-2720

Note: Values are maximum possible with maximum movement setting on link
connections.

Table 2-3. Steel Fitting Designators

DESIGNATOR PART NO. DESCRIPTION QUANTITY

S NO FITTINGS -------- ----------

1 J10152A-1 TEE SWIVEL, 1/2” OD TUBE 1

2 J10153A-2 TEE SWIVEL, 3/4” OD TUBE 1

3 J10153A-3 TEE SWIVEL, 1” OD TUBE 1

Table 2-4. Hose Designators

DESIGNATOR PART NO. DESCRIPTION

S NONE --------

1 J392-6 HOSE, 6 FT (1.83M)

2 J392-7 HOSE, 6 FT (2.13M)

3 J392-8 HOSE, 8 FT (2.44M)

4 J392-9 HOSE, 9 FT (2.74M)

5 J392-10 HOSE, 10 FT (3.05M)

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3: Installation

Pre-Installation Checkout
Prior to installing the Lift Truck Weight Indicating System, check that the hoist, tilt, and steering
mechanisms on the lift truck are in proper working order to assure satisfactory operation of the
system. Perform the following checks:
Warning: All the following items must be thoroughly checked to ensure
proper Weight Indicator operation.

a. Verify that the fluid in the lift truck reservoir is at the required level, and that there are no
hydraulic leaks.
b. Check that the slides on the mast of the truck are clean and well lubricated. If the sliders
are not clean, it is recommended then that they be steam cleaned, and the bearing
surfaces coated with a molydenum grease, such as Lubriplate, Molylube or Lubaloy.
c. Inspect the apron and mast rollers for frozen bearings and flat spots. Replace if badly
worn.
d. Inspect slides for any excessively worn or bent surfaces. Rework or replace as
necessary.
e. Make sure that the ram packing is not leaking or excessively tight.
f. Inspect the ram and piston for bent sections. Straighten or replace as necessary.
g. Inspect the lift truck hydraulic system for leaks at the hoist control value and the hoist
cylinder(s).

Weight Indicator Installation Without

Optional Gauge Isolation Valve
The following steps provide installation instructions for the Lift Truck Indicator Systems without the
optional gauge isolation valve. Actual mounting locations of the gauge and hydraulic hose will vary
with truck model and user preference. Refer to gauge and bracket dimensions shown in Figure 2.1
on page 8. Install the Indicator System as follows:
a. Verify that the gauge damper (Figure 3.1 on page 12) is closed (turned fully clockwise).
b. Select a suitable location on the lift truck to mount the gauge bracket. Position the gauge
for quick reference by the operator without restricting his view.
Caution: Tilt the mast back as far as possible and run the fork apron up and
down to insure the cross members will not hit the gauge.

c. Fasten the gauge bracket to the truck using four 1/4 in. bolts of suitable length.

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d. Install the gauge to the bracket using the lockwashers and 1/4-20 in. bolts supplied.
Caution: Turn off the truck motor and relieve hydraulic pressure from the hoist
mechanism as detailed iп the service тапиаl for the truck. With most trucks, this
is done by lowering and tilting the mast forward until the lift chains are slack.

Note: Use pipe sealing compound on all pipe fittings to avoid leaks.

Figure 3.1: Gauge Components and Mounting Bracket

Figure 3.2: Lift Truck Weight Indicator with Optional Push-to-Read Gauge Isolation
Value.

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e. Remove the plastic cap from the hose connection port on the gauge. Install the swivel
union (Figure 3.1 on page 12).
f. Disconnect the lift truck control valve-to-cylinder hydraulic hose at the appropriate point.
Note: Some lift trucks have sequencing valves, variable speed valves, or check
valves between the main control valve and the actual lift cylinder. The indicator
must sense true lift cylinder pressure to operate accurately. For this reason, there
should be no control devices between the gauge hose tap point and the lift
cylinder.
g. Install the appropriate fitting (reference "Table 2-3. Steel Fitting Designators" on page
10). It may be necessary for the customer to provide the fitting.
Note: Use this optional tee fitting if provided. In some installations, the existing
hoist cylinder hose fitting can be modified for connection of the gauge hydraulic
hose (Figure 3.3 on page 14). Remove the fitting. Drill and tap a 1/4 NPT hole (3/
16 in. hole if tubing is used). Clean out drill/tap fittings before reinstalling.
h. Remove the plastic cap from one end of the gauge hydraulic hose, and connect the
hose to the truck hoist hydraulic system at the fitting installed in Step g.
i. Route the hydraulic hose from the truck hydraulic connection to the gauge. Ensure the
hose is routed so that it does not become crimped or pulled tight during fork lift
operation.
j. Remove the plastic cap from the free end of the gauge hydraulic hose, and connect the
hose end to the swivel union on the gauge.
k. Position the hose so that it will not interfere with hoisting or will not be cut or crushed. Tie
in place and verify that all hydraulic hose connections are tight.

Weight Indicator Installation with

Optional Gauge Isolation Valve
The following steps provide installation instructions for the Lift Truck Weight Indicator System with
the optional gauge isolation valve. Actual mounting locations of the gauge and hydraulic hose will
vary with the truck model and user preference. The gauge isolation valve may be mounted in the
gauge mount bracket (Figure 3.2 on page 12) or in an appropriate panel or plate on the lift truck.
Install the system as follows:
a. If the gauge isolation valve kit KT1105A has been pre-assembled to the Lift Truck
Indictor (Figure 8.4 on page 32), proceed to step b. If the KT1105A kit is supplied
separately from the gauge and bracket, install the valve on the bracket as follows.
Refer to Figure 3.2 on page 12 and proceed with the following:

1. Install swivel (Item 3) into port P on the gauge isolator valve.

Note: Use Teflon sealant on all pipe fittings to prevent leaks.

2. Install a bushing (Item 4) and an elbow (Item 5) in ports T and G on the gauge isolator valve
at the orientation shown in Figure 8.4 on page 32.

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3. Loosen the knob screw set on the valve shaft. Remove the knob and unscrew the jam nut
from the gauge isolation valve. Install the internal-tooth washer (Item 2) on the valve. Insert
the threads of the valve through the .875 in. hole in the bracket. Position the valve as shown
in Figure 8.5 on page 33. Secure the valve in place with the jam nut.

Figure 3.3: Tapping into existing fitting for Weight Indicator System (Typical)

Note: If the bracket to be used does not have this hole, drill a .875 in. diameter
hole at the location shown in Figure 8-3.

4. Install the shaft extender (Item 8) on the valve shaft, place the knob on the shaft extender
and retighten all set screws.
5. Install bushing (Item 4) and the connector (Item 7) into the J640 fitting on the back of the
gauge damper.
6. Measure, form, and cut the tubing (Item 6, heavy wall, .187 OD) to the correct length and
install it from port G on the valve to the damper.
b. Verify that the gauge damper (Figure 3.1 on page 12) is closed (turned fully clockwise).
c. Select a suitable location on the lift truck to mount the gauge bracket. Position the gauge
in a place that is accessible to the operator without view restrictions.
Caution: Tilt the mast back as far as possible and run the fork apron up and down
to ensure the cross members will not hit the gauge, bracket or valve.

d. Fasten the gauge bracket to the truck using four 1/4 in. bolts of suitable length.

Caution: Turn off the truck motor and relieve hydraulic pressure from the hoist
mechanism as detailed in the service manual for the truck. With most trucks, this
is done by lowering and tilting the mast forward until the lift chains are slack.
e. Connect one end of the system pressure hose to the lift truck per "Weight Indicator
Installation Without Optional Gauge Isolation Valve" on page 11.

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f. Route the free end of the hydraulic hose from the truck hydraulic connection to the
gauge. Ensure the hose is routed so that it does not become crimped or pulled tight
during fork lift operation.
g. Remove the plastic cup from the free end of the gauge hydraulic hose and connect the
hose to the swivel fitting, port P (Item 3) on the isolator valve. Position the hose so it will
not interfere with hoisting or will not be cut or crushed. Secure in place with tie wraps
supplied with the gauge. Verify that all hydraulic hose connections are tight.
h. Make up the return line using light gauge tubing (Item 9). Connect it between the fitting
in the isolator valve port T and the lift truck reservoir. The actual method of installing the
return line into the reservoir will vary with the type and model of lift truck used. This
return line is a drain line from the gauge and valve and carries little or no pressure. One
method of connecting this return line to the reservoir is to drill and tap the lift truck
hydraulic system return line or the reservoir itself for installation of one of the “tubing” to
.125 NPT (Item 5 or 7) fittings supplied with the gauge isolation kit. Location for the
installation of the fitting will vary. If possible, this fitting should be located above the
normal fluid level line in the reservoir.
Caution: Extreme care must be taken to keep chips and cuttings out of the
reservoir if a hole must be drilled and tapped.
Hint: If this method is chosen, the drill tap and metal surface to be tapped must be
covered with a very heavy coat of grease to retain chips and keep them from
contaminating the reservoir.

Bleeding the Weight Indicator System

The following bleeding instructions must be performed before putting the system into operation:

a. Verify that the gauge damper (Figure 3.1 on page 12) is closed (turned fully clockwise).
Caution: The damper must be closed before continuing the bleeding procedure.

b. Loosen the bleed plug (Figure 3.1 on page 12) at the gauge.
c. Start the lift truck.
d. With the motor running, open the hoist control valve, actuate the push-to-read gauge
isolation valve (if installed), and bleed all air from the gauge and hose by opening the
damper. Continue bleeding until all air is bled from the system and a stream of fluid, free
of air bubbles, escapes at the bleed plug opening. Close the damper.
e. Tighten the bleed plug.
f. Open the damper. Turn two or three turns counterclockwise to ready the system for
operation.
Note: Repeat this procedure two days after installation and again five days after
installation to ensure all air is bled from the hydraulic system.

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4: Calibration and Operation

General Information
The gauge calibration range was set at the factory for the type of lift truck specified in the
purchase order. After installation of the hydraulic connectors, hose assemblies and gauge, check
the gauge calibration in accordance with the following paragraphs.

Caution: The gauge calibration range has been set for use on the lift truck
specified on the gauge tag. The gauge will require final calibration after installation.
Do not adjust the gauge calibration Item until the gauge’s response to a known
weight is checked.

Damper Adjustment
Begin with the damper (Figure 3.1 on page 12). Open it two or three turns then adjust it so the
pointer does not fluctuate excessively and still has good response for accurate weighing.

Weighing Height
All weight readings should be taken at the same height to ensure the greatest accuracy and
consistency. Typically, this will be with the fork 12 inches above the ground. NOV recommends
that the forks be raised to the weighing height and that a line be taped or painted on the fork lift
mast to correspond to a similar line or mark on the fork carriage.

Initial Lift Test to a Known Weight

For zero setting adjust the dial indicator as follows:
a. Lower the forks and lift a known weight equal to at least one-half the capacity of the
indicator. Lift and lower the load to the ground several times to seat the adjustable Item.
b. Remove the weight and set the truck mast vertical with the forks empty.
c. Place the lift forks on the ground.
d. Lift the forks to a point approximately two inches above the weighing height
(approximately 14 inches above ground).
e. Jog the forks down to the weighing height (12 in.), and as soon as the pointer has
settled, but before the starts to drop to a lower weight indication, set zero on the dial
indicator using the zero adjust knob (Figure 3.1 on page 12), to the point where the
needle has become steady.
Note: Steps d and e must be performed in sequence without undue delay.
Delays in reading the zero at step 3 will result in errors due to bleed-off
.
inherent in the truck hydraulic system.
f. Repeat Steps a through e at least three times and check that the zero setting is correct.
If necessary, reset and recheck until a satisfactory zero setting is obtained. If trouble is

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encountered setting the zero, check the fork lift hydraulic system per "Pre-Installation
Checkout" on page 11.
g. Lower the forks and lift the known weight, equal to at least one-half the capacity of the
truck weight indicator, to a point approximately two inches above weight height.
h. Jog the forks down to the weighing height, and as soon as the pointer has settled, but
before it starts to drop to a lower weight indication, take the weight reading.
i. Repeat Steps g and h to develop a “feel” for the weighing procedure and to obtain a
constant reading.
j. If the reading is incorrect, proceed to "Adjustable Item Calibration”. If the reading is
correct, take readings using known weight at one quarter and three quarters capacity to
verify correct indicator calibration. After performing this procedure the indicator is ready
for normal operation. Read "Operation" on page 20 before proceeding.

Adjustable Item Calibration

Warning: Do not make adjustments on the Item with a load on the forks.

a. Lift a known weight with the forks. If the gauge reads either lighter or heaver than the
known weight, lower the weight to the ground.
b. Back up the truck and raise the empty forks one foot off the ground.
c. Loosen the knurled knob (Figure 4.1 on page 20) on the adjustable Item and hold in
place to prevent it from moving.
d. Begin backing out the Item screw (pointer will begin to move clock-wise) until the pointer
stops. Continue backing out the screws two more times.
e. On the side of the gauge, slide the Item down 1/4 in. to obtain a heavier reading, i.e., to
speed up the gauge; move the Item up 1/4 in. to obtain a lighter reading i.e., slow down
the gauge.
f. Begin running the Item screw in. The pointer will continue to move counter-clockwise.
Continue until the pointer is back-set 40 to 45 degrees. For example, from the 6:00
o’clock position, turn the screw until the pointer rotates back to the 4:30 o’clock position.
Caution: Do not rotate the pointer counterclockwise more than 45 degrees.

g. Tighten the knurled knob on the Item adjust.

h. Drop the forks and pick up the known weight. Raise and lower two or three times to seat
the Item.
i. Repeat the zeroing procedure in "Initial Lift Test to a Known Weight" on page 17.
j. Drop the forks and pick up the known weight. The gauge reading should be the same as
the known weight. If not, repeat steps a through k.
k. The set screw (Figure 8-1, Item 39) may have to be moved to the opposite end of the
adjustment slide (Figure 8-1, Item 38) to allow for full adjustment of the Item.

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l. If the gauge cannot be correctly calibrated with the adjustable Item, i.e., the Item is
properly adjusted at the end of the slot and the gauge is still not reading accurately, take
gauge readings with known weights at 1/4, 1/2, and 3/4 of the gauge capacities. Leave
the Item properly adjusted at the end of the slot and return the gauge with the gauge
readings versus the known weight to the factory. The proper bourdon tube (Figure 8-1,
Item 37) will be installed and the gauge returned.
Note: If the lift truck is operated in harsh environments such as near salt water or
heavy dust conditions, seal the Item adjust cover with a silicone sealant to prevent
contamination of the indicator.

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Operation
The following procedure details the operating procedures for the Lift Truck Weight Indicator.
a. Weighing - Acceptable weighing results are obtained by raising the load to the same
height as that used for zero and calibration settings. Use the same procedure described
in steps g and h of "Initial Lift Test to a Known Weight" on page 17. Check the zero
setting of the indicator daily.
b. Pressure shut-off - Pressure shut-off may be accomplished by closing the damper
(Figure 3.3 on page 14) or by installation of the optional shutoff valve. Indicator wear can
be minimized by keeping the pressure shut off from the indicator except when weighing
is required.
Caution: Failure to shut off the pressure to the indicator may damage the
indicator from over-pressure and may void the calibration and warranty.

Figure 4.1: Adjustable Item Calibration

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5: Maintenance

Preventative Maintenance
The following preventative maintenance procedures are required to ensure proper operation of the
Lift Truck Weight Indicator system:
Hoist Mechanism Fluid Level
The lift truck hoist mechanism fluid must be maintained at the correct level as detailed in the lift
truck service manual.

Lubrication
Verify the slides on the mast of the lift truck are lubricated at all times. The Weight Indicator
System itself requires no lubrication.

Exterior Cleaning
Clean the dial indicator glass using a good commercial glass cleaner and a soft, lint, free clean
cloth.
Note: If the lift truck is operated in harsh environments such as near salt
water or heavy dust conditions, seal the Item adjust cover with a silicone
sealant to prevent contamination of the indicator.

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6: Troubleshooting
General
Troubleshooting the GA1035A Series Lift Truck Weight Indicator requires a common sense
approach to the problem. The Lift Truck Weight Indicator is a rugged, very precise pressure gauge
which measures and monitors the hydraulic pressure of the primary lift cylinder and translates this
pressure to a weight reading by use of a properly incriminated dial. If the weight indicator is not
weighing properly, attempt to determine what possible conditions would cause a pressure gauge
to react in the same manner.
Malfunction Isolation Chart
Malfunction
Pointer will not move.
Pointer will not move after Item
calibration.
Consistently incorrect weight
reading with same amount of
error at various test weights.
Consistently incorrect weight
reading with error amount
increasing or decreasing as test
weight are increased.
Weights properly at lower
weights, but not at higher
weights.
Inconsistent weight readings.
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Document number
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Page
Probable Cause
Incorrect damper setting.
Gauge hose not connected to
proper point of lift truck
hydraulic system.
Item adjustment turned in to far.
Zero improperly set.
Incorrect calibration.
Lift truck has two-speed or
speed control valve in hydraulic
system causing the weight
indicator to not receive true
cylinder pressure.
Lift truck has a mechanical or
hydraulic problem.
Air in hydraulic system.
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Corrective Action
See Damper Adjustment
(Chapter 3, titled "Installation)
See Installation (Chapter 3,
titled "Installation).
Reset Item adjustment screw
(see "Adjustable Item
Calibration" on page 18).
See "Initial Lift Test to a Known
Weight" on page 17.
See Chapter 4, titled
"Calibration and Operation.
See Chapter 3, titled
"Installation.
See Pre-Installation Checkout
("Pre-Installation Checkout" on
page 11.)
See "Bleeding the Weight
Indicator System" on page 15.
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Malfunction Isolation Chart
Malfunction Probable Cause
Gauge movement sticking/
Inconsistent weight readings.
pointer dragging.
Gauge will not return to zero. Improper damper adjustment.
Zero improperly set.
Gauge movement sticking.
Line from gauge isolator valve
to reservoir obstructed.
Improper damper adjustment.
Crimped hydraulic gauge hose.
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Corrective Action
Temporarily replace weight
indicator with a pressure gauge
or appropriate capacity to
determine if the lift truck
hydraulic system produces a
constant pressure with known
test weight. If the pressure
produced for several tests lifts is
consistent, return the weight
indicator to the factory for repair.
See Chapter 7 before removing
indicator. If pressure is not
constant, this indicates a
mechanical/hydraulic problem
with the lift truck. See "Pre-
Installation Checkout" on page
11.
See "Damper Adjustment" on
page 17.
See "Initial Lift Test to a Known
Weight" on page 17.
Temporarily replace the weight
indicator with a pressure gauge
of appropriate capacity to
determine if the lift truck
hydraulic system pressure
drops quickly and to the same
value (it may not be 0 psi) when
the forks are lowered to the
ground. If the hydraulic system
appears to be working properly,
return the weight indictor to the
factory for repair. Read Chapter
7 before removing the indicator.
Check for mechanical/hydraulic
problems as indicated by the
indicator pressure gauge. See
"Pre-Installation Checkout" on
page 11.
Clean line. Check for free flow
of fluid.
See "General Information" on
page 17).
Replace hose.
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Malfunction Isolation Chart

Malfunction Probable Cause Corrective Action

Gauge movement sticking/ Return gauge to the factory for

pointer dragging. repair.

Attempt to calibrate, see

Chapter 4. If gauge cannot be
Incorrect weight readings after
Gauge over-pressured due to calibrated, return to the factory
traveling with a load near gauge
improper damper adjustment. for repair. Include information
capacity.
requested in "General" on page
27.

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7: Factory Repair

In order for the repair facility at the factory to make repairs to malfunctioning gauges, it will
facilitate repairs more efficiently if the customer provides the following information.
a. Describe the gauge malfunction in as great detail as possible.
b. List the problems that may have caused the malfunction.
c. List the troubleshooting procedures used to determine the malfunction and the results
obtained.

Gauge Removal
To remove the gauge perform the following steps:
a. Place forks on the floor until the chain is slack.
b. Remove the four mounting screws that hold the gauge to the mounting bracket.
c. Remove the hose from the gauge carefully as there may be high pressure in the hose.
d. Close off the hose connector using a 1/4 in. NPT pipe cap. Tie off the hose to the truck
to prevent damage to the hose also ensuring there is no interference to the lift truck’s
operation.
e. Start the truck motor, raise the forks, and check hose ends for leaks.
f. Return the gauge to NOV for repair and calibration.

Reinstalling the Gauge

Upon return of the gauge or installation of a new one, perform the steps as follows:
a. Place forks on the floor until the chain is slack.
b. Put Teflon sealant on the hose ends and connect the hose to the gauge.
c. Install the gauge on the mounting bracket using the four mounting screws.
d. Bleed the system as described in "Bleeding the Weight Indicator System" on page 15.
e. Re-test as described in Chapter 4, titled "Calibration and Operation.
Note: If possible use the same weights used before in running this test.
Gauge reading should be close to previous readings. If not, contact NOV.

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8: Drawings and Parts Lists

GA1035A Weight Indicator System

Figure 8.1: GA1035A Weight Indicator System - Parts Breakdown

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Table 8-1. GA1035A Lift Truck Weight Indicator System

Item No. Part No. Description Quantity

1 J812-4PS SCREW, 1/4-20 X 1/2 7

2 B501A RING, CASE, 6 IN. 1
3 B60 GLASS, 6 IN. 1

4 10796-259A0 O-RING, 6.50 X 6.25 X .12 1

5 K357-1 POINTER, 5 IN. AND 6 IN. 1
6 1 DIAL 1

7 J640 ELBOW, STREET, 1/4 NPT 1

8 F149-2 6 DAMPER, BODY, 6 IN. 1
9 J826-1HB PLUG, PIPE, 1/8 NPT 1

10 100796-011A0 O-RING, .44 X .31. X .06 1

11 ---- ----- ----
12 F70 6 STEM, DAMPER 1

13 A10544A COVER, ADJUSTMENT 1

14 J812-3TS SCREW, 10-32 X 3/8 5
15 B63 GASKET, DAMPER 1

16 J811-3RE SCREW, 1/4-20 X 3/8 1

17 G163-4 SEAL, 1/4 IN. 1
18 M378 DIAL ADJUST, 6 IN. GAUGE 1

19 100796-115A0 O-RING 1
20 G177-4LB LOCKWASHER, 1/4 2
21 J811-10HB SCREW, 1/4 X 1-1/4 2

22 B10176A CASE 1
23 A10545A PLATE, BASE 1
24 J224 TUBING, COPPER, 1/8 6 IN.

25 G177-3MA LOCKWASHER, 1/4 3

26 K256-9 LINKAGE ASSEMBLY 1
27 D200B-2 MOVEMENT 1

28 G194 LOCKWASHER, MOVEMENT 1

29 J813-3HB SCREW 8-32 X 3/8 2
30 G176-6NB LOCKWASHER, NO. 6 2

31 J814-2NS SCREW, 6-32 X 1/4 2

32 B54A MOUNT, DIAL 1
33 K15-2 SCREW, SHOULDER, 3/16 X 7/16 2

34 G183 WASHER, LINKAGE 2

35 K16 NUT, LINKAGE 2
36 G180A-03012 WASHER, FLAT 3

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Table 8-1. GA1035A Lift Truck Weight Indicator System

Item No. Part No. Description Quantity

37 2 TUBE 1
38 A10542A SLIDES, ADJUSTMENT 1
39 J838-028NS SCREW, SET 10-32 1

40 M10085A KNOB, ADJUSTMENT 1

41 J812-8PS SCREW, 10-32 X 1 1
42 A10822A BRACKET, 6 IN. 3 1

SCREW, 4-20 X 1 3
43 J811-8FS 3
SWIVEL, 1/4 NPT, FEMALE 3
44 J541 1
FITTING, STEEL ADAPTER 3
45 4 1
(OPTIONAL)

46 5 HOSE, HYDRAULIC 3 1
47 A11405A BRACKET, ZERO STOP 1
48 D139 QUADRANT, STOP, MAX. 1

49 J812-4TS SCREW 1

1 - See table titled "Table 2-1. Dial Designators" on page 9.

2 - See table titled "Table 2-2. Tube Designators" on page 10.
3 - Not shown in illustration.
4 - See table titled "Table 2-3. Steel Fitting Designators" on page 10.
5 - See table titled "Table 2-4. Hose Designators" on page 10.
6 - Verify style of damper stem before ordering replacement parts as shown in Figure 8.2 and
Figure 8.3.

Figure 8.2: Present Production Style Damper Stem, P/N F70 (Item no. 12). Uses
Damper Body, P/N F149-2 (Item no. 8).

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Figure 8.3: Older style Damper Stem, P/N F13B. Use Damper Body, P/N F230-2.

Figure 8.4: Adjustable Gauge Mounting Bracket A10588A

Table 8-2. Adjustable Gauge Mount Bracket - A10588A

Item No. Part No. Description Quantity

1 A10822A BRACKET, GAUGE HALF 1

2 A10823A BRACKET, SURFACE MOUNT 1
3 G10014A-000062 LOCKWASHER, EXT. TOOTH 2

4 J816-6HB SCREW, .312-18 X .750 2

5 J806-5CP NUT, ELASTIC, STOP, .312-18 2
6 G130A-04813 WASHER, FLAT .312 4

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Figure 8.5: Gauge Isolation Valve Kit - KT1105A

Table 8-3. Gauge Isolation Valve Kit - KT1105A

Item No. Description Quantity

1 VALVE, GAUGE ISOLATION 1

2 WASHER, INTERNAL TOOTH 1
3 SWIVEL, ELBOW, .250 NPT 2

4 BUSHING, .250 X .125 NPT, CRES 4

5 ELBOW, .187 W/NUT 3
6 TUBING, .187, HEAVY WALL 3 FT

7 CONNECTOR, .187 W/NUT 2

8 SHAFT EXTENDER 1
9 TUBING, .187 8 FT

10 SCREW, SET, 6-32 X .187 2

11 SEALANT, W/TEFLON AR

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