Part Number TW608 Revision A: Installation and Operation

Part Number TW608
Revision A
INSTALLATION AND OPERATION
Lift Truck Weight Indicator

P/N GA35A & GD35
Manufacturers of Precision Instruments
Printed in U.S.A. November 17, 1995

List of Effective Pages
Manual TW608 contains 39 pages as follows:
i through iv . . . . . . . . . . . . . . . . . . . . . . . November 1995

TOC-1 through TOC-2 . . . . . . . . . . . . . . November 1995
1-1 through 1-2 . . . . . . . . . . . . . . . . . . . . November 1995
3-1 through 3-12 . . . . . . . . . . . . . . . . . . . November 1995
A-1 through A-4 . . . . . . . . . . . . . . . . . . . November 1995
B-1 through B-4 . . . . . . . . . . . . . . . . . . . November 1995
C-1 through C-7 . . . . . . . . . . . . . . . . . . . November 1995
All product, brand, or trade names used in this publication are the trademarks or registered trade-
marks 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 recom-
mended. 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.
iii November 17, 1995

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 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 LIABILITY. 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.
November 17, 1995 iv

M/D TOTCO
Lift Truck Weight Indicator Table of Contents
Manual TW608
Chapter 1 - Introduction
Introduction......................................................................................................................................... 1-1
Manual Scope.................................................................................................................................... 1-1
Intended Audience............................................................................................................................. 1-1
Personnel Qualifications.................................................................................................................... 1-1
Notes, Cautions, and Warnings......................................................................................................... 1-1
Chapter 2 - Overview
Overview of the Weight Indicator System.......................................................................................... 2-1
Chapter 3 - Installation
Introduction........................................................................................................................................ 3-1
Pre-installation Checkout................................................................................................................... 3-1
Weight Indicator Installation .............................................................................................................. 3-2
Bleeding the Weight Indicator System............................................................................................... 3-7
KT1105B Isolation Valve Installation ................................................................................................. 3-8
Chapter 4 - Operation
Introduction........................................................................................................................................ 4-1
Height Marking .................................................................................................................................. 4-1
Zero Setting ....................................................................................................................................... 4-1
Normal Weighing Procedure ............................................................................................................. 4-2
Weight Overload Procedure .............................................................................................................. 4-3
Appendix A - Preventative Maintenance and Troubleshooting

Introduction........................................................................................................................................ A-1
Preventative Maintenance ................................................................................................................. A-1
Troubleshooting................................................................................................................................. A-2
Weight Indicator Checkout ................................................................................................................ A-3
Appendix B - Repair
Introduction........................................................................................................................................ B-1
Hose Repair....................................................................................................................................... B-1
Refilling the Dial Indicator with Fluid.................................................................................................. B-2
Appendix C - Replacement Parts and Diagrams

Introduction........................................................................................................................................ C-1
Locating a Part .................................................................................................................................. C-1
Indicator and Dial Part Numbers ....................................................................................................... C-6
List of Figures
Figure 2-1. KT1105B Valve Placement ........................................................................................... 2-1
Figure 3-1. Dial Indicator Components............................................................................................ 3-2
Figure 3-2. Indicator and Bracket Dimensions ................................................................................ 3-3
Figure 3-3. Swivel and Hydraulic Hose Connection to Dial Indicator .............................................. 3-4
Figure 3-4. Tapping Into an Existing Fitting (Typical) ...................................................................... 3-5
Figure 3-5. Tee Fitting ..................................................................................................................... 3-5
Figure 3-6. Special 90° Elbow Fitting ............................................................................................... 3-6
Figure 3-7. 90 ° Street Elbow ........................................................................................................... 3-6
November 17, 1995 Page TOC-1

M/D TOTCO
Table of Contents Lift Truck and Weight Indicator
Manual TW608
Figure 3-8. Dial Indicator Components............................................................................................ 3-7

Figure 3-9. KT1105B Isolation Valve Bracket................................................................................. 3-10
Figure 3-10. KT1105B Isolation Valve Installation............................................................................ 3-10
Figure 4-1. Dial Indicator Components............................................................................................. 4-1
Figure 4-2. System Installation Overview ......................................................................................... 4-3
Figure B-1. Cutting Point .................................................................................................................. B-1
Figure B-2. Turning the Hose ........................................................................................................... B-1
Figure B-3. Lubricating the Connector.............................................................................................. B-2
Figure B-4. Tightening the Connector .............................................................................................. B-2
Figure C-1. GA34G 6-Inch Gauge Exploded Diagram ..................................................................... C-3
Figure C-2. GD9 8 1/2-Inch Gauge Exploded Diagram.................................................................... C-5
List of Tables
Table 3-1. Connector 1 Part Numbers and Sizes............................................................................ 3-5
Table 3-2. Tee Fitting Part Numbers and Sizes ............................................................................... 3-6
Table 3-3. Special Elbow Fitting Part Numbers and Sizes ............................................................... 3-6
Table 3-4. 90° Street Elbow .............................................................................................................3-6
Table A-1. Troubleshooting ...............................................................................................................A-2
Table C-1. GA34G 6-Inch Gauge Part Reference.............................................................................C-2
Table C-2. GD9 Gage 8 1/2-Inch Parts Reference............................................................................C-4
Table C-3. Weight Indicator Assembly and Indicator Part Numbers .................................................C-6
Page TOC-2 November 17, 1995

M/D TOTCO
Chapter 1
Introduction
1-1 Introduction
This manual contains installation, operating, and maintenance instructions for M/D TOTCO’s
Model GD35 and Model GA35A Lift Truck Weight Indicator Systems.
1-2 Manual Scope
This manual is divided into the following chapters:

q Chapter 1 - Introduction
q Chapter 2 - Overview
q Chapter 3 - Installation
q Chapter 4 - Operation
q Appendix A - Troubleshooting
q Appendix B - Repair
q Appendix C - Parts List
1-3 Intended Audience
This manual is intended for use by operation and maintenance personnel.
1-4 Personnel Qualifications
The procedures described in this manual should be performed only by persons who have read the
safety notice on Page iii of this manual and who are fully qualified and trained to perform the proce-
dures herein.
1-5 Notes, Cautions, and Warnings
Notes, Cautions, and Warnings are presented to aid in understanding and operating the equip-
ment or to protect personnel and equipment. Examples and explanations follow.
NOTE
Provides additional information about the current topic.
CAUTION
Provides information to prevent equipment malfunction or damage that
could result in interruption of service.
November 17, 1995 Page 1-1

M/D TOTCO
Chapter 1 Lift Truck and Weight Indicator
Introduction Manual TW608
WARNING
Provides information to prevent equipment malfunction or damage that

could result in serious or fatal injury to personnel or major property
loss.
Page 1-2 November 17, 1995

M/D TOTCO
Chapter 2
Overview
2-1 Overview to the Weight Indicator System
The Weight Indicator System provides the fork lift driver with an indication of the load lifted by the
truck during normal operation. The system operates off the existing lift truck hydraulic system and
does not require installation of a load cell for weight measurement.
The Model GA35A Weight Indicator System has a 6-inch Gauge (GA34G Series), and the Model
GD35 has an 8-1/2 inch Gauge (GD9 Series). Each indicator contains a manual tare adjustment to
zero the weight of the truck’s forks, pallets, or containers the operator does not want included in
the weight measurement. A controllable pulsation damper controls pointer oscillation and protects
the instrument during shock loading. Refer to Table C-3 in Appendix C for the available capacities
and part numbers of the Lift Truck Weight Indicator and Assembly Systems.
An optional KT1105B isolation valve is available to use between the Weight Indicator and the lift
truck control valve protecting the gauge from over-pressure or shock load conditions (Figure 2-1).
This optional valve kit is supplied with all necessary installation hardware. The KT1105B has a
“push-to-read” knob that delivers instant pressure to the gauge, but totally isolates pressure from
the pressure line until the knob is depressed. When the knob is released, a spring-loaded spool
closes and drains all fluid pressure from the gauge into the reservoir.
Bleed Plug Damper

4 Gauge and
7 Bracket
6
7
Part of
Valve
9
P 8
S
10 14
2
5 M 3
4 1 System Pressure
Hose
Line to
Reservoir
Figure 2-1. (Optional) KT1105B Valve Assembly

M/D TOTCO
Chapter 2 Lift Truck Weight Indicator
Overview Manual TW608

M/D TOTCO
Chapter 3
Installation
3-1 Introduction
This Chapter covers the procedures on how to properly install the Weight Indicator System.
3-2 Pre-installation Checkout
Upon receipt of the Weight Indicator System, check to ensure the information on the Indicator tag
and the packing slip correspond with the data on the specification tag of the fork lift.
CAUTION
The Weight Indicator has been calibrated for the specified fork lift. It
will not provide accurate weighing results if it is installed on other
trucks.
Prior to installing the Weight Indicator, check that the hoist, tilt, and steering mechanisms on the lift
truck are in proper working order. Also, perform the following specific checks:
1. Verify the oil in the lift truck reservoir is at the required level and there are no
hydraulic leaks. If leaks exist, perform repairs as necessary and restore fluid to
operating level.
2. Check the truck mast slides to ensure they are clean and well lubricated. If the
slides are not clean, it is recommended that they be steam cleaned and the bear-
ing surfaces coated with a molybdenum lubricant, such as Lubriplate, Molylube, or
Lubaloy.
3. Inspect the apron and mast rollers for seized bearings and flat spots. Replace
significantly worn items.
4. Inspect slides for excessive wear or distorted surfaces. Rework or replace to oper-
ational condition.
5. Check to ensure ram packing seal is not leaking or excessively tight.
6. Inspect the ram and piston for damaged sections. Repair or replace as necessary.
7. Inspect the lift truck hydraulic system for leaks at the hoist control valve and the
hoist cylinder(s).

M/D TOTCO
Installation Manual TW608
3-3 Weight Indicator Installation
Complete the following steps to install the Weight Indicator System:
NOTE
The actual mounting locations of the Indicator and hydraulic hose will vary
with truck model and user preference.
1. Verify the Indicator damper (Figure 3-1) is closed (turn fully clockwise).
GA34G GD9
(6-Inch) (8 1/2 Inch)
Bleed Plug Damper Bleed Plug
Zero Adjust
Knob
Damper Zero Adjust
Knob
Mounting Bracket
Mounting Bracket
Figure 3-1. Dial Indicator Components
2. Select a suitable location on the lift truck to mount the indicator bracket. Position
the Indicator for quick reference by the operator without restricting his view. Refer
to Figure 3-2 for gauge dimensions to determine proper mounting location.
CAUTION
Make sure the Indicator does not interfere with fork lift operation.

M/D TOTCO
Lift Truck Weight Indicator Chapter 3
Manual TW608 Installation
6-Inch Indicator and Bracket Dimensions.

7.50 6.50
(191 mm) (165 mm)
5.75
(146 mm)
9.75 6.00
(248 mm) (152 mm)
(3) ¼-20 UNC

120º Spacing
Bracket and Mounting

Hardware Included in
Assembly Only
2.00 (4) .30 MTG Holes
(51 mm)
4.50
(114 mm)
8.5-Inch Indicator and Bracket Dimensions
10.50 5.88 4.38

(267 mm) (149 mm) (111 mm)
8.50
(216 mm)
10.38 4.38
(264 mm) (111 mm)
5.75 (3) ¼-20 UNC

(146 mm)
Bracket and Mounting

Hardware Included in
Assembly Only
(4) .30 MTG Holes
1.75
(44 mm)
5.50
(140 mm)
Figure 3-2. Indicator and Bracket Dimensions

M/D TOTCO
3. Fasten the bracket to the truck using four 1/4-inch bolts of suitable length.
4. Install Indicator to the bracket using the supplied lock washers and I/4-20 bolts.
5. Turn the truck off and relieve hydraulic pressure from the hoist mechanism as
detailed in the user manual for the truck. With most trucks, this is done by tilting
the mast forward until the lift chains are slack.
NOTE
Use teflon tape or pipe sealing compound on all pipe fittings to avoid leaks.
6. Remove the plastic cap from the hose connection port on the Indicator, and install
the swivel fitting (Figure 3-3).
Indicator
Hose Connection
Port
Swivel Union
Hydraulic Hose
Connector
Figure 3-3. Swivel and Hydraulic Hose Connection to Dial Indicator

M/D TOTCO
7. Disconnect the lift truck’s valve-to-cylinder hydraulic hose at the hoist control valve
or at the hoist cylinder.
NOTE
In some installations, the existing hose fitting can be modified for
connection of the Weight Indicator hydraulic hose by drilling and tapping a
1/4 NPT hole in the fitting (Figure 3-4).
To Plunger Valve
Main Control Valve

J392 Hose
to Gage
Hose to Hoist
Cylinder Elbow
J392 Hose
to Gauge
J640 1/4 NPT 7/16 Drill and Tap for

Street Elbow Street Elbow in Fitting Hoist Cylinder
as Shown
Figure 3-4. Tapping Into an Existing Fitting (Typical)
8. Install appropriate fitting (refer to Figures 3-3, 3-4, 3-5 and Tables 3-1, 3-2, and
3-4) or supplied tee fitting furnished with the system between the existing hydrau-
lic hose and the control valve (or hoist cylinder). Connector (J10152A-1) is fur-
nished with the standard system, unless otherwise specified.
C
A B
Figure 3-5. Tee Fitting
Table 3-2. Tee Fitting Part Numbers and Sizes
Part Number Dimension A Dimension B Dimension C
J10152A-1 1/2” (female) 1/2” (male) 1/4” NPT (female)
J10153A-2 3/4” (female) 3/4” (male) 1/4” NPT (female)
J10153A-3 1” (female) 1” (male) 1/4” NPT (female)

M/D TOTCO
1/4 NPT to Indicator
1/4 NPT to Indicator “B” Thread size
“A” NPT Size
Figure 3-6. Special 90 ° Elbow Fitting
Table 3-3. Special Elbow Fitting Part Number and Size
Part Number A B
J798 7/8-14 UNF-2A 7/8-14 UNF-2B
1/4 NPT to Indicator
“A” NPT Size
Figure 3-7. 90° Street Elbow
Table 3-4. 90 ° Street Elbow Part Number and Size
Part Number A
210366 1/4

M/D TOTCO
NOTE
Due to the numerous fittings required for the varying makes and models of
lift trucks, M/D TOTCO offers only those most commonly used. If the offered
fittings can not be adapted, your distributor can assist you in obtaining the
correct fitting.
9. Remove the plastic cap from one end of the Weight Indicator hydraulic hose.Con-
nect the hose to the hydraulic hoist system at the installed fitting in step 8.
10. Route the supplied hydraulic hose from the truck hydraulic connection to the Indi-
cator. Ensure it does not become crimped or pulled tight during fork lift operation.
11. Remove the plastic cap from the free end of the supplied hydraulic hose and con-
nect the hose end to the swivel connector on the Indicator.
12. Position the hose so it can’t be cut or crushed, then tie wrap it in place.
13. Verify all hydraulic hose connections are tight.
3-4 Bleeding the Weight Indicator System
The following air bleeding instructions must be performed before placing the system into
operation:
1. Verify the Weight Indicator damper (Figure 3-8) is closed (turn fully clockwise-
until damper seats).
GA34G GD9
(6-Inch) (8 1/2 Inch)
Bleed Plug Damper Bleed Plug
Zero Adjust
Knob
Damper Zero Adjust
Knob
Mounting Bracket
Mounting Bracket

M/D TOTCO
2. Loosen the bleed plug (Figure 3-8) from the Indicator.
3. Start the lift truck engine.
4. With the truck running, open the hoist control valve and bleed all air from the Indi-
cator and hose by opening the damper. Continue bleeding until all air is bled from
the system and a stream of fluid (free from air bubbles) escapes at the bleed plug
opening. Close the damper.
NOTE
Presence of air in the Weight Indicator hose will cause degradation of the
load indicator system accuracy.
5. Replace and tighten the bleed plug.
6. Raise the forks to the maximum height.
7. With the hoist control valve open to allow maximum hydraulic pressure, check lift
truck hydraulics and Weight Indicator for leaks.
8. Lower the forks and open the Weight Indicator damper 1.5 to 3 turns (turn coun-
terclockwise).
3-5 Installation of Optional KT1105B Isolation Valve
If the gauge isolation valve kit, KT1105B, has not been pre-assembled on the Lift Truck
Weight Indicator, install the valve assembly on the gauge bracket as follows:
1. Release lift truck hydraulic system pressure by lowering forks to the ground.
NOTE
Ensure no pressure exists in the hydraulic system before proceeding.
2. Close the damper (turn stem clockwise- until the damper seats) and disconnect
hydraulic hose from damper.
3. Install swivel (item 3) into port “P” (refer to Figure 3-10) on the isolator valve.
NOTE
Use teflon sealant on all pipe fittings to prevent leaks.
4. Install bushing (item 4) and an elbow (item 5) in ports “M” and “S” on the gauge
isolator valve at the orientation shown in figure 3-9.

M/D TOTCO
5. Loosen the allen set screw on the valve shaft and remove knob. Unscrew the lock
nut from the gauge isolation valve. Insert the threads of the valve through the
1.188 inch hole in the bracket. Position the valve as shown in Figure 3-10. Secure
the valve with the lock nut.
NOTE
If the bracket to be used does not have pre-drilled hole, drill a 1.188-inch
diameter hole per Figure 3-10.
6. Install shaft extender (item 8) on the valve shaft, place the knob onto the extender
and tighten set screws.
7. Install bushing (item 4) and supplied connector (item 7) into the fitting on the back
of the gauge damper.
8. Measure, shape and cut the tubing (item 6) to the correct length and install it
between port “M” on the valve and the damper fitting per Figure 3-10.
9. Connect the supplied hose to the swivel fitting (item 3).The swivel fitting is located
in port “P” on the isolator valve. Position the hose to prevent interference while
hoisting and to protect the hose from being cut or crushed. Secure in place using
tie wraps supplied with gauge assembly. Verify all hose connections are tight.
10. Light gauge tubing (item 9) will be used for the return line to reservoir. Install the
return line between the “S” valve port in the isolation valve and the lift truck reser-
voir. The actual installation method into the reservoir will vary with the make and
model of lift truck. The return line is the drain line from the gauge and isolation
valve and carries little or no pressure. One method of connecting the return line to
the reservoir is to drill and tap the lift truck hydraulic system return line. Insert a
.125 NPT fitting (item 5 or 7) into tapped the hole.
NOTE
Location of the installation fitting will vary with various lift truck models. If
possible, locate the fitting above the normal fluid level line of the reservoir.
CAUTION
Extreme care must be taken to keep chips and cuttings out of the res-
ervoir, if a hole drilled and tapped. Cover the drill and tap with a thick
coat of heavy grease to retain chips and cuttings, thus not contaminat-
ing the reservoir.

M/D TOTCO
1.00
8.12
3.75
6.62 1.31
Figure 3-9. KT1105B Bracket Assembly
Bleed Plug Damper

44
DAMPER
Gauge and
7 Bracket
7
6
6
4
4
7
7 Part of
Valve
9
9
P 88
SS
P 10
10 14
5 2 14
5 M 3
M
4 4 1 System 3
Pressure
1 LINELine
TO to
Hose
SYSTEM PRESSURE
LINE TO HOSE
Reservoir
RESERVOIR
RESERVOIR
Figure 3-10. KT1105B Isolation Valve Installation

M/D TOTCO
3-6 Bleeding Instructions for KT1105B Installation
1. Verify the gauge damper valve is closed (turned clockwise to seat).
2. Loosen the bleed plug at the gauge.
3. Start the lift truck.
4. With the motor running, open the hoist control valve, actuate the push-to-read
gauge isolation valve. The isolation valve knob must be depressed throughout the
bleeding procedure until the bleed plug is tightened. Bleed all air from the hose.
Continue bleeding until a stream of fluid, free of air bubbles, escapes at the bleed
plug opening.
NOTE
During the air bleed process, the bleed plug is best left in the damper body,
loosened 1 or 2 turns, permitting a slow bleed off of the fluid and air mixture.
5. Close the damper and tighten the bleed plug.
6. Open the damper approximately 1 or 2 turns (counter-clock wise).

M/D TOTCO

M/D TOTCO
Chapter 4
Operation
4-1 Introduction
This chapter provides the procedures for marking a lift, zeroing the Indicator, weighing normal
loads, and use of the Weight Indicator in overloaded capacity situations.
4-2 Height Marking
To enable the load to be brought rapidly and accurately to the correct height for weighing, it is
recommended that the lift mast be marked. To mark the lift, raise the forks to a height of 12 inches
and place a line (tape or paint) on the fork lift mast to correspond with a similar line on the fork
carriage. Future lifts should use this reference point to achieve greater accuracy.
4-3 Zero Setting
Before using the Weight Indicator, the Indicator must be zeroed with the forks 12 inches from the
ground. To zero the Indicator, complete the following procedure:
1. Set the truck mast vertical.
2. Place the lift forks on the ground.
3. Lift the forks to a point approximately 2 inches below the weighing height.
4. Raise the forks to the weighing height. When the pointer has settled, but before
the pointer starts to drop to a lower weight, rotate the dial to zero. This is accom-
plished by turning the zero adjust knob (Figure 4-1) to move the dial to zero.
GA34G GD9
(6-Inch) (8 1/2 Inch)
Bleeder Plug Damper Bleeder Plug
Zero Adjust
Knob
Damper Zero Adjust
Knob
Mounting Bracket
Mounting Bracket

M/D TOTCO
Operation Manual TW608
NOTE
Steps 1 through 4 must be performed in order. Delays in reading the zero
at step 4 will result in errors due to bleed-off inherent in the truck hoist
hydraulic system.
5. Repeat steps 1 through 4 at least three times and ensure that the zero setting is
correct. If necessary, reset and recheck until a satisfactory zero is obtained. If
problems persist, check the fork lift hydraulic system.
6. Check the zero setting on the Indicator daily.
NOTE
If a pallet is to be used during normal weighing operations, the Indicator
must be zeroed with the pallet.
4-4 Normal Weighing Procedure
Accurate load readings are obtained by raising the load to the same height the Weight
Indicator was zeroed (12-inches). To weigh a load, complete the procedure below:
1. Pick up the load to be weighed.
2. Set the truck mast to vertical.
3. Raise the load to the pre-marked height (approx 12 inches).
4. Lower the load approximately 2 inches below the height mark.
5. Immediately take your weight reading on the Indicator dial face. This reading is the
weight of the lifted load.
Shaded part of illustration is existing Indicator Check Valve

lift truck equipment.
Hydraulic Hose
KT1105B Valve
Position 1
Tee
Position 2
Figure 4-2. System Installation Overview

M/D TOTCO
Manual TW608 Operation
4-5 Weight Overload Procedure
When the load to be carried on the lift truck is greater than the capacity of the Weight Indicator
System, close the Dial Indicator damper (Figure 4-1) by turning it clockwise. Hand tighten the
damper, but do not overtighten.
CAUTION
If the above statement is not followed when a weight overload exists,
damage may occur to the Weight Indicator System.

M/D TOTCO
Operation Manual TW608

M/D TOTCO
Appendix A
Preventative Maintenance and Troubleshooting
A-1 Introduction
This appendix provides information on preventative maintenance and troubleshooting of the

Weight Indicator System. If you require additional assistance, contact your M/D TOTCO
representative.
A-2 Preventative Maintenance
The following preventive maintenance checks are required to insure proper operation of the Lift
Truck Weight Indicator System:
1. Hoist Mechanism Fluid Level
• The lift truck hoist mechanism fluid load must be maintained at the
correct level. Refer to the fork lift user manual.
2. Lubrication
• Verify that the slides on the mast of the lift truck are properly lubri-
cated It all times.
NOTE
Lubrication of the Lift Truck Weight Indicator System is not necessary.
3. Exterior Cleaning
• Clean the Indicator glass using a commercially available glass

cleaner and a soft cloth.
November 17, 1995 Page A-1

M/D TOTCO
Appendix A Lift Truck and Weight Indicator
Preventative Maintenance and Troubleshooting Manual TW608
A-3 Troubleshooting
Use the following troubleshooting table to solve common problems of the Weight Indicator System
.
Table A-1. Troubleshooting
Trouble Probable Cause Corrective Action
Damper closed. Open damper.
Leaking hose coupling. Tighten coupling.
Leaking hoist cylinder. Repair leak.

No reading
Obstruction in hose. Clean out or replace hose.
Leaking Dial Indicator. Repair or replace Dial Indicator.
Dial Indicator internal mecha- Repair or replace Dial Indicator.

nism damaged.
Improper zero setting. Perform zero adjustment. Refer to

Chapter 4.
Erroneous reading Air in system. Bleed the hydraulic system per

instructions in Chapter 3.
Dial Indicator mechanism Repair or replace Dial Indicator.

damaged.
Improper damper setting. Correct damper setting.
Dial Indicator pointer rubbing Carefully bend pointer away from

glass or dial. glass.
Erratic or sluggish indications Hoist cylinder fluid low. Add fluid as required.
Sticky indicator movement. Repair or replace Dial Indicator.
Dial Indicator internal mecha- Repair or replace Dial Indicator.

nism damaged.
Page A-2 November 17, 1995

M/D TOTCO
Lift Truck Weight Indicator Appendix A
Manual TW608 Preventative Maintenance and Troubleshooting
A-4 Weight Indicator Checkout
Following a repair or whenever system inaccuracy is suspected, the following system checkout
procedure should be performed:
CAUTION
Exercise caution for personal safety at all times when loading the lift
truck for test purposes.
1. Zero the Lift Truck Weight Indicator.
2. Place a known load on the lift forks that equals approximately 1/8 of system
capacity (i.e.: 750 lbs. for a 6000 lb. Weight Indicator System) and raise the load to
a point about 2 inches above the 12-inch weighing height.
3. Lower the load to the weighing height. When the pointer settles, but before the
pointer starts to drop to a lower weight, note the Dial Indicator reading. The read-
ing should be within ±2% of the known load.
4. Repeat steps 1 through 4 using a known load equal to approximately 1/4 of sys-
tem capacity.
5. Repeat steps 1 through 4 using a known load equal to approximately 1/2 of sys-
tem capacity.
November 17, 1995 Page A-3

M/D TOTCO
Appendix A Lift Truck and Weight Indicator
Preventative Maintenance and Troubleshooting Manual TW608
Page A-4 November 17, 1995

M/D TOTCO
Appendix B
Repair
B-1 Introduction
This appendix provides information on how to repair the high-pressure hose and replace the fluid
in the Weight Indicator System.
B-2 Hose Repair
The high-pressure hose connections used on the hose assembly are factory crimped. If it is nec-
essary to alter the installation in the field, removal and re-installation of the high-pressure connec-
tor is a relatively simple procedure. When ordering replacement hose for your Weight Indicator
System, specify the length (in feet), as a suffix to the part number. Example: J392-6 specifies a six
foot hose. Replace the connector (Jl76A-2) as follows:
1. On the hose end, remove the outer rubber cover down to the wire braid. The cut-
ting point is illustrated in Figure B-1.
Figure B-1. Cutting Point

2. Place the connector sleeve in a vise (Figure B-2). Push the hose into the socket
while turning counterclockwise until the hose bottoms.
Figure B-2. Turning the Hose
November 17, 1995 Page B-1

M/D TOTCO
Appendix B Lift Truck and Weight Indicator
Repair Manual TW608
3. Liberally lubricate the inside of the hose and nipple threads (Figure B-3). Insert
the nipple into the sleeve.
Figure B-3. Lubricating the Connector

4. Using a wrench on the hex, screw the nipple into the hose (Figure B-4). Tighten
the nipple hex against the sleeve.
Figure B-4. Tightening the Connector
B-3 Refilling the Dial Indicator with Fluid
To refill the Dial Indicator with fluid, perform the following steps:
1. Remove the Indicator from its bracket and place it flat on its back.
2. Remove the screws that secure the ring and glass to the Dial Indicator. Carefully
remove the glass and ring.
3. Slowly pour W8 fluid into the case. Continue pouring until the case is full.
4. Install the glass, gasket, and ring on the case. Secure the items using the screws
removed in step 2.
5. Place the Dial Indicator in a vertical position. The fluid level should be approxi-
mately 1/2-inch down on the glass from the ring. Add or remove fluid as required
by removing the 1/4-20 pan head screw and sealing washer on the side of the
case. Replace and tighten the filler screw securely.
6. Mount the Dial Indicator to the mounting bracket.
7. Perform the Weight Indicator Checkout procedure outlined in Appendix A.
Page B-2 November 17, 1995

M/D TOTCO
Appendix C
Replacement Parts and Diagrams
C-1 Introduction
This appendix provides the list of replacement parts and exploded diagrams of the gauges.
C-2 Locating a Part
The following pages contain a complete listing of the replacement parts available for the Lift Truck
Weight Indicator System. To order a part, locate the part on the appropriate diagram and note the
Find Number. Cross-reference the Find Number with the corresponding part number in the parts
list. When ordering parts for your Lift Truck Weight Indicator System, be sure to state the model of
the item(s) being serviced.
NOTE
Dial Indicator repair should be performed only by authorized M/D TOTCO
service personnel.
November 17, 1995 Page C-1

M/D TOTCO
Appendix C Lift Truck and Weight Indicator
Replacement Parts and Diagrams Manual TW608
Table C-1. GA34G 6-Inch Gauge Parts Reference
Find # Description Part Number Find # Description Part Number
1 Case B500 25 Screw. #10-32 x 3/8, Rnd J812-3RS
2 Gasket, Damper Seal B63 26 Movement 220334
3 Damper Body F149-2 27 Tab Lockwasher G194
4 Lockwasher, 1/4-inch G177-4LB 28 Screw, #8-32 x 3/8 Hex J813-3HB
5 Screw, 1/4-20 x 1 1/4 999393-036A 29 Linkage Assembly K265-3

Hex (Includes Items 30 & 31)
6 O Ring, Stem 100796-011AO 30 Link Nut Kl6
7 Damper Stem F70 31 Shoulder Screw K15-2
8 Plug, Pipe 1/8 J826-1HB 32 Hub B54A
9 Elbow, Street, 1/4 NPT 210366 33 Lockwasher, #6 G176-6NB
10 Lock O-Seal G163-4 34 Screw, #6-32 x 1/4 Pan 999449-064
11 Screw, 1/4-20 x 3/8, Rnd 999334-100 35 Dial See Table C-3
12 Dial Adjust Assembly M378 36 Ring, Retainer G179B-0250E
13 O Ring 100796-115AO 37 Pointer K357-1
14 O Ring 100796-006AO 38 Glass B60
15 Knob and Shaft, Dial M347 39 O Ring B650-259AO

Adjust
16 Gear, Dial Adjust M378 40 Case Ring B501A
17 Set Screw, Socket #6-32 999324-185 41 Screw, 410-32 x 1/2 Fill 999383-056
x 1/8
18 O RING 100796-011AO Not Pressure Relief Valve 300304

Shown
19 Screw, Socket MTG. J130 Not Swivel Union, l/4 J541

Shown
20 Tube Assembly 0221-Series Not Fluid, clear W8

Shown
21 Tubing, 3/16 J197 Not Gage Mounting Bracket A609

Shown
22 Stop, Tube Max. D346
23 Washer, Flat, #10 Large G180-03133
24 Lock Washer, #10 G176-10 NB
Page C-2 November 17, 1995

M/D TOTCO
Lift Truck Weight Indicator Appendix C
Manual TW608 Replacement Parts and Diagrams
Figure C-1. GA34G 6-Inch Gauge Exploded Diagram

M/D TOTCO
Table C-2. GD9 Gage 8 1/2-Inch Parts Reference
Part
Find # Description Part Number Find # Description
Number
1 Case B1123-1 23 Tab Lockwasher G194
2 Lock O-seal, 1/4 G163-4 24 Screw, #8-32 x 3/8 Hex J813-3HB
3 Screw, 1/4-20 x 1/2 J811-4TS 25 Linkage Assembly K265-3

Truss (Includes Items 26 & 27)
4 O Ring 100796-113AO 26 Shoulder Screw K15-2
5 Dial Adjust M534A 27 Link Nut K16
6 Set Screw, #8-32 x J836-813N 28 Hub & Bridge Assembly B635A

3/16, Cup Pt.
7 Gasket, Damper B940A 29 Washer, Flat, #10 Small G180-02733
8 Damper Body F274 30 Washer, Lock, #10 G176-10NB
9 Plug, 1/4 NPT J826-2HB 31 Screw, #10-32 x 3/8 Truss J812-3TS
10 O Ring 100796-011AO 32 Dial See Table C-3
11 Stem Assembly F80 33 Ring, Retainer G179D-0750E

(Includes Item 10)
12 Washer, Flat, 1/4 G180-03732 34 Pointer K404-1

Small
13 Washer, Lock, I/4 G177-4LB 35 Glass B915 -2
14 Screw, 1/4-20 x 5/8 J811-5YJ 36 Gasket, Glass B916-2
15 Tubing, 3/16 J197 37 Case Ring B1057-2
16 Tube and Socket 0250-Series 38 Screw, #10-32 x 5/8 Flat J812-5FS

Assembly
17 Screw. #10-32 x 1/2 J812-4TS Not Gage Mounting Bracket A1084B

Truss Shown
18 Stop, Tube Max. D346 Not Swivel Union, l/4 J541

Shown
19 Washer, Flat, #10 G180-02733 Not Pressure Relief Valve F10056A

Small Shown Assembly
20 Washer, Lock, #10 G176-10NB Not Nut J10545A

Shown
21 Screw, #10-32 x 3/8 J812-3TS Not Washer G10095A

Truss Shown
22 Movement 220384 Not O Ring 100796-01780

Shown

M/D TOTCO
Figure C-2. GD9 8 1/2-Inch Gauge Exploded Diagram

M/D TOTCO
C-3 Indicator and Dial Part Numbers

Table C-3. Weight Indicator Assembly and Indicator Part Numbers
Model GA35A Model GD35
Capacity Assembly Indicator Assembly Indicator

(Pounds) Number Number Number Number
2000 x 5 GA35A-2 GA34G-FSSS GD35-2 GD9-FSSS
3000 x 10 GA35A-3 GA34G-JSSS GD35-3 GD9 -JSSS
4000 x 10 GA35A-4 GA34G-KSSS GD35-4 GD9-KSSS
5000 x 10 GA35A-5 GA34G-LSSS GD35-5 GD9-LSSS
6000 x 20 GA35A-6 GA34G-MSSS GD35-6 GD9-MSSS
8000 x 20 GA35A-8 GA34G-PSSS GD35-8 GD9-PSSS
10000 x 20 GA35A-10 GA34G-RSSS GD35-10 GD9-RSSS
12000 x 40 GA35A-12 GA34G-TSSS GD35-12 GD9-TSSS
15000 x 50 GA35A-15 GA34G-USSS GD35-15 GD9-USSS
16000 x 50 GA35A-16 GA34G-YSSS GD35-16 GD9-VSSS
18000 x 50 GA35A-18 GA34G-WSSS GD35-18 GD9-WSSS
20000 x 50 GA35A-20 GA34G-XSSS GD35-20 GD9-XSSS
25000 x 50 GA35A-25 GA34G-ZSSS GD35-25 GD9-ZSSS
30000 x 100 GA35A-30 GA34G-SISS GD35-30 GD9-SISS
40000 x 100 GA35A-40 GA34G-S2SS GD35-40 GD9-S2SS

M/D TOTCO
C-5 NOTES:

M/D TOTCO

M/D TOTCO

Part Number TW608 Revision A: Installation and Operation

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Part Number TW608

INSTALLATION AND OPERATION

Lift Truck Weight Indicator

Manufacturers of Precision Instruments

Printed in U.S.A. November 17, 1995

Manual TW608 contains 39 pages as follows:

i through iv . . . . . . . . . . . . . . . . . . . . . . . November 1995

Information in this manual is subject to change without notice.

iii November 17, 1995

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

The warranty periods for various products are:

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

November 17, 1995 iv

Appendix A - Preventative Maintenance and Troubleshooting

Appendix C - Replacement Parts and Diagrams

November 17, 1995 Page TOC-1

Figure 3-8. Dial Indicator Components............................................................................................ 3-7

Page TOC-2 November 17, 1995

1-2 Manual Scope

This manual is divided into the following chapters:

1-3 Intended Audience

This manual is intended for use by operation and maintenance personnel.

1-4 Personnel Qualifications

1-5 Notes, Cautions, and Warnings

November 17, 1995 Page 1-1

Provides information to prevent equipment malfunction or damage that

Page 1-2 November 17, 1995

2-1 Overview to the Weight Indicator System

Bleed Plug Damper

Figure 2-1. (Optional) KT1105B Valve Assembly

November 17, 1995 Page 2-1

Page 2-2 November 17, 1995

3-2 Pre-installation Checkout

5. Check to ensure ram packing seal is not leaking or excessively tight.

November 17, 1995 Page 3-1

3-3 Weight Indicator Installation

Complete the following steps to install the Weight Indicator System:

Figure 3-1. Dial Indicator Components

Page 3-2 November 17, 1995

6-Inch Indicator and Bracket Dimensions.

(3) ¼-20 UNC

Bracket and Mounting

8.5-Inch Indicator and Bracket Dimensions

10.50 5.88 4.38

5.75 (3) ¼-20 UNC

Bracket and Mounting

November 17, 1995 Page 3-3

Figure 3-3. Swivel and Hydraulic Hose Connection to Dial Indicator

Page 3-4 November 17, 1995

Main Control Valve

J640 1/4 NPT 7/16 Drill and Tap for

Figure 3-5. Tee Fitting

Table 3-2. Tee Fitting Part Numbers and Sizes

Part Number Dimension A Dimension B Dimension C

J10152A-1 1/2” (female) 1/2” (male) 1/4” NPT (female)

J10153A-2 3/4” (female) 3/4” (male) 1/4” NPT (female)

J10153A-3 1” (female) 1” (male) 1/4” NPT (female)

November 17, 1995 Page 3-5

1/4 NPT to Indicator

1/4 NPT to Indicator “B” Thread size

“A” NPT Size

Figure 3-6. Special 90 ° Elbow Fitting