In any industrial environment, load cells are the behind-the-scenes workers, quietly converting force into electrical signals that drive automation, safety and production.
But even the toughest load cells are not immune to time, wear or poor environmental conditions.
That’s why having a reliable load cell troubleshooting and maintenance checklist isn’t just a good idea but a safety net for your operations.
Read on for Massload’s top load cell maintenance tips!
Why Load Cell Maintenance Matters
Load cells are incredibly robust devices. At Massload, we build them to withstand extreme conditions, from dusty mines to frozen agricultural fields. But no load cell, no matter how tough, is immune to wear, environmental stress or electrical interference.
Having a regular maintenance and troubleshooting routine allows you to:
- Prevent unexpected equipment downtime
- Ensure system performance
- Comply with quality and safety standards
- Extend the life of your sensors and weighing infrastructure
- Catch early warning signs before they become failures
And it doesn’t have to be complicated. Just thorough, repeatable and informed by the right technical references.
Building Your Load Cell Maintenance Checklist
A good checklist should have four main sections: visual inspection, electrical verification, calibration records and troubleshooting logs. Here’s how to build each step:
1. Visual Inspection
Start with the basics, because many mechanical issues are visible before they become electrical.
- Look for physical damage: Cracks, dents, corrosion or deformation on the load cell body.
- Check mounting alignment: Is the sensor flat and firmly bolted? Misalignment can cause uneven loading or signal distortion.
- Inspect cables and glands: Look for fraying, loose shielding or signs of moisture ingress around the gland.
- Verify grounding: An ungrounded cell can cause noisy or erratic signal output.
Pro Tip: Even the best sensor won’t work if it’s poorly installed or exposed to harsh conditions without protection.
2. Electrical and Signal Verification
Once the physical check is complete, move to the electrical health of the sensor:
- Input and output resistance: Use a multimeter to check the resistance between excitation and signal wires.
- Signal mV output: Apply a known weight and check the output voltage matches expected values.
- Insulation resistance: Check the resistance between shield wire and all signal/excitation wires.
- Excitation and sense voltages: These should match the manufacturer’s values.
Note: Always disconnect load cell wires from the junction box before taking resistance measurements. Otherwise, you may get false readings or damage your meter.
3. Calibration Verification
Calibration is more than a one-time event. It’s a continuous process to ensure accuracy and accountability.
- Schedule regular calibration intervals based on your site’s usage and industry standards.
- Use certified test weights and compare with signal outputs using a calculator or control unit interface.
- Log results and deviations over time. Even small changes can indicate wear, environmental stress or internal drift.
- Consult the datasheet for reference values like sensitivity (e.g., 1.782 mV/V) and zero balance offset.
Reminder: If you’re seeing changes in zero balance or signal output without physical changes in load, calibration may be due or a fault is present.
4. Troubleshooting Common Load Cell Problems
Even with great maintenance, problems can occur. A good checklist prepares you to identify
and diagnose:
Fluctuating or noisy signals: Often caused by loose cables, electromagnetic interference or moisture.
- Zero shift: May be due to overloading, temperature variation or mounting stress.
- Overload readings: Check for improper handling, shock loads or system faults.
- Drift over time: Environmental conditions or insulation degradation could be the cause.
By checking resistance values, signal integrity and performance trends, you can act before failure occurs.
Environmental & Installation Considerations
Environmental stress is one of the biggest causes of load cell failure:
- Moisture ingress can cause short circuits or corrode internal components.
- Extreme temperatures affect the accuracy and stability of readings.
- Dust and vibration can compromise cable connections or cause mechanical fatigue.
- Poor cable routing can cause signal interference or damage during operation.
Prevent these risks by:
- Using proper enclosures
- Weatherproof glands and connectors
- Isolating vibration sources
- Correct mounting and cable management from the start
Download Massload’s Free Load Cell Maintenance Checklist
We’ve taken the work out of creating your own checklist by compiling the most important visual, electrical and calibration checks into a practical, editable template.
Our downloadable checklist is based on field-tested engineering standards and our own team’s experience across industries.
Use it during commissioning, monthly checks or troubleshooting events to keep your systems safe, accurate and reliable.
Keep the System Running
Creating a load cell maintenance and troubleshooting checklist isn’t about complexity. It’s about consistency.
Regular inspections, accurate calibration and early fault detection are the foundation of a solid weighing system. And when your team has a repeatable process, you prevent downtime, protect your equipment and build operational confidence.
At Massload Technologies, we build our load cells to last, but we also believe in empowering our customers to get the most out of their investment. From technical support to rugged, Canadian-made sensors, our goal is simple: keep your systems running as they should.
Need Help?
If you need help customizing your maintenance plan or selecting the right load cell for your application, our engineers are here to help you troubleshoot and learn more about proper maintenance practices. Contact Massload to get started today.
