Professional Documents
Culture Documents
DRAFT - FOR
User Manual
INFORMATION ONLY
ORIGINAL INSTRUCTIONS
Page 1 of 258
Revision C
Published by:
NOV Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2013 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV Elmar for loss,
damage or injury caused by any errors or omissions in this document.
Revision
Date
Amendments
18 September 2013
8 August 2013
A3
17 June 2013
A2
26 February 2013
Minor corrections
A1
20 February 2013
30 January 2013
Added fuel purifier descriptions on pages 17, 18,19, 40, 41, 170.
Instructions to tighten essential bolts on page 221. Referenced
documents on pages 246, 247. Instructions to use anti-seize
compound on page 248. Other minor corrections.
REVISION HISTORY
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Original Instructions
TABLE OF CONTENTS
1
2
Page 3 of 258
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Original Instructions
Table of contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Winch / Control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Unit systems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Unit access features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Transportation features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Specifications and data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.7 Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.9 Auxiliary drive (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.11 Depth and tension measurement systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.12 Winch subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.13 Wellhead pressure control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
UNIT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1 Power pack control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Winch left control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.3 Winch right control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2 Hoisting modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 First-time startup and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.5 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.1 Emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.2 Pre-start checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.3 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.4 Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.5 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.6 Charging hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.4 Depth and tensioning system maintenance schedule. . . . . . . . . . . . . . . . . . . . 107
8.5 FlyLine maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
8.6 Prepare for safe maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.7 Finalise maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.8 Change engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table of contents
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Appendix 1: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Appendix 2: Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Appendix 3: Unit Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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243
244
246
248
249
253
255
Table of contents
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INTRODUCTION
TXT-10004540/A
This user manual for the FlyLine well servicing product is intended for operating, maintenance
and supervisory personnel. It contains the following sections:
Safety (important safety aspects)
Description (of components and their function)
Unit Control description
Setup and Removal (including installation and storage)
Operation (startup, run, shutdown)
Maintenance (schedules and procedures)
Troubleshooting
Appendices (reference material)
1 Introduction
This manual (supplied in digital and printed formats) is part of the FlyLine documentation set and
must be read before initial equipment installation and operation.
The validity of the manual can be compromised by post-delivery engineering modifications or
regulatory changes that affect equipment use, ratings and limits. All NOV Elmar engineering
changes are documented in as-built drawings, even after product delivery. This means the latest
drawings always take precedence over manuals. If in doubt, contact NOV Elmar.
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SAFETY
TXT-10004141/A1
2.1
General Safety
High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be
present in Elmar equipment. Therefore, pay special attention to safety when working with this
equipment.
Meet all applicable codes, laws and local field regulations (including environmental and
additional owner/user company policy). This manual contains recommendations, but
should not be assumed to satisfy all requirements of legal regulations.
Read and understand each item in this manual and follow all procedures, precautions
and advice exactly - never take short cuts. Always consider your safety and that of others.
Only use the equipment within its design scope to avoid damage or dangerous situations.
This manual (in its most current revision) is a minimum requirement for all persons working with
Elmar equipment. All other current and applicable documents such as certification, drawings, bill
of materials, vendor documentation, etc, should be readily available at the worksite.
2.1.1
Employee responsibility
Never leave "operation-ready" equipment unattended.
Keep equipment clean (accumulated dirt and dust can hamper unit operations and may
increase the risk of ignition).
Wear personal protection equipment (PPE) where necessary; for example gloves and
protective footwear.
Never work alone if there is a possibility of an accident.
Keep loose clothing and long hair well away from moving mechanical parts.
Remove rings, wristwatch, etc, before working.
Never disconnect, change or remove safety devices, and use such devices correctly.
Be aware of all emergency equipment and procedures (such as alarms, abandon ship,
etc.) and make sure they are in place and valid.
Do not use the equipment after an emergency without verifying that the cause of the
emergency has been removed or rectified.
Immediately inform the employer and other workers of any situation that represents a
serious danger to safety and health, and of any shortcomings in protection arrangements.
Plan all operations including interdependencies with other equipment operations
If equipment is tied down using rope/line/chains, attach a "flag" to signal their location.
During installation, maintenance and/or equipment inspection:
where possible, make sure electrical/mechanical equipment is switched off completely,
and use a decal or similar to prevent unauthorized starting;
always relieve pressure before working on hydraulic and/or pneumatic systems.
2.1.2
Employer responsibility
Define the required competency of personnel working on the equipment (including
supervision) and provide the required consultation, information and training.
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2 Safety
Correctly maintain and use equipment, apparatus, tools, and dangerous substances.
Ensure that only trained, qualified and competent personnel can work on the equipment.
Ensure adequate safety equipment and emergency procedures are available (fire
extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them.
Ensure a suitable program for installation, operation, maintenance, periodic inspection
and testing of the equipment is defined, adhered to and recorded.
Do not allow work to proceed until a thorough examination and risk assessment of the
work site and equipment has been done. The examination should assess (as a minimum)
the condition of the work site and all critical components, plus the equipment structure.
Only give approval to proceed when controls to manage potential causes are in place and
measures are taken to mitigate potential consequences.
2.1.3
2 Safety
WARNING
TXT-10004296/A
ELECTRIC SHOCK
Connecting/disconnecting an energised (live) electrical cable can cause serious injury and or
equipment damage. Always ensure that an electrical cable is electrically de-energized (dead)
before connecting/disconnecting it.
CAUTION
TXT-10004378/A
EQUIPMENT DAMAGE
Components can be damaged during cleaning.
Take care when cleaning components; use appropriate cleaning tools.
Hearing protection
Wear ear protection during this procedure.
NOTE: A warning, caution or requirement icon (occasionally with accompanying text) is often
also affixed to the equipment at a prominent location.
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2.2
2.2.1
Emergency stop buttons are conveniently positioned on equipment and are easily recognized
because of their bright red colour. See examples in Figure 2.1.
2.2.2
Heavy equipment
Never attempt to move heavy equipment without the aid of a sufficiently dimensioned and
certified mechanical device.
Only hoist joined equipment after ensuring that the joined equipment has been certified
for single lifting by checking the certification in the Documentation Package that came
with your equipment.
Make sure you cannot get trapped between a lifted load and a wall, fixed object, etc.
Never walk under a hanging load or allow heavy objects to rest in an unstable position.
2.2.3
Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the
equipment is certified according to ATEX regulations, the following applies:
The power supply, including driven parts, has been manufactured and assessed
according to ATEX and tagged with a unique identification number.
Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1,
or Zone 2 compliance will be compromised.
Certified explosion safe equipment is suitable for use in gas hazardous classified
locations. Check your unit data plate(s) and the specifications tables in the Appendix for
the ATEX classification for your equipment.
The design and manufacturing is based on European Directive no. 94/9/EC following
conformity assessment procedure relating to internal control of production according
Annex VIII of the Directive. The construction is documented in a confidential Technical
Construction File held at the offices of Elmar.
NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013
Page 9 of 258
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2 Safety
TXT-10004562/A
2.2.4
While opening/closing hatches and doors, take account of wind conditions or sudden
movement. Hatches and doors may forcibly swing open/shut causing damage or injury.
When open, the hinge side of doors and hatches can create extremely hazardous pinch
points for fingers, clothing, hoses and cables. Always check the hinge side before closing
any door or hatch.
Always use any built-in retainers to anchor the door or hatch if you need to leave it open
or closed while you work.
2.2.5
Wireline
TXT-10004564/A
Never allow the number of wraps on a wireline winch drum to go below a minimum of
three (3) wraps. When the last layer is unwinding, winch-off slowly, and keep close
control on the remaining wraps.
Never allow the wireline to go slack! A slack wireline can be caused by an obstruction
that may clear suddenly, with an unexpected and potentially lethal tightening of the
wireline as a result.
2 Safety
If the wireline is rigged up but is not going to run for a period, clamp the wire, diminish the
tension, and "flag" the wire with signs.
During wireline operations, consider the zone in front of the winch as a danger zone (see the
shaded area in Figure 2.2):
Never allow anyone to enter this area when there is tension on the wireline!
Treat this area as a potential danger zone and take extreme care, even when there is no
tension on the wireline.
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PHYSICAL DESCRIPTION
3.1
Unit overview
This FlyLine consists of the following modules and sub-modules (see Figure 3.1).
front
left
2
right
1
back
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3 Physical description
3.2
Power pack
3.2.1
3 Physical description
5
6
4
7
8
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3.2.2
2
4
5
8
6
10
11
Suction filter
Air receiver
10
11
Air filter
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3 Physical description
3.2.3
2
3 Physical description
1
3
8
9
10
Engine exhaust
Radiator fan
Radiator stack
Hydraulic manifold
10
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3.2.4
2
3 Physical description
1
4
8
9
Engine exhaust
Radiator fan
Radiator stack
Hydraulic manifold
10
10
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3.2.5
3 Physical description
Radiator stack
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3.2.6
1
2
20
16
9
18
19
10
17
14
11
21
13
12
1
Exhaust silencer
12
13
Fuel tank
14
Starter motor
15
16
Control panel
17
Battery (optional)
Fuel pump
18
Engine compressor
19
20
10
21
11
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3 Physical description
15
3.2.7
3 Physical description
20
15
16
21
9
18
19
10
17
21
14
11
20
22
13
12
Exhaust silencer
12
13
Fuel tank
14
Starter motor
15
16
Control panel
17
Battery (optional)
Fuel pump
18
Engine compressor
19
20
10
21
11
22
3.2.8
1
2
15
20
21
18
19
10
17
14
11
22
13
12
1
Exhaust silencer
12
13
Fuel tank
14
Starter motor
15
16
Control panel
17
Battery (optional)
Fuel pump
18
Engine compressor
19
20
10
21
11
22
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3 Physical description
16
3.2.9
3 Physical description
Turbocharger
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3.3
3.3.1
3 Physical description
4
2
1
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3.3.2
Control console
3 Physical description
3
6
7
5
CombiGauge
Operator chair
Levelwind wheel
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3.3.3
3
1
3 Physical description
2
4
5
6
1
Winch drum
Levelwind chain
Measuring head
Air-out connector
Drum chain
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3.3.4
3 Physical description
8
6
3
1
5
4
Winch drum
Drum cover
Measuring head
Roof damper
Screen damper
Fold-in roof
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3.3.5
3 Physical description
2
1
Wireline oiler
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3 Physical description
3.3.6
2
1
5
3
4
1
Horn
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FUNCTIONAL DESCRIPTION
4.1
Unit configuration
This design is a split wireline winch unit comprised of a power pack, and a winch module with
integrated operator control.
The setup is suitable for cased hole slick line, braided line and mono-conductor operations. The
unit is suitable for onshore and offshore operations.
The four cylinder diesel engine in the power pack drives the Elmar's closed loop hydraulic system.
See 4.8 Hydraulic system on page 50.
A data plate is attached to the outside of each module, and contains specification information for
that module. Check your data plate and refer to Appendix 2: Unit Specifications on page 237 and
Appendix 5: Unit configuration on page 244 for more information.
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4 Functional description
4.2
3
Main hydraulic pump
Hydraulic circuit
Engine starter
Fuel supply
Fuel safety
valve
Diesel
engine and
gearbox
Cooling fan
Radiator
Coolant circuit
Coolant pump
Air inlet
Battery
Alternator
Air intake
Electric circuit
Exhaust gas
cooler
4 Functional description
Combigauge
Measuring
head
1
SmartMonitor
Pneumatic compressor
2
Drum brake
Pneumatic
circuit
Drum brake
Selection valve
Drum and wire
Hydraulic power
Pneumatic power
Mechanical power
Electrical power
Fuel
Cooling liquid
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Winch subsystem
Hydraulic system
Pneumatic system
Diesel engine
Electrical system
Cooling systems
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4 Functional description
The Diesel engine (5) powers the Hydraulic system (3), Pneumatic system (4), Electrical system
(6) and Cooling systems (7). The Cooling systems are used to cool the diesel engine and the
exhaust gases produced by the diesel engine (in Zone 2 certified units). The cabin heater uses
the heat from the Cooling systems (7) to warm the cabin. The Electrical system supplies electrical
energy for the SmartMonitor in the Depth and tension measurement systems.
4.3
11
4 Functional description
10
8
7
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Protects the engine against environment conditions. Protects from noise and heat.
Protects the engine against environment conditions. Protects from noise and heat.
Protects winch components from impact during transport. Keeps loose parts inside
winch bay. Protects from moving parts during operation.
Protects winch components from impact during transport. Keeps loose parts inside
winch bay.
Protects winch components from impact during transport. Keeps loose parts inside
winch bay. Protects from moving parts during operation.
Keyhole
Lock the power pack door closed with the supplied key.
Tumbler pin
10
Coolant hatch
11
This hatch gives access to the hydraulic fluid filler cap and gauge.
4 Functional description
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4.4
Transportation features
5
12
11
4
6
4 Functional description
10
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Only for lifting module in transport state: all parts stowed and all doors and hatches
closed and locked.
WARNING: The single point lifting bar and all fittings must be removed before using
the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the
lifting chains of the hoist might become entangled in the lifting bar/fittings.
Forklift pockets
(2 x 2 per module)
For fork lifting of separated modules in the transport state (all parts stowed and all
doors and hatches closed and locked).
Only for lifting module in transport state with a single sling: all parts stowed, all
doors and hatches closed and locked. The single point lifting bar must be removed
for operation.
WARNING: Do not use these forklift pockets for crane hoisting of the module.
WARNING: The single point lifting bar must not be used for offshore lifting.
WARNING: The single point lifting bar and all fittings must be removed before using
the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the
lifting chains of the hoist might become entangled in the lifting bar/fittings.
End rail
WARNING: The end rail must always be fitted before transporting the unit.
Use these brackets to store the end rail (6) during operations.
10
11
12
Four latch pins are used to secure the fold out roof in transport and operation
position.
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4 Functional description
6
7
4.5
4 Functional description
A data plate (Figure 4.3) is attached to the outside of the modules and is stamped with
specification information for the unit. Check your data plate to see whether your FlyLine is Rig
safe, Zone 2 or Zone 2 Arctic. If the field under MARKINGS is empty, it is Rig Safe. If it has ATEX
markings, it is Zone 2 certified. Refer to Appendix 2: Unit Specifications on page 237 for other
specification details.
ASEP
MARKINGS
External connections:
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4.6
Diesel engine
The engine systems are described in the following sections:
4.6.1 Engine oil on page 36
4.6.2 Engine safety features on page 38
4.6.3 Engine fuel system on page 40
4.6.4 Hydraulic engine starter (optional) on page 42,
4.6.5 Pneumatic engine starter (optional) on page 43,
4.6.6 Spring engine starter (optional) on page 44,
4.6.7 Cooling systems on page 45
4.6.8 Additional features of Heavy Duty power packs on page 46
Primary power is generated by a four cylinder diesel engine. The engine is Rig safe or Zone 2
compliant, with features to eliminate any risk of explosion during normal operation, and to shut
down the engine when there is risk of explosion.
The engine is available in regular and heavy duty configurations. The latter will include a turbo
charger in the engine assembly for additional power output.
The engine is liquid cooled with forced ventilation.
The engine air supply is drawn through an air filter in the power pack. An air shut-off valve in the
intake kills the engine or prevents it from starting when it is unsafe for the engine to run.
On Zone 2 units, engine exhaust is treated before discharge to prevent an explosion from heat or
sparks. The first stage is an exhaust gas cooler, which cools the exhaust gas enough to prevent
the ignition of potentially explosive ambient gases. The second stage is a spark arrester, which
filters hot solid particles from the exhaust gas.
The engine is started by an electric (Rig safe only), hydraulic, pneumatic or spring starter.
The engine is bolted to a subframe assembly. Four shock mounts attach the subframe assembly
to the power pack frame to ensure good vibration control.
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4 Functional description
The diesel fuel tank is situated in the power pack, underneath the engine. The fuel is filtered in
three stages between the tank and the engine: coarse particle filter, water/fuel separator, and fine
particle filter. An isolation valve beside the tank can be closed during maintenance and transport.
4.6.1
Engine oil
4 Functional description
1
4
5
2
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Use to fill or top up engine oil. One cap is located behind air compressor. Another
cap is located in top of the engine. Use a funnel to make filling easier.
CLOSED (lever across flow direction) at all times. Only open, when draining the
engine oil.
4 Functional description
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4.6.2
5
7
4 Functional description
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(Shown in operation state). Causes an instant engine shutdown by cutting off the
fuel supply. This valve controls the fuel supply to the engine, and is actuated by
engine oil pressure. Engine oil under pressure enters and exits through the upper
connections. Fuel from the fuel pump enters and exits to the engine injectors
through the lower connections. When there is sufficient engine oil pressure, the
valve stays open. If the oil pressure drops under approximately 0.5 bar (7.5 psi) the
valve will block the supply of fuel, shutting down the engine.
Before starting, the valve must be manually disarmed by rotating the lever down. It
will arm itself once the engine is running and generating oil pressure.
NOTE: Also referred to as sentinel valve or master valve.
Causes an instant engine shutdown by cutting off the air supply. When explosive
gases are present in the air, a diesel engine can sometimes continue to run, even
when the fuel and electrical supply are cut off. This butterfly valve in the air intake is
actuated by engine oil pressure. When there is sufficient engine oil pressure, the
valve stays open. The valve is manually latched open before starting, but will be
held open automatically once the engine is running and generating oil pressure.
See item 14 in Figure 5.2 on page 66. for the air inlet valve control.
This component requires periodic maintenance (cleaning).
This valve is placed in the oil pressure circuit to the engine safety valve. In the event
of excessive exhaust temperature (maximum 200 C), the valve will close, triggering
the Zone 2 engine shutdown.
The top opening for the crankcase air breather is connected to a flexible hose that
leads to a flame trap device. The flame trap prevents ignition of an explosive
atmosphere by a possible flame in the crankcase.
This component requires regular inspection and maintenance.
The silencer is equipped with a spark arrester to catch glowing soot in the exhaust
gases that may still be present after the exhaust gas cooler. The ash is collected in
the lower side of the silencer, and can be removed via the plugged cleaning opening
on the bottom.
This component requires regular inspection and cleaning.
During servicing, remove the plug to extract the spark ash through this opening
The cooler is a box-shaped water jacket that leads the exhaust gas flow through
cooling tubes from the engine exhaust manifold to the silencer. The exhaust
manifold (not shown) is also water-cooled. The water jacket coolant is itself cooled
in the cooling system radiator.This component requires no routine servicing.
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4 Functional description
4.6.3
4 Functional description
6
13
10
7
3
11
12
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Located in the right side plinth of the power pack, accessible for filling at a regular
service station. Use only diesel fuel of an approved grade (see specifications).
Fuel tank
Close during transport, and when servicing filters. Open before starting.
Second cleaning stage of diesel fuel. Accumulated water must be regularly drained
(manually). Disposable filter element in upper section.
Use only when the fuel tank has run empty or when air has entered the fuel system
during servicing of filters.
Press several times to pump fuel from the tank into the fuel pump before starting.
Third cleaning stage for diesel fuel after the fuel pump. Disposable element.
Fuel pump
Prevents fuel from passing through the fuel return line during an emergency
shutdown.
10
11
12
Fuel gauge
13
Fuel purifier
Removes suspended water and emulsions from fuel of dubious quality. Requires
periodic draining from bottom of vessel.
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4 Functional description
4.6.4
4 Functional description
5
4
2
6
Hydraulic starter
Used to start the engine. Stored pressure in the hydraulic accumulator is released to
the starter which in turn starts the engine.
Hydraulic accumulator
Used to isolate the accumulator to store the charge for later starts. Must be opened
before starting, and closed before shutting down (or after charging).
When turned, stored hydraulic pressure from the accumulator is released to the
hydraulic starter which in turn starts the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.
Hand pump
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4.6.5
3
4
When depressed, compressed air is delivered to the air starter which in turn starts
the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.
Air filter/dryer
Pneumatic starter
Used to start the engine. Compressed air from the rig/shore or another external
source turns the starter which starts the engine.
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4 Functional description
4 Functional description
4.6.6
2
4
Hand crank
Winding nut
Spring starter
Pulling this down engages the starter with the flywheel, releasing the spring
pressure to start the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.
Reset button
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This button should be pressed every time before winding up the starter, or the
starter could be damaged.
4.6.7
Cooling systems
6
5
3
5
1
1
Cooling fan
This v-belt driven fan draws cool air over the engine radiator
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4 Functional description
4.6.8
4 Functional description
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Turbocharger
Allows the engine to produce more power by forcing more air and fuel into the
combustion chambers.
Override for the automatic valve closure to enable the engine to start. When the
engine is running, the valve must be controlled by the Zone 2 safety system. PULL
before starting the engine, and hold in place. Then PUSH in when the engine oil
pressure reaches 2.0 bar (29 psi), so that the automatic control can take over after
the engine start. The air inlet valve is automatically closed to kill the engine when
the engine or winch safety systems detect a hazardous condition. Without air, the
combustion in the diesel engine cannot take place.
WARNING: Do not run the engine with the air inlet valve handle left in the pulled out
position. This can prevent the engine from shutting down in a Zone 2 hazardous
situation!
The tachometer in the main control panel is driven by the cable from the output
above the compressor. The cable passes through this pneumatic control valve (NC)
which is preset to open at 2500 rpm. The engine normally will run at a lower speed
than this. An overspeed may be a sign of an explosive air/gas mixture in the
ambient air. When the valve is opened, it triggers the Zone 2 engine shutdown.
The overspeed controller features a reset button. The engine cannot be started
again until the overspeed controller is manually reset by pressing this button.
In addition to the standard functions of the exhaust gas cooler (see Exhaust gas
cooler (optional) on page 39) this larger cooler also supplies cooling for the
turbocharger.
In addition to oil and coolant this radiator also cools incoming air for the
turbocharger.
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4 Functional description
4.7
Pneumatic system
5
10
4 Functional description
11
13
8
14
7
4
1
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12
compressor
governor valve
Draws filtered air from engine air intake (after engine air filter).
safety valve
Air receiver
Compressed air accumulator for air from compressor only (not rig air).
Connection 7
Connection 8
Air filter and water separator for air starter systems. mounted on power pack right
door.
10
11
Water separator/filter
12
13
Optional connection for rig air. Installed on units with an air starter.
14
Located on winch module. Can be used to supply power for pneumatic equipment.
4 Functional description
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4.8
Hydraulic system
13
2
4 Functional description
10
12
17
11
14
15
19
5
16
3
6
18
9
8
12
7
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This unit uses an NOV Elmar closed loop hydraulic system to transfer mechanical
energy from the power source (engine or motor) to the winch and auxiliary control
features. When necessary, this primary system may be augmented with one or
more additional open loop hydraulic circuits to power additional features, either from
the main power source or an auxiliary engine or motor.
Connection 5
Used for servicing of the hydraulic system, to drain off condensation water, or to
drain out all the oil.
Single suction filter to remove contamination from the oil before entering the pump
for the main (winch) circuit.
The filter must be replaced whenever the condition indicator moves into the yellow
zone (with power pack running).
NOTE: Never allow the filter condition to move into the red zone. When this
happens, the oil is no longer filtered!
Dual-head suction filter to remove contamination from the oil before entering the
pumps for the auxiliary circuit and cooling fan circuit.
Isolation valve = OPEN whenever the power pack is running.
Close the isolation valve when servicing the filters.
Connection 9
10
Connection 10
11
Connection11
12
Hydraulic pumps for the main, control and auxiliary circuits, mounted on the drive
shaft of the engine.
13
The oil radiator forms part of the cooling stack in the left side of the power pack.
Return flows from the main and auxiliary circuits are combined in a manifold, and
pass through the radiator before returning to the hydraulic tank.
14
15
16
17
Connection17
18
Connection 18
19
Connection 19
1
hydraulic reservoir
oil cooler
drain
suction
filter
pump
main circuit
winch
motor
various
motors
various
controls
control circuit
various
actuators
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4
5
4.9
4 Functional description
1
5
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AUXILIARY PRESSURE
Hydraulic filter
The optional auxiliary drive is an open loop hydraulic circuit intended to power additional
equipment, such as a mast. The pump is always operational when the power pack is running, with
the flow automatically returned to the oil reservoir unless activated at the control panel. Three
quick connectors located at the front of the winch bay are provided for connection to auxiliary
equipment. The attached equipment must have its own control features, as the FlyLine only has
a simple on/off control for the circuit.
4 Functional description
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4.10
Electrical system
5
2
4 Functional description
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ECP 2
AC IN socket
Alternator
24 VDC batteries
Supply standby power for all electrical functions, and starter power for units with
electric starter
Battery switch
There are different types of fuses and circuit breakers used in the FlyLine. The type
of fuse used depends on the specifications of the electrical system. In general, the
following rule applies:
12/24-volt blade type fuses (typical automotive fuse)
115/230-volt cartridge fuses (glass) and circuit breakers
The fuses are marked with an identification number that corresponds with the F
number stated on the electrical diagrams. The description on the diagram indicates
the trip level in Amps. See 8.44 Replace fuse or circuit breaker on page 198 for
information on fuses, and how to change them.
NOTE: See the electrical diagram in your documentation package for a full explanation of the
electrical system.
4 Functional description
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4.11
4 Functional description
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MP16 II
NOV Elmar depth and tension measurement device. See separate measure head
MP16 II documentation.
MP20
NOV Elmar depth and tension measurement device. See separate measure head
MP20 documentation.
SmartMonitor (optional)
CombiGauge
NOV Elmar analogue depth and tension display. See separate measure head
MP16 II documentation.
The FlyLine can be configured with either an NOV Elmar MP16 II (1) or MP20 (2) MeasureHead,
which provides wireline depth and tension signals to a separate remote display. The measuring
head is a three wheel wraparound design with two upper wheels and one lower wheel. Wireline
replacement can be achieved without cutting the wireline.
An accurate tension display can be achieved, when used together with an NOV Elmar
CombiGauge (4). Accurate depth display is provided mechanically via a cable running from the
depth gearbox to the CombiGauge. For more detailed tension and depth display, the unit can be
equipped with an optional NOV Elmar SmartMonitor (3). The SmartMonitor can visualise and
record all ongoing jobs, as well as visualise and record all relevant unit parameters.
4 Functional description
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4.12
Winch subsystem
4.12.1 Overview
15
20
6
21
17
1
13
4 Functional description
19
4
16
5
4
8
12
18
3
2
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Winch Drums
See Appendix 5: Unit configuration on page 244 for drum part numbers
Front drum
Drum motor
Reduction gearbox
Reduction transmission between the reduction gearbox and the drum. Acts directly
on drum rim sprocket. Requires periodic adjustment.
Complete bearing assembly for each end of each drum shaft. Adjusters on the
winch frame are used to position the shaft precisely.
Not shown. Covers drum motors and reduction gearboxes from dirt.
Drum control
Dual-lever control for winch drum direction, speed and torque. Both levers directly
control the hydraulic winch drive system. Each lever is continuously adjustable, and
can be locked or released in any position, leaving the operator's hands free.
left hand dual control handle: speed
right dual control handle: inhole/outhole
Normal gearbox oil level mid-point of this sight glass (one each gearbox, not shown
in this picture).
10
Filler point with cap for replenishing gearbox oil. (one each gearbox, not shown in
this picture).
11
Drain point with cap for draining gearbox oil. (one each gearbox, not shown in this
picture).
13
14
16
17
Levelwind shaft
18
19
20
21
The chain is attached to the measuring head, which runs along the levelwind shaft.
Requires periodic maintenance.
Smoothly polished shaft, that supports the measuring head, and allows it to travel
smoothly side to side on a slide bearing.
A roller at the rear of the measuring head carrier runs in this rail, keeping the
measuring head perfectly steady during operations. The rail can be removed during
rig-down so that the measuring head can be stowed.
See Appendix 5: Unit configuration on page 244 for available drums and part numbers.
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3
4
4 Functional description
3
4
7
9
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Brake cylinder
Brake piston
Expansion chamber
The drum(s) are braked by a brake system contracting the brake band around the rim of the
winch drum. This brake has two functions:
as a parking brake, to prevent the drum from turning due to downhole forces (weight of
tool string and wireline)
as an emergency brake, to rapidly and smoothly halt the drum in the event of an
emergency or sudden failure of the units systems
The brake is not intended to slow or stop the drum during normal operations.
1.
A spring (inside a hydraulic brake cylinder) is pre-compressed during assembly and retained
by the brake cylinder lid.
2.
When pressure is present in the brake pneumatic or hydraulic circuit (BRAKE released), a
piston is extended, releasing the brake - this movement compresses the spring. If pressure
is lost (BRAKE applied, EMERGENCY OFF pressed or a system failure), the spring will expand,
forcing the brake piston back into the cylinder, and applying the brake.
The brake band system is designed to be assisted by the inhole rotation of the drum. The brake
is therefore more effective in the inhole than the outhole direction.
Double drum winch frames have separate brake system(s) per drum.
See the maintenance section of this manual for procedures to test, inspect, adjust and replace
the brake band(s).
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4 Functional description
4.13
5
6
4 Functional description
8
2
3
4
9
10
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BOP PRESSURE
PRESSURE REGULATOR
BOP CONTROL
BOP CLOSE
BOP OPEN
Compressed air is supplied to the combined control panel. The compressed air drives a hydraulic
pump (represented by on the control panel). The air supply to the hydraulic pump is controlled by
a dial regulator (1), which can be set to achieve the desired hydraulic pressure. The hydraulic
pump supplies hydraulic pressure to the BOP. The hydraulic pressure supplied by the pump is
displayed on a gauge (2). The hydraulic pressure is backed-up by an accumulator (represented
by on the panel), which is mounted in the winch unit. This accumulator can be isolated from the
system by closing a valve in the winch module.
When the hydraulic pump is activated, hydraulic fluid from the oil tank (Figure 5.14) is pumped
via the high pressure hoses (Figure 5.14) to the BOP assembly, depending on the setting of
hydraulic selector valve (3). To control the BOP, hydraulic selector valve (3) can be set to either
OPEN, OFF, or CLOSE. Pressure gauges (4) displays the hydraulic pressure that is present at the
BOP assembly in either the open or closed positions.
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4 Functional description
9
10
4 Functional description
3
8
6
5
Figure 4.5 Stuffing box hydraulic pump in cabin and connection point at winch
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Pump handle
Insert into the pump handle socket to enable pumping hydraulic pressure.
Pressure gauge
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4 Functional description
The stuffing box control hose is connected to the stuffing box quick connector (3) located at the
front of the winch bay. The control hose can be found on a reel inside the winch door. A label
explains the connection function for the quick connector.
UNIT CONTROLS
5 Unit controls
7
6
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CombiGauge
Steering wheel
This wheel controls the lateral movement of the measuring head when spooling the
wire onto the drum. (outhole)
Battery switch
5 Unit controls
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5.1
10
11
5 Unit controls
12
13
14
15
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CONTROL PRESSURE
This gauge (0 to 41 bar (600 psi)) shows the hydraulic control pressure, which is used
for controlling the hydraulic system.
AUXILIARY PRESSURE
This gauge (0 to 280 bar (4000 psi)) shows the hydraulic pressure in the auxiliary
circuit
HYDRAULIC OIL
TEMPERATURE
This gauge (0 to +120 C (+250 F)) shows the hydraulic oil temperature. The value is
measured in the main hydraulic oil reservoir.
ENGINE TEMPERATURE
This gauge (0 to +120 C (+250 F)) shows the engine temperature. The value is
measured in the engine coolant between engine and radiator.
This gauge (0 to 11 bar (160 psi)) shows the engine oil pressure. The sentinel master
valve (fuel shut-off safety valve) will shut down the engine, when this value drops
below 0.5 bar (7.2 psi) (approximately). During normal working conditions the oil
pressure will be 2.3 bar (33 psi) (approximately); at maximum engine RPM, the oil
pressure will be 4 bar (58 psi) (approximately).
This gauge (0 to 11 bar (160 psi)) shows the air pressure in the system.
AIR PRESSURE
START PRESSURE
This gauge shows the current starting pressure available for the engine starter. This
(Only with air or hydraulic start) gives the hydraulic pressure (0 to 280 bar (4000 psi)) for the hydraulic starter and air
pressure (0 to 11 bar (160 psi)) for the pneumatic starter.
NOTE: This gauge is not present on units equipped with the other starter types.
EXHAUST TEMPERATURE
This gauge (0 to +250 C (+480 F)) shows the exhaust temperature. The value is
measured in the spark arrester/silencer. This gauge is present on Zone 2 units only,
not on rig-safe units.
TACHOMETER
This gauge (0 to 3000 rpm) shows the engine speed in revolutions per minute.
ENGINE START
This button starts the engine on units with air or hydraulic starters. The button is
returned to the starting position by a spring.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.
11
ENGINE STOP
Press and hold to shut down the engine of the power pack (normal shut down).
NOTE: If you release the button too soon, the motor will restart.
12
EMERGENCY STOP
Press this control to fully shut down the unit. To restart the unit, the main switch on the
main control panel must be reset.
Never restart the unit without checking that the cause for the emergency stop has
been resolved.
Never use the emergency stop as a control to stop the unit during normal
operations.
NOTE: There is also an EMERGENCY STOP button on winch right control panel.
13
AUXILIARY DRIVE
(Option)
14
Use this handle to control the engine safety air intake control valve. It overrides the
automatic air inlet valve closure to enable the engine to start.
The air inlet valve is automatically closed to kill the engine when safety systems detect
a hazardous condition. Without air, the combustion in the diesel engine cannot take
place.
General units: Push the handle up to bypass the engine motor oil pressure safety
system to allow the engine to be started. Hold the handle in the upper position until the
motor oil pressure has risen to approx. 2 bar.
Pull the handle down to emergency stop the diesel engine. Pulling the handle down
will close the engine air intake valve.
For restart wait for the engine derived vacuum to disappear.
Heavy duty units: Pull before starting the engine, to latch the air inlet valve open,
then push once the engine is running so that the automatic control can take over.
15
THROTTLE
Engine speed control. Push and hold the button to release the lock.
Pull to increase rpm
Push to decrease rpm
Release the button to lock the speed. Fine adjustment (when locked):
Turn counter-clockwise to increase rpm
Turn clockwise to decrease rpm
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5 Unit controls
9
10
5.2
5 Unit controls
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CONTROL PRESSURE
This gauge (0 to 41 bar (600 psi)) shows the hydraulic control pressure, which is used
for controlling the hydraulic system.
MAIN PRESSURE
This gauge (0 to 410 bar (6000 psi)) shows the hydraulic pressure generated by the
main hydraulic pump.
HORN
This lever (HIGH SPEED) controls the speed and torque obtained from the hydraulic
motor. The maximum up or down position will generate the fastest drum speed
(greatest hydraulic flow) with the least available torque.
The position of this lever limits the range of the right (INHOLE/OUTHOLE) lever.
This lever (INHOLE/OUTHOLE) controls the winch drum direction, speed and torque by
regulating the direction and flow delivered by the main hydraulic pump. The further the
joystick is moved in the INHOLE or OUTHOLE direction, the higher the speed. To slow
the winch down, move the stick back towards the neutral position.
INHOLE: spools wireline off the drum (into the hole)
STOP: neutral position (lift collar to release)
OUTHOLE: spools wireline onto the drum (out of the hole)
Near the middle position, speed is lowest, torque is highest. At the furthest position
(HIGH SPEED), the hydraulic flow is maximum, highest speed and lowest torque.
NOTE: The maximum possible torque is set by the LINE TENSION valve (See Line
Tension on page 73).
5 Unit controls
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5.3
5 Unit controls
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AIR PRESSURE
This gauge (0 to 11 bar (160 psi)) shows the air pressure in the system.
EMERGENCY STOP
Press this control to fully shut down the unit. To restart the unit, the main switch on the
main control panel must be reset.
Never restart the unit without checking that the cause for the emergency stop has been
resolved.
Never use the emergency stop as a control to stop the unit during normal operations.
NOTE: There is also an EMERGENCY STOP button on the power pack control panel.
BRAKE ON/OFF
This switch operates the brake. Move the switch down to activate the drum brake; move
the switch up to release the brake.
BRAKE SELECT
This switch selects which drum (front or rear) that the BRAKE will be applied to.
LINE TENSION
Rotary control for adjusting the pressure level, at which a pressure relief valve will open to
limit the torque delivered to the drum.
+ Increase the maximum possible pressure
Decrease the maximum possible pressure
To avoid parting the wire, always set this control to a level under the value specified for
your wireline.
CAUTION: EQUIPMENT DAMAGE. Prolonged operation of the unit at pressure levels
above the safety valve setting can overheat the hydraulic oil, damaging the system. If the
hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.
5 Unit controls
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6.1
Moving/positioning equipment
NOTE: This section provides general guidelines for moving and positioning the FlyLine
modules, using the standard features and unit accessories. For detailed instructions on
how to safely move and position equipment, refer to your local regulations.
WARNING
TXT-10004328/A
HOISTING HAZARD
Heavy suspended objects can fall down causing serious injury or death.
Never walk underneath a suspended load, or place yourself between a suspended load and
another object. Follow local safety regulations.
WARNING
TXT-10004327/A
HOISTING HAZARD
Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury
or death.
Never use the forklift pockets for hoisting.
WARNING
TXT-10004271/A
CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.
WARNING
TXT-10004360/A
SHARP OBJECT
Sharp or rough objects can cause severe cuts.
Always wear gloves when handling sharp or rough objects.
6.2
Hoisting modules
NOTE: The lifting equipment must only be used by qualified personnel.
1.
2.
Make sure any lifting equipment repairs have been carried out in accordance with EN 12079.
3.
Make sure the end rail is fitted, if applicable (winch module only).
4.
Make sure the module has been correctly prepared for transport: all parts stowed, and all
doors and hatches closed and locked.
5.
Make sure the single point lifting beam and all fittings have been removed.
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The lifting chains of the hoist might become entangled in the lifting beam and fittings if they
are not removed,
2.
Attach the lifting chains to the lifting pad eyes (4x) of the module as shown in
4.4 Transportation features on page 32. Make sure all shackles are correctly attached with
a bolt and nut and secured with a split pin.
3.
Remove the single point lifting beam from the storage brackets.
2.
Attach the single point lifting beam to the top of the winch module, using the supplied nuts
and bolts. Secure each nut and bolt with a split pin.
3.
4.
Make sure the shackle is correctly attached with the bolt and nut and secured with a split pin.
5.
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6.2.1
WARNING
TXT-10004272/A
CRUSH HAZARD
Heavy parts can drop suddenly during dismantling and assembly.
Keep hands, fingers, etc. away from heavy objects that are liable to move suddenly or drop.
Use suitable tools, chocks, blocks, etc. to support heavy objects.
1.
Align the jacking wheel pin with the hole in the frame.
Figure 6.1
2.
Push the jacking wheel pin into the frame until the pin holes in the jacking wheel align with
the pin holes in the frame.
Figure 6.2
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3.
Insert the locking pin in the pin holes, and secure with a linchpin.
Figure 6.3
4.
Lift the unit with the jack by turning the handle clockwise until the jack extends approximately
8 cm.
6 Setup and removal
Figure 6.4
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5.
Place the side wheel next to the opening in the raised part of the frame.
6.
Make sure the base of the side wheel is correctly oriented as shown in the following figure.
Figure 6.5
Push the side wheel base fully into the opening.
8.
7.
Figure 6.6
WARNING
TXT-10004272/A
CRUSH HAZARD
Heavy parts can drop suddenly during dismantling and assembly.
Keep hands, fingers, etc. away from heavy objects that are liable to move suddenly or drop.
Use suitable tools, chocks, blocks, etc. to support heavy objects.
9.
Turn the jacking wheel handle counter-clockwise to fully lower the module onto the two side
wheels.
Page 78 of 258
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Original Instructions
10. Remove the locking pin, and detach the jacking wheel.
11. Place the jacking wheel against the other side of the unit and repeat steps 1 through 10.
12. Unfold the towing handle.
The module can now be transported on the side wheels.
Figure 6.8
Page 79 of 258
Revision C
Original Instructions
Figure 6.7
6.3
Rig-up
6.3.1
Position unit
danger zone
1
6 Setup and removal
Page 80 of 258
Revision C
Original Instructions
6.3.2
1.
Move the modules to their operating positions by following the instructions in 6.1 Moving/
positioning equipment on page 74
2.
Align the unit or winch module to the hay pulley, as shown in Figure 6.9.
3.
Mark out the hazardous area between the FlyLine and the wellhead with tape, to prevent
unauthorized persons from entering the danger zone. See 2.2.5 Wireline on page 10.
4.
Anchor the winch to the ground surface, or some immovable point behind the winch,
according to site regulations.
Ground unit
WARNING
TXT-10004301/A
EXPLOSION HAZARD
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been correctly grounded before performing any work on the
unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.
1.
Ground the unit or individual modules to the rig/wellhead and to each other, as required by
site/government regulations.
2.
It must be long enough to reach between the two grounding points without disturbing
operations.
The terminators at each end must be undamaged, and free of corrosion. If necessary,
clean the terminators with a wire brush, and lightly grease them with acid-free petroleum
jelly.
The cable itself must be undamaged, with no kinks or snags, and with a full thickness over
the entire length.
3.
4.
Connect the grounding cable from the wellhead/rig, and firmly tighten the nut, using the brass
or SS washer between the nut and the cable ring lug.
5.
Page 81 of 258
Revision C
Original Instructions
The cable must be a proper grounding cable, with the right colour insulation (green &
yellow).
6.3.3
WARNING
TXT-10004268/A
CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.
Refer to the accompanying figures 6.10 and 6.11 for the following steps:
1.
2.
3.
Remove the securing pins for the end rail (2), and place rail into the storage brackets under
the dashboard.
4.
Release the locking pins (3) for the dashboard protective cover (4) on both sides and lock in
the open position.
5.
Swing the cover out and raise it up onto the roof and secure it in place using the same locking
pins.
6.
7.
Release the locking pins (6) for the operators window and roof on both sides.
NOTE: Rigging up the roof and windshield is normally a one man operation. However, if
necessary coordinate with an assistant to help raise and secure.
WARNING
TXT-10004270/A
CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.
8.
Lift the operators window and roof upwards and towards you on the hinges. When roof is
fully employed put the strut brackets (7) in place to lock the gas struts.
9.
Lock the operators window in place using the same locking pins (6) in front of the window.
Page 82 of 258
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Original Instructions
Page 83 of 258
Revision C
Original Instructions
9
8
Figure 6.11 Winch set up.
11. Remove the operators seat (9) from its transport location in front of the winch, and mount it
into the chair bracket to desired height using its securing pin.
Page 84 of 258
Revision C
Original Instructions
WARNING
TXT-10004322/A
HIGH PRESSURE
(Dis)connecting a pressurized line can cause serious injury and or equipment damage.
Never connect or disconnect any quick connectors when the supply line is pressurized.
Refer to 4.7 Pneumatic system on page 48 and 4.8 Hydraulic system on page 50 for descriptions
of the connections.
1.
Make sure the air out isolation valve in the winch module is closed.
2.
Make sure that the LINE TENSION control is set to minimum to release any residual pressure
in the circuit. See Appendix 5.3: Winch right control panel on page 72.
3.
Connect the hydraulic/pneumatic hoses from the winch to the appropriate connectors on the
power pack bulkhead as follows:
NOTE: Make sure you have plenty of unused, clean rags or wipes on hand.
a) Check the connection
number near the hose
connection ferrule.
6 Setup and removal
Page 85 of 258
Revision C
Original Instructions
5.
Page 86 of 258
Revision C
Original Instructions
6.3.5
If the drum and wireline are not installed or need to be replaced, load the drum as described
by the supplier, and install the drum as described in 8.42 Replace drum on page 191.
2.
Open the left side doors on the winch module to access the measuring head.
For MP16 measuring head continue with step 3; for the MP20 proceed to step 6 for setup.
3.
Refer to Figure 6.14. Release the measuring head from the transport position as follows:
a) Set the lock pin (2) to the horizontal position.
b) Slide the measuring head (3) by hand away from the transport position.
c) Return the lock pin (2) to the vertical position to prevent it from accidentally locking during
operations.
3
Figure 6.14 MP16 measuring head transport lock
4.
If necessary, adjust the levelwind chain by performing 8.11 Check/adjust levelwind chain
tension on page 126.
Page 87 of 258
Revision C
Original Instructions
Thread the wireline and check the measuring head for operations. Refer to the Measuring
Head User Manual in the Documentation Package for further information.
Refer to Figure 6.15. Release the measuring head (3) from the transport position as follows:
a) Set the measuring head lock pin (2) to the horizontal position.
b) Slide the measuring head by hand away from the transport position.
c) Return the lock pin to the vertical position to prevent it from accidentally locking during
operations.
7.
Remove pin from lower transport position (4) for the guide rail (5).
8.
Pull the measuring head towards you with the right hand and with the left hand pull out the
locking pin from the measuring head resting bracket (6), allowing the bracket to lower to the
bottom frame of the winch module.
9.
Lock the bracket in the lowest position with the locking pin so that measuring head rests
securely in place.
NOTE: The bracket has an adjusting screw (7) under it which can be used to adjust height of the
measuring heads guide roller (8) for positioning the guide rail.
4
Figure 6.15 MP20 measuring head set up initial
10. Remove pin from guide rails upper transport position (9) and carefully remove rail out of the
winch frame.
Page 88 of 258
Revision C
Original Instructions
11. Now place the guide rail over the guide roller (8) of the measuring head, and affix it to the
winch frame as shown at points (10).
12. Secure all fastening pins with the accompanying safety clips.
10
10
8
6.4
Page 89 of 258
Revision C
Original Instructions
1.
Perform the relevant procedures listed in 8.5.2 Maintenance schedules on page 110.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
2.
3.
4.
Move the hydraulic control lever for the pump direction (right DRUM CONTROL lever)
backwards, and lock it in the half-way back position.
5.
Slowly move the hydraulic control lever for the motor speed (left DRUM CONTROL lever) either
forward or backward to obtain a higher drum speed.
6.
7.
Return all control levers and knobs to their initial positions, and repeat the above procedure,
this time with the hydraulic control lever for the pump directional control locked in the fully
forward position.
8.
If there were no problems, check the hydraulic system by performing 8.53 Test hydraulic
system pressure on page 219.
9.
Shut down the unit as described in 7.5 Normal shut down on page 104.
Page 90 of 258
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Original Instructions
6.5
Rig-down
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
1.
If necessary, start up the unit as described in 7.3 Power up on page 97, and wind the wireline
fully onto the drum.
2.
Ensure that the system is completely shut down according to 7.5 Normal shut
down on page 104.
WARNING
TXT-10004359/A
SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.
3.
If required, unthread and fasten the free end of the wireline to the drum.
4.
Check the hydraulic and pneumatic systems for leaks and or damage.
5.
6.
If applicable:
a) Slowly close the rig/shore air supply at source.
b) Close the air isolation valves in the winch and power pack.
c) Remove any external hoses from the winch and power pack.
d) Fit the red protective caps.
WARNING
TXT-10004360/A
SHARP OBJECT
Sharp or rough objects can cause severe cuts.
Always wear gloves when handling sharp or rough objects.
7.
8.
Page 91 of 258
Revision C
Original Instructions
See the separate Measuring Head User Manual in the Documentation Package.
f) If required, fasten the hoses to the hook using tie-wraps or tape, to prevent damage
during transportation.
9.
6.5.1
6.5.2
Set the lock pin (Figure 6.14, item 2) to the horizontal position.
2.
Move the measuring head to the transport position and secure with the lock. See
Figure 6.14.
Finalize
NOTE: The end rail must always be fitted before transporting the unit.
1.
WARNING
TXT-10004316/A
HEAVY OBJECT
Incorrect lifting of certain heavy objects can cause serious injury if individually lifted by hand.
Before lifting any heavy object, always check your local safety regulations, and use lifting
equipment or additional personal if required.
WARNING
TXT-10004270/A
CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.
2.
Lower and secure the operator window and roof, by reversing the steps in section 5 For all
modules, connect ground cables between the modules. on page 81
3.
Make sure all access doors and panels are correctly closed and secured.
4.
5.
Dismantle and stow any barriers or warnings around the operational danger zone.
6.
Page 92 of 258
Revision C
Original Instructions
6.6
Storage
6.6.1
2.
6.6.2
3.
4.
Grease all exposed metal surfaces (such as drum, electrical connectors and cylinder rods
that are extended) to prevent corrosion.
5.
Close all doors and hatches on the unit and secure or lock them.
6.
Cover the unit with a suitable protection cover (these can be ordered from NOV Elmar if
required).
7.
Disconnect and remove any batteries in the unit and store them where they will not be
affected by large changes in temperature.
2.
Grease all exposed metal surfaces (such as drum, electrical connectors and cylinder rods
that are extended) to prevent corrosion.
3.
Grease all rubber seals to prevent them from perishing and cracking.
4.
Protect hydraulic hoses outside the unit from direct sunlight and extreme temperatures, and
plug open connections
5.
Page 93 of 258
Revision C
Original Instructions
OPERATION
WARNING
TXT-10004286/A
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual. Only
qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.
7.1
Emergency situations
The FlyLine has three types of emergency stop:
Manual - when an EMERGENCY STOP button is pushed in.
Manual - when the air intake lever on the control panel is pulled down.
This will shut off airflow to the engine.
Automatic - caused by an engine safety system condition (see 7.1.2 below).
7.1.1
7 Operation
The emergency stop buttons are on the power pack and operator controls. In an emergency, push
one of these buttons to choke the diesel air inlet and immediately stop the engine.
The emergency stop buttons should also be pushed in after the FlyLine has been shut down for
maintenance. This will prevent accidental start up of the unit during maintenance.
After resolving the emergency situation, perform a pre-start inspection and then restart the unit.
7.1.2
7.1.3
Ensure that the cause of the emergency shutdown has been solved.
2.
Perform all steps of the normal shut down procedure. See 7.5 Normal shut
down on page 104.
NOTE: The engine will already be stopped, but this procedure ensures that the system will
be in the safest stop situation.
3.
4.
NOTE: After the engine has come to a complete stop, the air intake valve cannot be immediately
opened due to the vacuum created by the engine. Forcing the AIR INLET VALVE open,
before the vacuum is relieved, may damage the air intake safety valve. Wait
approximately thirty seconds for the vacuum to dissipate.
Page 94 of 258
Revision C
Original Instructions
5.
On heavy duty power packs, ensure that the overspeed controller is reset to operating state
(Reset button is pressed). See 4.6.8 Additional features of Heavy Duty power
packs on page 46.
6.
Perform all steps of the normal startup procedure. See 7.3 Power up on page 97.
7.2
Pre-start checklists
7.2.1
Item
Check
Ensure that the unit has been rigged up as described in 6.3 Rig-up on page 80.
Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or
components, and structural damage.
Check all tanks and hoses for leaks and for other visible (transport) damage.
Check all mounting bolts on the winch module (drum bearings/supports).
Inspect the main hydraulic pump group and lines for damage, leaks, and insecure attachment.
Check all hydraulic oil filters for leaks.
Check the hydraulic suction filter indicators. Replace the elements as necessary. See 8.47 Replace hydraulic
suction filter on page 207.
Page 95 of 258
Revision C
Original Instructions
7 Operation
Ensure that the hydraulic oil tank suction filter isolation valves are open.
7.2.2
Item
State
Cabin controls
DRUM CONTROL levers. See 5.2 Winch left control panel on page 70.
BRAKE SELECT. See 5.3 Winch right control panel on page 72.
BRAKE
On
Pulled out
Off
Pulled out
Off
Overspeed controller reset switch (only for heavy duty power packs). See
4.6.8 Additional features of Heavy Duty power packs on page 46.
Pressed
7 Operation
Page 96 of 258
Revision C
Original Instructions
7.3
Power up
Before starting the unit make sure you have read and understood the following sections:
2 Safety on page 7
7.5 Normal shut down on page 104
7.1.1 Manual emergency stop on page 94
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
Ensure that all steps in the pre-start checklists have been done. See 7.2 Pre-start
checklists on page 95.
2.
Air starter
a) Ensure that an air supply (7 bar (100 psi) at 25 l/min) is connected to the rig-air
connection in the power pack
b) Open the shore/rig-air supply at the supply point.
c) Slowly open the rig-air intake valve on the unit.
Hydraulic starter
a) Check the START PRESSURE gauge on the power pack control panel to see if the starter
accumulator has sufficient pressure to start the unit.
The hydraulic engine starter needs 120 bar start pressure for one start attempt.
b) Ensure that the isolation valve for the starter accumulator is open.
c) If there is not enough hydraulic pressure to start the unit, charge the accumulator, as
described in 7.6.2 Charge starter accumulator using hand pump on page 106.
NOTE: Once the engine is running, the hydraulic starter circuit should be charged by
applying the drum brake and using the main hydraulic system to charge. For a
detailed explanation, see 7.6.1 Charge starter accumulator using
engine on page 105.
Page 97 of 258
Revision C
Original Instructions
7 Operation
1.
Spring starter
CAUTION
EQUIPMENT DAMAGE
Winding the spring starter with an air-hammer or any other type of power tool can seriously
damage it. Only use the supplied hand crank to wind the spring starter.
7 Operation
For a cold engine, use two extra turns, or until the red indicators are visible in the
window.
If the spring pressure needs to be relieved later without starting the engine, turn the crank
handle counter-clockwise until the green indicators are visible in inspection window.
e) Remove the crank from the winding nut, and return it to the storage/transit location.
3.
Set the fuel safety (Sentinel) valve by turning the control lever (1) against the spring
pressure. See Figure 7.2 on page 99, item 1.
Page 98 of 258
Revision C
Original Instructions
1
3
Figure 7.2 Fuel safety valve and air inlet valve on basic power packs
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
CAUTION
MACHINE DAMAGE
Activating the engine starter when the engine is running of within 15 seconds after a failed start
attempt will damage the engine starter. Never activate the engine starter when the engine is
running or within 15 seconds after a failed start attempt.
Page 99 of 258
Revision C
Original Instructions
7 Operation
WARNING
5.
Hydraulic starter:
a) Turn the ENGINE START button clockwise,
and hold it in until the engine starts.
Air starter:
a) Press the ENGINE START button, and hold it
in until the engine starts.
Spring starter:
a) Pull the trip lever (1) through 90 degrees in
the direction shown by the arrow in
Figure 7.3, and then immediately release
it.
6.
If the start the start attempt fails, wait at least 15 seconds and then repeat steps 2 to 5.
7.
When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), depending on
the type of power pack, do one of the following:
7 Operation
Check that the hydraulic CONTROL PRESSURE gauge stabilizes between 20 bar (290 psi) and
28 bar (406 psi). If the hydraulic control pressure is less than 15 bar (218 psi) refer to
Troubleshooting section, HYDRAULIC PROBLEM on page 227.
NOTE: The control pressure will vary slightly with the RPM of the engine.
9.
7.4
Running
1.
Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.
2.
Ensure that the DRUM CONTROL levers are in their neutral (middle) position.
CAUTION
TXT-10004393/A
EQUIPMENT DAMAGE
Running the wire inhole at high speed can entangle it in the hole.
Never use high drum speeds when going inhole.
WARNING
TXT-10004304/A
EXPLOSION HAZARD
An incorrectly adjusted brake band can cause an explosion hazard. When the brake is set to
off, the brake band must not rub against the drum, otherwise heat can be generated.
Before operating the unit, ensure that the brake band has been correctly adjusted.
CAUTION
TXT-10004385/A
EQUIPMENT DAMAGE
Prolonged operation of the unit at pressure levels above the LINE TENSION (SAFETY VALVE)
setting (maximum line tension) can overheat the hydraulic oil, damaging the system.
If the hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.
4.
Use the controls to spool the wireline on or off the drum at the desired speed:
The LINE TENSION rotary control knob sets the maximum pressure that can be supplied to
the drum, and therefore the maximum wireline tension. At pressures above this setting,
the valve will open, releasing the excess pressure. The maximum (+) position will stop
the valve from opening at all, allowing maximum torque. Opening the knob (turning
towards ) will reduce the pressure level, at which the valve will open, effectively limiting
the maximum wireline tension. Opening it all the way will remove all torque.
The right DRUM CONTROL lever controls the direction and the flow of the hydraulic pump.
Push the lever forward to spool off wire, pull the lever backwards to spool on wire (the
maximum up or down joystick position will generate the biggest flow). For high torque
(maximum pull) only, use this lever to Pull OUT OF HOLE (POOH).
The left DRUM CONTROL lever controls the speed and torque obtained from the hydraulic
motor. The maximum up or down position will generate the fastest drum speed (greatest
hydraulic flow) with the least available torque.
These levers can be used in combination with the LINE TENSION and THROTTLE for normal
speeds (see section 7.4.1), fast speeds (see section 7.4.2), or for a varying line pull. See
section 7.4.3.
5.
During wireline spooling, use the SPOOLING CONTROL steering wheel to move the measuring
head left and right on the levelwind shaft to follow the wire off the drum or wind the wire
evenly onto the drum.
6.
Continually check the system status: if the engine speed decreases during operations,
increase the power output by adjusting the throttle accordingly.
7.
When finished with wireline operations, shut down the system as described in 7.5 Normal
shut down on page 104.
7 Operation
3.
7.4.1
Normal speeds
1.
Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.
2.
7.4.2
High speeds
CAUTION
TXT-10004393/A
7 Operation
EQUIPMENT DAMAGE
Running the wire inhole at high speed can entangle it in the hole.
Never use high drum speeds when going inhole.
1.
Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.
2.
Set the right DRUM CONTROL (directional control) lever to desired direction inhole or outhole.
3.
Move the left DRUM CONTROL (motor speed) lever backward/forward for high speeds.
NOTE: The drum speed will gradually increase as the lever is moved back/forward. The higher
the speed, the less the line pull.
High speed = low torque
Low speed = high torque
4.
7.4.3
Use both handles together for fast drum response, for instance jarring in- or outhole.
CAUTION
TXT-10004385/A
EQUIPMENT DAMAGE
Prolonged operation of the unit at pressure levels above the LINE TENSION (SAFETY VALVE)
setting (maximum line tension) can overheat the hydraulic oil, damaging the system.
If the hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.
1.
7.4.4
Use the DEPTH/TENSION PANEL to read out the depth and tension of the wireline. See the NOV
Elmar documentation in the Documentation Package for a description.
2.
Check the other gauges on the control panels to ensure that the system is operating within
its limits.
3.
If the gauges show an exceptional condition, stop the machine and troubleshoot the potential
cause. If the exception condition is extreme, push one of the EMERGENCY STOP buttons to
immediately stop the engine and cut system power.
NOTE: The engine also has the following built-in safeguards to shut down automatically
and prevent system damage:
Engine over-speed
Loss of oil pressure
High exhaust temperature
High engine temperature
7 Operation
7.5
NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar
(2466 psi).
c) Ensure that the isolation valve for the starter accumulator is closed.
2.
3.
Set the engine THROTTLE control to minimum (screwed all the way in).
4.
5.
6.
Close the valve below the wire spray tank to stop the oil flow to the wireline.
7.
Push the ENGINE STOP button on the power pack control panel to stop the diesel engine.
8.
9.
7 Operation
WARNING
TXT-10004322/A
HIGH PRESSURE
(Dis)connecting a pressurized line can cause serious injury and or equipment damage.
Never connect or disconnect any quick connectors when the supply line is pressurized.
11. Release air from the system by slowly opening the rig air valve in the winch module.
12. Note the shut-down date and time in the running hours log. See Appendix 8: Running hours
log book on page 249
13. If the unit is being shut down for safe maintenance, push in one of the EMERGENCY STOP
buttons, and place an appropriate tag on it, indicating that the unit is under maintenance.
7.6
7.6.1
2.
3.
4.
Note the position of the LINE TENSION knob on the cabin control panel (so that you can return
it to this position), and then turn it fully clockwise (towards + ).
5.
WARNING
TXT-10004321/A
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
6.
Push the left DRUM CONTROL lever (motor speed control) to the fully forward position and lock
it there.
7.
Slowly move the right DRUM CONTROL lever (direction control) forward.
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
8.
Ask an assistant to observe the START PRESSURE gauge on the power pack until the start
pressure is reached: 120 bar (1740 psi). Maximum charging pressure of the starter
accumulator is factory preset at 170 bar (2466 psi).
9.
Ask an assistant to close the isolation valve of the starter accumulator. This will store the
charge so that the accumulator is fully charged for the next engine start.
7 Operation
WARNING
2.
Remove the pump handle from the holder and insert it into the pump.
3.
Turn the pump isolation lever to the lower position (on some units this is already factory
preset).
4.
5.
Observe the START PRESSURE gauge on the power pack until the minimum start pressure is
reached: 120 bar (1740 psi). Maximum charging pressure of the starter accumulator is
factory preset at 170 bar (2466 psi).
6.
Close the isolation valve of the starter accumulator to store the charge in case immediate
starting is not desired.
7.
7 Operation
7.6.2
MAINTENANCE
TXT-10004206/A1
8.1
Introduction
Only qualified and trained personnel should perform maintenance on Elmar wireline winch units.
The maintenance procedures described here include:
Scheduled periodic (e.g. cleaning, inspecting and testing components, filling fluid levels
and lubricating moving parts)
Corrective (troubleshooting and repairing any malfunctions, plus calibrating/adjusting)
Exchanging parts (for different operation requirements)
The FlyLine can experience extreme forces and rugged conditions, so certain scheduled
maintenance is regularly required to prevent damage to the equipment and potential hazards.
Inspections and tests should be carried out daily before working with the FlyLine unit, but regular
maintenance must be performed according to the number of hours the FlyLine has been run.
Running hours should be logged by the FlyLine operator following a strict discipline to ensure
maintenance activities are carried out on time (an example running hours log form is provided in
the Appendices to this manual). Elmar recommends basing the service intervals on hours of
running; you may prefer to use calendar time (weeks, months).
Refer to the Appendix Tightening Conventions for instructions on tightening nuts and bolts when
doing preventive or corrective maintenance.
Certified assemblies
Your FlyLine may include assemblies which are certified separately from the complete unit
certification (all certificates are included in the Documentation Package for your unit). These
assemblies (examples are winch drive motors and power unit transformers) may only be serviced
by Elmar service personnel, otherwise the certification (and possibly the warranty) for the
complete unit becomes invalid. A certified assembly is identified by its own data plate with serial
number, and is listed as a single top-level part number in the drawings and spare parts lists. If a
fault is detected in a certified assembly, do not attempt a repair yourself, but always contact Elmar
Service for advice (see Contact Us in the appendices).
8.3
OEM components
Certain components of your FlyLine are complete assemblies or subsystems supplied by Original
Equipment Manufacturers (OEM) than Elmar. Examples are measuring heads, air conditioning
units, motor-generator sets. The routine servicing schedules and instructions for these
components are usually not included in this User Manual, but supplied separately in the
Documentation Package for your unit. Ensure you can find this supplementary documentation,
and make yourself familiar with its contents, particularly the required periodic maintenance
schedules for these components.
8.4
8 Maintenance
8.2
8.5
8.8
114
8.9
116
8.10
123
8.11
126
Check/adjust V-belts
8.12
128
8.13
130
Check/fill coolant
8.14
132
8.15
135
8.16
137
8.17
139
8.18
141
8.19
143
8.20
145
8.21
147
8.22
149
8.23
150
Clean air inlet safety valve for heavy duty power packs
8.24
154
8.25
157
8.26
158
8.27
159
8.28
161
as required
113
1500/yearly
8.7
1200
900
600
112
300
8.6
daily
page number
Maintenance activity
8 Maintenance
section number
8.5.1
Drain/fill coolant
8.31
166
8.32
170
8.32
170
8.33
171
8.34
172
8.35
173
Grease unit
8.36
175
8.37
177
8.38
182
8.39
185
8.40
187
Replace V-belts
8.41
189
Replace drum
8.42
191
8.43
196
8.44
198
8.45
202
8.46
205
8.47
207
8.48
210
8.49
212
8.50
214
8.51
216
8.52
217
8.53
219
8.54
221
8 Maintenance
as required
165
1500/yearly
8.30
1200
Clean unit
900
163
600
8.29
300
page number
Maintenance activity
daily
section number
8.5.2
Maintenance schedules
Daily maintenance
section page
8.11
8.14
8.15
8.17
8.19
8.21
8.30
126
132
135
139
143
147
165
chk
Comment
section page
8.8
8.10
8.12
8.13
8.16
8.18
8.22
8.25
8.27
8.29
8.34
8.43
8.47
8.49
8.53
8.54
114
123
128
130
137
141
149
157
159
163
172
196
207
212
219
221
chk
Comment
section page
8.26
8.28
8.32
8.32
8.35
8.36
8.45
8.50
158
161
170
170
173
175
202
214
chk
Comment
section page
8.23 150
8.24 154
8.51 216
chk
Comment
8.6
Complete the wireline service operation, and spool all wire onto the drum.
NOTE: If it is necessary to perform maintenance with the wireline and tools downhole, then it is
critical to apply the brake and clamp the wire to a rigid structure to relieve it of tension to
the unit.
2.
Perform a regular shutdown. See 7.5 Normal shut down on page 104.
3.
Push in and tag one of the EMERGENCY STOP buttons. See 7.1.1 Manual emergency
stop on page 94.
4.
When working on engine or exhaust system components, allow the system time to cool down
to hand-touch or cooler.
5.
When working on hydraulic components, allow the system time to cool down. Do not open
any hydraulic connections unless you are certain that the hydraulic oil is sufficiently cooled
off.
6.
7.
Before opening pneumatic connections for maintenance, release all air pressure from the
pneumatic system:
a) Isolate the rig air supply and close the rig air input valve.
b) Disconnect the supply from the units rig air input, then slowly open the rig air input valve
to bleed off the air from the unit.
c) Close the isolation valves for the air receivers.
d) Check all air pressure gauges to verify that the residual pressure is zero.
8.
When working on electrical components, make absolutely certain that the main power switch
is turned OFF, and that there is no rig AC connected to the unit.
8.7
2.
If the unit is not immediately required for operations, make sure the unit has been correctly
shut down. See 7.5 Normal shut down on page 104.
3.
Make sure the unit and the work area around the unit is left in a safe state as described in
Safety. See 2 Safety on page 7.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
4.
WARNING
TXT-10004270/A
5.
6.
Record the maintenance task in the running-hours log. See Appendix 8: Running hours log
book on page 249.
7.
CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.
8.8
3
3
1
5
Figure 8.1 Engine oil filter and drain/ fill points (alternate fill points shown)
Refer to the Caterpillar documentation included in the Documentation Package that came with
your FlyLine for detailed servicing instructions.
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
3.
WARNING
TXT-10004338/A
HOT LIQUID
Hot oil can cause serious burns.
Take care when handling hot oil and associated components. Always wear appropriate
Personal Protective Equipment (PPE), such as gloves.
4.
5.
6.
Use the oil pump handle (4) to pump out the oil from the engine sump.
7.
8.
9.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
15. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.8 Change engine oil and filter
8.9
WARNING
TXT-10004355/A
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.
For the following tests it is critical that the drum drive chain is tensioned correctly. Perform
8.10 Check/adjust chain tension on page 123.
8.9.1
WARNING
TXT-10004355/A
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.
The drum is correctly adjusted when there is no contact between the brake band and the drum
when the brake is released.
1.
Start the unit for operations. See 7.3 Power up on page 97.
2.
3.
Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
4.
If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.
5.
6.
Using the DRUM CONTROL lever(s), start to turn the drum slowly INHOLE, and allow it to
continue to turn at a low speed.
7.
At the winch, listen (or have an assistant listen) for sounds that may indicate that the drum
is in excessive contact with the brake band(s).
8.
Check the MAIN PRESSURE gauge that the pressure is not increasing to compensate for brake
drag. If applicable, check both brakes.
9.
10. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
11. Apply the BRAKE.
12. If there was no brake-contact noise from the drum in step 7, then the brake has passed the
free-running test. Continue with the drum brake slip test (next section).
13. If brake-contact noise was heard, or there is indication that the MAIN PRESSURE increases
during the test, then the brake needs adjustment. See 8.9.2 Adjust Brake band
tension on page 119.
Drum brake slip test
WARNING
TXT-10004321/A
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
Refer to the winch specifications to identify the drum model currently being tested. See
Appendix 2: Unit Specifications on page 237.
2.
Refer to the recommended drum brake slip pressures in the FAT for the slip pressure range
for this drum. The FAT values are found in your documentation pack under the section
Quality Documents / Start Up Script / Brake slip-hold pressures (in older documentation
packages - refer to Quality Documents / Hydraulic Fat / Brake System).
3.
Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
4.
If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.
CAUTION
TXT-10004395/A
EQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the
brake is tested at LOW or MEDIUM speed ratio.
Always select HIGH speed ratio when testing the brake.
5.
For a multi-speed gearbox, select HIGH speed ratio (never LOW or MEDIUM speed ratio).
6.
7.
On units powered by a diesel engine or truck PTO: use the THROTTLE to set engine speed to
idle.
8.
Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE until the
drum slips in the brake.
9.
Check the MAIN PRESSURE gauge and note the brake slip pressure.
10. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
11. If the MAIN PRESSURE in step 9 was within the range as described in the FAT, then the brake
for this drum has passed the slip test. Continue with the drum brake stopping test (next
section).
12. If the drum slipped below the range (too slack) or above the range (too tight), then the brake
needs adjustment. See 8.9.2 Adjust Brake band tension on page 119.
1.
WARNING
TXT-10004355/A
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.
WARNING
TXT-10004751/A
DANGEROUS MACHINERY
A loose or misaligned chain can lead to equipment damage or personal injury. Ensure that the
drum drive chain is tensioned correctly.
The brake must stop quickly the drum in a controlled, smooth manner. i.e. without juddering or
causing extreme shock to the winch and other equipment. The effect during actual operations will
differ, depending on:
The tension and condition of the drum drive chain;
8.9 Check/adjust brake band tension
The amount of wire on the drum (a fully loaded drum has more momentum);
The weight of the tool string;
The effect of well pressure and resistance on the tool string and wire;
The direction of operation (inhole or outhole);
The speed and torque of the drum (selected gear, engine speed, etc.);
Moisture and oil on the drum rim;
The degree of wear on the brake band lining.
The test is conducted in one specific situation. It is recommended to always conduct the test in
the same situation and under the same conditions.
1.
If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.
2.
Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
3.
4.
5.
On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine
speed to the maximum torque range.
6.
Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE to about
100 bar (1450 PSI), so that the drum is rotating at a high speed.
7.
Apply the BRAKE while at the same time putting the DRUM CONTROL lever(s) into the neutral
(STOP) position.
The brake should quickly and smoothly halt the drum rotation.
8.
On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed
to the idling range.
9.
If the drum stopped quickly and smoothly at step 7, then the brake has passed the stopping
test.
If the drum did not completely stop, or did not stop smoothly, then the brake needs
adjustment. See Section 8.9.2 Adjust Brake band tension.
10. Shut down the unit.
8.9.2
Start the unit for operations. See 7.3 Power up on page 97.
2.
3.
Prepare the unit for safe maintenance. See 8.6 Prepare for safe maintenance on page 112.
If required, check with Elmar Service group for a complete list of brake release pressures/torques
for different drum types and different conditions.
X X
After adjusting ensure the locknut is tightened against the
brake linkage gaffel
d
Minimum thread depth in adjuster
female section X
>1d
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
4.
5.
6.
If the drum has two brake bands, release the brake and disable the brake band on one side
of the drum by slackening the adjuster at the brake cylinder connection sufficiently for the
brake band to be free of the drum rim.
7.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
8.
Start the unit for operations. See 7.3 Power up on page 97.
9.
If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.
10. Put the DRUM CONTROL joystick into the neutral (STOP) position.
CAUTION
TXT-10004395/A
11. On a unit with selectable speed range, select HIGH speed (never LOW or MEDIUM speed).
12. Gradually move the DRUM CONTROL joystick slowly INHOLE, increasing the MAIN PRESSURE
readout until the drum starts slipping in the brake.
NOTE: The MAIN PRESSURE readout is shown on the appropriate gauge on the control panel or
on the installed control system (e.g. SmartMonitor or SMARTVIEW). See Section 5 Unit
controls.
13. Note the MAIN PRESSURE readout at which the brake slips.
14. Return the DRUM CONTROL joystick to the neutral (STOP) position.
15. Set the BRAKE to ON.
16. If the MAIN PRESSURE readout when the drum slipped in step 13 was within the brake slip
range listed in the FAT, the brake has passed the adjustment slip test. Continue from step 18.
17. If the drum slipped below the range (too slack) or above (too tight):
a) Prepare the unit for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.
b) Loosen the locknut on the adjuster beside the brake cylinder.
c) Adjust the brake band:
Brake band too tight: loosen the brake adjuster.
Brake band too loose: tighten the brake adjuster.
NOTE: On larger drums, tighten or loosen the top turnbuckle to increase or decrease the
available adjustment on the lower adjuster.
d) Tighten the locknuts at the adjuster and (if applicable) top turnbuckle.
e) Repeat the test and adjustment again from step 8 until the adjustment is correct.
EQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the
brake is tested at LOW or MEDIUM speed ratio.
Always select HIGH speed ratio when testing the brake.
If the correct adjustment cannot be reached or there is no adjustment left in the adjuster,
replace the brake band(s). See related topic.
18. If the drum has a single brake band, continue from step 28.
Otherwise, continue as follows to adjust the second brake band.
19. Put the DRUM CONTROL joystick in the neutral (STOP) position.
20. Prepare the unit for safe maintenance. See 8.6 Prepare for safe maintenance on page 112.
21. At the drum, using a felt pen, or by counting the number of threads exposed on the adjuster,
note the position of the previously adjusted brake.
22. Disable the correctly adjusted brake by slackening the adjuster at the brake cylinder
connection sufficiently for the brake band to be free of the drum rim.
23. Repeat steps 8 through 16 for the second brake.
The brake slip MAIN PRESSURE of the
MAIN PRESSURE of the first brake.
24. When the second brake is correctly adjusted, reset the first brake as follows:
a) Put the DRUM CONTROL joystick in the neutral (STOP) position.
b) Prepare the unit for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.
c) At the drum, reset the first side brake by tightening the tension adjustment at the brake
cylinder connection to the adjustment you noted or marked in step 21 above.
25. Repeat the test from step 8 with both brakes applied, and verify that the MAIN PRESSURE when
the brake slips is within the range as specified in the FAT.
26. If the slip MAIN PRESSURE is higher, slacken the brake band tension by making identical minor
adjustments on both brakes sides, and repeat the adjustments until the brake slip MAIN
PRESSURE is within range.
27. Release the brake and check that there is no contact between the brake band and drum rim.
If so, slacken the brake band tension very slightly while still remaining within the slip MAIN
PRESSURE range.
28. Prepare the unit for safe maintenance. See 7.5 Normal shut down on page 104.
29. Refit the drum guards and tighten the drum guard attachment bolts.
30. Finalize maintenance tasks. See 8.7 Finalise maintenance tasks on page 113.
8.10
8.10.1 Prepare
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
If necessary, lower or raise the levelwind arm, depending on the chain you want to check/
adjust.
2 cm (3/4 in)
2 cm (3/4 in)
Check the total free play of the chain. It should be approximately 2 cm (0.75 in) at the middle
point. See Figure 8.3.
2.
Make sure the drum is correctly aligned to the gearbox. See Figure 8.3
The drum axis should be parallel with the gearbox axis.
The drum sprocket must be perfectly aligned with the gearbox sprocket.
The distances (a) and (b) between the adjustment block and the pillow blocks should be
the same on both sides of the drum. This will ensure that the drum is correctly aligned in
the winch.
3.
1
2
2
4
distance (a)
distance (b)
6
6
Check if the pillow block bearing (1) is equally positioned between the two adjustment blocks
(2).
The distances (a) and (b) should be approximately equal. This is to allow for correct
adjustment of the chain in the following steps.
2.
If there is not sufficient room to adjust the chain (distance a or b is too small), you should first
adjust the gearbox as follows. Otherwise, continue with step 3.
a) Loosen the drum attachment bolts (3) for both bearings.
b) Use the drum alignment bolts (4) for both bearings to position the pillow block equally
between the two adjustment blocks. See Figure 8.4.
c) Slightly loosen all three gearbox attachment bracket (5) bolts (6).
d) Remove the slack from the chain by adjusting the bracket up or down.
NOTE:
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
e) Tighten the gearbox attachment bracket bolts. For correct torque values, see
Appendix 6: Referenced Documents on page 246
f) Continue from step 4.
3.
4.
Use the drum alignment bolts (4) for each bearing to finely adjust the chain tension. Make
sure the chain is adjusted according to Appendix 8.10.2: Check chain tension and
alignment on page 123. See also Figure 8.3.
5.
Make sure the distance (a) between the adjustment block and the pillow block bearing is the
same on both sides of the drum. This will ensure that the drum is correctly aligned in the
winch module.
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
6.
Tighten the drum mounting bolts on both sides of the drum. For correct torque values, see
Appendix 6: Referenced Documents on page 246.
7.
Make sure both drum alignment bolts for each bearing are securely tightened.
8.
8.10.4 Finalize
1.
Perform the drum mount test by performing 8.52 Test drum mounting on page 217.
2.
Check the tension of the brake by performing 8.9 Check/adjust brake band
tension on page 116.
3.
If necessary, grease the drive chain to keep it flexible and prevent rusting.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
4.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
WARNING
8.11
8.11.1 Prepare
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004268/A
CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.
2.
If the unit is so equipped, lift the protective cover on the front of the winch module to access
the measuring head and levelwind chain. See 5 For all modules, connect ground cables
between the modules. on page 81
3.
Unlock the measuring head from the transport position, refer to 6.3.5 Prepare measuring
head assembly on page 87
1 cm free play
1.
Check the total free play of the chain. It should be approximately 1 cm (3/8 in) at the middle
point of the lower race. Refer to figure 8.3.
2.
If free play is adequate then you are finished. If the chain needs adjusting then go to the
following procedure 8.8.3
1
2
Locate fastening screw (1) and loosen completely so the adjusting turnbuckle (2) is free of
the measuring head carrier (3).
2.
To tighten the chain, use a suitable wrench to turn the turnbuckle in the direction of the arrow
shown until you have 3/8 in. play.
3.
To slacken the chain turn it in the opposite direction until you have 3/8 in. play.
4.
Once chain tension is adjusted adequately line up the hole in the turnbuckle with the
measuring head carrier and insert the fastening screw.
5.
8.11.4 Finalize
1.
If necessary, grease the drive chain to keep it flexible and prevent rusting.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
2.
Turn the steering wheel to move the measuring head left and right a few times to verify the
chain play.
3.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.12
Check/adjust V-belts
This procedure describes how to inspect and adjust the V belts of the Caterpillar diesel engine.
3
2
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
WARNING
TXT-10004348/A
MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Ensure that the engine cannot be started during maintenance.
2.
3.
4.
If necessary, replace the belts. See 8.41 Replace V-belts on page 189.
5.
Apply 10 Nm (10 ft lb) against the belt test point (1). There should be approximately 1 cm
(3/8 in) of play for both belts.
6.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
7.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.13
steel band
liner material
Figure 8.10 Cross section and rivet depth of new brake band
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
NOTE: All brakes used in NOV Elmar units are fail-safe, and are automatically applied
when the unit is off.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
3.
Measure the thickness of each brake band at the points shown in Figure 8.9.
NOTE: The thickness of new brake bands is 12 mm including liner. This provides 3.5 mm
of liner material to wear before the rivets begin to score the drum.
4.
If the total thickness at any of the measuring points is approaching 9 mm (0.5 mm liner, see
Figure 8.10), replace the brake band(s) by performing 8.40 Remove/replace brake
band on page 187.
5.
6.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
CAUTION
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
8.14
Check/fill coolant
Regularly check the coolant level, when the unit is cold, before starting it up. When filling the
radiator, remember that the volume will increase, as the engine/coolant warms up. Therefore,
always only fill to the bottom third of the coolant sight glass. If the coolant is overfilled, excess
coolant will be forced out of the coolant overflow valve during operations.
coolant
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
If the unit has been running, wait for the coolant to cool down (below 50 C).
If the coolant is not cooled down, the reading will be incorrect.
3.
Check the level of the coolant. The coolant should be visible in the bottom third of the sight
glass (1). See Figure 8.11.
4.
WARNING
TXT-10004340/A
HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.
5.
If the coolant is not visible in the sight glass you will need to check the level through the filler
cap to determine approximately how much to top up.
6.
CAUTION
TXT-10005152/A
EQUIPMENT DAMAGE
Using coolant containing silicates, borates, nitrates or phosphates will corrode aluminium
radiators, causing premature failure and leaks.
Only use coolant conforming to specification VW TL-774-D/F.
NOTE: The coolant is normally topped up from the radiator filler cap (2), but can also be filled
from the drain plug at the bottom of the unit (optional). This is necessary when refilling
the system after it has been drained. See 8.31 Drain/fill coolant on page 166.
NOTE: The following steps may require use of a ladder to access the radiator cap hatch.
WARNING
TXT-10004313/A
WARNING
TXT-10004340/A
HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.
1.
Open the COOLANT roof hatch (3) to access the radiator filler cap (2), and remove the cap.
2.
CAUTION
TXT-10004371/A
EQUIPMENT DAMAGE
Contaminated coolant can seriously damage the cooling system.
Always use approved coolant and an approved filter when refilling the cooling system.
3.
Pour coolant into the cooling system until the coolant is visible in the sight glass.
4.
5.
6.
7.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.
8.15
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
1.
Open the left door, so that you can see the fuel tank.
2.
2
Figure 8.13 Diesel fuel level options
3.
If the level is low, fill the tank by proceeding with 8.15.2, otherwise you are finished.
WARNING
TXT-10004301/A
EXPLOSION HAZARD
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been correctly grounded before performing any work on the
unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.
1.
Make sure both the unit and the refuelling facility are correctly grounded.
2.
Ensure that the diesel fuel to be used conforms to the EN 590 standard.
3.
Ensure that the unit has been shutdown for safe maintenance as described in 7.5 Normal
shut down on page 104.
4.
5.
Fill the fuel tank until you see it is almost full; allow 3-5 cm (1-2 in) for fuel expansion.
6.
7.
8.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
9.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.16
1
2
1.
Ensure that the unit has been shutdown for safe maintenance as described in 7.5 Normal
shut down on page 104.
2.
Wait a few minutes for the oil to settle, if the unit has been running.
3.
Open the right power pack door to access the engine oil dipstick (1).
4.
5.
Clean the dipstick with a clean rag, and push it back into position.
6.
Remove the dipstick and check the oil level. Correct level must be between the low and high
marks on the dipstick.
7.
If level is ok then proceed to 8.16.2. If level is below the low mark then fill the engine oil as
follows.
Open the left power pack panel to access the engine oil filling point (2).
2.
3.
CAUTION
TXT-10004366/A
EQUIPMENT DAMAGE
Overfilling the engine oil can damage the engine seals. Add oil slowly and wait until it has fully
run into the engine before rechecking the oil level.
4.
5.
6.
7.
CAUTION
TXT-10004386/A1
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to fail, as well as contaminate the local
environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before
refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and
are correctly tightened.
8.
8.16.2 Finalize
1.
Ensure that the dipstick and filler cap are screwed tight.
2.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
3.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.17
1
2
2.
Ensure that the hydraulic oil is cool enough to avoid burns (check temperature gauge!).
3.
Open the HYDRAULIC OIL roof hatch (1) to access the hydraulic oil tank filler cap (2) and
gauge (3).
4.
If the gauge shows more than 3/4-full you are finished, close and secure the roof hatch. To
confirm the gauge reading you can remove the filler cap and check the actual level inside the
tank.
5.
If the gauge shows less than 3/4-full, fill the tank as follows:
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.
a) Remove any dirt and debris from around the filler cap on top of the hydraulic tank using
a clean cloth.
WARNING
TXT-10004337/A
HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.
1.
c) Slowly add hydraulic oil of the correct grade (see Appendix 4: Unit hydraulic
oils on page 243 for approved types), until the gauge shows full. Do not overfill! Allow
for hydraulic oil to expand during operations.
d) Wipe the filler cap clean using a clean cloth, and fit it back on the tank.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
e) Remove all tools and materials from the work area, and dispose of used materials
according to local environmental regulations.
8.18
oil
correct oil level
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
View the oil level either through the hole in the cover plate or by removing the plate, if drum
capacity allows.
2.
Check the oil level. The oil should be near the top of the lowest sight glass (1), see Figure
8.15.
NOTE: The gearbox is installed at an angle and has 2 sight glasses, one on each side.
Make sure you check the lowest of the two sight glasses.
3.
If the oil level is correct, you are finished, otherwise continue with 8.18.2.
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.
1.
Remove the oil filler plug (2). Alternate fill point is to remove the breather plug (3).
2.
3.
4.
Slowly pour oil into the gearbox until the oil is visible at the top of the sight glass. DO NOT
OVERFILL!
5.
CAUTION
TXT-10004386/A1
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to fail, as well as contaminate the local
environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before
refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and
are correctly tightened.
6.
7.
Clean any spilled oil from around the oil inlet and gearbox.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
8.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.19
1
Figure 8.18 Wireline lubrication tank with filler cap/ dipstick
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
Make sure the flow valve (1) at the bottom of the wireline oil tank (2) is closed.
3.
4.
5.
6.
If necessary, add oil. Check with your wireline documentation for the correct lubrication oil
type for your wireline.
7.
8.
9.
Briefly open the flow valve at the bottom of the wireline oil tank to check the oil flows correctly.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
11. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.20
2.
Open the right power pack door to access the fuel pump (2) and gear drive (1). See
Figure 8.19.
3.
4.
Obtain a clean, small container marked with ccs or ml to collect the gear drive oil.
3
2
1
4
Figure 8.19 Fuel pump and gear drive
1.
5.
6.
Place the small container under the drain port (4) and use a 6mm hex key to unscrew the
drain plug.
NOTE: For units with spring starter it may be necessary to remove the starter to access the drain
plug. In this case contact maintenance personnel.
7.
Collect the oil and determine amount, this is the oil level.
8.
If required, replace the oil with new oil or simply add enough to obtain the proper amount of
100cc.
2.
Carefully pour the 100cc of oil from the container into the filler opening.
CAUTION
TXT-10004386/A1
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to fail, as well as contaminate the local
environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before
refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and
are correctly tightened.
3.
8.20.3 Finalize
1.
2.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
3.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
WARNING
TXT-10004270/A
CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.
4.
8.21
WARNING
TXT-10004337/A
HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.
CAUTION
TXT-10004383/A
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
Inspect the general condition of all hydraulic lines and hoses. Look for visible damage,
leakage, and sweating or swelling of hoses.
NOTE: The extension hoses (1) which connect the powerpack to the winch module are the
most susceptible to damage since they are the most exposed to the elements and
physical wear and tear. Ensure hereby that the rubber outer mantle is not cracked
or gouged, exposing the steel reinforcement strands. Any exposed steel strands will
rust and weaken, creating a potentially dangerous situation.
External hoses
joining power
pack and winch
modules
Inspect the entire unit for signs of leakage, such as oil drips, oily dust build-up, etc., around:
Tanks
EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.
Motors
4.
5.
After making repairs, test by performing 8.53 Test hydraulic system pressure on page 219.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
6.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.22
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
3.
Check the shock absorbers at each corner of the engine block. See Figure 8.21.
Pay special attention for worn rubber or loose mountings; (1) and (2) are joined by a
vulcanized rubber block, there must be no metal contact between (1) and (2).
4.
5.
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
6.
8.23
10
3
4
3
1
11
12
5
2
Figure 8.23 Air inlet safety valve cable clevis and pin
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
Loosen the flexible hose clamp (1) from the air intake hose (2), and push the hose out of the
way.
3.
Remove the two screws (3) attaching the bowden cable bracket (4) to the air inlet valve (5).
WARNING
TXT-10004285/A
DANGEROUS MACHINERY
Changing factory settings can affect the safety of the system, and result in personal and/or
equipment damage.
Take extreme care when adjusting factory settings. If in doubt, contact Elmar
NOTE: Be sure not to loosen the adjustment nuts (6) holding the bowden cable in the bracket;
by doing so the correct cable adjustment needed for shutdown may be lost.
4.
Push the clamp of the clevis pin (7) from the bowden cable clevis (8).
5.
6.
Place a rag under the oil line coupling (10) to catch any oil that drips.
7.
8.
Remove the four attachment bolts (11) to the intake manifold pipe (12).
9.
copper grease
copper grease
11
copper grease
WARNING
TXT-10004311/A
EXPLOSION HAZARD
Lubricating the air inlet valve with the incorrect type of grease can cause an explosion.
Use a clean rag to clean the air inlet valve. Only use copper grease to lubricate the spring of
the air inlet valve.
10. Place a clean temporary cover over the intake manifold pipe, to protect the engine from dirt
and debris.
13. If required, apply a small amount of copper grease to the spring (11) of the air inlet valve,
where shown in Figure 8.24.
14. Check the closing action of the valve over its full stroke.
15. Check all moving parts for wear.
16. Remove the temporary cover from the intake manifold pipe.
17. Inspect the air inlet valve gasket, and replace if necessary.
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
18. Reposition the air inlet valve, and refit the attachment bolts to the intake manifold pipe. Take
care not to damage the gasket.
For correct torque values, see Appendix 6: Referenced Documents on page 246
19. Refit the bracket.
20. Refit the clevis pin at the end of the bowden cable, and secure the clamp to the clevis.
21. Reconnect the oil line coupling.
22. Refit the flexible hose with hose clamp to the air inlet valve.
23. Position the hose clamp as close to the air valve housing as possible (see Figure 8.22) and
tighten it.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
24. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
Test the engine for correct operation. See 7.3 Power up on page 97.
25. Shut down the unit, as described in 7.5 Normal shut down on page 104.
Page 152 of 258
Revision C
Original Instructions
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
26. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.24
Clean air inlet safety valve for heavy duty power packs
7
4
8.24 Clean air inlet safety valve for heavy duty power
9
11
10
Valve lever
Swings across flow to open butterfly valve (normally closed) for starting. The valve
is then held open by the latch below the actuator.
Connected to AIR INLET VALVE control handle, which is pulled before starting.
Position of lever and cable shown with engine stopped.
Cable clamp
Applies cable force to lever. When AIR INLET VALVE handle pressed in after
starting, the clamp returns to the position shown.
While engine is running, engine oil pressure forces a plunger to press down,
releasing the latch but holding the valve open. When engine oil pressure drops, the
plunger retracts and the butterfly valve closes, cutting off engine air supply and
stopping engine abruptly.
Valve lever is in flow direction, unlatched, no air can enter engine. Note O ring on
edge of butterfly valve.
Valve lever is across flow, latched, air can enter engine. Flame trap behind.
10
Flame trap
11
Actuator mounting
Unscrew these 4 small bolts to detach actuator and allow removal of inlet valve.
Shut the unit down for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.
2.
Open the doors on the powerpack and locate the air inlet valve assembly. See
4.6.8 Additional features of Heavy Duty power packs on page 46.
3.
Loosen the hose clamp on the air intake side (2), and detach the hose from the intake.
4.
Remove the bolts from the engine air intake flange, and separate the air inlet valve assembly
from the flange.
5.
Place a temporary cover over the engine air intake to prevent foreign objects and particles
from entering.
6.
7.
Loosen the grub screw in the override cable clamp, and withdraw the override cable from the
assembly, taking care not to lose the clamp.
8.
Remove the mounting bolts of the engine oil pressure actuator assembly.
Take care not to lose these small bolts and washers.
9.
Leave the actuator attached to the engine oil pressure line and lift the actuator off the air inlet
valve.
10. Remove the air inlet valve from the power pack.
11. Clean the air inlet valve.
a) Carefully clean the discharge side flange.
b) Latch the butterfly valve open using the lever.
c) Wipe the throat on both sides of the flame trap clean using a clean cloth.
d) Clean any contamination off the butterfly valve.
12. Inspect the flame trap.
Provided the air filter has been regularly serviced, then the flame trap should need no
servicing. However, if engine peformance is affected due to a partially blocked flame trap,
then it should be cleaned as follows.
NOTE: Do not attempt to remove the flame arrester from the air inlet valve!
a) Latch the butterfly valve open using the lever.
b) Wash the flame arrester by agitating it in a container of clean diesel or degreaser, but use
no tools or brush which may damage it.
WARNING
TXT-10004256/A
COMPRESSED AIR
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never
point a compressed air pistol at exposed skin.
c) After cleaning, blow the flame arrester dry from both sides using a compressed air pistol.
d) Wipe clean all inside surfaces and the butterfly valve.
13. Lubricate the butterfly valve: apply a small amount of a suitable light grease (e.g. Dow
Corning MS4 or equivalent) around the edges of the butterfly O ring and the mating surface
in the valve throat.
NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013
8.24 Clean air inlet safety valve for heavy duty power
1.
NOTE: Excess grease will be sucked into the intake, so use lubricant sparingly.
14. At the AIR INLET VALVE control, ensure the handle is pressed all the way in.
15. Re-install the air inlet valve as follows:
a) Use a small flat screwdriver to press the latch down and allow the lever to close the
butterfly valve.
b) Mount the actuator (with engine oil hose attached) to the air inlet valve.
c) Remove the temporary cover from the engine intake.
d) Fit the air inlet valve to the flange and if necessary install a new gasket.
8.24 Clean air inlet safety valve for heavy duty power
e) Make sure no gap is present between valve and flange, and firmly tighten the bolts
according to Appendix 6: Referenced Documents on page 246.
f) Ensure that the lever is in the closed position (the lever is pointing towards the incoming
air side).
g) Insert the pull cable through the lever, and fasten the clamp tightly on the free cable end
beside the lever.
h) Fit the hose to the intake side of the air inlet valve, and tighten the hose clamp.
16. Lightly oil the valve lever mechanism and cable.
17. Operate the AIR INLET VALVE control a few times, inspecting the mechanism at the valve itself
to check that the cable is pulling and releasing correctly.
Use a small flat screwdriver each time to release the latch so that the lever springs back to
the closed position.
18. Start the unit for normal operations.
19. Test that the engine starts, runs and shuts down correctly, including a simulated emergency
stop. See 7.3 Power up on page 97 and 7.1.3 Startup after an emergency stop on page 94.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
20. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.25
4
3
1
2
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
3.
4.
Unscrew the blind cap (3) and remove the filter mesh(4).
5.
6.
Refit the cleaned filter mesh, and tighten the blind cap.
7.
Open the fuel tank isolation valve (valve in-line with the tubing).
8.
Prime the diesel system by performing 8.37 Prime diesel engine on page 177.
9.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
10. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.26
3
4
1
2
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
Loosen the securing wing nut (1), and remove the cover (2).
3.
Loosen the securing wing nut (3), and remove the primary (outer) filter element (4).
4.
Loosen the securing nut (5), and remove the safety (inner) filter element (6).
5.
Clean or replace the filter element where necessary. Filter can be cleaned from the inside
out using low pressure compressed air. Replace filter if damaged or extremely dirty.
NOTE: Never attempt to clean the safety filter, it can only be replaced; normally once every 3
changes of the primary filter.
6.
Refit or replace the safety element, and tighten the securing nut.
7.
8.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
9.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.27
3
4
5
5
2
4
CAUTION
TXT-10004368/A
EQUIPMENT DAMAGE
Any contact with the core of the flame trap element can bend and damage the metal foil.
Only handle the flame trap element by the rigid edges.
1.
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
3.
Remove the flame trap assembly (4) from the flame trap housing (5) by pressing together the
two wire strands of the retaining clip (3). See Figure 8.29.
4.
You may need to use pliers to grip the securing bolt (2) and, while pressing the retaining clip
ends together, lift the flame trap assembly out for cleaning. See Figure 8.29.
NOTE: Do not loosen the securing bolt (2) unless absolutely necessary for cleaning. Removing
it may allow the flame trap element to unwind, rendering it unusable.
5.
6.
Place a temporary cover over the flame trap housing, so that no dirt or objects can get into
the breather inlet.
7.
Place the flame trap in a suitable container and clean with diesel, or replace it with a new one.
8.
9.
Place the cleaned (or new replacement) flame trap in the housing.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
10. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.28
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
CAUTION
TXT-10004390/A
EQUIPMENT DAMAGE
The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked).
Never block (cap) the fuel tank breather.
2.
Use a spanner to unscrew the breather mesh (1) from the tank (2).
Be careful not to damage the mesh with the spanner. If the mesh is damaged, when
removing, it must be replaced.
3.
WARNING
TXT-10004256/A
COMPRESSED AIR
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never
point a compressed air pistol at exposed skin.
4.
5.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
6.
8.29
Figure 8.31 Spark arrestor/muffler (engine air filter removed for clarity)
This procedure describes how to empty soot and debris that has collected in the cleaning point
of the spark arrester/muffler.
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004342/A
HOT OBJECT
Emptying soot or debris from the spark arrester while it is still hot can cause serious burns.
Before emptying the spark arrester, ensure that the engine has stopped and the spark arrester
has cooled down. Wear appropriate Personal Protective Equipment (PPE).
2.
3.
Position a piece of rag or small container underneath the cleaning point (1) of the spark
arrester (2), so that the contamination will not fall inside the power pack.
WARNING
TXT-10004314/A
HAZARDOUS SUBSTANCE
Particles such as carbon dust can damage your eyes and lungs.
Always wear appropriate Personal Protective Equipment (PPE), such as safety goggles, and
a protective breathing mask when working in particle contaminated environments.
4.
5.
6.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
7.
8.30
Clean unit
Carry out the following clean-up tasks every day after shutting down the FlyLine, or at the first
opportunity following operations. A good freshwater supply will be necessary.
NOTE: If using a high-pressure water jet to clean the exterior, to avoid unit damage never point
the jet at any joints, panel seams, door or hatch openings, grills, electrical boxes and
connections, insulation foam and panels, intake filter housings or anywhere you cannot
clearly see.
Never use any kind of hose or water jet inside the power pack, and use them only with
great care to clean the winch bay.
1.
Drain the winch drip tray into a waste fluids container and place it back to collect waste from
the next steps.
2.
Use a brush with water and a cleaning agent to clean the exterior of the unit.
NOTE: Before using a degreaser to clean greasy remnants, test it on a small part of the body to
see if it can harm the paint work.
Take special care with windows: on the outside, first rinse with clean water, then wipe clean
using a glass cleaner.
4.
Continue into the winch bay, removing all dirt, salt, oil, grease, hydraulic fluid etc. from the
surfaces in the winch bay and measuring head.
5.
Rinse off the bodywork and winch bay with fresh water.
6.
In the winch bay, dry off any exposed metal surfaces using a rag, and apply a thin layer of
grease to prevent corrosion.
7.
Empty winch drip tray and open the unit drain plugs to allow waste water to drain off into
collecting containers.
8.
Clean winch control panel with a soft cloth and a mild spray cleaner. Wipe down the windows,
control panel (plus gauges, switches and joysticks), electrical panel and cabinets. Use
commercially available screen wipes on any control panel display screens.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
9.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
3.
8.31
Drain/fill coolant
This procedure describes how to drain the cooling system from the drain point at the bottom of
the radiator, and then refill it from the same point using a hand pump.
NOTE: The volume of the engine/coolant will increase, when it is hot. Do not to overfill the
radiator. If the coolant is overfilled, excess will run out of an overflow valve during
operations.
2
Figure 8.32 Coolant filling point access hatch
1.
Make sure the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
WARNING
TXT-10004340/A
HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.
3.
Open the coolant filling point access hatch (1) at the top of the power pack, and remove the
radiator filler cap (2).
This will allow air to escape from the cooling system during draining and refilling of the
cooling system.
3
4
WARNING
TXT-10004336/A
4.
Remove the blind cap (3), and connect a flexible hose to the drain valve.
5.
6.
Open the drain valve (4). Figure 8.33 shows drain valve in closed position.
7.
Wait until the coolant has drained from the cooling system, and then close the drain valve.
8.
9.
10. If the unit will not be refilled immediately, place warning tags on the starter and/or control
panel to prevent accidental starting.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
HOT LIQUID
Draining hot coolant can result in serious burns. Before draining the coolant, ensure that the
engine/motor has been stopped and the coolant has cooled down.
coolant
1.
6
Figure 8.35 Air bleed-point for cooling system
2.
Locate the air bleed valve (5) on top of the exhaust gas cooler (6).
3.
Place a rag around the bleed point to catch any run-off coolant.
4.
5.
6.
Connect a hand pump from the coolant container to the drain valve.
7.
8.
Pump coolant into the system, until it comes out air-free from the bleed valve.
9.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
14. Start the power pack (see 7.3 Power up on page 97), and run the engine for five minutes to
circulate the coolant thoroughly.
16. Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
17. Repeat 8.14 Check/fill coolant on page 132.
8.31.3 Finalize
1.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
2.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
15. Open the air bleed valve (5) once more to bleed off any remaining air and close when pure
coolant comes out.
8.32
Shut the unit down for safe maintenance. See related topic.
2.
Locate the fuel purifier. See item 13 in the figure on page 40.
3.
4.
Open the drain valve in the underside of the vessel to allow the contaminated fuel or other
fluids to drain out. Tap at least 1 litre of fluid, more if clean fuel does not appear.
Open the bleed valve in the top of the vessel to help the draining process.
5.
6.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
7.
8.
9.
Prime the fuel pump before starting, so that the vessel fills with clean fuel.
8.33
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
3.
Insert a flexible hose attached to a hand-pump into the hole all the way into the tank, until it
comes to rest on the bottom.
4.
5.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
6.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.34
1
2
4
Figure 8.37 Diesel prefilter with fuel/ water separator
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
You can observe the water/ contamination through the sight glass (2).
3.
Place a small container underneath the bowl (3) of the of the fuel/ water separator (1).
4.
Drain the water by loosening the drain plug (4) at the bottom of the bowl.
5.
6.
7.
Perform 8.37.1 Quick prime on page 177 to refill the fuel/ water separator and purge the fuel
system of air.
8.
9.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
10. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.35
1
2
Water can accumulate in the hydraulic oil tank. As long as the unit is in regular use, the water in
the hydraulic oil is emulsified by the pumps and motors in the system. Only when the unit has
been idle for more than a few days will the water separate out. Being heavier than the hydraulic
oil, it settles to the bottom of the tank, and can be drained.
1.
Ensure that the unit is shut down, and has not run for the past few days.
2.
Ensure that the drain valve (1) is closed. Figure 8.38 shows drain valve in closed position.
3.
4.
5.
6.
Slowly open the drain valve, and allow the water to run into the container.
7.
8.
9.
Ensure the suction filter isolation valve (3) is open before starting. Figure 8.33 shows
isolation filter valve in open position.
10. Check the oil level and replenish if necessary by performing 8.17 Check/fill hydraulic
oil on page 139.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Figure 8.38 Hydraulic oil tank valves (rear power pack grill removed for clarity)
11. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.36
Grease unit
This procedure explains how to grease a number of keys points in the unit. All grease points in
the unit should be lubricated on a regular basis.
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
NOTE: DO NOT fill grease until it comes out of the bearing. That will over-lubricate the bearing
and damage the seals.
3.
Use a hand-held grease gun to apply a small amount (one cc) of grease to the drum bearing.
4.
2.
Grease the drum drive chain to protect it from rusting, but remove excess grease before
running the drums to avoid spatter.
3.
4.
5.
Use the grease gun to apply grease to all other lubrication points on the unit.
The bearings supporting the drums (pillow block bearings) in NOV Elmar units are modern,
double-shielded ball bearings. These may not be greased by injecting grease until it begins
coming out. They should only be filled to approx. 40% of the bearing cavity volume.
6.
See the separate measuring head User Manual in the Documentation Package for a
description of the measuring head lubrication.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
7.
8.37
5
8.37 Prime diesel engine
3
Figure 8.40 Fuel system components.
1.
2.
Ensure that the fuel isolation valve (2) above the fuel tank (3) is open and locate the engine
fuel primer (1). Figure 8.40 shows the fuel isolation valve in the open position.
3.
Turn the control lever on the fuel safety valve (4) clockwise against the spring pressure until
it catches.
This will reset the fuel safety system and allow fuel to flow.
4.
5.
Place rags or a small container under the fuel/water separator to catch the fuel.
6.
Pump the engine fuel primer several times to fill the fuel/water separator.
7.
8.
Carefully loosen the banjo connector screw (6) on the fuel fine (secondary) filter.
9.
Place rags or a small container under the fuel fine filter to catch the fuel.
10. Pump the engine fuel primer several times to fill the fuel fine filter.
11. Carefully tighten the banjo screw once air-free fuel comes out.
12. Pump the engine fuel primer until the resistance is too high to pump.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
Figure 8.41 Left: Fuel primer pump; Right: view of fuel injectors
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
Ensure that the fuel isolation valve (2) above the fuel tank (3) is open.
3.
Pump the fuel primer (1) until the resistance is too high to pump.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
4.
Remove the plastic cover (7) next to the engines valve cover. This will provide access to the
injectors, the high-pressure fuel injector lines (9) and injector line coupling nuts (8).
5.
Slightly loosen the fuel line coupling nuts on the injectors; do not remove completely, but just
enough (1-2 turns) to allow air to bleed from the fuel.
6.
1.
WARNING
TXT-10004323/A
HIGH PRESSURE
Components and fluids under high pressure may be ejected at great force causing bodily harm
and damage to equipment. When working with or near components under pressure:
Prevent access by unauthorized persons.
Wear appropriate personal protective equipment (PPE).
NOTE: Ensure the battery, accumulator or air supply are sufficiently charged between start
attempts.
7.
Attempt to start the engine according to Section 7.3 Power up, causing it to turn over a few
times. This will force air out of the injector lines.
8.
When all air has been forced out of the injector lines, and fuel is present, tighten the injector
line coupling nuts one at a time and repeat start attempts for each cylinder.
9.
After tightening the last coupling nut, the next start attempt may actually start the engine. In
this case allow it to run for a short time and monitor it for indication of rough running.
10. Repeat above steps 7-9 until engine runs smoothly. This will ensure that all injectors are
sufficiently bled.
For spring starter equipped engines the procedure is slightly different, but the principle is
the same.
11. Push the reset knob on the starter.
12. Wind the spring starter for not more than two turns; when there is a noticeable resistance
stop cranking. DO NOT crank the starter completely to the white or red stripes.
13. Trip the starter handle as you would to start the engine. Starter pinion should now be
engaged to the flywheel, allowing starter to slowly rotate the engine.
14. Use the cranking handle to now slowly turn the engine. If engine does not turn then repeat
steps 11-13.
15. Pump the engine fuel primer several times to force fuel through the high-pressure fuel lines;
only one fuel line will be engaged at a time.
16. While pumping the fuel primer note which fuel line at the injectors is bleeding fuel and tighten
the nut once air-free fuel flows out.
17. Repeat this for each injector in the correct firing order; refer to the CAT engine User Manual
for firing order sequence. Typical for four cylinder is 1-3-4-2.
18. After tightening the last coupling nut, push the reset knob on the starter and wind the starter
normally for starting the engine. Refer also to Section 7.3 Power up.
19. Start engine and allow it to run for a short time and monitor it for indication of rough running.
20. Repeat above steps 11-19 until engine runs smoothly. This will ensure that all injectors are
sufficiently bled.
8.37.3 Finalize
1.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
2.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.38
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
1.
WARNING
TXT-10004293/A
DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.
WARNING
TXT-10004359/A
SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.
2.
Remove the wireline from the measuring head assembly, and secure it to the drum, as
described in the Measuring Head User Manual in the Documentation Package that came
with the unit.
3.
4.
5.
Slowly rotate the drum until the master link (1) in the drive chain can be easily accessed.
6.
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
2
2
WARNING
TXT-10004348/A
MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Ensure that the engine cannot be started during maintenance.
1.
Remove the drum guards on the left side of the drums by loosening the bolts (2).
2.
Remove the retaining clip from the master link, and carefully remove the master link.
3.
Remove the chain and reconnect it on itself using the master link, and refit the retaining clip.
4.
Check the condition of the winch frame. Use a rag to clean excess grease or dirt from the
winch frame, and report any damage.
2.
If necessary clean the chain of dirt and rust and ensure it is flexible and in good condition.
3.
Position the correct chain around the drive sprocket and drum sprocket.
The shorter chain is for the rear drum, the longer for the front drum.
4.
Refit the master link and retaining clip (see Figure 8.42). Make sure the retaining clip is
correctly secured.
5.
Adjust the chain, as described in 8.10 Check/adjust chain tension on page 123.
8.38.3 Finalize
1.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
2.
3.
Slowly rotate the drum in both directions. If necessary, lubricate the chain to protect it and
keep it flexible and in good condition.
4.
Check for correct drum movement and operation of the brake. Rectify any problems.
5.
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
6.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.39
1
4
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004268/A
CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.
2.
If the unit is so equipped, lift the protective cover on the front of the winch module to access
the measuring head and levelwind chain. See 5 For all modules, connect ground cables
between the modules. on page 81
3.
Unlock the measuring head from the transport position, refer to 6.3.5 Prepare measuring
head assembly on page 87
4.
Locate fastening screw (1) and loosen completely so the adjusting turnbuckle (2) is free of
the measuring head carrier (3).
5.
To slacken the chain, use a suitable wrench to turn the turnbuckle in the direction of the arrow
shown.
6.
Remove securing clips from the master links (4) on each end of the chain.
7.
Carefully remove the chain from the sprockets and use it to mark the length of the
replacement chain; dispose of old chain in a suitable manner.
8.
Once new chain has been cut to correct length, install the chain onto the sprockets.
WARNING
9.
Line up the first end of the chain with the adjustment bolt on the turnbuckle; insert the master
link and secure with the clip.
8.39.1 Finalize
1.
If necessary, grease the drive chain to keep it flexible and prevent rusting.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
Turn the steering wheel to move the measuring head left and right a few times to verify the
chain security and free play.
3.
Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
2.
8.40
6
Left-hand threads
2
Right-hand threads
4
6
8.40 Remove/replace brake band
5
3
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
If necessary, lower or raise the levelwind arm, depending on the brake band you want to
remove/replace.
3.
4.
5.
Loosen the brake adjustment turnbuckle (2), until it comes free of the brake band (6).
6.
Remove the linchpins (4) from the brake band rocker shaft (5), and slide the shaft out.
WARNING
TXT-10004359/A
SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.
7.
8.
9. Check the brake band for wear by performing 8.13 Check brake band wear on page 130.
Fit the replacement brake band over the brake
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
15. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.41
Replace V-belts
6
3
5
This procedure describes how to replace the V-belts on the Caterpillar diesel engine. The V-belts
used to manufacture this unit have special, antistatic properties, and cannot be replaced by
standard V-belts. Refer to the spare parts manual or contact NOV Elmar for ordering info.
1.
Ensure that the unit is shut down for safe maintenance, as described in 7.5 Normal shut
down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
3.
Remove the securing bolts (1) attaching the fan shaft (2) to the fan pulley (3).
4.
Loosen the nuts (4) and (6), securing the tensioner pulley bracket (5).
5.
6.
7.
Fit first the new inner V-belt, then the outer V-belt.
Use only the exact replacement belts referred to at the start of this procedure. These are
special, antistatic types, certified for Zone 2, ATEX operation.
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
8.
9.
Adjust the V-belt tension as described in 8.12 Check/adjust V-belts on page 128.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
11. Remove all tools and materials from the work area.
8.42
Replace drum
This procedure describes how to replace one drum.
For this procedure a suitable lifting device (crane, hoist), rated at minimal 2 tons, is required.
8.42.1 Prepare
WARNING
TXT-10004359/A
SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.
1.
Remove the wireline from the measuring head assembly, and secure it to the drum, as
described in the measuring head User Manual in the Documentation Package that came with
the FlyLine unit.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
3.
Remove the drum guards to gain access to the drum brake band and drive chain.
NOTE: There is a drum guard on both sides of the drum.
4.
If the unit has two drums, make sure the appropriate drum brake is selected .
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
5.
WARNING
TXT-10004293/A
DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.
6.
2.
7.
Slowly push the DRUM CONTROL levers forward until the master link in the drive chain can be
easily accessed. See Figure 8.47.
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
9.
Remove the brake band. See 8.40 Remove/replace brake band on page 187.
WARNING
TXT-10004330/A
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
10. Place appropriate lifting straps on both sides of the drum, and attach the straps to the lifting
device. See Section Figure 8.48 Ideal location for lifting straps.
3
front of winch module
2.
Remove the four pillow block attachment bolts (2) on both sides of the drum.
3.
Turn the rear drum-alignment-bolts clockwise to move drum slightly forward in able to
slacken the drive chain for removal.
4.
Remove the retaining clip and master link from the chain (Figure 8.47), and remove the chain
from the drum.
5.
Reconnect the chain on itself using the master link and retaining clip, and store the chain in
a safe place.
WARNING
TXT-10004271/A
CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.
6.
7.
Store the drum in a suitable shipping container taking care not to damage the flanges or the
brake surface.
8.
If the drum is being stored for any period, apply grease to the drum journals and bearings as
described in 8.36.1 Grease drum bearings on page 175.
NOTE: Please note the information given in 8.36.1.
Check the condition of the drive sprocket on the gearbox. If necessary, replace the drive
sprocket.
2.
3.
Use a rag to clean any excess grease or dirt from the winch frame.
1.
WARNING
TXT-10004330/A
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
4.
Place the lifting straps at either end of the drum, and attach the straps to the hoist.
WARNING
TXT-10004271/A
CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.
5.
Use the lifting device to lift the drum out of the shipping container.
6.
Carefully lower the drum so that the pillow blocks rest on the winch frame.
7.
8.
Position the chain around the drive sprocket and drum sprocket.
9.
Refit the master link and retaining clip (see Figure 8.47). Make sure retaining clip is correctly
secured.
10. Adjust the chain, as described in 8.10 Check/adjust chain tension on page 123.
11. Make sure the distance (a) between the adjustment block (3) and the pillow block is the same
on both sides of the drum (see following figure).
This will ensure that the drum is correctly aligned in the winch module.
distance (a)
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
12. Make sure the drum attachment bolts on both sides of the drum are securely tightened to
426 Nm (314 lb-ft).
8.42.4 Finalize
1.
2.
Refit the brake band, as described in 8.40 Remove/replace brake band on page 187.
3.
Refit the drum guards and tighten the drum guard attachment bolts.
NOTE: There is a drum guard on both sides of the drum.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
5.
6.
Check for correct drum movement and alignment. Check operation of the brake. Rectify any
problems.
7.
Perform the drum mount test, as described in 8.52 Test drum mounting on page 217.
8.
Shut the unit down for safe maintenance. See related topic.
9.
Apply grease to the drum journals and bearings as described in 8.36.1 Grease drum
bearings on page 175.
NOTE: Please note the information given in 8.36.1.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
10. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
4.
8.43
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
2.
3.
Unscrew and remove the filter element from the mounting head (2).
4.
Lubricate the top seal of the new filter element with clean diesel fuel.
5.
Fit the empty filter element to the mounting head. Turn the filter assembly until it contacts
the top seal, and then hand-tighten an additional full turn.
NOTE: Do not fill the element with diesel (the fuel would not be filtered before going to the
engine). Do not over tighten!
6.
Purge the diesel system by performing section 8.37 Prime diesel engine on page 177.
7.
8.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
9.
10. Check the system for correct operation, and recheck the fine particle filter for any leaks.
11. Rectify any problems.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
13. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.44
Identify and fix the situation that caused the circuit to overload.
2.
Ensure that the unit has been shut down for safe maintenance, as described in 8.6 Prepare
for safe maintenance on page 112.
3.
4.
5.
6.
7.
Restart the component or circuit that failed. Verify that the component or circuit works
correctly.
8.
Replenish the stock of spare fuses, and also make sure that there is a new spare fuse stowed
in cartridge type fuse holders (see 8.44.2 and 8.44.3).
NOTE: Not every type of fuse and circuit breaker described below may be present in your
equipment.
8.44.1
Rating (amps)
Colour
Part no.
purple
A0015291
light brown
A0015284
7.5
dark brown
A0015285
10
red
A0015286
15
blue
A0015287
20
yellow
A0015288
30
green
A0017156
Blade type fuses are the same type as used in the automotive industry. The fuses are colour
coded to indicate the rating. To replace a blade type fuse:
1.
Pull the fuse from the fuse block and discard it.
2.
Part no.
0.50
1.00
A0000934
1.50
A0011260
2.00
A0015219
3.15
A0015306
5.00
A0015575
6.30
A0010259
10.00
A0014805
Swing the holder out and up to give access to the holder side cover.
2.
Carefully open the cover. This will eject the blown fuse from the contacts.
3.
Remove the blown fuse and replace it with a new fuse (see Table 8.5). If you have no other,
use the spare inside the holder, but insert a new spare at the first opportunity.
4.
Carefully close the cover. This will press the new fuse into the contacts.
5.
Rating (amps)
1
1
2
3
2.
3.
Remove the blown fuse (4) and replace it with a new fuse (see Table 8.5). If you have no
other, use the spare (3) inside the holder, but insert a new spare at the first opportunity.
4.
5.
Automatic circuit breakers are the easiest to check/reset. When OFF (1) shows, the circuit has
been overloaded or short-circuited. To reset the circuit breaker, switch it to ON (2).
NOTE: Always replace a damaged automatic circuit breaker with an identical unit, i.e. same
rating, phase characteristic, and voltage. Only a qualified electrical technician may
perform maintenance/repairs to automatic circuit breakers.
8.45
1
3
4
3
4
8
6
7
5
3
10
The hydraulic high-pressure filters need to be changed when a red pin becomes visible in the
contamination indicator (1)
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
3.
Place a waste oil container and plenty of rags below the filter bowls (3) to catch any oil that
spills, when the bowl is removed.
TXT-10004337/A
HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.
4.
Unscrew the bowl using a suitable wrench affixed to the hex (4) at the end of the bowl.
5.
6.
Carefully loosen the element (5) from the spigot (7) of the filter head (6), using a slight
twisting and rocking motion.
7.
8.
Drain all the oil from the filter into a waste oil container.
9.
CAUTION
TXT-10004384/A
EQUIPMENT DAMAGE
Incomplete selection of the hydraulic ball valve can damage the valve seals:
Push the valve lever in one quick movement to the end position, and lock it in that position.
Never leave the ball valve in an unselected position.
10. Using a clean cloth, carefully clean the filter head, screw thread, spigot and seal flange.
11. Using a clean cloth, carefully clean the filter bowl inside and out, in particular the O-ring
seating (9), support ring and screw thread (10).
12. Take a new filter element of the specified type (see spare parts list for this unit), and lubricate
the element nose seal, the new O-ring and the support ring with clean hydraulic fluid.
WARNING
13. Carefully reposition the filter element over the spigot on the filter head. Fit the filter element
fully before fitting the bowl over the element.
14. Firmly tighten the bowl.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
15. Dispose of all used filter elements and oil as prescribed by site regulations.
16. After all filters have been replaced and all other hydraulic maintenance has been carried out:
a) Open all hydraulic supply valves (levers aligned with flow direction).
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
WARNING
TXT-10004293/A
DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.
d) With the unit running, check each filter head for leakage.
If there are leaks, shut the unit down for safe maintenance, remove the filter bowl and
element as described above, clean the facing parts and the seal, and re-fit the filter.
e) Inspect the seals again for leakage after operating for several hours, taking remedial
action if necessary.
17. Shut down for safe maintenance, as described in 7.5 Normal shut down on page 104.
18. Check and, if necessary, top off the hydraulic oil tank. See 8.17 Check/fill hydraulic
oil on page 139.
8.46
1
2
WARNING
TXT-10004337/A
HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
1.
Make sure the unit has been shut down for safe maintenance. See 7.5 Normal shut
down on page 104.
2.
Ensure that the drain valve (1) is closed. Figure 8,48 shows drain valve in closed position.
3.
Figure 8.58 Hydraulic oil tank drain valve (rear grill on power pack removed for clarity)
4.
5.
Put the other end in container large enough to hold the hydraulic oil.
6.
Slowly open the drain valve, and allow the oil to run into the container.
7.
8.
9.
Replace all suction filters in the hydraulic system. See 8.47 Replace hydraulic suction
filter on page 207.
10. Fill the tank with oil of the correct grade. See 8.17 Check/fill hydraulic oil on page 139.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
11. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.47
1
4
2
5
6
Figure 8.59 Hydraulic suction filter (rear grill on power pack removed for clarity)
Check the contamination indicator (1) while the engine is running.
The suction filter should be replaced before the contamination indicator goes into the red zone. If
the indicator is in the yellow zone the filter is partially contaminated and should be changed at the
first convenient opportunity.
If already in the red zone, the filter is contaminated and is being bypassed. It should be changed
immediately!
NOTE: On dual-filter filter heads there is a single contamination indicator for both filters.
1.
2.
Close the suction filter isolation valve (2). Figure 8.59 shows the isolation valve in open
position.
3.
WARNING
TXT-10004338/A
HOT LIQUID
Hot oil can cause serious burns.
Take care when handling hot oil and associated components. Always wear appropriate
Personal Protective Equipment (PPE), such as gloves.
4.
5.
Drain all the oil from the filter into a waste oil container.
6.
Using a clean cloth, clean the filter head (4) and the seal flange surface(5).
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.
7.
Take a new filter (see spare parts list for correct type), and Apply a thin film of hydraulic oil
to the new seal (6) supplied with the filter.
8.
Place the seal on the filter, and fill it with clean hydraulic oil of the same viscosity as the oil
in the unit.
9.
NOTE: Do not use tools to tighten the filter! It should be firmly tightened only by hand.
10. Open the hydraulic oil isolation valve.
11. When all filters have been replaced and all other hydraulic maintenance has been carried
out:
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
15. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.47 Replace hydraulic suction filter
8.48
4
2
3
Figure 8.60 Slip ring mounted on the drum assembly
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
CAUTION
TXT-10004379/A
EQUIPMENT DAMAGE
Components can be damaged during disassembly and temporary storage.
Take care when removing components and store them in a safe place.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal shut
down on page 104.
2.
Remove the four attachment screws (2) from the slip ring case flange.
3.
4.
5.
If the slip ring is to be placed onto a replacement drum, then the adapter ring (4) must also
be removed and installed onto the new drum.
Align the cable connector in the slip ring base with the connector in the drum axle.
2.
3.
Insert and tighten the attachment screws attaching the slip ring to the drum mounting.
4.
8.49
4
5
Figure 8.61 Fuel tank isolation valve and fuel/ water separator
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
Loosen the securing screw(2) and unscrew it carefully while holding the filter element (3),
sight glass (4) and bowl (5) firmly to the mounting head (6) by hand.
2.
When securing screw is completely loose, carefully remove the filter components from the
head and pour the fuel into a suitable waste container.
3.
Remove the bowl and glass from the filter element and discard the filter.
4.
Lubricate the top seal of a new filter with clean diesel fuel or motor oil, and fit it to the filter.
2.
Lubricate the new seals for the glass and bowl with clean diesel fuel or motor oil and fit the
seals and filter components together. Carefully hold them in place to the filter head by hand.
3.
Insert the securing screw and screw it into the bowl by hand until the filter assembly remains
in place.
4.
Finish turning the screw with a wrench until filter assembly is firmly seated. Do not overtighten!
5.
6.
Fill the fuel/water separator by performing 8.37 Prime diesel engine on page 177.
7.
8.
If possible start up the unit and monitor fuel system for leaks or problems, and correct if
necessary.
9.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
10. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.50
WARNING
TXT-10004269/A
HIGH PRESSURE
Air under high pressure may be ejected at great force causing bodily harm and damage to
equipment. When releasing air under pressure:
Prevent access by unauthorized persons.
Wear appropriate personal protective equipment (PPE), especially protective glasses.
2
1
Compressed air
reservoir
2
2
1
4
3
6
5
Figure 8.63 Air filter in detail
The filter removes solid particles and moisture from the incoming compressed air. The level of
captured moisture is visible in the sight glass (4) between automatic draining actions.
If the automatic drain fails to work properly and moisture builds up in the bowl (1), it can be
manually drained by pushing upwards on the centre pin in the drain (5) outlet.
Page 214 of 258
Revision C
Original Instructions
1.
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.
WARNING
TXT-10004351/A1
MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.
2.
Bleed off all pressure from the compressed air system; slowly open the RIG AIR outlet valve
(7) on the winch module.
3.
Unscrew the bowl (1), complete with O-ring, from the head (2) by turning it a quarter-turn and
removing it downwards (bayonet fitting).
NOTE: The water drain assembly (5) located in the bowl also consists of an internal floater which
must be handled very carefully.
Remove the filter element, which is mounted below the head, by carefully unscrewing the
baffle (3) at the bottom of the filter assembly.
5.
Clean the filter components, replacing any that are damaged or excessively contaminated:
6.
WARNING
TXT-10004256/A
COMPRESSED AIR
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never
point a compressed air pistol at exposed skin.
7.
8.
9.
Clean the filter bowl and sight glass (4) inside and outside with soapy water, and wipe it dry
with a clean rag.
10. Clean the water drain (5) and ribbed plastic nut (6) the same way.
11. Using a clean rag, remove all dust and dirt from the head.
12. Fit the filter element over the central rod, and gently hand-tighten the baffle.
13. Mount the bowl to the filter unit using a clean or replacement O-ring, and tighten it a quarterturn.
Position the bowl such that the sight glass can easily be inspected at any time.
CAUTION
TXT-10004376/A
ENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste
items in a responsible way according to local laws and regulations.
14. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
4.
8.51
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
WARNING
TXT-10004285/A
DANGEROUS MACHINERY
Changing factory settings can affect the safety of the system, and result in personal and/or
equipment damage.
Take extreme care when adjusting factory settings. If in doubt, contact Elmar
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
1.
2.
Run the unit at maximum throttle settings for a few seconds only.
3.
Compare the maximum rpm reading to the value given in Appendix 2: Unit
Specifications on page 237.
4.
If the engine is not reaching or is exceeding the maximum RPM then contact the NOV Elmar
office nearest you for assistance.
8.52
WARNING
TXT-10004359/A
SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.
1.
If necessary, remove the wireline from the measuring head assembly and secure it to the
drum.
WARNING
TXT-10004282/A
WARNING
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
2.
3.
4.
5.
Slowly push the dual control handles forwards and then backwards allowing the drum to
rotate several times in the in-hole and out-hole directions.
6.
Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
7.
8.
Check the chain tension, and readjust if necessary. See 8.10 Check/adjust chain
tension on page 123.
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
Repeat steps 2 through 8 two more times, making sure to check the drum alignment and
mounting, and chain tension each time.
9.
8.53
Ensure that the brake for the active drum is properly adjusted by performing 8.9 Check/
adjust brake band tension on page 116.
WARNING
TXT-10004282/A
DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.
TXT-10004358/A
NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.
2.
Power up the unit as described in sections 7.2 Pre-start checklists on page 95 and
7.3 Power up on page 97.
3.
If the unit has two drums, make sure the proper drum brake is selected on the control panel.
4.
5.
If your system has a multiple speed gearbox, always choose the highest speed (gear).
6.
WARNING
TXT-10004321/A
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
d) Gradually rotate the SAFETY VALVE clockwise to increase the main pressure towards
400 bar (5800 PSI). If necessary, move the pump DRUM CONTROL lever further in the
OUTHOLE direction.
e) When the MAIN PRESSURE gauge reaches 400 bar (5800 PSI), return the DRUM CONTROL
levers to neutral.
7.
WARNING
NOTE:
a) Move the motor (left) DRUM CONTROL lever completely to the maximum front or back
direction - this will lower the torque and maximize hydraulic flow.
b) Move the pump (right) DRUM CONTROL lever slowly to the INHOLE direction.
c) When the MAIN PRESSURE gauge reaches 400 bar (5800 PSI), hold this pressure for 2 to
3 seconds.
8.
9.
Inspect all hydraulic system hoses, couplings and high pressure filters for leakage that may
have been exposed by the high system pressures, and repair as necessary. See
8.21 Check/replace hydraulic hoses and couplings on page 147.
10. If applicable, repeat the test after carrying out any repairs.
8.54
WARNING
TXT-10004280/A
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.
WARNING
TXT-10004300/A
EXPLOSION HAZARD
An incorrectly sealed ATEX explosion proof cabinet can cause a dangerous, uncontrolled
explosion.
Ensure that all ATEX explosion proof cabinets are correctly sealed and that all bolts are
tightened to the correct torque value.
TROUBLESHOOTING
9.1
Troubleshooting principles
TXT-10004239/A
This section offers information for troubleshooting various problems encountered while operating
the equipment.
If you encounter a problem that is not covered here or cannot be corrected by the suggested
remedy, please contact NOV Elmar for technical guidance. Support contact information is
provided in the appendices to this manual. We are always grateful for customer feedback.
The troubleshooting guide is divided into sections according to the components or group that
need troubleshooting. Within each section, problem symptoms and their possible causes are
described, plus a suggested remedy that should enable you to get that component operational
again. More detail on the remedies is found in the maintenance section of this manual.
9.2
Troubleshooting table
NOTE: This general troubleshooting table will occasionally mention features that are not
available for the FlyLine.For measuring head troubleshooting information see separate
measuring head user manuals.
9 Troubleshooting
TXT-10004740/A1
POSSIBLE CAUSE
SUGGESTED REMEDY
Engine stops
POSSIBLE CAUSE
SUGGESTED REMEDY
Replace gauge
Replace thermostat
Thermostat malfunction
9 Troubleshooting
POSSIBLE CAUSE
SUGGESTED REMEDY
Engine does not shut down at the preadjusted over speed setting
9 Troubleshooting
TXT-10004741/A
POSSIBLE CAUSE
SUGGESTED REMEDY
Starter is defective
Engine is damaged
Starter is defective
TXT-10004742/A
9 Troubleshooting
TXT-10004743/A
POSSIBLE CAUSE
SUGGESTED REMEDY
Starter is defective
9 Troubleshooting
Engine is damaged
Repair leaks
Replace accumulator
TXT-10004745/A
POSSIBLE CAUSE
SUGGESTED REMEDY
Contaminated oil
9 Troubleshooting
HYDRAULIC PROBLEM
HYDRAULIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Repair leak
Replace oil cooler
Replace temperature sensor
9 Troubleshooting
HYDRAULIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
PNEUMATIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
TXT-10004747/A
Compressor is defective
Replace gauge
Horn inoperative
Horn is damaged
Replace horn
9 Troubleshooting
PNEUMATIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
POSSIBLE CAUSE
SUGGESTED REMEDY
Oil leaks
Worn seals
Replace seals
9 Troubleshooting
TXT-10004749/A
POSSIBLE CAUSE
SUGGESTED REMEDY
Brake applied
Hydraulic problem
SPOOLING/SLEWING PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Defective bearings
Replace rollers
Bearings fouled
TXT-10004750/A
9 Troubleshooting
SPOOLING/SLEWING PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Replace sensor
Replace bearing
Replace/repair as necessary
9 Troubleshooting
SPOOLING/SLEWING PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Head is blocked
Unblock head
9 Troubleshooting
APPENDICES
This section contains the following appendices:
Appendix 1: Quick reference on page 235
Appendix 2: Unit Specifications on page 237
Appendix 3: Unit Lubricants on page 241
Appendix 4: Unit hydraulic oils on page 243
Appendix 5: Unit configuration on page 244
Appendix 6: Referenced Documents on page 246
Appendix 7: Tightening conventions on page 248
Appendix 8: Running hours log book on page 249
Appendix 9: Air transportation on page 253
Appendices
TXT-10004286/A
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual. Only
qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.
NOTE: This is only for reference. Please see 7 Operation on page 94 for details.
Startup
Ensure that the air accumulator (receiver) isolation valve is open.
2.
Ensure that the hydraulic oil tank isolation valves are open.
3.
Prepare the engine starter (hydraulic, air, electric, or spring) for start-up.
4.
Reset the fuel safety (Sentinel) valve by turning the control lever against the spring pressure
(repeat this for every start attempt).
5.
Set the drum control levers on the control console to the middle position.
6.
7.
Set the valve below the wire spray tank to drip at the proper rate for the job.
8.
Push the AIR INLET VALVE lever fully up, and hold it in place.
9.
10. When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR
INLET VALVE lever.
11. Check that the hydraulic CONTROL PRESSURE stabilizes between 20 and 28 bar (if <15 bar,
troubleshoot the system).
Shutdown
1.
Check the START PRESSURE gauge on the power pack control panel.
2.
Hydraulic starter: If the hydraulic start pressure is less than 120 bar (1740 psi), charge the
starter accumulator by apply the brake and operating the drum control levers, as described
in 7.6.1 Charge starter accumulator using engine on page 105.
NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar
(2466 psi).
3.
Ensure that the isolation valve for the starter accumulator is closed.
4.
Set the drum control levers on the control console to the middle position.
5.
Set the engine THROTTLE control to idle. Make sure the drum is stopped.
6.
1.
7.
8.
Close the valve below the wire spray tank to stop the oil flow to the wireline.
Emergency stop
Quickly stop the machine in an emergency using one of the following methods:
Press one of the two red emergency stop buttons on the machine.
Pull down the AIR INTAKE valve on the control panel.
Emergency stop recovery
Ensure that the cause of the emergency shutdown has been identified and solved.
2.
Release an activated emergency stop button by pulling it firmly out until it releases.
3.
1.
Tare weight
Payload
Tare weight
Payload
Transport dimensions
L x W x H (overall with doors closed)
Tare weight
Payload
Operating conditions
ATEX area classification
Power system
Type
Caterpillar C4.4
Power output
Choose from:
54 kW (72 bhp) @ 2200 rpm
81 kW (109 bhp) @ 2200 rpm (heavy duty power pack)
Power system
Starter
Choose from
Spring starter
Hydraulic starter
Air starter
Electrical system
Alternator
Rig/shore
Choose from:
230 VAC (+/- 10%); 50 Hz (+/- 2%); 16A, 10kA
115 VAC (+/- 10%); 60 Hz (+/- 2%); 16A, 10kA
Pneumatic system
Source
5 kW
Pressure
Buffer
Flow volume
Hydraulic system
Type
Source
Main pressure
Construction
Controls
Main control panel for monitoring and control of hydraulic circuits, depth and
tension measurement, wireline winch.
Winch
Drum motor (2 x)
80 cc variable displacement
Transmission (2 x)
Mounting type
Choose from:
BC06, OD x ID x W = 700 x 260 x 700 mm (27.6 x 10.2 x 27.6 in)
SC05, OD x ID x W = 450 x 260 x 700 mm (17.7 x 10.2 x 27.6)
SC06, OD x ID x W = 600 x 350 x 700 mm (23.6 x13.8 x 27.6 in)
SC08, OD x ID x W = 700 x 500 x 700 mm (27.6 x 19.7 x 27.6 in)
Choose from:
SC05, OD x ID x W = 450 x 260 x 700 mm (17.7 x 10.2 x 27.6)
SC06, OD x ID x W = 600 x 350 x 700 mm (23.6 x13.8 x 27.6 in)
Drum brake (2 x)
Level winding
Choose from:
NOV Elmar MP16II
NOV Elmar MP20
Display
Choose from:
Combigauge 0 to 2.000 kg/ft
Combigauge 0 to 2.000 kg/m
Combigauge 0 to 2.000 lb/ft
Combigauge 0 to 2.000 lb/m
Combigauge 0 to 3.200 lb/ft
Combigauge 0 to 4.400 lb/ft
Combigauge 0 to 4.400 lb/m
optional: NOV Elmar SmartMonitor 12
Fluids
Engine fuel (power pack)
Fluids
Coolant (power pack)
Filter elements
Part number
A0018469
A1060581
A0000082
A1060585
A1060577
A0000161
Hoisting
Lifting sling set power pack
Choosing the right engine lubricant is critical to the proper functioning of the engine, to avoid
damage and/ or costly repairs.
Refer to the maintenance section for the change intervals required.
NOTE: Select a good quality lubricant that is suitable for the ambient temperature where the
machine is used. Data sheets and MSDS for all of the fluids used in the original assembly
are found in the units documentation package.
Ambient temperature
-30 C
(-20 F)
-20 C
(-2 F)
-10 C
(+14 F)
0 C
+10 C
+20 C
+30 C
+40 C
(+32 F) (+50 F) (+68 F) (+86 F) (+104 F)
SAE 5W20
SAE 5W30
SAE 10W40
SAE 10W30
SAE 15W50
SAE 15W40
SAE 20W50
SAE 20W40
SAE 10
SAE 20
SAE 30
SAE 40
Gearboxes include final drive reduction gearboxes and fuel pump gear drives.
Choosing the right gearbox lubricant is critical to the proper functioning of the gearboxes, to avoid
damage and/ or costly repairs.
Refer to the maintenance section for the change intervals required.
NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at
the time of delivery. Data sheets and MSDS for all of the fluids used in the original
assembly are found in the units documentation package.
Ambient temperature
-20 C to +5 C
(-2 F to +41 F)
IV 95
+5 C to +40 C
(+41 F to +104 F)
IV 95
+40 C to +55 C
(+104 F to +131 F)
IV 95
-30 C to +65 C
(-20 F to +149 F)
IV 165
ISO 3448
VG 100
VG 150
VG 320
VG 150-220
AGIP
Blasia 100
Blasia 150
Blasia 320
Blasia S 220
ARAL
Degol BG 100
Degol BG 150
Degol BG 320
Degol GS 220
BP MACH
GR XP 100
GR XP 150
GR XP 320
SGR XP 220
Enersyn HTX 220
CASTROL
Alpha SP 100
Alpha SP 150
Alpha 320
Alpha SN 150
Alpha SN 6
CHEVRON
ELF
Reductelf SP100
Reductelf SP150
Reductelf SP320
ESSO
Spartan EP 100
Spartan EP 150
Spartan EP 320
Comp. oil LG 50
FINA
Giran 100
Giran 150
Giran 320
Giran 220
EP lub. HD 150
EP lub. HD 320
GULF
I.P.
Mellana 100
Mellana 150
Mellana 320
KLUEBER
Gem 1-100
Gem 1-150
Gem 1-320
Synteso D 220
Mobilgear 632
Glygoyle 22
Glygoyle 30
SHC 630
MOBIL
Q8
Goya 100
Goya 150
Goya 320
Greco 228
SHELL
Tivela Oil SA
TOTAL
Carter EP 100 N
Carter EP 150 N
Carter EP 320 N
Normal temperatures
-5.0 C to +60 C (+25 F to +142 F)
ISO 26 oils
yes
no
no
ISO 46 oils
no
yes
no
ISO 68 oils
no
no
yes
BP
Energol H:LP 46
Castrol
Hyspin AWS 46
Chevron
Mechanism LPS 46
ELF
Visga 46
Esso / Exxon
Univis HVI26
Univis N46
Mobil
ATF 220
Q8
Haydn 46
Shell
Tellus T 46
Texaco
Rando HD 46
Figure 9.3 NOV Elmar recommended hydraulic oils for main power and control circuits
NOTE: Select an oil that is suitable for the ambient temperature in which the machine is to be
operated. Operating temperature of hydraulic oil will increase during operation.
Machines fitted with a winterization package may have an oil heater to pre-heat the oil
before operations.
Low temperatures
below -15 C (+5 F)
bar
bar
Basic configuration
Part number
L-6931048158V01
L-6931034250V01
L-6931041412V01
L-6931041412V02
Starter type
Part number
L-6501036746V01
L-6501036746V02
L-6501036746V03
Part number
MeasureHead MP16II
L-6501036755
MeasureHead MP20
L-6501036756
L-6501034275
L-6501034295
L-6501034294
non-standard option
L-6501038038
L-6501034293
non-standard option
L-6531052164
L-6501039118
Front drum
Part number
L-6501036751; L-6501036749
L-6501036752; L-6501036749
L-6501036753; L-6501036749
L-6501036754; L-6501036750
Rear drum
Part number
L-6501036751; L-6501036749
L-6501036752; L-6501036749
L-6501036747
L-6501036748
Miscellaneous options
Part number
L-6501036757
Hoisting beam
L-6501038110
Jacking wheel
L-6501034251
L-6501037565
L-6501039738
L-6501037598
A1106526
L-8601051652
L-8601038720
L-6501035690V01
L-6501035691
Fuel purifier
non-standard option
Part number
L-6501034306
L-6501034303
L-6501034299
L-6501034300
L-6501034296
L-6501034307
L-6501034302
L-6501034298
L-6501034301
L-6501034297
non-standard option
L-6931034250V01
DOCUMENT/DRAWING TITLE
DOCUMENT/DRAWING
FILE TYPE
DD6931034250V01
Electric Diagram
ES6931034250V01
Hydraulic Diagram
HS6931034250V01
SPL1034250V01
ITEM
L-6931048158V01
DOCUMENT/DRAWING TITLE
DOCUMENT/DRAWING
FILE TYPE
10
DD6931048158V01
11
Electric Diagram
ES6931048158V01
12
Hydraulic Diagram
HS6931048158V01
13
SPL1048158V01
14
15
16
17
18
ITEM
L-6931041412V01
DOCUMENT/DRAWING TITLE
DOCUMENT/DRAWING
FILE TYPE
19
D6931041412V01
20
Electric Diagram
ES6931041412V01
21
Hydraulic Diagram
S6931041412V01
22
SPL1041412V01
23
MAN-10003445
24
MAN-A1085130
25
MAN-1039176
L-6931041412V02
DOCUMENT/DRAWING TITLE
DOCUMENT/DRAWING
FILE TYPE
26
DD6931041412V02
27
Electric Diagram
ES6931041412V02
28
Hydraulic Diagram
HS6931041412V02
29
SPL1041412V02
30
MAN-10003445
31
MAN-A1085130
32
MAN-1039176
ITEM
ITEM
This section provides recommended torque to be applied to bolted connections in this unit. The
fasteners used in this unit are normally either stainless steel (quality A2/70) or plain high tensile
steel (quality 8.8 or better). These values are for dry (non lubricated) connections. Use lower
torque values for lubricated connections.
NOTE: Always apply anti-seize compound on all types of bolts. This prevents bolts from seizing
caused by corrosion around the bolts. The corrosion may cause the force necessary to
loosen these bolts to exceed their breaking strength, leading to broken bolts.
NOTE: When tightening a cover panel with a soft joint seal or gasket, e.g. for a tank inspection
opening, use lower torques than specified in the table below.
Metal
grade
M8
M10
M12
M14
M16
M20
M24
Comment
A2/70 (SS)
15
30
50
80
120
250
340
8.8 (plain)
20
40
70
110
175
350
600
10.9 (plain)
30
60
100
160
250
490
850
12.9 (plain)
35
70
120
195
300
580
1000
Examples:
M1025 DIN933A2-70, apply a torque of 30 Nm
M1265 DIN925-10.9, apply a torque of 100 Nm
Like all machinery, the FlyLine needs to be serviced at regular intervals. The work to be
performed at each interval is described in more detail in the Maintenance section of this manual.
The specific service intervals are:
Daily (once every 24 hours when the FlyLine is in use)
After job maintenance (after completion of each wireline job)
300-hour service (after 300 hours of wireline winch operation)
600-hour service
900-hour service
1200-hour service
1500-hour or annual service
It is also important to record the number of hours and the date at which each of the services (100,
300, etc.) is actually carried out. To make this easier, Elmar provides with this manual (see
page 252) a blank form for recording the running hours, and the interval-based services planned
and actually carried out.
NOTE: Every organization has its own rules and systems for logging running hours and service
activity. The form and procedures described here are no more than a suggestion for a
simple running hours and service logging system.
Because the service intervals are primarily aimed at the mechanical components, we recommend
logging all hours that mechanical components are in use. In other words, from the moment the
FlyLine enters stand-by prior to operations, to the moment the FlyLine is shut down.
NOTE: If the running hours for major subsystems of the FlyLine are different (e.g. the power
pack or engine are run for longer hours than the winch module), then log the usage hours
for each subsystem on separate forms, so that the service is carried out no earlier than
needed on the less-used subsystem.
Keep all log forms in a special folder, and make sure that the maintenance engineer knows where
to find this folder. Make sure that the lower section is properly filled-in whenever the UniTruck gets
an interval service (100, 300, etc hours).
The figure on page 250 shows a filled-in Elmar usage & service log form, for a wireline unit that
has already been running for 1823 hours before this sheet was opened. The hours have been
carried forward from the previous form.
Even if there is automatic logging of the number of hours the FlyLine is in operation, it is still
important to manually record all hours that the wireline winch is "running".
Carry the hours forward from the last row of the previous form (or enter zero for a new unit).
2.
3.
4.
Calculate or carry forward the running hours at which the next service is scheduled (for 100,
300, 900, 1200, and 1500 hours).
File the previous form in a running hours and service log folder.
At the start of the session, once the mechanical system is started, enter the start date and
time.
2.
At the end of the session, when the mechanical system is stopped (or if there is an
unscheduled halt due to job problems or corrective maintenance activity):
a) Enter the stop date and time.
b) Calculate and enter the session hours between the start and stop time.
c) Calculate and enter the cumulative hours by adding the session hours to the previous
cumulative hours.
d) Enter any remarks about the session that may be relevant to future problem diagnosis or
service activity (e.g. chain tension tightened, hydraulic oil topped up).
2.
Enter the actual date at which the service was carried out.
3.
Enter any remarks about the service activity that may be relevant to future problem diagnosis
or service activity (e.g. brake band inspected and OK, must be replaced at next service).
1.
Unit ID:_____________________________________
Running Hours
Start
Date
Stop
Time
Date
Hours
Time
Session
Remarks
Cumul.
Service Log
Next
service
(hours)
Due at
(hours)
Done at
(hours)
On
(date)
Remarks
300
600
900
1200
1500/
ann.
If the machine is to be transported by air, the carrier may require that all fluids are drained from
the reservoirs, systems and components of the machine(s).
Please refer to the maintenance instructions accompanying your product for specific instructions
on how to drain the fluid from each reservoir, system or component.
On the reverse side of this page, NOV Elmar provides a checklist as an aid to ensuring that no
part is overlooked when draining and refilling the machine.
Draining:
1.
2.
3.
Add any items that are present on the machine, but not on this list.
4.
Place this checklist in a prominent place on the machine (e.g. in the cabin, in a weatherproof
envelope attached to the main operator station, etc.)
Refilling:
Refer to the maintenance instructions or specifications pages of the manual for this machine,
for the quantity and specifications of the required fluids.
6.
Refer to the maintenance instructions for the procedure to check and replenish fluids for
each of the reservoirs, systems and components.
7.
Replenish the fluid in each of the items on the reverse side of this page, remembering to
bleed the system of air and again replenish if necessary.
8.
NOV Elmar recommends that new oil filters are used when replenishing systems that include
filters. If you have fitted new filters, please add your initials in the last column.
5.
Date drained:
Date replenished:
Ite
m
Description
Bleed
01
02
03
04
05
06
Winch gearboxes
07
Levelwind motor
09
10
Batteries
11
12
13
14
15
New
filter(s)
recomm.
INITIALS
Drained
Replen.
New filter
Y
Y
16
17
18
19
20
21
22
23
24
25
Address
NOV Elmar
www.nov.com
NOV Elmar - UK
Energieweg 26,
2964 LE Groot-Ammers,
The Netherlands
11995 FM 529,
Houston, TX77041,
United States of America
7 Loyang Way
Singapore 508721
Singapore
26 Chapaeva
Nizhegorodka
Bashkortostan Republic Ufa Region
Russian Federation 450520
6771 - 84 Street SE
Calgary, Alberta, T2C 4T6
Canada
Telephone
Elmar-Dubai@nov.com
Perth, Australia
Elmar-Perth@nov.com
Stavanger, Norway
Tel.: +47 51 81 81 81
Elmar-UK@nov.com
Representative Offices
Telephone
Louisiana, USA
Beijing, China
Moscow, Russia
Manufacturing Locations
Customer Notes
CUSTOMER NOTES
Customer Notes
Published by:
NOV Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2013 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV Elmar for loss,
damage or injury caused by any errors or omissions in this document.