MAN - AirPack

AirPack C
DRAFT - FOR
User Manual
INFORMATION ONLY
ORIGINAL INSTRUCTIONS
NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

Tel: +31 184 608 700, Fax: +31 184 608 790, www.nov.com
K-Winch AirPack C, MAN-1055734, 26 July 2013
Page 1 of 150
Revision A
AirPack C User Manual
This manual applies to the following parts:

L-6931055734 - AirPack C Base Assy Zone 2
All standard options available for this base assembly
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.
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.
Version
Date
26 July 2013
Amendments
This is the first version of this manual
REVISION HISTORY
Page 2 of 150
Revision A
Original Instructions

TABLE OF CONTENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3
PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Unit rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Unit right view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Unit right view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Unit right view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Unit front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7 Unit left view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8 Unit left view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9 Unit left view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Compressor (Pneumatic) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 Unit grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5
SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.5 Charge hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.4 Periodic maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 Check/adjust V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.6 Check/fill compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.7 Check/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.8 Check/fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.9 Check/fill engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.10 Check/fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.11 Check/fill fuel pump gear drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.12 Check/replace hoses and couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.13 Check shock absorbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.14 Clean engine air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Page 3 of 150
Revision A
7.15 Clean auxiliary pneumatic system filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.16 Clean fuel coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.17 Clean air dryer filter (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.18 Clean main compressor air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.19 Clean spark arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.20 Clean/replace compressor intake air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.21 Clean/replace crankcase breather flame trap . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.22 Clean/replace engine air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.23 Clean/replace fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.24 Drain/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.25 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.26 Drain fuel/water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.27 Drain water from hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.28 Prime diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.29 Replace air-oil separator filter (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.30 Change compressor oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.31 Change engine oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.32 Replace fuel fine filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.33 Replace fuel/water separator filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.34 Replace hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.35 Replace V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.36 Test maximum engine speed (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.2 Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Appendix 1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Appendix 2: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Appendix 3: Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Appendix 4: Unit hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Appendix 5: ASEP Elmar tightening conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Appendix 6: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Appendix 7: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Appendix 8: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
CUSTOMER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Page 4 of 150
Revision A

INTRODUCTION
TXT-10004540/A
This user manual for the AirPack C 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)
This manual (supplied in digital and printed formats) is part of the AirPack C 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.

Page 5 of 150
Revision A
SAFETY
TXT-10004141/A1
2.1
General Safety
High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be
present in ASEP 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
ASEP 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
2.1 General Safety
Never leave "operation-ready" equipment unattended.

Keep equipment clean (accumulated dirt and dust can hamper unit operations and may
increase the risk of ignition).
Correctly maintain and use equipment, apparatus, tools, and dangerous substances.
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.
Page 6 of 150
Revision A

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.
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
Warnings, cautions and requirements

Equipment handling may involve residual risks which cannot be reasonably reduced by design
alterations. To alert the user to potential hazards and recommend safe working practices,
additional information is provided as warnings, cautions and/or requirements:
CAUTION shows a relevant icon and the text CAUTION with a description of the hazard
and the best practise to avoid it. Ignoring a caution can result in damage to equipment.
REQUIREMENT shows an icon and a description of the required PPE to minimise
possible safety risks.
Warnings, cautions and/or requirements are listed in the manual as a preceding step to a
potentially dangerous action. Never proceed to following step(s) if you do not comply with or fully
understand a Warning/Caution/Requirement. See the following examples:
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.
Page 7 of 150
Revision A
2.1 General Safety
WARNING shows a relevant icon and the text WARNING with a description of the hazard
and the best practise to avoid it. Ignoring a warning can result in equipment damage, plus
serious injury and/or death.
2.2
Equipment specific safety
2.2.1
Emergency Stop buttons

TXT-10004568/A
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 Equipment specific safety
Figure 2.1 Examples of Emergency Stop buttons

Press the button in an emergency situation to instantly cut primary energy supply (electric,
hydraulic or pneumatic) to moving parts. This will disable further equipment movement and
reduce danger to the operator. Always notify a supervisor after pressing an EMERGENCY STOP.
2.2.2
Heavy equipment
TXT-10004562/A
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
ATEX and zoning

TXT-10004560/A
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, however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC).
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
Page 8 of 150
Revision A

Annex VIII of the Directive. The construction is documented in a confidential Technical

Construction File held at the offices of ASEP Elmar.
2.2.4
Doors and hatches

TXT-10004565/A
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 Equipment specific safety

Page 9 of 150
Revision A
PHYSICAL DESCRIPTION
3.1
Unit overview
The following figure shows the naming conventions of the physical views used in the remainder
of this section.
2
3
3.1 Unit overview
6
7
8
3.2 Unit rear view on page 11
3.3 Unit right view (spring starter) on page 12
3.4 Unit right view (hydraulic starter) on page 13
3.5 Unit right view (air starter) on page 14
3.6 Unit front view on page 15
3.7 Unit left view (spring starter) on page 16
3.8 Unit left view (hydraulic starter) on page 17
3.9 Unit left view (air starter) on page 18
Figure 3.1 Unit overview
Page 10 of 150
Revision A

3.2
Unit rear view
2
3
7
3.2 Unit rear view
6
5
Exhaust silencer/ spark arrestor
Exhaust gas soot collector point
Compressor air intake filter
Compressor
Engine shock absorber
Air receiver auxiliary air circuit
Air-oil separator element
Hydraulic start manifold (optional)
Figure 3.2 Unit rear view

Page 11 of 150
Revision A
3.3
Unit right view (spring starter)
3.3 Unit right view (spring starter)
2
3
5
4
6
Engine air inlet valve
Exhaust gas cooler
Engine oil dipstick
Compressor oil filter
Compressed air filter
Auto drain valve
Figure 3.3 Unit right view
Page 12 of 150
Revision A

3.4
Unit right view (hydraulic starter)
12
9
10
3
17
11
15
16 13
14
12
hydraulic charge hand pump
Exhaust gas cooler
13
hydraulic tank drain valve
Engine oil dipstick
14
hydraulic tank suction isolation valve w/ coarse particle

filter
Compressor oil filter (obstructed by inlet hose)
15
Air driven charge pump for hydraulic start circuit.

(mounted inside air inlet channel)
16
Activation valve for air driven charge pump
17
Rig air in connector
Auto drain valve (obstructed by inlet hose)
Hydraulic tank filler cap
hydraulic hand pump handle
Hydraulic tank sight glass (max level)
10
Hydraulic tank
11
Hydraulic tank sight glass (min level)

Page 13 of 150
Revision A
3.4 Unit right view (hydraulic starter)
3.5
Unit right view (air starter)
3.5 Unit right view (air starter)
3
4
7
8
6
Exhaust gas cooler
Engine oil dipstick
Compressor oil filter (obstructed by inlet hose)
auto drain valve (obstructed by inlet hose)
Rig air in connector
Air filter for starter circuit
Page 14 of 150
Revision A

3.6
Unit front view
3.6 Unit front view
Cooler stack - consisting of: engine coolant radiator;

compressed air cooler; compressor oil cooler
Air driven charge pump for hydraulic start circuit.
Figure 3.6 Unit front view (sound-proofed grills removed)

Page 15 of 150
Revision A
3.7
Unit left view (spring starter)
2
3.7 Unit left view (spring starter)
1
4
3
6
11
10
12
21
20
14
13
15
19
16
17
18
Engine air intake filter
12
Air output
Unit control panel
13
Fuel tank access cover
Fuel fine filter
14
Engine oil filter
Air inlet valve control handle
15
Fuel tank breather
Engine compressor (auxiliary pneumatics)
16
Fuel tank isolation valve/
Fuel pump gear drive
17
Fuel filler cap
Fuel pump
18
Fuel level gauge
Fuel prefilter/water separator
19
Auxiliary pneumatic system filter (behind panel)
Sentinel master valve (ENGINE SAFETY)
20
Spring starter
10
Compressor (main air system)
21
Spring starter hand crank
11
Air output
Figure 3.7 Unit left view (spring starter)

Page 16 of 150
Revision A

3.8
Unit left view (hydraulic starter)
2
1
66
8
9
5
21
10
11
12
20
19
14
22
13
15
17 18
16
12
Air output
Unit control panel
13
Fuel fine filter
14
Engine oil filter
Air inlet valve control
15
Fuel tank breather
16
Fuel tank isolation valve
17
Fuel filler cap
Fuel pump
18
Fuel level gauge
19
20
Hydraulic starter
10
21
Hydraulic accumulator
11
Air output
22
Hydraulic accumulator isolation valve
Figure 3.8 Unit left view (hydraulic starter)

Page 17 of 150
Revision A
3.8 Unit left view (hydraulic starter)
3.9
Unit left view (air starter)
3.9 Unit left view (air starter)
3
6
9
11
10
12
20
14
13
19
15
16
17
18
12
Air output
Unit control panel
13
Fuel fine filter
14
Engine oil filter
Air inlet valve control
15
Fuel tank breather
16
Fuel tank isolation valve
17
Fuel filler cap
Fuel pump
18
Fuel level gauge
19
20
Air starter
10
11
Air output
Figure 3.9 Unit left view (air starter)

Page 18 of 150
Revision A

FUNCTIONAL DESCRIPTION
4.1
Introduction
The AirPack C produces compressed air for sites requiring large amounts of pneumatic energy.
The main energy source is a 54 kW Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated.
It drives a Rotorcomp EVO9-NK-G compressor that can provide up to 5 m/min (177 cfm) of air
or a nominal pressure of 10 bar (145 psi). The engine is equipped with either spring, pneumatic
or hydraulic starter. The engine and exhaust gas are water-cooled and the coolant, along with the
compressors oil and supply air, are air-cooled over forced-air heat exchangers (radiators).
The unit is CE certified for Zone 2 ATEX operation.
See Appendix 1: Specifications on page 131 for specifications.
4.1 Introduction

Page 19 of 150
Revision A
4.2 Operator controls
4.2
Operator controls
12
13
10
11
Page 20 of 150
Revision A

1 ENGINE TEMPERATURE
This gauge (0 C to +120 C (+32 F to +230 F)) shows the engine coolant
temperature.
2 EXHAUST TEMPERATURE
This gauge (0 C to +250 C (+450 F)) shows the engine exhaust temperature.
3 ENGINE OIL PRESSURE
This gauge shows the oil pressure in the engine and the engine safety system.
4 COMPRESSOR
TEMPERATURE
This gauge (0 C to +120 C (+32 F to +230 F)) shows the temperature of the main
compressor.
5 AIR PRESSURE
This gauge shows the air pressure in the main compressed air system.
6 START PRESSURE
This gauge shows the current starting pressure available for the start system (on air
starter and hydraulic starter equipped engines).
7 EMERGENCY STOP
Press this knob to shut down the unit in an emergency. To reset it turn the knob
clockwise until it springs back out.
DO NOT restart the unit without checking that the cause for the emergency stop
has been resolved.
DO NOT use the emergency stop as a control to stop the unit during normal
operations.
8 TACHOMETER
This gauge shows the engine speed in RPM and the engine running hours.
9 ENGINE STOP
Push this button to stop the engine; it releases automatically

The engine safety sentinel valve cuts off fuel flow when the engine oil pressure drops
below a certain value.Turning lever against the spring-pressure overrides the valve
for starting.
11 AIR INLET VALVE
Use this handle to control the engine safety air intake control valve.
Push the handle up to bypass the engine 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 for emergency stop. This will close the air intake valve and stop
the engine.
For restarting wait 2 minutes for the shutdown-derived vacuum to disappear.
12 ENGINE START
Activator to start the engine. For a pneumatic start system it is a push button, for a
hydraulic start system it is a twist knob. (Not present on spring starter units). Refer to
6.2 Power up on page 35 for detailed use.
13 CONTROL PRESSURE
This gauge shows the air pressure in the auxiliary pneumatic system

Page 21 of 150
Revision A
4.2 Operator controls
10 ENGINE SAFETY
4.3
Engine
4.3 Engine
The AirPack C units main power source is a Caterpillar C4.4, 4-cylinder diesel engine, naturally
apirated. The engine drives a compressor directly (see Figure 4.1) for supplying compressed air.
The engine and the exhaust system are water cooled. The OEM documentation for the engine is
included in the Documentation Package.
Figure 4.1 Engine/compressor assembly
4.3.1
Engine safety system

The engine safety system serves as:
An automatic shut-off system in case of an over-speed situation caused by ingress of
hydrocarbon gases.
An automatic shut-off device in case of low engine oil pressure (<0.5 bar (7.25 psi))
An automatic shut-off device for high coolant temperature >+100 C (>+212 F) and high
exhaust temperature >+200 C (>392 F)
A manually controlled shut-off device in case of an emergency stop
The engine safety system consists of two main sub-systems which monitor the engine oil
pressure:
1.
Fuel:
The sentinel master valve (fuel shut-off valve) is positioned between the fine particle filter
and the fuel injection pump. See Figure 4.2.The sentinel master valve monitors the oil
Page 22 of 150
Revision A

pressure in the diesel engine. If the lubrication oil pressure drops under the factory setting of
0.5 bar (7.5 psi), the valve will block the supply of fuel and shut down the diesel engine. The
oil pressure is also distributed to the air intake valve.
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 ASEP Elmar
4.3 Engine
Figure 4.2 Engine fuel system safety valve

2.
Air intake:
An air intake filter assembly with disposable elements cleans the input air for the diesel engine.
An air inlet safety valve is positioned in the air intake system, and is used to shutdown the diesel
engine manually or automatically, by cutting off the air intake supply. It is factory pre-set to trip at
desired pressure values and RPM settings. See Figure 4.3 below
WARNING
TXT-10004285/A
DANGEROUS MACHINERY
equipment damage.
A lever on the control console is used to open and close this safety valve. See 4.2 Operator
controls on page 20. Pushing this lever up before starting the engine will mechanically open the

Page 23 of 150
Revision A
valve, which is normally closed (spring loaded). Once the engine has started, the engine oil
pressure will overcome the spring pressure and hold the valve open.
Figure 4.3 Air intake safety valve (roof removed for clarity)
4.3.2
Engine starters
4.3 Engine
The engine has options for either a spring starter, a pneumatic starter, or a hydraulic starter. See
Figure 4.4 below for starter examples.
a) Spring starter: is activated with a lever on the starter. Activating the lever releases spring
tension which turns the starter, which in turn rotates the engine.
b) Air starter: is activated from a button on the control panel. Activating the button opens a
pneumatic valve, and rig air turns the starter, which in turn rotates the engine.
c) Hydraulic starter: is activated from a button on the control panel. Activating the button
opens a hydraulic valve, and hydraulic accumulator pressure turns the starter, which in
turn rotates the engine.
See 6.2 Power up on page 35 for more details on how to start the engine.
Page 24 of 150
Revision A

4.3.3
Fuel system
The fuel is stored in a fuel tank equipped with a breather. The fuel passes from the fuel tank
through to the following components:
a) Isolation valve (this valve can be closed for maintenance purposes)
b) Coarse particle filter (strains large particles from the diesel)
c) Fuel/water separator filter (removes water contamination from the diesel)
d) Fuel gear pump
e) Fuel primer pump (runs parallel with d above)
f) Fuel fine particle filter (removes fine particles from the diesel)
g) The sentinel master valve (fuel shut-off valve)
h) Injector pump (pressurizes the fuel to the injectors)
For an overview of the fuel system see the as built FLUID DIAGRAM- ENGINE FUEL & OIL page in the
Documentation Package.
See Figure 4.5 below. A fuel/water separator (1) separates any water contamination from the
diesel fuel. The fuel fine particle filter (2) removes particles larger than 10 m. The frequency of

Page 25 of 150
Revision A
4.3 Engine
Figure 4.4 Starter options: clockwise from top left:, HD spring starter, air starter, hydraulic starter
water draining or filter element replacement depends on the quality of the fuel. The primer pump
(3) is used during the bleeding of the fuel system.
3
2
4.4 Compressor (Pneumatic) system
Figure 4.5 Fuel/water separator and primer pump
4.3.4
Exhaust system
The exhaust gases are led from the engine through an exhaust gas cooler, flame trap and silencer
(muffler) to the exhaust pipe which exits from the side of the unit. These components remove
excess heat, soot and sparks from the exhaust which could otherwise ignite an explosive
atmosphere near the exhaust outlet.
The exhaust gas cooler cools the exhaust by circulating engine coolant through its heat
exchanger.
4.4
Compressor (Pneumatic) system

Compressed air is provided by a directly driven compressor. Ambient air is drawn into the main
compressor through an air intake filter. It is then compressed to 10 bar (145 psi) in compression
chamber where cooling/ lubricating oil is injected for supply. The supply air from the compressor
passes through a separating tank and an air /oil separator filter to remove excess oil. The air is
finally cooled by an air-cooled heat exchanger and further dried by passing through a cyclone air
dryer (see Figure 4.6).
A part of the compressed air is used to activate a pneumatic cylinder which regulates the engine
speed, dependent on air consumption requirements.
Two air outputs are available for site consumption use. See belowFigure 4.7.
On air starter equipped units, rig air from the site provides air through a separate system for
powering the starter system.
The auxiliary pneumatic system is used to activate the ENGINE SAFETY system and EMERGENCY
STOP circuit. It is powered by a separate 225cc compressor and is equipped with its own air
cleaning and regulating components.
On hydraulic starter equipped units, an air-operated oil pump can charge the hydraulic
accumulator. This air-operated oil pump can be driven by rig air or by the auxiliary pneumatic
system.
Page 26 of 150
Revision A

NOTE: The ENGINE SAFETY and EMERGENCY STOP circuits must be powered by pneumatic
pressure or else the engine will not remain running.
.
4.4 Compressor (Pneumatic) system
Figure 4.6 Air-oil separator filters and cyclone air dryer
Figure 4.7 Compressed air outputs

Page 27 of 150
Revision A
The compressors lube oil is filtered by a disposable filter element and air-cooled through a
separate oil cooler. See Appendix 1: Specifications on page 131 for the compressor
specifications.
For an overview of the pneumatic system, see the as built FLUID DIAGRAM- HYDRAULICS &
PNEUMATICS Diagram in the Documentation Package that comes with the unit. For the main
compressor details see the supplier documentation also included in the Documentation Package.
4.5
Cooling system
The AirPack C unit is equipped with a belt-driven cooling fan. The fan draws ambient air through
the radiator stack, which has three separate heat exchangers for the following circuits:
Coolant (engine and exhaust gas cooling)
Compressor oil
Compressed air
Maintenance tasks include check/replenish the coolant level, drain/refill and bleed the (coolant)
cooling system, check compressor oil level, change filters and to check the system for leaks.
These are covered in 7.4 Periodic maintenance schedules on page 47.
4.6
Unit grounding
4.5 Cooling system
The AirPack C unit is equipped with grounding points on the right and left sides.
These shall be utilized to ground the unit to the rig or the well-head to prevent static electrical
discharge. See Figure 4.8.
Figure 4.8 Unit grounding point
Page 28 of 150
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SETUP AND REMOVAL

WARNING
TXT-10004286/A
DANGEROUS MACHINERY
5.1
Moving/positioning equipment
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-10004327/A
The unit may be moved and positioned by hoisting, or with a properly dimensioned forklift. See
certification in the Documentation Package that came with this AirPack C unit.
Make sure that the lifting equipment to be used is sufficiently dimensioned, has the correct
certification, and is marked accordingly. The lifting equipment may only be used by suitably
qualified personnel. All equipment lifting equipment must be subject to regular scheduled
inspection compliant with EN 12079 for deformation and wear. All lifting equipment repairs must
have been carried out compliant with EN 12079.
Always use the lifting eyes on the four corners for hoisting. Never use the two eye bolt sockets
on the top plate to lift the entire unit. These are for lifting the detached top plate only.
5.1.1
Land transportation
When loading and transporting ASEP Elmar modules on a truck, several things need to be taken
into consideration (most of these are also specified in the local traffic regulations):
Number of axles on the transport vehicle (to decide where to position one or more units)
Weight of unit(s) (total weight)
Height of the load (bridges, aqueducts, tunnels)
Width of the load (manoeuvring)
Travelling speed
Cornering (dead corner)
Securing modules and securing loose components
Check all these before loading and transportation:
Make sure lifting equipment is sufficiently dimensioned.

Page 29 of 150
Revision A
5.1 Moving/positioning equipment
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.
All equipment used for lifting must have the correct certification and be marked
accordingly.
Only qualified personnel are allowed to use lifting equipment.
Before each lift, always ensure that the lifting shackles have been correctly attached to
the unit.
5.1.2
Air transportation
Standard procedure for air freighting a unit depends on local travel organizations. See
Appendix 7: Air transportation on page 144
In general the following should be drained:
Fuel tank
Engine oil
Engine coolant
Gearboxes
5.1 Moving/positioning equipment
Air tank
Compressor oil sump
Other liquids within components will normally remain in the unit:
Fluid/oil coolers
Filters
Hoses
5.1.3
Draining
If the carrier requires that all fluids are drained from the reservoirs, systems and components of
the machine(s), please refer to 7.4 Periodic maintenance schedules on page 47 for specific
instructions on how to drain the fluid from each reservoir, system or component.
NOTE: Tag the unit or components to warn against starting before refilling.
Photocopy or print the checklist in Appendix 7: Air transportation on page 144 as an aid to
ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as
follows:
5.1.4
1.
Check off each item as it is drained, adding your initials.
2.
Strike-out the items that are NOT present on the machine.
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.
Refilling
Replenish the fluid in each of the items listed in the checklist. ASEP Elmar recommend that new
fluid/oil filters are used when refilling systems that include filters. If you have fitted new filters,
please add your initials in the last column.
Refer to the APPENDICES on page 130 for the quantity and specifications of the required fluids.
Refer to 7 Maintenance on page 47 for the procedures to check and replenish fluids for each of
the reservoirs, systems and components. Where applicable, remember to bleed the system of air
and refill as required.
Page 30 of 150
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5.2
Site preparation
Before positioning the unit at the site, survey the location where it will be used. There should be
sufficient room on all sides for opening doors/hatches.
5.3
Rig-up
5.3.1
Positioning and grounding
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.
1.
Move the unit to the operating position.
2.
Secure the unit in place according to site regulations.

TXT-10004301/A
3.
5.3.2
Connect ground cables to the grounding points on the unit according to site regulations.
Refer to 4.6 Unit grounding on page 28.
Testing
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.
5.4
1.
Start up and test the unit as described in 6 Operation on page 34.
2.
Shut down the unit by performing 6.3 Normal shut down on page 42.
Rig-down
WARNING
TXT-10004255/A
COMPRESSED AIR
Air and/or particles under high pressure can cause severe injury, particularly to the eyes.
Never connect/disconnect a compressed air coupling without first removing all pressure from
the connection.
To connect/disconnect a compressed air coupling:

a) Shut off the nearest valve on the supply side of the coupling.

Page 31 of 150
Revision A
5.2 Site preparation
WARNING
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.
b) Release all pressure on the consumption side of the coupling, either by operating the
control or appliance, or by slowly opening a valve on the consumption side.
c) Then with eyes protected or at a safe distance from the coupling, carefully connect/
disconnect the coupling.
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.
CAUTION
TXT-10004382/A
5.5 Storage
EQUIPMENT DAMAGE
Dirty or damaged quick connectors can leak and cause equipment damage.
Before connecting a quick connector, inspect and clean both ends.
5.4.1
1.
Ensure that the unit has been shut down according to 6.3 Normal shut down on page 42.
2.
Disconnect the pneumatic hoses in the AirPack one by one.
3.
With a clean cloth, thoroughly clean the dust caps for the connectors.
4.
Fit the dust caps.
5.
Check that all cables and hoses are correctly stowed.
Finalize
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.
1.
Make sure all access panels are correctly closed and secured.
2.
Disconnect the ground cables from the grounding points.
5.5
Storage
5.5.1
Short term storage (< 1 year)

When storing the system for a short term, always take the following actions:
1.
Complete the rig-down steps as described in 5.4 Rig-down on page 31.
2.
If the machine is going to be stored in temperatures under -18 C (0 F):

a) Refer to 7.4 Periodic maintenance schedules on page 47 for the procedures to remove
water from:
Fuel tank, filters & lines
Engine cooling system & reservoir
Pneumatic anti-frost system
b) Completely fill the following fluid reservoirs (if present) with appropriate fluid for expected
low temperatures:
Page 32 of 150
Revision A

Fuel tank, filters & lines (fill the diesel tank completely with winter diesel if available)
Engine cooling system & reservoir
c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures.
Refill with fluid again to full, if necessary.
5.5.2
3.
Close all panels and hatches on the unit and secure or lock them.
4.
Cover the unit with a suitable protection cover (these can be ordered from ASEP Elmar if
required).
Long term storage (> 1 year)

When storing the system for long periods, follow the steps in 5.5.1 Short term storage (< 1
year) on page 32, and take the following additional actions:
Grease exposed metal surfaces to prevent corrosion.
2.
Grease all rubber seals to prevent damage and cracking.
3.
Fill the diesel tank to prevent condensation.
4.
Drain the coolant tank as described in 7.24 Drain/fill engine coolant on page 91.
5.
See 7 Air transportation on page 144, and the checklist in the appendix, for information on
other possible drain points, and how to register your actions.
6.
Refer to your company policy for other possible storage requirements.

5.5 Storage
1.
Page 33 of 150
Revision A
OPERATION
6.1
Pre-start checklist
WARNING
TXT-10004286/A
DANGEROUS MACHINERY
1.
Ensure that you have read and understood section 2 Safety on page 6.
2.
Check environment for sufficient ventilation for dispersion of the exhaust gases.
3.
Ensure that the unit has been rigged up as described in 5.3 Rig-up on page 31.
4.
Perform all of the daily maintenance procedures listed in 7.4 Periodic maintenance
schedules on page 47.
5.
Ensure that the engine is not running and cannot be started.
6.1 Pre-start checklist
WARNING
TXT-10004360/A
SHARP OBJECT
Sharp or rough objects can cause severe cuts.
Always wear gloves when handling sharp or rough objects.
6.
Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks
from lines or components, and structural damage.
7.
Check all tanks and hoses for leaks, and for other visible damage.
8.
Ensure that the cooling air intake and exhaust openings are not obstructed.
9.
Ensure that all components requiring lubrication are serviced as necessary.
10. Check that no unauthorized modifications have been made to the unit.
Page 34 of 150
Revision A

6.2
Power up
The engine speed is self-regulating, dependent on the required air output. The speed will be
increased when the compressor system senses no pressure build-up. In order to have the engine
run at lower speeds until it reaches operating temperature, it is essential to close all air output
valves.
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 AirPack C 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
If starting the AirPack C for the first time, read this entire section thoroughly, and be certain you
understand every part before starting the unit, especially sections:
6.3 Normal shut down on page 42
1.
Ensure that 6.1 Pre-start checklist above has been done before proceeding.
2.
Refer to the figures on the following pages. Check that the EMERGENCY STOP button (6) is not
activated (i.e. it is pulled out or reset). If it is activated:
Check that it has not been pushed in to prevent starting the unit, because someone is
performing maintenance on it. (Lock out/tag out)
Rectify the problem that caused the emergency before continuing.
WARNING
TXT-10004255/A
COMPRESSED AIR
the connection.


Page 35 of 150
Revision A
6.2 Power up
6.4 Emergency stop on page 43
3.
If connected, remove at least one

hose to the valve air output
isolation valves (1) is open the
valve. See Figure 6.1.
4.
Alternatively, remove at least one

of the blind caps (2) from the output
and open the valve.
This is necessary to ensure that the
compressor offers minimal
resistance when starting the
engine.
5.
Close the isolation valves of any

remaining connected air outputs.
6.2 Power up
Figure 6.1 Air output valves

6.
6.2.1
Continue below for starter type indicated.
For spring starter equipped engines

NOTE: Starting with a spring starter may require two persons. One to activate the starter at
the engine, and one to hold open the AIR INLET VALVE.
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.
Page 36 of 150
Revision A

Figure 6.2 Start and stop controls
1.
Locate the spring starter on

left side of the engine; see
Figure 6.3.
2.
Depress and release the

reset button (3).
3.
Remove the hand crank from

its storage location and fit it to
the winding shaft (4).
4.
Using the handle, wind the

starter clockwise to the
required power output. The
maximum number of turns is
39. For most applications 3336 turns of the handle should
prove sufficient.
5
4
Figure 6.3 Spring Starter

Page 37 of 150
Revision A
6.2 Power up
NOTE: Over-winding will reduce the life of the starter.

NOTE: It is possible to unwind the starter, should it become necessary, by turning the
handle counter-clockwise; additional force will be required to overcome the initial
friction.
5.
Remove the handle from the starter, and return it to the storage/transit location.
NOTE: The starter should never be tripped with the winding handle in place.
6.
Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (1) clockwise
against the spring pressure; see Figure 6.2.
NOTE: This will override the diesel safety system, until the engine oil pressure holds the
valve open.
7.
Push the AIR INLET VALVE lever (2) on the control panel all the way up, and hold it in that
position.
8.
On the starter, pull the trip lever (5) through 90 degrees in the direction shown by the arrow
in Figure 6.3, to start the engine.
9.
When the ENGINE OIL PRESSURE gauge (6) shows a reading above 2 bar (29 psi), release the
AIR INLET VALVE from its upper position.
If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to
section 8 Troubleshooting on page 125.
6.2 Power up
10. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected
it in step 3 of section 6.2 Power up.
NOTE: This is necessary to keep the engine from revving too high before it is warmed up.
11. After the engine has run for about one minute check the engine oil pressure again. This
should be at least 3 bar.
If oil pressure has still not increased to above 2 bar then shut the engine down and
troubleshoot according to section 8 Troubleshooting on page 125.
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.
12. If required, open the isolation valves on the required air outputs.
6.2.2
For air starter equipped engines
CAUTION
TXT-10004515/A
EQUIPMENT DAMAGE
Leaving the pneumatic system under pressure, when the unit is not running can damage it.
Always close the rig-air input isolation valve and shut off the rig-air supply point, when the unit
is shut down for longer than a few minutes.
Page 38 of 150
Revision A

Supply air to the unit as follows:

a) Locate the rig air supply input connection
on the right side of the unit, and ensure
valve (6) is initially closed, as shown in
Figure 6.4.
NOTE: Rig air is used ONLY for starting the

engine. It should never be hooked up to the
AirPack C for any other purpose!
b) Connect a suitable air supply (7 bar
(100 psi) at 25 l/min) to the rig-air
connection.
rig air
connection
Figure 6.4 Rig air input
c) Open the rig-air supply at the supply point.

d) Slowly open the rig-air intake valve (6) on the unit.
1.
Go to the control panel. See Figure 6.5.
5
6.2 Power up
4
3
2
Figure 6.5 AirPack C starting and stopping controls

2.
Ensure that the START PRESSURE gauge (1) shows between 7 bar and 10 bar.

Page 39 of 150
Revision A
NOTE: A minimum of 7 bar is required to start the engine.
WARNING
TXT-10004270/A
CRUSH HAZARD
3.
Close all access panels and doors around the AirPack C, except for the control panel access
hatch.
4.
against the spring pressure.
valve open.
5.
position.
6.
Press and hold the ENGINE START button (4) until the engine starts, then release.
7.
When the ENGINE OIL PRESSURE gauge (5) shows a reading above 2
AIR INLET VALVE from its upper position.
bar (29 psi), release the
6.2 Power up
If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to
NOTE: Close the air output you opened to start the unit, and reconnect any hoses you may have
disconnected in step 3 of section 6.2 Power up above.
8.
After the engine has run for about one minute check the engine oil pressure. This should be
at least 3 bar.
troubleshoot engine according to section 8 Troubleshooting on page 125
WARNING
TXT-10004269/A
HIGH PRESSURE
9.
If required, open the isolation valves on the required air outputs.
10. Close the rig-air intake valve.

11. Close the shore/rig-air supply at the supply point.
12. Disconnect the shore/rig-air connection.
6.2.3
For hydraulic starter equipped engines

1.
Ensure that the isolation valve for the starter accumulator is open.
2.
Check the START PRESSURE gauge (1) on the power pack control panel to see if the starter
accumulator has sufficient pressure to start the unit.
Page 40 of 150
Revision A

NOTE: The hydraulic starter needs 120 bar start pressure for one start attempt.
3.
If there is not enough hydraulic pressure to start the unit, charge the accumulator as
described in 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45.
3
2
Figure 6.6 AirPack C starting and stopping controls

4.
against the spring pressure; see Figure 6.6.
valve open.
5.
position.
6.
Turn and hold the ENGINE START knob (4) clockwise until the engine starts, then release.
7.
When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR
INLET VALVE from its upper position.
If the engine fails to start, perform steps 1 to7 again or troubleshoot the system according to

Page 41 of 150
Revision A
6.2 Power up
8.
Close the air output you opened to start the unit, and reconnect the hose, if you disconnected
it in step 3 of section 6.2 Power up above.
9.
After the engine has run for about one minute check the engine oil pressure. This should be
at least 3 bar.
troubleshoot engine according to section 8 Troubleshooting on page 125
10. Once the engine is running, the hydraulic starter circuit maybe charged again to save it for
the next start. For a detailed explanation, see 6.5.2 Charge starter accumulator using the airoperated oil pump on page 45
WARNING
TXT-10004269/A
HIGH PRESSURE
6.3 Normal shut down
11. If required, open the isolation valves on the required air outputs.
6.3
Normal shut down

The engine speed is self-regulating, dependent on the required air output. Allow the engine to run
at near idle speed before shutdown by closing the air output valves.
1.
Close all isolation valves on the air outputs.
2.
Pull the ENGINE STOP lever (4) to stop the engine, See Figure 6.5
3.
Check the tachometer to ensure the engine speed drops to zero RPM.
WARNING
TXT-10004255/A
COMPRESSED AIR
the connection.

4.
Disconnect one of the hoses, if all three air outputs are connected.
5.
Carefully and slowly open a disconnected air output a few millimetres to bleed off the
compressed air left in the unit.
6.
After the gauge shows zero air pressure, close the valve.
7.
Note the shut-down date and time in the running hours log (see Appendix 6: Running hours
log book on page 140).
Page 42 of 150
Revision A

8.
Carry out the following daily shut-down tasks, and fix any problems as necessary:
a) Inspect all hoses, couplings, and components for signs of air leaks/ oil leaks, wear and
damage.
b) Check the levels of all fluid reservoirs, replenishing as necessary:
Engine fuel level
Engine oil level
Engine coolant level
Compressor oil level
Pneumatic line lubricator
Hydraulic starter system reservoir
c) Check that the pneumatic system automatic water drain is working correctly.
9.
6.4
If shutting down for safe maintenance, activate the EMERGENCY STOP button, and tag it with
a maintenance warning.
Emergency stop
The AirPack C has two modes of emergency stop:
System (automatic), which is caused by a system condition
6.4.1
Manual emergency stop

The unit has an EMERGENCY STOP button. In an emergency, push this button to immediately stop
the engine. This releases the air and oil pressure from the engine safety system, and chokes the
diesel air inlet and sentinel fuel valves.
After resolving the emergency situation, perform a pre-start inspection (6.1 Pre-start checklist),
and then restart the unit (6.2 Power up).
6.4.2
System (automatic) emergency stop

For some engine alarms, the system will automatically shut the engine down. This shutdown
procedure is triggered by one or combination of the following:
Low oil pressure: <0.5 bar (<7.25 psi)
High engine coolant temperature (exceeds 106 C (223 F))
High engine exhaust temperature (exceeds 200 C (425 F))
An engine overspeed situation: >2300 rpm. Excessive rpm caused by ingress of
explosive gases into the engine intake will increase intake vacuum, causing the Sentinel
valve to trip and cut off intake air.
6.5
Charge hydraulic starter accumulator

If the unit has been shut down and there is insufficient pressure to restart the unit, the starter
accumulator can be pressurized by using the hand pump or by using the air-operated oil pump
running on rig air.
Once the engine is running, the air-operated oil pump can also be utilized without rig air to
recharge the accumulator before shutting the engine down.

Page 43 of 150
Revision A
6.4 Emergency stop
Manual, which is initiated by a person pushing the EMERGENCY STOP button
6.5.1
Charge starter accumulator using hand pump
5
3
6.5 Charge hydraulic starter accumulator
6
2
7
Figure 6.7 Hydraulic starter accumulator and reservoir w/ hand pump.
1.
Locate the hydraulic start system reservoir (3) and hand pump (5) on the inside of the left
door.
2.
Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic
oil on page 61.
3.
Locate the hydraulic accumulator (1) on the inside of the right door.
4.
Ensure that the accumulator isolation valve (2) and reservoir isolation valve (7) are open.
5.
Ensure the hand pump activation knob (6) is fully closed (pointing down).
NOTE: This knob should ALWAYS be in the closed (fully clockwise) position, otherwise the
charging system will not work properly.
6.
Remove the pump handle (4) from the holder and insert it into the pumps handle socket.
7.
Operate the pump and observe the START PRESSURE gauge on the power pack control panel
until the minimum start pressure is reached: 120 bar (1740 psi).
NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465
psi).
8.
Remove the pump handle, and store it in the holder.
9.
Close the isolation valve of the starter accumulator to store the charge in case immediate
starting is not required.
Page 44 of 150
Revision A

6.5.2
Charge starter accumulator using the air-operated oil pump

The air-operated oil pump can be used when the engine is running or when rig air is connected.
To charge the accumulator using the hand pump refer to 6.5.1 Charge starter accumulator using
hand pump.
5
2
4
6
Figure 6.8 Hydraulic starter accumulator, reservoir and air-operated oil pump.
1.
Locate the hydraulic start system reservoir (3) on the inside of the left door.
2.
Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic
oil on page 61.
3.
When charging the starter accumulator with the engine:

a) Start up the unit according to section 6.2 Power up on page 35.
b) Continue to step 5.
4.
When charging the starter accumulator with rig air:

a) Connect an air supply with a pressure between 7 bar (100 psi) and 10 bar (145 psi) to the
rig air in connector.
b) Open the rig air in isolation valve on the AirPack C.
5.
Locate the hydraulic accumulator (1) on the inside of the right door.
6.
Ensure that the accumulator isolation valve (2) and the reservoir isolation valve (4) are open.

Page 45 of 150
Revision A
7.
Ensure the hand pump activation knob (5) is fully closed (fully clockwise, pointing down).
8.
Open the input air isolation valve (76) to activate the air-operated oil pump.
9.
Operate the pump and observe the START PRESSURE gauge on the control panel until the
minimum start pressure is reached: 120 bar (1740 psi).
NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465
psi).
10. Close the input air isolation valve to deactivate the pump and keep it from starting
unexpectedly.
11. Close the isolation valve on the starter accumulator to store the charge.
Page 46 of 150
Revision A

MAINTENANCE
TXT-10004206/A
7.1
Introduction
Only qualified and trained personnel should perform maintenance on ASEP 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 AirPack C 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 AirPack C unit, but
regular maintenance must be performed according to the number of hours the AirPack C has
been run. Running hours should be logged by the AirPack C 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). ASEP Elmar recommends basing the service
intervals on hours of running; you may prefer to use calendar time (weeks, months).
7.2
Certified assemblies
7.3
OEM components
Certain components of your AirPack C are complete assemblies or subsystems supplied by
Original Equipment Manufacturers (OEM) than ASEP 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.
7.4
Periodic maintenance schedules

Use the tables on the following pages to plan routine maintenance for your unit.

Page 47 of 150
Revision A
7.1 Introduction
Your AirPack C 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 ASEP 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 ASEP
Elmar Service for advice (see Contact Us in the appendices).
7.4 Periodic maintenance schedules
1500/yearly
1200
900
600
300
daily
manual
section
Maintenance activity
as required
Service interval (hours)
Check/adjust V-belts
7.5
Check/fill compressor oil (1)
7.6
Check/fill engine coolant (1)
7.7
Check/fill engine oil (1)
7.8
Check/fill engine fuel
7.9
Check/fill hydraulic oil
7.10
Check/fill fuel pump gear drive oil
7.11
Check/replace hoses and couplings
7.12
Check shock absorbers (1)
7.13
Clean engine air inlet valve
7.14
Clean auxiliary pneumatic system filter
7.15
Clean fuel coarse particle filter
7.16
Clean/replace compressor intake air filter
7.20
Clean main compressor air dryer
7.18
Clean/replace crankcase breather flame trap
7.21
Clean/replace engine air filter
7.22
Clean/replace fuel tank breather
7.23
Clean spark arrestor
7.19
Drain/fill engine coolant
7.24
Drain fuel tank
7.25
Drain fuel/water separator
7.26
Drain water from hydraulic tank
7.27
Prime diesel engine
7.28
Replace air-oil separator filter (compressor)
7.29
Change compressor oil and filter
7.30
Change engine oil and filter(2)
7.31
Replace fuel fine filter element
7.32
Replace fuel/water separator filter
7.33
Replace hydraulic oil
7.34
Replace V-belts
7.35
Test maximum engine speed (if applicable)
7.36
(1)
After each transport
(2)
After first 50 running hours
Table 7.1
Page 48 of 150
Revision A

7.5
Check/adjust V-belts
This procedure describes how to inspect the V belts of the Caterpillar diesel engine.
Related topics:
7.35 Replace V-belts on page 119
Ensure that the unit has been shut down for safe maintenance, as described in 6.3 Normal shut
down on page 42.
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.
Refer to fig Figure 7.1 below. Remove the right side belt guards, upper (1) and lower (2).
7.5 Check/adjust V-belts
Figure 7.1 V-belt protective guards and v-belt adjustment assembly

2.
Check the belts for damage or excessive wear.
3.
Replace belts where necessary. See 7.35 Replace V-belts on page 119.

Page 49 of 150
Revision A
NOTE: Double V-belts (V-belts installed in pairs) should always be replaced in pairs, to avoid
premature wear and slippage.
4.
Refer to Figure 7.1.Check the belts for correct tension: Apply 110 Nm (25 ft-lb) against the
midpoint (3) between idler pulley and the crankshaft pulley. There should be 9 to 15mm (0.35
to 0.6 in) deflection.
5.
If necessary, adjust the belts as follows:

a) Loosen the locknut on the adjustment plate securing bolt (4).
b) Loosen the hinge locknut (5).
c) Adjust the belts to the proper tension.
d) Tighten the adjustment plate securing bolt.
e) Tighten the hinge locknut.
f) Recheck the tension of the belt and adjust again as required.
6.
Replace the guards.
7.5 Check/adjust V-belts
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.
WARNING
TXT-10004270/A
CRUSH HAZARD
8.
Close any panels you opened.
Page 50 of 150
Revision A

7.6
Check/fill compressor oil

The compressor was filled with approx. 25 l (6.6 US Gal) of Mobil Rarus 426 at the factory.
Always use the same type oil as specified in the Appendix 3: Lubricants on page 135.
Related topics:
Appendix 3: Lubricants on page 135
1.
Ensure that the unit is shut down for safe maintenance, as described in 6.3 Normal shut
down on page 42, and cannot be accidentally started.
2.
Release all pneumatic pressure from the system by slowly opening one of the air outputs.
Verify that the air pressure is completely released by checking the AIR PRESSURE gauge.
3.
To avoid burns ensure the compressor oil is cooled off sufficiently by checking COMPRESSOR
TEMPERATURE gauge.
2
1
MAX
MIN
Figure 7.2 Engine oil filler cap and level
7.6.1
Check compressor oil level

1.
Open the right access door and locate the compressor oil filler cap (2) behind the air dryer
filter (1).
2.
Carefully remove accumulated dust and grit from around the filler using a clean cloth.
3.
Remove the filler cap and inspect the oil level; oil level should be between filler cap threads
and the bottom of the filler neck. See Figure 7.2.
4.
If the oil level is below the correct level go to the next procedure.

Page 51 of 150
Revision A
7.6 Check/fill compressor oil
7.6.2
Fill compressor oil

1.
Remove the oil filler cap (3).
2.
Add compressor oil until the oil level is above the MIN and below the MAX marks. Refer to
Appendix 3: Lubricants on page 135 for recommended compressor oils
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.
Replace the oil filler cap and tighten it.
4.
Clean any spilled oil.
7.6 Check/fill compressor oil
CAUTION
TXT-10004376/A
5.
WARNING
TXT-10004270/A
CRUSH HAZARD
6.
Close any access panels you opened.
Page 52 of 150
Revision A

7.7
Check/fill engine coolant

For optimum engine cooling, regularly check the coolant level. When filling the radiator always
keep in mind that the volume will increase when the engine coolant is hot. Therefore, 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.
NOTE: For cold weather operations, ensure the cooling system is filled with anti-freeze rated to
the minimum temperature expected; for example -20 C or -40 C.
Related topics:
7.24 Drain/fill engine coolant on page 91
7.7.1
Check coolant level

1.
Ensure that the unit has been shut down for safe maintenance, as described in 6.3 Normal
shut down on page 42.
2.
Wait for the coolant to cool down.

If the coolant is not cooled down, the level reading may be incorrect.
Open either of the side doors, and check the level of the coolant at the top of the radiator.
The coolant should be visible in the sight glass (1). See Figure 7.3 below.
sight glass correct

coolant level
Figure 7.3 Coolant sight glass

4.
7.7.2
If necessary, fill the cooling system with coolant by performing 7.7.2 below.
Top up coolant
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.

Page 53 of 150
Revision A
7.7 Check/fill engine coolant
3.
NOTE: The coolant is normally topped up from the top of the unit, but can also be filled from the
drain plug below the radiator (optional). This is necessary when refilling the system after
it has been drained. See 7.24 Drain/fill engine coolant on page 91.
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.
Locate coolant fill hatch (1) on unit roof. See Figure 7.4.
2.
Remove the securing bolt, and open the roof hatch on the.
3.
Remove the radiator filler cap (2).
Figure 7.4 Coolant fill hatch and radiator filling point

4.
Place a funnel in the filling point (3).
5.
Pour coolant into the radiator until the coolant reaches the correct level in the sight glass.
See Figure 7.3.
6.
Remove the funnel from the filling point.
CAUTION
TXT-10004386/A1
EQUIPMENT DAMAGE
7.
Replace the filler cap.
8.
Use clean rags to clean any spilled coolant.
9.
Close and secure the hatch.
Page 54 of 150
Revision A

CAUTION
TXT-10004376/A
10. Remove all tools and materials from the work area, and dispose of used materials according
WARNING
TXT-10004270/A
CRUSH HAZARD
11. Close any panels you opened.

Page 55 of 150
Revision A
7.8
Check/fill engine oil

Refer to the Caterpillar documentation included in the Documentation Package that came with
your AirPack C for detailed servicing instructions.
Related topics:
Shut down the unit for safe maintenance, as described in 6.3 Normal shut down on page 42.
2.
Wait a few minutes for the oil to settle.
Check engine oil level

1.
Open the right AirPack C door to access the engine oil dipstick (1). See Figure 7.5
2.
Unscrew the dipstick.
7.8 Check/fill engine oil
7.8.1
1.
Figure 7.5 Engine oil dipstick
7.8.2
3.
Clean the dipstick, and push it back into position.
4.
Remove the dipstick and check the oil level.
5.
If required, fill the engine oil as follows. Otherwise continue from 7.8.3.
Fill engine oil

1.
Open the left door to access the engine oil filling point. See Figure 7.6.
Page 56 of 150
Revision A

Figure 7.6 Engine oil filler cap (obscured)

2.
Remove the filler cap (2). Place a plastic tube into the filler neck.
3.
Push a funnel into the other end of the plastic tube.

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.
Slowly add a small amount of oil.
5.
Wait a moment for the oil to run into the engine.
6.
Check the oil level with the dipstick.
7.
Repeat steps 4 through 6, until the proper level has been reached.
8.
Remove the funnel and plastic tube.
9.
Clean any spilled oil from around the engine.
CAUTION
TXT-10004386/A1
EQUIPMENT DAMAGE
10. Replace the oil filler cap and tighten it.
7.8.3
Finalize
1.
Ensure that the dipstick and filler cap are screwed securely into place.
2.

Page 57 of 150
Revision A
CAUTION
CAUTION
TXT-10004376/A
3.
WARNING
TXT-10004270/A
CRUSH HAZARD
4.
Page 58 of 150
Revision A

7.9
Check/fill engine fuel

NOTE: Check the fuel level before using the unit; also check the fuel level regularly during
operations.
7.9.1
Check fuel level

1.
Open the door(s) so that you can see the fuel level gauge (2). See Figure 7.7 below.
2.
Check the gauge reading. The indicator is incremented into , , 3/4 and FULL.
3.
Refill as necessary for operations.
7.9 Check/fill engine fuel
Figure 7.7 Diesel fuel filler cap and level gauge
7.9.2
Fill fuel tank
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.
Remove the fuel filler cap (1). See Figure 7.7.
4.
Fill the fuel tank with clean diesel until the level gauge (2) shows full.
5.
Replace the filler cap.
6.
Use clean rags to clean any spilled fuel from around the filling point.
CAUTION
TXT-10004376/A

Page 59 of 150
Revision A
7.
WARNING
TXT-10004270/A
CRUSH HAZARD
Close any doors you opened.
7.9 Check/fill engine fuel
8.
Page 60 of 150
Revision A

7.10
Check/fill hydraulic oil

Related topics:
6.5 Charge hydraulic starter accumulator on page 43
7.10.1 Check hydraulic oil level
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.
WARNING
TXT-10004337/A
1.
Make sure the unit has been shut down for safe maintenance. See 6.3 Normal shut
down on page 42, and the unit cannot be accidentally started.
2.
Refer to Figure 7.8 and Figure 7.9 below. Open both doors so that you can easily access the
starter system accumulator (1) and the hydraulic reservoir (3).
Figure 7.8 Hydraulic starter system accumulator

3.
Ensure the hydraulic start system is relieved of all pressure, check the START PRESSURE
gauge.

Page 61 of 150
Revision A
7.10 Check/fill hydraulic oil
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.
If necessary, depressurize the start system accumulator by opening both the oil reservoir
isolation valve (4) and the accumulator isolation valve (2) on the opposite door. Figure 7.8
shows the accumulator isolation valve in CLOSED position.
correct oil level
7
5
7
6
4
Figure 7.9 Hydraulic start system oil reservoir
5.
Then either activate the starter circuit by pushing the start button or slowly open the start
system drain valve (6) on the hand pump (5) by turning it counter-clockwise until all pressure
has been relieved.
NOTE: If choosing to relieve pressure by activating starter circuit, make sure the engine cannot
actually start by pushing in the EMERGENCY STOP button.
6.
Once pressure is relieved, immediately close the start system drain valve (6) by turning it
clockwise all the way to the stop.
7.
Inspect the oil level sight glasses (7). The hydraulic oil level should be in the middle of the
top sight glass.
Page 62 of 150
Revision A

7.10.2 Fill hydraulic tank

If the oil level is below the correct level, proceed as follows:
Leave the oil reservoir isolation valve and the accumulator isolation valve open.
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
1.
Carefully remove accumulated dust and grit from around the filler neck using a clean cloth.
2.
Refer to Figure 7.9. Remove the hydraulic oil tank filler cap (8).
3.
Use only hydraulic oil from a clean container. Freshly opened, original plastic hydraulic oil
bottles are much cleaner than larger steel drums. Use a filtering device when filling the tank
with oil from a steel drum.
4.
Add hydraulic oil of the correct grade (viscosity grade 46 or 68) until the oil level is in the
middle of the top sight glass. See Appendix 3: Lubricants on page 135.
TXT-10004386/A1
EQUIPMENT DAMAGE
5.
Clean off the filler cap, and refit it to the tank.
6.
Charge the start system if required, according to 6.5 Charge hydraulic starter
accumulator on page 43.
CAUTION
TXT-10004376/A
7.
Remove all tools and materials from the work area.
WARNING
TXT-10004270/A
CRUSH HAZARD
8.
Close all doors.

Page 63 of 150
Revision A
CAUTION
7.11
Check/fill fuel pump gear drive oil

See Figure 7.10. The engines fuel pump (2) is a gear-type pump, and is driven by a gear drive
(1) connected to the PTO at the rear of the auxiliary compressor. The reservoir has a filler cap (3)
on top and drain port (4) on the bottom, but no dipstick. Checking the level requires a special
procedure.
The gear drive has a closed oil supply circuit and is factory filled with 100cc (100 ml or 3.4 oz.) of
Mobil Mobilgear SHC XMP 150tm oil. Refer to the Appendix 3: Lubricants on page 135 for the
recommended gearbox oil types.
Related topics:
7.11 Check/fill fuel pump gear drive oil
7.11.1 Check the gear drive oil level:

1.
2.
Open the right AirPack C door to access the fuel pump (2) and gear drive (1). See
Figure 7.10.
3.
If the engine has been running, wait a few minutes for the oil to settle.
4.
Obtain a clean, small container marked with ccs or ml to collect the gear drive oil.
3
2
1
4
Figure 7.10 Fuel pump and gear drive
Page 64 of 150
Revision A

5.
Unscrew the filler cap (3).
6.
Place the small container under the drain port (4) and use a 6mm hex key to unscrew the
drain plug.
NOTE: For unit 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.
7.11.2 Fill gear drive oil

1.
Replace the drain plug.
2.
Carefully pour the 100cc of oil from the container into the filler opening.
CAUTION
TXT-10004386/A1
3.
Replace the oil filler cap and tighten it.
7.11.3 Finalize
1.
Ensure that the filler cap is screwed securely into place.
2.
CAUTION
TXT-10004376/A
3.
WARNING
TXT-10004270/A
CRUSH HAZARD
4.

Page 65 of 150
Revision A
7.11 Check/fill fuel pump gear drive oil
EQUIPMENT DAMAGE
7.12
Check/replace hoses and couplings

Inspect the system as described below, noting which components need to be repaired, replaced
or tightened. Make a list of all required repairs, and perform these once the inspection is
complete.
Related topics:
6.2 Power up on page 35
1.
2.
Inspect the general condition of all engine oil, fuel, hydraulic, and pneumatic lines and hoses.
Look for visible damage, leakage, and sweating or swelling of hoses. Generally the hoses
can be categorized as follows:
7.12 Check/replace hoses and couplings
Fuel and engine oil system hoses are black and are labelled beginning with 1XX
Pneumatic hoses are typically blue and are labelled beginning with 2XX
Hydraulic hoses are black and are labelled beginning with 3XX
Exceptions are the special hoses for the pressure gauges, these may be black or blue, and
are labelled 7XX.
NOTE: Any exposed steel strands will rust and weaken, creating a potentially dangerous
situation.
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:
Wear appropriate personal protective equipment (PPE).
3.
Inspect the entire unit for signs of leakage, such as audible hiss (pneumatic), loss of
pressure, oil drips, oily dust build-up, etc., around the following:
Hydraulic tank/ reservoir
Hoses and lines
Couplings/connectors
Valve
Isolators
Filters
Hand pump
Air/ oil pump
Starter motor
Page 66 of 150
Revision A

WARNING
TXT-10004317/A
HIGH PRESSURE
Disconnecting a pressurized line can cause serious injury and or equipment damage.
Ensure that the hydraulic accumulator is pressure free and the accumulator isolation valve is
closed before loosening or removing hydraulic hoses.
4.
Replace/repair components as necessary.
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
5.
After making repairs, test the different systems by starting up the unit according to 6.2 Power
up on page 35 and recheck for signs of leaks.
TXT-10004376/A
6.

Page 67 of 150
Revision A
7.12 Check/replace hoses and couplings
CAUTION
7.13
Check shock absorbers

Related topics:
Appendix 5: ASEP Elmar tightening conventions on page 139
1.
2.
Open the doors so that you can easily access the engine shock absorbers.
3.
Check the four shock absorbers at each corner of the engine assembly. See Figure 7.11.
7.13 Check shock absorbers
5
4
1
5
2
Figure 7.11 Engine shock absorbers

4.
Pay special attention for worn rubber or loose mountings; each shock absorber consists of
an upper (1) and lower (2) part and that joined by a vulcanized rubber block. There must be
no metal contact between (1) and (2).
NOTE: Have any damaged or worn shock absorber replaced by a qualified mechanic!
5.
Check the mounting bolts (3) and (4) for tightness. Bolt (3) can be tightened through access
hole (5).
Page 68 of 150
Revision A

NOTE: There is one each of bolt (3) and two each of bolt (4) for each shock absorber.
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.
Tighten any loose mounting bolts;
7.
For correct torque values, see Appendix 5: ASEP Elmar tightening conventions on page 139
WARNING
TXT-10004270/A
CRUSH HAZARD
8.

7.13 Check shock absorbers

Page 69 of 150
Revision A
7.14
Clean engine air inlet valve

The air inlet valve is a critical part of the engine safety system.
For effective operation it must be serviced regularly.
Related topics:
7.14 Clean engine air inlet valve

1.
Shut the unit down for safe maintenance, as described in section 6.3 Normal shut
down on page 42.
2.
Open the top of the AirPack C so that you can easily access the air inlet valve (1). See
Figure 7.12.
Bowden cable
bracket
Figure 7.12 Air inlet valve (roof removed for clarity)

3.
Loosen the hose clamp (2) on the engine intake hose (3).
4.
Carefully remove the hose from the air inlet valve an push it out of the way.
5.
Locate where the Bowden cable from the AIR INLET VALVE handle on the control panel is
connected to the air inlet valve.
6.
Refer to Figure 7.13 below. Remove the two screws (4) attaching the Bowden cable bracket
(5) to the air inlet valve.
NOTE: Be sure not to loosen the adjustment nuts (6) holding the Bowden cable in the bracket
or the correct cable adjustment needed for shutdown may be lost.
Page 70 of 150
Revision A

WARNING
TXT-10004285/A
DANGEROUS MACHINERY
equipment damage.
5
4
8
Figure 7.13 Air inlet valve Bowden cable connection

7.
Push the clamp of the clevis pin (7) from the Bowden cable clevis (8).
8.
Remove the clevis pin from the clevis and the air inlet valves control lever (9).
9.
Refer to Figure 7.14 below. Place a rag under the oil line coupling (10) to catch any oil.
11
10
Figure 7.14 Oil line connection

10. Disconnect the oil line coupling.

Page 71 of 150
Revision A
11. Remove the four attachment bolts (11) to the intake manifold pipe.
12. Carefully remove the air inlet valve from the engine, taking care not to damage the gasket.
13. Place a clean temporary cover over the intake manifold pipe, to protect the engine from dirt
and debris.
14. Inspect the inside of the valve for cleanliness. See Figure 7.15 below.
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.
15. If necessary, clean the inside of the valve using a clean rag.
16. Where required, apply a small amount of copper grease to the spring of the air inlet valve as
shown at (12).
12
12
12
copper grease
Figure 7.15 Air inlet valve inside view

17. Check the closing action of the valve over its full stroke.
18. Check all moving parts for wear or damage.
19. Remove the temporary cover from the intake manifold pipe.
20. Inspect the air inlet valve gasket, and replace if necessary.
21. Reposition the air inlet valve, and refit the four attachment bolts to the intake manifold pipe.
Take care not to damage the gasket.
Page 72 of 150
Revision 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.
22. Tighten each bolt in sequence so as not to create any gaps between valve and air inlet pipe.
NOTE: For correct torque values, see Appendix 5: ASEP Elmar tightening
conventions on page 139.
23. Refit the Bowden cable bracket with the 2 screws.
24. Align the cable clevis with the control lever on the air intake valve.
25. Refit the clevis pin and secure the pins clamp to the clevis.
26. Reconnect the oil line coupling.
27. Refit the intake hose to the air inlet valve.
28. Reposition the hose clamp and tighten it.
TXT-10004376/A
CAUTION
TXT-10004370/A
EQUIPMENT DAMAGE
If the fuel tank is filled with non-approved diesel, this will damage the pump, injectors and other
critical components of the engine, which will result in expensive repairs.
Only fill the fuel tank with EN590:2009 approved diesel.

31. Test the engine for correct operation by performing 6.2 Power up on page 35 and
6.3 Normal shut down on page 42.

Page 73 of 150
Revision A
CAUTION
7.15
Clean auxiliary pneumatic system filter

The auxiliary pneumatic system filter removes solid particles and moisture from the incoming
compressed air.
Related topics:
WARNING
TXT-10004269/A
HIGH PRESSURE
Refer to Figure and Figure 7.17 below.
7.15 Clean auxiliary pneumatic system filter
Figure 7.16 Auxiliary compressed air filter

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 turning the drain (5) outlet counter-clockwise.
Page 74 of 150
Revision A

2
2
1
4
3
6
5
1.
WARNING
TXT-10004254/A
COMPRESSED AIR
Never open a pressurized container without first releasing all pressure from the container.
To open a pressurized container safely:

2.
Shut off the nearest valve on the supply side of the container.
3.
Release all pressure from the container, either by operating the control or appliance, or by
gradually opening a filler cap on the container allowing pressure to gradually escape.
4.
Then with eyes protected or at a safe distance from the container, carefully remove the filler
cap completely.
5.
Bleed off all pressure from the compressed air system by pushing in the EMERGENCY STOP
button; air will slowly bleed off. Verify that the pressure is completely relieved by checking
the CONTROL PRESSURE gauge.
6.
Remove the bowl (1), complete with O-ring, from the head (2) by turning it a quarter-turn and
moving it downwards.
NOTE: The water drain assembly located in the bowl also consists of an internal floater which
must be handled very carefully.
7.
Remove the filter element, which is mounted below the head, by carefully unscrewing the
baffle (3) at the bottom of the filter assembly.
8.
Clean the filter components, replacing any that are damaged or excessively contaminated:

Page 75 of 150
Revision A
Figure 7.17 Air filter in detail
9.
Wash the element in soapy water, and rinse it off.
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.
10. Blow-dry it with a compressed air pistol.

Make sure all contamination is removed. If necessary, replace the element.
11. Remove and clean the filter bowl O-ring seal.
12. Clean the filter bowl and sight glass (4) inside and outside with soapy water, and wipe it dry
with a clean rag.
13. Clean the water drain (5) and ribbed plastic nut (6) the same way.
14. Using a clean rag, remove all dust and dirt from the head.
15. Fit the filter element over the central rod, and gently hand-tighten the baffle.
16. Mount the bowl to the filter unit using a cleaned or replacement O-ring, and tighten it a
quarter-turn.
Position the bowl such that the sight glass can easily be inspected at any time.
CAUTION
TXT-10004376/A
Page 76 of 150
Revision A

7.16
Clean fuel coarse particle filter

Related topics:
7.28 Prime diesel engine on page 102
Figure 7.18 Fuel tank isolation valve and coarse filter

1.
2.
Close the diesel tank isolation valve (1). Valve is shown in open position.
3.
Place a small container underneath the coarse filter (2).
4.
Unscrew the blind cap (3) and remove the filter mesh(4). Take care not to damage the gasket
on the blind cap.
5.
Place the filter in a container and clean with diesel.
6.
Refit the cleaned filter mesh, and tighten the blind cap.
7.
Open the fuel tank isolation valve.
8.
Prime the diesel system by performing 7.28 Prime diesel engine on page 102.
9.
Use a rag to clean any spilled fuel.
CAUTION
TXT-10004376/A

Page 77 of 150
Revision A
7.16 Clean fuel coarse particle filter
7.17
Clean air dryer filter (air starter)

This part is only present on units with an air starter.
Related topics:
7 Rig air in connector on page 14
1.
Shut the unit down for safe maintenance. See 6.3 Normal shut down on page 42.
2.
Open the left door to access the air starter filter. See Figure 7.19.
The level of captured moisture is visible in the sight glass (3) 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 turning the drain (4) outlet counter-clockwise.
7.17 Clean air dryer filter (air starter)
3
1
Figure 7.19 Air starter filter assembly
WARNING
TXT-10004254/A
COMPRESSED AIR
Never open a pressurized container without first releasing all pressure from the container.
To open a pressurized container safely:

Shut off the nearest valve on the supply side of the container.
Release all pressure from the container, either by operating the control or appliance, or by
gradually opening a filler cap on the container allowing pressure to gradually escape.
Page 78 of 150
Revision A

Then with eyes protected or at a safe distance from the container, carefully remove the filler
cap completely.
3.
Bleed off all pressure from the rig air system by shutting off the rig air supply; then close the
rig air inlet valve. Refer to 7 Rig air in connector on page 14
4.
Disconnect the supply hose from the rig air inlet coupling, and slowly open the rig air inlet
valve. Verify that the pressure is completely relieved by checking the START PRESSURE
gauge.
5.
Remove the bowl (1), complete with O-ring, from the head (2) by turning it counter-clockwise
a half-turn and moving it downwards.
NOTE: The water drain assembly located in the bowl also consists of an internal floater which
must be handled very carefully.
Once bowl is removed, the internal filter element (5) is visible. Remove the filter element,
which is mounted below the head, by carefully unscrewing the baffle (6) at the bottom of the
filter assembly.
7.
Clean the filter components, replacing any that are damaged.
8.
Wash the element in soapy water, and rinse it off.
WARNING
TXT-10004256/A
COMPRESSED AIR
9.
Blow-dry it with a compressed air pistol.

Make sure all contamination is removed. If necessary, replace the element.
10. Remove and clean the filter bowl O-ring seal.

11. Clean the filter bowl and sight glass (4) inside and outside with soapy water, and wipe it dry
with a clean rag.
12. Clean the water drain (5) and ribbed plastic nut (6) the same way.
13. Using a clean rag, remove all dust and dirt from the head.
14. Fit the filter element over the central rod, and gently hand-tighten the baffle.
15. Mount the bowl to the filter unit using a cleaned or replacement O-ring, and tighten it a halfturn.
Position the bowl such that the sight glass can easily be inspected at any time.
CAUTION
TXT-10004376/A

Page 79 of 150
Revision A
7.17 Clean air dryer filter (air starter)
6.
7.18
Clean main compressor air dryer

The compressor air dryer filter is a cyclone-type filter which effectively removes the majority of the
water from the main compressors air supply.
It will require routine maintenance to remove water and oily sludge build-up.
1.
2.
Open the appropriate panel(s).
3.
Locate the air dryer filter on the AirPack C. See Figure 7.20.
WARNING
TXT-10004255/A
COMPRESSED AIR
the connection.
7.18 Clean main compressor air dryer

4.
1
3
Figure 7.20 Air cyclone filter
Page 80 of 150
Revision A

5.
Confirm that pressure is completely relieved by checking the AIR PRESSURE gauge.
6.
Unscrew the air dryer filter bowl (2) from the filter head (1).
7.
Carefully clean the filter bowl with soapy water, do not use a chemical cleaner!
NOTE: Take care not to damage or lose the o-ring seals for the bowl.
8.
Dry out the bowl and ensure the o-rings (3) are correctly installed; replace if necessary.
9.
Refit the bowl to the filter head.
10. Test the connection by starting up the AirPack C according to 6.2 Power up on page 35.
11. Correct any leaks by performing steps 4 to 10.
CAUTION
TXT-10004376/A
WARNING
TXT-10004270/A
CRUSH HAZARD

Page 81 of 150
Revision A
7.18 Clean main compressor air dryer
7.19
Clean spark arrestor

This procedure describes how to empty soot and debris that has collected in the cleaning point
of the spark arrester/muffler.
7.19 Clean spark arrestor
Figure 7.21 Spark arrestor/muffler

1.
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.
Ensure that the exhaust system has cooled down.
3.
See Figure 7.21. 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 AirPack C.
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.
Remove the hex plug from the spark arrester cleaning point.
The soot and debris will fall out of the spark arrester.
5.
Screw the plug back in.
Page 82 of 150
Revision A

6.
Use a rag to clean the area around the spark arrester/muffler.
CAUTION
TXT-10004376/A
7.
7.19 Clean spark arrestor

Page 83 of 150
Revision A
7.20
Clean/replace compressor intake air filter

Related topics:
7.20 Clean/replace compressor intake air filter
7.4 Periodic maintenance schedules on page 47

1.
Shut the unit down for safe maintenance, as described in section 6.3 Normal shut
down on page 42.
2.
Open the left side door.
3.
Locate the air intake filter assembly (1). See Figure 7.22.
Figure 7.22 Compressor air intake filter location

4.
Loosen the four securing clips (2), and remove the cover.
5.
See Figure 7.23. Remove the filter element (3) and inspect for damage.
Figure 7.23 Air intake filter cover and element
Page 84 of 150
Revision A

WARNING
TXT-10004256/A
COMPRESSED AIR
6.
Element can be cleaned with low pressure compressed air by carefully blowing from the
inside outwards.
7.
If the element is damaged or too dirty to clean effectively it must be replaced. Replace also
if change interval is surpassed. Refer to the 7.4 Periodic maintenance schedules on page 47
for replacement intervals.
8.
See Figure 7.24. Inspect the inside of the filter housing and thoroughly clean it out, taking
care not to get any dirt particles in the compressor intake (4).
7.20 Clean/replace compressor intake air filter
Figure 7.24 inside filter housing

9.
Refit the filter element, and clean the cover before refitting it.
10. Refit the cover, and attach the securing clips.
CAUTION
TXT-10004376/A
WARNING
TXT-10004270/A
CRUSH HAZARD
12. Close the doors you opened.

Page 85 of 150
Revision A
7.21
Clean/replace crankcase breather flame trap

1.
Locate the crankcase flame trap (1). See Figure 7.25.
7.21 Clean/replace crankcase breather flame trap
Figure 7.25 Location of crankcase breather flame trap
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.
See Figure 7.26. Remove the flame trap mesh element assembly (4) from the flame trap
housing (5) by pressing together the two wire strands of the retaining clip (3).
Figure 7.26 Crankcase flame trap and mesh assembly
Page 86 of 150
Revision A

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.
3.
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.
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.
Use a clean rag to clean the inside of the housing.
5.
Place a temporary cover over the flame trap housing, so that no dirt or objects can get into
the breather inlet.
6.
Place the flame trap in a suitable container and clean with diesel, or replace it with a new one.
7.
Remove the temporary cover from the housing.
8.
Place the cleaned (or new replacement) flame trap in the housing.
CAUTION
TXT-10004376/A
9.

Page 87 of 150
Revision A
7.21 Clean/replace crankcase breather flame trap
4.
7.22
Clean/replace engine air filter

1.
2.
Open the left side access door.
3.
Locate the filter restriction indicator (1)

on the engine intake air filter. See
Figure 7.27.
7.22 Clean/replace engine air filter
Figure 7.27 Filter restriction indicator

4.
If the indicator is in the red the filter is dirty and needs to be cleaned or elements replaced.
2
5
Figure 7.28 Air intake filter assembly

5.
See Figure 7.28. Loosen the three securing clips (2), and remove the cover (3).
6.
Remove the primary (outer) filter element (4).
7.
Clean or replace the primary filter element where necessary. Filter can be cleaned from the
inside out using low pressure compressed air. Replace filter if damaged or extremely dirty.
8.
Remove the safety (inner) filter element (4).
Page 88 of 150
Revision A

NOTE: Never attempt to clean the safety filter, it can only be replaced; normally once every 3
changes of the primary filter.
9.
Clean the inside of the filter housing and the cover. Take care not to get dirt or dust inside
the air intake to the engine.
10. Refit or replace the safety element.

11. Refit the primary element.
12. Refit the cover, and fasten the securing clips.
13. Reset the filter restriction indicator by pressing the top until the red part pops up.
CAUTION
TXT-10004376/A
7.22 Clean/replace engine air filter

Page 89 of 150
Revision A
7.23
Clean/replace fuel tank breather
1
7.23 Clean/replace fuel tank breather
Figure 7.29 Fuel tank breather

1.
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.
Open right side door to access the fuel tank (1) and breather (2).
3.
Use a spanner to unscrew the breather mesh (3) from the breather tube.
Be careful not to damage the mesh with the spanner. If the mesh is damaged when
removing, it must be replaced.
4.
Clean the mesh with diesel fuel.
WARNING
TXT-10004256/A
COMPRESSED AIR
5.
Blow it off with compressed air.
6.
Refit the cleaned mesh to the breather.
CAUTION
TXT-10004376/A
7.
Page 90 of 150
Revision A

7.24
Drain/fill engine coolant

This procedure describes how to drain the cooling system from the drain point below the engines
crankshaft pulley, 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, the excess will run out of the overflow valve during
operations.
Related topics:
7.7 Check/fill engine coolant on page 53
7.24.1 Drain coolant

1.
Make sure the unit has been shut down for safe maintenance, as described in 6.3 Normal
2.
Wait for the coolant to cool down.

TXT-10004340/A
3.
Open the coolant filling point access hatch (1) at the top of the AirPack C, and remove the
filler cap (2). See Figure 7.30.
This will allow air to escape from during draining and refilling of the cooling system.
Figure 7.30 Coolant fill hatch and radiator filling point

Page 91 of 150
Revision A
7.24 Drain/fill engine coolant
WARNING
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.
Figure 7.31 Coolant drain valve
WARNING
TXT-10004336/A
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.
4.
Locate the coolant drain valve below the engine crankshaft pulley.
5.
Remove the blind cap (3), and connect a flexible hose to the drain valve.
6.
Place the other end of the flexible hose in a suitable container.
7.
Open the drain valve (4). Figure 7.31 shows drain valve in closed position.
8.
Wait until the coolant has drained from the cooling system, and then close the drain valve.
9.
Remove the flexible hose and container.
10. Replace the cap on the drain valve.

11. 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
12. Dispose of the old coolant according to local environmental regulations.
7.24.2 Refill/bleed coolant

Perform the following procedure only if the coolant has been drained from the system. For just
topping up the coolant level see: 7.7 Check/fill engine coolant on page 53.
Page 92 of 150
Revision A

This procedure should avoid introducing excessive air into the coolant system making it easier to
bleed and ensure proper coolant circulation.
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.
1.
Remove the coolant filler cap at the top of the radiator. See Figure 7.30.
Figure 7.32 Air bleed-point for cooling system

2.
Refer to Figure 7.32. 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.
Open the air bleed valve using the special square key (part of the free spares kit).
5.
Remove the blind cap on the drain valve.
6.
Connect a hand pump from the coolant container to the drain valve.
7.
Open the drain valve.
8.
Slowly pump coolant into the system, until it comes out air-free from the bleed valve.
9.
Close the air bleed valve.
10. Close the drain valve.

11. Remove the pump, and replace the blind cap.
12. Finish topping up the coolant as described in 7.7 Check/fill engine coolant on page 53.
13. Place a clean rag loosely over the open coolant filling point to keep coolant from splashing.

Page 93 of 150
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WARNING
TXT-10004282/A
DANGEROUS MACHINERY
WARNING
TXT-10004358/A
NOISE HAZARD
14. Start the AirPack C (see 6.2 Power up on page 35), and run the engine for five minutes to
circulate the coolant thoroughly.
15. Open the air bleed valve (5) once more to bleed off any remaining air and close when pure
coolant comes out.
16. Shut down the unit for safe maintenance, as described in 6.3 Normal shut down on page 42.
7.24.3 Check coolant system for leaks
WARNING
TXT-10004358/A
NOISE HAZARD
1.
Start the AirPack C and run the engine.
2.
Wait until the engine is warm and the coolant is thoroughly circulated.
3.
Inspect all hoses, hose connections, flanges, and fill/drain points for leaks.
4.
If leaks are found:

a) Shut down the unit for safe maintenance, as described in 6.3 Normal shut
down on page 42.
b) Repair the leaks.
c) Top up the system as described in 7.7 Check/fill engine coolant on page 53.
d) If applicable, bleed the system as described in section 7.24.2.
7.24.4 Finalize
1.
Use clean rags to clean any spilled coolant.
CAUTION
TXT-10004376/A
2.
Page 94 of 150
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WARNING
TXT-10004270/A
CRUSH HAZARD
3.

Page 95 of 150
Revision A
7.25
Drain fuel tank

NOTE: This procedure requires a hand-pump with a clean, flexible hose attached.
Make sure the unit has been shut down for safe maintenance, as described in 6.3 Normal
2.
Locate the fuel filler cap in the fuel tank of the AirPack C. See Figure 7.33.
7.25 Drain fuel tank
1.
Figure 7.33 Fuel filler cap and level gauge
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.
3.
Carefully remove the diesel filler cap at the top of the tank.
4.
Place one end of a clean flexible hose in the fuel tank and make sure the hose is fed far
enough into the tank to reach the bottom of the tank.
5.
Place the other end of the flexible hose in a container large enough to contain the fuel
remaining in the fuel tank.
6.
Siphon or pump the fuel through the hose into the container.
7.
Wait until the fuel is siphoned as much as possible from the fuel tank.
8.
Remove the flexible hose and container.
9.
See Figure 7.34. Locate the fuel tank threaded drain plug (1) on the side of the tank, and
remove it.
Page 96 of 150
Revision A

2
Figure 7.34 Drain plug location
NOTE: Take care to collect any dripped fuel with absorbent cleaning rags
11. Using a crane or by levering in the forklift slots, tilt the unit gently to the rear and the right,
until the last of the fuel drips from the drain hole.
12. Replace the drain plugs.
13. Replace the fuel filler cap.
14. Use a cleaning rag to clean any spilled fuel.
CAUTION
TXT-10004376/A
WARNING
TXT-10004270/A
CRUSH HAZARD
16. Close any access panels you opened.

Page 97 of 150
Revision A
7.25 Drain fuel tank
10. Remove the units drain plug (2).
7.26
Drain fuel/water separator

The fuel/ water separator is installed to remove the initial contamination, including water, before
it gets to the fuel pump and other critical components.
7.26 Drain fuel/water separator
4
Figure 7.35 Diesel prefilter with fuel/ water separator
1.
2.
Open the left side door of the unit.
3.
You can observe the water/ contamination through the sight glass (2).
4.
Place a small container underneath the bowl (3) of the of the fuel/ water separator (1).
5.
Drain the water by loosening the drain plug (4) at the bottom of the bowl.
6.
Wait until the water/ contamination is completely drained.
7.
Retighten the drain plug once clean fuel starts draining.
8.
Perform 7.28.1 Quick prime on page 102 to refill the fuel/ water separator and purge the fuel
system of air.
9.
Remove the container.
10. Clean any moisture from around the fuel/ water separator.
CAUTION
TXT-10004376/A
Page 98 of 150
Revision A

WARNING
TXT-10004270/A
CRUSH HAZARD
12. Close the doors.
7.26 Drain fuel/water separator

Page 99 of 150
Revision A
7.27
Drain water from hydraulic tank

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. When the unit has been
idle for more than a few days the water will separate out. Being heavier than the hydraulic oil, it
settles to the bottom of the tank, and can be drained.
Related topics:
7.10 Check/fill hydraulic oil on page 61
7.27 Drain water from hydraulic tank
1.
Ensure that the unit is shut down, and has not run for a few days.
2
4
3
Figure 7.36 Hydraulic oil tank valves

2.
Open the right side access door, and locate the hydraulic tank (1) for the start system
hanging on the door.
3.
Ensure that the drain valve (2) is closed. Figure 7.36 shows drain valve in CLOSED position.
4.
Unscrew the blind cap (3).
5.
Attach a piece of clear plastic hose to the drain valve.
6.
Put the other end in a suitable container.
7.
Slowly open the drain valve, and allow the water to run into the container.
8.
When pure oil starts to flow, close the valve.
9.
Remove the hose, and replace the cap.
10. Ensure the coarse filter isolation valve (4) is open before starting unit. Figure 7.36 shows
filter isolation valve in open position.
Page 100 of 150

Revision A

11. Check the oil level and replenish if necessary by performing 7.10 Check/fill hydraulic
oil on page 61.
CAUTION
TXT-10004376/A
to local environmental regulations.If necessary, depressurize the start system accumulator
by opening both the oil reservoir isolation valve (4) and the accumulator isolation valve (2)
on the opposite door. Figure 7.36 shows the accumulator isolation valve in CLOSED
position.
7.27 Drain water from hydraulic tank

Page 101 of 150

Revision A
7.28
Prime diesel engine

The Caterpillar 3054C-DINA, 4-cylinder diesel engine, naturally apirated will require priming after
every fuel filter change and occasionally if water has been drained from fuel/ water separator, and
if the fuel tank has run dry. There are two ways to prime the fuel system; always try the quick
prime (7.28.1) method first. If this is not successful, prime the entire system (7.28.2).
Related topics:
7.28.1 Quick prime
7.28 Prime diesel engine
4
3
Figure 7.37 Fuel system components.
1.
Page 102 of 150

Revision A

2.
Open the left door on the AirPack C and locate the engine fuel components. Ensure that the
fuel isolation valve (2) above the fuel tank (3) is open. Figure 7.37 shows the fuel isolation
valve in the open position.
3.
On the control panel, turn the control lever on the ENGINE SAFETY valve (4) clockwise against
the spring pressure until it catches.
This will reset the fuel safety system and allow fuel to flow.
4.
Open the red bleed screw (5) on the fuel/water separator.
5.
Place rags or a small container under the fuel/water separator to catch the fuel.
6.
Pump the engine fuel primer (1) several times to fill the fuel/water separator.
7.
Close the bleed screw once air-free fuel comes out.
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
WARNING
TXT-10004358/A
NOISE HAZARD
13. Start the engine as described in 6.2 Power up on page 35.

14. It may take a few attempts.
7.28.2 Prime entire system

If the above steps are not sufficient in allowing the engine to start, it may be necessary to also
purge the high-pressure fuel lines.
In this case follow the below steps after performing 7.28.1 Quick prime.
NOTE: These steps must always be taken if any maintenance work has been performed on the
high-pressure fuel circuit; i.e. the fuel injector pump, the high-pressure fuel lines or the
fuel injectors.

Page 103 of 150

Revision A
NOTE: Do not over-tighten the banjo connector; the aluminum filter head may become
damaged.
1.
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.
This will supply fuel to the fuel injector pump.
10
9
7
8
Figure 7.38 Left: Fuel line cover; Right: View of fuel injectors with cover removed
4.
Loosen the three screws (10) and remove the plastic cover (7) next to the engines valve
cover. This will provide access to the injectors, the injector line coupling nuts (8) and the highpressure fuel injector lines (9).
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.
Place rags around the coupling nuts to catch fuel.
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:
Wear appropriate personal protective equipment (PPE).
For spring starter equipped engines go to step 11.

For hydraulic and air starter equipped engines proceed as follows:
NOTE: Ensure the accumulator or air supply are sufficiently charged between start attempts.
7.
Attempt to start the engine according to 6.2 Power up on page 35, 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.
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Revision A

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 to 8 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 wind up the starter completely.
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 to 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.
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 6.2 Power up on page 35.
19. Start engine and allow it to run for a short time and monitor it for indication of rough running.
20. If necessary, repeat above steps 11 to 19 until engine runs smoothly. This will ensure that
all injectors are sufficiently bled.
7.28.3 Finalize
1.
Clean any spilled fuel from around the engine.
CAUTION
TXT-10004376/A
2.

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Revision A
17. Repeat steps 14 to 16 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.
7.29
Replace air-oil separator filter (compressor)

For detailed description, see the supplier documentation for the compressor in the AirPack C
Documentation Package for further details.
Related topics:
1.
2.
Open the appropriate doors.
WARNING
TXT-10004255/A
7.29 Replace air-oil separator filter (compressor)
COMPRESSED AIR
the connection.

3.
4.
Confirm that pressure is completely relieved by viewing the AIR PRESSURE gauge.
5.
See Figure 7.39. Locate the air-oil separator filter (1) on the right side of the compressor of
the AirPack C.
1
1
Figure 7.39 Air-oil separator filters
Page 106 of 150

Revision A

6.
Unscrew the air-oil separator filter as a complete unit and discard.
7.
Apply a thin film of compressor oil or engine oil to the o-ring on the new filter.
8.
Firmly screw the new filter onto the filter body by hand. Do not use tools to tighten!
CAUTION
TXT-10004376/A
9.
TXT-10004270/A

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Revision A
7.29 Replace air-oil separator filter (compressor)
WARNING
CRUSH HAZARD
7.30
Change compressor oil and filter

See the supplier documentation for the compressor in the AirPack C Documentation Package for
further details.
The compressor was filled with approx. 25 l (6.6 US Gal) of Mobil Rarus 426 compressor oil at
the factory. Always use the same type oil as specified in the Appendix 3: Lubricants on page 135.
Related topics:
7.6.2 Fill compressor oil on page 52
7.30 Change compressor oil and filter
7.30.1 Change compressor oil filter

1.
2.
Open the appropriate doors and panels.
WARNING
TXT-10004255/A
COMPRESSED AIR
the connection.

3.
4.
Verify that the air pressure is completely released by checking the AIR PRESSURE gauge.
5.
See Figure 7.40. Locate the oil filter (1) on the right side of the compressor.
Page 108 of 150

Revision A

6.
Unscrew the oil filter element completely.
NOTE: The old filter is full of oil, take care not to spill any.
7.
Apply a thin film of fresh oil onto the replacement filters rubber seal.
8.
Holding the filter vertically, fill it with the same oil used to fill the compressor sump.
9.
Firmly screw the new filter onto the filter body by hand.
10. If oil only needs topping up, proceed to the next steps otherwise skip to 7.30.2 Change
compressor oil below.
11. Switch on the system according to 6.2 Power up on page 35.
12. The oil filter must then be checked for leaks with the system running.
13. Shut the unit down and check the oil level again; if necessary, top up according to 7.6.2 Fill
compressor oil on page 52.
7.30.2 Change compressor oil

For this procedure you may need to remove the rear protective grate from the unit to more easily
access the rear of the compressor.
1.
See Figure 7.41. Locate the drain plug (2) on the compressor.
2.
Place a suitable container under the drain port.
NOTE: The compressor sump contains about 25 l (6.6 US Gal) of oil. Be prepared to drain the
oil in steps depending on size of drain container.

Page 109 of 150

Revision A
Figure 7.40 Compressor oil filter
2
Figure 7.41 Compressor drain plug
3.
Using an 8mm hex key, remove the drain plug and collect the old oil.
4.
Once oil is completely drained, replace the plug and tighten securely.
5.
Refill the compressor according to 7.6.2 Fill compressor oil on page 52.
CAUTION
TXT-10004376/A
6.
WARNING
TXT-10004270/A
CRUSH HAZARD
7.
Page 110 of 150

Revision A

7.31
Change engine oil and filter

The engine has been factory filled with Mobil Delvac Super 1400 15W-40. Refer to
Appendix 3: Lubricants on page 135 for compatible oil types. Refer also to the Caterpillar
documentation included in the Documentation Package that came with your AirPack C for
detailed servicing instructions.
Related topics:
7.8.2 Fill engine oil on page 56
1.
2.
Open the left side door of the unit. See Figure 7.42.
3
7.31 Change engine oil and filter
3
4
1
5
2
Figure 7.42 Engine oil filter, drain pump and fill points (alternate fill points shown)
3.
Connect a hose to the drain tube (1).
4.
Place the other end of the hose in a suitable container.

Page 111 of 150

Revision A
NOTE: If no hose is available it may be possible to place a suitable container directly under the
drain tube.
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.
5.
Open the drain valve (2) (in-line with the tubing).
6.
Remove the oil filler cap (3). There are 2 oil fill points as shown in Figure 7.42. If the roof has
been removed for other maintenance purposes it may be easier to use the oil fill point on top
of the engine.
7.
Use the oil pump handle (4) to pump out the oil from the engine sump.
8.
Close the drain valve, and remove the hose if used.
9.
Place some rags underneath the engine oil filter (5).
7.31 Change engine oil and filter
10. Carefully unscrew and remove the engine oil filter taking care not to spill the spent oil.
11. Fill the new filter with fresh oil and lubricate the o-ring seal on the filter.
12. Fit the new filter into position and tighten by hand. Do not use tools to tighten the filter!
13. Clean the area around the oil filter, and remove the rags.
14. Refill the oil, and check the oil level. See 7.8.2 Fill engine oil on page 56.
15. Replace the filler cap.
16. Clean any spilled oil from the engine.
CAUTION
TXT-10004376/A
Page 112 of 150

Revision A

7.32
Replace fuel fine filter element

Related topics:
1.
2.
Open the left side door to access the fuel filters. See Figure 7.43.
7.32 Replace fuel fine filter element
Figure 7.43 Fuel fine particle filter

3.
Place some rags underneath the filter element (1).
4.
Unscrew and remove the filter element from the mounting head (2).
5.
Lubricate the top seal of the new filter element with clean diesel fuel.
6.
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!
7.
Purge the diesel system by performing section 7.28 Prime diesel engine on page 102.
8.
Check the fine particle filter for any leaks.
9.
Rectify any problems.

Page 113 of 150

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WARNING
TXT-10004282/A
DANGEROUS MACHINERY
WARNING
TXT-10004358/A
NOISE HAZARD
10. Start the unit as described in 6.2 Power up on page 35.

11. Check the system for correct operation, and recheck the fine particle filter for any leaks.
7.32 Replace fuel fine filter element
12. Rectify any problems.

13. Clean any excess diesel from around the filter/engine.
CAUTION
TXT-10004376/A
Page 114 of 150

Revision A

7.33
Replace fuel/water separator filter

Related topics:
7.26 Drain fuel/water separator on page 98
1.
2.
Open the left door to access the fuel filters.
7.33.1 Drain filter

1.
Drain the water and fuel by performing section 7.26 Drain fuel/water separator on page 98,
and continue until all fuel has drained out.
7.33 Replace fuel/water separator filter
3
4
Figure 7.44 Fuel tank isolation valve and fuel/ water separator
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.
7.33.2 Remove filter

1.
Loosen the securing screw(1) and unscrew it carefully while holding the filter element (2),
sight glass (3) and bowl (4) firmly to the mounting head (5) by hand.

Page 115 of 150

Revision A
2.
When securing screw is completely loose, carefully remove the filter components from the
head and pour any remaining fuel into a suitable waste container.
3.
Remove the bowl and glass from the filter element and discard the filter.
4.
Clean the bowl and glass.

NOTE: The bowl and glass are reusable, do not discard.
7.33 Replace fuel/water separator filter
7.33.3 Fit separator filter

1.
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.
Open the fuel tank isolation valve.
6.
Fill the fuel/water separator by performing 7.28 Prime diesel engine on page 102.
7.
Check filter assembly for leaks and refit if necessary.
8.
If possible start up the unit and monitor fuel system for leaks or problems, and correct if
necessary.
9.
Clean up any spilled fuel with rags and dispose of accordingly.
CAUTION
TXT-10004376/A
Page 116 of 150

Revision A

7.34
Replace hydraulic oil

If the hydraulic oil has become contaminated or is due to be replaced for servicing, the tank must
first be drained.
NOTE: Drain the tank also if required for special transport conditions.
Related topics:
7.10.1 Check hydraulic oil level on page 61
7.10.2 Fill hydraulic tank on page 63
1.
Make sure the unit has been shut down for safe maintenance. See 6.3 Normal shut
down on page 42.
2.
Open the right side access door, and locate the hydraulic tank (1) for the start system
hanging on the door. See Figure 7.45.
7.34 Replace hydraulic oil
2
3
Figure 7.45 Hydraulic oil tank valves

3.
Ensure the hydraulic system is relieved of pressure by first performing 7.10.1 Check
hydraulic oil level on page 61.
4.
Ensure that the drain valve (2) is closed. The drain valve is shown in closed position.
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.

Page 117 of 150

Revision A
CAUTION
TXT-10004383/A
EQUIPMENT DAMAGE
5.
Unscrew the valve cap (3).
6.
Attach a piece of clear plastic hose to the drain valve.
7.
Put the other end in container large enough to hold the hydraulic oil.
NOTE: If no hose is available, place the container or funnel directly under the drain.
8.
Slowly open the drain valve, and allow the oil to run into the container.
9.
When the tank is empty, close the valve.
7.34 Replace hydraulic oil
10. Remove the hose if used, and replace the cap.

11. Fill the tank with oil of the correct grade. See 7.10.2 Fill hydraulic tank on page 63.
CAUTION
TXT-10004376/A
Page 118 of 150

Revision A

7.35
Replace V-belts
This procedure describes how to replace the V-belts on the Caterpillar diesel engine.
WARNING
TXT-10004284/A
DANGEROUS MACHINERY
Using non-approved parts can cause personal and/or equipment damage.
Only use ASEP Elmar-approved parts. See the Spare Parts List, included in the
Documentation Package, for the correct part number.
The V-belts used to manufacture this unit have special, antistatic properties, and must not be
replaced by standard V-belts.
Related topics:
7.5 Check/adjust V-belts on page 49
1.
TXT-10004348/A
2.
Open the right side door. Refer to fig Figure 7.46 below.
5
1
3
2
4
Figure 7.46 V-belt protective guards and v-belt adjustment assembly

Page 119 of 150

Revision A
7.35 Replace V-belts
WARNING
MOVING PARTS
3.
Remove the right side belt guards, upper (1) and lower (2).
4.
Loosen the locknut on the adjustment plate securing bolt (4).
5.
Loosen the hinge locknut (5), and move the tensioner pulley assembly (3) inwards.
6.
See Figure 7.47. Remove the four securing bolts (6) attaching the fan shaft (7) to the idler
pulley (8).
8
6
7
Figure 7.47 Fan mounting detail

7.
Carefully remove the shaft and fan together as an assembly, taking care not to damage the
radiator or the fan blades.
8.
The idler pulley is also loose now; carefully remove first the outer V-belt, then the inner Vbelt without letting pulley fall away.
NOTE: Double V-belts (V-belts installed in pairs) should always be replaced in pairs, to avoid
premature wear and slippage.
9.
Install the new V-belts in reverse order, while holding the idler pulley in place and keeping
mounting holes aligned.
10. Reinstall the fan and shaft assembly, and tighten the connecting bolts. For torque specs, see
Appendix 5: ASEP Elmar tightening conventions on page 139.
11. Adjust the V-belt tension as described in 7.5 Check/adjust V-belts on page 49.
12. Replace the belt guards.
Page 120 of 150

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WARNING
TXT-10004270/A
CRUSH HAZARD

Page 121 of 150

Revision A
7.36
Test maximum engine speed (if applicable)

As part of the Lloyds certification, the maximum engine speed should be verified once a year.
NOTE: This test should only be performed when the engine is at full operating temperature.
Never run a cold engine at maximum speed, it could be damaged by doing so!
Related topics:
7.5 Check/adjust V-belts on page 49
1.
7.36 Test maximum engine speed (if applicable)
WARNING
TXT-10004348/A
MOVING PARTS
2.
Open the left side door to access the engine throttle. See Figure 7.48.
2
3
Figure 7.48 Engine throttle cylinder and linkage
3.
Locate the throttle cylinder (1).
4.
Loosen and remove the nuts (3) from the connecting ball joint (2), and lift it free of the throttle
linkage lever (4).
5.
Throttle lever can now be operated by hand.
Page 122 of 150

Revision A

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-10004282/A
DANGEROUS MACHINERY
Start the engine as described in 6.2 Power up on page 35.
7.
Allow engine to reach operating temperature.
8.
Use the throttle lever to slowly move the throttle to maximum RPM.
9.
Run the unit at maximum throttle settings for a few seconds only.
NOTE: The engine speed is factory preset and must not be set to a higher value.
10. Compare the maximum RPM reading to the value given in
Appendix 1: Specifications on page 131.
WARNING
TXT-10004285/A
DANGEROUS MACHINERY
equipment damage.
11. Notify maintenance personnel to make any necessary adjustments.

NOTE: Only qualified personnel familiar with NOV Elmar products shall make adjustments to the
throttle controls!

Page 123 of 150

Revision A
6.
Page 124 of 150

Revision A

TROUBLESHOOTING
8.1
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.
8.2
Troubleshooting tables
8.2.1
Engine and hydraulics
POSSIBLE CAUSE
SUGGESTED REMEDY
Engine stops
Fuel tank is empty
Fill fuel tank with diesel and restart

engine
Restriction in fuel line or failed fuel feed

circuit component
Inspect fuel feed circuit; remove

restriction or replace failed component
Engine exhaust is blocked
Remove obstruction from exhaust and

restart engine
Emergency stop button is pushed
Release emergency stop button and

restart engine
Air inlet valve is activated/ closed
Open air inlet valve and determine

cause of activation (overspeed,
temperature, oil pressure etc.)
In this case follow start-up procedure
as instructed in unit user manual.
NOTE: On applicable units the air inlet

valve may not open if start sequence is
not followed correctly
Diesel engine creates excessive noise

and vibration
Sentinel valve is tripped/ activated
Reset sentinel valve and determine

cause of activation (overspeed,
temperature, oil pressure etc.)
Worn or damaged shock mounts for

diesel engine
Replace faulty shock mounts
Engine damaged or otherwise worn out
Inspect further and consider engine

overhaul or replacement

Page 125 of 150

Revision A
8.1 Troubleshooting principles
DIESEL ENGINE PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Engine oil pressure too low
Engine oil level too low
Shut down engine immediately and

check oil level; replenish engine oil as
necessary
Leak in engine oil circuit
Locate leak and repair or replace

component; replenish engine oil before
restarting.
In zone 2 or rig safe equipped engine,

the engine safety monitoring circuit oil
pressure is viewed in the ENGINE OIL
PRESSURE gauge; Adjustable orifice
in this circuit may be closed or
damaged
Refer to user manual to locate engine

safety monitoring components and
open adjustable orifice slightly until oil
pressure returns; if necessary replace
orifice
Oil pump malfunction
Replace oil pump
Engine does not shut down at the preadjusted over speed setting
Incorrect setting of the over speed

controller (refer to user manual to
determine the type of overspeed
controller and manner of adjustment)
Adjust setting of the over speed

controller
Engine temperature too high
Coolant too low
Replenish coolant as necessary
Water-cooled exhaust manifold is

choked/ clogged
Refer to user manual section XXXX to

determine if manifold cooler can be
cleaned; if so proceed to decoke and
clean thoroughly. If not please contact
NOV ASEP Elmar for further
assistance.
8.2 Troubleshooting tables
DIESEL ENGINE PROBLEM
Cooling fan malfunction:

Units with belt driven radiator fan:
fan not turning
Check fan for physical blockage (snow,

dirt, debris etc.)
Tension the belts
Replace worn or broken belts
Replace fan assembly
Other engine problems
Page 126 of 150

Revision A
Leak in radiator or other cooling system

components
Locate leak and repair or replace

components
Coolant temperature gauge faulty
Replace gauge
Thermostat malfunction
Replace thermostat
Check the supplier documentation

SPRING STARTER PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Starter does not activate
Starter not wound up sufficiently
Wind the starter fully (normally to the

white or red stripe in view window; refer
to user manual instructions)
Starter is defective
Replace starter assembly if necessary
Starter is damaged/ defective
Check for damage to pinion gear
Starter activates but does not crank

engine
Check for proper meshing with flywheel

Repair or replace starter assembly if
necessary
Inspect flywheel and replace if
necessary
Engine is damaged
Try to turn engine by hand; if it is not

possible to perform or if engine cannot
be turned by hand, then have qualified
engine technician check for engine
damage
No air supply/ no start pressure
Check air supply, ensure rig air supply

hoses are connected and isolation
valves are open
Insufficient air supply: air pressure or

air flow too low
Refer to user manual for starter

requirement specifications, adjust air
supply as required
AIR STARTER PROBLEM

Starter does not turn engine/ does not
activate

engine

Engine flywheel is damaged


necessary
Page 127 of 150

Revision A
HYDRAULIC STARTER PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Starter does not activate
Accumulator isolation valve is closed
Open the isolation valve
Too little or no hydraulic start pressure
Check hydraulic start pressure and

recharge start system as required (refer
to user manual for instructions and
pressures)

engine
Repair or replace starter assembly if

necessary
Unable to charge hydraulic start system
Page 128 of 150

Revision A

necessary
Engine is damaged
Try to turn engine by hand; if it is not

possible to perform or if engine cannot
be turned by hand, then have qualified
engine technician check for engine
damage
Leak in hydraulic start charge circuit
Repair leaks
Air in hydraulic start charge circuit
Bleed circuit of all air (refer to user

manual)
Hydraulic accumulator has inadequate

nitrogen charge pressure
Have qualified technician check the

nitrogen pressure and recharge if
necessary (refer to accumulator
documentation for correct pressures)
Hydraulic accumulator is damaged/

defective
Replace accumulator

8.2.2
Auxiliary pneumatics table

The following table is for the auxiliary pneumatic system.
For troubleshooting the main compressor air system please refer to the Supplier documentation,
part of the AirPack C Documentation Package.
PNEUMATIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Air pressure too low
Leak in compressed air/ pneumatic

circuit
Check for air leaks, make repairs or

replace fittings/ hoses/ components.
Check condition of (quick) connectors
Check rig air source for adequate
supply for unit operations
Pressure regulator is out of adjustment
Check that pressure regulator is set

correctly, adjust if necessary
Pressure cut-off valve is out of

adjustment or faulty
Check cut-off valve and make

adjustments; replace if necessary
CAUTION: DO NOT SET PRESSURE
CUT-OFF HIGHER THAN 7.5 BAR!!
Compressor is defective
Repair/ Replace compressor
AIR PRESSURE gauge is defective
Replace gauge
Pressure sensor is defective
Replace compressed air pressure

sensor
For equipment so equipped: See also
pressure gauge on SmartMonitor >
System View -> Engine -> Air pressure.
Horn inoperative
Leak or restriction in air line
Repair leak or clear restriction
Horn is damaged
Replace horn

Page 129 of 150

Revision A
Rig air supply insufficient (if being

utilized)
APPENDICES
This section contains the following appendices:
Appendix 1: Specifications on page 131
Appendix 2: Quick reference on page 133
Appendix 4: Unit hydraulic oils on page 138
Appendix 6: Running hours log book on page 140
Appendix 7: Air transportation on page 144
Appendix 8: Contact us on page 146
Page 130 of 150

Revision A

Appendix 1: Specifications
Dimensions unit
Transport dimensions
L x W x H (overall with doors closed)
2940 x 1200 x 1510 mm (115.75 x 47.25 x 59.44 in)
Tare weight
2500 kg (5512 lbs)
Maximum rating
3500 kg (7716 lbs)
Operational conditions
Area classification
Zone 2
Operating temperature range
-20 C to +40 C (-4 F to +104 F)

Spring start unit: +5 C to +40 C (+41 F to +104 F)
Standards conformities
EN 12079/DNV 2.7-1
2006/42/EC Machinery Directive; ATEX
Type
Caterpillar diesel engine, 4-cylinder, liquid cooled, 4.4-litre (269 in) displacement,
naturally aspirated, Ex Zone 2 II 3G IIA
Power output
54 kW (72hp) @ 2200 rpm
Starter types:
Spring, pneumatic, hydraulic Ex Zone 2
Main fuel tank volume
109 l (28.8 US gal)
Air/ pneumatic system

Source
Rotorcomp EVO9-NK-G compressor
Compressor power rating
37 kW
Air pressure
10 bar (145 psi) nominal
Compressor flow volume
5 m3/min (177 cfm) Free Air Delivery (FAD) @ 2200RPM
Auxiliary circuit air compressor volume
495 L @ 2200RPM
Auxiliary circuit air receiver volume
10 L (2.6 US gal)
Hoisting
Lifting sling set
4-leg, wire rope, SWL 7000 kg (15 432 lb), WL 3 m (118 in), green pin bolt OD
22 mm, EN 12079/DNV 2.7-1, Lloyds certified

Page 131 of 150

Revision A
Power system
Fluids
Engine fuel
Tank capacity: 109 L (28.8 US gal.)

Fuel: EN 590-approved diesel or equivalent.
For detailed fuel specification, see Caterpillar engine manual, supplied separately.
Engine oil
Capacity: 11.4 L (3.0 US gal.)

Filled with: Mobil Delvac Super 1400 15W-40
For compatible oil types see Appendix 3: Lubricants
For detailed engine oil specification, see Caterpillar engine manual, supplied
separately.
Hydraulic oil
Tank capacity:20 L (5.3 US gal.)

Filled with: Univis N 46
Coolant
Capacity:
Filled with: Agip Permanent Fluid LL Alu Protect
Fluid: USE ONLY VW TL- 774-D/F SPEC. COOLANT

50/50 Glycol/water Mix For Aluminum Radiators.
Free Of Silicates, Borates, Nitrates, Phosphates.
Reduction gearbox (Fuel pump gear
drive) oil
Capacity: 100mL (3.3 fl.oz.)

Filled with: Mobilgear SHC XMP- 150
Compressor oil
Capacity: 25 l (6.6 US gal)

Filled with: Mobil Rarus 426
For detailed compressor oil specification, see Rotocomp compressor manual,
supplied separately.
NOTE: Data sheets and MSDS for all of the fluids used in the original assembly are found in the
units documentation package.
Filter elements
Part number
Engine air filter
A0018469
Engine oil filter
A1060581
Engine fuel coarse filter (Y-type)
A0000082
Engine fuel fine particle filter
A1060585
Engine fuel/water separator filter
A1060577
Hydraulic suction filter (bowl type)

10m
A0000161
Compressor intake air filter
For replacements please contact NOV Elmar After Sales
Compressor oil filter
L-8501059392
Compressor air-oil separator filter
L-8501059391
Page 132 of 150

Revision A

Appendix 2: Quick reference

WARNING
TXT-10004255/A
COMPRESSED AIR
the connection.

WARNING
TXT-10004358/A
Startup
1.
Ensure the pre-start checklist is completed.
2.
Ensure that one of the air outputs is disconnected and the isolation valve is open.
This is necessary, to ensure that the compressor gives as little resistance as possible, when
starting the engine.
3.
Determine starter type:

For air start engine:
a) Supply air to the unit as follows:
Ensure that an air supply (7 bar (100 psi) at 25 l/min) is connected to the rig-air connection on the unit.
Open the shore/rig-air supply at the supply point.
Slowly open the rig-air intake valve on the unit.
b) Ensure that the START PRESSURE is between 7 bar and 10 bar.
For hydraulic start engine:
Ensure that the START PRESSURE is at least 120 bar.
For spring start engine:
Wind starter up fully
4.
Reset the ENGINE SAFETY valve by turning the control lever clockwise against the spring
pressure.
5.
Push the AIR INLET VALVE lever on the control panel all the way up, and hold it in that position.

Page 133 of 150

Revision A
NOISE HAZARD
6.
For Air and hydraulic start, press and hold the ENGINE START button/ knob until the engine
starts.
7.
For spring starter trip the start lever.
8.
Hold the AIR INLET VALVE lever until the engine oil pressure is above 2 bar (29 psi), then
release it.
9.
Close the air output you opened to start the unit, and reconnect the hose, if you disconnected
it earlier.
10. After the engine has run for about one minute check the engine oil pressure. This should be
at least 3 bar.
Shutdown
1.
Set the engine speed to idle.
2.
Push the ENGINE STOP button to stop the engine.
3.
Check the tachometer to see that the engine has stopped.
4.
Close all isolation valves on the air outputs.
Manual Emergency shutdown

1.
Push the EMERGENCY STOP button on the control panel to kill the engine.
Emergency shutdown recovery

1.
Ensure that the cause of the emergency shutdown has been identified and solved.
2.
Release an activated EMERGENCY STOP button by turning it clockwise until it releases.
3.
Start up the machine as described above in Startup.
Page 134 of 150

Revision A

Appendix 3: Lubricants
Engine lubricants table
TXT-10004503/A
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.
Select a good quality lubricant that is suitable for the ambient temperature where the machine is
used.
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
-30 C
(-20 F)
-20 C
(-2 F)
-10 C
(+14 F)
0 C
(+32 F)
+10 C
(+50 F)
+20 C
(+68 F)
+30 C
(+86 F)
+40 C
(+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
Engine lubricants

Page 135 of 150

Revision A
Gearbox lubricants table

TXT-10004505/A
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.
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
non leaded gear

compound 100
non leaded gear

compound 150
non leaded gear

compound 320
ELF
Reductelf SP100
Reductelf SP150
Reductelf SP320
Elf ORITIS 125 MS

Elf Syntherma P 30
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
Telesia Oil 150
KLUEBER
Gem 1-100
Gem 1-150
Gem 1-320
Synteso D 220
Mobilgear SHC XMP150

Mobilgear 629
Mobilgear 632
Glygoyle 22
Glygoyle 30
SHC 630
MOBIL
Q8
Goya 100
Goya 150
Goya 320
Greco 228
SHELL
Omala Oil 100
Omala Oil 150
Omala Oil 320
Tivela Oil SA
TOTAL
Carter EP 100 N
Carter EP 150 N
Carter EP 320 N
Gearbox lubricants
Page 136 of 150

Revision A

NOTE: Select a lubricant that is suitable for the ambient temperature in which the machine is to
be operated.
Compressor oils compatibility table

The lubricating oil is critical to the proper operation of the rotary screw type compressor. Select
an oil that is suitable for the ambient temperature in which the machine is to be operated.
Operating temperature of compressor oil will increase during operation.
Mineral oils are generally less expensive but require more frequent change intervals (up to 2000
hrs). Synthetic oils are more expensive but change intervals can be increased (6000-8000 hrs).
Operating temperatures
-10 C to +110 C (+14 F to +230 F)
Oil type
Synthetic
ISO 26 oils
no
no
ISO 46 oils
no
yes
Recommended
Recommended
BP
See Castrol
See Castrol
Castrol
Aircol PD 68
Aircol SR 68 or Tribol 890/68
ISO VG 68 oils
Chevron/ Texaco
Total/Fina/ELF
Esso/ Exxon
Mobil
Q8
Cetus PAO 68
Total DACNIS 68
Compressor Oil 68
Rarus 426
CPC
Summit
Rarus SHC 1026
Schumann 68
Shell
Kluber
Total DACNIS SH 68
Corena S4 R 68
Summit PS 200
Summit SH 68
SC-68
Ultima-68
ASEP Elmar recommended compressor oils

Page 137 of 150

Revision A
Mineral
Appendix 4: Unit hydraulic oils

TXT-10004700/A
Hydraulic oils compatibility table

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.
Appendix 4: Unit hydraulic oils
Low temperatures
below -15 C (+5 F)
Normal temperatures
-5.0 C to +60 C (+25 F to +142 F)
Very high temperatures

to +75 C (+167 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
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.
Page 138 of 150

Revision A

Appendix 5: ASEP Elmar tightening conventions

TXT-10004458/A
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: 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.
M8
M10
M12
M14
M16
M20
M24
Comment
A2/70 (SS)
15
30
50
80
120
250
340
use spring washer or self-locking nut
8.8 (plain)
20
40
70
110
175
350
600
use self-locking nut
10.9 (plain)
30
60
100
160
250
490
850
12.9 (plain)
35
70
120
195
300
580
1000
Appendix 5: ASEP Elmar tightening conventions
Metal
grade
Recommended bolt tightening torques (Nm)
Examples:
M1025 DIN933A2-70, apply a torque of 30 Nm
M1265 DIN925-10.9, apply a torque of 100 Nm

Page 139 of 150

Revision A
Appendix 6: Running hours log book

TXT-10004509/A
Like all machinery, the AirPack C 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 AirPack C 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

Even if there is automatic logging of the number of hours the AirPack C is in operation, it is still
important to manually record all hours that the wireline winch is "running".
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, ASEP Elmar provides with this manual (see
page 143) 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
AirPack C enters stand-by prior to operations, to the moment the AirPack C is shut down.
NOTE: If the running hours for major subsystems of the AirPack C 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 141 shows a filled-in ASEP 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.
Page 140 of 150

Revision A

Example running hours & service log form
Open a new running hours and service log form:

1.
Carry the hours forward from the last row of the previous form (or enter zero for a new unit).
2.
Identify the AirPack C (e.g. registration plate).
3.
Enter the date the form was opened.
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.

Page 141 of 150

Revision A
Log session running hours

1.
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).
Log scheduled service activity
On completion of the service activity, on the currently open running hours and service log form:
1.
Enter the actual running hours at which the service was carried out.
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).
Page 142 of 150

Revision A

Unit ID:_____________________________________
Date form opened:_____________________________
Running Hours
Start
Date
Stop
Time
Date
Hours
Time
Session
Remarks
Cumul.
carried forward from previous sheet
carry forward to next sheet
Service Log
Next
service
(hours)
Due at
(hours)
Done at
(hours)
On
(date)
Remarks
300
600
900
1200
1500/
ann.

Page 143 of 150

Revision A
Appendix 7: Air transportation

TXT-10004443/A
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, ASEP Elmar provides a checklist as an aid to ensuring that no
part is overlooked when draining and refilling the machine.
Draining:
4.
Check off each item as it is drained, adding your initials.
5.
Strike-out the items that are NOT present on the machine.
6.
Add any items that are present on the machine, but not on this list.
7.
Tag out the unit or component to warn against starting before refilling.
8.
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:
9.
Refer to the maintenance instructions or specifications pages of the manual for this machine,
for the quantity and specifications of the required fluids.
10. Refer to the maintenance instructions for the procedure to check and replenish fluids for
each of the reservoirs, systems and components.
11. 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.
12. ASEP 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.
Page 144 of 150

Revision A

FLUID RESERVOIRS/SYSTEMS/COMPONENTS DRAINED / REPLENISHED

FOR TRANSPORTATION
Date drained:
Ite
m
Description
Date replenished:
Bleed
01
Hydraulic tank
02
Fuel tank
03
Engine oil sump
04
Compressor oil sump
05
Engine coolant
06
Gearbox, reduction final drive
07
Gearbox, fuel pump drive
New
filter(s)
recomm.
INITIALS
Drained
Replen.
New filter
Y
Y
08
09
Pneumatic line oiler
11
12
Batteries
13
Grease injection system reservoir
14
Pressure testing reservoir
10
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Page 145 of 150

Revision A
Appendix 8: Contact us
Appendix 8: Contact us
TXT-10004145/A1
Manufacturing Locations
Address
Telephone, Fax and E-mail
NOV Elmar
7909 Parkwood Circle Dr.,

Houston, TX 77036,
United States of America
www.nov.com
NOV Elmar - UK
Enterprise Drive, Westhill Ind. Estate,

Westhill, Aberdeen AB32 6TQ,
Scotland, United Kingdom
Tel.: +44 1224 740261

Fax: +44 1224 743138
Elmar-UK@nov.com
NOV Elmar - Netherlands
Energieweg 26,
2964 LE Groot-Ammers,
The Netherlands
Tel.: +31 184 608 700

Fax: +31 184 608 790
Elmar-NL@nov.com
NOV Elmar - USA
11995 FM 529,
Houston, TX77041,
United States of America
Tel.: +1 713 983 9281

Fax: +1 713 983 8892
Elmar-Americas@nov.com
NOV Elmar - UAE
Oilfields Supply Center B-17

Jebel Ali Free Zone
P.O. Box 18633
Dubai, United Arab Emirates
Tel.: +971 4 8835 910

Fax: +971 4 883 7087
Elmar-Dubai@nov.com
NOV Elmar - Singapore
7 Loyang Way
Singapore 508721
Singapore
Tel.: +65 6546 0928

Fax: +65 6546 0927
Elmar-Singapore@nov.com
NOV Elmar - Russia
26 Chapaeva
Nizhegorodka
Bashkortostan Republic Ufa Region
Russian Federation 450520
Tel.: +7 347 271 9490

ElmarCIS-Sales@nov.com
NOV Elmar - Canada

(DynaWinch Product Line)
6771 - 84 Street SE
Calgary, Alberta, T2C 4T6
Canada
Tel.: +1 403 319 2333

Fax: +1 403 319 2337
Elmar-Canada@nov.com
NOV Elmar - Brazil
Equipmentos E Servicos Para

Petroleo LTDA
Estrada Projetada 02, LT 07, N 341
Imboassica, Maca, RJ 27.925-530
Tel.: +55 22 9731 3384

Elmar-Brazil@nov.com
Regional Sales, Rental & Service
Telephone
E-mail
Al-Khobar, Saudi Arabia
Tel.: +966 3 887 9270
Elmar-Dubai@nov.com
Perth, Australia
Tel.: +61 8 9456 0999
Elmar-Perth@nov.com
Stavanger, Norway
Tel.: +47 51 81 81 81
Elmar-UK@nov.com
Representative Offices
Telephone
Louisiana, USA
Tel.: +1 337 839 0024 ext. 201
Beijing, China
Tel.: +86 10 8485 1973
Moscow, Russia
Tel.: +7 495 287 2691
Fidmash, Minsk, Belarus
Tel.: +375 17 298 24 11
Page 146 of 150

Revision A

CUSTOMER NOTES

NOV Elmar K-Winch AirPack C, MAN-1055734, 26 July 2013
Page 147 of 150

Revision A
Page 148 of 150

Revision A


Page 149 of 150

Revision A
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.
Page 150 of 150

Revision A


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AirPack C User Manual

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NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

7.15 Clean auxiliary pneumatic system filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

2.1 General Safety

Never leave "operation-ready" equipment unattended.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

Warnings, cautions and requirements

2.1 General Safety

AirPack C User Manual

Equipment specific safety

Emergency Stop buttons

2.2 Equipment specific safety

Figure 2.1 Examples of Emergency Stop buttons

ATEX and zoning

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

Annex VIII of the Directive. The construction is documented in a confidential Technical

Doors and hatches

2.2 Equipment specific safety

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

3.1 Unit overview

3.2 Unit rear view on page 11

3.3 Unit right view (spring starter) on page 12

3.4 Unit right view (hydraulic starter) on page 13

3.5 Unit right view (air starter) on page 14

3.6 Unit front view on page 15

3.7 Unit left view (spring starter) on page 16

3.8 Unit left view (hydraulic starter) on page 17

3.9 Unit left view (air starter) on page 18

Figure 3.1 Unit overview

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

Unit rear view

Exhaust silencer/ spark arrestor

Exhaust gas soot collector point

Compressor air intake filter

Engine shock absorber

Air receiver auxiliary air circuit

Air-oil separator element

Hydraulic start manifold (optional)

Figure 3.2 Unit rear view

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

AirPack C User Manual

Unit right view (spring starter)

3.3 Unit right view (spring starter)

Engine air inlet valve

Exhaust gas cooler

Engine oil dipstick

Compressor oil filter

Compressed air filter

Auto drain valve