Otras reservas

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.

6 .5 C harge hy dra u lic sta rte r a ccumul ator

6.5.1

Charge starter accumulator using 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 pump’s 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.

Figure 6.7 Hydraulic starter accumulator and reservoir w/ hand pump.

2

1

3

5

4

6

7

6 .5 C harge hy dra u lic sta rte r a ccumul ator

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.

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.

Figure 6.8 Hydraulic starter accumulator, reservoir and air-operated oil pump.

2

1

3

4

6

5

6 .5 C harge hy dra u lic sta rte r a ccumul ator

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.

7. 1 Introductio n

7

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

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).

7.3

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

7.4 P e riod ic main tenance sched ules Maintenance activity ma nual s ect ion

Service interval (hours)

as re qu ir e d da il y 30 0 60 0 90 0 1 200 1 500 /yea rly 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

7.5 C hec k/adjus t V-belts

7.5

Check/adjust V-belts

This procedure describes how to inspect the V belts of the Caterpillar diesel engine.

Related topics:

• 6.3 Normal shut down on page 42

• 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.

1. Refer to fig Figure 7.1 below. Remove the right side belt guards, upper (1) and lower (2).

2. Check the belts for damage or excessive wear.

3. Replace belts where necessary. See 7.35 Replace V-belts on page 119.

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.

Figure 7.1 V-belt protective guards and v-belt adjustment assembly

1

2

4

3

5

7.5

C

hec

k/adjus

t V-belts

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. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

8. Close any panels you opened.

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.

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.

7.6 C h eck/fill compress or oil

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

• 6.3 Normal shut down on page 42

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.

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.

Figure 7.2 Engine oil filler cap and level

2

1

2

MAX MIN

7.6 C h eck/fill compress or 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 .

3. Replace the oil filler cap and tighten it. 4. Clean any spilled oil.

5. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

6. Close any access panels you opened.

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.

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.

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.

7.7 C he ck/fill e ngine co olant

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:

• 6.3 Normal shut down on page 42

• 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.

3. 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.

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

7.7.2

Top up coolant

Figure 7.3 Coolant sight glass

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. sight glass correct

coolant level

7.7 C he ck/fill e ngine co olant

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.

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).

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.

7. Replace the filler cap.

8. Use clean rags to clean any spilled coolant. 9. Close and secure the hatch.

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.

Figure 7.4 Coolant fill hatch and radiator filling point

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

2

1

7.7 C he ck/fill e ngine co olant

10. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

11. Close any panels you opened.

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.

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.

7.8 C h eck/fill engine oil

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:

• 6.3 Normal shut down on page 42

1. 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.

7.8.1

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.

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.

7.8.2

Fill engine oil

1. Open the left door to access the engine oil filling point. See Figure 7.6. Figure 7.5 Engine oil dipstick

7.8 C h eck/fill engine oil

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.

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.

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. Clean any spilled oil.

Figure 7.6 Engine oil filler cap (obscured)

CAUTION

TXT-10004366/A EQUIPMENT DAMAGE

Overfilling the engine oil can damage the engine seals. Add oil slowly and wait until it has fully run into the engine before rechecking the oil level.

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.

7.8 C h eck/fill engine oil

3. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

4. Close any access panels you opened.

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.

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.

7.9 C h eck/fill engine fuel

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 ¼, ½, 3/4 and FULL. 3. Refill as necessary for operations.

7.9.2

Fill fuel tank

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.

Figure 7.7 Diesel fuel filler cap and level gauge

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.

CAUTION

TXT-10004376/A ENVIRONMENTAL HAZARD

Petroleum products and other chemicals are harmful to the environment. Dispose of waste items in a responsible way according to local laws and regulations.

1

7.9 C h eck/fill engine fuel

7. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

8. Close any doors you opened.

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.

7.10

Check/fil

l hydraulic

oil

7.10

Check/fill hydraulic oil

Related topics:

• 6.3 Normal shut down on page 42

• Appendix 3: Lubricants on page 135

• 6.5 Charge hydraulic starter accumulator on page 43

7.10.1 Check hydraulic oil level

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).

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

gauge.

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 HOT LIQUID

Hot hydraulic oil under pressure can cause serious burns.

Before working on components containing hydraulic oil, ensure that:

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