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FlyLine

Zone 2 base and options

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
NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 1 of 258
Revision C

FlyLine User Manual

This document applies to the following parts:


L-6931048158V01 - FLYLINE BASE HD PP ASSY ATX ZONE 2
L-6931034250V01 - FLYLINE BASE PP ASSY ATX ZONE 2
L-6931041412V01 - FLYLINE BASE SD ASSY ATX ZONE 2
L-6931041412V02 - FLYLINE BASE DD ASSY ATX ZONE 2
All standard options available for these base assemblies, see Appendix 5: Unit
configuration on page 244

Published by:
NOV Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2013 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV Elmar for loss,
damage or injury caused by any errors or omissions in this document.

Revision

Date

Amendments

18 September 2013

8 August 2013

Pictures of pre-engaged hydraulic starter on page 42. Updated


pictures of auxiliary drive on page 52. Added instructions to reset the
overspeed controller for heavy duty power packs after being
activated on pages 47, 95 and 96. Added instructions on selecting
approved engine coolant on pages 133 and 238. Added nonstandard combigauge options on page 237 and 242.

A3

17 June 2013

Updated sections: Connect hydraulic and pneumatic hoses and


Rig down with regard to the line tension control setting when
connecting and disconnecting hoses.

A2

26 February 2013

Minor corrections

A1

20 February 2013

Updated Appendix 3; Added Maintenance step 8.20 Check/ fill fuel


pump gear drive oil

30 January 2013

This is the first revision of this manual

Added fuel purifier descriptions on pages 17, 18,19, 40, 41, 170.
Instructions to tighten essential bolts on page 221. Referenced
documents on pages 246, 247. Instructions to use anti-seize
compound on page 248. Other minor corrections.

REVISION HISTORY

Page 2 of 258
Revision C
Original Instructions

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

TABLE OF CONTENTS
1
2

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 3 of 258
Revision C
Original Instructions

Table of contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Winch / Control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Unit systems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Unit access features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Transportation features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Specifications and data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.7 Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.9 Auxiliary drive (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.11 Depth and tension measurement systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.12 Winch subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.13 Wellhead pressure control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
UNIT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1 Power pack control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Winch left control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.3 Winch right control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2 Hoisting modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 First-time startup and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.5 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.1 Emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.2 Pre-start checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.3 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.4 Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.5 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.6 Charging hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.4 Depth and tensioning system maintenance schedule. . . . . . . . . . . . . . . . . . . . 107
8.5 FlyLine maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
8.6 Prepare for safe maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.7 Finalise maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.8 Change engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Table of contents

FlyLine User Manual

8.9 Check/adjust brake band tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116


8.10 Check/adjust chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.11 Check/adjust levelwind chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.12 Check/adjust V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.13 Check brake band wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.14 Check/fill coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.15 Check/fill engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.16 Check/fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.17 Check/fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.18 Check/fill reduction gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.19 Check/fill wireline oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.20 Check/fill fuel pump gear drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.21 Check/replace hydraulic hoses and couplings . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.22 Check/replace shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.23 Clean air inlet safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.24 Clean air inlet safety valve for heavy duty power packs . . . . . . . . . . . . . . . . . . 154
8.25 Clean fuel coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.26 Clean/replace air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
8.27 Clean/replace crankcase flame trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.28 Clean/replace fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.29 Clean spark arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.30 Clean unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.31 Drain/fill coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.32 Drain fuel purifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.33 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.34 Drain fuel/water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.35 Drain water from hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.36 Grease unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.37 Prime diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.38 Remove/replace drum chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.39 Replace levelwind chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.40 Remove/replace brake band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.41 Replace V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.42 Replace drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8.43 Replace fuel fine filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.44 Replace fuse or circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.45 Replace hydraulic high-pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.46 Replace hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.47 Replace hydraulic suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.48 Replace slip ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.49 Replace fuel/water separator filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.50 Service compressed air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8.51 Test maximum engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
8.52 Test drum mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.53 Test hydraulic system pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
8.54 Tighten Essential Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.2 Troubleshooting table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Appendix 1: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Appendix 2: Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Appendix 3: Unit Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 4: Unit hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Appendix 5: Unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 6: Referenced Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 7: Tightening conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 8: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 9: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 10: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

243
244
246
248
249
253
255

CUSTOMER NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Table of contents

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FlyLine User Manual

INTRODUCTION
TXT-10004540/A

This user manual for the FlyLine well servicing product is intended for operating, maintenance
and supervisory personnel. It contains the following sections:
Safety (important safety aspects)
Description (of components and their function)
Unit Control description
Setup and Removal (including installation and storage)
Operation (startup, run, shutdown)
Maintenance (schedules and procedures)
Troubleshooting
Appendices (reference material)

1 Introduction

This manual (supplied in digital and printed formats) is part of the FlyLine documentation set and
must be read before initial equipment installation and operation.
The validity of the manual can be compromised by post-delivery engineering modifications or
regulatory changes that affect equipment use, ratings and limits. All NOV Elmar engineering
changes are documented in as-built drawings, even after product delivery. This means the latest
drawings always take precedence over manuals. If in doubt, contact NOV Elmar.

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FlyLine User Manual

SAFETY
TXT-10004141/A1

2.1

General Safety
High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be
present in Elmar equipment. Therefore, pay special attention to safety when working with this
equipment.
Meet all applicable codes, laws and local field regulations (including environmental and
additional owner/user company policy). This manual contains recommendations, but
should not be assumed to satisfy all requirements of legal regulations.
Read and understand each item in this manual and follow all procedures, precautions
and advice exactly - never take short cuts. Always consider your safety and that of others.
Only use the equipment within its design scope to avoid damage or dangerous situations.
This manual (in its most current revision) is a minimum requirement for all persons working with
Elmar equipment. All other current and applicable documents such as certification, drawings, bill
of materials, vendor documentation, etc, should be readily available at the worksite.

2.1.1

Employee responsibility
Never leave "operation-ready" equipment unattended.
Keep equipment clean (accumulated dirt and dust can hamper unit operations and may
increase the risk of ignition).
Wear personal protection equipment (PPE) where necessary; for example gloves and
protective footwear.
Never work alone if there is a possibility of an accident.
Keep loose clothing and long hair well away from moving mechanical parts.
Remove rings, wristwatch, etc, before working.
Never disconnect, change or remove safety devices, and use such devices correctly.
Be aware of all emergency equipment and procedures (such as alarms, abandon ship,
etc.) and make sure they are in place and valid.
Do not use the equipment after an emergency without verifying that the cause of the
emergency has been removed or rectified.
Immediately inform the employer and other workers of any situation that represents a
serious danger to safety and health, and of any shortcomings in protection arrangements.
Plan all operations including interdependencies with other equipment operations
If equipment is tied down using rope/line/chains, attach a "flag" to signal their location.
During installation, maintenance and/or equipment inspection:
where possible, make sure electrical/mechanical equipment is switched off completely,
and use a decal or similar to prevent unauthorized starting;
always relieve pressure before working on hydraulic and/or pneumatic systems.

2.1.2

Employer responsibility
Define the required competency of personnel working on the equipment (including
supervision) and provide the required consultation, information and training.

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2 Safety

Correctly maintain and use equipment, apparatus, tools, and dangerous substances.

FlyLine User Manual

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:
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.
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.

2 Safety

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.

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FlyLine User Manual

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.

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
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/A1

Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the
equipment is certified according to ATEX regulations, the following applies:
The power supply, including driven parts, has been manufactured and assessed
according to ATEX and tagged with a unique identification number.
Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1,
or Zone 2 compliance will be compromised.
Certified explosion safe equipment is suitable for use in gas hazardous classified
locations. Check your unit data plate(s) and the specifications tables in the Appendix for
the ATEX classification for your equipment.
The design and manufacturing is based on European Directive no. 94/9/EC following
conformity assessment procedure relating to internal control of production according
Annex VIII of the Directive. The construction is documented in a confidential Technical
Construction File held at the offices of Elmar.
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2 Safety

TXT-10004562/A

FlyLine User Manual

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.

2.2.5

Wireline
TXT-10004564/A

Never allow the number of wraps on a wireline winch drum to go below a minimum of
three (3) wraps. When the last layer is unwinding, winch-off slowly, and keep close
control on the remaining wraps.
Never allow the wireline to go slack! A slack wireline can be caused by an obstruction
that may clear suddenly, with an unexpected and potentially lethal tightening of the
wireline as a result.

2 Safety

If the wireline is rigged up but is not going to run for a period, clamp the wire, diminish the
tension, and "flag" the wire with signs.
During wireline operations, consider the zone in front of the winch as a danger zone (see the
shaded area in Figure 2.2):
Never allow anyone to enter this area when there is tension on the wireline!
Treat this area as a potential danger zone and take extreme care, even when there is no
tension on the wireline.

Figure 2.2 Danger zone for wireline operations

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FlyLine User Manual

PHYSICAL DESCRIPTION

3.1

Unit overview
This FlyLine consists of the following modules and sub-modules (see Figure 3.1).

front

left

2
right

1
back

3.2 Power pack on page 12

Self-sufficient power source for wireline winch operations.


Based on diesel engine as primary energy source, the power
pack supplies hydraulic power, compressed air, and optionally
electrical power.

3.3.2 Control console on page 22

Winch operators control console, with controls for the winch


integrated in a single control panel.

3.3 Winch / Control console on page 21

Wireline winch with one or two selectable wireline drums and


depth and tension measurement system. The winch is
hydraulic-powered, and controlled pneumatically.

Figure 3.1 Unit overview and orientation

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3 Physical description

FlyLine User Manual

3.2

Power pack

3.2.1

Power pack overview


The following figure shows the naming conventions of the physical views used in the remainder
of this section.

3 Physical description

5
6
4

7
8

3.2.2 Power pack front view on page 13

3.2.3 Power pack left view on page 14

3.2.4 Power pack left view (heavy duty) on page 15

3.2.5 Power pack rear view on page 16

3.2.6 Power pack right view (spring starter) on page 17

3.2.7 Power pack right view (hydraulic starter) on page 18

3.2.8 Power pack right view (air starter) on page 19

3.2.9 Power pack right view (heavy duty) on page 20

Figure 3.2 Power pack overview

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3.2.2

Power pack front view

2
4

5
8

6
10
11

Hydraulic oil tank filler cap (protected by hatch)

Hydraulic oil tank

Hydraulic oil tank drain valve

Hydraulic oil tank isolation valve

Hydraulic oil high-pressure filters (2 x)

Suction filter

Suction filter (option, only with auxiliary drive)

Air receiver safety valve

Air receiver

10

Air receiver isolation valve

11

Air filter

Figure 3.3 Power pack front view


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3 Physical description

FlyLine User Manual

3.2.3

Power pack left view

2
3 Physical description

1
3

8
9

10

Engine exhaust

Engine air intake safety valve (Pyroban)

Exhaust gas cooler

Belt and pulley guard

Radiator fan

Radiator stack

Fuel filler cap

Engine oil dipstick

Hydraulic manifold

10

Engine frame shock mount (4 x)

Figure 3.4 Power pack left view

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3.2.4

Power pack left view (heavy duty)

2
3 Physical description

1
4

8
9

Engine exhaust

Engine air intake safety valve (Pyroban)

Exhaust gas cooler

Belt and pulley guard

Radiator fan

Radiator stack

Fuel filler cap

Engine oil dipstick

Hydraulic manifold

10

10

Engine frame shock mount (4 x)

Figure 3.5 Power pack left view (heavy duty)

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3.2.5

Power pack rear view

3 Physical description

Radiator filler cap (protected by hatch)

Radiator stack

Figure 3.6 Power pack rear view

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3.2.6

Power pack right view (spring starter)

1
2

20

16

9
18
19

10
17

14
11

21

13

12
1

Exhaust silencer

12

Pneumatic and hydraulic connectors

Engine flame trap breather

13

Fuel tank

Fuel safety (Sentinel) valve

14

Starter motor

Fuel fine filter

15

Electric junction box (optional)

Engine air intake filter

16

Battery isolation switch (optional)

Control panel

17

Battery (optional)

Fuel pump

18

Electrical connector (optional)

Engine compressor

19

Auxiliary drive pump (optional)

Fuel prefilter & water separator

20

Spring starter crank handle (optional)

10

Engine oil sump pump

21

Fuel purifier (optional, not shown)

11

Engine oil filter

Figure 3.7 Power pack right view (spring starter)


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3 Physical description

15

FlyLine User Manual

3.2.7

Power pack right view (hydraulic starter)

3 Physical description

20

15

16
21

9
18
19

10
17
21

14
11

20

22

13
12

Exhaust silencer

12

Pneumatic and hydraulic connectors

Engine flame trap breather

13

Fuel tank

Fuel safety (Sentinel) valve

14

Starter motor

Fuel fine filter

15

Electric junction box (optional)

Engine air intake filter

16

Battery isolation switch (optional)

Control panel

17

Battery (optional)

Fuel pump

18

Electrical connector (optional)

Engine compressor

19

Auxiliary drive pump (optional)

Fuel prefilter & water separator

20

Hydraulic accumulator & isolation valve (optional)

10

Engine oil sump pump

21

Accumulator charge pump & handle (optional)

11

Engine oil filter

22

Fuel purifier (optional, not shown)

Figure 3.8 Power pack right view (hydraulic starter)


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FlyLine User Manual

3.2.8

Power pack right view (air starter)

1
2

15

20

21

18
19
10
17

14
11

22

13
12
1

Exhaust silencer

12

Pneumatic and hydraulic connectors

Engine flame trap breather

13

Fuel tank

Fuel safety (Sentinel) valve

14

Starter motor

Fuel fine filter

15

Electric junction box (optional)

Engine air intake filter

16

Battery isolation switch (optional)

Control panel

17

Battery (optional)

Fuel pump

18

Electrical connector (optional)

Engine compressor

19

Auxiliary drive pump (optional)

Fuel prefilter & water separator

20

Air-in connector (optional)

10

Engine oil sump pump

21

Pneumatic filter for start circuit (optional)

11

Engine oil filter

22

Fuel purifier (optional, not shown)

Figure 3.9 Power pack right view (air starter)


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3 Physical description

16

FlyLine User Manual

3.2.9

Power pack right view (heavy duty)

3 Physical description

Engine air intake filter

Turbocharger

Engine overspeed control valve (pneumatic)

Air inlet valve (push / pull type)

NOTE: Only additional heavy duty features are mentioned.


See sections 3.2.6, 3.2.7 and 3.2.8 for other features.

Figure 3.10 Power pack right view (air starter)

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3.3

Winch / Control console

3.3.1

Winch / Control console overview


The following figure shows the naming conventions of the physical views used in the remainder
of this section.

3 Physical description

4
2
1

3.3.2 Control console on page 22

3.3.3 Winch front view (SD) on page 23

3.3.4 Winch left view (SD) on page 24

3.3.5 Winch right view (SD) on page 25

3.3.6 Winch right view (DD) on page 26

Figure 3.11 Winch / control console overview

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3.3.2

Control console

3 Physical description

3
6

7
5

Securing latch pins for roof flap

Left control panel

CombiGauge

Right control panel

Operator chair

Levelwind wheel

Operator seat securing pin

Operator safety screen

Figure 3.12 Control console

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3.3.3

Winch front view (SD)

3
1
3 Physical description

2
4
5

6
1

Levelwind guide shaft

Winch drum

Levelwind chain

Measuring head

Measuring head guide bar

Air-out connector

Hydraulic motor and gearbox (behind cover)

Drum chain

Figure 3.13 Winch front view (SD)

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3.3.4

Winch left view (SD)

3 Physical description

8
6

3
1

5
4

Winch drum

Cardan shaft for levelwind

Drum cover

Pillow block bearing

Measuring head

Measuring head transport securing pin

Roof damper

Screen damper

Fold-in roof

Figure 3.14 Winch left view (SD)

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3.3.5

Winch right view (SD)

3 Physical description

2
1

Wireline oiler

Hydraulic motor/gearbox assembly

Figure 3.15 Winch right view (SD)

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Winch right view (DD)

3 Physical description

3.3.6

2
1

5
3
4
1

Front winch drum

Rear winch drum

Horn

Hydraulic motor/gearbox assembly (2x)

Drum selection valve

NOTE: Mainly additional double winch drum features are


mentioned. See section 3.3.5 for other features.

Figure 3.16 Winch right view (DD)

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FlyLine User Manual

FUNCTIONAL DESCRIPTION

4.1

Unit configuration

This design is a split wireline winch unit comprised of a power pack, and a winch module with
integrated operator control.
The setup is suitable for cased hole slick line, braided line and mono-conductor operations. The
unit is suitable for onshore and offshore operations.
The four cylinder diesel engine in the power pack drives the Elmar's closed loop hydraulic system.
See 4.8 Hydraulic system on page 50.
A data plate is attached to the outside of each module, and contains specification information for
that module. Check your data plate and refer to Appendix 2: Unit Specifications on page 237 and
Appendix 5: Unit configuration on page 244 for more information.

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4 Functional description

Figure 4.1 Unit configuration

FlyLine User Manual

4.2

Unit systems overview

3
Main hydraulic pump

Hydraulic circuit

Engine starter
Fuel supply
Fuel safety
valve

Diesel
engine and
gearbox

Cooling fan

Radiator
Coolant circuit

Coolant pump

Air inlet
Battery

Alternator

Air intake

Electric circuit

Exhaust gas
cooler

4 Functional description

Combigauge

Measuring
head

1
SmartMonitor

Pneumatic compressor

2
Drum brake
Pneumatic
circuit

Hydraulic motor and gearbox

Drum and wire

Hydraulic motor and gearbox

Drum brake

Selection valve
Drum and wire

Hydraulic power

Pneumatic power

Mechanical power

Electrical power

Fuel

Cooling liquid

Figure 4.2 Typical system setup

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Depth and tension measurement


systems

4.11 Depth and tension measurement systems on page 56

Winch subsystem

4.12 Winch subsystem on page 58

Hydraulic system

4.8 Hydraulic system on page 50

Pneumatic system

4.7 Pneumatic system on page 48

Diesel engine

4.6 Diesel engine on page 35

Electrical system

4.10 Electrical system on page 54

Cooling systems

4.6.7 Cooling systems on page 45

Figure 4.2 shows the relationship between the various subsystem.


The Depth and tension measurement systems (1) is attached to the Winch subsystem (2), which
guides the wireline in and out of the well, during wireline operations. The (3) supplies hydraulic
energy for turning the drum, while the Pneumatic system (4) supplies pneumatic control for the
drum brakes.

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4 Functional description

The Diesel engine (5) powers the Hydraulic system (3), Pneumatic system (4), Electrical system
(6) and Cooling systems (7). The Cooling systems are used to cool the diesel engine and the
exhaust gases produced by the diesel engine (in Zone 2 certified units). The cabin heater uses
the heat from the Cooling systems (7) to warm the cabin. The Electrical system supplies electrical
energy for the SmartMonitor in the Depth and tension measurement systems.

FlyLine User Manual

4.3

Unit access features

11

4 Functional description

10

8
7

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Power pack right door

Protects the engine against environment conditions. Protects from noise and heat.

Power pack left door

Protects the engine against environment conditions. Protects from noise and heat.

Controls and connections hatch

Grants access to the power packs controls and connections

Winch bay right doors

Protects winch components from impact during transport. Keeps loose parts inside
winch bay. Protects from moving parts during operation.

Winch bay front door

Protects winch components from impact during transport. Keeps loose parts inside
winch bay.

Winch bay left doors

Protects winch components from impact during transport. Keeps loose parts inside
winch bay. Protects from moving parts during operation.

Power pack door handle

Turn this handle to open a power pack door.

Keyhole

Lock the power pack door closed with the supplied key.

Tumbler pin

Two latch pins are used to secure each winch door

10

Coolant hatch

This hatch give access to the coolant filler cap

11

Hydraulic fluid hatch

This hatch gives access to the hydraulic fluid filler cap and gauge.

4 Functional description

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4.4

Transportation features

5
12

11

4
6

4 Functional description

10

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FlyLine User Manual

Lifting pad eyes (4 per module)

Only for lifting module in transport state: all parts stowed and all doors and hatches
closed and locked.
WARNING: The single point lifting bar and all fittings must be removed before using
the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the
lifting chains of the hoist might become entangled in the lifting bar/fittings.

ISO corners (4 per module)

For storing, transporting, and anchoring each module.

Forklift pockets
(2 x 2 per module)

For fork lifting of separated modules in the transport state (all parts stowed and all
doors and hatches closed and locked).

Bracket (2x) for single point lifting


bar

Brackets to fit the single point lifting bar (5)

Single point lifting bar (optional)

Only for lifting module in transport state with a single sling: all parts stowed, all
doors and hatches closed and locked. The single point lifting bar must be removed
for operation.

WARNING: Do not use these forklift pockets for crane hoisting of the module.

WARNING: The single point lifting bar must not be used for offshore lifting.
WARNING: The single point lifting bar and all fittings must be removed before using
the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the
lifting chains of the hoist might become entangled in the lifting bar/fittings.
End rail

WARNING: The end rail must always be fitted before transporting the unit.

End rail storage brackets

Use these brackets to store the end rail (6) during operations.

Jacking wheel (option)

Detachable jacking wheel assembly

Side wheel (option)

Detachable side wheel for jacking wheel assembly

10

Jacking wheel mount point

Attachment point for detachable jacking wheel assembly

11

Fold out roof

Folds in for transport

12

Retractable latch pin

Four latch pins are used to secure the fold out roof in transport and operation
position.

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4 Functional description

6
7

FlyLine User Manual

4.5

Specifications and data plate

4 Functional description

A data plate (Figure 4.3) is attached to the outside of the modules and is stamped with
specification information for the unit. Check your data plate to see whether your FlyLine is Rig
safe, Zone 2 or Zone 2 Arctic. If the field under MARKINGS is empty, it is Rig Safe. If it has ATEX
markings, it is Zone 2 certified. Refer to Appendix 2: Unit Specifications on page 237 for other
specification details.

ASEP

MARKINGS

External connections:

NOV ASEP Elmar Netherlands BV


Energieweg 26 - NL 2964LE Groot-Ammers
ASEPElmar-NL.Service@nov.com - www.nov.com/ASEPElmar
A1107313_A

Figure 4.3 Data plate layout

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FlyLine User Manual

4.6

Diesel engine
The engine systems are described in the following sections:
4.6.1 Engine oil on page 36
4.6.2 Engine safety features on page 38
4.6.3 Engine fuel system on page 40
4.6.4 Hydraulic engine starter (optional) on page 42,
4.6.5 Pneumatic engine starter (optional) on page 43,
4.6.6 Spring engine starter (optional) on page 44,
4.6.7 Cooling systems on page 45
4.6.8 Additional features of Heavy Duty power packs on page 46
Primary power is generated by a four cylinder diesel engine. The engine is Rig safe or Zone 2
compliant, with features to eliminate any risk of explosion during normal operation, and to shut
down the engine when there is risk of explosion.
The engine is available in regular and heavy duty configurations. The latter will include a turbo
charger in the engine assembly for additional power output.
The engine is liquid cooled with forced ventilation.

The engine air supply is drawn through an air filter in the power pack. An air shut-off valve in the
intake kills the engine or prevents it from starting when it is unsafe for the engine to run.
On Zone 2 units, engine exhaust is treated before discharge to prevent an explosion from heat or
sparks. The first stage is an exhaust gas cooler, which cools the exhaust gas enough to prevent
the ignition of potentially explosive ambient gases. The second stage is a spark arrester, which
filters hot solid particles from the exhaust gas.
The engine is started by an electric (Rig safe only), hydraulic, pneumatic or spring starter.
The engine is bolted to a subframe assembly. Four shock mounts attach the subframe assembly
to the power pack frame to ensure good vibration control.

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4 Functional description

The diesel fuel tank is situated in the power pack, underneath the engine. The fuel is filtered in
three stages between the tank and the engine: coarse particle filter, water/fuel separator, and fine
particle filter. An isolation valve beside the tank can be closed during maintenance and transport.

FlyLine User Manual

4.6.1

Engine oil

4 Functional description

1
4

5
2

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Engine oil filler cap (2x)

Use to fill or top up engine oil. One cap is located behind air compressor. Another
cap is located in top of the engine. Use a funnel to make filling easier.

Engine oil filter

Filters the engine oil.

Engine oil dipstick

Used to check engine oil level. Screw fitting.

Engine oil sump pump

Hand-operated plunger pump to remove oil from bottom of engine sump.

Sump pump isolation valve

CLOSED (lever across flow direction) at all times. Only open, when draining the
engine oil.

4 Functional description

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4.6.2

Engine safety features

5
7

4 Functional description

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FlyLine User Manual

Engine fuel safety valve

(Shown in operation state). Causes an instant engine shutdown by cutting off the
fuel supply. This valve controls the fuel supply to the engine, and is actuated by
engine oil pressure. Engine oil under pressure enters and exits through the upper
connections. Fuel from the fuel pump enters and exits to the engine injectors
through the lower connections. When there is sufficient engine oil pressure, the
valve stays open. If the oil pressure drops under approximately 0.5 bar (7.5 psi) the
valve will block the supply of fuel, shutting down the engine.
Before starting, the valve must be manually disarmed by rotating the lever down. It
will arm itself once the engine is running and generating oil pressure.
NOTE: Also referred to as sentinel valve or master valve.

Air inlet valve

Causes an instant engine shutdown by cutting off the air supply. When explosive
gases are present in the air, a diesel engine can sometimes continue to run, even
when the fuel and electrical supply are cut off. This butterfly valve in the air intake is
actuated by engine oil pressure. When there is sufficient engine oil pressure, the
valve stays open. The valve is manually latched open before starting, but will be
held open automatically once the engine is running and generating oil pressure.
See item 14 in Figure 5.2 on page 66. for the air inlet valve control.
This component requires periodic maintenance (cleaning).

Exhaust temperature shutdown


valve (optional, normally open)

This valve is placed in the oil pressure circuit to the engine safety valve. In the event
of excessive exhaust temperature (maximum 200 C), the valve will close, triggering
the Zone 2 engine shutdown.

Crankcase breather flame trap

The top opening for the crankcase air breather is connected to a flexible hose that
leads to a flame trap device. The flame trap prevents ignition of an explosive
atmosphere by a possible flame in the crankcase.
This component requires regular inspection and maintenance.

Exhaust silencer with spark


arrester

The silencer is equipped with a spark arrester to catch glowing soot in the exhaust
gases that may still be present after the exhaust gas cooler. The ash is collected in
the lower side of the silencer, and can be removed via the plugged cleaning opening
on the bottom.
This component requires regular inspection and cleaning.

Spark arrester cleaning opening

During servicing, remove the plug to extract the spark ash through this opening

Exhaust gas cooler (optional)

The cooler is a box-shaped water jacket that leads the exhaust gas flow through
cooling tubes from the engine exhaust manifold to the silencer. The exhaust
manifold (not shown) is also water-cooled. The water jacket coolant is itself cooled
in the cooling system radiator.This component requires no routine servicing.

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4.6.3

Engine fuel system

4 Functional description

6
13

10
7
3

11

12

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Fuel tank cap

Located in the right side plinth of the power pack, accessible for filling at a regular
service station. Use only diesel fuel of an approved grade (see specifications).

Fuel tank

Tank installed in power pack.

Fuel isolation valve

Close during transport, and when servicing filters. Open before starting.

Fuel coarse particle filter

First cleaning stage for diesel fuel.


Cleanable metal Y-filter that sifts coarse contamination from the fuel drawn from the
tank. Requires routine servicing.

Fuel prefilter & water separator

Second cleaning stage of diesel fuel. Accumulated water must be regularly drained
(manually). Disposable filter element in upper section.

Fuel primer pump

Use only when the fuel tank has run empty or when air has entered the fuel system
during servicing of filters.
Press several times to pump fuel from the tank into the fuel pump before starting.

Fuel fine particle filter

Third cleaning stage for diesel fuel after the fuel pump. Disposable element.

Fuel pump

Fuel pump driven by adjacent PTO gearbox (behind compressor).


From here, the fuel passes to the engine injectors via the engine safety valve.

Fuel return line check valve

Prevents fuel from passing through the fuel return line during an emergency
shutdown.

10

Engine safety valve (shown in


engine running position

For description see 1 Engine fuel safety valve on page 39


NOTE: Also referred to as the Sentinel valve

11

Fuel tank breather

Ventilates the fuel tank.

12

Fuel gauge

Shows fuel level in tank.

13

Fuel purifier

Removes suspended water and emulsions from fuel of dubious quality. Requires
periodic draining from bottom of vessel.

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4.6.4

Hydraulic engine starter (optional)

4 Functional description

5
4
2
6

Hydraulic starter

Used to start the engine. Stored pressure in the hydraulic accumulator is released to
the starter which in turn starts the engine.

Hydraulic accumulator

Used to store hydraulic pressure for the hydraulic starter.

Accumulator isolation valve

Used to isolate the accumulator to store the charge for later starts. Must be opened
before starting, and closed before shutting down (or after charging).

Engine start button

When turned, stored hydraulic pressure from the accumulator is released to the
hydraulic starter which in turn starts the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.

Start pressure gauge

Indicates available start pressure in the accumulator.

Hand pump

Used to manually restore pressure to the hydraulic accumulator.

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4.6.5

Pneumatic engine starter (optional)

3
4

Start pressure gauge

Indicates available start pressure.

Engine start button

When depressed, compressed air is delivered to the air starter which in turn starts
the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.

Air filter/dryer

Compressed air filter/dryer for the starter pneumatic circuit..

Pneumatic starter

Used to start the engine. Compressed air from the rig/shore or another external
source turns the starter which starts the engine.

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FlyLine User Manual

Spring engine starter (optional)

4 Functional description

4.6.6

2
4

Hand crank

Used to turn the winding nut.

Winding nut

Turning this winds up the spring.

Spring tension sight glass

This shows the tension on the spring.


Green: not wound
White: standard charge for a warm start (ca. six turns)
Red: extra charge for a cold start (ca. 8 turns)

Spring starter

Spring-powered starter assembly

Spring trip lever

Pulling this down engages the starter with the flywheel, releasing the spring
pressure to start the engine.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.

Reset button

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This button should be pressed every time before winding up the starter, or the
starter could be damaged.

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FlyLine User Manual

4.6.7

Cooling systems

6
5
3

5
1
1

Engine coolant & hydraulic fluid


radiator

Coolant and hydraulic fluid circulates from this radiator

Cooling fan

This v-belt driven fan draws cool air over the engine radiator

Exhaust gas cooler

Lowers the exhaust gas temperature to a safe working temperature.

Coolant filling cap

Located behind access hatch. Use to fill coolant.

Coolant sight glass

Use to check coolant level.

Coolant filling cap access hatch

Protects inside of unit. Use to access coolant filling cap.

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FlyLine User Manual

4.6.8

Additional features of Heavy Duty power packs

4 Functional description

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FlyLine User Manual

Turbocharger

Allows the engine to produce more power by forcing more air and fuel into the
combustion chambers.

AIR INLET VALVE (push / pull


type)

Override for the automatic valve closure to enable the engine to start. When the
engine is running, the valve must be controlled by the Zone 2 safety system. PULL
before starting the engine, and hold in place. Then PUSH in when the engine oil
pressure reaches 2.0 bar (29 psi), so that the automatic control can take over after
the engine start. The air inlet valve is automatically closed to kill the engine when
the engine or winch safety systems detect a hazardous condition. Without air, the
combustion in the diesel engine cannot take place.
WARNING: Do not run the engine with the air inlet valve handle left in the pulled out
position. This can prevent the engine from shutting down in a Zone 2 hazardous
situation!

Engine overspeed control valve


(pneumatic)

The tachometer in the main control panel is driven by the cable from the output
above the compressor. The cable passes through this pneumatic control valve (NC)
which is preset to open at 2500 rpm. The engine normally will run at a lower speed
than this. An overspeed may be a sign of an explosive air/gas mixture in the
ambient air. When the valve is opened, it triggers the Zone 2 engine shutdown.
The overspeed controller features a reset button. The engine cannot be started
again until the overspeed controller is manually reset by pressing this button.

Larger exhaust gas cooler

In addition to the standard functions of the exhaust gas cooler (see Exhaust gas
cooler (optional) on page 39) this larger cooler also supplies cooling for the
turbocharger.

Larger engine radiator

In addition to oil and coolant this radiator also cools incoming air for the
turbocharger.

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FlyLine User Manual

4.7

Pneumatic system

5
10

4 Functional description

11

13
8
14
7

4
1

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FlyLine User Manual

Pneumatic energy supply system


1

compressor

Water-cooled air compressor driven directly by engine. See specifications.


Air intake is from engine air filter via the flexible metal suction line.

governor valve

Limits output pressure to a maximum (8 bar).

compressor intake line

Draws filtered air from engine air intake (after engine air filter).

compressor pressure line

(Metal-wrapped line). Delivers compressed air to receiver/filter setup.

safety valve

Relieves overpressure from receiver. Opens automatically at 10 bar.

Air receiver

Compressed air accumulator for air from compressor only (not rig air).

Connection 7

Female connector - air supply to winch

Connection 8

Female connector - air EM-stop

water separator/filter (optional)

Air filter and water separator for air starter systems. mounted on power pack right
door.

receiver isolation valve

Must be open during operations.


Close when necessary to store compressed air e.g. for cold start, or for safety
during maintenance.

10

11

Water separator/filter

Air filter and water separator for the pneumatic system.

12

engine & compressor air filter

Disposable-element air filter. See specifications.

13

Rig air in connector

Optional connection for rig air. Installed on units with an air starter.

14

Air out connector

Located on winch module. Can be used to supply power for pneumatic equipment.

4 Functional description

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4.8

Hydraulic system

13
2

4 Functional description

10
12
17

11
14
15

19
5

16

3
6

18
9

8
12
7

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FlyLine User Manual

Closed loop hydraulic system

This unit uses an NOV Elmar closed loop hydraulic system to transfer mechanical
energy from the power source (engine or motor) to the winch and auxiliary control
features. When necessary, this primary system may be augmented with one or
more additional open loop hydraulic circuits to power additional features, either from
the main power source or an auxiliary engine or motor.

Hydraulic oil filler cap

Hydraulic oil tank filler cap. Strict cleanliness is advised!

Hydraulic oil tank

Main reservoir for all hydraulic functions of the FlyLine.

Hydraulic fluid gauge

Gauge for hydraulic fluid

Connection 5

Male connector - control pressure

Hydraulic oil tank drain plug &


valve

Used for servicing of the hydraulic system, to drain off condensation water, or to
drain out all the oil.

Main circuit suction filter

Single suction filter to remove contamination from the oil before entering the pump
for the main (winch) circuit.
The filter must be replaced whenever the condition indicator moves into the yellow
zone (with power pack running).
NOTE: Never allow the filter condition to move into the red zone. When this
happens, the oil is no longer filtered!

hydraulic tank isolation valve

Dual-head suction filter to remove contamination from the oil before entering the
pumps for the auxiliary circuit and cooling fan circuit.
Isolation valve = OPEN whenever the power pack is running.
Close the isolation valve when servicing the filters.

Connection 9

Male connector - drain

10

Connection 10

Male connector - main outhole

11

Connection11

Female connector - main inhole

12

hydraulic pump stack

Hydraulic pumps for the main, control and auxiliary circuits, mounted on the drive
shaft of the engine.

13

hydraulic oil radiator

The oil radiator forms part of the cooling stack in the left side of the power pack.
Return flows from the main and auxiliary circuits are combined in a manifold, and
pass through the radiator before returning to the hydraulic tank.

14

Auxiliary drive connection

See 4.9 Auxiliary drive (optional) on page 52

15

Auxiliary drive connection

See 4.9 Auxiliary drive (optional) on page 52

16

Auxiliary drive connection

See 4.9 Auxiliary drive (optional) on page 52

17

Connection17

Female connector - servo Y1 outhole

18

Connection 18

Male connector - servo Y2 outhole

19

Connection 19

Female - line tension

1
hydraulic reservoir
oil cooler

drain

suction
filter
pump

main circuit

winch
motor

various
motors

various
controls

control circuit
various
actuators

Figure 4.4 Typical ASEP Closed Loop hydraulic system

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4
5

FlyLine User Manual

4.9

Auxiliary drive (optional)

4 Functional description

1
5

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Pressure quick connector

Drain quick connector

Return quick connector

AUXILIARY PRESSURE

This gauge shows the air pressure in the auxiliary circuit

Auxiliary drive lever

Use this lever to select between normal operation and auxiliary


drive mode

Auxiliary drive pump

This pump supplies hydraulic pressure for the auxiliary drive

Hydraulic filter

Additional hydraulic filter for the auxiliary circuit

The optional auxiliary drive is an open loop hydraulic circuit intended to power additional
equipment, such as a mast. The pump is always operational when the power pack is running, with
the flow automatically returned to the oil reservoir unless activated at the control panel. Three
quick connectors located at the front of the winch bay are provided for connection to auxiliary
equipment. The attached equipment must have its own control features, as the FlyLine only has
a simple on/off control for the circuit.

4 Functional description

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4.10

Electrical system

4.10.1 Zone 2 units

5
2
4 Functional description

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ECP 2

Controls for most electrical functions.

AC IN socket

Located on the inside of the winch bay left door

Alternator

24 VDC alternator. Generates power when unit running.

24 VDC batteries

Supply standby power for all electrical functions, and starter power for units with
electric starter

Battery switch

Isolation valve for the batteries

Fuses and circuit breakers

There are different types of fuses and circuit breakers used in the FlyLine. The type
of fuse used depends on the specifications of the electrical system. In general, the
following rule applies:
12/24-volt blade type fuses (typical automotive fuse)
115/230-volt cartridge fuses (glass) and circuit breakers
The fuses are marked with an identification number that corresponds with the F
number stated on the electrical diagrams. The description on the diagram indicates
the trip level in Amps. See 8.44 Replace fuse or circuit breaker on page 198 for
information on fuses, and how to change them.

NOTE: See the electrical diagram in your documentation package for a full explanation of the
electrical system.

4 Functional description

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4.11

Depth and tension measurement systems

4 Functional description

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FlyLine User Manual

MP16 II

NOV Elmar depth and tension measurement device. See separate measure head
MP16 II documentation.

MP20

NOV Elmar depth and tension measurement device. See separate measure head
MP20 documentation.

SmartMonitor (optional)

NOV Elmar SmartMonitor display. See separate NOV Elmar-supplied


documentation.

CombiGauge

NOV Elmar analogue depth and tension display. See separate measure head
MP16 II documentation.

USB connection (optional)

USB connection to SmartMonitor. See separate SmartMonitor documentation for


using the USB functionality.

The FlyLine can be configured with either an NOV Elmar MP16 II (1) or MP20 (2) MeasureHead,
which provides wireline depth and tension signals to a separate remote display. The measuring
head is a three wheel wraparound design with two upper wheels and one lower wheel. Wireline
replacement can be achieved without cutting the wireline.
An accurate tension display can be achieved, when used together with an NOV Elmar
CombiGauge (4). Accurate depth display is provided mechanically via a cable running from the
depth gearbox to the CombiGauge. For more detailed tension and depth display, the unit can be
equipped with an optional NOV Elmar SmartMonitor (3). The SmartMonitor can visualise and
record all ongoing jobs, as well as visualise and record all relevant unit parameters.
4 Functional description

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4.12

Winch subsystem

4.12.1 Overview

15
20
6

21
17
1
13

4 Functional description

19
4
16

5
4

8
12
18

3
2

NOTE: Picture shows double drum configuration.

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FlyLine User Manual

Winch Drums

See Appendix 5: Unit configuration on page 244 for drum part numbers

Front drum

Drum nearest wellhead.

Drum motor

Hydraulic drive motor for each drum.

Reduction gearbox

Increases torque delivered to drum. Requires periodic maintenance (oil level).

Drum drive chain

Reduction transmission between the reduction gearbox and the drum. Acts directly
on drum rim sprocket. Requires periodic adjustment.

Pillow block bearing (2 x)

Complete bearing assembly for each end of each drum shaft. Adjusters on the
winch frame are used to position the shaft precisely.

Drum drive chain guard

Drum motor transmission guard

Not shown. Covers drum motors and reduction gearboxes from dirt.

Drum control

Dual-lever control for winch drum direction, speed and torque. Both levers directly
control the hydraulic winch drive system. Each lever is continuously adjustable, and
can be locked or released in any position, leaving the operator's hands free.
left hand dual control handle: speed
right dual control handle: inhole/outhole

Gearbox sight glass (2 x)

Normal gearbox oil level mid-point of this sight glass (one each gearbox, not shown
in this picture).

10

Gearbox filler point (2 x)

Filler point with cap for replenishing gearbox oil. (one each gearbox, not shown in
this picture).

11

Gearbox drain point

Drain point with cap for draining gearbox oil. (one each gearbox, not shown in this
picture).

Drum brake system


12

Drum brake cylinder 2 x

13

Drum brake band 2 x

14

Drum brake guard

See 4.12.2 Drum brake system on page 60 for a description

Not shown. Covers drum brakes from dirt.

Level winding system


15

Levelwind drive chain

16

Levelwind drive chain

17

Levelwind shaft

18

Levelwind control wheel

19

Levelwind guide rail

20

Cardan shaft for levelwind

21

Measuring head transport lock

The chain is attached to the measuring head, which runs along the levelwind shaft.
Requires periodic maintenance.
Smoothly polished shaft, that supports the measuring head, and allows it to travel
smoothly side to side on a slide bearing.
A roller at the rear of the measuring head carrier runs in this rail, keeping the
measuring head perfectly steady during operations. The rail can be removed during
rig-down so that the measuring head can be stowed.

See Appendix 5: Unit configuration on page 244 for available drums and part numbers.

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4

FlyLine User Manual

4.12.2 Drum brake system

4 Functional description

3
4

7
9

HYDR/PNEUM PRESSURE APPLIED:


PISTON (5) EXTENDS,
SPRING (9) IS COMPRESSED,
BRAKE IS RELEASED

HYDR/PNEUM PRESSURE RELEASED:


SPRING (9) EXTENDS,
PISTON (5) RETRACTS,
BRAKE IS APPLIED

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FlyLine User Manual

Brake band section

Lower adjuster with locknut

Brake cylinder

Brake piston

Brake linkage attachment

Brake cylinder lid

Expansion chamber

Brake actuating spring

Hydraulic or pneumatic supply connection

The drum(s) are braked by a brake system contracting the brake band around the rim of the
winch drum. This brake has two functions:
as a parking brake, to prevent the drum from turning due to downhole forces (weight of
tool string and wireline)
as an emergency brake, to rapidly and smoothly halt the drum in the event of an
emergency or sudden failure of the units systems
The brake is not intended to slow or stop the drum during normal operations.

1.

A spring (inside a hydraulic brake cylinder) is pre-compressed during assembly and retained
by the brake cylinder lid.

2.

When pressure is present in the brake pneumatic or hydraulic circuit (BRAKE released), a
piston is extended, releasing the brake - this movement compresses the spring. If pressure
is lost (BRAKE applied, EMERGENCY OFF pressed or a system failure), the spring will expand,
forcing the brake piston back into the cylinder, and applying the brake.

The brake band system is designed to be assisted by the inhole rotation of the drum. The brake
is therefore more effective in the inhole than the outhole direction.
Double drum winch frames have separate brake system(s) per drum.
See the maintenance section of this manual for procedures to test, inspect, adjust and replace
the brake band(s).

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4 Functional description

The brake system is fail-safe and works as follows:

FlyLine User Manual

4.13

Wellhead pressure control systems


The FlyLine units can be optionally configured with wellhead pressure control equipment. This is
used to lower and raise the wireline and tool string into the well safely. It can also be used to
hermetically close off the well in an emergency situation (gas escaping).

4.13.1 BOP control (non-standard option)

5
6

4 Functional description

8
2
3
4

9
10

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FlyLine User Manual

Hydraulic accumulator for BOP

Upright hydraulic accumulator exclusively for actuation of dual


BOP rams. The accumulator has an isolation valve in the
underside.

Pneumatic booster pump

This pump is controlled with the PRESSURE REGULATOR to


pressurize the Hydraulic accumulator for BOP

Accumulator isolation valve

Isolates the pressure in the Hydraulic accumulator for BOP

Accumulator pressure gauge

Show the pressure stored in the hydraulic accumulator

BOP PRESSURE

This gauge shows the pressure available to the BOP rams.

BOP PORT PRESSURE

This gauge shows the pressure available to the BOP port.

PRESSURE REGULATOR

This control controls the Pneumatic booster pump to build up


pressure in the Hydraulic accumulator for BOP

BOP CONTROL

3-position valve. Controls the state of the UPPER BOP ram


set. Requires sufficient pressure ( 2,000 psi), as indicated in
the BOP PRESSURE gauge

CLOSE: Close BOP ram and maintain ram pressure.


The OPEN line will drain to the hydraulic tank.
OFF: Hold current BOP ram state, isolated from BOP
system hydraulic pressure supply or dump.
OPEN: Open BOP ram and maintain ram pressure. The
CLOSE line will drain to the hydraulic tank.

BOP CLOSE

Connector for the BOP CLOSE line

BOP OPEN

Connector for the BOP OPEN line

Compressed air is supplied to the combined control panel. The compressed air drives a hydraulic
pump (represented by on the control panel). The air supply to the hydraulic pump is controlled by
a dial regulator (1), which can be set to achieve the desired hydraulic pressure. The hydraulic
pump supplies hydraulic pressure to the BOP. The hydraulic pressure supplied by the pump is
displayed on a gauge (2). The hydraulic pressure is backed-up by an accumulator (represented
by on the panel), which is mounted in the winch unit. This accumulator can be isolated from the
system by closing a valve in the winch module.
When the hydraulic pump is activated, hydraulic fluid from the oil tank (Figure 5.14) is pumped
via the high pressure hoses (Figure 5.14) to the BOP assembly, depending on the setting of
hydraulic selector valve (3). To control the BOP, hydraulic selector valve (3) can be set to either
OPEN, OFF, or CLOSE. Pressure gauges (4) displays the hydraulic pressure that is present at the
BOP assembly in either the open or closed positions.

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4 Functional description

9
10

FlyLine User Manual

4.13.2 Stuffing box

4 Functional description

3
8
6
5

Figure 4.5 Stuffing box hydraulic pump in cabin and connection point at winch

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Pump handle

Insert into the pump handle socket to enable pumping hydraulic pressure.

Pressure gauge

Indicates pressure in the Stuffing box hydraulic system.

Pump handle socket

Insert the removable pump handle here.

Secondary isolation valve

To control pressure in the Stuffing box hydraulic system

Primary isolation valve

To control pressure in the Stuffing box hydraulic system

Hydraulic oil fill point

Replenish the hydraulic oil reservoir here

Hydraulic oil reservoir sight glass

Check the level of hydraulic oil in the reservoir here.

Stuffing box quick connector

Connect the stuffing box flexible hose quick connector here

NOTE: The FlyLine stuffing box is a non-standard option.


The stuffing box hydraulic hand pump and the stuffing box isolation valves and gauge are located
under the control panel.
The stuffing box hand pump has a built-in one-litre hydraulic oil reservoir that can be replenished
if necessary (2). The hand pump to applies pressure to the hydraulic packing nut in the stuffing
box.

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4 Functional description

The stuffing box control hose is connected to the stuffing box quick connector (3) located at the
front of the winch bay. The control hose can be found on a reel inside the winch door. A label
explains the connection function for the quick connector.

FlyLine User Manual

UNIT CONTROLS

5 Unit controls

Figure 5.1 Winch controls

7
6

Figure 5.2 Power pack controls

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Winch left control panel

See 5.2 Winch left control panel on page 70

CombiGauge

NOV Elmar analogue depth and tension display. See separate


MP20 and MP16 II documentation.

Steering wheel

This wheel controls the lateral movement of the measuring head when spooling the
wire onto the drum. (outhole)

SmartMonitor location (optional)

NOV Elmar SmartMonitor display. See separate NOV Elmar-supplied


documentation.

Winch right control panel

See 5.3 Winch right control panel on page 72

Battery switch

(Optional) Switches on the DC circuit for the FlyLine unit

Power pack control panel

See 5.1 Power pack control panel on page 68

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5.1

Power pack control panel

10

11

5 Unit controls

12

13
14

15

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CONTROL PRESSURE

This gauge (0 to 41 bar (600 psi)) shows the hydraulic control pressure, which is used
for controlling the hydraulic system.

AUXILIARY PRESSURE

This gauge (0 to 280 bar (4000 psi)) shows the hydraulic pressure in the auxiliary
circuit

HYDRAULIC OIL
TEMPERATURE

This gauge (0 to +120 C (+250 F)) shows the hydraulic oil temperature. The value is
measured in the main hydraulic oil reservoir.

ENGINE TEMPERATURE

This gauge (0 to +120 C (+250 F)) shows the engine temperature. The value is
measured in the engine coolant between engine and radiator.

ENGINE OIL PRESSURE

This gauge (0 to 11 bar (160 psi)) shows the engine oil pressure. The sentinel master
valve (fuel shut-off safety valve) will shut down the engine, when this value drops
below 0.5 bar (7.2 psi) (approximately). During normal working conditions the oil
pressure will be 2.3 bar (33 psi) (approximately); at maximum engine RPM, the oil
pressure will be 4 bar (58 psi) (approximately).
This gauge (0 to 11 bar (160 psi)) shows the air pressure in the system.

AIR PRESSURE

START PRESSURE
This gauge shows the current starting pressure available for the engine starter. This
(Only with air or hydraulic start) gives the hydraulic pressure (0 to 280 bar (4000 psi)) for the hydraulic starter and air
pressure (0 to 11 bar (160 psi)) for the pneumatic starter.
NOTE: This gauge is not present on units equipped with the other starter types.

EXHAUST TEMPERATURE

This gauge (0 to +250 C (+480 F)) shows the exhaust temperature. The value is
measured in the spark arrester/silencer. This gauge is present on Zone 2 units only,
not on rig-safe units.

TACHOMETER

This gauge (0 to 3000 rpm) shows the engine speed in revolutions per minute.

ENGINE START

This button starts the engine on units with air or hydraulic starters. The button is
returned to the starting position by a spring.
WARNING: Do not activate the starter when the engine is running or within 15
seconds after a failed start attempt.

11

ENGINE STOP

Press and hold to shut down the engine of the power pack (normal shut down).
NOTE: If you release the button too soon, the motor will restart.

12

EMERGENCY STOP

Press this control to fully shut down the unit. To restart the unit, the main switch on the
main control panel must be reset.
Never restart the unit without checking that the cause for the emergency stop has
been resolved.
Never use the emergency stop as a control to stop the unit during normal
operations.
NOTE: There is also an EMERGENCY STOP button on winch right control panel.

13

AUXILIARY DRIVE
(Option)

Rotary ON / OFF switch to enable / disable the auxiliary circuit


NOTE: This is an option, and is not present on all units. See Appendix 5: Unit
configuration on page 244 for part numbers

14

AIR INLET VALVE

Use this handle to control the engine safety air intake control valve. It overrides the
automatic air inlet valve closure to enable the engine to start.
The air inlet valve is automatically closed to kill the engine when safety systems detect
a hazardous condition. Without air, the combustion in the diesel engine cannot take
place.
General units: Push the handle up to bypass the engine motor oil pressure safety
system to allow the engine to be started. Hold the handle in the upper position until the
motor oil pressure has risen to approx. 2 bar.
Pull the handle down to emergency stop the diesel engine. Pulling the handle down
will close the engine air intake valve.
For restart wait for the engine derived vacuum to disappear.
Heavy duty units: Pull before starting the engine, to latch the air inlet valve open,
then push once the engine is running so that the automatic control can take over.

15

THROTTLE

Engine speed control. Push and hold the button to release the lock.
Pull to increase rpm
Push to decrease rpm
Release the button to lock the speed. Fine adjustment (when locked):
Turn counter-clockwise to increase rpm
Turn clockwise to decrease rpm

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5 Unit controls

9
10

FlyLine User Manual

5.2

Winch left control panel

5 Unit controls

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CONTROL PRESSURE

This gauge (0 to 41 bar (600 psi)) shows the hydraulic control pressure, which is used
for controlling the hydraulic system.

MAIN PRESSURE

This gauge (0 to 410 bar (6000 psi)) shows the hydraulic pressure generated by the
main hydraulic pump.

HORN

This button sounds the horn

Left DRUM CONTROL

This lever (HIGH SPEED) controls the speed and torque obtained from the hydraulic
motor. The maximum up or down position will generate the fastest drum speed
(greatest hydraulic flow) with the least available torque.
The position of this lever limits the range of the right (INHOLE/OUTHOLE) lever.

Right DRUM CONTROL

This lever (INHOLE/OUTHOLE) controls the winch drum direction, speed and torque by
regulating the direction and flow delivered by the main hydraulic pump. The further the
joystick is moved in the INHOLE or OUTHOLE direction, the higher the speed. To slow
the winch down, move the stick back towards the neutral position.
INHOLE: spools wireline off the drum (into the hole)
STOP: neutral position (lift collar to release)
OUTHOLE: spools wireline onto the drum (out of the hole)
Near the middle position, speed is lowest, torque is highest. At the furthest position
(HIGH SPEED), the hydraulic flow is maximum, highest speed and lowest torque.
NOTE: The maximum possible torque is set by the LINE TENSION valve (See Line
Tension on page 73).

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5.3

Winch right control panel

5 Unit controls

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AIR PRESSURE

This gauge (0 to 11 bar (160 psi)) shows the air pressure in the system.

EMERGENCY STOP

Press this control to fully shut down the unit. To restart the unit, the main switch on the
main control panel must be reset.
Never restart the unit without checking that the cause for the emergency stop has been
resolved.
Never use the emergency stop as a control to stop the unit during normal operations.
NOTE: There is also an EMERGENCY STOP button on the power pack control panel.

BRAKE ON/OFF

This switch operates the brake. Move the switch down to activate the drum brake; move
the switch up to release the brake.

BRAKE SELECT

This switch selects which drum (front or rear) that the BRAKE will be applied to.

LINE TENSION

Rotary control for adjusting the pressure level, at which a pressure relief valve will open to
limit the torque delivered to the drum.
+ Increase the maximum possible pressure
Decrease the maximum possible pressure
To avoid parting the wire, always set this control to a level under the value specified for
your wireline.
CAUTION: EQUIPMENT DAMAGE. Prolonged operation of the unit at pressure levels
above the safety valve setting can overheat the hydraulic oil, damaging the system. If the
hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.

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SETUP AND REMOVAL

6.1

Moving/positioning equipment
NOTE: This section provides general guidelines for moving and positioning the FlyLine
modules, using the standard features and unit accessories. For detailed instructions on
how to safely move and position equipment, refer to your local regulations.

WARNING

TXT-10004328/A

HOISTING HAZARD
Heavy suspended objects can fall down causing serious injury or death.
Never walk underneath a suspended load, or place yourself between a suspended load and
another object. Follow local safety regulations.

WARNING

TXT-10004327/A

HOISTING HAZARD
Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury
or death.
Never use the forklift pockets for hoisting.

WARNING

TXT-10004271/A

6 Setup and removal

CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.

WARNING

TXT-10004360/A

SHARP OBJECT
Sharp or rough objects can cause severe cuts.
Always wear gloves when handling sharp or rough objects.

6.2

Hoisting modules
NOTE: The lifting equipment must only be used by qualified personnel.
1.

Make sure all lifting equipment:


is sufficiently dimensioned.
has the correct certification and is marked accordingly.
has been regularly inspected for deformation and wear in accordance with EN 12079.

2.

Make sure any lifting equipment repairs have been carried out in accordance with EN 12079.

3.

Make sure the end rail is fitted, if applicable (winch module only).

4.

Make sure the module has been correctly prepared for transport: all parts stowed, and all
doors and hatches closed and locked.

5.

Attach the lifting chains to an appropriate lifting device.


Refer to your local regulations for the type of hoist required.
Refer to the module date plate for the weight of the module.

6.2.0.1 Hoisting modules using lifting pad eyes (4x)


1.

Make sure the single point lifting beam and all fittings have been removed.

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The lifting chains of the hoist might become entangled in the lifting beam and fittings if they
are not removed,
2.

Attach the lifting chains to the lifting pad eyes (4x) of the module as shown in
4.4 Transportation features on page 32. Make sure all shackles are correctly attached with
a bolt and nut and secured with a split pin.

3.

Hoist and position the module according to local regulations.

6.2.0.2 Hoisting winch module using single point lifting beam


NOTE: The single point lifting beam must not be used to transport the winch module in the field.
It should only be used during maintenance.
1.

Remove the single point lifting beam from the storage brackets.

2.

Attach the single point lifting beam to the top of the winch module, using the supplied nuts
and bolts. Secure each nut and bolt with a split pin.

3.

Attach the lifting chains to the single point lifting beam.

4.

Make sure the shackle is correctly attached with the bolt and nut and secured with a split pin.

5.

Hoist and position the module according to local regulations.

6 Setup and removal

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6.2.1

Position module using side wheels

WARNING

TXT-10004272/A

CRUSH HAZARD
Heavy parts can drop suddenly during dismantling and assembly.
Keep hands, fingers, etc. away from heavy objects that are liable to move suddenly or drop.
Use suitable tools, chocks, blocks, etc. to support heavy objects.

6 Setup and removal

1.

Align the jacking wheel pin with the hole in the frame.

Figure 6.1
2.

Push the jacking wheel pin into the frame until the pin holes in the jacking wheel align with
the pin holes in the frame.

Figure 6.2

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3.

Insert the locking pin in the pin holes, and secure with a linchpin.

Figure 6.3
4.

Lift the unit with the jack by turning the handle clockwise until the jack extends approximately
8 cm.
6 Setup and removal

Figure 6.4

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5.

Place the side wheel next to the opening in the raised part of the frame.

6.

Make sure the base of the side wheel is correctly oriented as shown in the following figure.

Figure 6.5
Push the side wheel base fully into the opening.

8.

Attach the opposite side wheel by repeating steps 5 through 7.

6 Setup and removal

7.

Figure 6.6

WARNING

TXT-10004272/A

CRUSH HAZARD
Heavy parts can drop suddenly during dismantling and assembly.
Keep hands, fingers, etc. away from heavy objects that are liable to move suddenly or drop.
Use suitable tools, chocks, blocks, etc. to support heavy objects.

9.

Turn the jacking wheel handle counter-clockwise to fully lower the module onto the two side
wheels.

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10. Remove the locking pin, and detach the jacking wheel.

11. Place the jacking wheel against the other side of the unit and repeat steps 1 through 10.
12. Unfold the towing handle.
The module can now be transported on the side wheels.

Figure 6.8

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6 Setup and removal

Figure 6.7

FlyLine User Manual

6.3

Rig-up

6.3.1

Position unit

danger zone

1
6 Setup and removal

Figure 6.9 Correct positioning of winch in respect to hay pulley


Before positioning the unit at the site, survey the location where it will be used. See Figure 6.9.
The unit should be aligned with the center line so that its operating angle (2) is less than
1.5 degrees.
The distance (1) from the measuring head to the lower hay pulley should not be less than:
15 m (50 ft) for 700 mm wide winch drums
20 m (65 ft) for 1054 mm wide winch drums
There should be sufficient room on all sides for opening doors/hatches.

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6.3.2

1.

Move the modules to their operating positions by following the instructions in 6.1 Moving/
positioning equipment on page 74

2.

Align the unit or winch module to the hay pulley, as shown in Figure 6.9.

3.

Mark out the hazardous area between the FlyLine and the wellhead with tape, to prevent
unauthorized persons from entering the danger zone. See 2.2.5 Wireline on page 10.

4.

Anchor the winch to the ground surface, or some immovable point behind the winch,
according to site regulations.

Ground unit

WARNING

TXT-10004301/A

EXPLOSION HAZARD
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been correctly grounded before performing any work on the
unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.

1.

Ground the unit or individual modules to the rig/wellhead and to each other, as required by
site/government regulations.

2.

Inspect each grounding cable carefully:

It must be long enough to reach between the two grounding points without disturbing
operations.
The terminators at each end must be undamaged, and free of corrosion. If necessary,
clean the terminators with a wire brush, and lightly grease them with acid-free petroleum
jelly.
The cable itself must be undamaged, with no kinks or snags, and with a full thickness over
the entire length.
3.

Inspect each grounding terminal carefully.


The terminal must be undamaged and free of corrosion. If necessary, clean the terminal
with a wire brush, and lightly grease it with acid-free petroleum jelly.
The washers and nuts (2 x) must be present on the terminal, and they must only be brass
or stainless steel. No steel washers or nuts may be used, and all nuts and washers must
be of the same type of metal as the terminal stud!

4.

Connect the grounding cable from the wellhead/rig, and firmly tighten the nut, using the brass
or SS washer between the nut and the cable ring lug.

5.

For all modules, connect ground cables between the modules.

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6 Setup and removal

The cable must be a proper grounding cable, with the right colour insulation (green &
yellow).

FlyLine User Manual

6.3.3

Set-up unit (open doors and hatches)

WARNING

TXT-10004268/A

CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.

6 Setup and removal

Refer to the accompanying figures 6.10 and 6.11 for the following steps:
1.

On the winch module, open doors and hatches as required.

2.

Remove the single lift beam (1), if applicable.

3.

Remove the securing pins for the end rail (2), and place rail into the storage brackets under
the dashboard.

4.

Release the locking pins (3) for the dashboard protective cover (4) on both sides and lock in
the open position.

5.

Swing the cover out and raise it up onto the roof and secure it in place using the same locking
pins.

6.

Raise the levelwind protective cover (5).

7.

Release the locking pins (6) for the operators window and roof on both sides.

NOTE: Rigging up the roof and windshield is normally a one man operation. However, if
necessary coordinate with an assistant to help raise and secure.

WARNING

TXT-10004270/A

CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.

8.

Lift the operators window and roof upwards and towards you on the hinges. When roof is
fully employed put the strut brackets (7) in place to lock the gas struts.

9.

Lock the operators window in place using the same locking pins (6) in front of the window.

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stupid

6 Setup and removal

Figure 6.10 Safety window locks


10. Release the securing pin and swing operators seat bracket (8) from the transport position
out to desired position.

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6 Setup and removal

9
8
Figure 6.11 Winch set up.
11. Remove the operators seat (9) from its transport location in front of the winch, and mount it
into the chair bracket to desired height using its securing pin.

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6.3.4

Connect hydraulic and pneumatic hoses

WARNING

TXT-10004322/A

HIGH PRESSURE
(Dis)connecting a pressurized line can cause serious injury and or equipment damage.
Never connect or disconnect any quick connectors when the supply line is pressurized.

Refer to 4.7 Pneumatic system on page 48 and 4.8 Hydraulic system on page 50 for descriptions
of the connections.
1.

Make sure the air out isolation valve in the winch module is closed.

2.

Make sure that the LINE TENSION control is set to minimum to release any residual pressure
in the circuit. See Appendix 5.3: Winch right control panel on page 72.

3.

Connect the hydraulic/pneumatic hoses from the winch to the appropriate connectors on the
power pack bulkhead as follows:
NOTE: Make sure you have plenty of unused, clean rags or wipes on hand.
a) Check the connection
number near the hose
connection ferrule.
6 Setup and removal

b) Identify the corresponding


coupling on the power
pack.
c) Remove the dust cap on
the power pack coupling,
and clean the coupling.
d) Remove the dust cap from
the hydraulic/pneumatic
hose, and clean the
coupling thoroughly.
e) Make the connection, and
pull on it to be sure it is
secure.
4.

Figure 6.12 Hydraulic/ pneumatic quick connectors

If rig/shore air is required proceed as follows:


a) Make sure a clean filtered compressed air supply (pressure between 7 and 10 bar) is
available.
b) Make sure the rig/shore air supply is isolated at source.
c) Make sure the air isolation valve in the power pack is closed.
d) Make sure the isolation valve on the air receiver is open.
e) Connect the air supply to the air connection point in the power pack.
f) Slowly open the rig/shore air supply at source.
g) Slowly open the air isolation valve in the power pack.
h) Check the air supply to the FlyLine. The AIR PRESSURE gauge on the power pack control
panel should read at least 7 bar, but no more than 10 bar. Troubleshoot the air supply, if
necessary.

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5.

If output air is required:


a) Make sure the air out isolation valve in the winch module is closed.
b) Remove the protective cap
c) Connect an external air hose to the connector.

6 Setup and removal

d) Open the air out isolation valve, as required.

Figure 6.13 Winch and power pack modules connected

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6.3.5

Prepare measuring head assembly


1.

If the drum and wireline are not installed or need to be replaced, load the drum as described
by the supplier, and install the drum as described in 8.42 Replace drum on page 191.

2.

Open the left side doors on the winch module to access the measuring head.

For MP16 measuring head continue with step 3; for the MP20 proceed to step 6 for setup.
3.

Refer to Figure 6.14. Release the measuring head from the transport position as follows:
a) Set the lock pin (2) to the horizontal position.
b) Slide the measuring head (3) by hand away from the transport position.
c) Return the lock pin (2) to the vertical position to prevent it from accidentally locking during
operations.

6 Setup and removal

3
Figure 6.14 MP16 measuring head transport lock
4.

If necessary, adjust the levelwind chain by performing 8.11 Check/adjust levelwind chain
tension on page 126.

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5.

Thread the wireline and check the measuring head for operations. Refer to the Measuring
Head User Manual in the Documentation Package for further information.

For MP 20 proceed as follows:


6.

Refer to Figure 6.15. Release the measuring head (3) from the transport position as follows:
a) Set the measuring head lock pin (2) to the horizontal position.
b) Slide the measuring head by hand away from the transport position.
c) Return the lock pin to the vertical position to prevent it from accidentally locking during
operations.

7.

Remove pin from lower transport position (4) for the guide rail (5).

8.

Pull the measuring head towards you with the right hand and with the left hand pull out the
locking pin from the measuring head resting bracket (6), allowing the bracket to lower to the
bottom frame of the winch module.

9.

Lock the bracket in the lowest position with the locking pin so that measuring head rests
securely in place.

6 Setup and removal

NOTE: The bracket has an adjusting screw (7) under it which can be used to adjust height of the
measuring heads guide roller (8) for positioning the guide rail.

4
Figure 6.15 MP20 measuring head set up initial

10. Remove pin from guide rails upper transport position (9) and carefully remove rail out of the
winch frame.

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FlyLine User Manual

11. Now place the guide rail over the guide roller (8) of the measuring head, and affix it to the
winch frame as shown at points (10).
12. Secure all fastening pins with the accompanying safety clips.

6 Setup and removal

10

10
8

Figure 6.16 MP20 measuring head set up final


13. Raise the resting bracket up out of the way, and lock into place.
14. Measuring head is now ready for spooling left and right.
15. If necessary, adjust the levelwind chain by performing 8.11 Check/adjust levelwind chain
tension on page 126.
16. Thread the wireline and check the measuring head for operations. Refer to the Measuring
Head User Manual in the Documentation Package for further information.

6.4

First-time startup and test


NOTE: The unit should be started and tested before performing wireline operations.
This procedure describes how to test the operation of one drum. If the unit has two drums, you
must repeat this procedure for each drum before using it for the first time, making sure the correct
drum and brake are selected each time.

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FlyLine User Manual

1.

Perform the relevant procedures listed in 8.5.2 Maintenance schedules on page 110.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

6 Setup and removal

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

2.

Start up the unit as described in 7.3 Power up on page 97.

3.

Adjust the engine THROTTLE to set the engine speed to medium.

4.

Move the hydraulic control lever for the pump direction (right DRUM CONTROL lever)
backwards, and lock it in the half-way back position.

5.

Slowly move the hydraulic control lever for the motor speed (left DRUM CONTROL lever) either
forward or backward to obtain a higher drum speed.

6.

Slowly return the motor control lever to the neutral mid-position.

7.

Return all control levers and knobs to their initial positions, and repeat the above procedure,
this time with the hydraulic control lever for the pump directional control locked in the fully
forward position.

8.

If there were no problems, check the hydraulic system by performing 8.53 Test hydraulic
system pressure on page 219.

9.

Shut down the unit as described in 7.5 Normal shut down on page 104.

10. After testing, check:


The hydraulic system hoses and couplings for leaks.
The mechanical winch components for loose bolts/nuts.

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FlyLine User Manual

6.5

Rig-down

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

1.

If necessary, start up the unit as described in 7.3 Power up on page 97, and wind the wireline
fully onto the drum.

2.

Ensure that the system is completely shut down according to 7.5 Normal shut
down on page 104.

WARNING

TXT-10004359/A

SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.

3.

If required, unthread and fasten the free end of the wireline to the drum.

4.

Check the hydraulic and pneumatic systems for leaks and or damage.

5.

Check all fluid levels, and perform maintenance as required.

6.

If applicable:
a) Slowly close the rig/shore air supply at source.
b) Close the air isolation valves in the winch and power pack.
c) Remove any external hoses from the winch and power pack.
d) Fit the red protective caps.

WARNING

TXT-10004360/A

SHARP OBJECT
Sharp or rough objects can cause severe cuts.
Always wear gloves when handling sharp or rough objects.

7.

Disconnect all electrical cables.

8.

Disconnect hydraulic/pneumatic hoses one by one:


a) Make sure that the LINE TENSION control on the winch control panel is set to minimum to
release any residual pressure in the circuit.
b) With a clean cloth, thoroughly clean the dust caps for each side of the connection.
c) Disconnect the quick-connector, and with a clean cloth, wipe all dust and oil off the
connector male and female side.
d) Fit the dust cap to each side.
e) Gather the hose into loops, and hang them neatly on the hose hooks.

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6 Setup and removal

See the separate Measuring Head User Manual in the Documentation Package.

FlyLine User Manual

f) If required, fasten the hoses to the hook using tie-wraps or tape, to prevent damage
during transportation.
9.

6.5.1

6.5.2

Make sure all cables and hoses are correctly stowed.

Lock measuring head assembly


1.

Set the lock pin (Figure 6.14, item 2) to the horizontal position.

2.

Move the measuring head to the transport position and secure with the lock. See
Figure 6.14.

Finalize
NOTE: The end rail must always be fitted before transporting the unit.
1.

Fit the end rail, if applicable (winch module only).

WARNING

TXT-10004316/A

HEAVY OBJECT
Incorrect lifting of certain heavy objects can cause serious injury if individually lifted by hand.
Before lifting any heavy object, always check your local safety regulations, and use lifting
equipment or additional personal if required.

6 Setup and removal

WARNING

TXT-10004270/A

CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.

2.

Lower and secure the operator window and roof, by reversing the steps in section 5 For all
modules, connect ground cables between the modules. on page 81

3.

Make sure all access doors and panels are correctly closed and secured.

4.

Fit the single point lifting beam, if applicable.

5.

Dismantle and stow any barriers or warnings around the operational danger zone.

6.

Disconnect the ground cables from the grounding points.


NOTE: After removing the grounding cable, always tighten the brass or SS nut and washer
on the grounding terminals, to ensure they do not get lost.

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FlyLine User Manual

6.6

Storage

6.6.1

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 6.5 Rig-down on page 91.

2.

If the unit is going to be stored in temperatures under -18 C (0 F):


a) Refer to 8.5 FlyLine maintenance schedules on page 108 for the procedures to remove
water from:
Fuel filters
Compressed-air conditioner (if present)
Hydraulic tank
b) Completely fill the following fluid reservoirs (if present) with appropriate fluid for expected
low temperatures:
Fuel tank, filters and lines (fill the diesel tank completely with appropriate diesel fuel)
Engine cooling system
Hydraulic system

Pneumatic anti-frost system


Wireline oiler tank
c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures.
Refill with fluid again to full, if necessary.

6.6.2

3.

Switch off all circuit breakers and power switches.

4.

Grease all exposed metal surfaces (such as drum, electrical connectors and cylinder rods
that are extended) to prevent corrosion.

5.

Close all doors and hatches on the unit and secure or lock them.

6.

Cover the unit with a suitable protection cover (these can be ordered from NOV Elmar if
required).

7.

Refer to your company policy for other possible storage requirements.

Long term storage (> 1 year)


When storing the system for long periods, follow the steps in 6.6.1, and take the following
additional actions:
1.

Disconnect and remove any batteries in the unit and store them where they will not be
affected by large changes in temperature.

2.

Grease all exposed metal surfaces (such as drum, electrical connectors and cylinder rods
that are extended) to prevent corrosion.

3.

Grease all rubber seals to prevent them from perishing and cracking.

4.

Protect hydraulic hoses outside the unit from direct sunlight and extreme temperatures, and
plug open connections

5.

Refer to your company policy for other possible storage requirements.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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6 Setup and removal

Pneumatic line oiler (if present)

FlyLine User Manual

OPERATION
WARNING

TXT-10004286/A

DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual. Only
qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

7.1

Emergency situations
The FlyLine has three types of emergency stop:
Manual - when an EMERGENCY STOP button is pushed in.
Manual - when the air intake lever on the control panel is pulled down.
This will shut off airflow to the engine.
Automatic - caused by an engine safety system condition (see 7.1.2 below).

7.1.1

Manual emergency stop

7 Operation

The emergency stop buttons are on the power pack and operator controls. In an emergency, push
one of these buttons to choke the diesel air inlet and immediately stop the engine.
The emergency stop buttons should also be pushed in after the FlyLine has been shut down for
maintenance. This will prevent accidental start up of the unit during maintenance.
After resolving the emergency situation, perform a pre-start inspection and then restart the unit.

7.1.2

Automatic emergency stop


Some engine alarms will automatically shut down the engine. This shutdown procedure is
triggered by one of the following:
Low oil pressure
high exhaust temperature
high engine temperature
An engine over speed situation. Excessive engine speed will create increased intake
vacuum causing the (air intake) safety valve to trip and cut off the intake air.

7.1.3

Startup after an emergency stop


1.

Ensure that the cause of the emergency shutdown has been solved.

2.

Perform all steps of the normal shut down procedure. See 7.5 Normal shut
down on page 104.
NOTE: The engine will already be stopped, but this procedure ensures that the system will
be in the safest stop situation.

3.

Check/reset all EMERGENCY STOP buttons.

4.

Reset the air intake safety valve.

NOTE: After the engine has come to a complete stop, the air intake valve cannot be immediately
opened due to the vacuum created by the engine. Forcing the AIR INLET VALVE open,
before the vacuum is relieved, may damage the air intake safety valve. Wait
approximately thirty seconds for the vacuum to dissipate.

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FlyLine User Manual

5.

On heavy duty power packs, ensure that the overspeed controller is reset to operating state
(Reset button is pressed). See 4.6.8 Additional features of Heavy Duty power
packs on page 46.

6.

Perform all steps of the normal startup procedure. See 7.3 Power up on page 97.

7.2

Pre-start checklists

7.2.1

Maintenance items checklist

Item

Check

Ensure that the unit has been rigged up as described in 6.3 Rig-up on page 80.
Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or
components, and structural damage.
Check all tanks and hoses for leaks and for other visible (transport) damage.
Check all mounting bolts on the winch module (drum bearings/supports).
Inspect the main hydraulic pump group and lines for damage, leaks, and insecure attachment.
Check all hydraulic oil filters for leaks.
Check the hydraulic suction filter indicators. Replace the elements as necessary. See 8.47 Replace hydraulic
suction filter on page 207.

Ensure that the air accumulator (receiver) isolation valve is open.


Ensure that the engine air intake/exhaust vents are not obstructed.
Ensure that all components requiring lubrication are serviced as necessary. See 8.36 Grease unit on page 175.
Check that no unauthorized modifications have been made to the unit.
Check/fill the engine fuel level by performing 8.15 Check/fill engine fuel on page 135. If required, fill with the
correct fuel for the climate.
Check/fill the hydraulic oil level by performing 8.17 Check/fill hydraulic oil on page 139.
Check the wire line lubrication oil level. See 8.19 Check/fill wireline oil on page 143. Refill with lubrication oil if
necessary (as recommended by your wireline supplier).
Check the oil level of the drum motor gear boxes. See 8.18 Check/fill reduction gearbox oil on page 141.
Check/fill the engine oil level, by performing 8.16 Check/fill engine oil on page 137.
Check/fill the coolant, by performing 8.14 Check/fill coolant on page 132.
Ensure that no maintenance is being carried out by others, and that there are no warning tags (e.g. DO NOT
OPERATE) any where on the unit.

Table 7.1 Pre-start checklist (maintenance items)

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7 Operation

Ensure that the hydraulic oil tank suction filter isolation valves are open.

FlyLine User Manual

7.2.2

Unit controls checklist


Refer to 5 Unit controls on page 66 for an explanation of the unit controls, while using this section.

Item

State

Cabin controls
DRUM CONTROL levers. See 5.2 Winch left control panel on page 70.

Middle (Neutral) position

BRAKE SELECT. See 5.3 Winch right control panel on page 72.

Select according to drum required

BRAKE

On

EMERGENCY STOP button

Pulled out

LINE TENSION knob

Set tension according to wireline/job

POWER switch (optional)

Off

Power pack control panel


EMERGENCY STOP button. See 5.1 Power pack control panel on page 68.

Pulled out

AUXILIARY (MAST) DRIVE lever (optional)

Off

Overspeed controller reset switch (only for heavy duty power packs). See
4.6.8 Additional features of Heavy Duty power packs on page 46.

Pressed

7 Operation

Table 7.2 Pre-start checklist (unit controls)

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

7.3

Power up
Before starting the unit make sure you have read and understood the following sections:
2 Safety on page 7
7.5 Normal shut down on page 104
7.1.1 Manual emergency stop on page 94

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

Ensure that all steps in the pre-start checklists have been done. See 7.2 Pre-start
checklists on page 95.

2.

Depending on the type of starter, do one of the following:

Air starter
a) Ensure that an air supply (7 bar (100 psi) at 25 l/min) is connected to the rig-air
connection in the power pack
b) Open the shore/rig-air supply at the supply point.
c) Slowly open the rig-air intake valve on the unit.
Hydraulic starter
a) Check the START PRESSURE gauge on the power pack control panel to see if the starter
accumulator has sufficient pressure to start the unit.
The hydraulic engine starter needs 120 bar start pressure for one start attempt.
b) Ensure that the isolation valve for the starter accumulator is open.
c) If there is not enough hydraulic pressure to start the unit, charge the accumulator, as
described in 7.6.2 Charge starter accumulator using hand pump on page 106.
NOTE: Once the engine is running, the hydraulic starter circuit should be charged by
applying the drum brake and using the main hydraulic system to charge. For a
detailed explanation, see 7.6.1 Charge starter accumulator using
engine on page 105.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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7 Operation

1.

FlyLine User Manual

Spring starter

CAUTION
EQUIPMENT DAMAGE
Winding the spring starter with an air-hammer or any other type of power tool can seriously
damage it. Only use the supplied hand crank to wind the spring starter.

a) Locate the spring starter


on the power pack.

b) Depress and release the


reset button (1).

c) Remove the hand crank


from its storage location
and fit it to the winding nut
(2).
d) To start a warm engine,
rotate the hand crank
clockwise approximately
6 turns, or until the white
indicators are visible
through the inspection window (3).

Figure 7.1 Spring starter

7 Operation

For a cold engine, use two extra turns, or until the red indicators are visible in the
window.
If the spring pressure needs to be relieved later without starting the engine, turn the crank
handle counter-clockwise until the green indicators are visible in inspection window.
e) Remove the crank from the winding nut, and return it to the storage/transit location.
3.

Set the fuel safety (Sentinel) valve by turning the control lever (1) against the spring
pressure. See Figure 7.2 on page 99, item 1.

NOTE: Repeat step for every start attempt.


4.

Depending on the type of power pack, do one of the following:

Basic power pack


a) Push the AIR INLET VALVE lever (2) on the power pack control panel (3) fully up, and hold
it in place.
Heavy duty power pack
a) Fully pull out the air inlet valve lever on the power pack control panel (3) and hold it in
place.

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FlyLine User Manual

1
3

Figure 7.2 Fuel safety valve and air inlet valve on basic power packs

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

CAUTION
MACHINE DAMAGE
Activating the engine starter when the engine is running of within 15 seconds after a failed start
attempt will damage the engine starter. Never activate the engine starter when the engine is
running or within 15 seconds after a failed start attempt.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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7 Operation

WARNING

FlyLine User Manual

5.

Do one of the following:

Hydraulic starter:
a) Turn the ENGINE START button clockwise,
and hold it in until the engine starts.
Air starter:
a) Press the ENGINE START button, and hold it
in until the engine starts.
Spring starter:
a) Pull the trip lever (1) through 90 degrees in
the direction shown by the arrow in
Figure 7.3, and then immediately release
it.

Figure 7.3 Starter trip lever

6.

If the start the start attempt fails, wait at least 15 seconds and then repeat steps 2 to 5.

7.

When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), depending on
the type of power pack, do one of the following:

Basic power pack


a) release the AIR INLET VALVE lever.

7 Operation

Heavy duty power pack


a) push in the AIR INLET VALVE lever.
8.

Check that the hydraulic CONTROL PRESSURE gauge stabilizes between 20 bar (290 psi) and
28 bar (406 psi). If the hydraulic control pressure is less than 15 bar (218 psi) refer to
Troubleshooting section, HYDRAULIC PROBLEM on page 227.

NOTE: The control pressure will vary slightly with the RPM of the engine.
9.

Where applicable, set the MAIN switch to ON.

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FlyLine User Manual

7.4

Running
1.

Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.

2.

Ensure that the DRUM CONTROL levers are in their neutral (middle) position.

CAUTION

TXT-10004393/A

EQUIPMENT DAMAGE
Running the wire inhole at high speed can entangle it in the hole.
Never use high drum speeds when going inhole.

WARNING

TXT-10004304/A

EXPLOSION HAZARD
An incorrectly adjusted brake band can cause an explosion hazard. When the brake is set to
off, the brake band must not rub against the drum, otherwise heat can be generated.
Before operating the unit, ensure that the brake band has been correctly adjusted.

CAUTION

TXT-10004385/A

EQUIPMENT DAMAGE
Prolonged operation of the unit at pressure levels above the LINE TENSION (SAFETY VALVE)
setting (maximum line tension) can overheat the hydraulic oil, damaging the system.
If the hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.

Release the BRAKE.

4.

Use the controls to spool the wireline on or off the drum at the desired speed:
The LINE TENSION rotary control knob sets the maximum pressure that can be supplied to
the drum, and therefore the maximum wireline tension. At pressures above this setting,
the valve will open, releasing the excess pressure. The maximum (+) position will stop
the valve from opening at all, allowing maximum torque. Opening the knob (turning
towards ) will reduce the pressure level, at which the valve will open, effectively limiting
the maximum wireline tension. Opening it all the way will remove all torque.
The right DRUM CONTROL lever controls the direction and the flow of the hydraulic pump.
Push the lever forward to spool off wire, pull the lever backwards to spool on wire (the
maximum up or down joystick position will generate the biggest flow). For high torque
(maximum pull) only, use this lever to Pull OUT OF HOLE (POOH).
The left DRUM CONTROL lever controls the speed and torque obtained from the hydraulic
motor. The maximum up or down position will generate the fastest drum speed (greatest
hydraulic flow) with the least available torque.
These levers can be used in combination with the LINE TENSION and THROTTLE for normal
speeds (see section 7.4.1), fast speeds (see section 7.4.2), or for a varying line pull. See
section 7.4.3.

5.

During wireline spooling, use the SPOOLING CONTROL steering wheel to move the measuring
head left and right on the levelwind shaft to follow the wire off the drum or wind the wire
evenly onto the drum.

6.

Continually check the system status: if the engine speed decreases during operations,
increase the power output by adjusting the throttle accordingly.

7.

When finished with wireline operations, shut down the system as described in 7.5 Normal
shut down on page 104.

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7 Operation

3.

FlyLine User Manual

7.4.1

Normal speeds
1.

Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.

2.

Use the right DRUM CONTROL lever to spool wire on or off:


To spool wire off, move the lever forward. The drum speed will increase as the control
lever is gradually pushed forward.
To spool wire on, move the lever backward. The drum speed will gradually increase as the
lever is moved backward.

7.4.2

High speeds

CAUTION

TXT-10004393/A

7 Operation

EQUIPMENT DAMAGE
Running the wire inhole at high speed can entangle it in the hole.
Never use high drum speeds when going inhole.

1.

Ensure that the LINE TENSION knob is fully closed or adjusted to limit the drum torque
required.

2.

Set the right DRUM CONTROL (directional control) lever to desired direction inhole or outhole.

3.

Move the left DRUM CONTROL (motor speed) lever backward/forward for high speeds.

NOTE: The drum speed will gradually increase as the lever is moved back/forward. The higher
the speed, the less the line pull.
High speed = low torque
Low speed = high torque
4.

7.4.3

Use both handles together for fast drum response, for instance jarring in- or outhole.

Varying line pull

CAUTION

TXT-10004385/A

EQUIPMENT DAMAGE
Prolonged operation of the unit at pressure levels above the LINE TENSION (SAFETY VALVE)
setting (maximum line tension) can overheat the hydraulic oil, damaging the system.
If the hydraulic oil temperature reaches +70 C (+158 F), remove the load from the unit, and
wait for the hydraulic oil to cool down.

1.

To reduce the maximum torque of the winch drum, do the following:


a) Screw out the LINE TENSION until the drum stops turning.
b) Screw in the LINE TENSION until the drum just starts to turn.
c) Screw in the LINE TENSION a further half turn.
The hydraulic pump will then supply a slightly higher hydraulic pressure than is required,
allowing the drum to stop when encountering restrictions or the surface without parting the
line or damaging tools.

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FlyLine User Manual

7.4.4

Check status and react to status changes


1.

Use the DEPTH/TENSION PANEL to read out the depth and tension of the wireline. See the NOV
Elmar documentation in the Documentation Package for a description.

2.

Check the other gauges on the control panels to ensure that the system is operating within
its limits.

3.

If the gauges show an exceptional condition, stop the machine and troubleshoot the potential
cause. If the exception condition is extreme, push one of the EMERGENCY STOP buttons to
immediately stop the engine and cut system power.
NOTE: The engine also has the following built-in safeguards to shut down automatically
and prevent system damage:
Engine over-speed
Loss of oil pressure
High exhaust temperature
High engine temperature

7 Operation

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FlyLine User Manual

7.5

Normal shut down


1.

If the unit has a hydraulic starter:


a) Check the START PRESSURE gauge on the power pack control panel.
b) If the hydraulic start pressure is less than 120 bar (1740 psi), increase the pressure by
performing 7.6.1 Charge starter accumulator using engine on page 105.

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar
(2466 psi).
c) Ensure that the isolation valve for the starter accumulator is closed.
2.

Set the DRUM CONTROL levers to the neutral (middle) position.

3.

Set the engine THROTTLE control to minimum (screwed all the way in).

4.

Make sure the drum is stopped.

5.

Engage the BRAKE.

6.

Close the valve below the wire spray tank to stop the oil flow to the wireline.

7.

Push the ENGINE STOP button on the power pack control panel to stop the diesel engine.

8.

Close the rig air isolation valve.

9.

Close the air receiver isolation valve.

7 Operation

10. Shut off and disconnect the rig air supply.

WARNING

TXT-10004322/A

HIGH PRESSURE
(Dis)connecting a pressurized line can cause serious injury and or equipment damage.
Never connect or disconnect any quick connectors when the supply line is pressurized.

11. Release air from the system by slowly opening the rig air valve in the winch module.
12. Note the shut-down date and time in the running hours log. See Appendix 8: Running hours
log book on page 249
13. If the unit is being shut down for safe maintenance, push in one of the EMERGENCY STOP
buttons, and place an appropriate tag on it, indicating that the unit is under maintenance.

7.6

Charging hydraulic starter accumulator


If the engine is running, the hydraulic starter circuit can be charged by as described in
7.6.1 Charge starter accumulator using engine on page 105.
If the unit has been shut down and there is insufficient pressure to restart the unit, the starter
circuit/accumulator should be pressurized by using the hand pump, as described in 7.6.2 Charge
starter accumulator using hand pump on page 106.
Before shutting down the unit:
Always ensure that the starter accumulator is sufficiently charged.
Close the isolation valve of the starter accumulator to store the charge.

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FlyLine User Manual

7.6.1

Charge starter accumulator using engine


This should be done before shutting down the unit, and preferably with 2 persons. One at the
winch controls and one to observe START PRESSURE on the control panel of the powerpack:
1.

Ensure that the engine is running.

2.

Ensure that the isolation valve of the starter accumulator is open.

3.

Set the BRAKE to ON.

4.

Note the position of the LINE TENSION knob on the cabin control panel (so that you can return
it to this position), and then turn it fully clockwise (towards + ).

5.

Increase the engine throttle to >1500 RPM.

WARNING

TXT-10004321/A

HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).

6.

Push the left DRUM CONTROL lever (motor speed control) to the fully forward position and lock
it there.

7.

Slowly move the right DRUM CONTROL lever (direction control) forward.
TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

8.

Ask an assistant to observe the START PRESSURE gauge on the power pack until the start
pressure is reached: 120 bar (1740 psi). Maximum charging pressure of the starter
accumulator is factory preset at 170 bar (2466 psi).

9.

Ask an assistant to close the isolation valve of the starter accumulator. This will store the
charge so that the accumulator is fully charged for the next engine start.

10. Return the DRUM CONTROL levers to the neutral position.


11. Return the LINE TENSION knob to the position you noted in step 4.
12. Return the throttle to idle.

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7 Operation

WARNING

FlyLine User Manual

Charge starter accumulator using hand pump


1.

Ensure that the isolation valve of the starter accumulator is open.

2.

Remove the pump handle from the holder and insert it into the pump.

3.

Turn the pump isolation lever to the lower position (on some units this is already factory
preset).

4.

Operate the pump.

5.

Observe the START PRESSURE gauge on the power pack until the minimum start pressure is
reached: 120 bar (1740 psi). Maximum charging pressure of the starter accumulator is
factory preset at 170 bar (2466 psi).

6.

Close the isolation valve of the starter accumulator to store the charge in case immediate
starting is not desired.

7.

Remove the pump handle, and store it in the holder.

7 Operation

7.6.2

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FlyLine User Manual

MAINTENANCE
TXT-10004206/A1

8.1

Introduction
Only qualified and trained personnel should perform maintenance on Elmar wireline winch units.
The maintenance procedures described here include:
Scheduled periodic (e.g. cleaning, inspecting and testing components, filling fluid levels
and lubricating moving parts)
Corrective (troubleshooting and repairing any malfunctions, plus calibrating/adjusting)
Exchanging parts (for different operation requirements)
The FlyLine can experience extreme forces and rugged conditions, so certain scheduled
maintenance is regularly required to prevent damage to the equipment and potential hazards.
Inspections and tests should be carried out daily before working with the FlyLine unit, but regular
maintenance must be performed according to the number of hours the FlyLine has been run.
Running hours should be logged by the FlyLine operator following a strict discipline to ensure
maintenance activities are carried out on time (an example running hours log form is provided in
the Appendices to this manual). Elmar recommends basing the service intervals on hours of
running; you may prefer to use calendar time (weeks, months).
Refer to the Appendix Tightening Conventions for instructions on tightening nuts and bolts when
doing preventive or corrective maintenance.

Certified assemblies
Your FlyLine may include assemblies which are certified separately from the complete unit
certification (all certificates are included in the Documentation Package for your unit). These
assemblies (examples are winch drive motors and power unit transformers) may only be serviced
by Elmar service personnel, otherwise the certification (and possibly the warranty) for the
complete unit becomes invalid. A certified assembly is identified by its own data plate with serial
number, and is listed as a single top-level part number in the drawings and spare parts lists. If a
fault is detected in a certified assembly, do not attempt a repair yourself, but always contact Elmar
Service for advice (see Contact Us in the appendices).

8.3

OEM components
Certain components of your FlyLine are complete assemblies or subsystems supplied by Original
Equipment Manufacturers (OEM) than Elmar. Examples are measuring heads, air conditioning
units, motor-generator sets. The routine servicing schedules and instructions for these
components are usually not included in this User Manual, but supplied separately in the
Documentation Package for your unit. Ensure you can find this supplementary documentation,
and make yourself familiar with its contents, particularly the required periodic maintenance
schedules for these components.

8.4

Depth and tensioning system maintenance schedule


Refer to the MP20 User Manual or the MP16 II User Manual for the maintenance procedures and
tables for the CombiGauge and measuring head used in your unit.

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8 Maintenance

8.2

FlyLine User Manual

8.5

FlyLine maintenance schedules


Some maintenance activities comprise both checking and servicing procedures. The service
interval mentioned in the maintenance schedules relates in this case only to the checking
procedure. The outcome of the checking procedure determines whether the servicing is required.
NOTE: On a new unit, the engine oil should be changed after the first 50 running hours. The
hydraulic oil should be changed after the first 100 hours.

Alphabetical list of procedures

Change engine oil and filter

8.8

114

Check/adjust brake band tension

8.9

116

Check/adjust chain tension

8.10

123

Check/adjust levelwind chain tension

8.11

126

Check/adjust V-belts

8.12

128

Check brake band wear

8.13

130

Check/fill coolant

8.14

132

Check/fill engine fuel

8.15

135

Check/fill engine oil

8.16

137

Check/fill hydraulic oil

8.17

139

Check/fill reduction gearbox oil

8.18

141

Check/fill wireline oil

8.19

143

Check/fill fuel pump gear drive oil

8.20

145

Check/replace hydraulic hoses and couplings

8.21

147

Check/replace shock absorber

8.22

149

Clean air inlet safety valve

8.23

150

Clean air inlet safety valve for heavy duty power packs

8.24

154

Clean fuel coarse particle filter

8.25

157

Clean/replace air filter

8.26

158

Clean/replace crankcase flame trap

8.27

159

Clean/replace fuel tank breather

8.28

161

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as required

113

1500/yearly

8.7

1200

Finalise maintenance tasks

900

600

112

300

8.6

daily

page number

Prepare for safe maintenance

Maintenance activity

8 Maintenance

Service interval (running


hours)

section number

8.5.1

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FlyLine User Manual

Drain/fill coolant

8.31

166

Drain fuel purifier

8.32

170

Drain fuel purifier

8.32

170

Drain fuel tank

8.33

171

Drain fuel/water separator

8.34

172

Drain water from hydraulic tank

8.35

173

Grease unit

8.36

175

Prime diesel engine

8.37

177

Remove/replace drum chain

8.38

182

Replace levelwind chain

8.39

185

Remove/replace brake band

8.40

187

Replace V-belts

8.41

189

Replace drum

8.42

191

Replace fuel fine filter element

8.43

196

Replace fuse or circuit breaker

8.44

198

Replace hydraulic high-pressure filter

8.45

202

Replace hydraulic oil

8.46

205

Replace hydraulic suction filter

8.47

207

Replace slip ring

8.48

210

Replace fuel/water separator filter

8.49

212

Service compressed air filter

8.50

214

Test maximum engine speed

8.51

216

Test drum mounting

8.52

217

Test hydraulic system pressure

8.53

219

Tighten Essential Bolts

8.54

221

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as required

165

1500/yearly

8.30

1200

Clean unit

900

163

600

8.29

300

page number

Clean spark arrester

Maintenance activity

daily

section number

Service interval (running


hours)

FlyLine User Manual

8.5.2

Maintenance schedules

Daily maintenance

section page

Check/adjust levelwind chain tension


Check/fill coolant
Check/fill engine fuel
Check/fill hydraulic oil
Check/fill wireline oil
Check/replace hydraulic hoses and couplings
Clean unit

8.11
8.14
8.15
8.17
8.19
8.21
8.30

126
132
135
139
143
147
165

chk

Comment

Table 8.1 Daily maintenance

300 running hours maintenance interval

Change engine oil and filter


Check/adjust chain tension
Check/adjust V-belts
Check brake band wear
Check/fill engine oil
Check/fill reduction gearbox oil
Check/replace shock absorber
Clean fuel coarse particle filter
Clean/replace crankcase flame trap
Clean spark arrester
Drain fuel/water separator
Replace fuel fine filter element
Replace hydraulic suction filter
Replace fuel/water separator filter
Test hydraulic system pressure
Tighten Essential Bolts

section page

8.8
8.10
8.12
8.13
8.16
8.18
8.22
8.25
8.27
8.29
8.34
8.43
8.47
8.49
8.53
8.54

114
123
128
130
137
141
149
157
159
163
172
196
207
212
219
221

chk

Comment

Table 8.2 Every 300 hours running

600 running hours maintenance interval

Clean/replace air filter


Clean/replace fuel tank breather
Drain fuel purifier
Drain fuel purifier
Drain water from hydraulic tank
Grease unit
Replace hydraulic high-pressure filter
Service compressed air filter

section page

8.26
8.28
8.32
8.32
8.35
8.36
8.45
8.50

158
161
170
170
173
175
202
214

chk

Comment

Table 8.3 Every 600 hours running

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FlyLine User Manual

1500 running hours maintenance interval

Clean air inlet safety valve


Clean air inlet safety valve for heavy duty power packs
Test maximum engine speed

section page

8.23 150
8.24 154
8.51 216

chk

Comment

Table 8.4 Yearly or every 1500 hours running

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FlyLine User Manual

8.6

Prepare for safe maintenance


Before carrying out any maintenance on or around the FlyLine unit, ensure that the unit is fully
shut down, the winch drum brake is applied, the drum is not under tension, and that there is no
residual energy in the hydraulic or pneumatic systems.
Proceed as follows to shutdown the FlyLine for safe maintenance.
1.

Complete the wireline service operation, and spool all wire onto the drum.

8.6 Prepare for safe maintenance

NOTE: If it is necessary to perform maintenance with the wireline and tools downhole, then it is
critical to apply the brake and clamp the wire to a rigid structure to relieve it of tension to
the unit.
2.

Perform a regular shutdown. See 7.5 Normal shut down on page 104.

3.

Push in and tag one of the EMERGENCY STOP buttons. See 7.1.1 Manual emergency
stop on page 94.

4.

When working on engine or exhaust system components, allow the system time to cool down
to hand-touch or cooler.

5.

When working on hydraulic components, allow the system time to cool down. Do not open
any hydraulic connections unless you are certain that the hydraulic oil is sufficiently cooled
off.

6.

Relieve all pressure from the hydraulic system:


a) Close the isolation valves for the hydraulic accumulators (e.g. start accumulator) and tag
them to prevent accidental opening.
b) Check the control and main hydraulic pressure gauges to verify that the system pressure
is zero.
c) Relieve residual hydraulic pressure in the control or main circuits by operating the DRUM
CONTROL levers a few times between INHOLE and OUTHOLE, and re-check the gauges.

7.

Before opening pneumatic connections for maintenance, release all air pressure from the
pneumatic system:
a) Isolate the rig air supply and close the rig air input valve.
b) Disconnect the supply from the units rig air input, then slowly open the rig air input valve
to bleed off the air from the unit.
c) Close the isolation valves for the air receivers.
d) Check all air pressure gauges to verify that the residual pressure is zero.

8.

When working on electrical components, make absolutely certain that the main power switch
is turned OFF, and that there is no rig AC connected to the unit.

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FlyLine User Manual

8.7

Finalise maintenance tasks


This procedure should be performed at the end of each maintenance session (a maintenance
session consisting of one or more maintenance procedures).
1.

Remove all tools and materials from the work area.

2.

If the unit is not immediately required for operations, make sure the unit has been correctly
shut down. See 7.5 Normal shut down on page 104.

3.

Make sure the unit and the work area around the unit is left in a safe state as described in
Safety. See 2 Safety on page 7.

CAUTION

TXT-10004376/A

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

4.

Dispose of used materials/liquids according to local environmental regulations.

WARNING

TXT-10004270/A

5.

Close access doors, panels, and hatches, as required.

6.

Record the maintenance task in the running-hours log. See Appendix 8: Running hours log
book on page 249.

7.

Report any unit damage or discrepancies.

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8.7 Finalise maintenance tasks

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.

FlyLine User Manual

8.8

Change engine oil and filter

3
3

8.8 Change engine oil and filter

1
5

Figure 8.1 Engine oil filter and drain/ fill points (alternate fill points shown)
Refer to the Caterpillar documentation included in the Documentation Package that came with
your FlyLine for detailed servicing instructions.
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Connect a hose to the drain tube (1).

3.

Place the other end of the hose in a suitable container.

WARNING

TXT-10004338/A

HOT LIQUID
Hot oil can cause serious burns.
Take care when handling hot oil and associated components. Always wear appropriate
Personal Protective Equipment (PPE), such as gloves.

4.

Open the drain valve (2) (in-line with the tubing).

5.

Remove the oil filler cap (3).

6.

Use the oil pump handle (4) to pump out the oil from the engine sump.

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FlyLine User Manual

7.

Close the drain valve.

8.

Place some rags underneath the engine oil filter (5).

9.

Carefully unscrew and remove the engine oil filter.

10. Fit the new oil filter.


11. Clean the area around the oil filter, and remove the rags.
12. Refill the oil, and check the oil level. See 8.16 Check/fill engine oil on page 137.
13. Replace the filler cap.
14. Clean any spilled oil from the engine.

CAUTION

TXT-10004376/A

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

15. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.8 Change engine oil and filter

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8.9

Check/adjust brake band tension


For correct and safe operation the brake band must be correctly tensioned.This procedure
describes how to check and adjust the brake band tension of one drum. If your unit has two
drums, you must repeat this procedure for both drums, making sure the correct drum and brake
are selected each time.
NOTE: The Brake slip-hold pressures necessary for adjusting the drum brakes are available in
the units Factory Acceptance Test (FAT).

WARNING

TXT-10004355/A

MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.

For the following tests it is critical that the drum drive chain is tensioned correctly. Perform
8.10 Check/adjust chain tension on page 123.

8.9 Check/adjust brake band tension

8.9.1

Check brake band tension


The brake should be tested periodically and especially after performing maintenance to the winch
and brake subsystems. Perform the three tests described below on each drum in the winch unit.
NOTE: The test refers to the MAIN PRESSURE. This is the system pressure in the main hydraulic
circuit, and is indicated by the MAIN PRESSURE pressure gauge on the winch control
panel. See Section 5 Unit controls.
Drum brake free-running test

WARNING

TXT-10004355/A

MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.

The drum is correctly adjusted when there is no contact between the brake band and the drum
when the brake is released.
1.

Start the unit for operations. See 7.3 Power up on page 97.

2.

Spool in all wireline cable and secure it to the drum.

3.

Put the DRUM CONTROL lever(s) into the neutral (STOP) position.

4.

If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.

5.

Release the BRAKE.

6.

Using the DRUM CONTROL lever(s), start to turn the drum slowly INHOLE, and allow it to
continue to turn at a low speed.

7.

At the winch, listen (or have an assistant listen) for sounds that may indicate that the drum
is in excessive contact with the brake band(s).

8.

Check the MAIN PRESSURE gauge that the pressure is not increasing to compensate for brake
drag. If applicable, check both brakes.

9.

Perform the test now OUTHOLE.

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FlyLine User Manual

10. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
11. Apply the BRAKE.
12. If there was no brake-contact noise from the drum in step 7, then the brake has passed the
free-running test. Continue with the drum brake slip test (next section).
13. If brake-contact noise was heard, or there is indication that the MAIN PRESSURE increases
during the test, then the brake needs adjustment. See 8.9.2 Adjust Brake band
tension on page 119.
Drum brake slip test

WARNING

TXT-10004321/A

HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).

Refer to the winch specifications to identify the drum model currently being tested. See
Appendix 2: Unit Specifications on page 237.

2.

Refer to the recommended drum brake slip pressures in the FAT for the slip pressure range
for this drum. The FAT values are found in your documentation pack under the section
Quality Documents / Start Up Script / Brake slip-hold pressures (in older documentation
packages - refer to Quality Documents / Hydraulic Fat / Brake System).

3.

Put the DRUM CONTROL lever(s) into the neutral (STOP) position.

4.

If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.

CAUTION

TXT-10004395/A

EQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the
brake is tested at LOW or MEDIUM speed ratio.
Always select HIGH speed ratio when testing the brake.

5.

For a multi-speed gearbox, select HIGH speed ratio (never LOW or MEDIUM speed ratio).

6.

Apply the BRAKE.

7.

On units powered by a diesel engine or truck PTO: use the THROTTLE to set engine speed to
idle.

8.

Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE until the
drum slips in the brake.

9.

Check the MAIN PRESSURE gauge and note the brake slip pressure.

10. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
11. If the MAIN PRESSURE in step 9 was within the range as described in the FAT, then the brake
for this drum has passed the slip test. Continue with the drum brake stopping test (next
section).
12. If the drum slipped below the range (too slack) or above the range (too tight), then the brake
needs adjustment. See 8.9.2 Adjust Brake band tension on page 119.

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8.9 Check/adjust brake band tension

1.

FlyLine User Manual

Drum brake stopping test

WARNING

TXT-10004355/A

MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger,
and cordon off the dangerous area.

WARNING

TXT-10004751/A

DANGEROUS MACHINERY
A loose or misaligned chain can lead to equipment damage or personal injury. Ensure that the
drum drive chain is tensioned correctly.

The brake must stop quickly the drum in a controlled, smooth manner. i.e. without juddering or
causing extreme shock to the winch and other equipment. The effect during actual operations will
differ, depending on:
The tension and condition of the drum drive chain;
8.9 Check/adjust brake band tension

The amount of wire on the drum (a fully loaded drum has more momentum);
The weight of the tool string;
The effect of well pressure and resistance on the tool string and wire;
The direction of operation (inhole or outhole);
The speed and torque of the drum (selected gear, engine speed, etc.);
Moisture and oil on the drum rim;
The degree of wear on the brake band lining.
The test is conducted in one specific situation. It is recommended to always conduct the test in
the same situation and under the same conditions.
1.

If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.

2.

Put the DRUM CONTROL lever(s) into the neutral (STOP) position.

3.

Release the BRAKE.

4.

If applicable, select HIGH speed ratio and medium LINE TENSION.

5.

On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine
speed to the maximum torque range.

6.

Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE to about
100 bar (1450 PSI), so that the drum is rotating at a high speed.

7.

Apply the BRAKE while at the same time putting the DRUM CONTROL lever(s) into the neutral
(STOP) position.
The brake should quickly and smoothly halt the drum rotation.

8.

On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed
to the idling range.

9.

If the drum stopped quickly and smoothly at step 7, then the brake has passed the stopping
test.

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FlyLine User Manual

If the drum did not completely stop, or did not stop smoothly, then the brake needs
adjustment. See Section 8.9.2 Adjust Brake band tension.
10. Shut down the unit.

8.9.2

Adjust Brake band tension


For correct and safe winch operation the brake band must be correctly tensioned for your drum
type as follows:
The drum breaks free of the applied brake when the winch motor is accelerated to a
predefined pressure/torque setting (pressure for a hydraulic driven winch motor; torque
for an electric driven winch motor)
There is no contact between the brake band and the drum when the brake is released
The predefined pressure/torque settings for releasing the brake on your drum type is listed in the
FAT - refer to your documentation pack under Quality Documents / Start Up Script / Brake sliphold pressures (in older documentation packs - refer to Quality Documents / Hydraulic Fat /
Brake System).

See Figure 8.2 Brake tension on each brake is adjusted at:


The brake adjuster at the connection between the brake cylinder and brake band
Optional on larger drums only: The adjustment turnbuckle at the top rear of the drum (
Each adjuster has two threaded ends, one with left-hand and the other with right-hand threads.
A locknut is located on the right-hand thread end of the central hexagon. It must be tightened
against the female block of the adjuster on the same side. It is vital to ensure that the male part
on each side of each adjuster has sufficient length in the female part to avoid it being pulled out
when the brake is applied. The length inside the female part must be a minimum of 1.5x the
diameter of the male section. (Applies to points marked X in Figure 8.2).
Adjust the brake when:
The unit fails one of the brake tests.
The brake bands have been replaced.
The brake assembly has been dismantled and reassembled for any reason.
1.

Start the unit for operations. See 7.3 Power up on page 97.

2.

Spool in all wireline cable and secure it to the drum.

3.

Prepare the unit for safe maintenance. See 8.6 Prepare for safe maintenance on page 112.

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8.9 Check/adjust brake band tension

If required, check with Elmar Service group for a complete list of brake release pressures/torques
for different drum types and different conditions.

FlyLine User Manual

Optional on larger drum


types- Upper turnbuckle with locknut

After adjusting ensure the locknut is tightened against the


threaded block in the brake
band

8.9 Check/adjust brake band tension

Adjuster at the cylinder

NOTE: The setup can differ


slightly depending on winch
type. For example, the
brake cylinder can be
mounted vertically or horizontally.

X X
After adjusting ensure the locknut is tightened against the
brake linkage gaffel

d
Minimum thread depth in adjuster
female section X

>1d

Figure 8.2 Drum brake band components

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

4.

Remove all guards surrounding the winch drum and brake(s).

5.

If the drum has a single brake band, continue from step 8.

6.

If the drum has two brake bands, release the brake and disable the brake band on one side
of the drum by slackening the adjuster at the brake cylinder connection sufficiently for the
brake band to be free of the drum rim.

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FlyLine User Manual

7.

Apply the brake

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

8.

Start the unit for operations. See 7.3 Power up on page 97.

9.

If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable,
disable the automatic winch control program.

10. Put the DRUM CONTROL joystick into the neutral (STOP) position.

CAUTION

TXT-10004395/A

11. On a unit with selectable speed range, select HIGH speed (never LOW or MEDIUM speed).
12. Gradually move the DRUM CONTROL joystick slowly INHOLE, increasing the MAIN PRESSURE
readout until the drum starts slipping in the brake.
NOTE: The MAIN PRESSURE readout is shown on the appropriate gauge on the control panel or
on the installed control system (e.g. SmartMonitor or SMARTVIEW). See Section 5 Unit
controls.
13. Note the MAIN PRESSURE readout at which the brake slips.
14. Return the DRUM CONTROL joystick to the neutral (STOP) position.
15. Set the BRAKE to ON.
16. If the MAIN PRESSURE readout when the drum slipped in step 13 was within the brake slip
range listed in the FAT, the brake has passed the adjustment slip test. Continue from step 18.
17. If the drum slipped below the range (too slack) or above (too tight):
a) Prepare the unit for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.
b) Loosen the locknut on the adjuster beside the brake cylinder.
c) Adjust the brake band:
Brake band too tight: loosen the brake adjuster.
Brake band too loose: tighten the brake adjuster.
NOTE: On larger drums, tighten or loosen the top turnbuckle to increase or decrease the
available adjustment on the lower adjuster.
d) Tighten the locknuts at the adjuster and (if applicable) top turnbuckle.
e) Repeat the test and adjustment again from step 8 until the adjustment is correct.

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8.9 Check/adjust brake band tension

EQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the
brake is tested at LOW or MEDIUM speed ratio.
Always select HIGH speed ratio when testing the brake.

FlyLine User Manual

If the correct adjustment cannot be reached or there is no adjustment left in the adjuster,
replace the brake band(s). See related topic.
18. If the drum has a single brake band, continue from step 28.
Otherwise, continue as follows to adjust the second brake band.
19. Put the DRUM CONTROL joystick in the neutral (STOP) position.
20. Prepare the unit for safe maintenance. See 8.6 Prepare for safe maintenance on page 112.
21. At the drum, using a felt pen, or by counting the number of threads exposed on the adjuster,
note the position of the previously adjusted brake.
22. Disable the correctly adjusted brake by slackening the adjuster at the brake cylinder
connection sufficiently for the brake band to be free of the drum rim.
23. Repeat steps 8 through 16 for the second brake.
The brake slip MAIN PRESSURE of the
MAIN PRESSURE of the first brake.

second brake should be within 5% of the brake slip

8.9 Check/adjust brake band tension

24. When the second brake is correctly adjusted, reset the first brake as follows:
a) Put the DRUM CONTROL joystick in the neutral (STOP) position.
b) Prepare the unit for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.
c) At the drum, reset the first side brake by tightening the tension adjustment at the brake
cylinder connection to the adjustment you noted or marked in step 21 above.
25. Repeat the test from step 8 with both brakes applied, and verify that the MAIN PRESSURE when
the brake slips is within the range as specified in the FAT.
26. If the slip MAIN PRESSURE is higher, slacken the brake band tension by making identical minor
adjustments on both brakes sides, and repeat the adjustments until the brake slip MAIN
PRESSURE is within range.
27. Release the brake and check that there is no contact between the brake band and drum rim.
If so, slacken the brake band tension very slightly while still remaining within the slip MAIN
PRESSURE range.
28. Prepare the unit for safe maintenance. See 7.5 Normal shut down on page 104.
29. Refit the drum guards and tighten the drum guard attachment bolts.
30. Finalize maintenance tasks. See 8.7 Finalise maintenance tasks on page 113.

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FlyLine User Manual

8.10

Check/adjust chain tension


This procedure describes how to check the drive chain tension of one drum, and adjust it if
necessary.

8.10.1 Prepare
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

If necessary, lower or raise the levelwind arm, depending on the chain you want to check/
adjust.

8.10.2 Check chain tension and alignment

8.10 Check/adjust chain tension

2 cm (3/4 in)

2 cm (3/4 in)

Figure 8.3 Free play and alignment of chain


1.

Check the total free play of the chain. It should be approximately 2 cm (0.75 in) at the middle
point. See Figure 8.3.

2.

Make sure the drum is correctly aligned to the gearbox. See Figure 8.3
The drum axis should be parallel with the gearbox axis.
The drum sprocket must be perfectly aligned with the gearbox sprocket.
The distances (a) and (b) between the adjustment block and the pillow blocks should be
the same on both sides of the drum. This will ensure that the drum is correctly aligned in
the winch.

3.

If necessary, adjust the chain tension, as described in 8.10.3 below.

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8.10.3 Adjust chain

1
2

2
4

distance (a)

distance (b)

8.10 Check/adjust chain tension

Figure 8.4 Drum bearing alignment

6
6

Figure 8.5 Gearbox attachment and adjustment bolts


NOTE: The chain can be adjusted with the drum guards still fitted.
1.

Check if the pillow block bearing (1) is equally positioned between the two adjustment blocks
(2).
The distances (a) and (b) should be approximately equal. This is to allow for correct
adjustment of the chain in the following steps.

2.

If there is not sufficient room to adjust the chain (distance a or b is too small), you should first
adjust the gearbox as follows. Otherwise, continue with step 3.
a) Loosen the drum attachment bolts (3) for both bearings.
b) Use the drum alignment bolts (4) for both bearings to position the pillow block equally
between the two adjustment blocks. See Figure 8.4.
c) Slightly loosen all three gearbox attachment bracket (5) bolts (6).
d) Remove the slack from the chain by adjusting the bracket up or down.

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FlyLine User Manual

NOTE:

The chain is finely adjusted in step 4 of this procedure.

WARNING

TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

e) Tighten the gearbox attachment bracket bolts. For correct torque values, see
Appendix 6: Referenced Documents on page 246
f) Continue from step 4.
3.

Loosen the drum attachment bolts (3) for both bearings.

4.

Use the drum alignment bolts (4) for each bearing to finely adjust the chain tension. Make
sure the chain is adjusted according to Appendix 8.10.2: Check chain tension and
alignment on page 123. See also Figure 8.3.

5.

Make sure the distance (a) between the adjustment block and the pillow block bearing is the
same on both sides of the drum. This will ensure that the drum is correctly aligned in the
winch module.
TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

6.

Tighten the drum mounting bolts on both sides of the drum. For correct torque values, see
Appendix 6: Referenced Documents on page 246.

7.

Make sure both drum alignment bolts for each bearing are securely tightened.

8.

Recheck the chain tension and alignment, and readjust if necessary.

8.10.4 Finalize
1.

Perform the drum mount test by performing 8.52 Test drum mounting on page 217.

2.

Check the tension of the brake by performing 8.9 Check/adjust brake band
tension on page 116.

3.

If necessary, grease the drive chain to keep it flexible and prevent rusting.

CAUTION

TXT-10004376/A

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

4.

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

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8.10 Check/adjust chain tension

WARNING

FlyLine User Manual

8.11

Check/adjust levelwind chain tension


It is important that the levelwind chain is not too loose and also not too tight. It should also be
adequately lubricated to keep it flexible and prevent it from rusting for smooth functioning.
This procedure describes how to check the levelwind chain tension, and adjust it if necessary.
It is advisable do this in combination with greasing the unit described in 8.36 Grease
unit on page 175.

8.11.1 Prepare

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

8.11 Check/adjust levelwind chain tension

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004268/A

CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.

2.

If the unit is so equipped, lift the protective cover on the front of the winch module to access
the measuring head and levelwind chain. See 5 For all modules, connect ground cables
between the modules. on page 81

3.

Unlock the measuring head from the transport position, refer to 6.3.5 Prepare measuring
head assembly on page 87

8.11.2 Check chain tension

1 cm free play

Figure 8.6 Levelwind chain tension

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FlyLine User Manual

1.

Check the total free play of the chain. It should be approximately 1 cm (3/8 in) at the middle
point of the lower race. Refer to figure 8.3.

2.

If free play is adequate then you are finished. If the chain needs adjusting then go to the
following procedure 8.8.3

8.11.3 Adjust levelwind chain tension

1
2

Figure 8.7 Levelwind chain adjustment


1.

Locate fastening screw (1) and loosen completely so the adjusting turnbuckle (2) is free of
the measuring head carrier (3).

2.

To tighten the chain, use a suitable wrench to turn the turnbuckle in the direction of the arrow
shown until you have 3/8 in. play.

3.

To slacken the chain turn it in the opposite direction until you have 3/8 in. play.

4.

Once chain tension is adjusted adequately line up the hole in the turnbuckle with the
measuring head carrier and insert the fastening screw.

5.

Tighten the screw to torque value specified in Appendix 6: Referenced


Documents on page 246

8.11.4 Finalize
1.

If necessary, grease the drive chain to keep it flexible and prevent rusting.

CAUTION

TXT-10004376/A

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

2.

Turn the steering wheel to move the measuring head left and right a few times to verify the
chain play.

3.

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

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8.11 Check/adjust levelwind chain tension

FlyLine User Manual

8.12

Check/adjust V-belts
This procedure describes how to inspect and adjust the V belts of the Caterpillar diesel engine.

3
2

8.12 Check/adjust V-belts

Figure 8.8 V-belt adjustment (protective screen removed for clarity)


1.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

WARNING

TXT-10004348/A

MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Ensure that the engine cannot be started during maintenance.

2.

Remove the protective screen.

3.

Check the belts for damage or excessive wear.

4.

If necessary, replace the belts. See 8.41 Replace V-belts on page 189.

5.

Apply 10 Nm (10 ft lb) against the belt test point (1). There should be approximately 1 cm
(3/8 in) of play for both belts.

6.

If necessary, adjust the belts as follows:


a) Loosen the nuts (3) and (4), securing the tensioner pulley bracket (2).
b) Adjust the belt tension.
c) Tighten the nuts, first (4) then (3).
d) Recheck the tension of the belt and adjust as required.

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FlyLine User Manual

CAUTION

TXT-10004376/A

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

7.

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

8.12 Check/adjust V-belts

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8.13

Check brake band wear


A brake band should be replaced just before the rivet heads, embedded in the brake band liner,
make contact with the drum. This will occur when there is approximately 3.5 mm of material left.

steel band

8.13 Check brake band wear

liner material

Figure 8.9 Brake band wear measuring points

Figure 8.10 Cross section and rivet depth of new brake band
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

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FlyLine User Manual

NOTE: All brakes used in NOV Elmar units are fail-safe, and are automatically applied
when the unit is off.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

If necessary, remove the drum guards to access to the brake bands.

3.

Measure the thickness of each brake band at the points shown in Figure 8.9.
NOTE: The thickness of new brake bands is 12 mm including liner. This provides 3.5 mm
of liner material to wear before the rivets begin to score the drum.

4.

If the total thickness at any of the measuring points is approaching 9 mm (0.5 mm liner, see
Figure 8.10), replace the brake band(s) by performing 8.40 Remove/replace brake
band on page 187.

5.

Refit the drum guards.


TXT-10004376/A

6.

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

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8.13 Check brake band wear

CAUTION

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

FlyLine User Manual

8.14

Check/fill coolant
Regularly check the coolant level, when the unit is cold, before starting it up. When filling the
radiator, remember that the volume will increase, as the engine/coolant warms up. Therefore,
always only fill to the bottom third of the coolant sight glass. If the coolant is overfilled, excess
coolant will be forced out of the coolant overflow valve during operations.

8.14.1 Check coolant level

8.14 Check/fill coolant

coolant

Figure 8.11 Coolant sight glass in radiator


1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

If the unit has been running, wait for the coolant to cool down (below 50 C).
If the coolant is not cooled down, the reading will be incorrect.

3.

Check the level of the coolant. The coolant should be visible in the bottom third of the sight
glass (1). See Figure 8.11.

4.

If the coolant level is correct, you are finished.

WARNING

TXT-10004340/A

HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.

5.

If the coolant is not visible in the sight glass you will need to check the level through the filler
cap to determine approximately how much to top up.

6.

If topping up is necessary proceed with the following steps.

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FlyLine User Manual

8.14.2 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.

NOTE: The coolant is normally topped up from the radiator filler cap (2), but can also be filled
from the drain plug at the bottom of the unit (optional). This is necessary when refilling
the system after it has been drained. See 8.31 Drain/fill coolant on page 166.

NOTE: The following steps may require use of a ladder to access the radiator cap hatch.

WARNING

TXT-10004313/A

FALLING FROM HEIGHT


Falling from a ladder can cause serious injury or death.
Take extra care when working from a ladder. Always follow local safety regulations.

WARNING

TXT-10004340/A

HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.

1.

Open the COOLANT roof hatch (3) to access the radiator filler cap (2), and remove the cap.

2.

Place a filtered funnel in the inlet.

CAUTION

TXT-10004371/A

EQUIPMENT DAMAGE
Contaminated coolant can seriously damage the cooling system.
Always use approved coolant and an approved filter when refilling the cooling system.

3.

Pour coolant into the cooling system until the coolant is visible in the sight glass.

4.

Remove the funnel from the inlet.

5.

Replace the radiator cap.

6.

Use clean rags to clean any spilled coolant.

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8.14 Check/fill coolant

Figure 8.12 Radiator cap access hatch

FlyLine User Manual

7.

Close and secure the hatch.

CAUTION

TXT-10004376/A

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

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

8.14 Check/fill coolant

8.

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FlyLine User Manual

8.15

Check/fill engine fuel


Before using the unit, always check the fuel level; also regularly check the fuel level during
operations.

8.15.1 Check fuel level


NOTE: The fuel level may be checked with engine running. In this case heed the following
warning.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

1.

Open the left door, so that you can see the fuel tank.

2.

Use one of two methods to check the fuel level.


a) On units with a fuel gauge: check the fuel level from the fuel gauge (1).
b) On units with no fuel gauge: check the fuel level, which is visible through the plastic tank
wall (2).
8.15 Check/fill engine fuel

2
Figure 8.13 Diesel fuel level options
3.

If the level is low, fill the tank by proceeding with 8.15.2, otherwise you are finished.

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8.15.2 Fill fuel tank

8.15 Check/fill engine fuel

Figure 8.14 Fuel filler cap

WARNING

TXT-10004301/A

EXPLOSION HAZARD
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been correctly grounded before performing any work on the
unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.

1.

Make sure both the unit and the refuelling facility are correctly grounded.

2.

Ensure that the diesel fuel to be used conforms to the EN 590 standard.

3.

Ensure that the unit has been shutdown for safe maintenance as described in 7.5 Normal
shut down on page 104.

4.

Remove the fuel filler cap (3).

5.

Fill the fuel tank until you see it is almost full; allow 3-5 cm (1-2 in) for fuel expansion.

6.

Use clean rags to clean the filler cap and inlet.

7.

Replace the filler cap.

8.

Clean any spilled fuel from around the filling point.

CAUTION

TXT-10004376/A

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

9.

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

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FlyLine User Manual

8.16

Check/fill engine oil


Refer to the Caterpillar documentation included in the Documentation Package that came with
your FlyLine for detailed servicing instructions.

1
2

1.

Ensure that the unit has been shutdown for safe maintenance as described in 7.5 Normal
shut down on page 104.

2.

Wait a few minutes for the oil to settle, if the unit has been running.

3.

Open the right power pack door to access the engine oil dipstick (1).

4.

Unscrew the dipstick.

5.

Clean the dipstick with a clean rag, and push it back into position.

6.

Remove the dipstick and check the oil level. Correct level must be between the low and high
marks on the dipstick.

7.

If level is ok then proceed to 8.16.2. If level is below the low mark then fill the engine oil as
follows.

8.16.1 Fill Engine oil


1.

Open the left power pack panel to access the engine oil filling point (2).

2.

Place a clean tube or hose into the oil filling point.

3.

Push a funnel into the other end of the tube or hose.

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.

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8.16 Check/fill engine oil

Figure 8.15 Engine oil dipstick and filler cap

FlyLine User Manual

4.

Slowly add a small amount of oil.


a) Wait a moment for the oil to reach the sump.
b) Check the oil level with the dipstick.

5.

Repeat step 4, until the oil is at the correct level.

6.

Remove the funnel and tube or hose.

7.

Clean any spilled oil from around the engine.

CAUTION

TXT-10004386/A1

EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to fail, as well as contaminate the local
environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before
refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and
are correctly tightened.

8.

Replace the oil filler cap and tighten it.

8.16 Check/fill engine oil

8.16.2 Finalize
1.

Ensure that the dipstick and filler cap are screwed tight.

2.

Clean any spilled oil.

CAUTION

TXT-10004376/A

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

3.

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.17

Check/fill hydraulic oil

1
2

Figure 8.16 Hydraulic oil tank filler cap roof hatch


Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Ensure that the hydraulic oil is cool enough to avoid burns (check temperature gauge!).

3.

Open the HYDRAULIC OIL roof hatch (1) to access the hydraulic oil tank filler cap (2) and
gauge (3).

4.

If the gauge shows more than 3/4-full you are finished, close and secure the roof hatch. To
confirm the gauge reading you can remove the filler cap and check the actual level inside the
tank.

5.

If the gauge shows less than 3/4-full, fill the tank as follows:

CAUTION

TXT-10004383/A

EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.

a) Remove any dirt and debris from around the filler cap on top of the hydraulic tank using
a clean cloth.

WARNING

TXT-10004337/A

HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.

b) Remove the hydraulic oil tank filler cap.


NOTE: 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.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.17 Check/fill hydraulic oil

1.

FlyLine User Manual

c) Slowly add hydraulic oil of the correct grade (see Appendix 4: Unit hydraulic
oils on page 243 for approved types), until the gauge shows full. Do not overfill! Allow
for hydraulic oil to expand during operations.
d) Wipe the filler cap clean using a clean cloth, and fit it back on the tank.

CAUTION

TXT-10004376/A

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

8.17 Check/fill hydraulic oil

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.18

Check/fill reduction gearbox oil

oil
correct oil level

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

8.18.1 Check oil level


1.

View the oil level either through the hole in the cover plate or by removing the plate, if drum
capacity allows.

2.

Check the oil level. The oil should be near the top of the lowest sight glass (1), see Figure
8.15.
NOTE: The gearbox is installed at an angle and has 2 sight glasses, one on each side.
Make sure you check the lowest of the two sight glasses.

3.

If the oil level is correct, you are finished, otherwise continue with 8.18.2.

8.18.2 Fill gearbox oil (if necessary)

CAUTION

TXT-10004383/A

EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.

1.

Remove the oil filler plug (2). Alternate fill point is to remove the breather plug (3).

2.

Place a tube in the inlet at the top of the gearbox.

3.

Insert a funnel into the other end of the tube.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.18 Check/fill reduction gearbox oil

Figure 8.17 Reduction gearbox from the front of the winch

FlyLine User Manual

4.

Slowly pour oil into the gearbox until the oil is visible at the top of the sight glass. DO NOT
OVERFILL!

5.

Remove the funnel and tube from the inlet.

CAUTION

TXT-10004386/A1

EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to fail, as well as contaminate the local
environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before
refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and
are correctly tightened.

6.

Refit and tighten the oil inlet plug.

7.

Clean any spilled oil from around the oil inlet and gearbox.

CAUTION

TXT-10004376/A

8.18 Check/fill reduction gearbox oil

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

8.

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.19

Check/fill wireline oil

8.19 Check/fill wireline oil

1
Figure 8.18 Wireline lubrication tank with filler cap/ dipstick
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Make sure the flow valve (1) at the bottom of the wireline oil tank (2) is closed.

3.

Unscrew the filler cap (3).


The dipstick (4) is secured to the filler cap.

4.

Clean the dipstick, and re-insert it back into position.

5.

Remove the cap/ dipstick, and check the oil level.

6.

If necessary, add oil. Check with your wireline documentation for the correct lubrication oil
type for your wireline.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

FlyLine User Manual

7.

Re-insert the dipstick, and screw it back into position.

8.

Clean any spilled oil from the wireline oil tank.

9.

Briefly open the flow valve at the bottom of the wireline oil tank to check the oil flows correctly.

10. Clean any spilled oil.

CAUTION

TXT-10004376/A

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

8.19 Check/fill wireline oil

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.20

Check/fill fuel pump gear drive oil


The engines fuel pump is a gear-type pump, and is driven by a gear drive connected to the PTO
at the rear of the auxiliary compressor. The reservoir has a filler cap on top and drain port 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: Unit Lubricants on page 241 for
the recommended gearbox oil types.
Related topics:
Appendix 3: Unit Lubricants on page 241
7.5 Normal shut down on page 104

8.20.1 Check the gear drive oil level:


Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

2.

Open the right power pack door to access the fuel pump (2) and gear drive (1). See
Figure 8.19.

3.

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 8.19 Fuel pump and gear drive

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Original Instructions

8.20 Check/fill fuel pump gear drive oil

1.

FlyLine User Manual

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 units with spring starter it may be necessary to remove the starter to access the drain
plug. In this case contact maintenance personnel.
7.

Collect the oil and determine amount, this is the oil level.

8.

If required, replace the oil with new oil or simply add enough to obtain the proper amount of
100cc.

8.20.2 Fill gear drive oil


1.

Replace the drain plug.

2.

Carefully pour the 100cc of oil from the container into the filler opening.

8.20 Check/fill fuel pump gear drive oil

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.

8.20.3 Finalize
1.

Ensure that the filler cap is screwed securely into place.

2.

Clean any spilled oil.

CAUTION

TXT-10004376/A

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

3.

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

WARNING

TXT-10004270/A

CRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors
and hatches are especially dangerous.

4.

Close any access panels you opened.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.21

Check/replace hydraulic 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.

WARNING

TXT-10004337/A

HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.

CAUTION

TXT-10004383/A

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Inspect the general condition of all hydraulic lines and hoses. Look for visible damage,
leakage, and sweating or swelling of hoses.
NOTE: The extension hoses (1) which connect the powerpack to the winch module are the
most susceptible to damage since they are the most exposed to the elements and
physical wear and tear. Ensure hereby that the rubber outer mantle is not cracked
or gouged, exposing the steel reinforcement strands. Any exposed steel strands will
rust and weaken, creating a potentially dangerous situation.

External hoses
joining power
pack and winch
modules

Figure 8.20 External hydraulic hoses prone to wear and tear


3.

Inspect the entire unit for signs of leakage, such as oil drips, oily dust build-up, etc., around:
Tanks

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Revision C
Original Instructions

8.21 Check/replace hydraulic hoses and couplings

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.

FlyLine User Manual

Hoses and lines


Couplings/connectors
Quick-connectors
Control levers
Valves
Filters
Pumps

8.21 Check/replace hydraulic hoses and couplings

Motors
4.

Replace/repair components as necessary.

5.

After making repairs, test by performing 8.53 Test hydraulic system pressure on page 219.

CAUTION

TXT-10004376/A

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

6.

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

Page 148 of 258


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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.22

Check/replace shock absorber

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Open all of the power pack panels.

3.

Check the shock absorbers at each corner of the engine block. See Figure 8.21.
Pay special attention for worn rubber or loose mountings; (1) and (2) are joined by a
vulcanized rubber block, there must be no metal contact between (1) and (2).

4.

Have any damaged shock absorber replaced by a qualified mechanic.

5.

Check the mounting bolts (3) and (4) for tightness.

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;


For correct torque values, see Appendix 6: Referenced Documents on page 246

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


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Original Instructions

8.22 Check/replace shock absorber

Figure 8.21 Engine mount shock absorber

FlyLine User Manual

8.23

Clean air inlet safety valve


See 4.6.2 Engine safety features on page 38 for a functional description of this valve.

10
3
4

3
1

11

12

8.23 Clean air inlet safety valve

5
2

Figure 8.22 Air inlet safety valve

Figure 8.23 Air inlet safety valve cable clevis and pin
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Loosen the flexible hose clamp (1) from the air intake hose (2), and push the hose out of the
way.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

3.

Remove the two screws (3) attaching the bowden cable bracket (4) to the air inlet valve (5).

WARNING

TXT-10004285/A

DANGEROUS MACHINERY
Changing factory settings can affect the safety of the system, and result in personal and/or
equipment damage.
Take extreme care when adjusting factory settings. If in doubt, contact Elmar

NOTE: Be sure not to loosen the adjustment nuts (6) holding the bowden cable in the bracket;
by doing so the correct cable adjustment needed for shutdown may be lost.
4.

Push the clamp of the clevis pin (7) from the bowden cable clevis (8).

5.

Remove the clevis pin.

6.

Place a rag under the oil line coupling (10) to catch any oil that drips.

7.

Disconnect the oil line coupling.

8.

Remove the four attachment bolts (11) to the intake manifold pipe (12).

9.

Remove the air inlet valve from the engine.

copper grease
copper grease

11

copper grease

Figure 8.24 Air inlet valve


11. Inspect the inside of the valve for contamination. See Figure 8.24.
12. If necessary, clean the inside of the valve with a clean rag.

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.

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Original Instructions

8.23 Clean air inlet safety valve

10. Place a clean temporary cover over the intake manifold pipe, to protect the engine from dirt
and debris.

FlyLine User Manual

13. If required, apply a small amount of copper grease to the spring (11) of the air inlet valve,
where shown in Figure 8.24.
14. Check the closing action of the valve over its full stroke.
15. Check all moving parts for wear.
16. Remove the temporary cover from the intake manifold pipe.
17. Inspect the air inlet valve gasket, and replace if necessary.

WARNING

TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

18. Reposition the air inlet valve, and refit the attachment bolts to the intake manifold pipe. Take
care not to damage the gasket.

8.23 Clean air inlet safety valve

For correct torque values, see Appendix 6: Referenced Documents on page 246
19. Refit the bracket.
20. Refit the clevis pin at the end of the bowden cable, and secure the clamp to the clevis.
21. Reconnect the oil line coupling.
22. Refit the flexible hose with hose clamp to the air inlet valve.
23. Position the hose clamp as close to the air valve housing as possible (see Figure 8.22) and
tighten it.

CAUTION

TXT-10004376/A

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

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

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

Test the engine for correct operation. See 7.3 Power up on page 97.
25. Shut down the unit, as described in 7.5 Normal shut down on page 104.
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FlyLine User Manual

CAUTION

TXT-10004376/A

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

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

8.23 Clean air inlet safety valve

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

FlyLine User Manual

8.24

Clean air inlet safety valve for heavy duty power packs

7
4

8.24 Clean air inlet safety valve for heavy duty power

9
11

10

Air inlet valve

Shown mounted in a typical power pack setup.


Pyroban SVG air inlet valve. Normally closed when engine not running.

Flexible hose with clamp

Air intake to valve

Engine air intake flange

Mounting flange for the air inlet valve.

Valve lever

Swings across flow to open butterfly valve (normally closed) for starting. The valve
is then held open by the latch below the actuator.

Valve lever cable

Connected to AIR INLET VALVE control handle, which is pulled before starting.
Position of lever and cable shown with engine stopped.

Cable clamp

Applies cable force to lever. When AIR INLET VALVE handle pressed in after
starting, the clamp returns to the position shown.

Engine oil pressure actuator

While engine is running, engine oil pressure forces a plunger to press down,
releasing the latch but holding the valve open. When engine oil pressure drops, the
plunger retracts and the butterfly valve closes, cutting off engine air supply and
stopping engine abruptly.

Butterfly valve closed

Valve lever is in flow direction, unlatched, no air can enter engine. Note O ring on
edge of butterfly valve.

Butterfly valve open

Valve lever is across flow, latched, air can enter engine. Flame trap behind.

10

Flame trap

Fine foil flame trap element. Viewed from engine side.

11

Actuator mounting

Unscrew these 4 small bolts to detach actuator and allow removal of inlet valve.

Figure 8.25 Air inlet valve detail (Pyroban SVG-4 shown)

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Shut the unit down for safe maintenance. See 8.6 Prepare for safe
maintenance on page 112.

2.

Open the doors on the powerpack and locate the air inlet valve assembly. See
4.6.8 Additional features of Heavy Duty power packs on page 46.

3.

Loosen the hose clamp on the air intake side (2), and detach the hose from the intake.

4.

Remove the bolts from the engine air intake flange, and separate the air inlet valve assembly
from the flange.

5.

Place a temporary cover over the engine air intake to prevent foreign objects and particles
from entering.

6.

Carefully clean the engine air intake flange.

7.

Loosen the grub screw in the override cable clamp, and withdraw the override cable from the
assembly, taking care not to lose the clamp.

8.

Remove the mounting bolts of the engine oil pressure actuator assembly.
Take care not to lose these small bolts and washers.

9.

Leave the actuator attached to the engine oil pressure line and lift the actuator off the air inlet
valve.

10. Remove the air inlet valve from the power pack.
11. Clean the air inlet valve.
a) Carefully clean the discharge side flange.
b) Latch the butterfly valve open using the lever.
c) Wipe the throat on both sides of the flame trap clean using a clean cloth.
d) Clean any contamination off the butterfly valve.
12. Inspect the flame trap.
Provided the air filter has been regularly serviced, then the flame trap should need no
servicing. However, if engine peformance is affected due to a partially blocked flame trap,
then it should be cleaned as follows.
NOTE: Do not attempt to remove the flame arrester from the air inlet valve!
a) Latch the butterfly valve open using the lever.
b) Wash the flame arrester by agitating it in a container of clean diesel or degreaser, but use
no tools or brush which may damage it.

WARNING

TXT-10004256/A

COMPRESSED AIR
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never
point a compressed air pistol at exposed skin.

c) After cleaning, blow the flame arrester dry from both sides using a compressed air pistol.
d) Wipe clean all inside surfaces and the butterfly valve.
13. Lubricate the butterfly valve: apply a small amount of a suitable light grease (e.g. Dow
Corning MS4 or equivalent) around the edges of the butterfly O ring and the mating surface
in the valve throat.
NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.24 Clean air inlet safety valve for heavy duty power

1.

FlyLine User Manual

NOTE: Excess grease will be sucked into the intake, so use lubricant sparingly.
14. At the AIR INLET VALVE control, ensure the handle is pressed all the way in.
15. Re-install the air inlet valve as follows:
a) Use a small flat screwdriver to press the latch down and allow the lever to close the
butterfly valve.
b) Mount the actuator (with engine oil hose attached) to the air inlet valve.
c) Remove the temporary cover from the engine intake.
d) Fit the air inlet valve to the flange and if necessary install a new gasket.

8.24 Clean air inlet safety valve for heavy duty power

e) Make sure no gap is present between valve and flange, and firmly tighten the bolts
according to Appendix 6: Referenced Documents on page 246.
f) Ensure that the lever is in the closed position (the lever is pointing towards the incoming
air side).
g) Insert the pull cable through the lever, and fasten the clamp tightly on the free cable end
beside the lever.
h) Fit the hose to the intake side of the air inlet valve, and tighten the hose clamp.
16. Lightly oil the valve lever mechanism and cable.
17. Operate the AIR INLET VALVE control a few times, inspecting the mechanism at the valve itself
to check that the cable is pulling and releasing correctly.
Use a small flat screwdriver each time to release the latch so that the lever springs back to
the closed position.
18. Start the unit for normal operations.
19. Test that the engine starts, runs and shuts down correctly, including a simulated emergency
stop. See 7.3 Power up on page 97 and 7.1.3 Startup after an emergency stop on page 94.

CAUTION

TXT-10004376/A

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

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

Page 156 of 258


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Original Instructions

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.25

Clean fuel coarse particle filter

4
3
1
2

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Close the diesel tank isolation valve (1).

3.

Place a container underneath the coarse filter (2).

4.

Unscrew the blind cap (3) and remove the filter mesh(4).

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 (valve in-line with the tubing).

8.

Prime the diesel system by performing 8.37 Prime diesel engine on page 177.

9.

Use a rag to clean any spilled fuel.

CAUTION

TXT-10004376/A

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

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.25 Clean fuel coarse particle filter

Figure 8.26 Fuel tank isolation valve and coarse filter

FlyLine User Manual

8.26

Clean/replace air filter

3
4
1
2

8.26 Clean/replace air filter

Figure 8.27 Air intake filter assembly


1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Loosen the securing wing nut (1), and remove the cover (2).

3.

Loosen the securing wing nut (3), and remove the primary (outer) filter element (4).

4.

Loosen the securing nut (5), and remove the safety (inner) filter element (6).

5.

Clean or replace the filter element where necessary. Filter can be cleaned from the inside
out using low pressure compressed air. Replace filter if damaged or extremely dirty.

NOTE: Never attempt to clean the safety filter, it can only be replaced; normally once every 3
changes of the primary filter.
6.

Refit or replace the safety element, and tighten the securing nut.

7.

Refit the primary element, and tighten the securing nut.

8.

Refit the cover, and tighten the securing nut.

CAUTION

TXT-10004376/A

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

9.

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.27

Clean/replace crankcase flame trap

3
4
5
5

2
4

Figure 8.29 Crankcase flame trap (typical)

CAUTION

TXT-10004368/A

EQUIPMENT DAMAGE
Any contact with the core of the flame trap element can bend and damage the metal foil.
Only handle the flame trap element by the rigid edges.

1.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.27 Clean/replace crankcase flame trap

Figure 8.28 Location of crankcase flame trap (1)

FlyLine User Manual

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.

Locate the crankcase flame trap (1).

3.

Remove the flame trap assembly (4) from the flame trap housing (5) by pressing together the
two wire strands of the retaining clip (3). See Figure 8.29.

4.

You may need to use pliers to grip the securing bolt (2) and, while pressing the retaining clip
ends together, lift the flame trap assembly out for cleaning. See Figure 8.29.

8.27 Clean/replace crankcase flame trap

NOTE: Do not loosen the securing bolt (2) unless absolutely necessary for cleaning. Removing
it may allow the flame trap element to unwind, rendering it unusable.
5.

Use a clean rag to clean the inside of the housing.

6.

Place a temporary cover over the flame trap housing, so that no dirt or objects can get into
the breather inlet.

7.

Place the flame trap in a suitable container and clean with diesel, or replace it with a new one.

8.

Remove the temporary cover from the housing.

9.

Place the cleaned (or new replacement) flame trap in the housing.

CAUTION

TXT-10004376/A

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

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.28

Clean/replace fuel tank breather

Figure 8.30 Breather


1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

CAUTION

TXT-10004390/A

EQUIPMENT DAMAGE
The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked).
Never block (cap) the fuel tank breather.

2.

Use a spanner to unscrew the breather mesh (1) from the tank (2).
Be careful not to damage the mesh with the spanner. If the mesh is damaged, when
removing, it must be replaced.

3.

Clean the mesh with diesel fuel.

WARNING

TXT-10004256/A

COMPRESSED AIR
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never
point a compressed air pistol at exposed skin.

4.

Blow it off with compressed air.

5.

Refit the cleaned mesh to the breather.

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8.28 Clean/replace fuel tank breather

FlyLine User Manual

CAUTION

TXT-10004376/A

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

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

8.28 Clean/replace fuel tank breather

6.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.29

Clean spark arrester

Figure 8.31 Spark arrestor/muffler (engine air filter removed for clarity)
This procedure describes how to empty soot and debris that has collected in the cleaning point
of the spark arrester/muffler.
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004342/A

HOT OBJECT
Emptying soot or debris from the spark arrester while it is still hot can cause serious burns.
Before emptying the spark arrester, ensure that the engine has stopped and the spark arrester
has cooled down. Wear appropriate Personal Protective Equipment (PPE).

2.

Ensure that the exhaust system has cooled down.

3.

Position a piece of rag or small container underneath the cleaning point (1) of the spark
arrester (2), so that the contamination will not fall inside the power pack.

WARNING

TXT-10004314/A

HAZARDOUS SUBSTANCE
Particles such as carbon dust can damage your eyes and lungs.
Always wear appropriate Personal Protective Equipment (PPE), such as safety goggles, and
a protective breathing mask when working in particle contaminated environments.

4.

Remove the plug from the spark arrester cleaning point.


The soot and debris will fall out of the spark arrester.

5.

Screw the plug back in.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.29 Clean spark arrester

FlyLine User Manual

6.

Use a rag to clean the area around the spark arrester/muffler.

CAUTION

TXT-10004376/A

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

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

8.29 Clean spark arrester

7.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.30

Clean unit
Carry out the following clean-up tasks every day after shutting down the FlyLine, or at the first
opportunity following operations. A good freshwater supply will be necessary.
NOTE: If using a high-pressure water jet to clean the exterior, to avoid unit damage never point
the jet at any joints, panel seams, door or hatch openings, grills, electrical boxes and
connections, insulation foam and panels, intake filter housings or anywhere you cannot
clearly see.
Never use any kind of hose or water jet inside the power pack, and use them only with
great care to clean the winch bay.
1.

Drain the winch drip tray into a waste fluids container and place it back to collect waste from
the next steps.

2.

Use a brush with water and a cleaning agent to clean the exterior of the unit.

NOTE: Before using a degreaser to clean greasy remnants, test it on a small part of the body to
see if it can harm the paint work.
Take special care with windows: on the outside, first rinse with clean water, then wipe clean
using a glass cleaner.

4.

Continue into the winch bay, removing all dirt, salt, oil, grease, hydraulic fluid etc. from the
surfaces in the winch bay and measuring head.

5.

Rinse off the bodywork and winch bay with fresh water.

6.

In the winch bay, dry off any exposed metal surfaces using a rag, and apply a thin layer of
grease to prevent corrosion.

7.

Empty winch drip tray and open the unit drain plugs to allow waste water to drain off into
collecting containers.

8.

Clean winch control panel with a soft cloth and a mild spray cleaner. Wipe down the windows,
control panel (plus gauges, switches and joysticks), electrical panel and cabinets. Use
commercially available screen wipes on any control panel display screens.

CAUTION

TXT-10004376/A

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

9.

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

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


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Original Instructions

8.30 Clean unit

3.

FlyLine User Manual

8.31

Drain/fill coolant
This procedure describes how to drain the cooling system from the drain point at the bottom of
the radiator, and then refill it from the same point using a hand pump.
NOTE: The volume of the engine/coolant will increase, when it is hot. Do not to overfill the
radiator. If the coolant is overfilled, excess will run out of an overflow valve during
operations.

8.31.1 Drain coolant

8.31 Drain/fill coolant

2
Figure 8.32 Coolant filling point access hatch

1.

Make sure the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Wait for the coolant to cool down.

WARNING

TXT-10004340/A

HOT LIQUID
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, ensure that the unit has
been prepared for safe maintenance and the coolant has cooled down.

3.

Open the coolant filling point access hatch (1) at the top of the power pack, and remove the
radiator filler cap (2).
This will allow air to escape from the cooling system during draining and refilling of the
cooling system.

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FlyLine User Manual

3
4

Figure 8.33 Coolant drain valve

WARNING

TXT-10004336/A

4.

Remove the blind cap (3), and connect a flexible hose to the drain valve.

5.

Place the other end of the flexible hose in a suitable container.

6.

Open the drain valve (4). Figure 8.33 shows drain valve in closed position.

7.

Wait until the coolant has drained from the cooling system, and then close the drain valve.

8.

Remove the flexible hose and container.

9.

Replace the cap on the drain valve.

10. If the unit will not be refilled immediately, place warning tags on the starter and/or control
panel to prevent accidental starting.

CAUTION

TXT-10004376/A

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

11. Dispose of the old coolant according to local environmental regulations.

8.31.2 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: 8.14 Check/fill coolant on page 132.

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Original Instructions

8.31 Drain/fill coolant

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.

FlyLine User Manual

coolant

Figure 8.34 Coolant sight glass


Remove the filler cap (4) at the top of the radiator.

8.31 Drain/fill coolant

1.

6
Figure 8.35 Air bleed-point for cooling system
2.

Locate the air bleed valve (5) on top of the exhaust gas cooler (6).

3.

Place a rag around the bleed point to catch any run-off coolant.

4.

Open the bleed valve.

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.

Pump coolant into the system, until it comes out air-free from the bleed valve.

9.

Close the bleed valve.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

10. Close the drain valve.


11. Remove the pump, and replace the blind cap.
12. IFinish topping up the coolant as described in 8.14 Check/fill coolant on page 132.
13. Place a clean rag loosely over the open coolant filling point to keep coolant from splashing.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

14. Start the power pack (see 7.3 Power up on page 97), and run the engine for five minutes to
circulate the coolant thoroughly.

16. Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
17. Repeat 8.14 Check/fill coolant on page 132.

8.31.3 Finalize
1.

Use clean rags to clean any spilled coolant.

CAUTION

TXT-10004376/A

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

2.

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.31 Drain/fill coolant

15. Open the air bleed valve (5) once more to bleed off any remaining air and close when pure
coolant comes out.

FlyLine User Manual

8.32

Drain fuel purifier


Related topics:
4.6.3 Engine fuel system on page 40
8.6 Prepare for safe maintenance on page 112
The purifier should be drained of accumulated contamination about once every 600 hours, more
often if the fuel is particularly dirty, and less often if using very high grade fuel.
1.

Shut the unit down for safe maintenance. See related topic.

2.

Locate the fuel purifier. See item 13 in the figure on page 40.

3.

Lead the drain hose into a suitable waste fuel container.

4.

Open the drain valve in the underside of the vessel to allow the contaminated fuel or other
fluids to drain out. Tap at least 1 litre of fluid, more if clean fuel does not appear.

8.32 Drain fuel purifier

Open the bleed valve in the top of the vessel to help the draining process.
5.

Close the drain plug and bleed valve.

6.

Remove the waste fuel container.

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.

Dispose of any drained liquid according to local environmental regulations.

8.

Clean any spillage from around the fuel purifier.

9.

Prime the fuel pump before starting, so that the vessel fills with clean fuel.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.33

Drain fuel tank


This procedure describes how to drain the diesel tank in preparation for air transport, or if the unit
is to be stored for a lengthy period.

8.33 Drain fuel tank

Figure 8.36 Fuel filler cap


1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Remove the fuel tank cap (1).

3.

Insert a flexible hose attached to a hand-pump into the hole all the way into the tank, until it
comes to rest on the bottom.

4.

Pump the fuel from the tank into a suitable container.

5.

Use a cleaning rag to clean any spilled fuel.

CAUTION

TXT-10004376/A

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

6.

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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FlyLine User Manual

8.34

Drain fuel/water separator

1
2

8.34 Drain fuel/water separator

4
Figure 8.37 Diesel prefilter with fuel/ water separator
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

You can observe the water/ contamination through the sight glass (2).

3.

Place a small container underneath the bowl (3) of the of the fuel/ water separator (1).

4.

Drain the water by loosening the drain plug (4) at the bottom of the bowl.

5.

Wait until the water/ contamination is completely drained.

6.

Retighten the drain plug once clean fuel starts draining.

7.

Perform 8.37.1 Quick prime on page 177 to refill the fuel/ water separator and purge the fuel
system of air.

8.

Remove the container.

9.

Clean any moisture from around the fuel/ water separator.

CAUTION

TXT-10004376/A

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

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

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Original Instructions

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.35

Drain water from hydraulic tank

1
2

Water can accumulate in the hydraulic oil tank. As long as the unit is in regular use, the water in
the hydraulic oil is emulsified by the pumps and motors in the system. Only when the unit has
been idle for more than a few days will the water separate out. Being heavier than the hydraulic
oil, it settles to the bottom of the tank, and can be drained.
1.

Ensure that the unit is shut down, and has not run for the past few days.

2.

Ensure that the drain valve (1) is closed. Figure 8.38 shows drain valve in closed position.

3.

Unscrew the blind cap (2).

4.

Attach a piece of clear plastic hose to the drain valve.

5.

Put the other end in a suitable container.

6.

Slowly open the drain valve, and allow the water to run into the container.

7.

When pure oil starts to flow, close the valve.

8.

Remove the hose, and replace the cap.

9.

Ensure the suction filter isolation valve (3) is open before starting. Figure 8.33 shows
isolation filter valve in open position.

10. Check the oil level and replenish if necessary by performing 8.17 Check/fill hydraulic
oil on page 139.

CAUTION

TXT-10004376/A

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.35 Drain water from hydraulic tank

Figure 8.38 Hydraulic oil tank valves (rear power pack grill removed for clarity)

FlyLine User Manual

8.35 Drain water from hydraulic tank

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

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Original Instructions

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.36

Grease unit
This procedure explains how to grease a number of keys points in the unit. All grease points in
the unit should be lubricated on a regular basis.

8.36.1 Grease drum bearings

Figure 8.39 Pillow block bearing detail

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Clean off the grease nipple (1).

NOTE: DO NOT fill grease until it comes out of the bearing. That will over-lubricate the bearing
and damage the seals.
3.

Use a hand-held grease gun to apply a small amount (one cc) of grease to the drum bearing.

4.

Do this for all of the drum bearings.

8.36.2 Grease all other points


1.

Grease the levelwind chain.

2.

Grease the drum drive chain to protect it from rusting, but remove excess grease before
running the drums to avoid spatter.

3.

Use a grease gun to apply grease to the door hinges.

4.

Use a rag to remove any excess grease.

5.

Use the grease gun to apply grease to all other lubrication points on the unit.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Revision C
Original Instructions

8.36 Grease unit

The bearings supporting the drums (pillow block bearings) in NOV Elmar units are modern,
double-shielded ball bearings. These may not be greased by injecting grease until it begins
coming out. They should only be filled to approx. 40% of the bearing cavity volume.

FlyLine User Manual

6.

See the separate measuring head User Manual in the Documentation Package for a
description of the measuring head lubrication.

CAUTION

TXT-10004376/A

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

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

8.36 Grease unit

7.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.37

Prime diesel engine


The Caterpillar 4 Cylinder 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 (8.37.1) method first. If this is not successful, prime the entire system
(8.37.2).

8.37.1 Quick prime

5
8.37 Prime diesel engine

3
Figure 8.40 Fuel system components.
1.

Open the left power pack panel.

2.

Ensure that the fuel isolation valve (2) above the fuel tank (3) is open and locate the engine
fuel primer (1). Figure 8.40 shows the fuel isolation valve in the open position.

3.

Turn the control lever on the fuel safety valve (4) clockwise against the spring pressure until
it catches.
This will reset the fuel safety system and allow fuel to flow.

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FlyLine User Manual

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 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

8.37 Prime diesel engine

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

13. Start the engine as described in 7.3 Power up on page 97.


14. It may take a few attempts.

8.37.2 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 Section 8.37.1 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.

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FlyLine User Manual

Figure 8.41 Left: Fuel primer pump; Right: view of fuel injectors
Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Ensure that the fuel isolation valve (2) above the fuel tank (3) is open.

3.

Pump the fuel primer (1) until the resistance is too high to pump.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

This will supply fuel to the fuel injector pump.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

4.

Remove the plastic cover (7) next to the engines valve cover. This will provide access to the
injectors, the high-pressure fuel injector lines (9) and injector line coupling nuts (8).

5.

Slightly loosen the fuel line coupling nuts on the injectors; do not remove completely, but just
enough (1-2 turns) to allow air to bleed from the fuel.

6.

Place rags around the coupling nuts to catch fuel.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.37 Prime diesel engine

1.

FlyLine User Manual

WARNING

TXT-10004323/A

HIGH PRESSURE
Components and fluids under high pressure may be ejected at great force causing bodily harm
and damage to equipment. When working with or near components under pressure:
Prevent access by unauthorized persons.
Wear appropriate personal protective equipment (PPE).

For spring starter equipped engines go to step 11.


For electric, hydraulic and air starter equipped engines proceed as follows:

8.37 Prime diesel engine

NOTE: Ensure the battery, accumulator or air supply are sufficiently charged between start
attempts.
7.

Attempt to start the engine according to Section 7.3 Power up, causing it to turn over a few
times. This will force air out of the injector lines.

8.

When all air has been forced out of the injector lines, and fuel is present, tighten the injector
line coupling nuts one at a time and repeat start attempts for each cylinder.

9.

After tightening the last coupling nut, the next start attempt may actually start the engine. In
this case allow it to run for a short time and monitor it for indication of rough running.

10. Repeat above steps 7-9 until engine runs smoothly. This will ensure that all injectors are
sufficiently bled.
For spring starter equipped engines the procedure is slightly different, but the principle is
the same.
11. Push the reset knob on the starter.
12. Wind the spring starter for not more than two turns; when there is a noticeable resistance
stop cranking. DO NOT crank the starter completely to the white or red stripes.
13. Trip the starter handle as you would to start the engine. Starter pinion should now be
engaged to the flywheel, allowing starter to slowly rotate the engine.
14. Use the cranking handle to now slowly turn the engine. If engine does not turn then repeat
steps 11-13.
15. Pump the engine fuel primer several times to force fuel through the high-pressure fuel lines;
only one fuel line will be engaged at a time.
16. While pumping the fuel primer note which fuel line at the injectors is bleeding fuel and tighten
the nut once air-free fuel flows out.
17. Repeat this for each injector in the correct firing order; refer to the CAT engine User Manual
for firing order sequence. Typical for four cylinder is 1-3-4-2.
18. After tightening the last coupling nut, push the reset knob on the starter and wind the starter
normally for starting the engine. Refer also to Section 7.3 Power up.
19. Start engine and allow it to run for a short time and monitor it for indication of rough running.
20. Repeat above steps 11-19 until engine runs smoothly. This will ensure that all injectors are
sufficiently bled.

8.37.3 Finalize
1.

Clean any spilled fuel from around the engine.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

CAUTION

TXT-10004376/A

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

2.

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

8.37 Prime diesel engine

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

FlyLine User Manual

8.38

Remove/replace drum chain

Figure 8.42 Master link in the drive chain

8.38 Remove/replace drum chain

This procedure requires two persons to perform it safely.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

1.

Start the unit as described in 7.3 Power up on page 97.

WARNING

TXT-10004293/A

DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.

WARNING

TXT-10004359/A

SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.

2.

Remove the wireline from the measuring head assembly, and secure it to the drum, as
described in the Measuring Head User Manual in the Documentation Package that came
with the unit.

3.

Release the BRAKE.

4.

Open the left access panels on the winch module.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

5.

Slowly rotate the drum until the master link (1) in the drive chain can be easily accessed.

6.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

8.38.1 Remove chain

2
2

WARNING

TXT-10004348/A

MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Ensure that the engine cannot be started during maintenance.

1.

Remove the drum guards on the left side of the drums by loosening the bolts (2).

2.

Remove the retaining clip from the master link, and carefully remove the master link.

3.

Remove the chain and reconnect it on itself using the master link, and refit the retaining clip.

4.

Store the chain in an appropriate place, free of moisture and dirt.

8.38.2 Fit chain on drum


1.

Check the condition of the winch frame. Use a rag to clean excess grease or dirt from the
winch frame, and report any damage.

2.

If necessary clean the chain of dirt and rust and ensure it is flexible and in good condition.

3.

Position the correct chain around the drive sprocket and drum sprocket.
The shorter chain is for the rear drum, the longer for the front drum.

4.

Refit the master link and retaining clip (see Figure 8.42). Make sure the retaining clip is
correctly secured.

5.

Adjust the chain, as described in 8.10 Check/adjust chain tension on page 123.

8.38.3 Finalize
1.

Refit the drum guards.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.38 Remove/replace drum chain

Figure 8.43 Examples of drum guards and mounting bolts

FlyLine User Manual

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

8.38 Remove/replace drum chain

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

2.

Start up the unit, as described in 7.3 Power up on page 97.

3.

Slowly rotate the drum in both directions. If necessary, lubricate the chain to protect it and
keep it flexible and in good condition.

4.

Check for correct drum movement and operation of the brake. Rectify any problems.

5.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

CAUTION

TXT-10004376/A

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

6.

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.39

Replace levelwind chain

1
4

Figure 8.44 Levelwind chain

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004268/A

CRUSH HAZARD
Wind can cause an unrestrained door or hatch to slam open or closed with considerable force,
causing serious injury and possible equipment damage. Always:
Latch every closed door or hatch.
Use the retainers to secure any door or hatch that must be left open.

2.

If the unit is so equipped, lift the protective cover on the front of the winch module to access
the measuring head and levelwind chain. See 5 For all modules, connect ground cables
between the modules. on page 81

3.

Unlock the measuring head from the transport position, refer to 6.3.5 Prepare measuring
head assembly on page 87

4.

Locate fastening screw (1) and loosen completely so the adjusting turnbuckle (2) is free of
the measuring head carrier (3).

5.

To slacken the chain, use a suitable wrench to turn the turnbuckle in the direction of the arrow
shown.

6.

Remove securing clips from the master links (4) on each end of the chain.

7.

Carefully remove the chain from the sprockets and use it to mark the length of the
replacement chain; dispose of old chain in a suitable manner.

8.

Once new chain has been cut to correct length, install the chain onto the sprockets.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.39 Replace levelwind chain

WARNING

FlyLine User Manual

9.

Line up the first end of the chain with the adjustment bolt on the turnbuckle; insert the master
link and secure with the clip.

10. Repeat for the other end of the chain.


11. Adjust the chain by performing 8.11.3 Adjust levelwind chain tension on page 127

8.39.1 Finalize
1.

If necessary, grease the drive chain to keep it flexible and prevent rusting.

CAUTION

TXT-10004376/A

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

Turn the steering wheel to move the measuring head left and right a few times to verify the
chain security and free play.

3.

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

8.39 Replace levelwind chain

2.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.40

Remove/replace brake band

6
Left-hand threads

2
Right-hand threads

4
6
8.40 Remove/replace brake band

5
3

Figure 8.45 Brake adjustment nut and locknut


This procedure can be used for replacing a worn-out brake band, or as a sub-procedure, when
the drum must be removed for maintenance purposes. This procedure describes how to replace
the brake band of one drum. If the unit has two drums, you must repeat this procedure for both
drums.
NOTE: A new brake band must be installed whenever a drum is replaced.
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

If necessary, lower or raise the levelwind arm, depending on the brake band you want to
remove/replace.

3.

Remove the drum guard(s).

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

FlyLine User Manual

4.

Loosen the brake adjustment locknut (1).

5.

Loosen the brake adjustment turnbuckle (2), until it comes free of the brake band (6).

6.

Remove the linchpins (4) from the brake band rocker shaft (5), and slide the shaft out.

WARNING

TXT-10004359/A

SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.

7.

Remove the brake band from the drum.

8.

Clean/inspect the brake ring on the drum. Report any damage.

9. Check the brake band for wear by performing 8.13 Check brake band wear on page 130.
Fit the replacement brake band over the brake

CAUTION

TXT-10004376/A

8.40 Remove/replace brake band

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

10. ring on the drum.


11. Refit the rocker shaft, and secure it with the linchpins.
12. Install the adjustment turnbuckle; keep in mind it has left- and right-hand threads. Tighten it
completely then back off two turns.
NOTE: This is not an adjustment. The brake must be properly adjusted in the following step.
13. Adjust the brake band tension by performing 8.9 Check/adjust brake band
tension on page 116.
14. Refit the drum guards.

CAUTION

TXT-10004376/A

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

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.41

Replace V-belts

6
3
5

This procedure describes how to replace the V-belts on the Caterpillar diesel engine. The V-belts
used to manufacture this unit have special, antistatic properties, and cannot be replaced by
standard V-belts. Refer to the spare parts manual or contact NOV Elmar for ordering info.

1.

Ensure that the unit is shut down for safe maintenance, as described in 7.5 Normal shut
down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Remove the protective guards.

3.

Remove the securing bolts (1) attaching the fan shaft (2) to the fan pulley (3).

4.

Loosen the nuts (4) and (6), securing the tensioner pulley bracket (5).

5.

Loosen the belt tension as much as possible.

6.

Remove first the outer V-belt, then the inner V-belt.


NOTE: Always replace both belts as a set, never just one.

7.

Fit first the new inner V-belt, then the outer V-belt.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.41 Replace V-belts

Figure 8.46 V-belt and fan mounting detail (before painting)

FlyLine User Manual

Use only the exact replacement belts referred to at the start of this procedure. These are
special, antistatic types, certified for Zone 2, ATEX operation.

WARNING

TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

8.

Reattach the fan shaft to the fan pulley.

9.

Adjust the V-belt tension as described in 8.12 Check/adjust V-belts on page 128.

10. Refit the protective guards.

CAUTION

TXT-10004376/A

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

8.41 Replace V-belts

11. Remove all tools and materials from the work area.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.42

Replace drum
This procedure describes how to replace one drum.
For this procedure a suitable lifting device (crane, hoist), rated at minimal 2 tons, is required.

8.42.1 Prepare

WARNING

TXT-10004359/A

SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.

1.

Remove the wireline from the measuring head assembly, and secure it to the drum, as
described in the measuring head User Manual in the Documentation Package that came with
the FlyLine unit.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

3.

Remove the drum guards to gain access to the drum brake band and drive chain.
NOTE: There is a drum guard on both sides of the drum.

4.

If the unit has two drums, make sure the appropriate drum brake is selected .

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

5.

Start the unit as described in 7.3 Power up on page 97.

WARNING

TXT-10004293/A

DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.

6.

Release the BRAKE.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.42 Replace drum

2.

FlyLine User Manual

7.

Slowly push the DRUM CONTROL levers forward until the master link in the drive chain can be
easily accessed. See Figure 8.47.

8.42 Replace drum

Figure 8.47 Master link in the drive chain


8.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

9.

Remove the brake band. See 8.40 Remove/replace brake band on page 187.

WARNING

TXT-10004330/A

HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.

10. Place appropriate lifting straps on both sides of the drum, and attach the straps to the lifting
device. See Section Figure 8.48 Ideal location for lifting straps.

Figure 8.48 Ideal location for lifting straps

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.42.2 Remove drum

3
front of winch module

Figure 8.49 Drum alignment and attachment bolts


Loosen the front drum-alignment-bolts (1) on both pillow block bearings.

2.

Remove the four pillow block attachment bolts (2) on both sides of the drum.

3.

Turn the rear drum-alignment-bolts clockwise to move drum slightly forward in able to
slacken the drive chain for removal.

4.

Remove the retaining clip and master link from the chain (Figure 8.47), and remove the chain
from the drum.

5.

Reconnect the chain on itself using the master link and retaining clip, and store the chain in
a safe place.

WARNING

TXT-10004271/A

CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.

6.

Use the lifting device to lift out the drum.

7.

Store the drum in a suitable shipping container taking care not to damage the flanges or the
brake surface.

8.

If the drum is being stored for any period, apply grease to the drum journals and bearings as
described in 8.36.1 Grease drum bearings on page 175.
NOTE: Please note the information given in 8.36.1.

8.42.3 Refit drum


1.

Check the condition of the drive sprocket on the gearbox. If necessary, replace the drive
sprocket.

2.

Check the condition of the winch frame. Report any damage.

3.

Use a rag to clean any excess grease or dirt from the winch frame.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 193 of 258


Revision C
Original Instructions

8.42 Replace drum

1.

FlyLine User Manual

WARNING

TXT-10004330/A

HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.

4.

Place the lifting straps at either end of the drum, and attach the straps to the hoist.

WARNING

TXT-10004271/A

8.42 Replace drum

CRUSH HAZARD
Heavy objects can trap limbs and cause serious injury or death.
Never place yourself between object(s) that can suddenly move. Follow local safety
regulations.

5.

Use the lifting device to lift the drum out of the shipping container.

6.

Carefully lower the drum so that the pillow blocks rest on the winch frame.

7.

Insert the drum attachment bolts, and tighten to finger-tight.

8.

Position the chain around the drive sprocket and drum sprocket.

9.

Refit the master link and retaining clip (see Figure 8.47). Make sure retaining clip is correctly
secured.

10. Adjust the chain, as described in 8.10 Check/adjust chain tension on page 123.
11. Make sure the distance (a) between the adjustment block (3) and the pillow block is the same
on both sides of the drum (see following figure).
This will ensure that the drum is correctly aligned in the winch module.

distance (a)

Figure 8.50 Drum bearing alignment

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.

Page 194 of 258


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Original Instructions

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

12. Make sure the drum attachment bolts on both sides of the drum are securely tightened to
426 Nm (314 lb-ft).

8.42.4 Finalize
1.

Remove the straps from the drum

2.

Refit the brake band, as described in 8.40 Remove/replace brake band on page 187.

3.

Refit the drum guards and tighten the drum guard attachment bolts.
NOTE: There is a drum guard on both sides of the drum.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

Start up the unit, as described in 7.3 Power up on page 97.

5.

Slowly rotate the drum in both directions.

6.

Check for correct drum movement and alignment. Check operation of the brake. Rectify any
problems.

7.

Perform the drum mount test, as described in 8.52 Test drum mounting on page 217.

8.

Shut the unit down for safe maintenance. See related topic.

9.

Apply grease to the drum journals and bearings as described in 8.36.1 Grease drum
bearings on page 175.
NOTE: Please note the information given in 8.36.1.

CAUTION

TXT-10004376/A

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

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 195 of 258


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Original Instructions

8.42 Replace drum

4.

FlyLine User Manual

8.43

Replace fuel fine filter element

8.43 Replace fuel fine filter element

Figure 8.51 Fuel fine particle filter


1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

2.

Place some rags underneath the filter element (1).

3.

Unscrew and remove the filter element from the mounting head (2).

4.

Lubricate the top seal of the new filter element with clean diesel fuel.

5.

Fit the empty filter element to the mounting head. Turn the filter assembly until it contacts
the top seal, and then hand-tighten an additional full turn.
NOTE: Do not fill the element with diesel (the fuel would not be filtered before going to the
engine). Do not over tighten!

6.

Purge the diesel system by performing section 8.37 Prime diesel engine on page 177.

7.

Check the fine particle filter for any leaks.

8.

Rectify any problems.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

9.

Start the unit as described in 7.3 Power up on page 97.

10. Check the system for correct operation, and recheck the fine particle filter for any leaks.
11. Rectify any problems.

CAUTION

TXT-10004376/A

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

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.43 Replace fuel fine filter element

12. Clean any excess diesel from around the filter/engine.

FlyLine User Manual

8.44

Replace fuse or circuit breaker


Your Elmar equipment may have up to four different types of fuses and circuit breakers to protect
the electrical circuits and components from electrical overload. The type of fuse used depends on
the specifications of the electrical system. In general, the following rule applies:
12-24 volt: blade type fuses (typical automotive fuse)
110-240 volt: cartridge fuses (glass) and circuit breakers
380 volt and higher 3-phase: mesh type fuses, cartridge fuses and circuit breakers
The fuses are marked with an identification number that corresponds to the "F" number stated on
the electrical diagrams in the Documentation Package. The description on the diagram states the
trip level in amperes.

8.44 Replace fuse or circuit breaker

Before restoring a blown fuse or tripped circuit breaker:


1.

Identify and fix the situation that caused the circuit to overload.

2.

Ensure that the unit has been shut down for safe maintenance, as described in 8.6 Prepare
for safe maintenance on page 112.

3.

Shut down the electrical system, and disconnect rig AC power.

4.

If your unit is equipped with a BATTERY SWITCH on ECP 1, turn it off.

5.

Replace/restore the fuse/circuit breaker using the appropriate section below.

6.

Restart the electrical system.

7.

Restart the component or circuit that failed. Verify that the component or circuit works
correctly.

8.

Replenish the stock of spare fuses, and also make sure that there is a new spare fuse stowed
in cartridge type fuse holders (see 8.44.2 and 8.44.3).

NOTE: Not every type of fuse and circuit breaker described below may be present in your
equipment.

8.44.1

Blade type fuses

Rating (amps)

Colour

Part no.

purple

A0015291

light brown

A0015284

7.5

dark brown

A0015285

10

red

A0015286

15

blue

A0015287

20

yellow

A0015288

30

green

A0017156

Table 8.5 Blade type fuse specifications

Figure 8.52 Blade fuses and block


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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Blade type fuses are the same type as used in the automotive industry. The fuses are colour
coded to indicate the rating. To replace a blade type fuse:
1.

Pull the fuse from the fuse block and discard it.

2.

Insert a spare fuse of the same colour/rating. See Table 8.5.

8.44.2 Swing-out cartridge fuses

Part no.

0.50

1.00

A0000934

1.50

A0011260

2.00

A0015219

3.15

A0015306

5.00

A0015575

6.30

A0010259

10.00

A0014805

Table 8.5 Cartridge fuse specifications

Figure 8.53 Swing-out cartridge fuse holder


Cartridge (glass) fuses (1) are clamped between contacts in a swing-out holder (2). The swingout holder also contains a spare fuse (3). Elmar equipment uses standard 5 mm x 20 mm
cartridge fuses with the ratings specified in Table 8.5.
To replace the cartridge fuse in a swing-out holder:
1.

Swing the holder out and up to give access to the holder side cover.

2.

Carefully open the cover. This will eject the blown fuse from the contacts.

3.

Remove the blown fuse and replace it with a new fuse (see Table 8.5). If you have no other,
use the spare inside the holder, but insert a new spare at the first opportunity.

4.

Carefully close the cover. This will press the new fuse into the contacts.

5.

Swing the holder back into position.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.44 Replace fuse or circuit breaker

Rating (amps)

FlyLine User Manual

8.44.3 Pull-out cartridge fuses

1
1

8.44 Replace fuse or circuit breaker

2
3

Figure 8.54 Pull-out cartridge fuse holder


Cartridge (glass) fuses are clamped between contacts in a pull-out holder. See Figure 8.54. The
pull-out holder also contains a spare fuse. The same standard 5 mm x 20 mm cartridge fuses are
used as in the swing-out type, as specified in Table 8.5.
To replace the cartridge fuse in a pull-out holder:
1.

Grip the tab (1) and pull out the holder.

2.

Prise open the small side cover (2).

3.

Remove the blown fuse (4) and replace it with a new fuse (see Table 8.5). If you have no
other, use the spare (3) inside the holder, but insert a new spare at the first opportunity.

4.

Close the cover.

5.

Push the holder back into position.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.44.4 Circuit breakers

Automatic circuit breakers are the easiest to check/reset. When OFF (1) shows, the circuit has
been overloaded or short-circuited. To reset the circuit breaker, switch it to ON (2).
NOTE: Always replace a damaged automatic circuit breaker with an identical unit, i.e. same
rating, phase characteristic, and voltage. Only a qualified electrical technician may
perform maintenance/repairs to automatic circuit breakers.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.44 Replace fuse or circuit breaker

Figure 8.55 Automatic circuit breaker

FlyLine User Manual

8.45

Replace hydraulic high-pressure filter

8.45 Replace hydraulic high-pressure filter

1
3
4
3
4

Figure 8.56 Hydraulic oil high-pressure filters

8
6
7
5
3
10

Figure 8.57 Disassembled high-pressure filter

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

The hydraulic high-pressure filters need to be changed when a red pin becomes visible in the
contamination indicator (1)
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Close the hydraulic suction filter isolation valve (2).


The valve is closed when the lever is at right angles to the flow direction. Figure 8.46 shows
valve in open position.

3.

Place a waste oil container and plenty of rags below the filter bowls (3) to catch any oil that
spills, when the bowl is removed.
TXT-10004337/A

HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.

4.

Unscrew the bowl using a suitable wrench affixed to the hex (4) at the end of the bowl.

5.

WIthdraw the bowl as far as possible.

6.

Carefully loosen the element (5) from the spigot (7) of the filter head (6), using a slight
twisting and rocking motion.

7.

Remove the element and bowl together.

8.

Drain all the oil from the filter into a waste oil container.

9.

Remove the O-ring (8) from the bowl.


NOTE: Some pressure filters have a separate synthetic support ring for the O-ring. Take
care not to damage or lose this ring, as there is no replacement in the filter element
set.

CAUTION

TXT-10004384/A

EQUIPMENT DAMAGE
Incomplete selection of the hydraulic ball valve can damage the valve seals:
Push the valve lever in one quick movement to the end position, and lock it in that position.
Never leave the ball valve in an unselected position.

10. Using a clean cloth, carefully clean the filter head, screw thread, spigot and seal flange.
11. Using a clean cloth, carefully clean the filter bowl inside and out, in particular the O-ring
seating (9), support ring and screw thread (10).
12. Take a new filter element of the specified type (see spare parts list for this unit), and lubricate
the element nose seal, the new O-ring and the support ring with clean hydraulic fluid.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.45 Replace hydraulic high-pressure filter

WARNING

FlyLine User Manual

13. Carefully reposition the filter element over the spigot on the filter head. Fit the filter element
fully before fitting the bowl over the element.
14. Firmly tighten the bowl.

CAUTION

TXT-10004376/A

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

15. Dispose of all used filter elements and oil as prescribed by site regulations.
16. After all filters have been replaced and all other hydraulic maintenance has been carried out:
a) Open all hydraulic supply valves (levers aligned with flow direction).

8.45 Replace hydraulic high-pressure filter

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

b) Start the unit as described in 7.3 Power up on page 97.


c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that the pressure
stabilizes. Perform test described in 8.53 Test hydraulic system pressure on page 219.

WARNING

TXT-10004293/A

DANGEROUS OPERATIONS
The following activities can only be performed with the unit energized and running.
Ensure that no unauthorized persons have access to the unit. Always position visual barriers
(e.g. tape) around the entire unit.

d) With the unit running, check each filter head for leakage.
If there are leaks, shut the unit down for safe maintenance, remove the filter bowl and
element as described above, clean the facing parts and the seal, and re-fit the filter.
e) Inspect the seals again for leakage after operating for several hours, taking remedial
action if necessary.
17. Shut down for safe maintenance, as described in 7.5 Normal shut down on page 104.
18. Check and, if necessary, top off the hydraulic oil tank. See 8.17 Check/fill hydraulic
oil on page 139.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.46

Replace hydraulic oil

1
2

WARNING

TXT-10004337/A

HOT LIQUID
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, ensure that:
The unit has been shut down.
The hydraulic oil has cooled down.
All pressure has been safely released from the hydraulic system.

CAUTION

TXT-10004383/A

EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.

CAUTION

TXT-10004376/A

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

1.

Make sure the unit has been shut down for safe maintenance. See 7.5 Normal shut
down on page 104.

2.

Ensure that the drain valve (1) is closed. Figure 8,48 shows drain valve in closed position.

3.

Unscrew the valve cap (2).

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.46 Replace hydraulic oil

Figure 8.58 Hydraulic oil tank drain valve (rear grill on power pack removed for clarity)

FlyLine User Manual

4.

Attach a piece of clear plastic hose to the drain valve.

5.

Put the other end in container large enough to hold the hydraulic oil.

6.

Slowly open the drain valve, and allow the oil to run into the container.

7.

When the tank is empty, close the valve.

8.

Remove the hose, and replace the cap.

9.

Replace all suction filters in the hydraulic system. See 8.47 Replace hydraulic suction
filter on page 207.

10. Fill the tank with oil of the correct grade. See 8.17 Check/fill hydraulic oil on page 139.

CAUTION

TXT-10004376/A

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

8.46 Replace hydraulic oil

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.47

Replace hydraulic suction filter

1
4
2
5
6

Figure 8.59 Hydraulic suction filter (rear grill on power pack removed for clarity)
Check the contamination indicator (1) while the engine is running.
The suction filter should be replaced before the contamination indicator goes into the red zone. If
the indicator is in the yellow zone the filter is partially contaminated and should be changed at the
first convenient opportunity.
If already in the red zone, the filter is contaminated and is being bypassed. It should be changed
immediately!
NOTE: On dual-filter filter heads there is a single contamination indicator for both filters.
1.

Ensure that the unit is safe for hydraulic maintenance:


The unit has been shut down for safe maintenance, as described in 7.5 Normal shut
down on page 104.
Tag out the control panel so the unit cannot be accidentally started.
The hydraulic oil is cooled enough to avoid burns (check temperature gauge!).

2.

Close the suction filter isolation valve (2). Figure 8.59 shows the isolation valve in open
position.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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8.47 Replace hydraulic suction filter

FlyLine User Manual

3.

Place a container under the filter to catch any oil.

WARNING

TXT-10004338/A

HOT LIQUID
Hot oil can cause serious burns.
Take care when handling hot oil and associated components. Always wear appropriate
Personal Protective Equipment (PPE), such as gloves.

4.

Unscrew and remove the filter element (3).

5.

Drain all the oil from the filter into a waste oil container.

6.

Using a clean cloth, clean the filter head (4) and the seal flange surface(5).

CAUTION

TXT-10004383/A

8.47 Replace hydraulic suction filter

EQUIPMENT DAMAGE
Hydraulic systems can be accidentally contaminated during servicing.
Always apply maximum standards of cleanliness. Before reassembling hydraulic components,
use a clean cloth to thoroughly clean all parts.

7.

Take a new filter (see spare parts list for correct type), and Apply a thin film of hydraulic oil
to the new seal (6) supplied with the filter.

8.

Place the seal on the filter, and fill it with clean hydraulic oil of the same viscosity as the oil
in the unit.

9.

screw the filter by hand up onto the filter head.

NOTE: Do not use tools to tighten the filter! It should be firmly tightened only by hand.
10. Open the hydraulic oil isolation valve.
11. When all filters have been replaced and all other hydraulic maintenance has been carried
out:

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

a) Start the unit as described in 7.3 Power up on page 97.


b) Operate the unit for a few minutes to let any air in the hydraulic system move to the tank.
c) Slowly rotate the drum in both directions, checking for correct drum movement and
operation of the brake.
d) Check each filter head:
The contamination indicator should be in the green zone.
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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

There should be no leakage from the filter seals.


12. Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.
13. If there are leaks, attempt to hand-tighten the filter further until the leak stops.
If necessary, remove the filter, clean the facing parts and the seal, and re-fit the filter.
14. Check and replenish the hydraulic oil in the tank, as described in 8.17 Check/fill hydraulic
oil on page 139.

CAUTION

TXT-10004376/A

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

15. Remove all tools and materials from the work area, and dispose of used materials according
to local environmental regulations.
8.47 Replace hydraulic suction filter

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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FlyLine User Manual

8.48

Replace slip ring

4
2

8.48 Replace slip ring

3
Figure 8.60 Slip ring mounted on the drum assembly

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

CAUTION

TXT-10004379/A

EQUIPMENT DAMAGE
Components can be damaged during disassembly and temporary storage.
Take care when removing components and store them in a safe place.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal shut
down on page 104.

8.48.1 Remove slip ring


1.

Remove the two bracket attachment screws (1).

2.

Remove the four attachment screws (2) from the slip ring case flange.

3.

Disconnect the cable connector (3).

4.

Carefully remove the slip ring.

5.

If the slip ring is to be placed onto a replacement drum, then the adapter ring (4) must also
be removed and installed onto the new drum.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.48.2 Refit slip ring


1.

Align the cable connector in the slip ring base with the connector in the drum axle.

2.

Insert and connect securely.

3.

Insert and tighten the attachment screws attaching the slip ring to the drum mounting.

4.

Reattach the cable connector to the slip ring.

8.48 Replace slip ring

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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FlyLine User Manual

8.49

Replace fuel/water separator filter

8.49 Replace fuel/water separator filter

4
5
Figure 8.61 Fuel tank isolation valve and fuel/ water separator
1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Close the fuel tank isolation valve (1).

8.49.1 Remove filter


1.

Loosen the securing screw(2) and unscrew it carefully while holding the filter element (3),
sight glass (4) and bowl (5) firmly to the mounting head (6) by hand.

2.

When securing screw is completely loose, carefully remove the filter components from the
head and pour the fuel into a suitable waste container.

3.

Remove the bowl and glass from the filter element and discard the filter.

4.

Clean the bowl and glass.


NOTE: The bowl and glass are reusable, do not discard.

8.49.2 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.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

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 8.37 Prime diesel engine on page 177.

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

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.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.49 Replace fuel/water separator filter

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

FlyLine User Manual

8.50

Service compressed air filter

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.

8.50 Service compressed air filter

2
1

Compressed air
reservoir

Rig Air on winch module


Figure 8.62 Compressed air filter and isolation valves

2
2

1
4
3
6
5
Figure 8.63 Air filter in detail
The filter removes solid particles and moisture from the incoming compressed air. The level of
captured moisture is visible in the sight glass (4) between automatic draining actions.
If the automatic drain fails to work properly and moisture builds up in the bowl (1), it can be
manually drained by pushing upwards on the centre pin in the drain (5) outlet.
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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

1.

Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal
shut down on page 104.

WARNING

TXT-10004351/A1

MOVING PARTS
Moving parts (drum, chain, levelwind, brake, etc.) can cause serious injury or death.
Ensure that the unit cannot be operated during maintenance or rig-up activity.

2.

Bleed off all pressure from the compressed air system; slowly open the RIG AIR outlet valve
(7) on the winch module.

3.

Unscrew the bowl (1), complete with O-ring, from the head (2) by turning it a quarter-turn and
removing it downwards (bayonet fitting).

NOTE: The water drain assembly (5) located in the bowl also consists of an internal floater which
must be handled very carefully.
Remove the filter element, which is mounted below the head, by carefully unscrewing the
baffle (3) at the bottom of the filter assembly.

5.

Clean the filter components, replacing any that are damaged or excessively contaminated:

6.

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.

7.

Blow-dry it with a compressed air pistol.


Make sure all contamination is removed. If necessary, replace the element.

8.

Remove and clean the filter bowl O-ring seal.

9.

Clean the filter bowl and sight glass (4) inside and outside with soapy water, and wipe it dry
with a clean rag.

10. Clean the water drain (5) and ribbed plastic nut (6) the same way.
11. Using a clean rag, remove all dust and dirt from the head.
12. Fit the filter element over the central rod, and gently hand-tighten the baffle.
13. Mount the bowl to the filter unit using a clean or replacement O-ring, and tighten it a quarterturn.
Position the bowl such that the sight glass can easily be inspected at any time.

CAUTION

TXT-10004376/A

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

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.50 Service compressed air filter

4.

FlyLine User Manual

8.51

Test maximum engine speed


As part of the 3rd party certification, the maximum engine speed should be verified once a year.
NOTE: This test should only be performed when the engine is at operating temperature. Never
run a cold engine at maximum speed! Refer to the User Manual Appendix for the normal
operating temperature.
The engine speed is factory preset and must not be set to a higher value.

WARNING

TXT-10004282/A

8.51 Test maximum engine speed

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

WARNING

TXT-10004285/A

DANGEROUS MACHINERY
Changing factory settings can affect the safety of the system, and result in personal and/or
equipment damage.
Take extreme care when adjusting factory settings. If in doubt, contact Elmar

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

1.

Start the engine as described in 7.3 Power up on page 97.

2.

Run the unit at maximum throttle settings for a few seconds only.

3.

Compare the maximum rpm reading to the value given in Appendix 2: Unit
Specifications on page 237.

4.

If the engine is not reaching or is exceeding the maximum RPM then contact the NOV Elmar
office nearest you for assistance.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.52

Test drum mounting


The test drum mounting procedure must be performed every time a drum is exchanged or the
chain is adjusted.
This procedure describes how to test the drum mounting of one drum. If your unit has two drums,
you must repeat this procedure for both drums.

WARNING

TXT-10004359/A

SHARP OBJECT
Wireline can have sharp points, and small pieces of wire can be ejected from a wireline moving
at high speed. Always wear gloves and eye protection when handling wireline or in the vicinity
of a moving wireline.

1.

If necessary, remove the wireline from the measuring head assembly and secure it to the
drum.

WARNING

TXT-10004282/A

WARNING

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

2.

Start up the unit, as described in 7.3 Power up on page 97.

3.

If the unit has two drums, make sure:


The appropriate drum is selected in the winch module.
The appropriate BRAKE is selected on the control panel, either FRONT DRUM or REAR DRUM.

4.

Release the BRAKE.

5.

Slowly push the dual control handles forwards and then backwards allowing the drum to
rotate several times in the in-hole and out-hole directions.

6.

Shut down the unit for safe maintenance, as described in 7.5 Normal shut
down on page 104.

WARNING

TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

7.

Check the drum alignment and mounting, and readjust if necessary.

8.

Check the chain tension, and readjust if necessary. See 8.10 Check/adjust chain
tension on page 123.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.52 Test drum mounting

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

FlyLine User Manual

Repeat steps 2 through 8 two more times, making sure to check the drum alignment and
mounting, and chain tension each time.

8.52 Test drum mounting

9.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.53

Test hydraulic system pressure


This test procedure places the entire hydraulic system under high pressure for a short period (2
to 3 seconds) to expose leaks and weak points in the entire system. The test relies on the drum
remaining stationary while the pressure increases.
NOTE: If CONTROL PRESSURE falls below the minimum required during testing, contact
NOV Elmar.
1.

Ensure that the brake for the active drum is properly adjusted by performing 8.9 Check/
adjust brake band tension on page 116.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY
Once the unit is started, all systems are energized and components can move when the
controls are operated. Do not start the FlyLine unless:
You are authorized to operate the equipment and have read this manual.
The unit is properly positioned and anchored for operation.
All essential maintenance has been carried out.
There are no unauthorized persons within the danger zone.

TXT-10004358/A

NOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
Always wear suitable hearing protection when working around the running engine.

2.

Power up the unit as described in sections 7.2 Pre-start checklists on page 95 and
7.3 Power up on page 97.

3.

If the unit has two drums, make sure the proper drum brake is selected on the control panel.

4.

Apply the drum BRAKE.

5.

If your system has a multiple speed gearbox, always choose the highest speed (gear).

6.

Test the hydraulic pressure in the OUTHOLE direction as follows:


a) Minimize the main hydraulic system pressure by setting the SAFETY VALVE to the
minimum.
b) Move the motor (left) DRUM CONTROL lever completely to the maximum front or back
direction - this will lower the torque and maximize hydraulic flow.
c) Move the pump (right) DRUM CONTROL lever half-way in the OUTHOLE direction.

WARNING

TXT-10004321/A

HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).

d) Gradually rotate the SAFETY VALVE clockwise to increase the main pressure towards
400 bar (5800 PSI). If necessary, move the pump DRUM CONTROL lever further in the
OUTHOLE direction.
e) When the MAIN PRESSURE gauge reaches 400 bar (5800 PSI), return the DRUM CONTROL
levers to neutral.
7.

Test hydraulic pressure in INHOLE direction:

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

8.53 Test hydraulic system pressure

WARNING

FlyLine User Manual

NOTE:

When reeling in-hole, the SAFETY VALVE has no effect.

a) Move the motor (left) DRUM CONTROL lever completely to the maximum front or back
direction - this will lower the torque and maximize hydraulic flow.
b) Move the pump (right) DRUM CONTROL lever slowly to the INHOLE direction.
c) When the MAIN PRESSURE gauge reaches 400 bar (5800 PSI), hold this pressure for 2 to
3 seconds.
8.

Return the DRUM CONTROL levers to neutral.

9.

Inspect all hydraulic system hoses, couplings and high pressure filters for leakage that may
have been exposed by the high system pressures, and repair as necessary. See
8.21 Check/replace hydraulic hoses and couplings on page 147.

8.53 Test hydraulic system pressure

10. If applicable, repeat the test after carrying out any repairs.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

8.54

Tighten Essential Bolts


Vibration during operations will cause a number of essential bolts to untighten.

WARNING

TXT-10004280/A

DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in machine damage and possibly dangerous situations.
Always ensure that all attachment bolts and locknuts are correctly tightened.

WARNING

TXT-10004300/A

EXPLOSION HAZARD
An incorrectly sealed ATEX explosion proof cabinet can cause a dangerous, uncontrolled
explosion.
Ensure that all ATEX explosion proof cabinets are correctly sealed and that all bolts are
tightened to the correct torque value.

Ensure to tighten the followings bolts:


ATEX explosion proof cabinet sealing bolts
winch gearbox attachment and adjustment bolts
8.54 Tighten Essential Bolts

engine shock absorber mounting bolts


hydraulic pump mounting bolts

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Original Instructions

FlyLine User Manual

TROUBLESHOOTING

9.1

Troubleshooting principles
TXT-10004239/A

This section offers information for troubleshooting various problems encountered while operating
the equipment.
If you encounter a problem that is not covered here or cannot be corrected by the suggested
remedy, please contact NOV Elmar for technical guidance. Support contact information is
provided in the appendices to this manual. We are always grateful for customer feedback.
The troubleshooting guide is divided into sections according to the components or group that
need troubleshooting. Within each section, problem symptoms and their possible causes are
described, plus a suggested remedy that should enable you to get that component operational
again. More detail on the remedies is found in the maintenance section of this manual.

9.2

Troubleshooting table
NOTE: This general troubleshooting table will occasionally mention features that are not
available for the FlyLine.For measuring head troubleshooting information see separate
measuring head user manuals.

9 Troubleshooting

TXT-10004740/A1

DIESEL ENGINE PROBLEM

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

Page 222 of 258


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Original Instructions

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

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

On engines so equipped, the electrical


oil pressure sensor may be faulty

Check wiring; repair defect or replace


oil pressure sensor

Oil pump malfunction


Engine temperature too high

Replace oil pump


Replenish coolant as necessary

Water-cooled exhaust manifold is


choked/ clogged

Refer to functional description to


determine if manifold cooler can be
cleaned; if so proceed to decoke and
clean thoroughly. If not please contact
Elmar for further assistance.

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

Cooling fan malfunction: Units with


hydraulically driven radiator fan: fan not
turning effectively (see also Hydraulic
oil overheating below)
NOTE: Cooler fan normally turns slowly
when coolant temperature is below
approx. 75C; fan should start turning
rapidly at coolant temperature above
approx. 75C

Check fan for physical blockage (snow,


dirt, debris etc.)
Check fan hydraulic circuit for
restrictions or other problems
Adjust fan circuit relief valve
Replace temperature switch
(THERMO) valve located under
radiator

Leak in radiator or other cooling system


components
On engines so equipped, the electrical
coolant temperature sensor may be
faulty
Coolant temperature gauge faulty

Locate leak and repair or replace


components
Check wiring; repair defect or replace
coolant temperature sensor

Replace gauge
Replace thermostat

Thermostat malfunction

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

9 Troubleshooting

Coolant too low

FlyLine User Manual

DIESEL ENGINE PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

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

Check the supplier documentation

9 Troubleshooting

Other engine problems

Page 224 of 258


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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

TXT-10004741/A

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
Engine flywheel is damaged

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

Starter is defective

Replace starter assembly if necessary

Starter is damaged/ defective

Check for damage to pinion gear

TXT-10004742/A

Starter does not turn engine/ does not


activate

Starter activates but does not crank


engine

Check for proper meshing with flywheel


Replace starter assembly if necessary
Engine flywheel is damaged

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Inspect flywheel and replace if


necessary

Page 225 of 258


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Original Instructions

9 Troubleshooting

AIR STARTER PROBLEM

FlyLine User Manual

TXT-10004743/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)

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

9 Troubleshooting

Repair or replace starter assembly if


necessary

Unable to charge hydraulic start system

Page 226 of 258


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Original Instructions

Engine flywheel is damaged

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

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

TXT-10004745/A

POSSIBLE CAUSE

SUGGESTED REMEDY

Control/Pilot pressure drops below


normal value or fluctuates (Refer to
user manual for the normal pressure
value)

Hydraulic system oil level low

Replenish hydraulic oil as necessary

Broken coupling between motor and


pump group

Replace coupling as required

Major leak in pressure lines (hose/


fitting)

Retighten line or remove line and clear


obstruction. Replace line if necessary

Restricted or broken suction line

Remove line and clear obstruction.


Replace line if necessary

Worn or broken pump drive shaft


coupling

Replace pump drive shaft or entire


pump if necessary.

Control pump section of main winch


pump leaking internally

Repair or replace pump where


necessary

Main winch motor defective/ leaking


internally

Repair or replace motor where


necessary

Main relief valve defective/ leaking


internally

Repair or replace valve where


necessary

Flush valve may be defective/ leaking


internally

Replace valve seals or replace valve


where necessary

If unit is equipped with slow speed


valve, the valve may be defective/
leaking internally

Repair or replace valve where


necessary

System cavitating; Air bubbles in oil

Check hydraulic oil level, refill as


necessary.

Suction filter isolation valve closed

Open valve if necessary.

Contaminated oil

Drain contaminated oil and flush entire


hydraulic system; replenish with fresh
oil of the correct viscosity.

Contaminated/ clogged oil filters.

Clean and/or replace oil filter(s) as


necessary

Suction lines blocked or otherwise


restricted

Check for restrictions in suction lines


and resolve where necessary

Hydraulic pressure lines to winch motor


restricted or damaged/ leaking

Check lines, connect or replace hose(s)

Pump not generating pressure to


hydraulic motor

Check for control pressure and main


pressure on gauges; If control pressure
present but no main pressure then
check relief valve setting and adjust
accordingly
If no pressures at all then pump is likely
defective

Hydraulic control pressure insufficient

See Control/Pilot pressure drops below


normal value or fluctuates problem
description above

Drive chain missing, loose or damaged

Inspect chain, replace where necessary

Hydraulic pump(s) noisy.

Drum does not turn when DRUM


CONTROL lever is operated

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

9 Troubleshooting

HYDRAULIC PROBLEM

FlyLine User Manual

HYDRAULIC PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Hydraulic oil overheats


(Refer to user manual for type of cooler
fan installed)

Hydraulic oil level too low

Top off hydraulic oil to proper level


using recommended oil type and
viscosity (refer to user manual for
details)

Hydraulic oil viscosity value too low for


high ambient temperature

Drain off oil and replace with higher


viscosity type (refer to user manual for
additional details)

Flow to oil cooler restricted

Remove any restrictions in oil cooler


and/or hoses
Replace oil cooler

Leak in hydraulic cooler circuit

Repair leak
Replace oil cooler
Replace temperature sensor

Oil temperature gauge is faulty

Replace temperature gauge

Units with belt driven oil cooler fan:


fan not turning

Check fan for physical blockage (snow,


dirt, debris etc)

9 Troubleshooting

Oil temperature sensor is faulty

Tension the belts


Replace worn or broken belts
Replace fan assembly

Hydraulically operated level wind arms


cannot go up or down

Drum keeps turning Outhole when


drum control lever is in full outhole and
the line tension knob is turned to
minimum
Note: For logging units equipped with
Constant Tension (CT system)

Page 228 of 258


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Original Instructions

Hydraulic leak or loose connector

Repair leak or tighten connector

Leak or restriction in line

Repair leak or clear restriction

24 VDC power is off

Check 24 VDC power is on

Hydraulic valves are adjusted


incorrectly or defective

Adjust or replace valves

Hydraulic cylinders are leaking or


damaged

Repair leak or replace cylinder

Main relief valve for the Constant


Tension (CT) circuit may be out of
adjustment

Slightly turn adjustment screw on valve


Clockwise until drum stops

Replace valve if necessary

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

HYDRAULIC PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Outhole maximum system pressure


cannot be reached but control press
stays stable
Note: For logging units equipped with
Constant Tension (CT system)

Main relief valve for the Constant


Tension (CT) circuit may be out of
adjustment

Slightly turn adjustment screw on valve


to increase pressure; replace valve if
necessary

1.5mm and 1mm orifices in the CT


circuit are fouled

Check CT circuit for signs of debris or


fouling; clean thoroughly or replace
components where necessary

Main relief valve may be leaking/


defective

Repair or replace valve

Tension/ speed shutdown valve may be


actuated

Check tension and speed alarm


parameters and reset shutdown signal
on SmartMonitor

Shutdown valve may be damaged or


sticking

Check by removing signal solenoid


from shutdown valve; if remedied clean
or replace valve

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.

Loss of Outhole control for the drum


control levers (Control pressure is
stable)
Note: For units equipped with
SmartMonitor and alarm shutdown (see
also SMARTMONITOR PROBLEM
below

TXT-10004747/A

Rig air supply insufficient (if being


utilized)

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 229 of 258


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Original Instructions

9 Troubleshooting

Check condition of (quick) connectors

FlyLine User Manual

PNEUMATIC PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Wire spray inoperative

Drum not turning

Depending on unit configuration, wire


spray may not operate if drum is
stopped

Wire spray tank is empty

Refill tank with wire/ cable spray


lubricant;

Spray nozzles are clogged

Clean the spray nozzles


NOTE: If wire spray lubricant is too
viscous (too thick) it may clog the spray
nozzles.
Use thinner lubricant mixture

Leak or restriction in air line

Repair leak or clear restriction

24 VDC power is off

Check 24 VDC power is on

Leak or restriction in air line

Repair leak or clear restriction

24 VDC power is off

Check 24 VDC power is on

Pneumatic valves are adjusted


incorrectly or defective

Adjust or replace valves

Pneumatic cylinders are leaking or


damaged

Repair leak or replace cylinder

DRUM AND TRANSMISSION


(REDUCTION GEAR/ FINAL
DRIVE) PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Oil leaks

Worn seals

Replace seals

Leakage at plugs/ site glasses

Replace/re-tighten plugs/ site glasses

9 Troubleshooting

Pneumatically operated level wind


arms inoperative

TXT-10004749/A

Replace metal seals for plugs/ site


glasses
Excessive noise from final reduction
gearbox

Low gearbox oil level

Fill final reduction gearbox with oil to


proper level
Check further if gearbox may have
damaged gears; turn slowly and listen
closely to pinpoint source of noise;
inspect further and repair or replace as
necessary

Page 230 of 258


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Original Instructions

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

DRUM AND TRANSMISSION


(REDUCTION GEAR/ FINAL
DRIVE) PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Drum is not turning smoothly

Brake band adjustment

Check if the brake band is not too tight;


adjust according to user manual
maintenance section instructions

Drum bearings seized or damaged

Check the drum bearings for damage;


grease or replace as necessary

Reduction Gearbox low on oil or


damaged

Check the oil level in the gearbox; refill


or replace oil
Check further if gearbox may have
damaged gears; turn slowly and listen
for strange noises coming from
gearbox; repair or replace as necessary

Drum does not move when DRUM


CONTROL lever is operated

Brake applied

Disengage drum brake

Hydraulic problem

See HYDRAULIC PROBLEM


troubleshooting

Pneumatic pressure loss (indicated by


pressure gauge on control panel)

Check air compressor and air


receivers.

Check all pneumatic lines in body and


control panel.
Defective control lever or open circuit

Inspect/repair control lever circuit;


replace control lever if necessary
Check/replace fuses (refer to units
electrical diagram for the correct fuse
number)

Drum continues turning with DRUM


CONTROL levers in neutral

Valve spool defective or damaged

Remove valve and repair or replace as


necessary.

Pump not balanced properly

Refer to pump documentation for


balancing instructions

SPOOLING/SLEWING PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Noisy levelwind chain

Excessive slack in levelwind drive chain

Tighten levelwind drive chain

Wireline guide rollers not rotating


smoothly

Defective bearings

Replace rollers

Bearings fouled

Clean rollers & bearings

TXT-10004750/A

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

Page 231 of 258


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Original Instructions

9 Troubleshooting

Repair gauge if defective.

FlyLine User Manual

SPOOLING/SLEWING PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Shuddering movement or jamming of


levelwind carriage while spooling

Side forces on levelwind carriage


caused by excessive fleet angle

Reposition winch to reduce fleet angle

Levelwind drive chain too loose

Tighten levelwind drive chain

Levelwind drive chain too tight

Slightly slacken the drive chain

Worn sleeve bearing

Replace sleeve bearing

Broken, damaged or rusty drive chain

Grease, repair or replace drive chain

Measure head to drive chain


connection bolts broken

Replace connection bolts

Levelwind drive chain sprockets


damaged

Replace sprockets and chain

Hydraulic motor defective

Replace hydraulic motor

Lateral deflection sensors on


measuring head need adjustment

Check and adjust the sensors

Pneumatic lines to the deflection


sensors on measuring head are
damaged

Inspect lines and replace where


necessary

Electrical cables to the deflection


sensors on measuring head are
damaged

Inspect cables; repair connection or


replace as necessary

24V/12VDC signal interrupted

Check the 24V/12VDC signal to the


solenoids of the hydraulic spooling
valve

Defective lateral deflection sensor

Replace sensor

Levelwind shaft running dry

Lightly grease the shaft, add grease to


support bearing

Excessive fleet angle of winch rig-up

Reposition winch to reduce fleet angle

Levelwind drive chain too slack or too


tight

Adjust chain tension

Levelwind drive chain damaged

Replace levelwind drive chain

Worn rear support roller bearing

Replace bearing

Rear support roller bearing fouled

Clean or replace support bearing

Measuring head guide wheel jamming


in rail

Clean/replace guide wheel:


Repair rail

Damaged levelwind motor or drive


sprocket

Replace/repair as necessary

9 Troubleshooting

Autospooling not functioning correctly


NOTE: Autospooling is an option and
might not be installed on your unit

Levelwind does not move smoothly

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FlyLine User Manual

SPOOLING/SLEWING PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Cannot spool measuring head

Winch stop is pressed

Release Winch stop

Spooling control joystick is faulty

Check if other functions of the joystick


are OK; if not, check joystick
documentation for troubleshooting

230 VAC power is off

Check main power switch on winch JB

Head is blocked

Unblock head

9 Troubleshooting

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FlyLine User Manual

APPENDICES
This section contains the following appendices:
Appendix 1: Quick reference on page 235
Appendix 2: Unit Specifications on page 237
Appendix 3: Unit Lubricants on page 241
Appendix 4: Unit hydraulic oils on page 243
Appendix 5: Unit configuration on page 244
Appendix 6: Referenced Documents on page 246
Appendix 7: Tightening conventions on page 248
Appendix 8: Running hours log book on page 249
Appendix 9: Air transportation on page 253

Appendices

Appendix 10: Contact us on page 255

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 1: Quick reference


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.

NOTE: This is only for reference. Please see 7 Operation on page 94 for details.
Startup
Ensure that the air accumulator (receiver) isolation valve is open.

2.

Ensure that the hydraulic oil tank isolation valves are open.

3.

Prepare the engine starter (hydraulic, air, electric, or spring) for start-up.

4.

Reset the fuel safety (Sentinel) valve by turning the control lever against the spring pressure
(repeat this for every start attempt).

5.

Set the drum control levers on the control console to the middle position.

6.

Set the brake to ON.

7.

Set the valve below the wire spray tank to drip at the proper rate for the job.

8.

Push the AIR INLET VALVE lever fully up, and hold it in place.

9.

Do one of the following to start the engine:


a) Pneumatic or hydraulic starter: In the cabin press the ENGINE START button, and hold it
in until the engine starts.
b) Spring starter: At the power pack pull the trip lever through 90 degrees, and then
immediately release it to start the engine.
c) Electric starter: Push in the ignition key and turn to start the engine.

10. When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR
INLET VALVE lever.
11. Check that the hydraulic CONTROL PRESSURE stabilizes between 20 and 28 bar (if <15 bar,
troubleshoot the system).
Shutdown
1.

Check the START PRESSURE gauge on the power pack control panel.

2.

Hydraulic starter: If the hydraulic start pressure is less than 120 bar (1740 psi), charge the
starter accumulator by apply the brake and operating the drum control levers, as described
in 7.6.1 Charge starter accumulator using engine on page 105.

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar
(2466 psi).
3.

Ensure that the isolation valve for the starter accumulator is closed.

4.

Set the drum control levers on the control console to the middle position.

5.

Set the engine THROTTLE control to idle. Make sure the drum is stopped.

6.

Set the brake ON.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Original Instructions

Appendix 1: Quick reference

1.

FlyLine User Manual

7.

Push the ENGINE STOP button to stop the engine.

8.

Close the valve below the wire spray tank to stop the oil flow to the wireline.

Emergency stop
Quickly stop the machine in an emergency using one of the following methods:
Press one of the two red emergency stop buttons on the machine.
Pull down the AIR INTAKE valve on the control panel.
Emergency stop recovery
Ensure that the cause of the emergency shutdown has been identified and solved.

2.

Release an activated emergency stop button by pulling it firmly out until it releases.

3.

Start up the machine as described above in Startup.

Appendix 1: Quick reference

1.

Page 236 of 258


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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 2: Unit Specifications

Power pack dimensions


Transport dimensions
L x W x H (overall with doors closed)

2000 x 1200 x 1480 mm (6.56 x 3.94 x 4.78 ft)

Maximum gross weight

2500 kg (5 512 lb)

Tare weight

See data plate

Payload

See data plate

Single drum winch/ dimensions


2250 x 1300 x 1480 mm (7.38 x 4.27 x 4.86 ft)

Maximum gross weight

3500 kg (7 716 lb)

Tare weight

See data plate

Payload

See data plate

Appendix 2: Unit Specifications

Transport dimensions
L x W x H (overall with doors closed)

Double drum winch dimensions


Transport dimensions
L x W x H (overall with doors closed)

2460 x 1365 x 1420 mm (8.07 x 4.48 x 4.66 ft)

Maximum gross weight

3200 kg (7055 lb)

Tare weight

See data plate

Payload

See data plate

Operating conditions
ATEX area classification

Ex Zone 2, ATEX / Category 3, EEx, Gasgroup IIA, Temperature Class T3

Ambient operating temperature range

-20 C to +40 C (-4 F to +104 F)

Power system
Type

Caterpillar C4.4

Power output

Choose from:
54 kW (72 bhp) @ 2200 rpm
81 kW (109 bhp) @ 2200 rpm (heavy duty power pack)

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


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FlyLine User Manual

Power system
Starter

Choose from
Spring starter
Hydraulic starter
Air starter

Electrical system
Alternator

Optional +24 VDC, 25 A, 1.68 kW, belt-driven, self-exciting

Rig/shore

Choose from:
230 VAC (+/- 10%); 50 Hz (+/- 2%); 16A, 10kA
115 VAC (+/- 10%); 60 Hz (+/- 2%); 16A, 10kA

Appendix 2: Unit Specifications

Pneumatic system
Source

On-board compressor, PTO-driven


Rig/shore air in, crowsfoot.

Compressor power rating

5 kW

Pressure

7 bar nominal (100 psi)

Buffer

Receiver: 10 L (2.6 US gal.)

Flow volume

280 L/min @ 8 bar (9.9 cfm @ 116 psi)

Hydraulic system
Type

Elmar closed loop

Source

Variable displacement hydraulic pump, 56 cc, PTO-driven

Main pressure

400 bar (5800 psi) max

Winch control console


Mounting

Integrated into container-type frame with winch

Construction

Steel plate construction


Glass window with view onto wireline winch.
Ex Zone 2, ATEX.

Controls

Main control panel for monitoring and control of hydraulic circuits, depth and
tension measurement, wireline winch.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Winch
Drum motor (2 x)

80 cc variable displacement

Transmission (2 x)

Fixed-ratio gearbox and chain final transmission

Mounting type

NOV Elmar 700/600 series double drum mount

Front winch drum

Choose from:
BC06, OD x ID x W = 700 x 260 x 700 mm (27.6 x 10.2 x 27.6 in)
SC05, OD x ID x W = 450 x 260 x 700 mm (17.7 x 10.2 x 27.6)
SC06, OD x ID x W = 600 x 350 x 700 mm (23.6 x13.8 x 27.6 in)
SC08, OD x ID x W = 700 x 500 x 700 mm (27.6 x 19.7 x 27.6 in)

Rear winch drum

Choose from:
SC05, OD x ID x W = 450 x 260 x 700 mm (17.7 x 10.2 x 27.6)
SC06, OD x ID x W = 600 x 350 x 700 mm (23.6 x13.8 x 27.6 in)

Drum brake (2 x)

Brake band for double drum mount, failsafe, pneumatic release

Level winding

Chain-actuated levelwind carriage, steering wheel driven

Appendix 2: Unit Specifications

Depth & tension measurement


Measuring head

Choose from:
NOV Elmar MP16II
NOV Elmar MP20

Display

Choose from:
Combigauge 0 to 2.000 kg/ft
Combigauge 0 to 2.000 kg/m
Combigauge 0 to 2.000 lb/ft
Combigauge 0 to 2.000 lb/m
Combigauge 0 to 3.200 lb/ft
Combigauge 0 to 4.400 lb/ft
Combigauge 0 to 4.400 lb/m
optional: NOV Elmar SmartMonitor 12

Fluids
Engine fuel (power pack)

Tank capacity: 120 L (31.7 US gal.)


Fuel: EN 590-approved diesel or equivalent.
For detailed fuel specification, see Caterpillar engine manual, supplied separately.

Engine oil (power pack)

Capacity: 11.4 L (3.0 US gal.)


Oil: Mobil Delvac Super 1400 15W-40 or equivalent (see Appendix 3: Unit
Lubricants on page 241).
For detailed engine oil specification, see Caterpillar engine manual, supplied
separately.

Hydraulic oil (power pack)

Tank capacity: 98 L (23.8 US gal.)


Oil: Univis N 46

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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FlyLine User Manual

Appendix 2: Unit Specifications

Fluids
Coolant (power pack)

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.

Wireline lubrication (measuring head)

Tank capacity: 3 L (0.8 US gal.)


Oil: See your wireline specifications

Reduction gearbox oil (winch)

1 or 2 gearboxes: @ 1.1 L (37 fl.oz.)


For oil types see Appendix 3: Unit Lubricants on page 241.

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) 10

A0000161

Hoisting
Lifting sling set power pack

A1106700 - 4-leg wire rope, WLL 3.5t@30, WL 2 m, Greenpin bolt OD 19 mm,


designed acc. EN 12079 / DNV 2.7-1.

Lifting sling set heavy duty power pack

A1106700 - 4-leg wire rope, WLL 3.5t@30, WL 2 m, Greenpin bolt OD 19 mm,


designed acc. EN 12079 / DNV 2.7-1.

Lifting sling set SD winch

L-8601041186 - 4-leg wire rope, WLL 3.5t@30, WL 3 m, Greenpin bolt OD 19


mm, designed acc. EN 12079 / DNV 2.7-1.

Lifting sling set DD winch

A1089953 - 4-leg wire rope, WLL 7t@30, WL 3 m, Greenpin bolt OD 22 mm,


designed acc. EN 12079 / DNV 2.7-1.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 3: Unit Lubricants


Engine lubricants table
TXT-10004503/A1

Choosing the right engine lubricant is critical to the proper functioning of the engine, to avoid
damage and/ or costly repairs.
Refer to the maintenance section for the change intervals required.
NOTE: Select a good quality lubricant that is suitable for the ambient temperature where the
machine is used. Data sheets and MSDS for all of the fluids used in the original assembly
are found in the units documentation package.

Ambient temperature
-30 C
(-20 F)

-20 C
(-2 F)

-10 C
(+14 F)

0 C
+10 C
+20 C
+30 C
+40 C
(+32 F) (+50 F) (+68 F) (+86 F) (+104 F)

SAE 5W20
SAE 5W30

Appendix 3: Unit Lubricants

SAE 10W40
SAE 10W30
SAE 15W50
SAE 15W40
SAE 20W50
SAE 20W40
SAE 10
SAE 20
SAE 30
SAE 40

Figure 9.1 Engine lubricants

Gearbox lubricants table


TXT-10004505/A1

Gearboxes include final drive reduction gearboxes and fuel pump gear drives.
Choosing the right gearbox lubricant is critical to the proper functioning of the gearboxes, to avoid
damage and/ or costly repairs.
Refer to the maintenance section for the change intervals required.
NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at
the time of delivery. Data sheets and MSDS for all of the fluids used in the original
assembly are found in the units documentation package.

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FlyLine User Manual

Appendix 3: Unit Lubricants

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

Figure 9.2 Gearbox lubricants


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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 4: Unit hydraulic oils


TXT-10004700/A1

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.
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.

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

Figure 9.3 NOV Elmar recommended hydraulic oils for main power and control circuits
NOTE: Select an oil that is suitable for the ambient temperature in which the machine is to be
operated. Operating temperature of hydraulic oil will increase during operation.
Machines fitted with a winterization package may have an oil heater to pre-heat the oil
before operations.

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


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Original Instructions

Appendix 4: Unit hydraulic oils

Low temperatures
below -15 C (+5 F)

FlyLine User Manual

Appendix 5: Unit configuration


Unit identification
Serial number:
Drum brake slip/hold pressure value (front):

bar

Drum brake slip/hold pressure value (rear):

bar

Basic configuration

Part number

FlyLine base assembly power pack (ATEX Zone 2 Heavy Duty)

L-6931048158V01

FlyLine base assembly power pack (ATEX Zone 2)

L-6931034250V01

FlyLine base assembly single drum (ATEX Zone 2)

L-6931041412V01

FlyLine base assembly double drum (ATEX Zone 2)

L-6931041412V02

Appendix 5: Unit configuration

Starter type

Part number

Starter assembly air

L-6501036746V01

Starter assembly hydraulic

L-6501036746V02

Starter assembly spring

L-6501036746V03

Depth and tension measurement type(s)

Part number

MeasureHead MP16II

L-6501036755

MeasureHead MP20

L-6501036756

CombiGauge 0-2.000 kg/ft

L-6501034275

CombiGauge 0-2.000 kg/m

L-6501034295

CombiGauge 0-2.000 lb/ft

L-6501034294

CombiGauge 0-2.000 lb/m

non-standard option

CombiGauge 0-3.200 lb/ft

L-6501038038

CombiGauge 0-4.400 lb/ft

L-6501034293

CombiGauge 0-4.400 lb/m

non-standard option

SmartMonitor 115V supply

L-6531052164

SmartMonitor 230V supply

L-6501039118

Front drum

Part number

SC05 Winch drum; Driveline, ratio 5.8:1

L-6501036751; L-6501036749

SC06 Winch drum; Driveline, ratio 5.8:1

L-6501036752; L-6501036749

SC08-M Winch drum; Driveline, ratio 5.8:1

L-6501036753; L-6501036749

BC06 Winch drum; Driveline, ratio 7:1

L-6501036754; L-6501036750

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Rear drum

Part number

SC05 Winch drum; Driveline, ratio 5.8:1

L-6501036751; L-6501036749

SC06 Winch drum; Driveline, ratio 5.8:1

L-6501036752; L-6501036749

Brake assembly rear drum

L-6501036747

Rear motor assembly

L-6501036748

Miscellaneous options

Part number

Auxiliary drive assembly

L-6501036757

Hoisting beam

L-6501038110

Jacking wheel

L-6501034251

Generator assembly 24 VDC with batteries

L-6501037565

Generator assembly 24 VDC without batteries

L-6501039738

Protection netting winch

L-6501037598

PVC cover power pack

A1106526

PVC cover single drum winch

L-8601051652

PVC cover double drum winch

L-8601038720

Slip ring 2 ring assembly (Zone 2 ATEX)

L-6501035690V01

Slip ring 4 ring assembly (Zone 2 ATEX)

L-6501035691

Fuel purifier

Depth drive options

non-standard option

Part number

Depth drive assembly MP16II imperial 0.125 3/16

L-6501034306

Depth drive assembly MP16II imperial 0.125 7/32

L-6501034303

Depth drive assembly MP16II imperial 0.092 0.108

L-6501034299

Depth drive assembly MP16II imperial 0.125 0.108

L-6501034300

Depth drive assembly MP20 imperial 0.160 0.125

L-6501034296

Depth drive assembly MP16II metric 0.125 3/16

L-6501034307

Depth drive assembly MP16II metric 0.125 7/32

L-6501034302

Depth drive assembly MP16II metric 0.092 0.108

L-6501034298

Depth drive assembly MP16II metric 0.125 0.108

L-6501034301

Depth drive assembly MP20 metric 0.125 0.160

L-6501034297

Depth drive assembly MP16 imperial 0.108 0.125

non-standard option

NOTE: Contact NOV Elmar for more information on non-standard options.

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Original Instructions

Appendix 5: Unit configuration

FlyLine User Manual

Appendix 6: Referenced Documents


The content of this manual makes reference to information contained in other documents, such
as manuals, drawings and spare parts lists.

FLYLINE BASE PP ASSY ATX ZONE 2

L-6931034250V01

DOCUMENT/DRAWING TITLE

DOCUMENT/DRAWING

FILE TYPE

General Arrangement Drawing

DD6931034250V01

PDF

Electric Diagram

ES6931034250V01

PDF

Hydraulic Diagram

HS6931034250V01

PDF

Spare Parts List

SPL1034250V01

PDF

Caterpillar: Operation and Maintenance Manual for C4.4


(Mech) Industrial Engine

PDF

Caterpillar: Caterpillar C4.4 Engine Sales Manual


Mechanical FIE only

PDF

Bosch Rexroth: Repair Instructions Variable Pump


A4VG

PDF

Chalwyn: Self Exciting Flame Proof Alternator,


Selection, Application and Maintenance

PDF

Riegler: Safety valves, 226 Series (DN 8) / 227 Series


(DN 10)

PDF

Appendix 6: Referenced Documents

ITEM

FLYLINE BASE HD PP ASSY ATX ZONE 2

L-6931048158V01

DOCUMENT/DRAWING TITLE

DOCUMENT/DRAWING

FILE TYPE

10

General Arrangement Drawing

DD6931048158V01

PDF

11

Electric Diagram

ES6931048158V01

PDF

12

Hydraulic Diagram

HS6931048158V01

PDF

13

Spare Parts List

SPL1048158V01

PDF

14

Caterpillar: Operation and Maintenance Manual for C4.4


(Mech) Industrial Engine

PDF

15

Caterpillar: Caterpillar C4.4 Engine Sales Manual


Mechanical FIE only

PDF

16

Bosch Rexroth: Repair Instructions Variable Pump


A4VG

PDF

17

Chalwyn: Self Exciting Flame Proof Alternator,


Selection, Application and Maintenance

PDF

18

Riegler: Safety valves, 226 Series (DN 8) / 227 Series


(DN 10)

PDF

ITEM

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

L-6931041412V01

DOCUMENT/DRAWING TITLE

DOCUMENT/DRAWING

FILE TYPE

19

General Arrangement Drawing

D6931041412V01

PDF

20

Electric Diagram

ES6931041412V01

PDF

21

Hydraulic Diagram

S6931041412V01

PDF

22

Spare Parts List

SPL1041412V01

PDF

23

MP16II User Manual

MAN-10003445

PDF

24

MP20 User Manual

MAN-A1085130

PDF

25

SmartMonitor WL User Manual

MAN-1039176

PDF

FLYLINE DD BASE ASSY ATX ZONE 2

L-6931041412V02

DOCUMENT/DRAWING TITLE

DOCUMENT/DRAWING

FILE TYPE

26

General Arrangement Drawing

DD6931041412V02

PDF

27

Electric Diagram

ES6931041412V02

PDF

28

Hydraulic Diagram

HS6931041412V02

PDF

29

Spare Parts List

SPL1041412V02

PDF

30

MP16II User Manual

MAN-10003445

PDF

31

MP20 User Manual

MAN-A1085130

PDF

32

SmartMonitor WL User Manual

MAN-1039176

PDF

ITEM

ITEM

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Appendix 6: Referenced Documents

FLYLINE SD BASE ASSY ATX ZONE 2

FlyLine User Manual

Appendix 7: Tightening conventions


TXT-10004458/A1

This section provides recommended torque to be applied to bolted connections in this unit. The
fasteners used in this unit are normally either stainless steel (quality A2/70) or plain high tensile
steel (quality 8.8 or better). These values are for dry (non lubricated) connections. Use lower
torque values for lubricated connections.
NOTE: Always apply anti-seize compound on all types of bolts. This prevents bolts from seizing
caused by corrosion around the bolts. The corrosion may cause the force necessary to
loosen these bolts to exceed their breaking strength, leading to broken bolts.

Appendix 7: Tightening conventions

NOTE: When tightening a cover panel with a soft joint seal or gasket, e.g. for a tank inspection
opening, use lower torques than specified in the table below.

Metal
grade

M8

M10

M12

M14

M16

M20

M24

Comment

A2/70 (SS)

15

30

50

80

120

250

340

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

use self-locking nut

12.9 (plain)

35

70

120

195

300

580

1000

use self-locking nut

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

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 8: Running hours log book


TXT-10004509/A

Like all machinery, the FlyLine needs to be serviced at regular intervals. The work to be
performed at each interval is described in more detail in the Maintenance section of this manual.
The specific service intervals are:
Daily (once every 24 hours when the FlyLine is in use)
After job maintenance (after completion of each wireline job)
300-hour service (after 300 hours of wireline winch operation)
600-hour service
900-hour service
1200-hour service
1500-hour or annual service

It is also important to record the number of hours and the date at which each of the services (100,
300, etc.) is actually carried out. To make this easier, Elmar provides with this manual (see
page 252) a blank form for recording the running hours, and the interval-based services planned
and actually carried out.
NOTE: Every organization has its own rules and systems for logging running hours and service
activity. The form and procedures described here are no more than a suggestion for a
simple running hours and service logging system.
Because the service intervals are primarily aimed at the mechanical components, we recommend
logging all hours that mechanical components are in use. In other words, from the moment the
FlyLine enters stand-by prior to operations, to the moment the FlyLine is shut down.
NOTE: If the running hours for major subsystems of the FlyLine are different (e.g. the power
pack or engine are run for longer hours than the winch module), then log the usage hours
for each subsystem on separate forms, so that the service is carried out no earlier than
needed on the less-used subsystem.
Keep all log forms in a special folder, and make sure that the maintenance engineer knows where
to find this folder. Make sure that the lower section is properly filled-in whenever the UniTruck gets
an interval service (100, 300, etc hours).
The figure on page 250 shows a filled-in Elmar usage & service log form, for a wireline unit that
has already been running for 1823 hours before this sheet was opened. The hours have been
carried forward from the previous form.

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Appendix 8: Running hours log book

Even if there is automatic logging of the number of hours the FlyLine is in operation, it is still
important to manually record all hours that the wireline winch is "running".

Appendix 8: Running hours log book

FlyLine User Manual

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 FlyLine (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.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

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:
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).

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Appendix 8: Running hours log book

1.

FlyLine User Manual

Unit ID:_____________________________________

Date form opened:_____________________________

Running Hours
Start
Date

Stop
Time

Date

Hours
Time

Session

Remarks

Cumul.

Appendix 8: Running hours log book

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.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 9: Air transportation


TXT-10004444/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, NOV Elmar provides a checklist as an aid to ensuring that no
part is overlooked when draining and refilling the machine.
Draining:
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 (e.g. in the cabin, in a weatherproof
envelope attached to the main operator station, etc.)

Refilling:
Refer to the maintenance instructions or specifications pages of the manual for this machine,
for the quantity and specifications of the required fluids.

6.

Refer to the maintenance instructions for the procedure to check and replenish fluids for
each of the reservoirs, systems and components.

7.

Replenish the fluid in each of the items on the reverse side of this page, remembering to
bleed the system of air and again replenish if necessary.

8.

NOV Elmar recommends that new oil filters are used when replenishing systems that include
filters. If you have fitted new filters, please add your initials in the last column.

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


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Appendix 9: Air transportation

5.

FlyLine User Manual

FLUID RESERVOIRS/SYSTEMS/COMPONENTS DRAINED / REPLENISHED


FOR TRANSPORTATION
(excludes vehicle of self-propelled units)

Appendix 9: Air transportation

Date drained:

Date replenished:

Ite
m

Description

Bleed

01

Fuel tank, filters & lines

02

Engine cooling system & reservoir

03

Engine oil sump

04

Hydraulic system & reservoir

05

Winch motor & hoses

06

Winch gearboxes

07

Levelwind motor

09

Pneumatic anti-frost system

10

Batteries

11

Wire oiler system & reservoir

12

Winch oil collection tray

13

Grease injection system reservoir

14

Pressure testing reservoir

15

Drinking water tank

New
filter(s)
recomm.

INITIALS
Drained

Replen.

New filter

Y
Y

16
17
18
19
20
21
22
23
24
25

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Appendix 10: Contact us


TXT-10004145/A1

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

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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Appendix 10: Contact us

Manufacturing Locations

FlyLine User Manual

Customer Notes

CUSTOMER NOTES

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

FlyLine User Manual

Customer Notes

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


NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013

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FlyLine User Manual

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.

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NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013