Download 6931055734 - MAN - AirPack PDF

Title6931055734 - MAN - AirPack
TagsValve Engines Diesel Engine Personal Protective Equipment Pneumatics
File Size7.4 MB
Total Pages150
Table of Contents
                            Table of contents
1 Introduction
2 Safety
	2.1 General Safety
		2.1.1 Employee responsibility
		2.1.2 Employer responsibility
		2.1.3 Warnings, cautions and requirements
	2.2 Equipment specific safety
		2.2.1 Emergency Stop buttons
		2.2.2 Heavy equipment
		2.2.3 ATEX and zoning
		2.2.4 Doors and hatches
3 Physical Description
	3.1 Unit overview
	3.2 Unit rear view
	3.3 Unit right view (spring starter)
	3.4 Unit right view (hydraulic starter)
	3.5 Unit right view (air starter)
	3.6 Unit front view
	3.7 Unit left view (spring starter)
	3.8 Unit left view (hydraulic starter)
	3.9 Unit left view (air starter)
4 Functional description
	4.1 Introduction
	4.2 Operator controls
	4.3 Engine
		4.3.1 Engine safety system
		4.3.2 Engine starters
		4.3.3 Fuel system
		4.3.4 Exhaust system
	4.4 Compressor (Pneumatic) system
	4.5 Cooling system
	4.6 Unit grounding
5 Setup and removal
	5.1 Moving/positioning equipment
		5.1.1 Land transportation
		5.1.2 Air transportation
		5.1.3 Draining
		5.1.4 Refilling
	5.2 Site preparation
	5.3 Rig-up
		5.3.1 Positioning and grounding
		5.3.2 Testing
	5.4 Rig-down
		5.4.1 Finalize
	5.5 Storage
		5.5.1 Short term storage (< 1 year)
		5.5.2 Long term storage (> 1 year)
6 Operation
	6.1 Pre-start checklist
	6.2 Power up
		6.2.1 For spring starter equipped engines
		6.2.2 For air starter equipped engines
		6.2.3 For hydraulic starter equipped engines
	6.3 Normal shut down
	6.4 Emergency stop
		6.4.1 Manual emergency stop
		6.4.2 System (automatic) emergency stop
	6.5 Charge hydraulic starter accumulator
		6.5.1 Charge starter accumulator using hand pump
		6.5.2 Charge starter accumulator using the air-operated oil pump
7 Maintenance
	7.1 Introduction
	7.2 Certified assemblies
	7.3 OEM components
	7.4 Periodic maintenance schedules
	7.5 Check/adjust V-belts
	7.6 Check/fill compressor oil
		7.6.1 Check compressor oil level
		7.6.2 Fill compressor oil
	7.7 Check/fill engine coolant
		7.7.1 Check coolant level
		7.7.2 Top up coolant
	7.8 Check/fill engine oil
		7.8.1 Check engine oil level
		7.8.2 Fill engine oil
		7.8.3 Finalize
	7.9 Check/fill engine fuel
		7.9.1 Check fuel level
		7.9.2 Fill fuel tank
	7.10 Check/fill hydraulic oil
		7.10.1 Check hydraulic oil level
		7.10.2 Fill hydraulic tank
	7.11 Check/fill fuel pump gear drive oil
		7.11.1 Check the gear drive oil level:
		7.11.2 Fill gear drive oil
		7.11.3 Finalize
	7.12 Check/replace hoses and couplings
	7.13 Check shock absorbers
	7.14 Clean engine air inlet valve
	7.15 Clean auxiliary pneumatic system filter
	7.16 Clean fuel coarse particle filter
	7.17 Clean air dryer filter (air starter)
	7.18 Clean main compressor air dryer
	7.19 Clean spark arrestor
	7.20 Clean/replace compressor intake air filter
	7.21 Clean/replace crankcase breather flame trap
	7.22 Clean/replace engine air filter
	7.23 Clean/replace fuel tank breather
	7.24 Drain/fill engine coolant
		7.24.1 Drain coolant
		7.24.2 Refill/bleed coolant
		7.24.3 Check coolant system for leaks
		7.24.4 Finalize
	7.25 Drain fuel tank
	7.26 Drain fuel/water separator
	7.27 Drain water from hydraulic tank
	7.28 Prime diesel engine
		7.28.1 Quick prime
		7.28.2 Prime entire system
		7.28.3 Finalize
	7.29 Replace air-oil separator filter (compressor)
	7.30 Change compressor oil and filter
		7.30.1 Change compressor oil filter
		7.30.2 Change compressor oil
	7.31 Change engine oil and filter
	7.32 Replace fuel fine filter element
	7.33 Replace fuel/water separator filter
		7.33.1 Drain filter
		7.33.2 Remove filter
		7.33.3 Fit separator filter
	7.34 Replace hydraulic oil
	7.35 Replace V-belts
	7.36 Test maximum engine speed (if applicable)
8 Troubleshooting
	8.1 Troubleshooting principles
	8.2 Troubleshooting tables
		8.2.1 Engine and hydraulics
		8.2.2 Auxiliary pneumatics table
APPENDICES
	Appendix 1: Specifications
	Appendix 2: Quick reference
	Appendix 3: Lubricants
	Appendix 4: Unit hydraulic oils
	Appendix 5: ASEP Elmar tightening conventions
	Appendix 6: Running hours log book
	Appendix 7: Air transportation
	Appendix 8: Contact us
Customer Notes
                        
Document Text Contents
Page 1

AirPack C
DRAFT - FOR
INFORM N ONLY

User Manual

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-A
Tel: +31 184 608 700, Fax: +31 184 608 790, www.
K-Winch AirPack C, MAN-1055734, 26 July 2013

OR
ATIO
mmers, The Netherlands
nov.com Page 1 of 150

Revision A

IGINAL INSTRUCTIONS

Page 2

AirPack C User Manual

Page 2 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
Revision A K-Winch AirPack C, MAN-1055734, 26 July 2013
Original Instructions

This manual applies to the following parts:

• L-6931055734 - AirPack C Base Assy Zone 2

• All standard options available for this base assembly

WARNING TXT-10004286/A
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with this equipment must read and understand this manual. Only
qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

Version Date Amendments

A 26 July 2013 This is the first version of this manual

REVISION HISTORY

Published by:
NOV Elmar
Energieweg 26
2964 LE Groot-Ammers
The Netherlands

© 2013 No part of this document may be reproduced by any means without
the written consent of the publisher.
Whilst every care has been taken to ensure that the information in this
document is correct, no liability can be accepted by NOV Elmar for loss,
damage or injury caused by any errors or omissions in this document.

Page 75

AirPack C User Manual

7
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5
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filte
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1. Ensure that the unit has been shut down for safe maintenance, as described in 6.3 Normal
shut down on page 42.

To open a pressurized container safely:

2. Shut off the nearest valve on the supply side of the container.

3. Release all pressure from the container, either by operating the control or appliance, or by
gradually opening a filler cap on the container allowing pressure to gradually escape.

4. Then with eyes protected or at a safe distance from the container, carefully remove the filler
cap completely.

5. Bleed off all pressure from the compressed air system by pushing in the EMERGENCY STOP
button; air will slowly bleed off. Verify that the pressure is completely relieved by checking
the CONTROL PRESSURE gauge.

6. Remove the bowl (1), complete with O-ring, from the head (2) by turning it a quarter-turn and
moving it downwards.

NOTE: The water drain assembly located in the bowl also consists of an internal floater which
must be handled very carefully.

7. Remove the filter element, which is mounted below the head, by carefully unscrewing the
baffle (3) at the bottom of the filter assembly.

8. Clean the filter components, replacing any that are damaged or excessively contaminated:

Figure 7.17 Air filter in detail

WARNING TXT-10004254/A
COMPRESSED AIR
Air and/or particles under high pressure can cause severe injury, particularly to the eyes.
Never open a pressurized container without first releasing all pressure from the container.

3

2

2

5

1

4

6

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 75 of 150
K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A

Original Instructions

Page 76

AirPack C User Manual

7
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9. Wash the element in soapy water, and rinse it off.

10. Blow-dry it with a compressed air pistol.

Make sure all contamination is removed. If necessary, replace the element.

11. Remove and clean the filter bowl O-ring seal.

12. Clean the filter bowl and sight glass (4) inside and outside with soapy water, and wipe it dry
with a clean rag.

13. Clean the water drain (5) and ribbed plastic nut (6) the same way.

14. Using a clean rag, remove all dust and dirt from the head.

15. Fit the filter element over the central rod, and gently hand-tighten the baffle.

16. Mount the bowl to the filter unit using a cleaned or replacement O-ring, and tighten it a
quarter-turn.

Position the bowl such that the sight glass can easily be inspected at any time.

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

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.

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.
Page 76 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
Revision A K-Winch AirPack C, MAN-1055734, 26 July 2013
Original Instructions

Page 149

AirPack C User Manual
NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 149 of 150
NOV Elmar K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A

Original Instructions

Page 150

AirPack C User Manual

Page 150 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
Revision A K-Winch AirPack C, MAN-1055734, 26 July 2013
Original Instructions

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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