PEMEX UniTruck Rev3

Hydraulic UniTruck User Manual
ORIGINAL INSTRUCTIONS
Operation and Maintenance Manual
NOV ASEP Elmar – U.S.A., 11995 F.M. 529, Houston, TX 77041, USA Page 1 of 150
Tel: 1 713 983 9281, Fax: +1 713 983 8892, www.nov/ASEPElmar.com Revision 1
Project 36881-36888 Pemex Original Instructions
WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with the unit must read and understand this manual.
Only qualified personnel are allowed to rig up, rig down, operate, or maintain
the unit.
Published by:
NOV ASEP Elmar
11993 FM 529
Houston Texas 77041
United States of America
© 2011 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 ASEP Elmar
for loss, damage or injury caused by any errors or omissions in this
document.
Version Date Amendments
1 12/27/2011 First Version for this

delivery
Revision History
Table of Contents
SECTION/DESCRIPTION PAGE
1.0 SCOPE ............................................................................................................................................................ 5
2.0 SAFETY .......................................................................................................................................................... 5
2.1 Maintenance and Pre-Start Safety ..................................................................................................... 6
2.2 Warnings and cautions ....................................................................................................................... 8
3.0 GENERAL INFORMATION .......................................................................................................................... 11
4.0 SYSTEM INFORMATION AND SPECIFICATIONS ..................................................................................... 12
4.1 Overall Dimensions .......................................................................................................................... 12
4.2 Truck Chassis and Engine (Customer Supplied) ............................................................................. 12
4.3 Logging Cabin .................................................................................................................................. 12
4.4 Electrical System .............................................................................................................................. 13
4.5 Winch and Generator Hydraulic Systems ........................................................................................ 13
4.6 Pneumatic System ........................................................................................................................... 14
4.7 Wireline Safety Valve System .......................................................................................................... 14
4.8 Measuring System............................................................................................................................ 14
4.9 Rear Bumper Spooler ...................................................................................................................... 14
5.0 PHYSICAL DESCRIPTION .......................................................................................................................... 15
5.1 Unit Left side .................................................................................................................................... 15
5.2 Unit right side ................................................................................................................................... 18
5.3 Rear overview .................................................................................................................................. 21
5.4 Unit interior ....................................................................................................................................... 30
6.0 FUNCTIONAL DESCRIPTION ..................................................................................................................... 33
6.1 Systems overview ............................................................................................................................ 34
6.2 Well monitoring and logging system ................................................................................................ 36
6.3 Wireline winch system ...................................................................................................................... 37
6.4 Truck – transportation and power supply ......................................................................................... 40
6.5 Electric energy supply system .......................................................................................................... 40
6.6 Hydraulic System ............................................................................................................................. 41
6.7 Pneumatic system ............................................................................................................................ 43
6.8 Cabin comfort system ...................................................................................................................... 43
6.9 Hydraulic Oil Cooling system ........................................................................................................... 43
6.10 Wireline Safety Valve System .......................................................................................................... 43
7.0 UNIT CONTROLS AND CONNECTIONS .................................................................................................... 44
7.1 Hoistman‘s Console ......................................................................................................................... 44
7.2 Hoistman‘s Console, left .................................................................................................................. 45
7.3 Hoistman‘s Console, middle ............................................................................................................. 47
7.4 Hoistman‘s Console, right ................................................................................................................ 48
7.5 Cabin AC electrical panel ................................................................................................................. 50
7.6 Cabin DC electrical panel ................................................................................................................. 51
7.7 Backup air-conditioning system control............................................................................................ 53
7.8 Shore Power input and battery switch.............................................................................................. 54
7.9 Air connection / airbag control panel ................................................................................................ 55
7.10 Wireline safety valve control panel................................................................................................... 56
7.11 Transport truck cabin interior ........................................................................................................... 57
8.0 SETUP AND REMOVAL .............................................................................................................................. 58
8.1 Prepare unit for transport ................................................................................................................. 58
8.2 Rig-up ............................................................................................................................................... 60
8.3 Rig-down .......................................................................................................................................... 67
9.0 OPERATION ................................................................................................................................................. 69

9.1 Introduction ....................................................................................................................................... 69
9.2 Emergency situations ....................................................................................................................... 69
9.3 Startup .............................................................................................................................................. 70
9.4 Run ................................................................................................................................................... 77
9.5 Monitor unit status ............................................................................................................................ 78
9.6 Shutdown ......................................................................................................................................... 79
9.7 Perform daily cleanup tasks ............................................................................................................. 80
9.8 Accessories ...................................................................................................................................... 81
10.0 TROUBLESHOOTING.................................................................................................................................. 82
10.1 Troubleshooting principles ............................................................................................................... 82
10.2 Troubleshooting table ....................................................................................................................... 82
11.0 MAINTENANCE ............................................................................................................................................ 86
11.1 Introduction ....................................................................................................................................... 86
11.2 Regular, scheduled maintenance is essential .................................................................................. 86
11.3 OEM components............................................................................................................................. 87
11.4 UniTruck periodic maintenance schedule ........................................................................................ 87
11.5 Measuring head maintenance schedules ........................................................................................ 90
11.6 250 Hour Maintenance ..................................................................................................................... 91
11.7 Prepare unit for safe maintenance ................................................................................................... 92
11.8 Inspect electrical system .................................................................................................................. 93
11.9 Inspect UniTruck body ..................................................................................................................... 98
11.10 Inspect hydraulic hoses & couplings ................................................................................................ 99
11.11 Check/fill hydraulic oil ..................................................................................................................... 100
11.12 Replace hydraulic oil ...................................................................................................................... 102
11.13 Replace hydraulic suction filters* ................................................................................................... 103
11.14 Bleed air from a hydraulic component ........................................................................................... 107
11.15 Drain condensation water from hydraulic oil tank* ......................................................................... 108
11.16 Service truck compressor ............................................................................................................... 109
11.17 Inspect pneumatic system .............................................................................................................. 109
11.18 Inspect winch .................................................................................................................................. 110
11.19 Service final reduction gearbox ...................................................................................................... 112
11.20 Lubricate winch drum bearings ...................................................................................................... 113
11.21 Remove/install winch drum ............................................................................................................ 115
11.22 Inspect drum brake bands .............................................................................................................. 118
11.23 Adjust drum brake .......................................................................................................................... 120
11.24 Replace drum brake bands ............................................................................................................ 125
11.25 Test drum brake band .................................................................................................................... 126
11.26 Check drum alignment ................................................................................................................... 128
11.27 Check/adjust drum chain ................................................................................................................ 129
11.28 Test drum mounting ....................................................................................................................... 131
11.29 Replace motor/gearbox assembly.................................................................................................. 132
11.30 Assemble motor and gearbox (as required) ................................................................................... 134
APPENDICES .......................................................................................................................................................... 135
APPENDIX 1. LUBRICANTS ................................................................................................................. 136
APPENDIX 2. RECOMMNDED SPARE PARTS ................................................................................... 137
APPENDIX 3. STORAGE UNIT INSPECTION CHECKLIST ................................................................ 144
APPENDIX 4 CONTACT US................................................................................................................. 148
APPENDIX 5 RUNNING HOURS & SERVICE LOG FORM ................................................................. 149
1.0 SCOPE
This document provides descriptive and operational information solely for the NOV ASEP Elmar
unit specified. All users should familiarize themselves with the content of this manual prior to
operating or performing maintenance on the specified unit.
2.0 SAFETY
Before engaging in the operations of the unit specified in this document, all users should read and
familiarize themselves with the instructions in the accompanying NOV ASEP Elmar General Safety
document in this book. Failure to do so could result in damage to equipment and/or increase the
danger to personnel operating the equipment.
When applicable, instructions in NOV ASEP Elmar manuals are earmarked with warning notices.
It is important to observe and follow these notices. Below is an explanation of the types of notices
used.
WARNING! - Used to earmark a piece of text that may be vital to ensure safe unit
operation as well as warning of the increased potential danger to personnel. Ignoring a
WARNING! may result in unsafe conditions for personnel as well as damage to
equipment.
NOTE -Used to earmark a piece of text that gives additional and crucial
information generally pertaining, but not limited to operations procedures
General Safety Instructions
WARNING! Read and understand this document thoroughly BEFORE operating any
NOV ASEP Elmar equipment.
While working with any equipment, follow specific rules and regulations for your specific area or
location, in addition to best practices and safety standards. Use this document as a guide for system
operations in conjunction with best known methods and operator(s) experience.
Always wear appropriate clothing and personal protective equipment as required, including but not
limited to hearing protection. Internal sound levels of NOV ASEP Elmar equipment can exceed 65
decibels (dB).
Allow only qualified and experienced personnel to operate NOV ASEP Elmar equipment to further
decrease the chance for dangerous situations arising.
Before starting any diesel or gas powered engines, check to ensure the operating environment is
suitable for the emission of toxic exhaust gases.
WARNING! Exhaust gases contain carbon monoxide, a colorless, odorless and

poisonous gas.
All NOV ASEP Elmar equipment is designed and built for specific purposes. DO NOT attempt to
utilize the equipment for any purpose outside its designed scope. This may lead to damage to the
equipment or increased danger to personnel.
During all wireline operations, consider the work zone in front of the wireline unit as a DANGER
ZONE. For safety reasons, keep the following in mind:
 The area ALWAYS presents a DANGER.

 NEVER step over the wireline.
 NEVER allow spectators to stand in or near the working area.
 When possible, designate the DANGER ZONE by outlining the area with appropriate
signs or brightly colored tape.
 When the wireline is rigged up, but not being run for any period, clamp the wire and ―flag‖
it with warning signs.
 When the wireline unit is tied down on deck using rope, cable, or chains, ―flag‖ the tie-
downs with warning signs.
While operating hatches and/or doors on any unit, be aware of wind conditions. Hatches and doors
may swing open or shut with force that could cause damage or injury.
When the operations are finished, shut down all engines and close all hatches and doors.
When lifting any equipment by crane or hoist, make certain no personnel are in a position that
could ―trap‖ them between the load and a wall or other fixed object. When possible, all personnel
should be in a position visible to the crane/hoist operator. If this is not possible, position flagmen to
provide communication between crane operator and the ―hidden‖ personnel.
 NEVER walk under a hanging load.
 Make certain that all lifting equipment and devices are sufficient and certified for the
load.
 DO NOT operate damaged equipment that could lead to further damage and/or injury.
 Respect and maintain your working environment. Dispose of any waste materials
correctly and as specified by local laws and regulations.
 Keep all safety guards in position while operating NOV ASEP Elmar and any other
equipment. Removing safety devices will increase the probability of accidents or
injury.
2.1 Maintenance and Pre-Start Safety

When engaged in maintenance or performing system/unit checks on NOV ASEP Elmar equipment,
adhere to the following safety and common sense guidelines:
 Consider your safety and that of others first.
 Always exit the cabin and winch bay, using steps provided, and with three points of
contact on steps and hand rails.
 Always exit facing the door or winch, using handrails and three points of contact on steps
and hand rails.
 Make certain all equipment is switched OFF completely and use a Lock out Tag Out
placard or similar device to prevent unauthorized personnel from starting the equipment
during the maintenance or check.
 NEVER work on a hydraulic or pneumatic system that is under pressure. Always relieve
the system prior to any work in order to reduce the likelihood of injury or accidents.
 NEVER attempt to move or lift heavy items without assistance from a mechanical lifting
device.
 DO NOT allow heavy objects to rest in an unstable position.
 ALWAYS use the proper and recommended tools for the task.
 Only allow qualified personnel with the correct tools to perform maintenance on the NOV
ASEP Elmar equipment. This will help prevent further damage to the equipment or injury
to personnel.
 Only use replacement parts or equipment that are certified by NOV ASEP ELMAR.
Unqualified parts cannot be relied upon to be the correct material strength, dimensions,
finish, or quality. NOV ASEP Elmar is not responsible for any damage or injury arising
from the use of unqualified or improper parts.
When performing a pre-start check on a unit, observe the following prior to starting the unit:
 Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks
from the lines or components, and structural damage.
 Check all tanks and hoses for leaks, and visible damage possibly caused by transport.
 Check all mounting bolts on the winch module (reel bearings and supports).
 Inspect the hydraulic pump(s) and lines for any damage, evidence of leaks and secure
attachment.
 Check all hydraulic oil filter(s) for proper attachment and leaks.
 Inspect the filter element(s) and clean/ replace as necessary.
 Ensure that all cooling, air intake(s) and exhaust vent(s) openings are not obstructed.
 Check all components requiring lubrication, and service as required.
 Ensure that no unauthorized modifications have been made to the unit.
Fluid Levels
 Check engine fuel, and keep filled as necessary
 Check hydraulic oil level(s). On NOV ASEP Elmar equipment, the level should be
approximately 3/4 in the sight glass.
 Check the wireline lubrication oil level. Refill with a thin surface lubricant ( for example, a
mixture of 30- to 40- weight engine oil and diesel) as prescribed by the manufacturer.
 Check the oil level in all drum drive gears.
2.2 Warnings and cautions

The following alerts are used in this manual:
• WARNINGS alert users of potentially dangerous situations. Failure to obey a warning can
result in serious injury and/or death.
• CAUTIONS alert users of potential equipment damage. Ignoring a caution can result in
damage to equipment.
Warnings and cautions in this manual are indicated by:
 An icon
 The text WARNING or CAUTION
 A textual description, which states the hazard and how to avoid it.
See following examples:
WARNING
FALLING FROM HEIGHT
Falling from the top of the unit can cause serious injury or death.
When working on top of the unit: make sure the roof is locked, and always attach a safety
line to one of the safety bars
CAUTION
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
2.2.1 Warning and caution icons

This manual uses the following icons to highlight safety aspects during operating and maintenance
steps. These same icons are attached to ASEP systems at appropriate locations to warn of a
safety aspect.
General Caution or Warning

Dangerous voltage
Corrosive liquids or adhesive
Grounding required
Potentially explosive substances or

environments
Automatically starting and stopping of

machine parts
Lifting with forklift - beware of falling loads
Danger of falling from height
Hoisted object that can fall
Inflammable substances
Crushing danger
Hot object
Moving parts
3.0 GENERAL INFORMATION

The NOV ASEP Elmar UniTruck is built and designed for inland wireline operations. Unit design
and engineering enable the UniTruck to be upgraded to operate equipment and tools as technology
evolves.
The logging truck consists of the following major operating sections:
 Truck Chassis with Diesel Engine
 Logging Cabin and Winch Compartments
 Winch, Generator and Auxiliary Hydraulic System Circuits
 Electrical Distribution System
 Pneumatic System
 Wireline Safety Valve System
The chassis consists of a truck cab, rails, axles and driveline with a power take-off used to turn the
generator and winch hydraulic system pumps.
The logging cabin consists of a drum control panel, electronic winch control system, wireline safety
valve system, power panels, environmental systems, storage cabinetry and racks for the data
acquisition system. The winch compartment consists of the reels and frame assembly, pneumatic
brakes, and pneumatic panel, levelwind arms, cable reels and line oiler.
External boxes are mounted to the body for work tool storage. Internal tool racks are mounted in
the winch bay and between the chassis rails to store and protect wireline tools.
Power from the truck‘s engine is used to turn the PTO, which in turn delivers power to the hydraulic
system. NOV ASEP Elmar’s patented ClosedLoop hydraulic system consists of pumps, lines and
motors coupled with a planetary sprocket drive transmissions (speed reducing gearboxes). The
drum assembly features 2 wireline reels and cables that are mounted on a moveable/removable
frame to allow for the drums to be positioned for adjustment or removed.
A 30kW generator supplies primary AC electrical power to the unit. A regulator and electronic
speed control module are utilized to adjust the power output according to electrical load
requirements and drum speed. Power is routed through the power distribution panel and then to
unit components.
The pneumatic system receives its supply from the truck‘s air brake reservoirs. This system powers
the winch brake control air, tool trough airbags, and wireline safety valve system.
4.0 SYSTEM INFORMATION AND SPECIFICATIONS

4.1 Overall Dimensions
Height ...................................................... 144" (365.7 cm)
Width ....................................................... 97" (246 cm)
Length ..................................................... 408" (1036.3 cm)
4.2 Truck Chassis and Engine (Customer Supplied)

4.2.1 Chassis
Make and Model…………………………..International WorkStar 6x4,
Wheelbase………………………………….285‖ (723.9 cm)
4.2.1.1 Engine
Engine Model………………………………/ MaxxForce-10, 350 hp. at 2200 RPM
NOTE – Modern engines are meant to be run on diesel with a sulphur content of less than 15ppm.
4.3 Logging Cabin

4.3.1 Dimensions
Height…………......................................81" (206 cm)
Width………………………………………96" (244 cm)
Length…………………………………….250" (635 cm)
4.3.1.1 Exterior
Material……………………………………Polyester
Construction………………………………Unibody design
Cabin Entrances………………………….One drivers side access door
Video Monitoring…………………………Optional feature
4.3.2 Interior
General…………………………………… One tilting window facing winch compartment, one window in
cabin door, one window in each side wall
Consoles…………………………………. Operator console with one SmartMonitor unit, one Combi Gauge,
dual Wireline Safety Valve System with stuffing box control, DC
and AC power distribution panels, breakers and fuses,
Environmental……………………………. Two 220V-powered air conditioners, double paned windows, 12V
powered pressurization fan
4.4 Electrical System

Below are general specifications regarding the electrical system: See Electrical System section for details
on this system:
Generator………………………………… .One 30 kW generator with voltage regulator
Hoist and Generator………………………Sauer MC2420 hydraulic pump speed controller
House Power Inlet…………………………Plug access on generator compartment
4.4.1 Power Distribution

220VAC System…………………………Air Conditioning unit supplied by 220 step up transformer
120VAC System………………………… Data acquisition system, air-conditioner, microwave oven and
receptacle outlets
12V DC System………………………….. Interior and exterior lighting, truck chassis systems and lights and
heater fan, SmartMonitor, and measuring head
Outlets...................................................Utility receptacles for 120VAC components
4.5 Winch and Generator Hydraulic Systems

Below are general specifications regarding the hydraulic system; Sauer-Danfoss pump and motor circuits
drive the drum rotation, spooling system, hoist controls, generator and winch gearbox. Refer to the
Hydraulic System section for more information.
System Pressure ..................…5000 PSI (344 bar) maximum, 217 PSI (15 bar) minimum
Pumps ..................................….Series 90 variable displacement 100cc pump - winch circuit
Series 90 variable displacement 55cc pump - generator circuit
Motors....................................... Series Motor variable displacement 80cc motor on the winch circuit
Series fixed displacement 56cc motor on the generator circuit
Gearbox .................................…Planetary gearboxes both 5.8:1 gear ratio
Drums.....................................…Double drum Waterfall with 450 x 260 x 700 and 600 x 350 x 700 drums
Wireline Cable Oiler...................Adjustable-flow cable oiler (ASEP)
Reservoir ...................................0.9 USG (3.4 L) capacity
4.6 Pneumatic System

Pneumatic pressure runs the wireline safety valve system, air bag system and drum brakes and the
Wireline Safety Valve System. Below are general specifications regarding the Pneumatic System:
System Pressure ........................120 PSI (8.2 bar) maximum (created by truck engine compressor)
Tool Trough Air Bags...................Adjustable tool retention air bags (ASEP), 20 PSI (1.3 bar) max
4.7 Wireline Safety Valve System

System Pressure……………………5000 PSI
Reservoir…………………………….8 US gallon
Pump…………………………………AW35 Air Driven Fluid Pump 35:1 Max pressure 5000 PSI
Hand pump…………………………..NOV ASEP Elmar High pressure hand pump Max pressure 6000 PSI
4.8 Measuring System

Depth and tension display panel……..NOV ASEP Elmar SmartMonitor 12 and NOV ASEP Elmar
CombiGauge Hydro/ Mechanical Depth and Tension Gauge
Measuring head………………………..NOV ASEP Elmar MP16 Hydro/ Mechanical Measuring Head
4.9 Rear Bumper Spooler

Motor ……………………………………Free running Gerotor series 195CC
Pump…………………………………….Axial piston variable displacement 45CC hydraulic pump
5.0 PHYSICAL DESCRIPTION

5.1 Unit Left side
5.1.1 Left side overview
6 8 9 10 11
2
4
Figure 5.1 Unit exterior, left
1 Wind diffusor Disperses airflow over the roof
2 Shore power AC in Hubble connection for 120V input
3 Cabin door See 5.1.3 Cabin door and fold out stairs
4 Cabin stairs Fold-out stairs, stowed in belly box below cabin door.
5 Generator Hydraulic-powered AC generator in enclosure
6 Belly box General purpose storage
7 Storage compartment Short tool storage compartment with slickline tool mounts. Accessible
via the short and long side hatches.
8 Storage belly box General purpose storage.
9 Winch bay drain left Drain point for winch bay. Intake is in left side tool compartment; drain
valve is in front of leading rear tires, beside mudguard. See
10 Winch bay rear gutter drain left Drain point for winch bay rear gutter. Intake is in the left end of the rear
gutter; drain valve is behind trailing rear tires, beside chassis member.
11 Belly box Storage
5.1.2 Slickline Tool Storage
Figure 5.2 Slickline tool storage
1 Slickline tool storage Steel screw in storage plates
5.1.3 Cabin door and fold out stairs
3
4
Figure 5.3 Cabin and fold out stairs
1 Stairs stowed Fold-out cabin stairs stowed in belly box below door.
2 Handrail stowed Stairs handrail stowed on cabin door (lift to remove).
3 Handrail socket (2x) Firmly mount handrail in the upper and lower socket before using the
stairs.
4 Stair light (At back of stair compartment, not visible in photo.)
Once the stairs are unfolded and the electrical systems in the cabin are
started, the stair light can be turned on at the cabin electrical panel.
5.2 Unit right side

5.2.1 Right side overview
1
2
7 6
4 3 3 3
Figure 5.4 Unit exterior, right
1 Long storage compartment Long tool storage compartment with shelving. Accessible via the two
long side hatches, and normally loaded/unloaded via the hatch in the
right rear above the bumper.
2 Hydraulic servicing compartment Contains reservoir and cooling fans
3 Storage belly box General purpose storage.
4 Belly box General purpose storage
5 Cabin window Double paned glass
6 Winch bay drain right Drain point for winch bay. Intake is in right side tool compartment;
drain valve is in front of leading rear tires, beside mudguard.
7 Winch bay rear gutter drain right Drain point for winch bay rear gutter. Intake is in the right end of the
rear gutter; drain valve is behind trailing rear tires, beside chassis
member.
5.2.2 Hydraulic servicing compartment

2
1
4
3
6
5
8
7
Figure 5.5 Hydraulic servicing compartment
1 Hydraulic reservoir tank Storage for 40 gallons of hydraulic oil

2 Filler cap Filler point for hydraulic oil.
3 Sight glasses Use to check level of hydraulic oil. With hydraulic system not running,
level should be midpoint of top sight glass.
4 Inspection opening Use during major overhaul to thoroughly clean inside of hydraulic tank
or for removal of severe contamination.
5 Drain point and valve Capped drain point with valve for periodic draining of condensation
water and/or replacement of hydraulic oil (see maintenance schedule).
6 Tank temperature sensor Sensor for temperature of hydraulic oil in tank (as shown in the UNIT
(not visible) DISPLAY). Used to start the hydraulic oil cooler, if the temperature
exceeds the maximum permitted temperature.
7 Generator suction filter Replaceable canister filter with individual condition indicator and
isolation valve for the generator circuit.
8 Hoist suction filter Replaceable canister filters with individual condition indicator and
isolation valve for the main (winch & control) circuit.
9 Filter condition indicator Typical filter condition indicator. Always replace the filter(s) when the
needle starts to point into the yellow zone with the engine running and
PTO engaged
NOTE: Never allow the filter condition to move into the red zone.
When this happens, the oil is no longer filtered!
5.2.3 Rear belly box storage
Figure 5.6 Rear storage box
1 Rear belly box
5.3 Rear overview

See next page for legend
3
4
6 2 6
17
8
9
7
11
10
12
13 14 15
16
Figure 5.7 Rear overview
1 Winch bay Tarp Sliding tarp. Opens on rear floor of winch bay and slides forward into
the UniTruck body roof.
2 Winch bay window Operator‘s window onto the winch bay and work area.
3 Winch lights Illuminate the winch bay.
4 Spot lights Aim these where specific lighting is needed.
5 Flood lights Illuminate the general work area.
6 Air conditioner units Outside condensers and fans
7 Winch module Winch module with drums
8 Reels Ground reel,
9 Wire lubrication system (Not shown, attached to MP16 measurehead)
10 Sheave racks Floor-mounted racks for WTI wireline sheaves.
11 Tool storage compartment Access doors to the side storage compartments.
12 Tool trough Long under floor tool storage compartment, accessible from rear, and
equipped with air bags to prevent tool movement during transport. The
air bag controls are located in the right rear belly box.
13 Bumper box Top-loading general purpose storage compartment built into rear
bumper, containing bumper spooler motor.
bumper, containing bumper spooler motor controller.
bumper, containing swing out vice.
16 Winch bay stairs Latch able, fold-down stairs. Always fold up and secure before driving.
17 Wireline Safety Valve System (Not shown 8 USG reservoir, 5000PSI pump and five reels)
5.3.1 Winch module
2 5
4
6
1
8
Figure 5.8 Waterfall Drum Package over view
1 Winch drum Drum slickline type, with single brake rim and chain drive sprocket.
Inhole/ outhole direction, speed and torque controlled by DRUM
CONTROL lever.SC06 drum dimensions 600 x 350 x 700
2 Winch motor Drum slickline type, with single brake rim and chain drive sprocket.
Inhole/ outhole direction, speed and torque controlled by DRUM
CONTROL lever.SC05 drum dimensions 450 x 260 x 700
3 Winch frame Winch frame assembly with drip pan not shown
4 Drum guard left Safety and contamination cover over the drum brake. Must be
removed for brake inspection and adjustment.
5 Drum guard right Safety and contamination cover over the chain transmission. Must be
removed for drive chain inspection and adjustment.
6 Motor/gearbox guard Safety and contamination cover over the drum brake. Must be
removed for brake inspection and adjustment.
7 Pillow block (One each side of each drum). Winch drum shaft bearing mounted in a
sealed case and bolted to winch frame. Can be adjusted in winch
pulling direction as necessary to ensure correct drive chain tension,
using adjustment bolts on either side of pillow block.
8 Levelwind assembly Front pivoting frame which supports the measuring head. The system
uses two pneumatic cylinders to adjust the measuring head position
vertically. Measuring head position in the horizontal axis is controlled
by a hydraulically driven autospooler chain assembly.
5.3.2 Reel & connection
1
3
Figure 5.9 Reel and Ground connection
1 Ground reel Once the reel is unwound, attach the truck end to the grounding point
in the winch bay below the reel.
2 Intercom reel Once the reel is unwound, plug the truck end to the socket labelled
Speaker on the signal connections panel.
3 Grounding point Use to attach the truck end of the earth reel. Only use the stainless
steel washers and nut provided, or if lost or damaged, use only brass
fittings as a substitute. This is normally attached to the winch frame.
NOTE: You should never mix metal parts on grounding points.
5.3.3 Wire lubricator
Figure 5.10 Wire Lubricator
1 Wire oil tank Storage tank for wireline lubrication and preservation oil.
2 Flow valve Adjust this needle valve to the desired position when oil needs to be
applied on the wire.
3 Wire oil applicator Output from wire oil tank to wire
5.3.4 Bumper-mounted vice
2
1
Figure 5.11 Bumper mounted vice
1 Open lid Using the supplied square key, unlock the lid of the vice compartment
in the bumper and open the lid.
2 Swing out vice Swing the vice up and out of the compartment onto the bumper.
3 Lock vice to bumper Pull the lock-bolt below the vice out, so that the vice settles fully onto
the bumper, then, release the bolt, which will lock the vice to the
bumper.
4 Close lid Close the lid of the vice compartment.

NOTE: You may need to either open the vice a little or turn it on the
turntable, so that the vice compartment lid can close
5.3.5 Winch bay drain points
2
3
1
Figure 5.12 Winch bay drain ports
1 Winch bay rear gutter Collects fluids and contamination falling from wireline and measuring
head in rear part of winch bay.
2 Rear gutter left drain Leads fluids and contamination from gutter to left drain valve.
3 Rear gutter right drain Leads fluids and contamination from gutter to right drain valve.
4 Rear gutter right drain valve Located against the chassis member, just behind the trailing rear
wheels.
Open to drain fluids from gutter into a suitable container when the truck
is tilted to the right.
The left side valve is in the same position on the opposite side.
5 Winch bay right drain valve Located against the mudguard, just in front of the leading rear wheels.
Open to drain fluids from the right side tool compartment. Fluids
leaking from the winch and from tools in the compartment will flow
towards this point located in the tool compartment slightly forward of
the winch bay.
The left side valve is in the same position on the opposite side.
5.3.6 Bumper Spooler Motor
1 2
Figure 5.13 Spooling Arm accumulator and pump
1 Motor shaft Couples motor to customer spooling assembly mounted in roadside

bumper box
2 Motor 195CC free running Gerotor series hydraulic motor mounted in

roadside bumper box
3 Motor controller Electrically controlled motor controller operated from operator‘s

console
5.4 Unit interior

5.4.1 Transport cabin interior
Figure 5.14 Transport cabin interior
1 Driver entrance
2 Console
3 Console close up Hydraulic oil cooler switch, cabin pressurization switch, and PTO knob
5.4.2 Logging cabin interior
1 2 3
5
4
Figure 5.15 Logging cabin interior
6 7
8
9
1 Roadside rear compartment
2 Centerline rear compartment
3 Roadside rear compartment
4 Roadside window
5 Curbside window
6 Operators console
7 Load panel and cabinet storage 120V and 12V power distribution panel
8 Cabinet storage
9 Intercom and pressurization louver
5.4.3 Cabin climate control
6.0
Figure 5.16 Cabin climate control
1 Pressurization blower Winch bay mounted controlled by switch on transport cabin dashboard
2 Air-conditioner - indoor unit Wall mounted 220V ductless air conditioner units
3 Air-conditioner - outdoor unit Condenser units mounted left and right in winch bay
4 Air-conditioner - remote control Use to set temperature and fan speed. Mounted on cabin inside wall.
See separately supplied manufacturer’s documentation
FUNCTIONAL DESCRIPTION
6.1 Systems overview
This UniTruck comes with a number of functional subsystems. See the overview in figure 6.1.
1. Well monitoring and logging system
2. Wireline winch system
3. Electric energy supply system
4. Hydraulic System
5. Pneumatic system
6. Wireline Safety Valve System
7. Operator comfort system / UniTruck body
8. Cooling system
9. Tool storage system
10. Bumper Spooling System
Figure 6.1 shows how these systems are interconnected to each other in terms of power
distribution. The Hydraulic system is powered by the PTO and provides power to the Hydraulic
pumps which drive the winch motor and generator motor. The Electric system is powered by shore
power or by the hydraulic powered generator. The electrical system powers both the System power
and Utility power circuits. The Pneumatic system will power parts of the Wireline winch brake circuit
and also the airbags in the Tool storage system. The Hydraulic Cooling Circuit cools the hydraulic
fluid.
Figure 6.1 Systems Overview
6.2 Well monitoring and logging system

Related documentation:
 NOV ASEP Elmar MP16 measuring head user manual
 NOV ASEP Elmar SmartMonitor system user manual
Tension and depth are electronically measured at the measuring head. An optional slipring
collector on the drum shaft transfers logging data from the tool string to the logging system. The
signal cables from the measuring head and slip ring enter the cabin via customer-supplied
connector panels at the front left of the cabin bulkhead. The wireline can be replaced in the
measuring head without cutting the wire.
6.2.1 Measuring head
This unit is equipped with the MP16 measuring head - this

is a combined hydro-mechanical wireline depth and
tension measurement system enabling both wireline depth
and tension signals to be sent to a separate remote
display (e.g. SmartMonitor). An accurate tension display
can be achieved when used in conjunction with a
SmartMonitor. See the MP16 User Manual for more on
this measuring head
Figure 6.2: MP16 measuring head
The measuring head is mounted on the support shaft between the levelwind arms. The levelwind
carriage travels along the levelwind support shaft on a sleeve bearing which is enclosed in a
housing, inside the levelwind carriage. The housing passes through a bushing to which the drive
chain is attached. The bushing rotates around the sleeve bearing housing to take up rotational
movement of the measurehead/carrier assembly about the levelwind support shaft, caused by
movements of the levelwind arm and/or the wireline in relation to one another. The MP16 can be
swivelled on its mounting on the support shaft, and locked in place ready for transport
6.2.2 Depth and tension display
This unit is equipped with digital depth and tension measurement and
display. The digital measurement is displayed on the NOV ASEP Elmar
SmartMonitor system. The SmartMonitor also provides for extensive
digital control of the functions of the winch and prime mover (truck
engine and PTO). For more information, please refer to the related
documentation (supplied separately).
Figure 6.3: SmartMonitor
6.3 Wireline winch system

The winch assembly comprises:
1. Drums
2. Drum brake system (brake cylinders mounted inside of drum frame)
3. Hydraulic Drive System
4. Wire oiling system (spray bar mounted on measure head)
5. Wire spooling system (levelwind spooling,)
The complete winch assembly is mounted in the winch bay.
Figure 6.4 Waterfall drum package
6.3.1 Winch
The drum is driven by a hydraulic motor coupled to a 5.8:1 gearbox, and which drives the drum via
a chain transmission. The speed and direction of rotation of the drum is governed by control of the
hydraulic oil flow between the pump and motor, which are electronically controlled by a lever on the
operator‘s console. The reduction gearbox increases the torque at the winch main shaft, while the
speed/torque ranges provided by electronic control. The total torque can be limited by the torque
control on the operator‘s console.
The winch is equipped with a powerful band-type brake mounted one side of the winch frame that
grips the rim of the drum. The brake is applied by a powerful spring enclosed in a hydraulic cylinder
which can only be released by sufficient hydraulic pressure applied to the piston in the same
cylinder. In the event of a loss of power (electrical, pneumatic, and/or hydraulic), the brake will
automatically be applied. This ensures that the winch cannot run away under load from the tool
string when the drum control is in the stationary position. The brake is intended to be applied
manually to park the drum safely when wireline spooling inhole or outhole stops, either temporarily
or for a longer period. It must be manually released before the drum is turned.
The wireline is spooled onto and off the drum via the levelwind system with a head that under
manual or automatic control feeds the wireline along the drum for tight, precise consecutive winds.
The head is an integrated high-precision measuring head, supplying the electronic control system
with accurate depth and tension data on the wireline.
During operations, the levelwind arms will raise or lower using the depending on the tension, to
ensure the straightest possible path for the wireline from the drum to the hay pulley via the
measuring head. Pneumatic damping cylinder attached between the levelwind arms and the winch
frame eliminate vibration of the arms and measuring head assembly caused by varying tension on
the wireline.
The size of the drum depends on the wireline used. The minimum bending radius of the wire
requires the drum to have a certain minimum core diameter. For maximum flexibility, the winch
assembly is designed to enable drums to be exchanged in the field, provided there is a suitable
hoist available.
6.3.2 Drum brake system

The drum or drums in ASEP winch units are equipped with a brake system. 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) or uphole forces (well pressure) when stationary;
 as an emergency brake, to rapidly and smoothly halt the drum in the event of an
emergency or sudden failure of the unit‘s systems
The drum brake is not intended to stop the drum during normal operations. The drum control in the
winch control panel is intended for that purpose.
The brake band system is designed to be assisted (dragged) by the inhole rotation of the drum.
The brake is therefore more effective in the inhole than outhole direction.
NOTE: The lining used on NOV ASEP Elmar brake bands is an asbestos-free composite, woven
from yarns containing brass wire.
The drum brake on this unit is based on a brake band applied by spring power to the rim of the
winch drum at one or both ends (left and right) of the drum. On larger drums, to ease installation
and removal, the brake band is a two-piece assembly joined with a turnbuckle connection at the
top. The brake's design incorporates a spring inside a hydraulic or pneumatic brake cylinder. This
spring is pre-compressed during assembly and retained by the brake cylinder lid. When pressure is
present in the brake pneumatic or hydraulic circuit (BRAKE released), the piston is extended,
releasing the brake. In the event of pressure loss (BRAKE applied, EMERGENCY OFF pressed or
a system failure), the spring will expand, retracting the brake piston into the cylinder, and applying
the brake. On dual-drum winch frames, there will be a separate brake system per drum.
NOTE: Refer to the specifications for this unit to establish whether the drum brake is a pneumatic-
release or hydraulic-release type.
See the maintenance section of this manual for procedures to:
 test the brake;
 inspect the brake band condition;
 adjust the brake;
 replace the brake band(s)
6.3.3 Wire spooling

The unit is equipped with an auto spooling function to move the measuring head backwards and
forwards along the guide rail between the levelwind arms and thus spool the wireline evenly on/off
the drum. An electric motor turns a chain to control the left and right movement of the measuring
head.
The spooling movements can be controlled manually via the SPOOLING CONTROL joystick, or
automatically (the AUTOSPOOLING switch must be set to ON). The motor is actuated either by
signals from the sensors on the measuring head or using the joystick control on the winch control
panel. The automatic spooling function can be switched off for fully manually-controlled spooling
using the control joystick.
If AUTOSPOOLING is set to ON (for levelwinding and drum slewing), the measuring head sensors
determine if the wireline needs to be moved left or right while (un)winding on the drum.
6.3.4 Wireline oiling system

The wireline oiling system uses a drip system to deliver oil from the wire reservoir directly on the
line, so that the wire is coated with oil to lubricate its path to the wellhead and prevent sparking that
might occur on a dry wireline.
The reservoir is mounted to the measuring head. The flow is regulated by the needle valve on the
bottom of the reservoir.
Excess oil from the drum is drained through a drip pan mounted to the floor of the winch bay.
6.4 Truck – transportation and power supply

Several systems from the truck are used to power, control and transport the UniTruck wireline
system. These include the alternator, PTO, compressor, air-conditioner and battery. Please refer to
the supplier documentation and NOV ASEP Elmar UniTruck diagrams for more information on
these systems.
6.5 Electric energy supply system

The UniTruck electrical system supplies power to the ancillary devices inside the cabin and winch
bay as well as the external lighting of the cabin/winch, and provides a stable electrical platform for
controlling the winch.
The UniTruck obtains its primary DC power directly from the 12VDC truck battery. The 12VDC
circuits power many lights and other accessories. 12VDC is also used to power specific 12V
accessories and systems (SmartMonitor, lighting, 12 VDC utility sockets in cabin).
The UniTruck obtains its AC power from the on-board hydraulic-powered generator or from a site
power source. Site power can be supplied via the external plug located near the DC isolator. The
AC system supplies major interior appliances, including the air conditioning units (2x) and
equipment in the computer rack, plus certain (spare) sockets in the winch cabin and bay.
The main circuit breakers for the electrical system and switches for most electrical components are
located on the electrical panel; other components can be started from the winch control panel or
the SmartMonitor control unit.
Refer to the electrical specifications in the Section 4 for the specific voltages and frequencies that
apply to this UniTruck and its installed components. Refer to the separately supplied electrical
diagrams when performing modifications or maintenance.
NOTE: The UniTruck must be properly grounded before connecting site power.
6.5.1 Shore power connection

The unit can be power by shore power. In that case the truck diesel motor doesn‘t need to be
running for the unit to be operational. All systems will be available.
6.5.2 Generator
The unit can be powered by the diesel engine from the truck. In that case the PTO from the diesel
engine gearbox drives a generator that is mounted under the truck chassis. This generator feeds
120V single phase current into the electric system which is inverted, transformed and transported
to other systems that require single phase or AC electrical energy.
6.5.3 Truck alternator

The truck alternator is powered by the truck diesel engine. It generates 12 VDC. This circuit is used
to power the unit lights, cabin pressurization heater fan. The battery switch on the battery enclosure
box opens and closed the connection between the truck battery on the truck side and the power
consumers on the logging winch side. Since the 12VDC system is used to power up the generator,
it is the first electric circuit to be activated when starting up the logging unit.
6.5.4 Fuses and circuit breakers

There are different types of fuses and circuit breakers used in the unit. The type of fuse used
depends on the specifications of the electrical system. In general, the following rule applies:
 12 volt - blade type fuses (typical automotive fuse)
 120 volt – 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.
6.6 Hydraulic System

This unit employs an NOV ASEP Elmar ClosedLoop hydraulic system to transfer mechanical
energy from the power source (engine or motor) to the winch and auxiliary control features. This
system forms the basis of virtually all standard NOV ASEP Elmar wireline winches. 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.
6.6.1 Main circuit

Hydraulic oil is circulated through the main circuit between the main pump and the winch motor,
which both have a continuously variable displacement. This circuit is bidirectional, with the speed
and direction of the pump and winch motor being governed by valves and control of the angle of
the swash plate in the pump and motor. These components are actuated by the controls at the
winch control panel, or by an automatic winch control system. This system provides infinite control
over the winch performance, enabling the winch to be run inhole or outhole at high speed, but also
at lower speed with great precision.
To prevent overheating of the hydraulic oil in the main circuit, the closed loop forms part of an open
loop which draws oil from the hydraulic reservoir and returns it to the reservoir via a radiator with
forced air cooling. The charge pump attached to the main pump constantly introduces cooled oil to
the main circuit, and the drain lines from the main pump and winch motor return hot oil to the cooler
and reservoir via a manifold. Suction filters mounted either below or inside (strainers) the hydraulic
reservoir ensure that the pump and motor are not exposed to harmful particles.
On units with dual winch motors, a manual or automatic ball valve in the winch bay is used to
redirect the flow in both directions to the second motor.
6.6.2 Control circuit

The control circuit is supplied with a high pressure flow using the excess capacity of the charge pump
of the main pump. In most NOV ASEP Elmar units, this circuit powers a variety of important auxiliary
control features, via circulating flow and static pressure, which can include the following:
 main pump and winch motor control valves
 winch gearbox ratio select mechanism
 winch drum brakes (apply or release)
 spooling support arm (raise/lower cylinder)
 generator
The return flow for the control circuit is combined with flow from the main circuit in the manifold for
cooling and returns to the hydraulic reservoir.
Please refer to the hydraulic and pneumatic diagram in the documentation package for more
information.
hydraulic
reservoir
suction filter
drain
oil cooler
pump
winch motor
Main circuit
various motors
various controls
various actuators
control circuit
Figure 6.5 Typical NOV ASEP Elmar ClosedLoop hydraulic system
6.7 Pneumatic system

This UniTruck obtains its compressed air from the compressor of the truck. Pneumatic pressure is
used to:
 drum brake operation
 inflate the tool storage air bags
 Power air tools and accessories via the hose reel in the winch bay.
6.8 Cabin comfort system

6.8.1 Air-conditioning
The hoistman‘s cabin is fitted with two ductless 220-volt air conditioners. These systems provide
comfort for the operator and ideal conditions for electronic equipment on board. The cooling system
is ducted to provide cooled airflow throughout the cabin and to logging instruments.
Cooling system operation is controlled by the load panel and remote control for the air conditioner.
Powers for the units come from a step up transformer located beneath the roadside seat.
6.9 Hydraulic Oil Cooling system

The unit contains a two 12 volt electrically driven cooling fans and radiator for the hydraulic oil
cooling.
6.10 Wireline Safety Valve System

The Wireline Safety Valve System is located in the winch bay and is controlled by a pressure
control panel in the logging cabin. It is designed to use inlet air from the truck‘s air supply to run a
fluid pump that compresses air and draws hydraulic fluid from the reservoir. The fluid is injected at
high pressure from the pump, (5000 PSIG [345 bar] maximum system pressure) through a high-
pressure line into wellhead equipment to form a seal around working wireline. The operational
pressure is set to 5000 PSI.
7.0 UNIT CONTROLS AND CONNECTIONS

7.1 Hoistman’s Console
Figure 7.1 Hoistman’s Console
7.2 Hoistman’s Console, left
1
2
3
4
6
7 8
1 Engine Parameter Display Digital multi-gauge that relays available data on the truck
engine from its electronic control module (ECM)
2 Engine Speed Controls truck engine throttle; click up to increase engine RPM, click down
to decrease engine RPM.
3 Autospooler ON/OFF Switch to engage and disengage the Autospooler. Select
ON to engage or OFF to disengage auto spooler system
4 Line tension Control valve used to alter the required maximum torque.
5 Spooling Override Joystick is used to temporarily override the position of the spooling
system. Move control left to move the measurehead to the left, and Move
right to move measurehead to the right
6 Bumper Spooler Control Lever Joystick controls the oil direction and speed in the bumper spooler circuit.
Push the lever forward (up) to spool cable off (downhole); pull the lever
back (down) to spool cable on (uphole).
7 Bumper Spooler System Displays hydraulic system pressure generated by the auxiliary hydraulic
pressure gauge pump. Maximum hydraulic pressure is 3000psi (200 bar)
8 Bumper Spooler Line tension Control valve used to alter the required maximum torque on the bumper
spooler circuit
7.3 Hoistman’s Console, middle
1 2 3 4 5
6
7
1 Check Hydraulic Oil Alarm Light illuminates when hydraulic oil level in reservoir falls below
approx. two-thirds capacity
2 Engine Stop Emergency kill switch stops truck engine electronically. Use only in
case of emergency as the PTO will not automatically disengage from
hydraulic system pumps.
3 Over Tension Drum Stop Switch to engage and disengage the drum over tension. Select
ON to engage ,when pre-set line tension value is reached, the drum
will shut down to prevent breaking the wireline
4 Brake ON/OFF Switch to engage and disengage the drum brakes. Select
ON to engage or OFF to disengage brakes
5 Horn Depress to sound the truck horn
6 CombiGauge
7 SmartMonitor
7.4 Hoistman’s Console, right
1
2
3
4
5 6
7
8
1 Main Pressure Gauge Displays hydraulic system pressure generated by the main hydraulic pump.
Minimum hydraulic pressure (from the hoist pump‗s charge pressure pump)
should never fall below 217 PSI; maximum working pressure should not
2900 PSI, however the pumps bypass/safety valves are all set at the
factory to 5000 PSI.
2 Hoist Charge Pressure Displays pressure being applied from the charge pump. Minimum pressure
Gauge for controls to operate correctly is 217 PSI, maximum pressure in both Low
and Medium speed modes should not exceed 200 PSI, and High (normal)
speed mode should not exceed 350 PSI.
3 Air Pressure Gauge Displays air pressure in the system. Maximum available air pressure from
the truck‗s compressor is 120 PSI. If air pressure falls below 60 PSI,
components will begin to lose efficiency; loss of air pressure will result in
failure of the pneumatic system.
4 Hydraulic Oil Displays temperature of hydraulic oil in the system. Minimum temperature
Temperature Gauge is ambient/environmental, normal operating temperature is ~140°F,
maximum hydraulic oil temperature should never exceed 180°F (for type oil
in these units), max and min temps will change with the viscosity range of
oil in system.
5 Hydraulic System Hours Displays total hours that charge pressure has been applied to any
Counter hydraulic system circuit
6 Generator Pressure Displays hydraulic system pressure in the generator hydraulic circuit.
Gauge Pressure in the generator circuit is maintained at 400 PSI. If pressure
deviates significantly above or below this value, the electronic speed
controller will initiate a shutdown ramp
7 High Speed Selector Joystick controls the oil direction and speed in the hydraulic hoist motor
circuit. . Push the lever forward (up) to spool cable off (downhole) at high
speed pull the lever back (down) to spool cable on (uphole) at high speed.
Leaving the joystick at neutral position will run the motor at regular speed.
8 Drum Control Lever Joystick controls the oil direction and speed in the hydraulic hoist pump
circuit. Push the lever forward (up) to spool cable off (downhole); pull the
lever back (down) to spool cable on (uphole).
CAUTION!! Brake must be SET when drum is STOPPED
7.5 Cabin AC electrical panel
1 2 3
7 11
4
8 12
5 13
9
6 10 14
Figure 7.2 Cabin AC Electrical Panel
1 LINE VOLTAGE Monitors voltage on AC circuit
2 LOAD CURRENT Monitors current draw on AC circuit

3 FREQUENCY Monitors frequency on AC circuit
4 GENERATOR OFF/ON Starts hydraulic generator
5 GENERATOR 50 AMPS On/Off –Supplies 120 to 120 VAC load panel
6 REVERSE POLARITY Detects improper phase
7 OUTLETS LEFT On/Off - AC sockets inside cabin, left side
8 OUTLETS RIGHT On/Off - AC sockets inside cabin, right side
9 WINCH On/Off – enables the power outlets in the winch bay
10 CD PLAYER Supplies power to AC outlet mounted behind CD player
11 AIR COND 1 On/Off - enables air conditioning unit to be used. The unit itself is
controlled using the remote controller. 220VAC supplied by
transformer
12 AIR COND 2 On/Off - enables air conditioning unit to be used. The unit itself is
controlled using the remote controller. 220VAC supplied by
transformer
13 Converter Supplies power for desktop light on DC panel. Eliminates load on
battery for routine lighting while on shore power.
14 SPARE Not in use
7.6 Cabin DC electrical panel
4
1 2
5
6
3
7
8 11 14
9 12 15
10 13 16
Figure 7.3 Cabin DC Electrical Panel
1 Line voltage Monitors 12V DC voltage supplied by truck battery via DC isolator
2 Load current Monitors current draw on 12V DC circuit from truck battery
3 Battery test Battery source display
4 Main 100 amps On/Off - Main circuit breaker for DC circuits drawn from truck 12VDC
supply to cabin via DC isolator.
CAUTION: avoid switching off by mistake! This will instantly shut down
the entire UniTruck if it is running!
5 Panel instrument On/Off - Switches DC supply to all control units and panels.
CAUTION: avoid switching off by mistake! This will instantly shut down
the entire UniTruck if it is running!
6 Cabin lights On/Off - Ceiling lights in winch cabin
7 Winch lights left) On/Off - Wall mounted lights in winch bay
8 Winch lights (right) On/Off - Wall mounted lights in winch bay
9 Spotlights On/Off - spotlight above rear hatch, illuminate work area. left side
10 Spotlights On/Off - spotlight above rear hatch, illuminate work area. right side
11 Side lights On/Off - Illuminates access stair from inside the stair stowage
12 Side lights On/Off - cigar lighter socket inside cabin, left side
13 Stair light On/Off - cigar lighter socket inside cabin, right side
14 Flood light (left) On/Off - floodlights at rear of UniTruck; illuminate work area
15 Flood light (right) On/Off - floodlights at rear of UniTruck; illuminate work area
16 Desktop light On/Off - Illuminates the desk inside the cabin via strip lights under the
cabinets. Each light fitting also has its own switch.
7.7 Backup air-conditioning system control
Figure 7.4 Air Conditioning Control
1 Remote control Use to set temperature and fan speed. Mounted on cabin inside wall.
See separately supplied manufacturer’s documentation
7.8 Shore Power input and battery switch
Figure 7.5 Shore Power connection
1 Shore power connection Hubble connection located left side Unitruck beneath generator
2 Battery switch 12V DC isolator on battery enclosure box
7.9 Air connection / airbag control panel
2
3
Figure 7.6 Air connection/ Air Bag Control Panel
1 Rig air out Quick connector for pneumatic power supply to external tools.
2 Pneumatic pressure regulator Set and lock air pressure to 20 psi.
3 Air pressure gauge Displays pressure in pneumatic system
4 Middle airbag control ON/OFF switch to activate middle air bag system beneath winch bay
floor
7.10 Wireline safety valve control panel
4 8
3 7
2 9
5
1 6
10
Figure 7.8 Wireline Safety Valve System Control Panel
Connects system to air supply from truck compressor. ON to open

1 Air supply
valve, OFF to close valve
Valve supplying fluid to Lower BOP. OPEN to supply fluid, CLOSE to
2 Lower BOP cut off fluid. A locking device beneath valve handle must be depressed
before switching states, preventing accidental closing of valve.
Shear valve supplying fluid to Upper BOP. OPEN to supply fluid,
CLOSE to cut off fluid. A locking device beneath valve handle must be
3 Upper BOP
depressed before switching states, preventing accidental closing of
valve.
Gauge relaying pressure output of system to Stuffing Box. Gauge
4 Stuffing Box Pressure
range is 0-5000 PSI
Dump valve which drains pressure from line back to reservoir.
5 BOP Dump
Normally in OFF position during operations.
6 Air Regulator Regulator allows adjustment of air to system. Max input is 120 PSI
Gauge monitoring system pressure to BOP ,Gauge range is 0- 3,000

7 BOP Hydraulic Pressure
PSI
Dump valve which drains pressure from Stuffing Box line back to
8 SB Dump
reservoir.
Hand Pump Valve connecting high pressure hand pump to BOP circuit. Switch
9
ON/OFF valve to ON to supply BOP lines.
High pressure hand pump used for charging Stuffing box up to 6,000
10 Hand Pump PSI. The unit can also be used to charge BOP lines in event of air
supply loss.
7.11 Transport truck cabin interior
1
2
Figure 7.9 Transport Truck Cabin Interior
1 Control console
2 PTO selection
3 Cabin pressurization and hydraulic
cooler switches
4 PTO shows PTO engaged position
5 PTO shows PTO disengaged position
8.0 SETUP AND REMOVAL

This chapter describes the following important procedures.
 8.1 Prepare unit for transport - how to make sure that the UniTruck is properly prepared
for driving to another destination, so that it will arrive undamaged and ready for
operations.
 8.2 Rig-up - how to rig up the UniTruck at the site of wireline operations, including a first
time start up and shutdown.
 8.3 Rig-down - how to rig down the UniTruck at the site of wireline operations. Once this is
complete, the truck can be prepared for transport once more.
8.1 Prepare unit for transport

Before driving the UniTruck, you must take steps to ensure that the UniTruck, personnel in the
vehicle and other road users are safe from possible damage caused by:
 moving objects or components;
 shocks and vibration to sensitive equipment;
 tampering by unauthorized persons;
 escaping fluids and gases under pressure (e.g. in a road accident)
Carefully check off every item in the UniTruck Transport Checklist below, and do not drive the
vehicle until you are certain that every item is in order.
8.1.1 Unit transport checklist

Copy this checklist and check off each item before driving the UniTruck.
Item Check
UniTruck is already fully shutdown, and all electrical panels are inactive
Wireline fully spooled onto the winch and wire is anchored to drum
Drum brake is applied
Levelwind arms are lowered and docked
Measuring head is locked for transport
Site power supply disconnected from AC IN plug of UniTruck, and site power cable reeled
up and stowed.
Grounding cable is disconnected from site, coiled and stowed in winch bay
All other cables and hoses are disconnected, coiled and stowed on reels in winch bay
Barriers and warnings around operational danger zone are dismantled and stowed
All wheel chocks have been removed from wheels and stowed in holders on the truck
Dirty oil in winch collection tray drained and tray wiped clean, drain plug in place
All well tools are stowed
No loose items in winch bay
No loose items in cabin
All cabin windows are securely closed and locked on the inside
Winch bay hatch is closed and locked
Cabin door is closed and locked
Cabin entry stairs are stowed
Winch bay access stairs are stowed
All belly box doors and hatches are locked
MAIN SWITCH 12 VDC is switched OFF and the key is removed (hangs on chain)
With truck engine running, storage air bags are inflated and hatches are closed and locked
Figure 8.1 unit transport checklist
8.2 Rig-up
Rig-up of the UniTruck at a new site consists of the following main steps, each of which is described in
the following sections:
 8.2.1 Position UniTruck for wireline operations on page 60
 8.2.2 Open unit and make site connections on page 62
 8.2.3 Setup access to winch cabin on page 63
 8.2.4 Start-up UniTruck for operations on page 64
 8.2.5 Test main systems on page 64
 8.2.6 ReleaseMP16 from transport lock on page 65
 8.2.7 Rig up measuring head on page 66
 8.2.8 Shutdown UniTruck on page 66
Only when all these steps have been completed, can you be certain that your UniTruck is properly
rigged up and ready to perform operations.
8.2.1 Position UniTruck for wireline operations

The advantage of the UniTruck is that it can be driven to the site of operations, requires no crane to
set it up, needs almost no levelling for slightly uneven ground, and also needs no outriggers or
other stabilizing features before it can be used. In most cases, the driver simply needs to carefully
reverse the truck into position in line with the wellhead.
During wireline operations it is vital to minimize friction and lateral forces on the wireline. This will
ensure a long lifespan for the measurehead, the sheaves, the wireline (and enclosed conductors),
and will reduce the risk of accidents, snags and data errors. The angle between the wireline and
the running centerline of the hay pulley is known as the fleet angle (see Figure 8.2). By minimizing
this angle, the lateral forces are also minimized.
Proceed as follows to position the UniTruck with minimum fleet angle.
1. Inspect the terrain where the truck will be positioned. It must be as flat and firm as possible.
2. Pace out or measure a distance of at least 15 meters (50 feet) from the lower hay pulley, and
mark that position with an object on the ground, a flag, or by having an assistant signal to
you.
3. Reverse the truck in a straight line towards the wellhead, stopping when the rear of the truck
is at the marked point.
NOTE: The truck centerline should be aligned as closely as possible with the lower hay pulley. See
Figure 8.1.
4. Engage the parking brake of the truck.

5. Switch off the engine of the truck and remove the key.
6. Place chocks before and behind the front and rear truck wheels.
7. As described in the safety section of this manual, mark out the hazardous area between the
UniTruck and the wellhead with tape, to prevent unauthorized persons from entering the
danger zone (see Figure 8.2).
Figure 8.2 correct positioning of UniTruck in respect to hay pulley
8.2.2 Open unit and make site connections

Related topics:
 7.8 Shore Power Input and Battery Switch page 54
1. Make certain that the truck parking brake is applied and the wheels are chocked.
2. Turn off the truck engine and remove the key.
3. Ensure that the MAIN SWITCH 12 VDC is OFF before continuing.
NOTE: The UniTruck circuits must not be live before the unit has been properly grounded.
4. Unlock and slide back the winch bay hatch of the UniTruck.
5. Connect the grounding cable between the grounding point in the winch bay and a suitable
grounding point at the wellhead. Make certain to tighten the grounding cable clamps securely
to a clean metal grounding point on the wellhead.
WARNING
ELECTRIC SHOCK
Connecting or disconnecting an energized electrical cable can cause serious
injury and or equipment damage.
Always ensure that all cables are not electrically energized before connecting
them.
6. If using shore power:

 Verify that the site power is compatible with the UniTruck AC power specification. Do not
connect to an incompatible power supply!
 Connect a suitable extension cable between the site AC power source and the UniTruck
AC IN power socket.
7. Make the remaining site connections:
 Unwind the intercom cable, hang the speaker at or near the wellhead, and make the truck
end connection.
 Unwind and connect the SP cable (if applicable).
 Unwind and connect the DLL cable (if applicable).
8. Verify that all cables from the measuring head and slip ring are connected to the correct
sockets on the signal connections panel and that the plugs and cables are undamaged, can
move freely, and are not subject to contact with any moving parts.
9. Setup access to the cabin.
8.2.3 Setup access to winch cabin

The cabin entry stairs are stowed in a belly box below the door. The stair handrail is stowed on the
cabin door.
A B C
D E
Figure 8.3 Setting up cabin stairs and handrail

To setup access to the UniTruck cabin, proceed as follows, referring to Figure 8.3.
1. Unlock the belly box below the cabin door.
2. Open the belly box and pull the hatch open (A).
The hatch will fall partly open and be retained by the chain from the stairs.
3. Pull the handgrips to fold the stair assembly out of the belly box towards you and down until
it can go no further (B). The upper stairs are now in place.
The stairs are in two sections, hinged in the middle.
4. Unfold the lower stairs, which are resting on the upper stairs (C).
5. Go up the stairs and open the cabin door far enough to give access to the handrail, which
is stowed on the door (D).
6. Pull the handrail out of the clamp on the door.
7. Using two hands, lift the handrail up and off the two holders on the door
8. Place the handrail in the sockets in the bottom and top stair, on the opposite side from the
door hinge, and make certain it is firmly settled in the sockets (E).
NOTE: Do not leave the handrail “half-mounted”, as this could cause a serious accident. Give the
handrail a good shake to make sure it cannot come loose unexpectedly.
Stow the handrail and fold away the stairs as the as the very last action before leaving a worksite.
Simply work through the above steps in reverse.
8.2.4 Startup UniTruck for operations

Before you start up the UniTruck for operations, make yourself thoroughly familiar with every
aspect of start-up and shutdown, as described in 9 Operation of this manual.
To start up the UniTruck for operations, perform the following procedures from the operations
chapter, and then continue with 8.2.5:
 9.3.1 Daily pre-start procedure
 9.3.2 Check/set controls and switches to start up state
 9.3.4 Start-up to operations mode
8.2.5 Test main systems

Once the UniTruck is running, the critical systems must be tested.
Perform the following test procedures, and carry out any repairs that may be required in the event
of failure of any of the tests. Once the tests have been satisfactorily completed, continue with 8.2.6.
 11.25 Test drum brake band on page 126
 11.28 Test drum mounting on page 131
8.2.6 Release Measuring Head from transport dock

This procedure assumes the winch has been transported to a site for operations, and is undergoing
first-time rig-up. Please refer to MP16 Operations Manual
1. Ensure that the winch is in the following safe state:
 The levelwind arms are in the transport position (in docking station).
 The winch is in manual mode, i.e. the automatic control program (e.g. SmartMonitor)
has been disabled.
 The winch is fully shut down, and there is no hydraulic pressure and no pneumatic
pressure showing on the pressure gauges of the winch control panel.
 All possible mechanical movement is disabled and the truck engine is OFF.
8.2.7 Rig up measuring head

Please refer to the Setup & Transport chapter of the separately supplied NOV ASEP Elmar MP16
measuring head user manual, specifically the following topic:
8.2.8 Shutdown UniTruck

Now that the unit has been fully rigged up, including the measuring head, you now need to ensure
that the unit can also be properly shutdown.
Complete the rig-up procedure by going through a controlled shutdown: See 9.6 Shutdown on page
79. Once completed, you can start up the UniTruck to the required standby or operating state.
8.3 Rig-down
Rig-down of the UniTruck following completion of well servicing operations consists of the following
main steps, each of which is described in the following sections:
 8.3.1 Rig down measuring head on page 67
 8.3.2 LockMP16 for transport on page 67
 8.3.3 Disconnect site connections and clean-up site on page 68
NOTE: If you intend to drive the UniTruck, you must also complete the steps and checklists in
8.1 Prepare UniTruck for transport on page 58.
8.3.1 Rig down measuring head

 Unthread wireline from the measuring head
8.3.2 Lock Measuring Head for transport

1. If necessary, spool the wireline fully onto the drum, and fasten the free end to the drum to
secure it and maintain tension on the wireline.
2. Ensure that the winch is in the following safe state:
 The spooling joystick is in the neutral position
 The winch is in manual mode, i.e. the automatic control program (e.g. SmartMonitor) has
been disabled.
 The winch is fully shut down, and there is no hydraulic pressure and no pneumatic
pressure showing on the pressure gauges of the winch control panel.
 All possible mechanical movement is disabled with the PTO disengaged.
8.3.3 Disconnect site connections and clean-up site

Following a full shutdown, the truck and winch are fully de-energized and depressurized, and the
auxiliary heating and generating systems are shut down. Proceed as follows to finalize site
operations.
1. If the UniTruck is running, perform a normal shutdown. See 9.6 Shutdown page 79
2. Stow all tools and lock the tool boxes and tool storage compartments.
3. Turn off the truck engine and remove the key.
4. If you were using site power, verify that the site power supply is switched OFF.
5. Disconnect both ends of all signal and communication cables (intercom, SP/DLL, etc.),
stow the truck end connectors inside the reel centers, and wind in the reels.
6. Disconnect the site AC power, and (if applicable) air connections, reel up all cables and
hoses and stow them on their reels. Fit the dust caps to the disconnected sockets on
the signal connections panel.
7. Ensure that the external MAIN SWITCH 12 VDC is OFF before continuing.
NOTE: The UniTruck circuits must be electrically de-energized before the unit is disconnected from
the ground.
8. Disconnect both ends of the ground cable, stow the truck end terminal inside the reel
center, and wind in the reel. Clamp the wellhead end to the reel stowage frame in the
winch bay. Tighten the nut and washers back on the winch bay grounding terminal.
9. Remove all barriers and warnings around the operational danger zone.
10. Remove all chocks from the wheels and stow them in the holders on the truck.
9.0 OPERATION
9.1 Introduction
We distinguish in general, three possible operating modes for this truck.
Transport: In transport mode, the truck may be driven. The PTO is not engaged and the
generator is not running.
Operations: The truck is started, the PTO is running and the generator is operational. The winch
and spooling systems are supplied with hydraulic energy, making the winch bay a
highly hazardous area. The truck must be properly positioned and chocked for
operations.
Shutdown: All energy sources are stopped or switched off, i.e. the truck engine, site power, and
the DC isolator. This is the only safe mode when performing maintenance on
mechanical, pneumatic and electrical components, especially in the winch bay.
9.2 Emergency situations

9.2.1 Emergency stop
As described in the safety section, the UniTruck winch can be brought to an instant and complete
stop by pressing an ENGINE STOP button. The following ENGINE STOP button is located on the
Middle Hoistman‘s Console.
9.2.2 Emergency stop recovery

Related topics:
 9.3.2 Check/set controls and switches to start up state on page 73
 9.3.3 Start the PTO on page 74
 9.3.4 Start-up to operations mode on page 74
This procedure describes how to recover from an emergency shutdown caused by pressing an
ENGINE STOP button, or by the truck engine being switched off with the PTO engaged (possibly
unintentionally).
WARNING
MOVING PARTS
A dangerous situation may have caused the emergency shutdown.
Before re-starting the unit, make sure:
- the cause of the emergency shutdown has been eliminated
- all personnel in the immediate surroundings have been warned of the re-start
- you have read and understood the emergency stop recovery procedure
NOTE: If you attempt to re-start with the PTO engaged, the truck will briefly start, and immediately
be shut down again by the emergency control system.
1. Ensure that the cause of the emergency stop has been eliminated.
2. Check/set the controls and switches to the start-up state. See 9.3.2 Check/set controls and
switches to start up state on page 73
3. Engage the PTO. See 9.3.3 Start the PTO on page 74
4. Start-up the truck for operations. See 9.3.4 Start-up to operations mode on page 74
5. Resume operations.
9.3 Startup
Main steps of UniTruck start-up:
 9.3.1 Daily pre-start procedure on page 70- a checklist of daily inspection and service
items to make sure that unit is fit for use
 9.3.2 Check/set controls and switches to start up state on page 73 - a series of steps to
ready the unit for starting (whenever the unit has been stopped)
 9.3.4 Start-up to operations mode on page 74- a series of steps to start the main power
systems and verify readiness for unit operations
9.3.1 Daily pre-start procedure

Before starting the UniTruck, you must ensure that the unit is in a fit state for operation. Carefully
check off every item in the UniTruck pre-start checklist below, and do not operate the unit until you
are certain that every item is in order. Refer to the appropriate procedures for more detail, if
applicable.
Use this checklist to check off each item before starting the UniTruck for operations.
Item Check
Truck - engine oil - check/fill
Truck - fuel level - check/fill - minimum 1/4 full
Truck - engine coolant - check/fill
Truck - radiator fan belt - check/adjust
Truck - check that all wheel chocks are in place and the parking brake is applied
Hydraulic system - oil level - check/fill
Hydraulic system - suction/return filters - replace filters if necessary (condition indicators
checked when running)
Hydraulic system - inspect/rectify - check for leaks, e.g. oil drips, oily dust build-up
around tanks, hoses, lines, couplings/connections, filters, pumps, motors, actuators,
accumulators.
Electrical - inspect/rectify- check exposed electrical cables for signs of wear, breakage,
looseness.
Electrical - check that the total draw of all equipment attached to the AC wall sockets
does not exceed the maximum circuit breaker rating of 100 amps.
Electrical - check/rectify – MAIN SWITCH 12VDC is OFF
Electrical - check/rectify - grounding cable properly attached at both ends.
Electrical - check/rectify - intercom cable (if applicable) properly attached at winch end,
speaker properly mounted at wellhead
Electrical - check/rectify - attachment of slip ring (if applicable), and measure head
cables.
Winch - final reduction gearbox oil level - check/fill
Winch - wireline oiler tank - check/fill
Winch - drip tray - check and if necessary drain
Winch - mounting bolts of winch module (drum bearings and supports) - check/tighten
Winch - levelwind arms - released from transport clamps (if applicable)
Winch - levelwind arms - wipe down
Winch - measuring head - inspect closely, wipe off oil and dirt, ensure undamaged
Operator cabin - Joysticks and SmartMonitor – check if unobstructed
Operator cabin – ENGINE STOP - check if unobstructed
Operator cabin - SmartMonitor connectors - check if connected
General - check/rectify all mechanical and other components for loose/missing parts,
foreign objects, transport damage, etc.
Ensure winch bay free of oil, mud, dust and debris.
Lubricate all moving parts as necessary
Check that no unauthorized modifications have been made to the equipment
Check that barriers and warnings around operational danger zone are present
Valves of any pneumatic accumulators (if applicable) are closed (e.g. overhead boom,
brake)
Pressure control equipment (if applicable): check that the grease injection tank is
sufficiently filled for the planned work.
Other...
Figure 9.1 UniTruck pre-start checklist
9.3.2 Check/set controls and switches to start up state

Related topics:
 7.1 Hoistman’s Console on page 44
 7.5 Cabin AC electrical panel 50
 7.6 Cabin DC electrical panel 51
 7.8 Shore Power Input and battery switch page 54
 7.9 Air Connection/ air bag control panel on page 55
 7.11 Transport truck cabin interior on page 57
Before starting the Unitruck, check, and if necessary, set the controls and switches listed below (if
present) to the default pre-start state.
1. At battery enclosure box in the left of chassis (7.8 Shore Power Input and battery switch on
page 54):
 Battery switch = off

2. On the AC electrical panel in the cabin (see 7.5 Cabin AC electrical panel on page 50):
 All switches= OFF

3. At the DC electrical panel in the cabin (see 7.6 Cabin DC electrical panel on page 51):
 All switches= OFF
4. At the Hoistman‘s Console (see 7.1 Hoistman’s Console on page 44)
 BRAKE = ON
 AUTOSPOOLING* = OFF
 GENERATOR* = OFF
 SPEED SELECT* = LOW
 LINE TENSION* = minimum tension
 DRUM CONTROL lever(s) = neutral (middle) position
 SPOOLING CONTROL joystick = neutral (middle) position
5. At the hydraulic servicing compartment on the right side:
 Hydraulic filter isolation valves = open (lever in flow direction)
6 In the truck cab:
 PTO switch = OFF
 Truck ignition switch = OFF.
9.3.3 Start the PTO

Related topics:
 7.11 Transport Truck cabin interior on page 57
NOTE: This procedure describes the start-up of the supplied truck (see 4.2 Truck Chassis and
Engine (Customer Supplied) on page 12).
1. Ensure that the truck is in park mode and engage the parking brake.
2. Ensure your foot is on the brake pedal.
3. Turn the truck key to the ON position. The truck will initiate pre-checks. This will be displayed
on the dashboard and with audible chimes.
4. Turn the key to start.
5. Engage the PTO by engaging clutch and pulling PTO knob.
6. Slowly release clutch
7. Engage the engine fan for engine cooling in hot climates.
9.3.4 Start-up to operations mode

Related topics:
• 6.3 Wireline Winch System on page 37
• 7.1 Hoistman’s Console on page 44
• 7.5 and 7.6 Cabin electrical panels on pages 50 and 51
• 7.8 Shore Power Input and Battery Switch on page 54
• 9.3.2 Check/set controls and switches to start-up state on page 73
Before attempting to start the UniTruck, first read this entire section thoroughly and make certain
you understand every part.
NOTE: Do not start up the UniTruck unless you know how to perform a controlled shutdown - See
9.6 Shutdown on page 79.
NOTE: It is essential to conserve the charge in the truck batteries. Whenever the batteries have a
lower charge for any reason at all (e.g. repeated failed start attempts), they must be charged at the
first opportunity.
WARNING
DANGEROUS MACHINERY
Risk of serious injury or death from moving parts, live electrical components and
hydraulic or pneumatic systems under high pressure.
Once the unit is started, all systems are energized and the winch can start to
move when the controls are operated. Do not start the UniTruck unless:
- you are fully authorized to operate the equipment;
- all essential maintenance has been carried out;
- there are no unauthorized persons within the danger zone;
- the unit is properly positioned and anchored for operation
Once started, the UniTruck is fully energized, and all wireline winch functions can be operated.
To start the UniTruck for operations, proceed as follows:
1. Make certain that the truck is properly positioned for safe operation, i.e. the parking brake is
applied and all wheels are properly chocked.
2. Set all controls and switches to the start-up state.
3. At the external electrical connections
a) If using site AC power ensure the site AC power cable is plugged into the AC IN
b) If using generator-supplied AC power, ensure the generator AC OUT cable is plugged into
the AC IN socket.
4. Switch the external DC isolator to ON.
The UniTruck is now directly supplied with 12VDC power from the truck batteries. The following
circuits are now powered, and will be functional if the switch is set ON: cabin lights, side lights,
spotlight, and stair lights.
5. At the electrical panel in the winch cabin:
a) Switch the MAIN 100 AMPS to ON.
The LINE VOLTAGE and LOAD CURRENT digital meters on both sections of the panel should
light up. The meters in the lower section will indicate the voltage and current drawn from the truck
batteries.
b) If required, switch CABIN LIGHTS to ON.
c) Switch PANEL INSTRUMENTS to ON.
The winch control panel and control circuits are now supplied with power.
6. In the cab of the truck:
a) Engage NEUTRAL gear.
7. Turn on the ignition, and wait several seconds until the warning lamps are dimmed.
a) Start truck engine.
b) Depress the clutch pedal.
c) Using the switch on the dashboard, engage the PTO drive.
d) Release the clutch pedal. The engine speed should automatically increase to 800 RPM.
8. At the winch control panel, in the UNIT DISPLAY, check the engine speed.
a) Adjust the speed to suit your planned operations using the THROTTLE control.
NOTE: When the throttle control is operated for the first time, the engine speed will increase to a
pre-set speed.
9. In the UNIT DISPLAY, check the hydraulic pressures:
 MAIN PRESSURE should stabilize between 24- 28 bar (350-406 PSI).
 CONTROL PRESS should stabilize between 27- 28 bar (390-406 PSI).
NOTE: If the pressures are outside these ranges, refer to troubleshooting.
NOTE: The control pressure will fluctuate with truck engine RPM.
NOTE: Normal minimum engine speed for stable generator operation is ± 1220 RPM.
10. Adjust the speed if necessary using the THROTTLE control.
(If using site power supply, skip to step 14.)
11. At the winch control panel, turn the GENERATOR ON/OFF switchto ON, then release the
switch.
 You will hear the generator start up. The engine speed should automatically increase to
about 1100-1200 RPM.
12. In the UNIT DISPLAY, check the generator pressure:
 GEN. PRESSURE should stabilize about 24-28 bar (350-406 PSI).

13. At the electrical panel, switch the GENERATOR 50 AMPS to ON.
 The LINE VOLTAGE, LOAD CURRENT and FREQUENCY digital meters on the upper
section of the panel should light up and indicate the voltage and current drawn from the
generator 120 VAC circuit. When the gauges have stabilized (5 to 10 seconds), the
120VAC appliances and accessories should be started.
14. Switch the 12 VOLT CONVERTER to ON.
 The 12VDC accessory circuits of the UniTruck are now supplied with 12VDC power from
the 120VAC/12VDC converter, whose primary supply is the generator 120VAC. The
following circuits are now powered, and will be functional if the switch is set ON: 12 volt
outlets, winch lights, rear lights, desk lights.
15. At the winch control panel, switch the SmartMonitor on (see separately supplied
documentation).
 The SmartMonitor display will light up, and the SmartMonitor control program will go
through normal boot-up.
16. Write the date and time onto the running-hours log.
17. If you have started from cold, wait for 20 minutes before starting operations, so that the
hydraulic and electrical systems can stabilize.
18. The UniTruck is now fully energized and ready for operations.
9.4 Run
1. Attach the wireline tools as required for the planned job.
2. Ensure that the wire cannot snag in or behind the measurehead system as the drum rotates.
3. Choose on the SmartMonitor if you want to run the machine in complete automatic control
mode (SmartMonitor), or use the joystick to manually move the wireline in/out hole. Refer to
the SmartMonitor documentation for how to do choose automatic or manual mode, and other
settings.
4. Release the drum brake on the SmartMonitor.
5. Test the drum brake.
6. Use the SmartMonitor controls (or joystick) to spool the wireline on or off the drum at the
desired speed and tension.
7. Check the system status continuously. The system has a special overheating safety feature
which will shut down the complete UniTruck if the temperature exceeds +140 °C (+284 °F)
CAUTION
EQUIPMENT DAMAGE
An overheated cooling system can severely damage the motor.
Always monitor the temperature, and do not allow the temperature to exceed
100°C (212°F).
If the temperature remains high, stop winch operations and rectify the problem or
consult the troubleshooting guide.
WARNING
RISK OF EXPLOSION
Applying the winch brake on a running drum can cause sparks and/or heat, which
can cause an explosion.
Do not apply the winch brake, while the drum is moving.
9.5 Monitor unit status

While the unit is running, you must continually check the SmartMonitor screens for unit status. Get
familiar with the normal operating state of all readouts so that you can quickly see when any of the
unit subsystems is in an abnormal state, and if necessary adjust or stop the unit.
When actually spooling wireline inhole or outhole, you must continue monitoring these subsystems
while at the same time operating the drum control and spooling control, visually monitoring the
depth and tension display and observing the winch (via the built in camera) for possible problems.
See the SmartMonitor User Manuals for more information.
9.6 Shutdown
Proceed as follows to shut down the UniTruck in the normal way, following operations.
1. At the control panel and SmartMonitor touch screens, set the following controls:
 BRAKE = ON
 DRUM CONTROL joystick = in neutral position
 WINCH LIGHTS = OFF
2. In the cabin:
a) Turn off the SmartMonitor on touch screen.
b) On the Cabin control panel set: POWER INPUT SELECTOR tot OFF
c) On the Cabin AC electrical panel switch off: GENERATOR 50 AMPS
d) On the Cabin DC electrical panel switch off: PANEL INSTRUMENT
e) On the Cabin DC electrical panel switch off: CABIN LIGHTS
f) On the Cabin DC electrical panel switch off: MAIN 100 AMPS
3. At battery enclosure box and AC inlet:
a) Turn the battery switch to OFF
b) Disconnect plugs if necessary.
4. Note the shutdown date and time in the running hours log
5. Perform the daily clean-up tasks
9.7 Perform daily cleanup tasks

Carry out the following clean-up tasks every day when shutting down the UniTruck, 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, never point the jet at any joints,
panel seams, door or hatch openings, grills, electrical boxes and connections, insulation
foam and panels, or anywhere you cannot clearly see.
Never use any kind of hose or water jet inside the cabin or 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.
2. If necessary, using water and cleaning agent, clean the exterior of the unit. Use degreaser if
grease remnants are present.
3. Continue into the winch bay, removing all dirt, salt, oil, grease, etc. from the surfaces in the
winch bay.
4. Rinse off the exterior and winch bay with fresh water.
5. In the winch bay, dry off any exposed metal surfaces using a rag, and apply a thin layer of
grease to prevent corrosion.
6. Clean cabin interior with soft cloth and appropriate spray cleaner. Wipe down the windows,
control panel (plus gauges, switches and joysticks), electrical panel and cabinets. Use
commercially available screen wipes on the control panel display screens (SmartMonitor, etc.)
7. Mop the floor clean, allow it to dry.
8. Check in-cabin consumables and replenish if necessary.
9.8 Accessories
9.8.1 Air conditioning
Operate the individual air conditioning units to suit your environment conditions. See the separate
supplier manuals for your specific unit(s).
10.0 TROUBLESHOOTING
10.1 Troubleshooting principles
However, it is not a substitute for a thorough knowledge of the UniTruck unit and its related
systems.
If you strike a problem that is not covered, or is not corrected by the suggested remedy, please
contact NOV ASEP Elmar for qualified technical guidance on how to proceed further. Support
contact information is provided near the Appendix of this manual.
The troubleshooting guide is divided into sections according to components or group that may 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 once more.
Always review the complete list of possible causes for each problem, before selecting which
remedy to apply. More detail on the remedies is frequently available in the maintenance section of
this manual.
Most of the problems you may encounter in this equipment will arise in the hydraulic and electrical
systems. We have therefore attempted to anticipate every likely malfunction in these systems, and
provide diagnostic and remedial information for these. For all other parts of the UniTruck, this
troubleshooting guide is restricted to those problems that may be symptoms of more serious
problems or which have more than one possible cause and remedy. In other words, problems with
an obvious cause and remedy are not included in this guide.
However, if you should encounter a problem that you feel should be included in this troubleshooting
guide, please notify NOV ASEP Elmar of this problem, the possible causes you considered, and
the remedy/remedies you applied. We will be very grateful for your feedback. Contact details for
NOV ASEP Elmar Service after Sales are provided in the Appendix of this manual.
10.2 Troubleshooting table

The troubleshooting table for the UniTruck is provided on the following pages.
For troubleshooting of the NOV ASEP Elmar MP16 measuring head, please refer to the separately
supplied user manual for this product.
PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY

Truck engine stops when PTO Failure to follow correct starting Switch all electrical panel
engaged sequence switches off as well as DC
isolator and start again, following
correct sequence.
Defective switches Follow correct starting sequence,

and carefully check status at
each step, in order to isolate the
defect.
No electrical power Main circuit breaker tripped Switch all appliances and circuits
off. Reset circuit breaker
Loose AC generator/shore Unplug/re-plug connection firmly
connection
Check functioning of isolator, and
Faulty DC isolator replace if necessary
Generator [hydraulically driven AC Generator System: 30kW, see manufacturer's documentation].
Generator will not start Incorrect shutdown of UniTruck: Follow emergency recovery
truck engine stopped with PTO procedure
engaged and/or with generator
switched on
Check that the electrical panel
has DC.
No 12VDC supply from truck Check the DC isolator switch
Check the control box connector
and ensure it is tightly fitted.
Open circuit Check the generator pulse

pickup and the AC feed on the
Speed Controller and the 7.5A
fuse to the speed controller.
Check all connections on pump
solenoids.
Generator damaged Refer to manufacturer's

documentation
Generator voltage and/or Hydraulic problem Switch control solenoids on the
frequency oscillates pump. If this remedy corrects the
trouble, the problem is
contamination to the pump and
will persist until the
contamination issue is
addressed.
Check hydraulic fluid
temperature to ensure it is
neither too low nor too high.
Test to see if the problems
persist once a steady load on the
generator is achieved.

Generator running, but has no Check all circuit breakers in the
voltage output. generator compartment.
Closed/open circuit Check the power connector.
Check the generator exciter field
circuit.
Speed too low Check the generator speed

(1220
RPM).
(Requires a hand-held
tachometer)
Diagnose hydraulic system.
Generator running, frequency OK Incorrect generator settings Consult the manufacturer's
but excessive voltage. documentation for recommended
settings, and adjust as necessary
HYDRAULICS
Hydraulic pump(s) noisy. Air bubbles in oil Check hydraulic oil level.
Replenish oil as necessary.
Contaminated oil filters. Clean and/or replace oil filter(s)

as necessary.]
Zero hydraulic control pressure Hydraulic system oil level low. Replenish oil as necessary.]
Broken coupling between motor Inspect through hole in coupling

and pump group body.
Repair/replace coupling.
Major leak in main or control Repair as required

pressure lines (hose/coupling)
Restricted or broken suction line. Remove line and clear

obstruction or replace as
necessary.
Worn or broken pump drive shaft Repair as required

coupling or drive plate.
Drum does not turn when DRUM Hydraulic pressure lines to winch Check lines, connect or replace
CONTROL joystick is operated. motor restricted or open hose(s)
Pump not generating pressure to Check setting relief valve (back

hydraulic motor of hydraulic motor)
Hydraulic control pressure is zero See problem description above
Main relief valves (hydraulic Screw in or remove/replace

motor) not screwed in or cartridge
cartridge leaking

Drum does not turn when DRUM Worn packing ring or HD seal. Replace seals.
CONTROL joystick is operated.
Fluid escaping via straining panel Worn packing ring or HD seal. Replace seals.
in the lower cap.
WINCH TRANSMISSION
Oil Leaks Worn seals Replace seals
Leakage at plugs Replace / re-tighten plugs
Excessive noise from final Low gearbox oil level Fill final reduction gearbox with
reduction gearbox oil
Drum does not move when
DRUM CONTROL lever is Brake applied Disengage drum brake
operated
Hydraulic problem See HYDRAULICS
Pneumatic pressure loss Check truck's air compressor and

(indicated by pressure gauge on air receivers.
control panel) Repair if defective.
Check all pneumatic lines in body

and control panel.
Inspect/repair controller section.

Defective controller or open
controller power circuit Check/replace in-line 7.5A fuse.
Drum continues turning with
DRUM CONTROL lever in Excessive temperature caused Change oil using recommended
neutral by contaminated oil viscosity and flush system.
Valve spool sticking due to Remove valve and repair or

scored spool. replace as necessary.
Valve spool sticking due to weak Remove valve and repair or

or broken return spring replace as necessary.
Valve spool sticking due to Check pressure across relief

excess pressure caused by valve and repair or replace as
defective relief valve. necessary.
11.0 MAINTENANCE
11.1 Introduction
Only qualified and trained personnel should perform maintenance on NOV ASEP Elmar well
servicing units.
Maintenance can be described as, but not limited to:
 Checking and testing components
 Installing and removing parts from the unit
 Filling up the fluid levels on the unit
 Lubricating moving parts
 Troubleshooting any malfunctions that may occur on the unit before, during and after
operations
 Calibrating and adjusting settings on the unit's hydraulic, pneumatic, mechanical, electrical
and diesel systems
11.2 Regular, scheduled maintenance is essential

Certain scheduled maintenance is required on a regular basis. Inspections and tests should be
carried out daily before working with the UniTruck unit, but regular maintenance should be
performed according to the number of running hours the UniTruck has been used.
Running hours should be logged by the UniTruck operator following a strict discipline. Failure to
accurately log the running hours can mean that certain maintenance and service activities are not
carried out in a timely manner, and can lead to damage to the equipment, and potentially even
hazardous situations.
The UniTruck carries a powerful winch that exerts extreme forces on its own mountings, on the
frame, the mounting points, and (as applicable) track & pivot base or truck body and chassis.
Furthermore, powerful shocks to the entire unit are possible, when sudden resistance is
encountered during winching operation, or when jarring the wireline for an effect in the hole. It is
therefore essential to service and maintain the UniTruck at intervals at least as frequent as
suggested by NOV ASEP Elmar in the maintenance schedules below. NOV ASEP Elmar
recommends basing the service intervals on hours of running. You may prefer to use calendar time
(weeks, months) to dictate the service interval. That is for each customer to decide, but the
maximum service intervals recommended here must always be observed. An example running
hours log form is provided in the Appendices to this manual for your convenience.
11.3 OEM components

Certain components of your NOV ASEP Elmar UniTruck are complete assemblies or subsystems
supplied by other manufacturers than NOV ASEP Elmar (Original Equipment Manufacturers).
Examples are vehicles, power pack engines, air conditioning units, motor-generator sets. Routine
servicing of these components will not be included in this User Manual. However, the complete
operation and service documentation for these components and assemblies is supplied separately
to this manual, in the full Documentation Package for your unit. Ensure that you know where to find
this supplementary documentation, and make yourself familiar with its contents.
11.4 UniTruck periodic maintenance schedule

The table on the following pages gives a summary of the procedures to be carried out at each
standard maintenance interval, expressed in duty hours of the UniTruck. There are also specific
procedures to be performed whenever the unit has been transported to a new worksite, or at the
end of the running-in period of the unit (from new) or component (following replacement or
reconditioning).
NOTE: Certain procedures should be carried out more frequently when the unit is operated in
unusually harsh working conditions or extreme climates.
NOTE: The running in period for this UniTruck unit is 100 hours. Ensure that you carry out the
procedures marked as “after running in” once the unit has completed 100 hours of duty.
NOTE: The schedule “After each transport” does not refer to routine movements between
worksites. This schedule refers solely to major long-distance transportation by air or surface
transport, e.g. relocation, international shipping, delivery to a regional service point, etc.
Service intervals
After each transport

Maintenance procedure
as required
1000 hrs.
1500 hrs.
2000 hrs.
100 hrs.
250 hrs.
500 hrs.
daily
General
Prepare unit for safe maintenance         
Finalize maintenance tasks         
Check/restore fuses and circuit breakers         
Hydraulic System         
Check hydraulic coolant fan in operation         
Check/fill hydraulic fluid         
Check hydraulic hoses for general condition         
Check change indicators on high pressure filters         
Check all connections for fluid leaks         
Inspect welds in hydraulic oil tank for fatigue cracking         
Check each fitting for corrosion         
First filter change, two charge pressure filters and two         
high-pressure loop circuit filters
Second filter change, two charge pressure filters and         
two high-pressure loop circuit filters
Third filter change, two charge pressure filters and two         
high-pressure loop circuit filters
Hydraulic oil change. Fourth filter change. Replace         
hydraulic oil suction filters
Logging cabin         
Inspect DataTruck Light cabin         
Inspect DataTruck Light body         
Service air-conditioning unit         
Truck         
Service truck compressor         
Service intervals

as required
1000 hrs.
1500 hrs.
2000 hrs.
100 hrs.
250 hrs.
500 hrs.
daily
Winch bay
Check/fill wireline lubrication tank         
Inspect all pneumatic lines on the truck for general         
condition
Inspect all connections between pneumatic lines and         
devices ,coating with soapy water, observe for bubbles
indicating air leaks
Inspect all pneumatic devices for general condition and         
security of installation
Replace or repair any bad lines, fittings or components         
Inspect drum brake band         
Test drum brake band         
Check drum alignment         
Lubricate pillow block with grease gun until excess         
appears. Wipe off excess
Check/fill reduction gearbox oil         
Adjust drum brake band         
Check/adjust drum chain         
Test drum mounting         
Check drum and frame for corrosion         
Drain wireline oil tank (pressurized)         
Replace drum brake band         
Replace motor/gearbox assembly         
Remove/replace slipring         
Replace drum         
11.5 Measuring head maintenance schedules

NOTE: Refer to the BenchMark User Manual for the maintenance procedures listed in the
following table:
Service intervals

as required
1000 hrs.
1500 hrs.
2000 hrs.
100 hrs.
250 hrs.
500 hrs.
daily
Measuring head
Lubricate measuring head 
Inspect MP16 frame 
Please refer to the MP16 user manual

Service spooling arm sleeve bearing 
Remove/inspect/install tension load pin and pulley  
Remove/inspect/install guide pulleys & bearings  
Check depth measurement wheel diameter  
Safe maintenance shutdown 
Check/adjust lateral deflection sensors 
Remove/install depth encoder 
Remove/install depth measurement arm 
Remove/install magnetic mark sensor 
Remove/installMP16 in winch 
Check/calibrate tension measurement system 
11.6 250 Hour Maintenance

The following procedures are to be performed every 250 hours of logging unit operation, and
primarily address the truck chassis and engine requirements. Refer to the operations and
maintenance manuals provided by the chassis and engine manufacturers for additional information.
Engine Maintenance
 Change oil and filters
 Drain and clean fuel tank
 Replace all fuel filters
 Drain and replace coolant in radiator
 Inspect the alternator, fan and accessory drive belts. Replace if necessary.
 Inspect all hoses for cracking, softness and loose clamps. Replace hoses that are cracked
or soft and tighten clamps.
 Check the air induction system for leaks, damage and restrictions
 Check battery, fluid level in cells and electrolyte concentration

Truck and chassis
 Check transmission oil. Fill with recommended lubricant if required.
 Check front and rear axles for oil and fill if low. Fill with recommended lubricant if required.
 Check air brake system
 Inspect tires and replace if worn
 Check all gauges for proper operation

 Check rear air suspension for proper ride
11.7 Prepare unit for safe maintenance

Related topic:
 9.6 Shutdown on page 79
Before carrying out any maintenance on or around the hazardous parts of the UniTruck, it is
essential to ensure that the unit is fully shut down, the winch drum brake is applied (and not under
tension), and that there is no residual energy in the hydraulic or pneumatic system.
Proceed as follows to shut down the UniTruck for safe maintenance.
1. Complete the wireline service operation, and spool all wire onto the drum.
NOTE: If it is necessary to perform maintenance with the wire inhole, then you must apply the
brake and clamp the wire to a rigid structure, such that the wire is relieved of all tension, and no
incident in the hole or BOP can cause the wire to come under tension.
2. Perform a regular shutdown. See related topic.
NOTE: Before turning off the external DC isolator, check that all hydraulic and pneumatic pressure
gauges in the UNIT DISPLAY on the winch control panel are reading zero pressure.
3. Put the truck ignition key in a safe place (e.g. your pocket) so that nobody can start the truck
engine.
4. Once you have completed the shutdown, verify on all gauges on the hydraulic and pneumatic
system, that the pressure is zero.
5. Release any residual air from the pneumatic system air receivers, e.g. by using an air tool.
6. If you intend to work on any hydraulic component, allow the system time to cool down, and do
not open any hydraulic connection unless you are certain that the hydraulic oil is cool.
7. If you intend to work on any electrical component, make absolutely certain that the external DC
isolator is OFF with the key removed from the isolator, and that there is no site AC connected
to the UniTruck.
11.8 Inspect electrical system

To ensure reliable and safe operation of the UniTruck, the electrical system should be thoroughly
inspected at regular intervals. Inspect as follows, noting items for repair or adjustment.
1. Inspect the grounding cable reel, cable and terminals at both ends for good, clean connection.
2. Inspect all exposed cables for:
a) Condition of insulation (damage, cracking, corrosive fluids, moisture penetration);
b) Condition of entry glands at cabinets, terminal boxes, controls;
c) Condition of labels on cables;
d) Exposure to moving parts that may cause damage to the cable.
3. Inspect all control panels, cabinets and junction boxes for condition of labels, tags and signage.
Replace all damaged labels, tags and signs.
4. Check the mountings of all cabinets, armatures and control devices, and tighten where
necessary.
5. During the 1200-hour service, check continuity/insulation resistance of cables.
11.8.1 Check/restore fuses and circuit breakers

Your NOV ASEP Elmar equipment may have up to 4 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:
 12-24VDC: blade type fuses (typical automotive fuse)
 110-240 VAC: cartridge fuses (glass) and circuit breakers
 380V 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. The description on the diagram states the trip level in Amps.
1. Before restoring a blown fuse or tripped circuit breaker:
2. First identify and rectify the situation that caused the circuit to overload.
3. Then shut down the electrical system.
4. Replace/restore the fuse/circuit breaker (see following paragraphs).
5. Re-start the electrical system.
6. Re-start the component or circuit that failed. Verify that the component or circuit is working
correctly.
7. Replenish the stock of spare fuses, and also make sure that there is a new spare fuse stowed
in cartridge type fuse holders (see below).
NOTE: Not every type of fuse and circuit breaker described below may be present in your
equipment.
1. Identify and fix the situation that caused the circuit to overload.
2. Prepare the unit for safe maintenance (especially the electrical system), as described in
11.7 Prepare unit for safe maintenance on page 92.
3. Replace/restore the fuse/circuit breaker using the appropriate subsection of this procedure:
 11.8.1 Check/replace blade type fuses
 11.8.2 Check/replace cartridge fuses - swing-out holder
 11.8.3 Check/replace cartridge fuses—pull-out holder
 11.8.4 Check/reset circuit breakers
4. Restart the electrical system.
5. Restart the component or circuit that failed. Verify that the component or circuit is working
correctly.
6. Replenish the stock of spare fuses.
11.8.2 Check/replace fuses and circuit breakers
Figure 11.1 Blade fuses and block
Blade type fuses are the same type as used in the automotive industry. The fuses are color coded
to indicate the rating. To replace a blade type fuse:
WARNING
ELECTRIC SHOCK
Working on high voltage components while they are still energized can cause serious injury or death. Before
removing protective covers, make sure all electrical power has been isolated, and wait a minimum of 15 minutes for
any residual electricity to dissipate.
1. Pull the fuse from the fuse block and discard it.
2. Insert a spare fuse of the same color / rating. See Figure 11.2.
Rating (amps) Color ASEP Elmar part no.

3 purple A0015291
5 light brown A0015284
7.5 dark brown A0015285
10 red A0015286
15 blue A0015287
20 yellow A0015288
30 green A0017156
Figure 11.2 Blade type fuse specifications
11.8.3 Check/replace cartridge fuses - swing-out holder
Spare fuse
Live fuse
Figure 11.3 Swing-out cartridge fuse holder
Cartridge (glass) fuses are clamped between contacts in a swing-out holder. See Figure 11.2. The
swing-out holder also contains a spare fuse. NOV ASEP Elmar equipment uses standard 5 mm x
20 mm cartridge fuses with the ratings specified in Figure11.2.
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 also ejects the blown fuse from the contacts.
3. Remove the blown fuse and replace it with a new fuse (see Figure 11.2).
4. If there are no other spares, use the spare inside the holder, but replace the spare at the first
opportunity.
5. Carefully close the cover - this will press the new fuse between the contacts.
6. Swing the holder back into position.
Spare fuse
Live fuse
Figure 11.4 Pull-out cartridge fuse holder
11.8.4 Check/reset circuit breakers
Circuit is OFF (dead)
Figure 11.5 Automatic circuit breaker
Automatic circuit breakers are the easiest to control / reset. When OFF shows, the circuit has been
overloaded or short-circuited. To reset an automatic circuit breaker, switch it to the ON position.
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.
11.9 Inspect UniTruck body

The UniTruck body exterior should be regularly inspected, point by point, noting all items that are
damaged and need either repair or replacement.
 Be particularly alert to early signs of potentially serious structural damage.
 Wipe items carefully with a clean cloth as you make your inspection.
 Immediately replace any defective lamps, etc.
 Lightly oil any moving parts (hinges, locks)
1. Inspect body for fatigue cracks.
2. Inspect the mounting points of the truck frame to the aluminum truck bed:
 Look for deformations, cracked welds and other possible damage
 Check the condition of the mount springs.
 Check the tightness of the mounting bolts.
3. Inspect the mounting of the UniTruck polyester body to the aluminum truck bed. Especially
look for cracks or small ruptures that may indicate more serious structural damage.
4. Inspect paint and logos. Touch up with paint or repair as required.
5. Inspect doors, cabinet doors, and windows (including winch bay window):
 Inspect doors, handle, seals and swing arm for fatigue cracking. Open and close
every door.
 Inspect that all door and window hardware is securely fastened. Check hardware for
corrosion.
 Make sure all locks work correctly.
 Lubricate door and window latches and hinges.
 Check all rubber seals for tears and missing pieces. Replace as required.
6. Inspect the sliding hatch of the winch bay.
7. Inspect fold-out stairs.
8. Check all exterior lighting, making sure glass is not cracked, mountings are secure, wiring
is undamaged. Turn every light on and off.
11.10 Inspect hydraulic hoses & couplings

Related topics:
 9.3.4 Startup to operations mode on page 74

The complete hydraulic system should be subjected to a thorough inspection:
 every day before duty (described in the operations section);
 on a regular basis (see maintenance schedule).
Inspect the system as described below, noting which components need to be repaired, replaced or
tightened.
NOTE: Make a list of all required repairs, and perform these once the inspection is complete, the
system has been pressure-tested, and the unit has then been fully shut down and
depressurized.ruck compressor
WARNING
RISK OF BURNS
If the unit has been running, the hydraulic oil and components can be at an extremely
high temperature. Never attempt to dismantle hydraulic connections or replace
hydraulic filters until the hydraulic oil has cooled to a safe temperature of 50 degrees
Celsius or less. Check the hydraulic oil temperature gauge (usually the reservoir
temperature), then carefully check the temperature of the applicable component by
touch before you start maintenance.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as
grit and metal fragments, which can be accidentally introduced during servicing
activity.
Apply maximum standards of cleanliness when servicing hydraulic components.
Before reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using
a clean cloth.
1. Shut the unit down for safe maintenance.

2. Inspect the general condition of all hydraulic lines and hoses. Look for visible damage,
leakage, and ―sweating‖ or ―swelling‖ of hoses.
3. Inspect the entire unit for signs of leakage, e.g. oil drips, oily dust build-up, etc., around:
• tanks
• hoses and lines
• couplings/connectors
• control levers
• valves
• filters
• pumps
• motors
4. Start the unit. See related topic.
5. Pressure-test the hydraulic system. See related topic.
6. If repairs are necessary, shut down the system for safe maintenance and carry out the repairs.
11.11 Check/fill hydraulic oil

Related topics:
 5.2.2 Hydraulic servicing compartment on page 19
WARNING
RISK OF BURNS
high temperature. Never attempt to dismantle hydraulic connections or replace hydraulic
filters until the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or
less. Check the hydraulic oil temperature gauge (usually the reservoir temperature), then
carefully check the temperature of the applicable component by touch before you start
maintenance.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit
and metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean
cloth.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environment
friendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.

2. Locate the hydraulic oil tank and filler point.
3. If the unit is equipped with hydraulic accumulators, depressurize the accumulators.
NOTE: The correct oil level in any hydraulic system is always measured with no pressure in the
system, and no oil stored in any hydraulic accumulators. Failure to depressurize the accumulators
can cause the system to be inadvertently overfilled. Always depressurize the accumulators.
4. Inspect the oil level in the sight glasses of the hydraulic oil tank.
The correct oil level is mid-point in the upper sight glass of the hydraulic oil tank.
Correct hydraulic oil level: mid-point of

upper sight glass
Figure 11.6 Hydraulic upper sight glass
5. If the oil level is below the correct level:

a) Ensure you have a supply of hydraulic oil of the correct grade.
b) Remove the hydraulic oil tank filler cap.
c) Carefully remove accumulated dust and grit from around the filler using a clean cloth.
d) Add hydraulic oil of the correct grade until the level is at the mid-point of the upper sight
glass.
e) Carefully wipe the filler cap clean using a clean cloth, and fit it back on the filler.
11.12 Replace hydraulic oil

Related topics:
 11.11 Check/fill hydraulic oil on page 100
 11.13 Replace hydraulic suction filters* on page 103
WARNING
RISK OF BURNS
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as
grit and metal fragments, which can be accidentally introduced during servicing activity.
cloth.
CAUTION
Fuels, oils, grease and similar petroleum products are harmful to the environment.
Dispose of used or excess oil, oily rags, used filters and other waste items in a
responsible, environment friendly manner. Separate recyclable products from other,
non-recyclable waste. Heed site regulations and obey local environmental by-laws.
NOTE: Always replace the suction and return filters whenever you replace the hydraulic oil.
Figure 11.7 Hydraulic oil tank drain valve (two different types)
1. Shut the unit down for safe maintenance. See related topic.
NOTE: The correct oil level in any hydraulic system is always measured with no pressure in the
system, and no oil stored in any hydraulic accumulators. Failure to depressurize the
accumulators can cause the system to be inadvertently overfilled.
Always depressurize the accumulators.
3. Ensure you have a supply of hydraulic oil of the correct grade. See related topic.
4. Open covers to gain access to the underside of the hydraulic oil tank and drain valve.
5. Unscrew the cap from the drain valve built into the bottom of the hydraulic oil tank.
6. Attach an open ended hose to the drain valve.
7. Lead the hose into a suitable waste oil collection tank of the same capacity as the hydraulic oil
tank
8. Open the drain valve and drain all oil from the hydraulic oil tank into the waste oil collection
tank.
9. If excessive contamination is suspected, flush the hydraulic oil tank once with clean hydraulic
oil of the correct grade.
10. Close the drain valve, remove the hose, and re-fit the cap.
11. Replace all suction and return filters in the hydraulic system. See related topic.
12. Fill the tank with oil of the correct grade.
13. Dispose of all filters and used oil as prescribed by site regulations.
11.13 Replace hydraulic suction filters*

Related topics:
 11.7 Prepare Unit for Safe maintenance shutdown on page 92
The hydraulic suction or return filter should be replaced at the first opportunity after:
 Suction filter: the contamination indicator on the filter head goes into the yellow zone, or
 Return filter: the pressure gauge on the filter head reads 0.5 bar.
Note that on dual-filter filter heads there is a single contamination indicator.
WARNING
RISK OF BURNS
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit
and metal fragments, which can be accidentally introduced during servicing activity.
cloth.
CAUTION
Fuels, oils, grease and similar petroleum products are harmful to the environment.
Dispose of used or excess oil, oily rags, used filters and other waste items in a
responsible, environment friendly manner. Separate recyclable products from other,
non-recyclable waste. Heed site regulations and obey local environmental by-laws.

2. Shut the valve on the hydraulic tank side of the filter head.
The valve is usually - but not always - adjacent to the filter head. The valve is shut when the lever
is at right angles to the flow direction.
3. Place a waste oil container below the filter assembly to catch the oil that may flow from the
filter head.
 On horizontally-mounted filters, the filter will completely drain out when loosened.
4. Turn the filter anticlockwise to unscrew it from the filter head.
5. Drain all the oil from the filter into a waste oil container, and discard the filter.
6. Using a clean cloth, thoroughly clean the filter head and the seal flange.
7. Take a new filter of the specified type (see spare parts list for this unit), and half fill it with
hydraulic oil of the correct grade.
8. Apply a thin film of hydraulic oil to the new seal supplied with the filter.
9. Place the seal on the filter, and 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. If the filter head is a dual-type, then repeat steps 4 through 9 for the second filter.
11. Open the valve in the intake side of the filter head.
12. Repeat the above steps for any other suction or return filters that are due for replacement.
14. When all filters have been replaced and all other hydraulic maintenance has been carried out:
a) Check that all filter intake valves are open (levers aligned with flow direction).
b) Start the unit.
c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that the pressure
stabilizes at the pressure gauges of the unit control panel.
d) With the unit running, check each filter head: The contamination indicator should be in the
green zone (suction filter) or read 0 bar (return filter).
e) • There should be no leakage from the filter seals.
f) If there are leaks, shut the unit down as described in step 1, and 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.
g) e) Inspect the seals again for leakage after operating for several hours, taking remedial action
if necessary.
h) 15. Check and if necessary fill the hydraulic oil in the tank.
Typical single-filter head is shown. Filter is mounted

vertically, and oil will flow out when it is loosened.
Typical dual-filter head, with intake valve open. The

contamination indicator is mounted on the outlet side
(obscured). The filters are mounted vertically, and there
should be only minimal spillage when the filters are loosened.
Typical disposable filter canister is shown. The

rubber seal is correctly located in its seating on
the filter.
Underside of filter head showing threaded nipple onto which
the filter is screwed hand-tight. This flange must be carefully
cleaned before the filter is fitted!
Figure 11.8 Hydraulic filters
11.14 Bleed air from a hydraulic component

Air will enter the hydraulic system whenever connections are opened. Dynamic hydraulic
components like pumps and motors form part of a hydraulic circulation, and included air is pumped
with the oil to the hydraulic oil tank, where it rises to the surface. However, static hydraulic
components (pressure-actuated) like cylinders and brake actuators cannot release their included
air, and must be manually bled. There will normally be a bleed nipple mounted on the top of the
component for this purpose.
Air bleeding is normally one of the last steps in a maintenance activity, and requires that the
hydraulic system is pressurized. It therefore usually requires start-up of the mechanical system.
To bleed any point:
1. Ensure that the hydraulic system is at pressure, but that the mechanical systems are safe for
you to work on the component.
NOTE: If you are bleeding a component (e.g. a cylinder) that raises another object, first raise the
object and fasten it at that position so that it cannot fall suddenly if the bleed nipple is over-loosened
causing a loss of pressure!
2. Locate the bleed nipple.
3. Attach a clear plastic hose of a small diameter that fits snugly over the bleed nipple.
4. Feed the free end of the hose into a clear container.
5. Using an appropriately sized wrench, slightly loosen the bleed nipple until oil and/or air starts to
flow into the hose.
6. When the air bubbles stop appearing, firmly tighten the nipple again, and remove the hose and
container.
11.15 Drain condensation water from hydraulic oil tank*

Related topics:
 11.7 Prepare Unit for Safe maintenance shutdown on page 92
WARNING
RISK OF BURNS
If the unit has been running, the hydraulic oil and components can be at an extremely high
temperature. Never attempt to dismantle hydraulic connections or replace hydraulic filters until
the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or less. Check the
hydraulic oil temperature gauge (usually the reservoir temperature), then carefully check the
temperature of the applicable component by touch before you start maintenance.
CAUTION
1. Water can accumulate in the hydraulic oil tank. Being heavier than the hydraulic oil, it settles to
the bottom of the tank when the system is not running. To drain off the accumulated water:
4. Open covers to gain access to the underside of the hydraulic oil tank and drain valve.
5. Unscrew the cap from the drain valve built into the bottom of the hydraulic oil tank. Attach an
open ended hose to the drain valve.
6. Lead the hose into a suitable collection tank, but make sure you can see the fluid that flows
from the hose.
7. Slowly open the drain valve, and allow the water to run out.
8. When pure oil starts to flow, close the valve.
9. Remove the hose, and replace the cap.
10. Check and if necessary fill the hydraulic oil in the tank.
11.16 Service truck compressor

Please refer to the documentation supplied by the truck chassis manufacturer.
11.17 Inspect pneumatic system

To ensure reliable and safe operation of the UniTruck, the pneumatic system should be checked
once daily (see daily start procedure), and thoroughly inspected at regular intervals as described
below. Inspect the system as follows, noting components that need to be repaired, replaced or
tightened. Make a list of all required repairs, and perform these once the inspection is complete,
and the UniTruck is fully shut down and depressurized.
WARNING
HIGH PRESSURE
Disconnecting a pressurized line can cause serious injury and/or equipment damage. Make
sure all pressure has been released from the pneumatic system before attempting any repairs.
Disconnect or shut off all compressed air sources and open all external valves to release
pressure, and then check at every pneumatic pressure gauge that there is no residual pressure.
Remember also to release the pressure from any attached accumulator vessels.
1. Pressurize the system to normal operating pressure by connecting site compressed air or
starting the compressor (if applicable).
2. Inspect the general condition of all pneumatic lines and hoses. Look and listen for signs of
damage, leakage, and wear of hoses.
3. Referring to the specifications and/or pneumatic diagram for the unit, make certain to check
every pneumatic component and its couplings and hoses.
 Typical components are: auxiliary compressor, drum brake, levelwind arms actuators,
wellhead pressure control panel and tools, pneumatic filter/ lubricator, anti-frost system,
air starter, pneumatic control levers and valves, etc.
4. Inspect all fittings for corrosion. Check for tightness, and tighten if necessary.
5. Apply soapy water to each coupling or suspected leak, to see if bubbles are formed.
6. If repairs are indicated:
a) Shut down the UniTruck and depressurize the pneumatic system.
b) Verify at the gauges that there is no residual air pressure in the system.
c) Replace/repair components as necessary.
d) Pressurize the system again, and check for leak at all points where the system has been
opened.
11.18 Inspect winch

Related topics:
 6.3 Winch module on page 37
 11.19 Service final reduction gearbox on page 112
 11.22 Inspect drum brake bands on page 118
 11.25 Test drum brake on page 126
The winch frame, its mountings and components are subjected to considerable forces during daily
operation. The daily start-up inspection (see separate procedure) is intended to identify any problems
before they become serious. The entire winch section should also be thoroughly inspected point by
point on a regular basis.
Carefully check off every item in Table 11.1 Winch inspection checklist and do not operate the winch
until you are certain that every item is in order.
Item Check
Unit is shut down for safe maintenance (see related topic)

Check entire winch frame for signs of bending, cracks, corrosion or other damage to:
• structure
• welds
• lugs and mounting points
• pivot points
• if applicable, spooling arm transport clamps
Check and if necessary tighten all bolted mounts on winch and winch transmission:
• winch frame to unit or truck chassis
• drum bearing pillow blocks to frame
• hydraulic motor
• gearbox
• safety covers
• slip ring to flange on drum shaft
Check and if necessary tighten all bolted mounts on levelwind system:
• measuring head mounting
Check all pivot points for free (but not excessive) movement, and lubricate if necessary:
• levelwind assembly
• if applicable, levelwind elevation cylinders
• if applicable, levelwind damping cylinders
• if applicable, brake linkages
Inject grease into both winch drum bearings, and wipe off excess grease with a rag.
On chain-driven winches:
• check chain tension
• check condition of sprockets and chain
• if necessary, lubricate the chain.
Check the final reduction gearbox oil level (see related topic)
Inspect winch drum brake band(s) or pads for wear (see related topic)
Test winch drum brake operation (see related topic)
Check (optional) wireline oiler or wire spray operation (see related topic)
Test levelwind arms operation (see related topic)
Table 11.1 Winch inspection checklist
11.19 Service final reduction gearbox

Related topics:
• 9.6 Shutdown on page 79
• Appendix 1: Lubricants on page 136
CAUTION
The final reduction gearbox requires periodic servicing. The oil level should be checked every day,
and whenever possible oil leaks are indicated by oil drips below the gearbox.
An oil change is required the first time after running-in the gearbox, thereafter on a regular
(periodic) basis. Refer to the maintenance schedule for the recommended running hour interval
between changes.
For recommended oil quantity and type, refer to the hydraulic diagram in the documentation
package, and the table of gearbox lubricants in the appendix.
NOTE: Although a sight glass is installed, the gearbox is rotated. The sight glass will not show a
proper fill level. This unit requires 2.2 US pints. If the sight shows oil, the unit is overfilled.
fill access port
Figure 11.9 Winch transmission - final reduction gearbox access

1. Shutdown the UniTruck for safe maintenance.
2. The winch installed on this unit does not have a sight glass mounted at 90 degrees. The fill
port is mounted approximately as shown. The gear box takes 2.2 US pints of oil.
3. If necessary, top up the gearbox oil as follows.

a) Remove fill plug
b) Using a funnel and plastic tube, add oil through the top hole until oil starts to flow from
port.
c) Replace the fill plug.
11.19.1 Replace gearbox oil

At regular service intervals (see maintenance schedule), replace the gearbox oil as follows.
NOTE: In the next steps, be sure to thoroughly clean the fill plug and drain plug and their ports in
the gearbox.
1. Shutdown the UniTruck for safe maintenance. See related topic.
2. Place a container below the gearbox to collect the dirty oil.
3. Remove the drain plug from the underside and allow the oil to fully drain out.
4. Re-fit the drain plug.
5. Fill the gearbox with oil as described above.
11.20 Lubricate winch drum bearings

Related topics:
Lubricate the drum bearings of the drum as described below.
WARNING
MOVING PARTS
Moving parts (drum, chain, spooling arm, brake, etc.) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
grease nipple
Figure 11.10 Drum bearing top view
1. Shut down the unit for safe maintenance.

2. Using a grease gun, carefully inject grease into the drum bearings in the pillow blocks on the
right and left side of the winch until it starts to appear from the sides of the bearing. See Figure
11.11
drum bearing mounting

bolts
drum bearing
Figure 11.11 Drum bearing, side view

NOTE: Avoid applying excessive grease pressure. This can blow the side seals off the bearing!
3. Using a rag, remove any excess grease.
11.21 Remove/install winch drum

Related topics:
• • 9.3.4 Startup to operations mode on page 74
• 11.22 Inspect drum brake bands on page 118
• 11.23 Adjust drum brake on page 120
• 11.24 Replace drum brake bands on page 125
• Test drum mounting on page 134
alignment bolts 2 on each side (L + R)
Figure 11.12 Drum bearing pillow blocks and alignment bolts
11.21.1 Remove drum

NOTE: It is not necessary to disconnect any hydraulic hose connections when removing or installing the
drum.
half link
master link
Figure 11.13 Drive chain master link and half link configuration
1. Fully open the winch bay hatch.

2. Start the UniTruck for operations, in manual mode.
3. Retrieve all wireline through the measurehead assembly and secure it to the drum.
4. Remove measurehead from the levelwind assembly.
5. Disengage PTO or engine to disable winch movement
6. Remove the chain guard and brake guard on both sides.
7. Unscrew the bolts in the slip ring/drum shaft flange, and withdraw the slip ring from the drum
shaft. Set it down carefully in the tool storage bay.
8. Engage PTO to enable winch movement.
9. Set the brake OFF.
10. Slowly rotate the drum until either the master link or half link in the drive chain is visible.
11. Shutdown the UniTruck for safe maintenance.
WARNING
MOVING PARTS
12. Remove all brake bands as described in the section on brake band replacement.
13. Loosen the bearing alignment bolts, after first removing the locknuts. See Figure 11.12.
14. Loosen and remove the drum bearing pillow block mounting bolts from the frame.
15. Slide/move the drum assembly towards the drive sprocket to slacken the chain.
16. Disconnect the chain master link (see Figure 11.13) and remove the chain from the winch.
17. Lift out the drum using a chain hoist and lifting beam, with the drum supported at both ends by
adequately rated lifting straps.
WARNING
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.
18. If the drum is to be stored for any period, apply high quality multipurpose grease to the drum
bearings.
19. Store the drum in a suitable shipping container.
11.21.2 Install drum

1. Mount a new drive sprocket on the motor gearbox.
2. Lift the new drum using a chain hoist and lifting beam, with the drum supported at both ends by
adequately rated lifting straps.
WARNING
HOISTING HAZARD
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.
3. Carefully lower the drum so that the bearing pillow blocks settle onto the bearing supports.
4. Use the bearing alignment bolts to align the drum sprocket with the drive sprocket. Ensure
correct:
 Alignment left and right by measuring the distance between the pillow block and the
alignment lug.
 It must be identical on both sides (left and right) of the winch. See Figure 11.12.
5. Insert the drum bearing pillow block mounting bolts, fit the nuts and tighten to finger-tight.
6. Take a new drive chain and wrap it around both drive sprocket and drum sprocket. Close the
chain using the master link.
NOTE: Double-check that the master link has been correctly fitted, and that the chain connection is
secure.
7. Adjust the chain tension. See related topic.
8. Ensure all pillow block mounting bolts and adjustment bolts are firmly tightened, including nuts
and locknuts.
9. Install new brake bands.
10. Re-install the chain guard and brake guards.
11. Start the UniTruck for operations, in manual mode.
12. Using the DRUM CONTROL joystick, slowly rotate the drum in both directions, checking for
correct drum movement and operation of brake. Rectify any problems.
13. Perform the drum mount test.
14. Lubricate the drum bearings on both sides with high quality multipurpose grease.
15. Using a grease gun carefully inject grease until grease starts to appear outside the bearings.
16. Wipe off the excess grease.
NOTE: Avoid applying excessive grease pressure. This can blow the side seals off the bearing!
11.22 Inspect drum brake bands

Related topics:
 11.24 Replace drum brake bands on page 125
Replace brake bands before the rivet heads in the lining contact the drum, which can lead to costly
repairs. The rivet heads will contact the drum when there is about 3.5 mm of lining thickness
remaining. Ensure that you order replacement brake bands before this point is reached.
steel band 0.1968 inch
brake lining
rivet head 0.2755 inch

0.1337 inch
Figure 11.14 Cross section and rivet depth of new brake bands
WARNING
MOVING PARTS
Moving parts (drum, chain, spooling arm brake, etc.) can cause serious injury or
death. Make sure the winch cannot be operated during maintenance or rig-up activity.
2. If required for inspection access, remove all guards surrounding the winch drum and brake(s).
3. Measure the thickness of each brake band at the points shown in Figure 11.14.
NOTE: The total thickness of new brake bands (steel band plus lining) is 12 mm (0.4723 inch). This
gives 3.5 mm (0.1337 inch) of lining thickness before the rivet heads contact the drum.
4. If the total band thickness at any of the measuring points is less than 9 mm (0.3543 inch) (see
Figure 11.16) replace the brake band(s).
NOTE: Always replace all bands at the same time on any single drum.
5. On completion, replace all removed guards.
Figure 11.15 Brake band wear measuring points
11.23 Adjust drum brake

Related topics:
 11.24 Replace drum brake bands on page 125
 11.25 Test drum brake on page 126
It is vital for correct and safe operation that the brake band is correctly tensioned for your drum
type.
Correct adjustment is when the drum breaks free of the applied brake within the range of hydraulic
system main pressure for your drum type. There must also be no contact between the brake band
and the drum when the brake is released.
Brake tension on this brake is adjusted at only one point (see Figure 11.17):
 the brake adjuster at the connection between the brake cylinder and band;
Each adjuster has two threaded ends and a locknut on one side of the central hexagon which 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 11.17).
Adjust the brake when:
 The unit fails one of the brake tests;
 The brake bands have been replaced;
 The brake has been dismantled and reassembled for any reason.
Proceed as follows to adjust brake tension.
The table below shows recommended values for the main hydraulic system pressure required to
overcome the spring-actuated drum brake (brake slip pressure). This simulates a greater load than the
winch brake is ever expected to hold within its design limits.
NOTE: On a winch unit with a selectable speed range (e.g. with an auxiliary 2-speed gearbox), to
avoid damage to the winch and brake components when testing and/or adjusting the
brake, always:
- select the highest available speed range (lowest torque range)
- only operate the winch at very low speed
Drum type bar psi
SC05, SC06, BC06, BC22 120 ± 14 1740 ± 200
SC08, BC08, BC11/26, BC15, BC20, BC21 150 ± 14 2175 ± 200
BC07 185 ± 14 2683 ± 200
BA51, BA54 275 ± 14 3989 ± 200
Figure 11.16 Recommended brake slip pressures
For special drum configurations, please contact the NOV ASEP Elmar Service Department for the
recommended brake slip pressure.
Adjust drum brake band

Related topics:
 11.24 Replace drum brake band on page 125
It is vital for correct and safe operation that the brake band is correctly tensioned.
Correct adjustment is when the drum breaks free of the applied brake, and the winch motor is
running at about 1,740 PSI of System Pressure, and there is no contact between the brake band
and the drum when the brake is released.
WARNING
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).
NOTE: The setup can differ

slightly from one winch to
another. For example, the
brake cylinder can be
mounted vertically or
horizontally. The brake
piston may act directly, or X X
via a linkage.
adjuster at the cylinder

minimum thread depth in
adjuster female section: x
Figure 11.17 Drum brake band components
1. Refer to the winch specifications to identify the drum model currently being tested.
2. Refer to the table for recommended drum brake slip pressures in the appendix (see related
topic) for the slip pressure range for this drum.
3. Wind in all wireline cable and secure it to the drum.
WARNING
MOVING PARTS
5. Remove all guards surrounding the winch drum and brake(s).

6. If the drum has a single brake, skip to step 7.
If the drum has two brakes, then with the brake still applied, disable the brake on one side by
slackening the adjuster at the brake cylinder connection sufficiently for the brake band to be free of
the drum rim maintenance.
WARNING
DANGEROUS MACHINERY
There is risk of serious injury or death from moving parts, live electrical components
and hydraulic or pneumatic systems under high pressure.
Once the unit is started, all systems are energized and the winch can start to move
when the controls are operated. Do not start the UniTruck unless:
- You are authorized to operate the equipment, and have read this manual.
- All essential maintenance has been carried out.
- There are no unauthorized persons within the danger zone.
- The unit is properly positioned and anchored for operation.
7. Start the unit for operations.

8. Put the unit into manual mode. If applicable, disable the automatic winch control program (e.g.
SmartMonitor).
9. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
CAUTION
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.
10. On a unit with selectable speed range, select HIGH speed (never LOW or MEDIUM speed).
11. On units powered by a diesel engine or truck PTO: use the THROTTLE to set engine speed to
idle.
12. Gradually move the DRUM CONTROL lever(s)) INHOLE, increasing the MAIN PRESSURE
until the drum slips in the brake.
13. Check the MAIN PRESSURE and note the brake slip pressure.
15. Apply the BRAKE.
16. If the slip pressure in step 12 was within range, then the brake has passed the adjustment slip
test. Continue from step 18.
17. If the drum slipped below the range (too slack) or above the range (too tight), do the following:
a) Shut the unit down for safe maintenance.
b) Loosen the locknut on the adjuster beside the brake cylinder, then:
c) Brake band too tight: loosen the brake adjuster.
d) 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.
a) Tighten the locknuts at the adjuster and (if applicable) top turnbuckle.
b) Repeat the test and adjustment again from step 4 until the adjustment is correct.
c) If the correct adjustment cannot be reached or there is no adjustment left in the adjuster, it
will be necessary to replace the brake band(s) of this drum. See related topic.
18. If the drum has a single brake, skip to step 28. Otherwise, continue as follows to adjust the
second brake.
21. At the drum, using a felt pen, or by counting the number of threads exposed on the adjuster,
note carefully the position of the first 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 step 4 through step 22 above, this time for the second brake.
 The brake slip pressure of the second brake should be within 20 bar of the brake slip
pressure of the first brake.
24. When the second brake is correctly adjusted, reset the first brake as follows:
a) Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
b) Shut the unit down for safe maintenance.
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 4 with both brakes applied, and verify that the brake slip pressure is
no greater than the top of the range as described in the slip pressure table.
26. If the slip pressure is higher, slacken the brake band tension by making identical minor
adjustments on both sides, and repeat the adjustments until the brake slip pressure is within
the range.
27. Release the brake and check that there is no contact between the brake bands and drum rim.
If so, slacken the brake band tension very slightly while still remaining within the slip pressure
range.
29. Reinstall the guards surrounding the drum and brakes.
11.24 Replace drum brake bands

Related topics:
 11.23 Adjust drum brakes on page 120
WARNING
MOVING PARTS
NOTE: On a dual-brake drum, always replace both bands at the same time.

2. Apply the BRAKE.
4. For each brake on the drum, remove each of the old brake bands:
5. Observe how the existing brake is assembled, and which parts belong where.
a) Remove all guards surrounding the winch drum and brakes.
b) Completely loosen and detach the lower brake band adjuster at the brake cylinder.
c) Remove the pivot pin and detach the other end of the brake band from the brake cylinder
assembly.
d) If applicable (split band): completely loosen and detach the upper turnbuckle between the
two brake band segments.
e) Withdraw the old brake band segments from around the drum.
f) If applicable (split band): remove the retaining clips and pivot pins from the turnbuckle
attachment blocks.
g) Remove the blocks from both ends of each brake band segment.
6. Discard the used brake band.
7. For each brake on the drum, install the new brake band by proceeding through the removal
steps in reverse order.
8. If applicable (split band): leave sufficient play in the turnbuckle so that the ends of the
assembled brake band are easier to connect at the brake cylinder.
NOTE: Ensure the retaining pins are inserted through the pivot points in both turnbuckle
attachments.
9. With the brake still applied under spring pressure from the brake cylinder, tighten each brake at
the lower adjuster until it presses firmly against the drum, then tighten the locknut against the
threaded block.
NOTE: This is only an initial adjustment. The brake must now be properly adjusted.
10. Perform the brake adjustment procedure.
11.25 Test drum brake band

Related topics:
 11.27 Check/adjust drum chain on page 129
It is vital for correct and safe operation that the drum brake functions correctly. The brake should be
tested on a periodic basis and after any 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 torque reading from the winch motor. This is indicated by the motor
torque readout on the SmartMonitor. See SmartMonitor documentation.
11.25.1 Drum brake free-running test

The drum is correctly adjusted when there is no contact between the brake band and the drum with
the brake released.
WARNING
MOVING PARTS
Moving parts (such as drum, gearbox, chain, spooling arm 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.

3. Put the unit into manual mode. If applicable, disable the automatic winch control program on
the SmartMonitor.
4. Put the DRUM CONTROL joystick into the neutral (STOP) position.
5. Release the BRAKE.
6. Using the DRUM CONTROL joystick, 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
contact with the brake band(s). If applicable, check both brakes.
8. Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
9. Apply the BRAKE.
10. 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).
If brake-contact noise was heard, then the brake needs adjustment.
11.25.2 Drum brake slip test

The drum is correctly adjusted when the drum slips in the applied brake when the motor is running
at a torque of about 700 Nm.
11. If applicable, wind in all wireline cable and secure it to the drum.
13. Put the unit into manual mode. If applicable, disable the automatic winch control program
(SmartMonitor).
16. Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the power until the
drum slips in the brake.
17. Check the TORQUE gauge on the SmartMonitor and note the exact reading at which the
brake starts to slip.
20. If the torque reading when the drum slipped in step 15 was within the range of
approximately 650 to 750 Nm, then the brake has passed the slip test. If the drum slipped
below 650 Nm (too slack) or above 750 Nm (too tight), then the brake needs adjustment.
11.26 Check drum alignment

Related topics:
To ensure that the drum mountings can be depended upon even when subjected to the highest
winch forces, e.g. during jarring, perform the following test.
1. Spool the wire fully onto the drum and anchor it to the drum so that it can turn with the drum.
2. Lock the measurehead into its transport position.
3. Inspect the drum shaft pillow blocks on each side of the winch. The position on each side must be
identical, to ensure that the drum shaft is not out of alignment.
4. Adjust the alignment if necessary: see the chain adjustment procedure.
5. On each side (left, right) of the winch drum, inspect the pillow block mounting and adjustment bolts,
tightening if necessary:
6. The pillow block mounting bolts must be securely tightened.
7. The front and rear drum adjustment bolt must be screwed tightly against the pillow block and the
locknut must also be tight on each bolt.
8. Start the winch into operations mode.
9. Simulate a jarring action using the drum.
10. Disable winch movement using the controls, and apply the drum brake.
11. Repeat steps 3 through 7 two more times, checking the pillow block mounts carefully each time.
pillow block pillow block

mounting bolts mounting bolt
adjustment bolt adjustment bolt
A
B
Figure 11.18 Pillow block, driven side of drum

11.27 Check/adjust drum chain

Related topics:
 Safe maintenance shutdown
 Replace drum brake band
 Test drum mounting
1. Set the BRAKE to OFF.
2. Shut the unit down for safe maintenance. See related procedure.
3. Check the chain is firmly tightened with approximately 2 cm (0.75 in) total free play at the
middle point. See Figure 11.19.
2 cm (0.75 in)
Figure 11.19 Free play in chain
4. Check the drum is correctly aligned to the gearbox:

 the drum axis should be parallel with the gearbox axis
 the distances (a) and (b) between the bearing housing adjustment block and the bearing
housing should be approximately the same on both sides of the drum. This will ensure that
the drum is correctly aligned in the winch. See Figure 11.18
tensioner plate
pivot bolt
push plate tensioner plate

mounting bolts
push bolt
lock nut
Figure 11.20 chain tensioner assembly
5. If the chain tension is not correct, adjust it by performing steps 8 to 15.

6. Make sure the drum adjustment bolts (2x for each bearing) are fully tightened against the
bearing housing. See Figure 11.18.
7. Make sure the drum mounting bolts (2x for each bearing) are tightened.
8. Loosen lock nut on chain tensioner plate push bolt.
9. Loosen tensioner plate mounting and pivot bolts.
10. Tighten push bolt, this will lower the motor gear box assembly tightening the chain.
11. Tighten lock nut.
12. Tighten tensioner plate mounting bolts.
13. If slack is needed, reverse orientation of push plate.
14. Loosen lock nut on chain tensioner plate push bolt.
15. Loosen tensioner plate mounting and pivot bolts.
16. Tighten push bolt, this will raise the motor gear box assembly loosening the chain.
17. Tighten lock nut
18. Tighten tensioner plate mounting bolts
19. Check the condition of the chain, and lubricate if necessary.
20. Test the mounting of the drum
21. Use a rag to remove any excess oil or grease from the work area.
22. Refit any removed components.
11.28 Test drum mounting

Related topics:
 11.7 Safe maintenance shutdown on page 92
 11.26 Check drum alignment on page 128
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, making sure the correct drum and
brake are selected each time.
1. If necessary, remove the wireline from the measuring head and secure it to the drum.
2. Start up the unit.
3. Set the brake to OFF.
4. Slowly push the joystick forwards and then backwards to simulate an in-hole/out-hole
action.
5. Press the Engine Stop button to shut down power to the unit and disable all winch
movement.
WARNING
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during operation,
resulting in dangerous situations.
Always make sure all attachment bolts and locknuts are correctly tightened.
6. Check the drum alignment and mounting, and readjust if necessary.

7. Check the chain tension, and readjust if necessary.
8. Repeat steps 3 through 7 two more times, making sure to check the drum alignment and
mounting, and chain tension each time.
11.29 Replace motor/gearbox assembly

Related topics:
 11.7 Safe maintenance shutdown on page 92
 11.19 Service final reduction gearbox oil on page 112
 11.21 Replace drum on page 115
 11.28 Test drum mounting on page 131
1. Dock the levelwind arm.
3. Remove left and right drum covers.
4. Remove chain from sprocket.
WARNING
HOISTING HAZARD
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.
5. Remove and cap all hydraulic hoses and fittings.
6. Remove and cap electrical connectors where necessary
gearbox mounting bolts
motor mounting
bolts
Figure 11.23
Figure 11.21 Gearbox/ Drain
motor pan hose side view
attachments,
7. Place hoist above motor assembly.

8. Place the lifting straps beneath the motor assembly, and attach the straps to the hoist.
WARNING
HOISTING HAZARD
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.
9. Depending on space, the motor might need to be separated from the gearbox. This is
accomplished by removing the four motor mounting bolts.
10. Remove motor from winch bay.
11. Place hoist above gearbox.
12. Place the lifting straps beneath the gearbox assembly, and attach to the hoist.
13. Remove eight mounting bolts and nuts.
14. Carefully remove gearbox and sprocket from winch bay.
15. Place gearbox on suitable work table.
16. Measure the distance from the end of the shaft to the side of the sprocket. This
measurement will be used later to align the sprocket to the chain drive.
17. Remove the sprocket lock bolt.
sprocket shaft
sprocket lock bolts
measure this distance

key
sprocket
Figure 11.22 Gearbox sprocket attachment
18. Place heat resistant material behind the sprocket, and then heat the sprocket so that it can be
removed from the shaft.
WARNING
HOT OBJECT
The sprocket and sprocket shaft are hot and can burn your hands.
Always wear appropriate Personal Protective Equipment (PPE), such as gloves to prevent burning
hands.
26. Remove the sprocket from the shaft, and place in a safe location.
11.30 Assemble motor and gearbox (as required)

1. Make sure the sprocket shaft and sprocket are clean.
WARNING
RISK OF EXPLOSION
Using a heat source (naked flame) in a zone 2 area can cause an explosion.
Before using a heat source, make sure a "hot work permit" has been issued.
2. Heat the sprocket so that it can be fitted to the shaft.
WARNING
HOT OBJECT
The sprocket and sprocket shaft are hot and can burn your hands.
Always wear appropriate Personal Protective Equipment (PPE), such
as gloves.
3. Slide the sprocket onto the shaft, making sure it is correctly aligned for the chain and drum. Refer
to the measurement made previously.
4. Tighten the sprocket attachment bolt.
5. Place hoist above gearbox
6. Place lifting straps beneath the gearbox assembly, and attach the straps to the hoist
WARNING
HOISTING HAZARD
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.
7. Mount gearbox to winch frame with 8 mounting bolts and nuts.

8. Place hoist above motor assembly.
9. Place lifting straps beneath the motor assembly, and attach the straps to the hoist.
10. Attach motor assembly to gearbox using 4 mounting bolts.
11. Reattach all hydraulic connections.
12. Reattach all electrical connections.
APPENDICES
This section contains the following appendices:
Appendix 1: Lubricants
Appendix 2: Recommended Spare Parts List
Appendix 3: Storage Unit Inspection Checklist
Appendix 4: Contact Us
Appendix 5: Running Hours and Service Log Form
APPENDIX 1. LUBRICANTS
Ambient Temperature
-30 C -20 C -10 C 0C +10 C +20 +30 C +40 C
-20 F -2 F +14 F +32 F +50 F +68 F +86 F +104F
SAE        
5W20
SAE        
5W30
SAE        
10W40
SAE        
10W30
SAE        
15W50
SAE        
15W40
SAE        
20W50
SAE        
20W40
SAE 10        
SAE 20        
SAE 30        
SAE 40        
-20 °C to +5 °C +5 °C to +40 °C +40 °C to +55 °C -30 °C to +65 °C

(-2°F to +41°F)IV 95 (+41 °F to +104 °F)IV (+104 °F to +131 (-20 °F to +149 °F)IV
95 °F)IV 95 165
GULF EP lub. HD 150 EP lub. HD 320
I.P. Mellana 100 Mellana 150 Mellana 320 Telesia Oil 150
KLUEBER Gem 1-100 Gem 1-150 Gem 1-320 Synteso D 220
MOBIL Mobilgear XMP Mobilgear 632 Glygoyle 22Glygoyle
150Mobilgear 629 30SHC 630
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
NOTE: Select a good quality lubricant that is suitable for the ambient temperature where the machine is
used
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
APPENDIX 2. RECOMMNDED SPARE PARTS

Maintenance 100 HOUR/ BREAK IN
Major maintenance items are gear box oil change and hydraulic filter change
Suction Filter 2 U502347
Charge Filter 2 3 micron filter U502189

Return filter 1 3 micron filter U502189
Gearbox Oil 4.4 US Pint Shell Morlina
S4 B200
Hydraulic Fluid Up to 5 US Gallons hydraulic fluid SHELL Tellus 46
Wireline Oiler Fluid 0.9 USG capacity SHELL Tellus 46
Wireline Safety valve 8 US Gallons capacity SHELL Tellus 46

fluid
Maintenance 250 HOURS
Major maintenance items are truck engine checks such as fluid checks, filter replacement and general
chassis operability Refer to the operations and maintenance manuals provided by the chassis and engine
manufacturers for additional information
Maintenance 500 HOURS

The following procedures are to be performed every 500 hours of logging unit operation, and primarily
address the hydraulic system. Hydraulic maintenance:
The pumps and motors are relatively maintenance free. Maintenance work is confined to the system by way
of oil changes and renewal of filter elements. Monitoring and periodic maintenance of the system can
prevent premature breakdowns and repairs. Under normal conditions, the following maintenance intervals
are suggested
500 hours CombiGauge calibration should be checked. First filter change, two charge pressure filters, one
return filter, and two suction filters.
1000 hours Second filter change, two charge pressure filters, one return filter, and two suction filters.
CombiGauge calibration should be checked
1500 hours Third filter change, two charge pressure filters, one return filter, and two suction filters. Gearbox
oil change. CombiGauge calibration should be checked
2000 hours Hydraulic oil change. Fourth filter change. two charge pressure filters, one return filter, and two
suction filters CombiGauge calibration should be checked
Hydraulic Fluid 45 US Gallons hydraulic fluid Shell Tellus 46
Gearbox Oil 4.4 US Pint per gearbox Shell Morlina

S4 b200
Wireline Oiler Fluid 0.9 USG capacity Shell Tellus 46
Wireline Safety valve 8 US Gallons capacity Shell Tellus 46

fluid
Suction Filter 2 U502347
Charge Filter 2 3 micron filter U502189
Return filter 1 3 micron filter U502189
Drum bearing Grease 14 US ounces Ultra Lube‖
Multi-Purpose Grease
Drum Brake bands 1 per drum inspection/replacement SC05 brake A1025521
band
1 per drum inspection/replacement SC06 brake A1013510
band
Drive shaft Universal 14 US ounces Ultra Lube
Joint Multi-Purpose Grease
CONSUMABLES AND REPAIR PARTS FOR FIRST THROUGH THIRD YEAR OF OPERATION
Pressurization System 4 Air filter 8501040137/A

SAFETY 2 Eye wash station U501538/A
16 oz.
SAFETY 2 First-aid kit 16 .63003/A
unit standard
steel-case
SAFETY 2 Fire ex.t CO2 5lb .22645/A
a-b-c
CombiGauge 2 Depth Counter A0006604
gear box angle
(Measurehead)
0.658:1
CombiGauge 2 Depth Counter A0006735
gear box angle
(CombiGauge)
0.857:1
CombiGauge 2 Splitter box A0005970
0.99913:1
Fuses 6 7.5Amp blade

automotive
Load panel
Circuit breakers 2 10amp 206-153
2 15amp 206-154
2 20 amp L-8501037952
Circuit breaker, 2 50 amp 206-169
generator ac,
Circuit breaker, dc 2 100 amp 206-177

main,
Circuit breaker, 2 100 amp 242478000

120/240 ac main,
Relay, throttle 2 .75922
Generator Feedback 2 U502054

Module fuse
Bumper DOT lights 2 U500826

Set
Cabin fluorescent 6 Sylvania standard

lights F8W/T5/154
Spot light bulbs 6 Osram H3 12 V 55 W
Complete set of 1
external light bulbs
Spot light bulbs 4 Osram H3 12 V 55 W
Winch light bulb 4 Osram H3 12 V 55 W
Side Light Bulb 4 Osram H3 12 V 55 W
Rear light bulbs ( 2 Narva 5 W - 12 V
reverse - tail - signal )
Stop light bulb 2 Narva P21 21 W
Top Counter light bulb 4 Osram 12 V C5W
( red - White )
Sidelights bulb ( 4 Osram 2845 12 V
replaceable )
Stair light bulb 2 Osram 12 V R10W
3/2 VALVE AIR 2 390-0026-50/A
OPERATED
VALVE 4/3 (NEN6) 4 390-0048-50/A
ABPT CLOSED
SOLENOID VALVE 2 U501772/A
3-WAY
CONTROLLR MC2420 1 U501925/A

PLUS 1 24-PIN
TRANSFORMER 115 1 U502052/A
VAC TO 10 VAC
FUSE GDB 500mA 2 U502054/A
5x20MM
SWITCH PRESSURE 2 U501997/A
2K PSI 1/4 NPT
SWITCH RED TLM 2 U501150/A
FLUSH-HEAD
SWITCH TLM N/O 2 U501042/A
CONTACT BLOCK
BASE
SWITCH BLACK TLM 2 U501014/A
FLUSH HEAD
SWITCH TLM N/C 2 U501036/A
CONTACT BLOCK
LAMP 12MB FOR 2 U501931/A
BRAKE SWITCH
SWITCH 2 U501015/A
BLACK TLM SPRING
RETURN
SWITCH TLM N/O 2 U501041/A
CONTACT BLOCK
SWITCH 2 POSITION 2 U501877/A
SWITCH TLM N/O 2 2 U501041/A
CONTACT BLOCK
VALVE RELIEF 2 TORQUE .87768/A
5800/PSI VALVE
3/2 VALVE W/ 2 390-0027-50/A
SELECTOR SWITCH
JOYSTICK W/ 1 U501879/A
SENSOR
MP16 SHAFT 2 A1008759
ROLLER GUIDE
MP16 WIRE GUIDE 2 A1008768
ROLLER
MP16 FLANGE 2 A1008929
DIAPHRAGM
MP16 MEASURING 2 A1008829

WHEEL UPPER
MP16 MEASURING 2 A1008810
WHEEL LOWER
MAJOR COMPONENT PART NUMBERS
PUMP 100 CC EL U501758/A

LEFT ROTATION
5000 PSI
PUMP 55 CC EL LEFT U501760/A
ROTATION
5000 PSI
PTO SAE 116% U501169/A
ASSY AUX
SPOOLING MOTOR 6501041623/3
DRIVE-SHAFT 1410 180551026/B
26.50-IN RUN
LENGTH
MOTOR HYD 32CC .84064/A
REV REAR-PORTS
GENERATOR U502019/A
30KW 60HZ
WIRELINE SAFETY 6501042108/1
VALVE CONTROL
FLUID PUMP
SMARTMONITOR V2 6931036586/B3
12" P.MOUNT W/
SOFTWARE
COMBIGAUGE A0015311/A1
2000LBS 25B, 1:1
WINCH DRUM SC05 A1009489/A1
450X260X700MM
WINCH DRUM SC06 A1007840/B
600X350X700
GEARBOX 5.8:1 A0021124/A
HYD MOTOR BENT DRUM MOTOR A1019407/A1
AXIS
HYD CYL SA BRAKE A1012983/B1
60mm/30mm/30mm CYLINDER
STROKE
GAS SPRING 2000N, LEVELWIND A1023623/A
L=835MM, STROKE STRUT
L=325>
LEVELWIND 160CC A1024031

SPOOLER MOTOR
3-WAY BALL VALVE A1018717/B1
1" BSP
MP16 SHAFT A1008759
ROLLER GUIDE
MP16 WIRE GUIDE A1008768
ROLLER
MP16 FLANGE A1008929
DIAPHRAGM
MP16 MEASURING A1008829
WHEEL UPPER
MP16 MEASURING A1008810
WHEEL LOWER
APPENDIX 3. STORAGE UNIT INSPECTION CHECKLIST

OWNER: UNIT DESCRIPTION:
Type/ Series:
Customer Unit No.:
Chassis Type:
VIN:
Odometer:
ASEP Project No.:
Sales Order No Safe/Storage PO #

Start Date
Inspection Date Clean NO Requested
Inspection? Delivery Date
Ensure battery disconnect switch is OFF before returning unit to storage (For US supplied truck switch off battery isolator. For
None US trucks such as Mercedes, the Manufacturer may not have installed a battery isolator; in this case disconnect the
positive battery terminal, grease the terminal and install a plastic terminal protector.
Checker Initials Maintenance Results Corrective Results Corrective
Description (Pre Storage) Action Needed (Post Storage) Action Needed
Chassis:
Please check chassis manufacturer handbook for specific information on long term storage
Radiator fluid
level
Fuel level
Tire pressure
Wiper fluid
level
Engine oil level
Fluid leaks
Transaxle fluid
level
Brake fluid
level*
(HES units
only)
Transmission
fluid level*
(If automatic
transmission)
Drain any
condensate
from air tank
Description Pre Storage Action Needed Post Storage Action Needed
Radiator
Cooling fan
operable
Pulleys and
belts
Cold weather
system
operable
Environmental
system
operable
Wireline Cabin and Winchbay
Cabin exterior
clean
Rivets and
welds free from
damage
Cabin mounting
screws properly
torqued
Cabin door latch
oiled and
operates
correctly
Operator‘s
window clean
and operates
properly
Window seals
clean and
undamaged
Shore power
terminals clean
and free from
corrosion
Cabinet doors
are greased and
operate properly
Line oiler fluid
level
All gauges
operate
properly
Description Pre Storage Action Needed Post Storage Action Needed
Cabin, floors
and
countertops
are clean
Drum bearings
greased
Measurehead
wheels are
greased
Chain oiler
level
Gearbox fluid
level
Brake band
pad sufficient
thickness
Electrical
connections in
winch bay are
free from
corrosion (I/O
box, cable
spool
connections
and wire
connectors)
Sheave wheel
storage
brackets
secure and
free from
corrosion
Record Initial Generator Hours: _______________

Record Hoist System Hours: _________________
Start Up:
 Ensure battery switch is ON prior to start up.
 If disconnect switch is not supplied, remove protective cap from positive battery post, clean and
install positive battery cable terminal.
 After Start-up allow unit to run for 20 minutes.
Checker Maintenance Description Results Corrective Action Needed
Initials
Air pressure OK (pressure on
truck dash matches gauge in
recorder cabin)
Oil Pressure OK
Battery Voltage OK
Water temperature OK
Oil cooler fan operates
Charge pressure OK
Pressurization system operates
properly
Start-up Hydraulic Generator and Hoist System
Hydraulic generator operates
properly
Spooling arm and brake
accumulator pressure OK
Intercom operates properly
Spooling arm operates properly
Heater operates properly
(if applicable)
All air conditioners operate
properly
Drum brake operates properly
Tool storage air bags operate
properly (if applicable)
Slow speed system operates
CANBUS monitor operating

(if applicable)
Battery balancer operates
Record Final Generator Hours: ______________
Record Hoist System Hours: _________________
BY:
Inspector
APPENDIX 4 CONTACT US
Service & After Sales (US)
Please help us to help you by checking the following:
NOV ASEP Elmar Service After Sales Department ([email protected]).
Please provide details as complete as possible with your request to enable us to investigate more quickly.
During periods of high activity it may be that we are unable to respond to you by the date requested.
1. (if applicable)
Response Required by
(DATE)
Product Type/Product Name
Part Number
OA's Affected
WO / PO Reference
2. Detail of Enquiry/Support Request

Please ensure all relevant details are supplied for us to action your request.
3. SAS Response/Feedback
SAS staff will complete this section with feedback comments.
4. Action to be taken
SAS staff to describe action to be taken to complete the request.
5. Assigned Person
The SAS staff member who is allocated to this request will apply their name here.
89NOV ASEP Elmar – U.S.A., 11995 F.M. 529, Houston, TX 77041, USA Page 148 of 150
Tel: 1 713 983 9281, Fax: +1 713 983 8892, www.nov.com Revision 1
Project No. 38661-38668 Original Instructions
APPENDIX 5 RUNNING HOURS & SERVICE LOG FORM

Unit ID ____________________ Date form opened________________
Running Hours
Start Stop Hours Remarks
Date Time Date Time Session Cumulative
carried forward from previous sheet
carry forward to next sheet
Service Log
Next Due at Done at On Remarks
Service (hours) (hours) (date)
CUSTOMER NOTES
Published by:
NOV ASEP Elmar
11995 F.M. 529,
Houston, TX, 77041
United States
© 2011 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 ASEP Elmar for loss, damage or
injury caused by any errors or omissions in this document.

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Hydraulic UniTruck User Manual

Operation and Maintenance Manual

Version Date Amendments

1 12/27/2011 First Version for this

9.0 OPERATION ................................................................................................................................................. 69

General Safety Instructions

WARNING! Exhaust gases contain carbon monoxide, a colorless, odorless and

 The area ALWAYS presents a DANGER.

2.1 Maintenance and Pre-Start Safety

 Consider your safety and that of others first.

2.2 Warnings and cautions

Warnings and cautions in this manual are indicated by:

 The text WARNING or CAUTION

2.2.1 Warning and caution icons

General Caution or Warning

Corrosive liquids or adhesive

Potentially explosive substances or

Automatically starting and stopping of

Lifting with forklift - beware of falling loads

Danger of falling from height

Hoisted object that can fall

3.0 GENERAL INFORMATION

4.0 SYSTEM INFORMATION AND SPECIFICATIONS

4.2 Truck Chassis and Engine (Customer Supplied)

4.3 Logging Cabin

4.4 Electrical System

4.4.1 Power Distribution

4.5 Winch and Generator Hydraulic Systems

4.6 Pneumatic System

4.7 Wireline Safety Valve System

4.8 Measuring System

4.9 Rear Bumper Spooler

5.0 PHYSICAL DESCRIPTION

Figure 5.1 Unit exterior, left

1 Wind diffusor Disperses airflow over the roof

2 Shore power AC in Hubble connection for 120V input

5 Generator Hydraulic-powered AC generator in enclosure

6 Belly box General purpose storage

8 Storage belly box General purpose storage.

11 Belly box Storage

5.1.2 Slickline Tool Storage

Figure 5.2 Slickline tool storage

1 Slickline tool storage Steel screw in storage plates

5.1.3 Cabin door and fold out stairs

Figure 5.3 Cabin and fold out stairs

5.2 Unit right side

Figure 5.4 Unit exterior, right

2 Hydraulic servicing compartment Contains reservoir and cooling fans

3 Storage belly box General purpose storage.

4 Belly box General purpose storage

5 Cabin window Double paned glass

5.2.2 Hydraulic servicing compartment

Figure 5.5 Hydraulic servicing compartment

1 Hydraulic reservoir tank Storage for 40 gallons of hydraulic oil

5.2.3 Rear belly box storage

Figure 5.6 Rear storage box

1 Rear belly box

5.3 Rear overview

Figure 5.7 Rear overview