KOLLER Maschinen- und Anlagenbau GmbH Operating Manual

Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

Translation of the original

Operating Manual
This operating manual in accordance with Machinery Directive 2006/42/EC
is only valid for the „Wireline Combi Unit PP“ identified below with its article number!
For an overview of the contents please see Pages 1-2 and following.

Wireline Combi Unit PP

28.05.2013 (Rev. a)

Keep this operating manual within reach at the KMA Article No.: ...
place of use of the „Wireline Combi Unit PP“.
Please ask for a replacement
if it becomes illegible or damaged!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

1. List of contents of this operating manual

Chapter 1 - Introduction Chapter 3 - Transport
1.1 List of contents .........................................1-2 3.1 Safety information .......................... Page 3-1
1.2 Identification of the machine,
3.2 Attachment, lifting and transport
type plate .................................................. 1-6
(use of lifting gear) .................................. 3-1
1.2.1 Hazard information on the machine ......... 1-6
3.2.1 Road transport of the unit ....................... 3-3
1.3 Purpose of the operating manual .............. 1-7 3.2.2 Air transport ............................................ 3-3
1.4 Validity of this operating manual .............. 1-7
3.3 The delivered unit .................................... 3-3
1.5 Guarantee ................................................. 1-7
3.3.1 Packaging, preservation .......................... 3-3
1.5.1 Guarantee according to our General
3.3.2 Completeness of the delivery .................. 3-3
Terms and Conditions .............................. 1-7
3.3.3 What to do in the event of
1.5.2 Guarantee and liability
transportation damage ............................. 3-3
according to our General Terms and
Conditions ................................................. 1-8
3.4 Long-term or intermediate storage .......... 3-4
1.6 Conformity of the machine ....................... 1-8 3.4.0.1 Monthly inspection of the Wireline
1.7 Structure of this operating manual ........... 1-8 Container Unit PP ................................... 3-4
1.7.1 Abbreviations, terminology ....................... 1-9 3.4.0.2 Inspections every 6 months ..................... 3-4
3.4.0.3 Annual inspections (every 12 months) .... 3-5
3.4.0.4 Inspections every 4 years ....................... 3-5
Chapter 2 - Safety
2.1 Directives, ordinances,
regulations/provisions ..................... Page 2-1 Chapter 4 - Description
4.1 Intended use ................................... Page 4-2
2.2 Safety fundamentals ................................ 2-2 4.1.1 Misuse and non-intended use ................... 4-2
2.2.1 Informal safety measures ....................... 2-2
2.2.2 Obligation of the owner/user ................... 2-3 4.2 Technical data .......................................... 4-2
2.2.3 Qualification of the operating 4.2.0.1 Environmental influences and/or
personnel ................................................. 2-3 emissions .................................................. 4-2
2.3 Hazards/residual risks ............................. 2-3 4.2.0.2 Permissible ambient conditions .................4-2
2.3.1 Hazard information .................................. 2-3 4.2.0.3 Functional criteria,
2.3.1.1 Use of lifting gear and transport ............. 2-4 inadmissible operating conditions .............. 4-2
2.3.1.2 Manual transport ..................................... 2-4 4.2.0.4 Technical documentation according
2.3.1.3 Preparation for operation ........................ 2-5 to the Machinery Directive ....................... 4-2
2.3.1.4 Start-up/commissioning, operation ........... 2-5
2.3.1.5 Maintenance work .................................. 2-6 4.2.1 Hazard zones and hazardous area ............ 4-4
4.2.1.1 Hazardous area ........................................4-4
2.4 Hazard zones and hazardous area .......... 2-8
4.2.2 Organizational safety measure,
2.5 Protection devices/guards and safety operating and handling instructions ........... 4-4
components on the machine .................... 2-9 4.2.3 Connection to ground/equipotential
bonding .....................................................4-4
2.6 Disposal and environmental protection ... 2-9
4.3 Description of the
Tables
Wireline Combi Unit PP ...........................4-5
Hazard analysis, risk assessment, protection/
4.3.1 Container .................................................. 4-5
safety devices/guards on the unit (in
4.3.1.1 Components installed under the floor
accordance with the Machinery Directive),
in the container frame .............................. 4-5
see Chapter 9!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

4.3.1.2 Air conditioning unit ................................. 4-5 Chapter 5 - Installation/set-up

4.3.1.3 Storage box/tool rack under the container 4-5
and preparation for operation
5.1 Safety information .......................... Page 5-2
4.3.2 Engine compartment ................................ 4-5
5.1.1 Instruction of the operating personnel ..... 5-2
4.3.2.1 Engine oil system ...................................... 4-6
5.1.2 Tools, consumables and auxiliary
4.3.2.2 Engine cooling system .............................. 4-6
equipment required for preparation for
4.3.2.3 Fuel system ............................................... 4-6
operation .................................................. 5-3
4.3.2.4 Combustion air system .............................4-7
4.3.2.5 Exhaust system ........................................4-7
5.2 Installation/set-up of the Wireline
4.3.2.6 Electrical system of the engine ................4-8
Combi Unit PP ........................................ 5-3
4.3.2.7 Engine electronics .................................... 4-8
5.2.0.1 Permissible conditions at the
place of installation/set-up ....................... 5-3
4.3.3 Control room ............................................. 4-9
5.2.0.2 Preparation of the work site area ............ 5-3
4.3.4 Operating elements ................................ 4-12
5.2.0.3 Attachment, lifting and transport
4.3.4.1 Operating elements on the container ..... 4-12
of the machine ......................................... 5-3
4.3.4.2 Operating elements on the control panel 4-13
5.2.1 Installation and alignment of the machine 5-4
4.3.4.3 Operating elements on the electric
5.2.1.1 Roof structure ......................................... 5-4
switch cabinet ........................................ 4-15
4.3.4.4 Operating elements on the PCE
5.3 Preparations for operation ....................... 5-4
pressure control panel ............................ 4-15
5.3.1 Topping up consumables/auxiliary
substances ............................................... 5-4
4.3.5 Winch cab .............................................. 4-15
5.3.1.1 Checking/topping up the engine
4.3.6 Winches .................................................. 4-15
consumables ............................................ 5-5
4.3.6.1 Winch drive ............................................ 4-17
5.3.1.2 Checking/topping up hydraulic oil ............ 5-5
4.3.6.2 Brake system .......................................... 4-17
5.3.1.3 Topping up the wire oiler ......................... 5-5
4.3.6.3 Operating the winches and brakes ......... 4-18
5.3.2 General preparations for operation .......... 5-5
4.3.7 16" measuring head Dolphin ................... 4-18
5.3.2.1 Electrical connection ............................... 5-6
4.3.7.1 Spooling mechanism ............................... 4-18
5.3.2.2 Connection of the grounding cable .......... 5-6
4.3.7.2 Measuring head oiler/wire oiler .............. 4-18
5.4 Setting up individual components ............. 5-7
4.3.8 Pressure control equipment (PCE) ........ 4-18
5.4.1 Winches ................................................... 5-7
4.3.8.1 PCE in the engine compartment ............ 4-19
5.4.2 Band brakes ............................................ 5-7
4.3.8.2 PCE in the winch cab ............................ 4-19
5.4.3 Spooling mechanism and measuring head 5-7
4.4 Hydraulic system .................................... 4-19
5.4.3.1 Unlocking the measuring head ................ 5-9
4.4.0.1 Hydraulic oil reservoir ............................ 4-20
5.4.3.2 Preparations for operation at the
4.4.0.2 Return filter ............................................ 4-20
measuring head ........................................ 5-9
4.4.0.3 Operation and monitoring ....................... 4-20
5.4.3.3 Threading in the wireline/cable at the
4.4.0.4 Hydraulic oil/air cooler ........................... 4-21
measuring head ........................................ 5-9
4.5 Pneumatic system .................................. 4-22
5.4.4 Hydraulic system ..................................... 5-9
4.5.0.1 Compressed air supply ........................... 4-22
5.4.4.1 Return filter ............................................. 5-9
5.4.4.2 Hydraulic hose lines ................................ 5-9
4.6 Electricity (power) supply ...................... 4-22
5.4.4.3 Connecting PCE hoses .......................... 5-10
4.6.0.1 Battery (24V supply) .............................. 4-22
5.4.6 Hydraulic oil/air cooler .......................... 5-11
4.7 Delivery scope ....................................... 4-22
5.4.7 Compressed air system ......................... 5-11

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

5.4.8 Electrical system ................................... 5-11 6.4.3 Wireline speed, pull force/tension and
5.4.8.1 Batteries ................................................ 5-11 monitoring of operation .......................... 6-10
6.4.3.1 Operation at low speed
5.5 Function control or and max. pull force/tension ................... 6-10
first time start-up ................................... 5-11 6.4.3.2 Operation at high speed ........................ 6-10
5.5.0.1 Function check of the operating 6.4.3.3 Operation with variable pull
elements ................................................ 5-11 force/tension .......................................... 6-11
5.5.1 Visual inspection prior to initial 6.4.3.4 Monitoring of operation ......................... 6-11
start-up .................................................. 5-11
5.5.2 Hydraulic system test ............................ 5-12 6.4.4 EMERGENCY STOP switching
5.5.3 Test for the wireline/cable speed/drum device .................................................... 6-11
rotational speed and rotational direction 5-12 6.4.4.1 Autom. cut-out devices ......................... 6-11
5.5.4 Testing the safety functions .................. 5-13 6.4.4.2 Start-up after
an EMERGENCY STOP actuation ...... 6-11
5.6 Operational readiness of the machine ... 5-13
6.5 Operation of the pressure control
equipment (PCE) ................................... 6-12
Chapter 6 - Commissioning/
6.6 Shutting down the machine ................... 6-12
start-up of the Wireline Combi
6.6.1 Brief operating interruption ................... 6-12
Unit PP 6.6.2 Shutting down for up to 6 months ......... 6-12
6.1 Safety information .......................... Page 6-2 6.6.2.1 Removal of water from, filling and
system bleeding/venting
6.2 Installation/set-up of the Wireline of the consumables containers .............. 6-13
Combi Unit PP and preparation for 6.6.2.2 Spooling (winding up) and securing
operation .................................................. 6-2 the wireline/cable .................................. 6-13
6.6.2.3 Disconnecting the electrical
6.3 Commissioning/start-up ........................... 6-2 connection and grounding cables ........... 6-13
6.3.1 Instruction of the operating personnel ..... 6-2 6.6.2.4 Winding up the PCE hoses .................... 6-13
6.3.2 Visual inspection as a safety inspection .. 6-3 6.6.3 Decommissioning (mothballing) ............ 6-13

6.3.3 Operating elements ................................. 6-4 6.7 Recommissioning ................................... 6-14

6.3.3.1 Operating and monitoring elements
on the container ....................................... 6-4
6.3.3.2 Operating elements on the control panel . 6-4 Chapter 7 - Maintenance
6.3.3.3 Operating elements on the electric
7.1 Safety information .......................... Page 7-2
switch cabinet (Fig. 6-3) ......................... 6-6
7.1.1 Instruction of the maintenance personnel . 7-2
6.3.3.4 Operating elements on the PCE panel
7.1.2 Necessary qualification of the
(Fig. 6-4) .................................................. 6-6
maintenance personnel .............................7-3
7.1.3 Permissible spare parts .............................7-3
6.3.4 Switching on the engine .......................... 6-7
6.3.4.1 Measures in the event of a false start
7.2 Required tools, measuring instruments,
of the engine ............................................ 6-8
auxiliary equipment and consumables ...... 7-3
6.3.5 Function check ........................................ 6-8
7.2.0.1 Tools ......................................................... 7-3
7.2.0.2 Measuring instruments .............................7-4
6.4 Operation ................................................. 6-9
7.2.0.3 Consumables ............................................ 7-4
6.4.1 Starting up the machine ........................... 6-9
7.2.0.4 Auxiliary equipment .................................. 7-4
6.4.1.1 Benchmark display unit ........................... 6-9
6.4.2 Operation of the Wireline Combi
Unit PP .................................................... 6-9

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

7.3 Technical data for 7.6 Regular maintenance work on

maintenance work .................................... 7-4 components ............................................. 7-10
7.3.1 Consumables ............................................ 7-4 7.6.1 Container maintenance ........................... 7-10
7.3.4.1 Fuel/diesel oil ............................................ 7-4 7.6.2 CAT diesel engine .................................. 7-11
7.3.4.2 Coolant .....................................................7-4 7.6.2.1 Fuel system ............................................. 7-11
7.3.2 Lubricants ................................................. 7-4 7.6.2.2 Engine oil system .................................... 7-11
7.3.2.1 Engine oil .................................................. 7-4 7.6.2.3 Engine cooling system ............................ 7-11
7.3.2.2 Hydraulic oil ............................................. 7-4 7.6.2.4 Intake/air filter ........................................ 7-12
7.3.2.3 Lubricating/gear oil ................................... 7-4 7.6.2.5 Exhaust system ....................................... 7-12
7.3.2.4 Lubricating grease .................................... 7-5
7.3.2.5 Preservation oil .........................................7-5 7.6.3 Replacing the winch drums .................... 7-14
7.6.3.1 Safety fundamentals ............................... 7-14
7.4 Inspections/visual inspection and 7.6.3.2 Removing the winch drum ...................... 7-15
monitoring ................................................. 7-5 7.6.3.3 ?Fitting the winch drum .......................... 7-15
7.4.1 Regular checking of connection to
ground/equipotential bonding .................... 7-5 7.6.4 Roller chain maintenance ....................... 7-16
7.4.2 Compressed air vessel, regular 7.6.4.1 Lubricating the roller chain ..................... 7-16
inspection/testing 7.6.4.2 Cleaning and greasing the roller chain .... 7-16
in accordance with BGR 500 ................... 7-5 7.6.4.3 Tensioning/slackening the roller chain .... 7-17
7.4.3 Pressure relief valve (safety valve) 7.6.4.4 Removing/fitting the roller chain ............. 7-17
setting ....................................................... 7-5 7.6.5 Planetary gear unit ................................. 7-17
7.4.4 Brake test ................................................. 7-5 7.6.5.1 Checking the oil level, topping up if
7.4.4.1 Establishing the free running state necessary ................................................ 7-17
of the drums ............................................. 7-6 7.6.5.2 Changing the gear oil .............................. 7-17
7.4.4.2 Determining the main pressure at the
point where the brakes slip ....................... 7-6 7.6.6 Band brakes ........................................... 7-18
7.4.4.3 Brake holding test ..................................... 7-6 7.6.6.1 Checking the brake band pretension ...... 7-18
7.4.5 Checking the max. engine speed (rpm) ...7-7 7.6.6.2 Resetting the brake band pretension ...... 7-18
7.6.6.3 Replacing the brake band ....................... 7-19
7.5 General maintenance work ....................... 7-7
7.5.1 Putting the machine into a safe 7.6.7 Measuring head and spooling
standstill condition ..................................... 7-7 mechanism .............................................. 7-19
7.5.2 Maintenance intervals and maintenance 7.6.7.1 Measuring head ...................................... 7-19
schedule ....................................................7-7 7.6.7.2 Spooling mechanism ............................... 7-20
7.5.3 Cleaning and care ..................................... 7-8 7.6.7.3 Wire oiler ................................................ 7-20
7.5.3.1 Auxiliary cleaning equipment .................... 7-8
7.5.3.2 Cleaning (dry) ........................................... 7-8 7.7 Hydraulic system .................................... 7-20
7.5.3.3 Cleaning (wet) .......................................... 7-8 7.7.0.1 Safety fundamentals ............................... 7-20
7.5.3.4 Care measures .........................................7-8 7.7.0.2 Monitoring the condition of the system .. 7-21
7.5.3.5 Disposal of cleaning agents ...................... 7-9 7.7.1 Checking the hydraulic oil level/
7.5.4 Wear/damage of components .................. 7-9 topping up ............................................... 7-21
7.5.4.1 Function checks ........................................7-9 7.7.1.1 Hydraulic oil change ............................... 7-21
7.5.4.2 Repair welding .......................................... 7-9 7.7.1.2 Checking the hydraulic oil condition ....... 7-21
7.5.5 Visual inspection of rubber and 7.7.1.3 Bleeding the hydraulic system ................ 7-22
plastic components ................................... 7-9 7.7.2 Replacing the hydraulic return
7.5.6 Screw/bolt connections .............................7-9 filter element .......................................... 7-22
7.5.7 Relubricating grease lubrication points ... 7-10 7.7.3 Checking the hydraulic hoses ................. 7-22
7.7.3.1 Replacing the hose lines ......................... 7-22
7.7.4 Oil/air cooler ........................................... 7-23

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

7.8 Compressed air system, regular 1.2 Identification of the

drainage of the compressed air vessels .. 7-23
Wireline Combi Unit PP
7.9 Electrical equipment ............................... 7-23 For identification please refer to the type plate. For
7.9.1 Maintenance of the battery .................... 7-23 questions and ordering spare parts please specify:
7.9.1.1 Maintenance/replacement of the battery 7-23 • The article No. and
• the year of manufacture (delivery date)
7.10 Completion of maintenance work ........... 7-23
7.10.1 Visual inspection after maintenance
work ....................................................... 7-24 1.2.1 Hazard information on the
machine
Table
The following hazard information (pictographs in
7.I Screw/bolt tightening torques ................... 7-3
accordance with BGV A8) and information signs
7.II Maintenance schedule ............................ 7-25
specifying particular safety-relevant conduct etc. are
located on the unit.
W00 - Warning of a (general)
Chapter 8 - Malfunctions hazardous point/danger zone, its
8.1
8.2
Malfunction causes ......................... Page 8-1
Troubleshooting ........................................8-1
! meaning being described under
Warning in Chapter 1.7.

8.3 Checklist: Operating malfunctions ............ 8-3 W08 - Warning of dangerous electrical
8.3.1 Truck/main engine malfunctions ...............8-3 voltage
8.3.2 Malfunctions of the hydraulic system ....... 8-4
8.3.3 Noise emissions, erratic operation ............ 8-6
8.3.4 Malfunctions in the compressed
air system ................................................. 8-7 W27 - Warning of hand injuries, e.g.
8.3.5 Electrical malfunctions and danger of crushing hands. Serious
switching errors ........................................8-8 laceration/abrasion injuries from the
wireline/cable.

P06 - No access for unauthorized

Chapter 9 - Tables persons!
9.I Hazard analysis acc. to DIN EN ISO
14121-1
9.II Risk assessment acc. to DIN EN ISO
14121-2 Rotational direction arrow(s) identify the rotational
9.III Protection/safety devices/guards of the direction of drive motors/gears.
Wireline Combi Unit PP (acc. to Machinery
Directive) For occupational safety and health, the following
mandatory signs (BGV A8) may be attached to the
unit by the user/owner, e.g. according to company
regulations:
Read the operating manual prior to
commencing any work on the unit!

1) The „Wireline Combi Unit PP“ is also referred to in this

operating manual as the „Container“ or „Unit/Machine“.
3) For information on the abbreviations see Chapter 1.7.1.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

M01 - Use/wear eye/face operation of the machine, safe operation and

protection necessary maintenance work to be performed
correctly and in a safety-focused manner.
• Your personal safety and safe operation of the unit
is only guaranteed if all instructions in this operating
M02 - Wear a safety helmet manual, the Health and Safety at Work/
occupational safety and health (regulations of the
Employer’s Liability Insurance Association) and the
respective safety regulations are observed.
• You as the owner/user have to ensure that the
M03 - Wear hearing protection
operating manual is handed over to your operating
personnel prior to the first start-up/commissioning,
that it remains available at the unit and that all
hazard information is adhered to!
M04 - Use respiratory protection

1.4 Validity of this

operating manual
M05 - Wear safety boots • This operating manual is only valid for the particular
Wireline Combi Unit PP identified by the article
No. on the type plate!
• Reference is made in this operating manual to the
third-party operating manuals of the engine (power
M06 - Wear protective gloves pack), generator etc. For details, please refer to the
third-party operating manuals in Section III of the
technical documentation.
• This operating manual only refers to KMA’s
delivery scope. The owner/user has the sole
If personnel are employed who speak a different responsibility for ensuring the safe handling of the
language, it is the responsibility of the user/owner to measuring cable/wireline, tools etc. to be used by
have the texts of warning/information signs translated the owner/user for the intended use of the Wireline
into the respective languages spoken by the personnel Combi Unit PP; see Chapt. 4.2.2!
and to attach these to the unit accordingly.

1.5 Guarantee
1.3 Purpose of this 1.5.1 Guarantee in our General
operating manual Terms and Conditions
The purpose of this operating manual is to safeguard Details concerning the guarantee terms are specified
„man and machine“ (EC Machinery Directive 2006/42 in KMA’s General Terms and Conditions entitled
EC). It is aimed at all persons involved with the „General Terms and Conditions of KOLLER Maschi-
Wireline Combi Unit PP, its set-up/installation, nen- und Anlagenbau GmbH, Celle“.
operation or maintenance. The most recent version valid at the time of delivery
• All operating/maintenance personnel must read this shall prevail. Any deviations from our General Terms
operating manual prior to first start-up/ and Conditions (AGB) must be specified in writing in
commissioning. Familiarize yourself with the the KMA order confirmation!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

1.5.2 Guarantee and liability equipment not approved by KMA, the submitted
Declaration of Conformity shall become null and
in accordance with the General
void.
Terms and Conditions
KMA declines all liability for damage to the delivered
unit resulting from one or more of the following
reasons:
• Improper use or use of the unit that is not in
1.7 Safety/information symbols in
compliance with the intended use. this operating manual
• Non-observance of the instructions in this operating Statements to be especially observed, important
manual regarding transport, storage, commissioning/ information concerning the safe and correct handling
start-up, operation, maintenance/service or any of the machine, as well as hazard information are
other measures performed on the unit. identified as follows.
• Inadequately qualified or insufficiently trained
personnel, as well as incorrect or negligent ! Note
treatment of the unit.
Important information about the machine and its
• Operation of the unit with defective, incorrectly
assembly groups, other (supplementary)
attached or non-functioning safety components and
chapters of this operating manual, safety
protective devices/guards.
regulations and other regulations, as well as
• Unauthorized modifications or conversions.
information regarding the correct and safe
• Working with operating data other than that agreed
execution of work of all kinds.
for the intended use and laid down in the KMA
order confirmation. Attention
• Natural wear! !
For explanation see DIN 31 051 Part 4. Minor damage to health (injuries) and/or
• Unsuitable equipment and substitute materials or material damage (damage to the machine and
spare parts that have not been tested and approved other damage to assets) may occur when the
by KMA. respective precautionary measures - e.g. in
• Improperly performed repair work. accordance with the BGV and this operating
• Defective construction work and unsuitable place manual - are not adhered to.
of installation (foundations/substructure).
• Chemical, electrochemical and electrical influences, ! Warning
as well as third-party influences and force majeure. Serious damage to health (e.g. bodily injury)
and damage to assets may occur when the
respective precautionary measures - e.g. in
accordance with the BGV and this operating
1.6 Conformity of the unit manual - are not adhered to.
• The EC directives and (harmonized) EN standards
listed in Chapt. 2.1 are adhered to for the design ! Danger
and manufacture of the agreed scope of delivery of Severe damage to health (e.g. life-threatening
the Wireline Combi Unit PP. injuries) and damage to assets will occur when
the respective precautionary measures, e.g. in
• With regard to the conformity of the Wireline
accordance with the BGV and this operating
Combi Unit PP, also refer to the Declaration of
manual, are not adhered to.
Conformity according to EC Machinery Directive
2006/42/EC, Annex II A in „Section I“ of the • For hazard information on the machine, please refer
technical documentation. to the information in Chapter 1.2.1.
• In the event of unauthorized modifications to the
machine design and the fitting of spare parts or

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 1 - Introduction

1.7.1 Abbreviations, technical terms Expert, is someone who has sufficient knowledge in
abbr, abbreviation the field of the device/equipment to be inspected
AGB, KMA’s General Terms and Conditions due to his/her specialist training and experience and
ArbSchG, Arbeitsschutzgesetz (German law on who is sufficiently familiar with the applicable state
occupational safety and health) (13.06.1996); law occupational safety and health regulations, the
on the implementation of „Health and Safety at BGV, EC directives and the generally recognized
Work“ measures to improve the safety and the codes of engineering practice to be able to assess
protection of the health of employees at the the safe operational condition of the device/
workplace, see EC Directive 89/391/EEC equipment to be inspected.
ArbStättV, Arbeitsstättenverordnung (German
workplace ordinance) (20.03.1975). Hazard, the spatial and temporal coincidence of man
with hazards (hazard sources and hazard zones) or
BetrSichV, Betriebssicherheitsverordnung (German hazardous substances.
ordinance on occupational safety and health) Hazardous chemical substances, see GefStoffV
(27.09.2002) and list in the code of practice BGI 536.
BG, Berufsgenossenschaft (German Employer’s Hazard event, Event susceptible to causing damage.
Liability Insurance Association), also refer to HGB Hazard situation, Situation in which a person is
BGI …, also BGR …, identification with indenture exposed to at least one hazard.
numbers for the directive, safety rule and code of Hazard sources, dangerous uncontrolled movement
practice collection of the HGB of components that leave the defined path or fly
BGV …, identification with indenture numbers for out, and falling objects.
Accident Prevention Regulations and Hazardous substances, substances which according
implementation directives (DA) (previously to the ChemG have one or more dangerous or
VBG...), damaging properties.
BImSchG, Federal immission protection law; German Hazard zones, dangerous movement of components
law for the protection against harmful environmen- following defined paths, e.g. crushing, shearing,
tal effects caused by emissions, noise, vibration etc. pull-in or overrun points.
BImSchV, ordinances on the BlmSchG.
GefStoffV, Gefahrstoffverordnung (German
ChemG, Chemikaliengesetz (Chemicals Act) ordinance on hazardous substances) (26.08.1986)
(14.03.1990); German Act on the Protection
Against Hazardous Substances. h, hour, here in the sense of operating hour

DA, German implementation directives on the i.e. id est, that is

individual BGVs (German Trade Association
Ordinances). KMA, KOLLER Maschinen- und Anlagenbau
dB, decibel GmbH, D-29227 Celle, for postal address and Tel.
DIN, Deutsches Institut für Normung e.V., Berlin No. see above
(German Institute for Standardization) KrW-/AbfG, Kreislaufwirtschafts- und Abfallgesetz
DIN EN, (harmonized) EN standards published by (German Waste Avoidance, Recycling and
DIN Disposal Act) (28.09.1996)

e.g. for example MRL, EC Machinery Directive 2006/42/EC

EN …, identification with indenture numbers for
European standards (European standard). op.hrs.,operating hours
et seq. and following opt., optional
EU, European Union; previously European
Community EC; historically European Economic PCE, pressure control equipment
Community EEC. poss. possibly

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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PP, power pack

PPE, prescribed or recommended Personal Protective
Equipment, such as hard hat, protective gloves,
safety boots etc.

Reasonably foreseeable incorrect use, use of the

machine in a way not intended by the design
engineer, which can, however, result from easily
predictable human behaviour.

Safety data sheet, according to Directive 2006/1907/

EC (or 91/155 EEC or 2001/58/EC), contains the
physical data, information for occupational safety
and health, disposal etc. for the respective chemical
substance and is published by the manufacturer of
the substance.

Tab., Table
TR, Technical Regulations, e.g.
TRGS – Technische Regeln für Gefahrstoffe
(German Technical Regulations for Hazardous
Substances) etc.

u.o. among others

WHG, German Water Management Law

(23.09.1986)

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2. Occupational safety and health, safety regulations, environ-

mental protection Important information
The information/instructions and warnings
Table of Contents specified in Chapter 2.3 and following chapters
2.1 Directives, ordinances, do not represent a full list of all precautionary
regulations/provisions ..................... Page 2-1 measures required for safe operation or
2.2 Safety fundamentals ................................ 2-2 maintenance of the „Wireline Combi Unit PP“1)!
2.2.1 Informal safety measures ....................... 2-2 Particular installation conditions or local/on-site
2.2.2 Obligation of the owner/user ................... 2-3 conditions may make further safety measures
2.2.3 Qualification of the operating necessary!
personnel ................................................. 2-3 Therefore, this operating manual does not
release the user/owner from the obligation of
2.3 Hazards/residual risks ............................. 2-3
developing and applying his own health and
2.3.1 Hazard information .................................. 2-3
safety rules, as well as safety-focused operating
2.3.1.1 Use of lifting gear and transport ............. 2-4
procedures designed to meet the company’s
2.3.1.2 Manual transport ..................................... 2-4
requirements, and monitoring the observance of
2.3.1.3 Preparation for operation ........................ 2-5
these rules accordingly. This applies in particular
2.3.1.4 Start-up/commissioning, operation ........... 2-5
to the handling of the wireline/cable, tools etc.,
2.3.1.5 Maintenance work .................................. 2-6
please also refer to Chapt. 4.2.2.
2.4 Hazard zones and hazardous area .......... 2-8 If you require additional information, please
2.5 Protection devices/guards and safety contact KMA directly under the above specified
components on the machine .................... 2-9 address/telephone number.

2.6 Disposal and environmental protection ... 2-9

Tables
Hazard analysis, risk assessment and
2.1 Directives, ordinances,
protection/safety devices/guards (in regulations/provisions
accordance with the Machinery Directive), The EC directives pertaining to health and safety at
see Chapter 9! work, the BetrSichV2) 3), as well as the accident
prevention regulations (German BGV ...) in their
individual valid wording applicable to the installation
• Ensure that this chapter is submitted to the owner/ site and to the owner/user’s company are binding and
user’s safety officer prior to initial start-up/ have to be adhered to for transport, installation and
commissioning. connection, operation and maintenance of the Wireline
Combi Unit PP1), as well as for each measure
outlined in this operating manual.

1) The „Wireline Combi Unit PP“ is also referred to in this EC directives applied to the design and manufacture
operating manual as the „Container“ or „Unit“. of the Wireline Combi Unit PP (also see Chapter 1.6):
2) Users located outside of the EEC should always follow the - Directive 2006/42/EC, the „Machinery Directive“,
safety practices and procedures in accordance with the
recommendations of The Occupational Safety and Health
- Directive 2006/95/EC, the „Low Voltage
Administration (OSHA), The National Safety Council (NSC), Directive“,
The Hand Tools Institute (HTI), The International Association - Directive 2004/108/EC on electro-magnetic
of Drilling Contractors (IADC) etc. All applicable governmental compatibility (EMC),
rules, regulations or restrictions, now in effect or which may be - Directive 2001/45/EC, Use of machines, working
promulgated, take precedence over the suggestions in this
publication! means and work equipment,
3) For information on the abbreviations see Chapter 1.7.1. - Directive 2000/14/EC, Noise emission in the

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Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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environment by equipment for use outdoors. • When handling hazardous substances/formulations

(ChemG), adhere to the regulations in the safety
Harmonized standards applied to the design and data sheet according to Directive 2006/1907/EC (or
manufacture of the Wireline Combi Unit PP: 91/155/EEC and/or 2001/58/EC).
- DIN EN ISO 12 100 Safety of machinery, Request the safety data sheet from the
Basic terms, Governing manufacturer of the substance if necessary.
principles for general design, • When disposing of fluid/solid waste materials,
- DIN EN ISO 13 850 Emergency Stop - Principles adhere to the regulations from the BImSchV
for Design, (Federal Immission Control Ordinance), the KrW-/
- DIN EN ISO 13 857 Safety distances to prevent AbfG (Waste Avoidance, Recycling and Disposal
hazard zones being reached Act), the TA-Abfall (German Technical
by upper limbs, Instructions on Waste), the WHG3) (Federal Water
- DIN EN ISO 13 854 Minimum gaps to avoid Act) etc.
crushing of parts of the • Always adhere to the more stringent version of a
human body, regulation if a statement in this operating manual
- DIN EN ISO 14 120 General requirements for the does not correspond to the local/company
design and construction of regulations.
fixed and movable guards,
- DIN EN ISO 4413 Hydraulic fluid power -
General rules and safety
requirements for systems and 2.2 Safety fundamentals
their components
• The information given in this operating manual
- DIN EN ISO 4414 Pneumatic fluid power -
refers to the KMA scope of delivery! Refer to the
General rules and safety
„operating and handling instructions“ to be issued by
requirements for systems and
the owner/user for the safe handling of the wireline/
their components
cable, tools etc. to be provided by the owner/user
- DIN EN 60 204 Electrical equipment of
(Chapter 4.2.2).
industrial machines.
The Wireline Combi Unit PP corresponds to the state
of the art. The Wireline Combi Unit PP is safe to
Adhere to the employer’s liability insurance
operate when it is in a perfect, technically safe
association regulations and accident prevention
condition, used as intended and in compliance with the
regulations (BGV ...), including their implementation
agreed technical data.
directives (DA) when operating the Wireline Combi
Wireline Unit PP:
! Warning
BGV A1 - Prevention basics
BGV A3 - Electrical systems and equipment Risks to the operating personnel, third parties,
BGV A8 - Safety signs the unit or other assets may emanate from the
machine if it is installed/set-up, operated or
as well as the ordinances and Employers’ Liability maintained incorrectly by insufficiently qualified
Insurance rules: personnel, not in accordance with the intended
BetrSichV - Betriebssicherheitsverordnung (German use or when it is not in a technically safe and
ordinance on occupational safety and perfect condition.
health),
(CHV 16) for the use of work
equipment (devices/machines/machine 2.2.1 Informal safety
lines) by employees during work ... measures
BGR B3 - Accident prevention regulation, noise • This operating manual forms part of the unit1),
BGR 500 - Operation of work equipment therefore ensure that it is made directly accessible
to the operating and maintenance personnel at all

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times. • Work requiring direct, personal responsibility can

• Pass on this operating manual to each subsequent only be performed by expert personnel who have
owner or user of the unit. the appropriate technical training (BGV A1).
• The third-party operating manuals for equipment • Only allow experienced, qualified expert personnel
etc. can be found in the appendix of this operating to perform work on the hydraulic/pneumatic drives,
manual. units or equipment!
• Always keep the type plate (Chapter 1.2) and the • Only allow work on electrical drives, devices or
safety and hazard information on the unit in a equipment to be performed by experienced,
legible condition. qualified electricians (BGV A3)!
• Immediately replace hazard information signs or
It is the sole responsibility of the owner/user to ensure
decals if they become damaged.
the qualification of his/her employees, their instruction
on the unit, the knowledge of hazards (residual risks),
of the contents of this operating manual and of the
2.2.2 Obligation of the owner/user „Operating and handling instructions“ (to be issued by
• Ensure that all those persons involved with the unit the owner/user) for the handling of the tools etc.
commit themselves to adhere to all information/ (provided by the owner/user) (Chapt. 4.2.2).
instructions in this operating manual, the third-party
operating manuals, the occupational safety and
health regulations, and the safety instructions/
regulations.
• Immediately take appropriate measures to prevent
2.3 Hazards or
hazards or to adhere to occupational safety and residual risks
health regulations and safety instructions as soon as • Hazard information/signs and warnings on the
you become aware of such a hazard. Wireline Combi Unit PP indicate particular residual
• Only allow qualified and instructed persons to risks, some of which cannot be prevented by KMA
perform any measures (Chapter 2.2.3). or cannot be prevented without impairing the
• Clearly define responsibilities for preparation for intended use of the machine.
operation, operation, maintenance work etc.
Assign a supervisor. ! Danger
• Exclude the possibility of hazards resulting from Severe damage to health, damage to the unit or
unclearly defined competencies/responsibilities. other assets may result if the following hazards,
• Take precautions to ensure the correct disposal of warnings and information/instructions are not
all waste and used substances occurring during observed.
preparation for operation, operation and The owner/user bears the sole risk!
maintenance!

2.3.1 Warnings of hazards

2.2.3 Qualification of the
operating personnel ! Attention
Ensure that each person entrusted with one of
! Danger the measures described in this operating manual
Lack of specialist knowledge or non- on the unit has read and understood the
observance of the safety regulations when operating manual beforehand, especially this
working on mechanical/hydraulic/pneumatic/ safety chapter.
electrical devices/equipment can lead to severe During operation it will be too late to
damage to health and damage to assets. obtain the necessary information!
• Restrict operation and other work on the unit to • Hazard due to lack of specialist knowledge or non-
qualified, trained or instructed personnel only! observance of the safety regulations when working

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Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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on the unit and/or hydraulic/pneumatic/electrical 2.3.1.1 Risks when using lifting gear4) and
devices/equipment. during transport
This could entail the most severe damage to health • The following applies to every use of lifting gear:
and assets. Ensure that no risk emanates from the suspended
• Adhere to the Health and Safety at Work/ load during lifting or transport!
occupational safety and health, and safety • Hazard due to incorrect attachment of the container
regulations; only apply correct and safe working to lifting gear:
methods and practices. - Attachment only by experienced expert
• Hazard resulting from not wearing the prescribed personnel,
personal protective equipment (PPE), including for - attachment to shackles, attached to the
instance, attachment points, see Fig. 3-1.
- hard hat,
- eye and hearing protection, ! Warning
- protective gloves, Adhere to the safety regulations for handling
- safety boots, etc. loads according to BGV D6 and D8!
Only use PPE that is in perfect condition!
• Hazard due to lack of or left open protection • Hazards resulting from the lifting and transporting
devices/guards/safety components. of the container/a winch drum of the Wireline
Only switch on the Wireline Combi Unit PP when Combi Unit PP:
all protection devices/guards (barriers/fencing for - Prior to any transport, wind up the wireline and
the wireline/cable on the path to the wellhead/ cable and fasten the ends to the drums.
borehole, see Fig. 2-1, contact protection hoods, - Always remove the electric cable of an external
closed panoramic window etc.) have been properly power supply prior to transporting a container.
fitted and closed. - Always lift/lower the container vertically, never
pull at an angle!
• Prior to commencing work, inform yourself about - Protect equipment items on the container from
- hazard zones on the unit and at the installation site damage during lifting/transport.
(Table 9.I),
- protective devices/guards/safety devices on the Danger
unit (Table 9.III),
!
- the operating elements, especially the switching When using lifting gear, never work or stand
measures to ensure reliable switch-off/shut-down beneath
of the machine. suspended loads or between the load and
• During operation and all work on the Wireline stationary limitations (container wall, winch
Combi Unit PP, adhere to the information/ frame etc.).
instructions contained in the „Operating and Danger to life!
handling instructions“ issued by the owner/user • Deposit the container with due care, immediately
regarding the handling of the wireline/cable, tools secure against tipping over, and protect from
etc., see Chapt. 4.2.2! external forces (collision with industrial trucks) and
• Avoid carrying out dangerous work on your own, falling objects.
e.g. in confined service areas next to the winches.
Ensure that a second person is in the control room
and can switch off the machine if necessary. 2.3.1.2 Hazards emanating from manual
transport
• Individual components may not be unloaded and
transported by hand if they weigh more than 25 kg
(BGV A1, ArbSchG, ArbStättV)!
4) Use of lifting gear, e.g. when the container is detached from the
truck and set up separately (Chapt. 5.2 and following) as well
as during maintenance work, e.g. the replacement of a winch
drum.

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2.3.1.4 Hazards during commissioning/start-up

! Warning
and during normal operation
All manual transport entails an increased risk of • Hazard due to insufficient operational safety and/or
injury and accident! operational readiness of the unit. Prior to each
start-up, ensure unrestricted operational safety and
operational readiness.
2.3.1.3 Hazards during preparation for • Hazard due to lack of/left open protection/safety
operation devices/guards, see Table. 9.III.
• Hazard due to risk of tripping and slipping at the Prior to starting up and switching on, ensure that
installation site. the protection/safety devices/guards are correctly
- Thoroughly clean the installation surface. fitted and functioning.
Remove dirt/soiling, solid matter, building and • Hazard due to lack of personal protective
installation residue with a broom. equipment (PPE), see Chapter 2.3.1.
- Route electric cables such that they can be safely Only use PPE that is in perfect condition!
driven over and do not present a tripping hazard.
• Hazard due to non-observance of information/
instructions contained in the „Operating and
! Warning
handling instructions“ issued by the owner/user for
Hazard if the container centerline is not the handling of the wireline/cable, tools etc., as well
precisely aligned to the wellhead/borehole etc.! as any supplementary safety regulations, see Chapt.
• Hazard emanating from crushing your feet when 4.2.2.
depositing loads, e.g. placing the container • Hazard due to measures/work performed on the
separately at the place of operation. machine by unauthorized persons.
Maintain a sufficient safety distance from the Only authorized personnel are allowed to work on
container base frame! the Wireline Combi Unit PP and start it up or shut it
• Danger of crushing: In poor weather/when there is down in regular mode/during normal operation.
a strong wind, ensure that the winch cab doors are • Hazard due to insufficient visual inspection/
opened by two people if necessary and immediately monitoring of the unit. Refrain from any actuation/
secured to the container. switching and method of operation that could
endanger or impair the safety of persons or cause
! Danger damage to assets.
When an external energy supply is connected or
the engine is running (power pack) always ! Danger
maintain a sufficient safety distance (as defined Contact with the running wireline/cable can
by DIN EN ISO 13 857) from moving cause serious injuries.
components! Always maintain a sufficient safety distance
Drives can start up unexpectedly at any time from the cable/wire when the machine is
due to system faults or unauthorized/erroneous operating, see Fig. 2-1!
switching.
• Hazard can result from the unit starting up. Do not
• Access limiting guards/fencing (railings, protective switch on until it has been ensured that
fence etc.) required in order to meet local - no persons will be endangered by the unit starting
conditions or prescribed by supervisory bodies are up or by its operation,
to be provided by the owner/user and installed prior - any possible system malfunctions have been
to initial start-up/commissioning in accordance with completely remedied,
DIN EN ISO 14 120. - all maintenance work has been correctly
• Reliably prevent access of unauthorized persons to completed,
the unit, especially the winch cab, and any possible - damaged or worn components have been
hazard points! replaced,

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- all protection/safety devices/guards are fitted and 2.3.1.5 Hazards during maintenance work
fully functioning! (service)
• Only experienced, qualified expert personnel are
! Warning permitted to perform work on the hydraulic/
Do NOT enter the winch cab during operation, pneumatic drives/units/equipment!
when the unit is activated. Always maintain a • Only allow work on electrical drives/devices/
safety distance from the hazard zones during equipment to be performed by qualified electricians
maintenance work etc.! (BGV A3)!
Hydr./pneum./electr. drives could start up • Hazard due to inadvertent/unauthorized switching
unexpectedly at any time! and unexpected start-up of hydr./pneum./electr.
• Danger of crushing and shearing between fixed and drives.
moving machine components. Only perform inspections and maintenance work
• When the machine is active/running, never reach when the machine is in a safe standstill condition
behind cladding, protection hoods etc. or into areas and secured against reactivation (Chapt. 7.5.1).
you cannot look into! • Hazard due to carrying out work alone (without a
• Hazard due to insufficient visual inspection/ second person).
monitoring. Check at intervals to be specified by the If maintenance work/inspections have to be
owner/user according to operating requirements performed with the drums rotating/machine parts
that the machine is safe, functioning and free of moving, ensure that a second person is in the
emissions. control room to take over supervision and actuate
• Hazard due to poor function control/inspection and/ the EMERGENCY STOP button in an emergency.
or changes to the unit or its operating behavior. • With the unit activated (running power pack and
Immediately report any changes in operating generator), never reach with your hands behind
behavior to the supervisory person or a department/ protection devices/guards (covers/cladding) or into
person to be determined by the user/owner. areas you cannot look into!

Attention ! Warning
!
Immediately switch off the unit, if necessary, by Changes, attachments to or conversions of the
pressing the EMERGENCY STOP button, Wireline Combi Unit PP are not permissible if
- in the event of abnormal/unusual operating they influence its active/passive safety.
behavior, noise or vibrations, • Hazard due to loose screw connections! Tighten
- in the event of erratic/uneven movements of screws/bolts/nuts according to the prescribed
the winches or fluttering run of the cable/ tightening torques (Chapter 7.5.6).
wireline, • Risk of damage to assets due to use of force.
- in the event of malfunctions of the hydr./ Ensure that the force used does not exceed the
pneum./electr. energy (power) supply, required level for loosening/tightening bolted
- if unauthorized persons access dangerous connections or screw connections!
zones/points of the unit! • Danger of cutting / abrasion on sharp structural
• Immediately have malfunction causes established elements (corners and edges).
and fully remedied in accordance with safety • Hazard due to spare parts, equipment or substitute/
regulations. alternative materials that do not meet the original
• Hazard due to premature start-up before defects specifications; they may endanger the active and
and damage have been fully remedied! passive safety of the unit.

! Warning
Hazard due to worn or damaged components.
Damaged/faulty components impair safety and
must be replaced immediately!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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• Hazard due to lack of, inadequate or left open relief valves (safety valves)!
protection/safety devices/guards. Immediately refit • Hazard due to the mixing up of connections. Label
protection devices/guards after completing work. dismantled connection lines to drives/valves etc.;
take care not to accidently interchange them during
• Hazard due to contamination in the hydraulic
subsequent assembly, otherwise this will lead to
system. Ensure the utmost level of cleanliness
malfunctions.
when working on hydraulic components to avoid the
risk of malfunctions and damage to assets!
! Danger
• Hazard due to residual energy in the hydraulic
system. Prior to performing any work on the Once the electrical system has been switched
hydraulic system, wait until it is completely on with „2Q1“, certain components of the
depressurized or have the system depressurized by electrical devices carry dangerous voltage!
expert personnel - watch the pressure gauge • Immediately have any damaged, scorched or
reading. chafed/frayed cables replaced, and any loose/
• Hazard caused by contamination! Secure (tape off) unsealed cable connections retightened or resealed
and label opened hydraulic connections immediately by a qualified electrician.
to prevent the ingress of soiling.
• Danger of burns - hydraulic components have a • Only remove dust deposits and loose soiling by
high surface temperature of up to +120 °C directly vacuuming with an industrial vacuum cleaner (DIN
after shut-down. EN 60 335-2/AA) or by hand (with a cloth,
• Danger of scalding while changing the oil - high scrubbing brush).
temperatures of oil at operating temperatures of Do NOT blow off with compressed air!
approx. +70 °C! • Hazard emanating from aggressive, easily
• Risk of environmental damage from used inflammable or hazardous solvents or cleaning
lubricants. Only collect and dispose of old oil in agents for cleaning hands, components or tools.
approved containers in accordance with KrW-/ Only use substances without trichloroethylene,
AbfG and/or AltölV. perchloroethylene/tetrachloroethylene, carbon
• Risk of environmental damage from leaking oil or tetrachloride/tet/tetrachloromethane or CFCs!
the leakage of ground water endangering • Hazard when washing oiled components or
substances. Immediately remove any leaked components containing grease using white spirit or
substances by wiping up (BGV A1); bind or petroleum ether (FAM petroleum spirits). Only use
neutralize any larger amounts, never allow them to petroleum spirits with a flash point above 21° C.
enter the sewage system. NEVER use gasoline (commercially available
normal/super gasoline)!
• Hazard emanating from all work on hydraulic • Hazard emanating from the non-observance of
drives/components. Prior to commencing any instructions printed on packaging or contained in the
measure: safety data sheet of the chemical substances used
- Perform the measures to ensure that the machine (cleaning agents or similar).
is in a safe standstill condition (Chapt. 7.5.1), Request the safety data sheet from the
- Depressurize system sections to be opened manufacturer of the substance if necessary.
(devices/equipment/hose lines, etc.), • Hazard due to rubber or plastic components coming
Wait until the pressure gauge indicates p = 0 bar! into contact with oil, solvent or cleaning agents, or
• Hazard emanating from damaged, kinked, pinched other chemical substances.
or chafed hose lines and loose/leaking connections; • Hazard due to any cleaning work involving high-
have them replaced, retightened or re-sealed pressure water/steam jets, e.g. due to the washing
immediately by expert personnel. out of roller bearings, causing them to run dry.
• Hazard due to aged hydraulic hose lines. Inspect Prior to wet cleaning, cover and seal off all
hoses regularly and renew within the specified components that must not be penetrated by
period. moisture due to their function.
• Never change the factory settings on pressure Immediately remove any temporary covers/tape/

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Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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seals after completing the work. 2.4.0.1 Hazardous area

Adhere to the safety regulations specified in the A hazardous area involving
operating manual of the respective appliance - risk of injury from moving, rotating components,
manufacturer. - risk of burns on hydraulic components subject to
high surface temperatures,
- risk of injury caused by the transported material and
the danger of whipping ends in the event of a break
2.4 Hazard zones and in the wireline/cable,
- risk of injury from the cable in the event of broken
hazardous area strands and sharp, protruding strand ends,
For details regarding hazard zones, hazard events and encompasses the entire area of the winch cab (Fig. 2-
hazard situations, amongst others according to DIN 1)
EN ISO 14121-1, please refer to Table 9.I. as well as the area between the Wireline Combi Unit
PP and the wellhead. Maintain a sufficient safety
! Danger distance of at least 10.0 m (as defined by DIN EN
Contact with the running cable/wireline can 13857) from the danger zones during operation.
cause serious injuries.
Always maintain a sufficient safety distance
from the wireline/cable when the winches
are rotating, see Fig. 2-1!
• For all work with the unit1) adhere to the safety
regulations, e.g. according to BGV A1, BGR
5002)3) etc.

! Danger
During operation, it is forbidden for persons to
remain in the hazardous area, the winch cab Fig. 2-1: Hazardous area on the Wireline Combi Unit
and in the vicinity of the path of the wireline/ PP due to whipping ends in the event of a break in the
cable. wire/cable. The hazardous area stretches from the
The operator must switch off the unit if the rear of the truck to at least the first guide pulley/hay
hazardous area is accessed by unauthorized pulley with a width of
persons. 10 m on each side of the wireline/cable.
During operation, the hazardous area is to be clearly
marked and secured with barricades to prevent the
access of unauthorized persons.
10 m

Gefahrenbereich
10 m

Draht/Kabel Umlenkrolle

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 2 - Safety

persons, e.g. in the vicinity of traffic routes,

! Danger - to protect the operating personnel from hazards
The partial hazards/hazardous situations by means of organisational measures, sufficient
specified in Table 9.I cannot be secured/ instruction/briefing and the selection of suitable
prevented by KMA without limiting the personnel,
intended use. - to take additional protection measures required by
Ensure that the instruction/briefing of the supervisory bodies prior to initial start-up, and to
operator includes operation of the machine in provide and install any additionally prescribed
accordance with safety procedures! protection devices/guards and safety equipment
so that they function perfectly prior to initial start-
up/commissioning!
• It is the personal responsibility of the user/owner to
2.5 Protection devices/guards and supplement the factory-attached hazard signs in
safety components accordance with BGV A8 (see Chapter 1.2) in
order to meet the local regulations.
Attention • Ensure that the hazard signs and type plate are
! always in a legible state!
Only operate the Wireline Combi Unit PP when
it is in perfect, technically safe condition!
Removal, switching off or bridging of
protection/safety devices/guards is forbidden!
2.6 Disposal and
• The protection and safety devices/guards fitted in
the factory by KMA include the equipment listed in environmental protection
Table 9.III. Attention
!
Danger Dispose of used substances in accordance with
! the regulations prescribed by the BImSchV,
Hazard information and warnings on the unit KrW-/AbfG and according to the rules of the
indicate residual hazards that cannot be WHG3).
prevented by KMA or cannot be prevented
without impairing the intended use of the The following substances may accumulate during
machine. maintenance or repair work, the disposal of which is
the personal responsibility of the owner/user:
• It is the sole responsibility of the user/owner - Hydraulic oil/lubricants,
(Chapter 2.2.2 and following), - Cleaning agents and consumables,
- to inform the operating and maintenance - Other waste of all kinds, including worn
personnel of the residual risks on the unit (see the components of the Wireline Combi Unit PP.
risk assessment in Table 9.II and hazard Fluid waste being substances hazardous to ground
information acc. to BGV A8), water (see WHG) must be collected in closed,
- to ensure that the prescribed personal protection approved containers and correctly disposed of.
equipment (PPE) is worn, for instance
- eye and hearing protection, • Immediately bind or neutralize any leaked or spilled
- hard hat, fluids (BGV A1)!
- protective gloves, • Never allow used consumables (e.g. hydraulic oil/
- safety boots, etc. lubricants) to enter the sewage system.
as well as any additional PPE in accordance with • Whenever disposing of a substance, always adhere
the company regulations of the user/owner, to the company, local and regional regulations.
- to secure the unit and the running wireline/cable
as shown in Fig. 2-1 with protective fencing/ When disposing of the unit (scrapping), preferably
barricades to prevent the access of unauthorized have all the components recycled according to their

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 2 - Safety

material group.
Once all containers have been completely emptied and
possible residue of lubricants removed from all
components, the following materials groups can result
from the subsequent dismantling:
- Metals: Aluminum, steel, gray-cast iron, nickel
chromium steel
- Elastomers/plastics: Hoses, cable sheathing,
- Hydr./pneum./electr. components, devices/
equipment.
Dismantled components are to be separated and
collected according to their material group; it is the
personal responsibility of the user/owner to dispose of
the non-recyclable remains in accordance with KrW-/
AbfG.
• For disposal of items of equipment, please refer to
the third-party operating manuals in Section III of
the technical documentation.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 3 - Transport

3. Lifting and transporting, use of lifting gear, storage

Table of Contents 3.1 Safety information
3.1 Safety information .......................... Page 3-1 Observe the regulations, warnings and instructions
contained in Chapt. 2 „Occupational safety and health,
3.2 Attachment, lifting and transport
safety regulations and environmental protection“ when
(use of lifting gear) .................................. 3-1
lifting and transporting the container 4) as well as for
3.2.1 Road transport of the unit ....................... 3-3
intermediate or long-term storage!
3.2.2 Air transport ............................................ 3-3

3.3 The delivered unit .................................... 3-3

3.3.1 Packaging, preservation .......................... 3-3
3.3.2 Completeness of the delivery .................. 3-3 3.2 Lifting and transportation
3.3.3 What to do in the event of transportation (use of lifting gear)
damage .................................................... 3-3
Weight:
- Container total weight ............................... 15,000 kg
3.4 Long-term or intermediate storage .......... 3-4
3.4.0.1 Monthly inspection of the Wireline Area and space required (container):
Container Unit PP ................................... 3-4 - Length ....................................................... 7,300 mm
3.4.0.2 Inspections every 6 months ..................... 3-4 - Width ........................................................ 2,500 mm
3.4.0.3 Annual inspections (every 12 months) .... 3-5 - Height ....................................................... 2,729 mm
3.4.0.4 Inspections every 4 years ....................... 3-5 • Always transport the Wireline Combi Unit PP1) to
the place of installation by means of tested and
approved lifting gear (crane) of sufficient load
bearing capacity.
• Only use certified attachment gear as 4-point lifting
tackle for attachment to lifting equipment.
• Only allow attachment for unloading or transport to
be performed by experienced, instructed personnel
(personnel with experience in attachment work).
Also see the information sign in the winch cab!
• Attachment points for attachment for crane
transport are located on top of the container and in
the winch cab in the form of eyebolts for the
attachment of shackles (Fig. 4-3).
• Prior to attachment wind up the wireline/cable and
fasten to the drums.
• Fully open the roof structure prior to attachment,
see Fig. 5-3, fit the shackles and adjust the cables/
ropes/chains to the correct length, see Fig. 3-1.
• Close the winch cab doors.
• Disconnect the electric cables for the external
electricity supply from the container, see Fig. 5-4.
1) The „Wireline Combi Unit PP“ is also referred to in this • Disconnect the twistlock connection between truck
operating manual as the „Container“ or „Unit“. and container.
3) For information on the abbreviations see Chapter 1.7.1.
4) Use of lifting gear and transport of the container without truck, • Whenever using lifting gear, always adhere to the
e.g. when the unit is installed separately and external energy regulations from BGV D63) and BGV D8.
supply (Chapter 5.2 and following) as well as during • Ensure that no risk emanates from the suspended
maintenance work, e.g. the replacement of a winch drum.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 3 - Transport

load at any time during lifting and transport! • Protect components/equipment from damage during
lifting and in-house transport.
! Danger to life! • Handle the Wireline Combi Unit PP with due care
Never stand or work beneath suspended loads during unloading, transport and intermediate/long-
or between the load and stationary limitations term storage and protect it from external forces and
(container wall, winch frame 4) etc.). falling objects.

• Ensure that nobody is located between the lifted Manual transport

load and fixed parts of the building/machine during • Components may not be unloaded and transported
container lifting. Risk of crushing. by hand if they weigh more than 25 kg (BGV A1,
• Always post a signal person/supervisor for all ArbSchG, ArbStättV)!
lifting/transport tasks who can give the crane
operator emergency signals if necessary.

Fig. 3-1: 4-point lifting tackle/gear,

cables/ropes, ring/eyebolt etc. fastened
with shackles to the attachment points at
the top of the container and in the winch
cab.
Attention:Fully push back the roof
structure of the winch cab prior to
attachment (Fig. 5-3)!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 3 - Transport

Warning 3.3.1 Packaging, preservation

! The Wireline Combi Unit PP is delivered without
All manual transport entails an increased risk of packaging.
injury and accident! • Do not remove any covers/adhesive tape from
sensitive devices until just before preparation for
operation (provided that no transport damage is
3.2.1 Road transport to the work site suspected - see below).
The Wireline Combi Unit PP is transported by road as
• The Wireline Combi Unit PP is preserved for a
a completely assembled unit (owner/user’s own
standard transport period and commissioning/start-
vehicle and container).
up within approx. 6 months after delivery.
For road transport, the national regulations apply
• For measures regarding long-term/intermediate
without reservation (e.g. in Germany the rules of the
storage of the Wireline Combi Unit PP, please refer
StVZO apply).
to Chapter 3.4.

3.2.2 Air transport 3.3.2 Completeness of the delivery

Due to the air transport regulations of the air freight
• Check the completeness of the delivery
carriers and national air transport regulations,
immediately after receipt!
hydraulic oil reservoirs, lubricant tanks, fuel tanks, air
• Immediately notify the carrier who delivered the
vessels etc. have to be emptied/drained.
machine if any parts are missing.
This includes tanks/reservoirs/vessels for:
• Submit a notification of missing parts and notify
- Fuel (diesel oil)
KMA; see above for address and telephone
- Engine oil sump
numbers.
- Engine cooler
- Compressed air vessel
- Hydraulic oil reservoir
- Batteries (battery acid/distilled water) 3.3.3 Transport damage
• Check the machine for transport damage
Small fluid volumes remain in the system despite immediately after delivery of the Wireline Combi
careful draining, e.g. in the Unit PP.
- air/oil cooler Check for externally visible damage (breakage,
- return filter kinks, dents, tears, cracks etc.)!
- pipe/hose lines, etc.
• If there is any sign of transportation damage,
• For details regarding the draining of the different immediately:
containers, please refer to Chapter 7 - Inform the transportation company, the carrier, in
„Maintenance“. writing and
- if you had the transport risk insured yourself, also
inform your insurance company in writing.
• Adhere to the terms and conditions of the insurance
3.3 The delivered unit policy!
When a new unit is delivered, the above mentioned Delayed notification of damage may lead to loss of
containers/reservoirs/tanks have to be filled again with insurance protection!
consumables/auxiliary substances prior to
commissioning/start-up as described in Chapter 5.3 • Document any suspected transport damage by
and following chapters. means of:
- Photographs (digital or Polaroid®)
- Sketch with the damage exactly marked
- A detailed description (report)
• „Hidden“ transport damage (damage that can only

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 3 - Transport

be determined after dismantling the unit) should be • Store the unit in a dry, enclosed room and cover
included in the report to the carrier/insurance carefully to protect against moisture and dust.
company as a precautionary measure. • Avoid long-term storage or intermediate storage at
We recommend including the express reservation in locations with highly fluctuating ambient
writing that the notification of damage only refers to temperatures, e.g. outdoors.
externally visible damage and might not include the Temperature fluctuations may lead to the formation
actual extent of the damage! of condensation with subsequent corrosion (rust).
• Please also send a copy of your notification of • Protect the unit from falling objects and external
damage to KMA, see above for address and damage, e.g. from collision with industrial trucks!
telephone number. • For information on storing drives/devices/
equipment, please also refer to the third-party
Have any necessary dismantling of the Wireline
operating manuals of the respective manufacturers
Combi Unit PP only performed by KMA expert
in the appendix.
personnel if possible.
• Never store the machine and replacement hydraulic
hoses in a room together with solvents
(hydrocarbons), fuel, oil or other chemicals.
3.4 Long-term or intermediate Vapors released from solvents, chemicals etc.
accelerate the aging of hoses and reduce their
storage operating life!
If the Wireline Combi Unit PP is not commissioned
• Ambient conditions for electrical devices/
within about 6 months after delivery, or if the unit is
equipment, as normal limit values:
shut down for longer than 6 months, carry out the
- Ambient temperatures +5 °C to +40 °C,
following measures:
- Air humidity max. 76 % (annual average),
• For information on safe shut-down of the unit (after
also refer to the information provided by the
winding up the wireline/cable) refer to Chapt. 6.5
respective manufacturers!
and following chapters.
• Depending upon the intended storage time, remove
• For shutting down and storage measures for the
the batteries and store separately.
components, please also refer to the third-party
operating manuals in the appendix.
• Thinly coat bare metallic components, except 3.4.0.1 Monthly inspections of the Wireline
stainless steel parts (CrNi-steel/SS) with an acid- Combi Unit PP
and resin-free grease, or spray with an anti- • Visually inspect the stored unit for externally visible
corrosion oil, see Chapt. 7.3.4. damage of machine/devices/equipment/
components.
! Attention Record the results of the inspection.
Never apply oil, solvents or chemical
substances to plastic/rubber components,
bellows, hoses, cable jacketing etc.! 3.4.0.2 Checks to be carried out twice a year
(every six months)
• Check consumables/auxiliary substances and refill Perform the following visual inspections and value-
if necessary preserving measures:
- Fill up with fuel, • Check for loose or damaged devices/components,
- engine oil, and refasten or replace them.
- engine coolant, check fluid level and antifreeze, • Check closed components/switchgears etc. (stored
- hydraulic oil, with e.g. silica gel for long-term storage) for
- gear oil (planetary gear unit/winch drive), moisture. Renew the silica gel if necessary.
- battery acid, • Touch up the protective coating if damaged.
see chapter 7.3.1 and following chapters, and the • Determine necessary cleaning measures, clean the
third-party operating manuals.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 3 - Transport

unit and cover again, seal/tape off components if • Prepare the unit for operation, see Chapter 5.3 and
necessary. following chapters, run through all functions,
• Check the consumables/auxiliary substance fillings, subsequently:
top up if necessary, and find and remedy the cause - Regrease all grease points (Chapter 7.5.7),
for the loss of fluid. - Oil the roller chain, see Chapt. 7.6.4.
• Check bare metallic components for corrosion, if • Check the hydraulic oil level and top up oil, if
necessary, apply a coat of acid- and resin-free necessary.
lubricating grease or spray with an anti-corrosion • Have the electrical equipment checked by a
oil. qualified electrician (BGV A3).
• Check rubber/plastic components (hoses/electric
cable jacketing) for signs of aging.
3.4.0.4 Checks every four (4) years
! Attention • Have all hydraulic/pneumatic/electrical devices/
Never apply oil, solvents or chemical equipment checked (and dismantled and repaired if
substances to plastic/rubber components, hoses, necessary) by expert personnel prior to
cable jacketing etc.! recommissioning/restarting.
• Replace the hydraulic filter element.
• Store replacement hydraulic hoses in a cool, dry, • Renew the hydraulic hose lines as described in
dust-free and only moderately ventilated room. Chapter 7.7.4.
- Storage temperature approx. -10 °C to +25 °C,
- Relative air humidity approx. 65 % (annual
average).
• Protect hoses against exposure to light, seal in black
(!) plastic film for storage periods exceeding 6
months.
Permissible storage time: max. 2 years!

! Attention
Do not use replacement hydraulic hoses after a
storage time of two (2) years!
• Protect fitted hose fittings (screw-connections)
against corrosion, close connection openings with
caps/plugs or tape off.
• Relubricate drum shaft bearings, see Chapt. 7.5.7.
• Oil the roller chain, see Chapt. 7.6.4.
• Relubricate the flange bearings of the spooling
mechanism, grease universal/cardan joints/guides.
• Take an oil sample from the hydraulic oil reservoir,
and if necessary remove any water and bleed the
system as described in Chapter 7.7.1, subsequently
top up with hydraulic oil.

3.4.0.3 Annual check (every 12 months)

• Start up the power pack in accordance with Chapt.
6.3.4 and following.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

4. Description of the Wireline Combi Unit PP

Table of Contents 4.3.4.3 Operating elements on the electric
switch cabinet ........................................ 4-15
4.1 Intended use ................................... Page 4-2
4.3.4.4 Operating elements on the PCE
4.1.1 Misuse and non-intended use ................... 4-2
pressure control panel ............................ 4-15
4.2 Technical data .......................................... 4-2
4.3.5 Winch cab .............................................. 4-15
4.2.0.1 Environmental influences and/or
4.3.6 Winches .................................................. 4-15
emissions .................................................. 4-2
4.3.6.1 Winch drive ............................................ 4-17
4.2.0.2 Permissible ambient conditions .................4-2
4.3.6.2 Brake system .......................................... 4-17
4.2.0.3 Functional criteria,
4.3.6.3 Operating the winches and brakes ......... 4-18
inadmissible operating conditions .............. 4-2
4.2.0.4 Technical documentation according
4.3.7 16" measuring head Dolphin ................... 4-18
to the Machinery Directive ....................... 4-2
4.3.7.1 Spooling mechanism ............................... 4-18
4.3.7.2 Measuring head oiler/wire oiler .............. 4-18
4.2.1 Hazard zones and hazardous area ............ 4-4
4.2.1.1 Hazardous area ........................................4-4
4.3.8 Pressure control equipment (PCE) ........ 4-18
4.2.2 Organizational safety measure,
4.3.8.1 PCE in the engine compartment ............ 4-19
operating and handling instructions ........... 4-4
4.3.8.2 PCE in the winch cab ............................ 4-19
4.2.3 Connection to ground/equipotential
bonding .....................................................4-4
4.4 Hydraulic system .................................... 4-19
4.4.0.1 Hydraulic oil reservoir ............................ 4-20
4.3 Description of the
4.4.0.2 Return filter ............................................ 4-20
Wireline Combi Unit PP ...........................4-5
4.4.0.3 Operation and monitoring ....................... 4-20
4.3.1 Container .................................................. 4-5
4.4.0.4 Hydraulic oil/air cooler ........................... 4-21
4.3.1.1 Components installed under the floor
in the container frame .............................. 4-5
4.5 Pneumatic system .................................. 4-22
4.3.1.2 Air conditioning unit ................................. 4-5
4.5.0.1 Compressed air supply ........................... 4-22
4.3.1.3 Storage box/tool rack under the
container ...................................................4-5
4.6 Electricity (power) supply ...................... 4-22
4.6.0.1 Battery (24V supply) .............................. 4-22
4.3.2 Engine compartment ................................ 4-5
4.3.2.1 Engine oil system ...................................... 4-6
4.7 Delivery scope ....................................... 4-22
4.3.2.2 Engine cooling system .............................. 4-6
4.3.2.3 Fuel system ............................................... 4-6
4.3.2.4 Combustion air system .............................4-7
4.3.2.5 Exhaust system ........................................4-7
4.3.2.6 Electrical system of the engine ................4-8
4.3.2.7 Engine electronics .................................... 4-8

4.3.3 Control room ............................................. 4-9

4.3.4 Operating elements ................................ 4-12
4.3.4.1 Operating elements on the container ..... 4-12
4.3.4.2 Operating elements on the control panel 4-13

1) The „Wireline Combi Unit PP“ is also referred to in this

operating manual as the „Container“ or „Unit“.
3) For information on the abbreviations see Chapter 1.7.1.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

4.1 Intended use Wireline Combi Unit PP is largely insensitive to

common environmental influences.
The Wireline Combi Unit PP1), equipped with winch
The standard limit values for ambient temperature, air
drums for slickline with d = 0.092" - 0.125" and for
humidity, etc. apply to electrical apparatus, equipment
e-line with d = 7/32", is intended for workovers or
and other items of equipment, please refer to DIN IEC
measurements in deep drilling.
721, DIN 40 040 amongst others.
The intended use includes observing the EC directives,
BG regulations (BGV...)2)3), DIN EN standards and
other occupational safety and health regulations, 4.2.0.3 Functional criteria, inadmissible
safety and disposal regulations, as well as correct and operating conditions
safety-focused operating methods for all measures Operating and system malfunctions are to be
performed at the container. expected:
• If installation and connection, function checks,
setting work and a subsequent trial run have not
4.1.1 Misuse and non-intended use been correctly performed.
Any use of the container for purposes other than • If the electrical data, hydraulic oil or compressed air
those described above is deemed as non-intended use. conditions do not meet the required connection
data.
The user/owner bears the sole risk of non-intended • Malfunctions may also occur if cleaning,
use or incorrect use with regard to persons, the maintenance and repair measures are not correctly
Wireline Combi Unit PP1), other assets and operating performed and the prescribed intervals are not
results. observed.
A non-intended use or incorrect use includes for • For details regarding items of equipment, please
example: refer to the respective manufacturer’s
- Use of the winches as lifting gear for general crane documentation/third-party operating manuals in
work. „Section III“ of the technical documentation (see
- Insufficient alignment of the container longitudinal below).
axis in relation to the borehole.

4.2.0.4 Technical documentation

The „Technical Documentation“ in accordance with
4.2 Technical data Supplement VII of the Machinery Directive 2006/42/
For the technical data of the container please refer to EC is contained in the overall documentation for the
the KMA specifications. Wireline Combi Unit PP:
- Denomination: Wireline Combi Unit PP Section Designation
- Conformity: Machinery Directive 2006/42/EC I - KMA Declaration of Conformity,
II - Operating manual (in accordance with
Machinery Directive 2006/42/EC),
4.2.0.1 Environmental influences and/or III - Third-party operating manuals/information/
emissions spare parts list for equipment items.
• Environmentally harmful emissions: IV - Certificates, reports,
- Fuel/consumable/lubricant leaks V - Technical data,
- Noise emissions, VI - Hydraulic and pneumatic circuit diagrams,
there are no other emissions generated during device parts lists etc.,
operation of the Wireline Combi Unit PP. VII - Electrical/electronic system, circuit diagrams
and wiring diagrams, cable specifications,
device/parts lists etc.,
4.2.0.2 Permissible ambient conditions VIII - Drawings with spare parts lists (ETL).
When installed in Western Central Europe, the

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

Fig. 4-1: Wireline Combi Unit PP, RH

container side with opened front sliding
door to the engine compartment and
entrance door with steps to the
workroom.

Terms such as „left/right“ (LH/RH)

and „front“ or „rear“ always refer to
Front Rear the vehicle.

Fig. 4-2: Wireline Combi Unit PP, RH

container side with open winch cab door,
window to the workroom and ventilation
grids for the engine cooler.
A storage box for small tools is located
under the vehicle frame.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

• The documentation specified above, provided in

addition to the operating manual, is contained in the ! Warning
appendix of this operating manual. The hazard zones/points cannot be secured
without restricting the unit’s intended use.
Ensure that the instruction/briefing of the
4.2.1 Hazard zones and hazardous operator includes operation of the unit in
accordance with safety procedures.
area
• Regarding the individual danger zones, dangerous
situations and hazard events, please refer to the
hazard analysis acc. to DIN EN ISO 14121-1.
4.2.2 Organisational safety measure:
Operating and handling
! Danger instructions
Contact with the running wireline/cable can • As an organisational safety measure, the user/
cause serious injuries! owner is to write up „Operating and Handling
When the winches are rotating, always Instructions“ to ensure the safe handling of the
maintain a sufficient safety distance of at wireline/cable, the tools, the pressure control
least 10.0 m (as defined by DIN EN 13857) equipment (PCE), etc. that do not form part of the
on both sides of the wireline/cable and on KMA delivery scope.
all sides of the wellhead! The operating personnel are to be instructed and
trained by the user/owner prior to initial start-up/
• For all work with the Wireline Combi Unit PP commissioning according to these „Operating and
adhere to the national safety regulations, in Handling Instructions“ (BGV A1).
Germany e.g. acc. to BGV A1, BGV A3, BGR • Ensure that the hazard signs and type plate on the
5002)3) etc. Wear the prescribed personal container are always in a legible state!
protective equipment (PPE) see Chapt. 2.3.1.

! Warning
4.2.3 Grounding/equipotential
Only operate the Wireline Combi Unit PP when
it is in perfect, technically safe condition!
bonding
• All devices/components of the container are
• The operator must switch off the engine (power conductive or connected to each other by
pack) before the hazardous area is accessed by equipotential bonding cables.
unauthorized persons! A grounding cable is provided on the inside of the
winch cab door for connecting the container to
ground. Connect the cable to conductive
4.2.1.1 Hazardous area components of the wellhead using a grounding
A hazardous area involving clamp, see TRBS 2153.
- risk of injury from moving, rotating components, • Ensure that the leakage resistance to ground does
- risk of injury through dangerous high pressure, not exceed 106 Ohm (leakage resistance < 106
- risk of burns on components subject to high surface Ohm).
temperatures (> 55 °C), • Check the devices/equipment for connection to
- risk of injury caused by the running wireline/cable ground and equipotential bonding prior to initial start-
and the danger of whipping ends in the event of a up/commissioning and subsequently at regular
break in the wireline/cable, intervals (see TRBS 2153)!
comprises the entire area of the winch cab, as well as
the area between the container and the wellhead on
both sides of the wireline/cable. Maintain a sufficient
safety distance from the hazard zones during
operation!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

4.3 Description of the Wireline electricity supply via a socket (IEC 60309) is used,
among others, for the lighting in the control room and
Combi Unit PP winch cab. A second hydraulic pump supplies a
4.3.1 Truck and container hydraulic Dynaset generator with 12 kVA, 400V AC,
The Wireline Combi Unit PP is arranged on a truck 50 Hz.
with a swap frame, and the container is fastened to The container is equipped with attachment points on
the frame by means of twistlocks (DIN EN 284), see the roof and inside the winch cab for lifting and
Fig. 4-1, 4-2 and 4-14. transport by crane (Fig. 4-3).
The container contains four areas that are separated
from one another:
- The engine compartment, 4.3.1.1 Underfloor components
- the workroom, The compressed air receivers as well as the hydraulic
- the control room with the operator’s workplace and and compressed air lines are located under the floor in
- the winch cab. the container base frame, also see Fig. 4-15.
The engine compartment is equipped with two The components are accessed by opening
lockable sliding doors for service work at the rear of maintenance flaps in the floor of the control room/
the container, between the container and driver’s cab workroom; the drain valves of the compressed air
(Fig. 4-7 and 4-8). receivers can be accessed underneath the truck.
The workroom has a lockable door on the side to
allow convenient access and exit by the operator.
Pull-out steps with handrail are provided under the 4.3.1.2 Air conditioning unit
door to ensure safe access to the workroom. The The control room and workroom are air conditioned.
handrail is folded together and stowed away in a The split-type air conditioning unit is located in the
rectangular receptacle next to the steps. winch cab (condenser) and as an evaporator on the
The control room with control panel is accessed via side next to the entrance door in the workroom/control
the workroom. A partition with sliding door separates room.
the two areas.
The winch cab has two fully opening doors (Fig. 4-2).
The roof structure above the winch cab (Fig. 5-3) can 4.3.1.3 Storage box/tool rack under the
be opened and pushed back into various open container and/or in the container frame
positions, e.g. for fitting/removing the winch drums. Tools for daily use such as drill collars, measuring
Through the open roof structure, the operator has an probes etc. can be stowed in two tool racks (drawers)
unobstructed view of the wireline/cable run as far as running on heavy duty rollers under the container floor
the hay pulley and/or wellhead/crane. (Fig. 4-21).
The winch cab contains the front and rear winch and Two storage boxes for accommodating small tools are
the pressure control equipment (PCE) with hydraulic located underneath the vehicle frame at the side, one
oil group etc. Pull-out steps with handrail are provided of the boxes contains a vise (Fig. 4-12).
next to the winch frame to ensure safe access to the
winch cab.
Two pull-out tool racks running on heavy duty rollers 4.3.2 Engine compartment
and a light-weight tool rack for small parts are located The engine compartment is accessed through two
under the winch cab (Fig. 4-21). sliding doors located at the front of the container (Fig.
The container is supplied with energy from a 4- 4-1). The compartment accommodates the diesel
cylinder diesel engine, CAT C4.4, via an infinitely engine CAT C4.4 driving the main hydraulic pump, a
controlled hydraulic pump with pressure oil, p = 380 second appended hydraulic pump (piggy back) for the
bar, and with compressed air of p = 8 bar by a PCE hydraulic group, and a connected compressor
compressor connected to the engine. generating the compressed air.
The container can be connected to an external power The 2 x 12V, 110 Ah batteries for the electricity
supply delivering 400 V, 50 Hz. The external supply of the control system are located in the engine

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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compartment on the left-hand side above the engine A dipstick is provided for checking the oil level, for
(Fig. 4-9). The engine compartment also contains which the engine has to be at a standstill (Fig. 5-6).
other items of equipment for the engine such as the The oil filler neck is located at the top of the engine
engine oil filter, fuel main filter, safety filter, three- behind the protection cover (Fig. 5-7).
phase generator, turbocharger etc. The engine cooler,
an intake air filter, etc. are also located in the engine
compartment. 4.3.2.2 Engine cooling system
The fuel tank is located in the base frame of the A heat exchanger with thermostat serves for cooling
container, the tank filler neck is located next to the the engine and controlling the coolant temperature.
sliding door to the engine compartment. The cooling circuit includes a circulation pump directly
The hydraulic oil reservoir and the hydraulic oil cooler fitted to the engine. The cooler closure is located at
are located in the engine compartment on the right- the top of the cooler (Fig. 4-9); a drain plug is provided
hand side, see Fig. 7-14. at the bottom of the cooler.

4.3.2.1 Engine oil system 4.3.2.3 Fuel system

The engine oil system is equipped with an oil pump, oil The fuel tank with a volume of 150 liters is
filter and a pressure relief valve with a bypass line in accommodated under the engine compartment in the
case a filter element is soiled. container base frame; the tank filler neck is located

Fig. 4-3: Attachment point, and compressed air Fig. 4-4: Winch cab pull-out steps in park position, on
connection for small tools in the winch cab. the left next to the winch frame.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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next to the LH sliding door (Fig. 4-13). The tank is refer to the CAT operating manual in „Section III“
provided with a fuel level measuring device so that the of the technical documentation.
fuel level can be read off at the display „10P1“ on the The combustion air is taken in via an intake air filter
control panel. with a dust separation valve arranged in the engine
The engine is equipped with a direct injection system compartment that requires maintenance at regular
with high pressure pump, fuel distributor, fuel safety intervals. The air filter is located behind the engine
filter and fuel main filter with water separator and (Fig. 4-7). The combustion air is taken directly from
hand-operated bleeding pump. the atmosphere.
The intake air system includes an exhaust turbo-
! Warning charger with boost controller and charge air cooler
The fuel lines are subject to dangerous high that is integrated in the engine cooling system. The
pressure during operation. combustion air is compressed and cooled by the
Only perform work on the fuel system when the turbocharger, and flows through a filter before
unit is at a safe standstill, the engine has cooled entering the engine.
down and the system is depressurized!
4.3.2.5 Exhaust system
4.3.2.4 Combustion air system The exhaust flows from the engine via a muffler to the
• For details of the combustion air system, please exhaust pipe. The exhaust system/muffler is located

Fig. 4-5: Pull-out steps for accessing the workroom. Fig. 4-6: Winch cab pull-out steps extended and with
Stairs with plug-in railing. plug-in railing inserted.

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above the engine. switched off when the unit is shut down. Otherwise
the batteries may discharge.

4.3.2.6 Electrical system of the engine

• For details, please refer to the electrical 4.3.2.7 Engine electronics
documentation in „Section VII“ of the technical An electronic engine management system (CAN
documentation. TRAC) serves for monitoring the engine operating
conditions. According to the programming by the
The required electricity is generated by the 24V
operator, the electronic engine management system
generator. 2 x 12V, 110 Ah batteries, charged by the
displays the following, among others:
generator during operation, are provided for start-up.
- Preselected NOMINAL and current ACTUAL
The batteries are located in the engine compartment
speed (rpm)
(Fig. 4-9).
- Oil pressure
A control box (Fig. 4-17) with the battery main switch
- Coolant temperature etc.
„4Q1“ is located in the workroom on the left next to
the entrance door. „4Q1“ serves for disconnecting the • For detailed information please refer to the CAN
control system from the batteries and must always be TRAC operating manual in the appendix of this

Fig. 4-7: Engine compartment with the

CAT C4.4 engine, hydraulic oil filter,
engine oil filter and fuel filter, as well as
intake air filter (at the top of the figure
on the right)

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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operating manual. mechanism, and by looking through the open front

doors and the retracted roof structure he can also see
• The electronic monitoring system includes an
the wellhead/crane. In other words, the operator can
automatic cut-out in the event of insufficient oil
see the entire operating area.
pressure and excessively high engine speed (rpm).
The control or operating panel inclined towards the
operator allows ergonomic control of the winches (for
information about the operating elements please see
4.3.3 Control room with Chapt. 6.3.3).
operator’s workplace Frequently used winch control handles,
The operator’s workplace is located in the control „L1“ - Wireline/cable speed,
room. „L2“ - Drum rotational direction (In Hole/Out Hole),
The operator has an unobstructed view through a „R2“ - Controller (twist handle) for the tension/pull
panoramic safety glass window into the winch cab of force,
the winches, the measuring head and the spooling
Continued on Page 4-12

Fig. 4-8: Engine compartment with CAT

C4.4 engine, compressed air compressor
with air filter, engine oil filter and oil
dipstick (arrow).

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Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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Fig. 4-11: Cable drum with grounding cable and

EMERGENCY STOP button „4S4“ on the LH winch
cab door.

Fig. 4-9: Batteries in the engine compartment, engine

cooler with cooler closure (arrow). Fig. 4-12: Storage box with extendable vise, as well
as a twistlock (arrow) for connecting the container
and trailer.

Fig. 4-10: 5 pole CEE plug connector for 3 ph, 400V

AC, 50 Hz, 32A, for external power supply and NATO
receptacle for 24V supply, e.g. for starting the power
pack with connection to the truck.

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Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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Fig. 4-15: Compressed air receivers/vessels, 60 l and

20 l, under a maintenance flap in the control room/
workroom.
The drain valves (regular maintenance necessary) are
located on the bottom of the compressed air receivers
and are accessed from underneath the vehicle.
Fig. 4-13: Tank filler neck next to the RH sliding door
to the engine compartment.

Fig. 4-14: Holder for the winch room doors and

twistlock for connecting the container and trailer. Fig. 4-16: Hydraulic Dynaset generator (3 ph, 400V
AC, 50 HZ, 12 kVA, 17.3A) behind the power pack in
the engine compartment.

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Continued from Page 4-9 • For details of the tension, depth and speed display,
please refer to the third-party operating manuals
„3S4“ - Control handle for the brake, (Benchmark and M. Decker) in „Section III“ of the
are provided on the right and left in front of the technical documentation.
control panel (Fig. 4-18). The indicating devices for hydraulic pressures and
A touch screen monitor „B1“ for the digital display hydraulic oil temperature are located to the left of the
and storage of the tension, depth and speed, and the analog measuring instrument „D3“. The operating
analog hydr. tension measuring instrument „D3“ are elements for the engine with display „9A1“ for the
located directly in the operator’s field of vision. A current engine data (CAN TRAC) are located on the
backup storage unit „B2“ as an analog depth counter left-hand side of the control panel.
is arranged on the left above the monitor (Fig. 6-1). An EMERGENCY STOP hit button „4S1“ and
operating elements for the winches (Winch Control)
are located on the right above the monitor.
The electrical switch cabinet with control main switch
„2Q1“, the toggle switches for the wire oiler, Dynaset
Fig. 4-17: Battery main switch „4Q1“ next to the generator and lighting, is located on the right next to
entrance door to the workroom. the control panel.
A panel accommodating the operating and monitoring
elements of the PCE (pressure control equipment) is
located on the left next to the control panel.

4.3.4 Operating elements

4.3.4.1 Operating elements on the container
For the position numbers stated below please also
refer to Chapt. 6.3.3, Fig.
6-1 and following; for information regarding the
electrical operating elements also refer to the
electrical documentation.
Pos. Designation
4Q1 - Battery main switch, located on the left next to
the entrance door to the control room (Fig. 4-
17). The switch isolates the 24V container
electrics/electrical control system from the
4Q1 batteries and must always be switched off when
the system is shut down, otherwise the batteries
may discharge.
4S4- EMERGENCY STOP hit button, red, for
immediate disconnection of the system from the
power supply, on the right-hand side door of the
winch cab.
The following are switched off:
- the electr. control system (24V),
- the winch, the drum brakes are applied,
- when the shut-off valve closes, the engine
with connected hydraulic pump.
A possibly connected external 400V power
supply is not switched off in order to ensure the

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Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 4 - Description

lighting in the workroom/control room and in the • HYDRAULICS

winch cab. - Pressure gauge (Main Pressure)
- Pressure gauge (Control Pressure)
- Thermometer for indicating the oil temperature
4.3.4.2 Operating elements on the control
panel
• SAFETY CONTROL
The operating elements described in Chapt. 6.3.3.2
- Illuminated push-button, black, for actuating the
are arranged on the control panel. The control panel is
pneumatic horn.
divided into four areas including:
- EMERGENCY STOP hit button, red, for
immediate disconnection of the system from the
• ENGINE CONTROL
power supply, as described above for „4S4“.
- The electronic management system (CAN
TRAC) for display of the engine data,
• WINCH CONTROL
- Fuel/tank gauge,
- Illuminated push-button, green, „Winch Release“.
- Toggle switch (IGNITION):
To be pressed by the operator as a confirmation
- Ignition OFF
that the preparations for winch operation have
- Ignition ON
been completed, e.g.
- Signal light, green, IGNITION switched on
- Push-button, white, to START the engine (push
to start) when the ignition is switched on
- Toggle switch for engine speed setting (+/-)
- Illuminated push-button (IDLE speed), white, for
selecting the idle speed of 800 rpm Fig. 4-18: Control panel in the control room for the
power pack and winches.

4S1

L1 L2
E1
R2 3S4

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- Main switch turned on, and back to ensure that the wireline/cable is
- engine/power pack running, properly and uniformly spooled at the desired
- winch pre-selected, position.
- control handles „L1“ and „L2“ in neutral
position, etc. • CONTROL HANDLE, LH
- Illuminated push-button, red, „Winch Override“. - Control handle „L1“ - LH outside - for increasing
Press the Override button when normal winch the wireline/cable speed (drum rotational speed).
operation is no longer possible, e.g. due to a The control handle „L1“ can be pushed or pulled,
control error, and the cable/wireline still needs to only the extent of the deflection determines the
be pulled. speed of the wireline/cable.
- Toggle switch for winch pre-selection, with the - Control handle „L2“ - LH inside - for the drum
following switch positions: rotational direction,
- turned to the left: pre-selection of the front - Push the control handle forward for unwinding
drum, i.e. the winch drum facing the operator, the wireline/cable in the direction of the
- center: Neutral position, wellhead/borehole,
- turned to the right: Pre-selection of the rear - Pull the control handle to wind up the wireline/
drum, i.e. the rear winch drum at the front of cable onto the drums.
the container. • When a rotational direction is preselected with
- Toggle switch, Wire Oiler ON/OFF. „L2“, the drum already starts rotating at slow
speed!
• HANDWHEEL
- By turning the handwheel, the measuring head • CONTROL HANDLE/CONTROLLER (TWIST
can be moved from the right to the left drum side HANDLE) RH
- Control handle for the electro-pneumatic holding/
locking brake.
- Push the control handle forward to release the
Fig. 4-19: Electric switch cabinet with main switch brake (BRAKE RELEASE),
„2Q2“, signal light for Dynaset generator and toggle - Pull the control handle for applying the brake
switch for the lighting. (BRAKE ACTIVE).

! Attention
The brake does not serve as an operating
brake! To brake, gently slow down the drum
hydraulically by moving „Control handle L2, LH
inside“ in the opposite direction to the current
rotational direction of the drum.
- Controller (twist handle) for tension limitation by
means of the pressure relief valve (safety valve),
also see Chapt. 6.4.2.
- Clockwise rotation (cw), direction „+“, the drum
pull force/tension is increased.
- Counterclockwise rotation (ccw), direction „-“,
the drum pull force/tension is reduced until it is
just sufficient for the drum to hold a load
(balanced state).

• OPERATING/DISPLAY ELEMENTS
- Analog hydraulic pull force/tension display,
Martin Decker

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- Operator monitor, Benchmark, digital display of - Valves as main valve for compressed air, shut-off
pull force/tension, depth and speed, valve for the accumulators.
- Backup display for the depth.
• For details regarding the tension, depth and speed
displays, please refer to the third-party operating 4.3.5 Winch cab
manuals in „Section III“ of the technical The winch cab can be accessed through two doors
documentation. opening at a wide angle and located at the rear of the
container (Fig. 4-2 and 4-20).
The roof structure of the winch cab can be pushed
4.3.4.3 Operating elements on the electric back and fully opened. Latches operated by a wire
switch cabinet (Fig. 6-3) cable, each between two stops, engage in the lateral
• For detailed information regarding the operating guides of the roof structure, allowing different opening
elements please refer to Chapt. 6.3.3.5. positions. When closed, the rear doors also lock the
roof structure, ensuring that the winch drums are
The electrical switch cabinet accommodates the protected from exposure to the weather.
following operating elements: Due to the wide opening of the roof structure the
- Main switch for the container electrics: operator has an unobstructed view of the hay pulley,
0 - Hydraulic generator - Mains, wellhead and/or crane.
- Toggle switch, lighting, Winch Area 24V, The winch cab accommodates the front and rear
- Toggle switch, lighting, Door Area 24V, drum (as seen from the operator’s seat, see Fig.
- Toggle switch, lighting, Winch Area 230V, 4-20) with their hydraulic drives, roller chain drives
- Signal light, Dynaset Generator Protection. and band brakes. The spooling mechanism for guiding
The indicating instruments for frequency (Hz), the wireline/cable from right to left and back, i.e. for
amperes (A) and volts (V), as well as the fuses 2F1 uniformly spooling it onto and from the winch drum, is
and following are located on the switch cabinet. For located behind the winches. The spooling mechanism
details, please also refer to the electrical including the appended measuring head is moved using
documentation in section VII of the technical handwheel „E1“ located in front of the control panel
documentation. (Fig. 4-18). The measuring head is moved to the left-
hand side and secured by a bolt in the park position
(Fig. 5-17).
4.3.4.4 PCE pressure control panel (Fig. 6-4) The front and rear drums are arranged in a winch
• For details regarding the function and equipment of frame that is bolted to a steel structure in the
the pressure control system, please also refer to container base frame.
Chapter 4.10. When required, it is possible to lift an individual winch
• For detailed information regarding the operating drum out of the winch frame after removing the
elements please refer to Chapt. 6.3.3.5. contact guard devices, the roller chain and band brake,
and simply undoing the centring flange fastening
The pressure control panel accommodates the
screws.
operating and monitoring elements for
- Valve control handle, function CLOSE/OPEN, in
the connection between the wellhead and pumps.
- Pressure control valves permit sensitive regulation 4.3.6 Winches
of the air pressure for the pneumatic pumps and The winch drums are designed for wireline/slickline
thus adjustment of the pump pressure to the d = 0.125" and cable/E-line d = 7/32".
respective wellhead pressure, The drum diameter is matched to the permissible
- Compressed air main valve (V1), function CLOSE/ bending radii of the individual wireline/cable
OPEN, diameters.
- Pressure gauges indicate the pressure in the lines to To allow removal of the front/rear drum, open the roof
the stuffing box, lower/upper wireline valve etc. structure and lower the spooling mechanism into the
- Hand pumps P1 - P3, operating position.

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Fig. 4-20: Winch cab with front and

Left Right rear winch as well as measuring head in
the park position on the LH side of the
spooling mechanism.

Front

Rear

Terms such as „left/right“ (LH/RH)

and „front“ or „rear“ always refer to
the vehicle.
The front/rear winches, however, are
referred to as seen by the operator.

Fig. 4-21: Tool rack on the right and

left-hand side under the winch cab. In
the center, a pull-out tray for small tools.
The drain sockets for the drip pan under
the measuring head (arrow) is also
located in the center.

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4.3.6.1 Winch drive Using the selector switch on the control panel „5S1“,
The two drums are each driven by adjustable the operator can switch on the front drum or the rear
hydraulic motors via a planetary gear and a duplex drum. The brake and hydraulic motor for the selected
roller chain. The adjustment pump accommodated in drum are activated simultaneously.
the engine compartment and the regulating motors, The deselected drum is shut down and the brake
together with the step-down ratio provided by the applied (BRAKE ACTIVE).
planetary gearing, not only permit low drum rotational
speeds but also high torques and high rotational speeds
with wireline speeds of 1 - 400 m/min (3.28 - 13,000 4.3.6.2 Brake system
ft/min), i.e. they are variable throughout a large speed Each winch drum is held by the brake system in the
range. position predetermined by the operator. The brakes,
A tensioning device ensures the correct pretensioning designed as band brakes with large diameter, are
of the roller chains. actuated by spring-loaded, pneumatically released
cylinders. Released by the air pressure, the spring in
the brake cylinder automatically applies the brake if a
respective control command is given, should the
compressed air system fail (no or dropping air
pressure) or in the event of a system fault.
Fig. 4-22: Brake cylinder and brake lever with brake The tangentially actuated brake bands automatically
band for the rear winch, inside the winch frame. increase their effect when applied, as a result of the
direction of force acting against a downhole load on
the wireline.
• The brakes functions as:
- A locking brake, preventing the drums from
rotating under load, e.g. under the weight of the
tools in the borehole.
- An emergency brake after actuation of the
EMERGENCY STOP button „4S1“ or „4S4“ to
immediately yet gently stop the winch drums in a
Brake band hazardous situation.
• The band brakes are not intended to be used as
Adjustment operating brakes for stopping the winch drums
screw during normal operation!
During normal operation, the the drum rotational
speed or wire speed is exclusively hydraulically
reduced to zero.
- Bring back control handle „L1“ - LH outside - to
neutral position, and
- gently brake the drum with control handle „L2“ -
LH inside -, deflected for the opposite drum
rotational direction.
The brake bands are divided and bolted together at the
top by two „blocks“. This divided design facilitates
dismantling for changing the drums and/or speeds up
brake band replacement.

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4.3.6.3 Operating the winches and brakes spooled onto/taken up by the winch drum.
The winches and band brakes are operated from the The spooling mechanism comprises a handwheel,
control panel, using the following control handles (Fig. connected to the steering column with length
6-1): compensation through a chain drive. The steering
„L1“ - Wireline/cable speed, column moves another horizontal chain drive via a
„L2“ - Drum rotational direction (In Hole/Out Hole), cardan joint. The horizontal chain drive is connected to
„R2“ - Controller (twist handle) for the tension/pull the measuring head by a chain gripper (Fig. 5-14/15).
force,
„3S4“ - Control handle for the brake,
as described in Chapt. 6.3.3.2. 4.3.7.2 Measuring head oiler/wire oiler
An oil container is installed above the measuring head,
supplying the wireline/cable on the measuring head
4.3.7 16" measuring head „Dolphin“ with a small amount of (preservation) oil acting as a
The Wireline Combi Unit PP is equipped with a 16" gliding agent (Fig. 5-8). The container is equipped with
measuring head, type Dolphin from Benchmark. This a solenoid valve that is opened or closed with toggle
measuring head picks up and transmits signals for switch „7S2“ on the electrical switch cabinet.
depth and tension to the Benchmark display unit „B1“ A drip pan is provided underneath the winch and
(operator monitor) (Fig. 6-1). measuring head that is emptied when required by
Measurement is performed as follows: means of a discharge valve (Fig. 4-21).
- For the pull force/tension measurement as pressure
on a load cell,
- the depth measurement is performed electrically by 4.3.8 Pressure control equipment
means of an incremental encoder. (PCE)
The measured tension values can be directly read off The operating panel for the pressure control
by the operator at the analog display device „D3“ (Fig. equipment is located on the left of the control panel
4-18 and 6-1). (Fig. 6-4).
The measuring head has two measuring wheels, over A hydraulic pressure built up by a compressed air
which the wireline/cable is to be guided (Fig. 5-16). pump and three hand pumps ensures a state of
The wireline/cable is held in the grooves of the equilibrium in relation to the pressures at the lower
measuring wheels by contact pressure rollers. One of and upper wireline valve, stuffing box, subsurface
these rollers is spring loaded. Two pairs of rollers in a safety valve etc. The pressure control system is
vertical position guide the wireline/cable from right to equipped with the following:
left to ensure that it is evenly spooled/unspooled on • A 5,000 psi high-pressure pump for the oil supply
the winch drums. and for the connection to the lower and upper
• For more details regarding the 16" measuring head, wireline valve, subsurface safety valve, stuffing
type Dolphin from Benchmark, please refer to the box.
Benchmark operating manual in „Section III“ of the Max. pressure ............................. 345 bar (5,000 psi)
technical documentation! • Three hand pumps, one for 5,000 psi for the lower
The measuring head glides horizontally from right to and upper wireline valve and
left and back (see below) on a guide axle and runs in 2 x 10,000 psi for the subsurface safety valve and
the guide rail with a vertical guide roller (Fig. 4-24). the stuffing box
For the park position, move the measuring head on the The following operating/monitoring elements are
guide axle into the left-hand end position and secure it located on the PCE panel in the control room:
with a locking bolt on the guide rail, see Chapt. 5.4.3.1. - Valve control handle, function CLOSE/OPEN, in
the connection between the wellhead and pumps.
- Pressure control valves permit sensitive regulation
4.3.7.1 Spooling mechanism of the air pressure for the pneumatic pump and thus
The spooling mechanism, operated with handwheel adjustment of the pump pressure to the respective
„E1“, ensures that the wireline/cable is perfectly

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wellhead pressure.
- Compressed air main valve, function CLOSE/
OPEN.
- Pressure gauges indicate the pressure in the lines to
the lower and upper wireline valve, subsurface
safety valve, stuffing box etc.
• The owner/user’s hose lines are to be connected to
the connection panel in the winch cab for
connecting the pressure control system to the
Guide roller
wellhead (Fig. 4-26).

4.3.8.1 PCE equipment in the engine

compartment
The compressed air dryer and a 5 l compressed air
receiver (Fig. 4-27) are located in the engine
compartment.

4.3.8.2 PCE equipment in the winch room

The winch room accommodates the 5,000 psi
compressed air pump in a hydraulic oil reservoir (Fig.
4-25), as well as a panel for the hose lines (Fig. 4-26)
Fig. 4-23: Vertical guide roller and horizontal wireline/ to the wellhead, with connections for:
cable contact pressure roller on the measuring head. - Lower wireline valve,
- upper wireline valve,
- subsurface safety valve,
- stuffing box

4.4 Hydraulic system

Fig. 4-24: Measuring head guide roller (arrow) in the ! Warning - risk of burns
guide rail.
Hydraulic components have a high surface
temperature immediately after switch-off (t >
55 °C)!
For the winch operation, an axial piston adjustment
pump is installed at the engine. The engine
compartment also accommodates the hydraulic oil
reservoir with oil level inspection glasses and the oil
filler neck with ventilation filter (Fig. 7-15). The return
filter is located on the top of the oil reservoir.
The hydraulic motors of the winches are supplied with
hydraulic oil in an enclosed system. A change-over
valve controls the respective winch motor (front or
rear drum) individually selected by the operator using
the selector switch „5S1“.

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The enclosed system, with infinite rpm controlled

hydraulic pump and hydraulic motors, offers a
constant ratio of speed to torque and permits high pull
forces/tensions or high line speeds.

! Note
The higher the rotational speed, the lower the
torque or the pull force/tension and vice versa:
Low speed - high pull force
High speed - low pull force
The connection pipework between the hydraulic
components is routed in the container base frame.
Hose lines are only connected in the engine
compartment and directly to the hydraulic motors.

4.4.0.1 Hydraulic oil reservoir

The reservoir is equipped with the following
instruments:
- Oil level inspection glasses are located in front of
the reservoir in the engine compartment (Fig. 7-15),
- Oil temperature probes; the operating temperature
indicator is located as „C3“ on the control panel.
Ensure that the hydraulic oil temperature does not
Fig. 4-25: PCE equipment in the winch cab - exceed 70 °C (158 °F),
hydraulic group with 5,000 psi compressed air pump. - Oil filler neck with ventilation filter,
- Return filter as described below.

4.4.0.2 Return filter

The enclosed hydraulic system is equipped with a
return filter at the top of the hydraulic oil reservoir.
• The filter element is to be changed at regular
intervals, as well as following repairs or after
prolonged standstill.
Fig. 4-26: Example for a connection panel in the
• For details regarding the return filter please refer to
winch cab for the PCE hose lines to the wellhead.
the third-party operating manual in „Section III“ of
the technical documentation.

4.4.0.3 Operation and monitoring

• For the operation of the hydraulic drive, please refer
to Chapt. 6.4 and following.
• The pressure gauges are arranged on the control
panel next to the oil temperature indicator „C3“:
- for the main pressure „C1“ with
pmax = 380 bar, and

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- the control pressure „C2“ with If no cooling is required, or the return filter or cooler is
p = 30 bar, pmin = 20 bar blocked, a bypass opens and the oil flows uncooled
and unfiltered back into the oil reservoir.
• Should during bypass operation the hydraulic oil
4.4.0.4 Hydraulic oil/air cooler temperature exceed 70 °C, filter maintenance
A large dimensioned cooler with hydraulically driven (Chapt. 4.4.0.2) or cooler maintenance is
ventilator is provided for cooling the oil. The oil/air necessary!
cooler is located in the engine compartment behind the For the temperature indicator, see „C3“ on the
oil container (Fig. 7-15). control panel.

Compressed air dryer

5 l receiver

Fig. 4-27: Compressed air dryer and 5 l

compressed air receiver in the engine
compartment.
The exhaust pipe and the muffler with
insulation are located above the engine.

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• For details regarding the oil/air cooler, please refer • The drain valves are located at the bottom of the
to the third-party operating manual in „Section III“ compressed air vessels and can be accessed from
of the technical documents. underneath the vehicle.

4.5 Pneumatic system 4.6 Power supply

4.5.0.1 Compressed air supply The two batteries supply 24V DC for the engine start
The compressed air serves for supplying the pneum. and/or electrical control system. The batteries are
brake cylinders. directly charged by the generator connected to the
- Operating pressure ........................................... 8 bar engine.
- Air pressure, max. .......................................... 12 bar If the power pack is running and the hydraulic system
Control air that is dried, treated, and lubricant-free is operating, the hydraulically operated 12 kVA
according to industrial standards is required, generated Dynaset generator (Fig. 4-16) supplies 400V AC, 50
by the compressor attached to the engine and stored in Hz, 17.3A, among others, for the lighting. The Dynaset
the compressed air vessels under the control room. generator is protected by a generator protection
A pressure relief valve (safety valve) maintains the (overload) switch (Fig. 4-28) located in the engine
operating pressure at max. p = 10 bar. compartment that trips in the event of overload.
The compressed air vessels are equipped with
manually operated drain valves that have to be The lighting in the control room and winch cab is
checked at regular intervals. supplied with 24V DC by electricity from the above
mentioned Dynaset generator or by an external 400V,
50 Hz, 32A power supply.

4.6.0.1 Batteries
Fig. 4-28: Generator protection (overload) switch as The 2 x 12V, 110Ah batteries for the control system and
well as compressed air connection in the engine for permanent supply of the measuring system with 24V
compartment DC etc. are located in the engine compartment.
In the event of a battery malfunction, e.g. also for starting
the engine, a 24V DC connection (NATO receptacle) is
provided for supplying electricity from an external power
source, e.g. the vehicle batteries, (Fig. 5-4).
• For details regarding the batteries, please refer to the
third-party operating manual in “Section III” of the
technical documentation.

4.7 Delivery scope

The KMA delivery scope comprises the Wireline Combi
Unit PP, as described in the order confirmation. The
container is equipped with the accessories listed in the
KMA order confirmation, and is designed and
manufactured in accordance with the normative
regulations.
• Any additional guards/protective/safety devices (such
as access-limiting fencing) required due to local

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requirements or specifications of the Employer’s

Liability Insurance Association or other responsible
supervisory bodies etc. to ensure the safe operation of
the Wireline Combi Unit PP do not form part of the
KMA delivery scope!
• It is the responsibility of the owner/user to provide any
additional guards/protective/safety devices, barriers/
fencing etc. and ensure that they are installed prior to
initial start-up/commissioning!

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5. Installation/set-up and preparation for operation

Table of Contents 5.4.3.3 Threading in the wireline/cable at the
measuring head ........................................ 5-9
5.1 Safety information .......................... Page 5-2
5.1.1 Instruction of the operating personnel ..... 5-2
5.4.4 Hydraulic system ..................................... 5-9
5.1.2 Tools, consumables and auxiliary equipment
5.4.4.1 Return filter ............................................. 5-9
required for preparation for operation ..... 5-3
5.4.4.2 Hydraulic hose lines ................................ 5-9
5.4.4.3 Connecting PCE hoses .......................... 5-10
5.2 Installation/set-up of the Wireline Combi
Unit PP .................................................... 5-3
5.4.6 Hydraulic oil/air cooler .......................... 5-11
5.2.0.1 Permissible conditions at the
place of installation/set-up ....................... 5-3
5.4.7 Compressed air system ......................... 5-11
5.2.0.2 Preparation of the work site area ............ 5-3
5.2.0.3 Attachment, lifting and transport
of the machine ......................................... 5-3 5.4.8 Electrical system ................................... 5-11
5.2.1 Installation and alignment of the machine 5-4 5.4.8.1 Batteries ................................................ 5-11
5.2.1.1 Roof structure ......................................... 5-4
5.5 Function control or
5.3 Preparations for operation ....................... 5-4 first time start-up ................................... 5-11
5.3.1 Topping up consumables/auxiliary 5.5.0.1 Function check of the operating
substances ............................................... 5-4 elements ................................................ 5-11
5.3.1.1 Checking/topping up the engine 5.5.1 Visual inspection prior to initial
consumables ............................................ 5-5 start-up .................................................. 5-11
5.3.1.2 Checking/topping up hydraulic oil ............ 5-5 5.5.2 Hydraulic system test ............................ 5-12
5.3.1.3 Topping up the wire oiler ......................... 5-5 5.5.3 Test for the wireline/cable speed/drum
rotational speed and rotational direction 5-12
5.3.2 General preparations for operation .......... 5-5 5.5.4 Testing the safety functions .................. 5-13
5.3.2.1 Electrical connection ............................... 5-6
5.3.2.2 Connection of the grounding cable .......... 5-6 5.6 Operational readiness of the machine ... 5-13

5.4 Setting up individual components ............. 5-7

5.4.1 Winches ................................................... 5-7
5.4.2 Band brakes ............................................ 5-7

5.4.3 Spooling mechanism and measuring head 5-7

5.4.3.1 Unlocking the measuring head ................ 5-9
5.4.3.2 Preparations for operation at the
measuring head ........................................ 5-9
1) The „Wireline Combi Unit PP“ is also referred to in this
operating manual as the „Container“ or „Unit“.
2) Users located outside of the EEC should always follow the
safety practices and procedures in accordance with the
recommendations of The Occupational Safety and Health
Administration (OSHA), The National Safety Council (NSC),
The Hand Tools Institute (HTI), The International Association
of Drilling Contractors (IADC) etc. All applicable governmental
rules, regulations or restrictions, now in effect or which may be
promulgated, take precedence over the suggestions in this
publication!
3) For information on the abbreviations see Chapter 1.7.1.

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5.1 Safety information

Adhere to the regulations, warnings and information
given in Chapt. 2 „Occupational safety and health,
safety regulations and environmental protection“
during installation/set-up and all measures required for
preparing the Wireline Combi Unit PP1) for operation!

! Attention
Read the operating manual prior to switching on
the container!
During operation it will be too late to obtain the
necessary information!

5.1.1 Instruction of the

Fig. 5-1: The door holder for the winch cab doors and operating personnel
twistlock for fastening the container to the trailer Prior to setting up the machine, the operator must read
(arrow). both this operating manual and also the „Operating and
handling instructions“ (Chapter 4.2.2) issued by the
user/owner concerning the safe handling of the
wireline or cable, tools etc., and perform measures
correctly, according to training/instruction and the
generally recognised codes of engineering practice.
• Refrain from any measure/method of operation at
the container that could lead to injury to persons or
Fig. 5-2: Holder for fastening the opened door to the damage to assets!
winch cab. • The hazardous area, the control room and the work
Attention: The doors must always be opened or area, i.e. the winch cab and the area up to the
closed by two persons due to the possible wind wellhead, are to be secured by fencing to prevent
pressure! the access of unauthorized persons.
• For all work on the container, wear/use the
prescribed personal protective equipment (PPE) as
required by law/company rules, see Chapter 2.3.1.
Only use PPE that is in perfect condition!

! Danger
While the engine is running, always maintain a
sufficient safety distance (as defined by DIN
EN ISO 13 857) from moving components!
• Drives can start up unexpectedly at any time due to
system faults or unauthorized/erroneous switching!
• Risk of crushing between moving and stationary
components!
• Keep well away from the moving wireline/cable,
winches, measuring head etc., when the container is
operational and during operation, and never reach
behind cladding into areas you cannot look into!

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• During operation, it is forbidden for unauthorized

persons to be within the hazardous area of the
Wireline Combi Unit PP!

5.1.2 Tools and consumables/

auxiliary equipment
Tools, consumables and auxiliary equipment are
required for setting up and preparing the container for
operation, as described in Chapter 7.2.

Fig. 5-3: Roof structure with handles, pull cable for

unlocking. Detent pins engage in the respective guides 5.2 Installation/set-up of the
of the container structure for fixing the roof flap in the Wireline Combi Unit PP
open position.
5.2.0.1 Permissible conditions at the
The hook stick for actuating the pull cable is located
installation/work site area
on the RH container wall.
• Prior to installing the container, clean the installation/
work site area. Remove any rubble, wood,
installation waste etc.
• Eliminate any risks of tripping and slipping at the
installation/work site area.

5.2.0.2 Preparation of the installation/

work site area
Before finally installing/setting up the container, have
an expert check that
• the work site area/installation site is level and that
there is sufficient space on all sides of the container
Fig. 5-4: 5 pole CEE plug connector for 3ph, 400V
for opening the doors and/or for performing
AC, 50 Hz, 32A, for connecting an external power
maintenance work,
supply, and the NATO receptacle for 24V, e.g. for
• that the installation/work site area has a sufficient
starting the power pack in the event of battery
load bearing capacity for the container that has a
malfunctions.
- weight of approx. ................................... 15,000 kg

5.2.0.3 Attachment, lifting and transport of the

container

! Attention
The container contains electrical/electronic
devices and must be treated with due care
during transport, and deposited gently without
knocks!
The container is to be attached to the lifting gear/crane
using 4 point lifting tackle/gear (cables, eyebolt/ring,

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shackles etc.) (also refer to DIN EN 12079-2).

• Only fasten the attachment gear to the 2x fittings at
the top of the container and the 2x fittings in the
winch cab (Fig. 4-3).
For transport information, please also refer to
Chapt. 3.

! Danger to life!
Never stand or work under suspended loads!
Danger to life!

5.2.1 Installation and alignment of the

machine
• Precisely align the longitudinal axis of the container,
center of front and rear drum, to the wellhead,
check that the position of the container is horizontal.
Fig. 5-5: Tank filler neck next to the door to the • Ensure that the distance between the winch cab and
engine compartment. wellhead, or to the first hay pulley is at least 15 m
(50 ft). Otherwise wireline/cable running problems
Fig. 5-6: Engine oil dipstick (arrow); the engine oil are to be expected.
filler neck is located on top of the engine behind the • Fully open the winch cab door. The doors must
cover. always be moved by 2 persons due to wind
pressure!
• Secure doors immediately after opening (Fig. 5-1/2).

! Danger of crushing
Only use the door handles for opening and
closing the doors. Never reach into the door
rebate!

5.2.1.1 Roof structure

• To open the roof structure, pull the wire cable to
unlock the side detent pins, allowing the roof
structure to be pushed back by the handles.

5.3 Preparations for operation

5.3.1 Checking/topping up
consumables/auxiliary
substances
Insofar as necessary, e.g. following extended shut-
down or after being airfreighted (all containers need to
be emptied before dispatch), check the fluid levels and

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top up the consumables/auxiliary substances to the

designated mark; it might be necessary to remove
water from the hydraulic oil reservoir and bleed the
hydraulic system, also see Chapter 7.7.1 and following
chapters.

5.3.1.1 Checking/topping up engine

consumables/auxiliary substances
For detailed information about filling, please also refer
to the CAT operating manual in “Section III” of the
technical documentation. Check and fill the following:
• Fuel tank (400 l diesel oil tank); the tank filler neck
is located next to the rear doors to the engine
compartment (Fig. 5-5),
Fig. 5-7: Oil filler neck on top of the engine (arrow). • Check engine oil level/top up,
- pull the dipstick at the engine (Fig. 5-6), read the
oil level and top up if required as described below,
- the oil filler neck is located at the top of the
engine behind the cover (Fig. 5-7).
• Top up engine coolant, including antifreeze for
winter operation. The cooler closure is located at
the top of the cooler (Fig. 5-9).

5.3.1.2 Checking/topping up hydraulic oil

• The hydraulic oil level can be read off at the
inspection glasses on the front of the tank, also see
Fig. 7-15.
• If necessary, top up with hydraulic oil “HLP”, ISO
VG 46, see Chapt. 7.7.1. The filler neck is located
next to the oil level inspection glasses.

Fig. 5-8: Example of the wire oiler with 0.5 l oil

container on top of the spooling mechanism. 5.3.1.3 Topping up the wire oiler
• Top up the oil container on the spooling mechanism
or above the measuring head (Fig. 5-8) prior to
commissioning/start-up.
• The wire oiler or solenoid valve is actuated using
the toggle switch “7S2” on the control panel when
required.

5.3.2 General preparations for

operation
To prepare for operation, perform the following
measures and check at the container or on the basis of
service/maintenance/repair logs,

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• that the container does not have any externally • that the air pressure and quantities in the
visible damage or defects, compressed air receivers are sufficient,
• that the operating elements are readily accessible • that the compressed air receivers have been drained
and functioning, the display devices/indicating (drain valves under the receivers).
instruments are legible and the panoramic window
! Warning
to the winch cab is clean,
• that there are no loose objects in the winch cab or Have any damaged, kinked, pinched or chafed
on the control panel in the control room, hydraulic/compressed air hoses and damaged
• that there are no loose screw/bolt connections on devices immediately replaced by expert
the winches, measuring head and spooling personnel!
mechanism, Have a qualified electrician perform a visual inspection
• that there are no visible lubricant leaks on the to ensure:
hydraulic components, especially at the hydraulic • that electric cables are not damaged, scorched or
motors with planetary gear units, chafed,
• the hydraulic motors are securely fastened, • that plug-connectors/sockets are not damaged,
• that the air intake and air outlet on the oil/air cooler • that there are no loose connections,
are not soiled or damaged, • that there is no moisture in terminal boxes/
• that the hydraulic oil return filter element has been connections etc.
replaced if necessary,
• that there are no leaks at the compressed air ! Danger
system, on components or connections, Have any damaged, kinked, pinched or chafed
electric cables and damaged devices
immediately replaced by a qualified electrician!

Fig. 5-9: Engine compartment with batteries and 5.3.2.1 Electrical connection
cooler closure (arrow). • A connection for the external energy supply of 3
phase, 400V AC, 50 Hz, 32A, as 5 pole CEE plug
connector acc. to IEC 60309, is provided
underneath the engine compartment doors (Fig. 5-
5).

! Attention
Route external electric cables such that they
can be safely driven over and do not present a
tripping hazard.
• A 24V NATO receptacle serves for supplying 24V,
as required, e.g. from a truck for operating or
starting up the power pack and control system.

5.3.2.2 Connecting the machine to ground/

connecting the equipotential bonding
cable
• The grounding cable is to be found on the inside of
the winch cab door. The cable is conductively
connected to the container.

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• Connect the cable to the ground connection of the

system and/or wellhead using a screw/grounding
clamp.
• After connection, measure the leakage resistance;
ensure that there is a leakage resistance of
< 106 Ohm.
• For information on regular testing of the connection
to ground/equipotential bonding in accordance
with TRBS 2153, see Chapt. 7.4.1.

5.4 Setting up individual

components
5.4.1 Winch
• As required, after prolonged shut-down/
decommissioning, repairs etc.,
- relubricate the drum bearings (Chapter 7.5.7),
- grease/relubricate the spooling mechanism,
- oil the roller chains (Chapter 7.6.4.1).
• Check the fastening of the drum bearings, tighten
the screws if necessary.
Fig. 5-10: Checking the brake band between the • Fit a new winch drum if necessary, as described in
drums. Lining thickness > 2 mm! Chapt. 7.6.3.
Fig. 5-11: Roller chain drive, oil level sight glass
(arrow) and oil infill opening (top arrow) on the
gearbox. 5.4.2 Band brakes
• Inspect the brake band between the front and rear
winch (Fig. 5-10).
• Check the brake band lining thickness; at
a lining thickness .............................. less than 2 mm,
replace the brake band as described
in Chapt. 7.6.6.3.
• Check the brake band pre-tension, adjust if
necessary, see Chapter 7.6.6.1/2.

5.4.3 Spooling mechanism and

measuring head
• The spooling mechanism is moved automatically up/
down. It may be necessary to loosen the clamping
screws, particularly if the wireline/cable is not
running virtually horizontal and the spooling
mechanism has to be set at an angle to the
horizontal.

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Wireline guide roller

Fig. 5-14: Moving the carrier to the roller chain or

Friction bearing chain carrier.

Contact pressure roller

Fig. 5-12: Chain gripper and guide axle friction

bearing.
Fig. 5-13: Horizontal contact pressure roller and
vertical guide roller. When in operation, the guide roller
engages in the guide rail (Fig. 4-24).

Fig. 5-15: Couple the carrier to the roller chain such

that the spring-loaded locking pin engages in the chain
carrier.

Guide roller

Contact pressure roller

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5.4.3.1 Unlocking the measuring head • As required, after prolonged shut-down/

• The measuring head is moved into the park position decommissioning, repairs etc.,
with transport securing device and secured from - relubricate the flange bearings (Chapter 7.5.7),
moving sideways by a locking bolt, see Chapt. - relubricate the friction bearings of the guide axle
6.5.2.4. (Fig. 5-12),
The locking bolt engages in the guide rail (Fig. 5-17) - oil the roller chain (Chapt. 7.6.4),
and blocks the guide roller. - grease the length compensation of the steering
column, cardan joint, etc.
• Always open the winch cab doors and the roof flap.
• Remove the locking bolt from the guide rail.
• If removed prior to shut-down: Insert the chain
5.4.3.2 Preparations for operation at the
gripper (Fig. 5-14/15) at the chain carrier.
measuring head
• For preparing the measuring head for operation
please also refer to the Benchmark operating
manual in „Section III“ of the technical
documentation.

Fig. 5-16: Wireline/cable guidance at the measuring 5.4.3.3 Threading in the wireline/cable at the
head between the vertical guide rollers, measuring measuring head
wheels and contact pressure rollers. • Thread the wireline/cable between the vertical
guide rollers and between the measuring wheels and
contact pressure rollers as shown in Fig. 5-16.
Wireline/
cable
5.4.4 Hydraulic group
• After extended shut-down or repairs and similar,
check the oil condition/quality, as described in
Chapt. 7.7.1.2.
In the event of contamination, air/water in the oil, or
soiling, change the oil and flush the oil container
with fresh oil prior to commissioning/start-up.
• Check hydraulic components and connections for
leaks.

5.4.4.1 Return filter

• After extended shut-down or repairs and similar,
Contact pressure roller

replace the return filter element as described in

Chapt. 7.7.3.

5.4.4.2 Hydraulic hose lines

• Check hydraulic hose lines and connection couplings
(also see Chapt. 7.7.4),
- check connection couplings for leaks/wear/
damage,

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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- check hose lines for externally visible damage 5.4.4.3 Connecting PCE hose lines
(cuts/punctures, pinched or chafed points as well • Connect the hose lines (not part of the KMA
as porosity), delivery scope) to the PCE connection panel in the
- previous duration of use of the hose lines. belly box under the truck (Fig. 4-26).
• Eliminate any pinching points, chafing points, etc. or
hoses routed with bends smaller than their minimum Warning
!
bending radius.
• Replace the hydraulic hoses, Material damage to the hose or hose drum will
- in the event of damage (see above) result from applying hydraulic pressure to a
- due to aging, after a service life of hose when it is rolled up!
48 months or every 4 years. • Connect the hoses to the wellhead according to the
owner/user’s instructions.

Locking bolt

Guide roller

Guide rail

Fig. 5-17: Spooling mechanism and

measuring head pushed up into the end
position for demonstration purposes.
Locking bolt for securing the measuring
head from moving sideways in the park/
transport position.
Refer to Fig. 4-24 for the guide roller
and its engagement in the guide rail.

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• For operation, open the ball valves at the PCE maintenance/repair/preparation logs to ascertain
operating panel (Fig. 6-4). that the work required for preparation for operation
as described in Chapter 5.3 and 5.4 has been
correctly completed.
5.4.6 Hydraulic oil/air cooler • During the function test, ensure that the front and
• No special measures are required for preparing the rear drum, and all other rotating/moving components
oil cooler for operation. run smoothly and uniformly.
• For information about preparing the hydraulic oil • Check that all operating elements are functioning
cooler for operation, please refer to the third-party perfectly.
operating manual in “Section III” of the technical • During the function test, check the following:
documentation. - The perfect function of the hydraulic system,
• Check the air intake and air outlet, and clean if - the function and holding load of the band brakes,
necessary before commissioning/start-up. - the perfect, smooth run of the winch at different
rotational speeds and rotational directions.

5.4.7 Compressed air system

5.5.0.1 Function check of the operating
• No special measures are required for preparing the
elements
compressed air system for operation.
• Drain the water from the compressed air receiver ! Warning
by opening the drain valve at the bottom of the Only switch on if there is no risk of danger to
receiver. persons or damage to assets resulting from the
• For information about regular drainage of water start-up of the engine, winches etc., drum
from the compressed air receiver, please also see rotation, wireline/cable run, etc.
Chapt. 7.4.2.
• For preparing the compressor directly driven by the • Check the functions of the operating elements, test
engine for operation, please also refer to the third- the switch/button/control handle switching routines
party operating manual in “Section III” of the on the control panel:
technical documentation. - Any actuation of switches/buttons/control handles
must remain without effect when the main switch
of the control system “2Q1” is turned OFF and/or
5.4.8 Electrical system one of the EMERGENCY STOP buttons “4S1”
or “4S4” is pressed.
• No special measures are required to prepare the
- With the main switch turned ON and the
electrical system for operation.
EMERGENCY STOP buttons rearmed, each
switch/button/control handle must function as
intended.
5.4.8.1 Battery
• After extended shut-down, repairs, or similar, check • Check that the hydraulic motors are running quietly,
the battery acid level (Chapt. 7.9.1), and, if smoothly and with minimum vibration.
necessary, top up with distilled water to the mark on
the battery case, also see Fig. 5-9.
5.5.1 Visual inspection prior to the
first start-up
• Perform a visual inspection (safety check) as
5.5 Function check described in Chapter 6.3.2,
Perform a function check prior to initial start-up and document the results.
following extended shut-down or maintenance/repair • Check that the container does not have any
work. externally visible damage or defects.
• Carry out a visual inspection and/or consult service/ • Check that the type plate, safety and hazard signs

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on the machine are complete and legible. reached, either pull the control handle “L2” back
• Ensure that the operating elements on the control fully (as far as possible) or push it fully forward,
panel are readily accessible at all times. and repeat the above mentioned test with this
• Check that the EMERGENCY STOP hit buttons setting.
“4S1” and “4S4” function correctly, i.e. they must - If the control pressure, pressure gauge “C2”, goes
be re-armed. below
15 bar (218 psi), contact KMA!
09 - Release the hand brake lever “4S3”.
5.5.2 Hydraulic system test 10 - Move control handle “L2” to the center or neutral
To perform a trial run/hydraulic system test run to position, gently brake the slowing down drum by
check the tension/pull force, perform the following slightly deflecting “L2” in the opposite direction.
steps 01 to 12 in the specified order:
11 - Pull the control handle “L2” slightly back
01 - Check that the front or rear drum to be tested is (spooling the wireline/cable onto the drum).
correctly selected with the selector switch “5S1”. Repeat the above described test with the opposite
02 - Ensure that the hand brake “4S3” is firmly drum rotational direction.
applied, BRAKE ACTIVE.
12 - After completion of the trial runs with one drum
03 - Set control handle “L1” to the center/neutral
in both rotational directions, perform the tests
position.
with the second drum as described above.
04 - Push control handle “L2” slightly forward
• After completion of the tests, check that
(wireline running in the direction of the wellhead/
- there are no leaks at hydraulic components, hose
borehole).
lines and screw connections,
This defines the drum rotational direction.
- there are no loose screw connections on the
05 - Turn controller (twist handle) “R2” clockwise, winch.
direction “+” (cw), i.e. to max. pull force/tension
so that the drums will not stop turning even when
the tension increases. 5.5.3 Test of the drum rotational
06 - Pull control handle “L1” back approximately to
half deflection to achieve medium drum rotational speed and rotational direction,
speed. or of the wireline/cable running
The drum is held only by the locking brake. speed and direction
07 - Turn controller (twist handle) “R2” slowly To perform a trial run/hydraulic system test run to
counterclockwise, direction “-” (ccw), i.e. check the rotational speed or wireline/cable speed,
causing a pull force/tension limitation. perform steps 01 to 10 in the following order:
08 - Monitor the main pressure at pressure gauge
“C1”. Due to the closing of the controller (twist 01 - Check that the front or rear drum to be tested is
handle) “R2”, the operating pressure in the correctly selected with the selector switch “5S1”.
hydraulic system increases. 02 - Ensure that the hand brake “4S3” is inactive,
For the test, do not allow the operating pressure 03 - Turn controller (twist handle) “R2”
of 150 bar (2,175 psi) to be exceeded; maintain counterclockwise, direction “-” (ccw), reducing
this pressure for approx. 30 sec., subsequently the pull force/tension such that eventually a load
reduce the pressure in the system by opening the (tension) is held by the winch.
controller (twist handle). 04 - Push control handle “L2” forward (wireline run
• If during the test, towards the wellhead/borehole), to define the
- the drum is not held by the brake but slips, check drum rotational direction.
the band brake; see Chapter 7.6.6; increase the 05 - Check (visual inspection) that the drum rotational
brake band pre-tension if necessary. direction corresponds to the deflection of “L2”,
- an operating pressure of approx. 150 bar is not also refer to Chapt. 4.3.5 and following.

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06 - Pull or push control handle “L1” to increase the normal operating interruptions, only use it for
rotational speed as required. immediate shut-down in hazardous situations!
• NEVER brake the rotating drum using the hand
07 - Move control handle “L2” to the center or neutral
brake lever “4S3”.
position, gently brake the slowing down drum by
The band brake is a holding/locking brake and not
slightly deflecting “L2” in the opposite direction.
an operating brake!
08 - Pull control handle “L2” back (spooling the
wireline/cable onto the drum). ! Warning
Repeat the above described test with the opposite
If the hand brake lever “4S3” is used to brake
drum rotational direction.
the rotating drum, overheating may occur,
09 - After completion of the trial runs with one drum possibly leading to flying sparks implying the risk
in both rotational directions, perform the tests of fire/explosion!
with the second drum as described above.
• If the wireline/cable runs at maximum speed into
10 - Finally firmly apply the hand brake “4S3”.
the borehole, this may cause wireline/cable run
• After completion of the tests, check that problems (tangling).
- there are no leaks at hydraulic components, hose Only switch to maximum wireline speed/drum
lines and screw connections, rotational speed when pulling the wireline/cable out
- there are no loose screw connections on the of the hole (Pull Out Of Hole)!
winch.
For information on trouble-shooting and malfunction
causes also refer to Chapter 8.

5.5.4 Testing the safety functions

• Check the function of the EMERGENCY STOP hit
buttons “4S1” and “4S4”.
- During operation/trial run, hit each of the
5.6 Operational readiness
EMERGENCY STOP buttons “4S1” and “4S4” • After completion of the function checks restore the
individually, function of all guards/protective devices/safety
the drums must stop in the respectively reached equipment.
position,
- the engine will be switched off, ! Danger
- the 230V power supply for the lighting is It is not permissible to start up the unit unless it
maintained as long as there is an external power is in a perfect, technically safe condition!
supply connected.
• The Wireline Combi Unit PP is now ready for
• Rearm the EMERGENCY STOP button by pulling/
operation!
turning the mushroom button and allowing it to
disengage. • Have the operational safety and operational
readiness confirmed by the user/owner’s safety
• As soon as the EMERGENCY STOP button is re-
officer according to the company regulations!
armed, operation may only be resumed through
intentional switching measures (DIN EN 60 204),
i.e. the machine must be shut down according to a
shut-down routine, and then restarted; also see
Chapt. 6.4.5.

5.5.5 Information on switching or

operating errors
• Never use an EMERGENCY STOP button for

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 6 - Commissioning

6. Commissioning/start-up of the Wireline Combi Unit PP

Table of Contents 6.4.3.4 Monitoring of operation ......................... 6-11
6.1 Safety information .......................... Page 6-2
6.4.4 EMERGENCY STOP switching
device .................................................... 6-11
6.2 Installation/set-up of the Wireline Combi
6.4.4.1 Autom. cut-out devices ......................... 6-11
Unit PP and preparation for operation .... 6-2
6.4.4.2 Start-up after
an EMERGENCY STOP actuation ...... 6-11
6.3 Commissioning/start-up ........................... 6-2
6.3.1 Instruction of the operating personnel ..... 6-2
6.5 Operation of the pressure control
6.3.2 Visual inspection as a safety inspection .. 6-3
equipment (PCE) ................................... 6-12
6.3.3 Operating elements ................................. 6-4
6.6 Shutting down the machine ................... 6-12
6.3.3.1 Operating and monitoring elements
6.6.1 Brief operating interruption ................... 6-12
on the container ....................................... 6-4
6.6.2 Shutting down for up to 6 months ......... 6-12
6.3.3.2 Operating elements on the control panel . 6-4
6.6.2.1 Removal of water from, filling and
6.3.3.3 Operating elements on the electric
system bleeding/venting
switch cabinet (Fig. 6-3) ......................... 6-6
of the consumables containers .............. 6-13
6.3.3.4 Operating elements on the PCE panel
6.6.2.2 Spooling (winding up) and securing
(Fig. 6-4) .................................................. 6-6
the wireline/cable .................................. 6-13
6.6.2.3 Disconnecting the electrical connection
6.3.4 Switching on the engine .......................... 6-7
and grounding cables ............................. 6-13
6.3.4.1 Measures in the event of a false start
6.6.2.4 Winding up the PCE hoses .................... 6-13
of the engine ............................................ 6-8
6.6.3 Decommissioning (mothballing) ............ 6-13
6.3.5 Function check ........................................ 6-8
6.7 Recommissioning ................................... 6-14
6.4 Operation ................................................. 6-9
6.4.1 Starting up the machine ........................... 6-9
6.4.1.1 Benchmark display unit ........................... 6-9
6.4.2 Operation of the Wireline Combi
Unit PP .................................................... 6-9
6.4.3 Wireline speed, pull force/tension and
monitoring of operation .......................... 6-10
6.4.3.1 Operation at low speed
and max. pull force/tension ................... 6-10
6.4.3.2 Operation at high speed ........................ 6-10
6.4.3.3 Operation with variable pull
force/tension .......................................... 6-11
1) The „Wireline Combi Unit PP“ is also referred to in this
operating manual as the „Container“ or „Unit“.
2) Users located outside of the EEC should always follow the
safety practices and procedures in accordance with the
recommendations of The Occupational Safety and Health
Administration (OSHA), The National Safety Council (NSC),
The Hand Tools Institute (HTI), The International Association
of Drilling Contractors (IADC) etc. All applicable governmental
rules, regulations or restrictions, now in effect or which may be
promulgated, take precedence over the suggestions in this
publication!
3) For information on the abbreviations see Chapter 1.7.1.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
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6.1 Safety information ! Danger

Take the regulations, warnings and information given
When the power pack is operating, always
in Chapter 2 „Occupational safety and health, safety
maintain a sufficient safety distance (as defined
regulations and environmental protection“ into
by DIN EN ISO 13857) from moving
consideration during commissioning, operation and
components, particularly the running wireline/
when shutting down the unit1)!
cable!
Drives can start up unexpectedly at any time
! Attention
due to system faults or unauthorized/erroneous
Read the operating manual prior to turning on switching.
the unit! Danger of serious injuries!
During operation it will be too late to obtain the
• During operation, the operator must remain at the
necessary information!
operator’s station of the machine in front of the
control panel!

! Attention
6.2 Preparation for operation If the operator does have to leave the
• Do not put the unit into service until the
operator’s station for an important reason, it is
preparations for operation according to Chapters
imperative that the unit is safely shut down
5.3 and 5.4 have been fully completed. This
beforehand, see Chapt. 7.5.1!
includes, among others:
- Consumables (diesel and hydraulic oil) checked/ • Risk of crushing between moving and stationary
topped up components!
- Grounding/potential equalization cables • Keep well away from the moving wireline/cable,
connected. winches, measuring head etc., when the unit is
operational and during operation, and never reach
behind cladding into areas you cannot look into!
• During operation, it is forbidden for unauthorized
6.3 Commissioning/start-up persons to be within the hazardous area of the
6.3.1 Instruction of the container or even in the winch cab!
operating personnel Warning
!
Prior to initial start-up/commissioning, the operator
must read both this operating manual and also the The operator must stop work and actuate the
„Operating and handling instructions“ (Chapt. 4.2.2) EMERGENCY STOP button if unauthorized
issued by the owner/user concerning the safe handling persons enter the hazardous area or even try to
of the wireline/cable, tools etc., and perform measures reach the running wireline/cable.
correctly, according to training/instruction and the • Immediately switch off the unit by pressing the
generally recognised codes of engineering practice. EMERGENCY STOP hit button „4S1“, see Fig.
• Refrain from any measure on the unit or method of 6-1, in the event of
operation with the winch, spooling mechanism etc. - abnormal operating noise or
that could lead to injury to persons or damage to vibration,
assets! - erratic/uneven movements of the winch or
• For all work on the container, wear/use the erratic, jerky/fluttering run of the wireline/cable,
prescribed personal protective equipment (PPE) as - malfunctions of the hydraulics/pneumatics/
required by law/company rules, see Chapter 2.3.1. electrics.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 6 - Commissioning

instruments are legible and the panoramic window

! Warning to the winch cab is clean,
Only switch on again when the malfunction has • that there are no loose objects in the winch cab or
been fully remedied! on the control panel,
• Whenever the container is shut down, always • that there are no loose screw/bolt connections on
perform the necessary measures to ensure that it is the winch, e.g. on the winch base frame, flange
in a safe standstill condition as described in Chapter bearings etc.
7.5.1. • that there are no visible lubricant leaks on the winch
• Ensure that unauthorized/erroneous start-up is drives, the hydraulic motors with planetary gear
absolutely impossible at all times! units,
• that the consumables/auxiliary substance containers
have been filled to the specified mark with the
6.3.2 Visual inspection as a safety prescribed consumables/auxiliary substances.
inspection These include:
- Fuel tank/diesel oil tank; diesel oil according to the
Prior to each start-up of the unit, carry out a visual
engine operating manual
inspection daily or determine on the basis of service/
maintenance/repair logs to ensure
• that no persons are within the hazardous area or
working at the machine,
• that the Wireline Combi Unit PP does not have any
externally visible damage or defects. Fig. 6-1: Control panel with control/operating and
• that the operating elements are readily accessible monitoring elements for the engine, the winches, the
and functioning, the display devices/indicating hydraulic system etc.

4S1 7S1 4S2

C1 C2 C3
B2
5S2 7S2 4H2 5S1
D3
10P1 9H3 9H4
B1
9A1

9S2
9S1
L1 L2 9S3
9S4

4S3
E1 R2

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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- Engine oil according to CAT operating manual

- Engine cooler according to CAT operating manual ! Warning
- Hydraulic oil reservoir according to Chapt. 7.7 Have any damaged, kinked, pinched or chafed
and following chapters in this operating manual, hydraulic/compressed air hoses and electric
- PCE hydraulic group. cables, as well as any damaged devices
immediately replaced by expert personnel!
• that there are no visible leaks at the hydraulic
system, on components or connections,
• that the hydraulic motors and planetary gear units
are securely fastened, 6.3.3 Operating elements
• that the return filter element (Fig. 7-16) does not Regarding the operating elements, please refer to the
show any service requirement or that the filter reference numbers in Fig. 6-1 and to the battery main
element has been exchanged, switch „4Q1“ in Fig. 6-2.
• that the air intake and air outlet on the oil/water/air For the electrical operating elements, please also refer
cooler are neither soiled nor damaged, to the wiring diagram in the electrical documentation
in „Section VII“ of the technical documentation.
• that there are no leaks at the compressed air
system, at components or connections, and that the
compressed air receivers have been drained. The 6.3.3.1 Operating elements on the container
drain valves are located at the bottom of the
receivers. Pos. Designation

• That electric cables and plug-connectors/sockets 4Q1 - Battery main switch in the workroom, on the
are not damaged, left behind the entrance door, see Fig. 6-2.
• that the battery acid level has been checked and The switch isolates the 24V container electrics
topped up with distilled water if necessary. from the batteries and must always be
switched off when the system is shut down,
otherwise the batteries may discharge.
4S4 - EMERGENCY STOP hit button, red, located
on the left-hand winch cab door, for immediate
disconnection of the system from the energy
supply. The following are switched off:
Fig. 6-2: Battery main switch „4Q1“ in the workroom, - the electr. control system (24V),
on the left next to the entrance door. - the winches; the drum brakes are applied,
- the engine, the shut-off valve closes, the
engine with hydraulic pumps and hydr.
generator (Dynaset) is shut down.
A possibly connected external 400V electricity
supply is not switched off in order to guarantee
that the 230V lighting remains on.
4Q1
6.3.3.2 Operating elements on the
control panel (Fig. 6-1)
ENGINE CONTROL
Pos. Designation
9A1 - Engine control (display), with displays
programmed by the owner/user, please refer
to the third-party operating manual.
10P1 - Fuel/tank gauge,

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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9S1 - Toggle switch (IGNITION):

- Ignition OFF ! Warning
- Ignition ON When the „Winch override“ button is pressed,
9H3 - Signal light, yellow, warning! all safety functions are disabled!
9H4 - Signal light, red, STOP! Only the EMERGENCY STOP hit buttons
remain operative.
9S2 - Illuminated push-button, green, START of the
engine. Press the button after „9S1“ when the 5S1 - Selector switch for preselecting one of the two
signal light has extinguished, otherwise a cold drums, with the switching positions:
start will be carried out. - turned to the left: Pre-selection of the front
9S3 - Toggle switch for engine speed setting (+/-). drum, i.e. the winch drum facing the operator,
9S4 - Push-button, white, for selecting the idle speed - center: Neutral position,
of approx. 800 rpm. - turned to the right: Pre-selection of the rear
drum, i.e. the winch drum at the rear as seen
HYDRAULICS from the operator’s workstation.
C1 - Pressure gauge (Main Pressure), 7S2 - Toggle switch, Wire Oiler OFF/ON,
pmax = 380 bar 4H2 - Signal light BRAKE ACTIVE
C2 - Pressure gauge (Control Pressure)
p = 30 bar, pmin = 20 bar HANDWHEEL
C3 - Thermometer indicating the oil temperature, E1 - Turning the handwheel moves the measuring
tMax = 70 °C. head from the right-hand to the left-hand side of
the drum and back.
SAFETY CONTROL
4S1 - EMERGENCY STOP hit button, red, for CONTROL HANDLE, LH OUTSIDE -
immediate shut-down of the winch. The brakes WIRELINE/CABLE SPEED
are applied, and the engine is shut down as L1 - Control handle for increasing the wireline/cable
described above for „4S4“. speed (drum rotational speed). Push or pull
5S2 - Push-button, black, for actuating the horn. control handle „L1“, only the extent of the
deflection determines the speed of the wireline/
WINCH CONTROL cable.
4S2 - Illuminated push-button, green, „WINCH • The neutral/zero position of „L1“ is located in the
RELEASE“. To be pressed by the operator to center.
confirm that the preparations for winch
operation have been completed. Attention
- Main switch turned on,
!
- truck engine is running, Only switch on the maximum wireline speed
- a particular winch is selected, with „L1“ when pulling the wireline out of the
- control handles „L1“ and „L2“ in neutral borehole (Pull Out Of Hole) and spooling it onto
position etc. the drums!
The winch release releases all safety valves in If the wireline runs at maximum speed into the
the system, only then is control of the winch borehole when unspooling, this can lead to
possible. problems with the wireline run in the borehole
7S1 - Illuminated push-button, white. „OVERRIDE“, (tangling).
press and hold down the button when normal
winch operation, e.g. due to a control error, is no CONTROL HANDLE, LH INSIDE - WIRELINE/
longer possible and the cable/wireline still needs CABLE DIRECTION
to be pulled. L2 - Control handle for the drum rotational direction,
- Push the control handle forward for unwinding
the wireline in the direction of the wellhead/
borehole,

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 6 - Commissioning

- Pull the control handle back to spool the 6.3.3.3 Operating elements on the electric
wireline onto the drum. switch cabinet (Fig. 6-3)
• When a rotational direction is preselected with 2Q1 - Main/change-over switch for the electricity
„L2“, the drum already starts rotating at slow supply at the switch cabinet in the control room
speed! (Fig. 4-11)
• The speed is only increased by actuating „L1“! - 0, OFF, switches off the entire
• The neutral/zero position of „L2“ is located in the container electrics,
center. - Mains, external connection 400V, 3ph, 32A,
50Hz,
RH CONTROL HANDLE - HAND BRAKE - hydr. driven Dynaset P = 12 kVA,
4S3 - Control handle for the electropneumatic 400V, 3ph, 17.2A, 50Hz
holding/locking brake. 5S3 - Toggle switch, lighting, Winch Area 24V,
- Push the control handle forward to release 5S4 - Toggle switch, lighting, Door Area 24V,
the brake (BRAKE RELEASE), 5S5 - Toggle switch, lighting, Winch Area 230V,
- Pull the control handle to apply the 7S2 - Signal light, Dynaset Generator Protection.
brake (BRAKE ACTIVE).

! Attention 6.3.3.4 Operating elements on the PCE panel

The brake does not serve as an operating (Fig. 6-4)
brake! For braking, deflect „L2“ opposite to the • For details regarding the function and equipment of
current rotational direction and gently the pressure control equipment, please also refer to
decelerate the drum! Chapter 4.10.
The pressure control panel accommodates the
TENSION CONTROLLER ON THE RIGHT following operating and monitoring elements:
R2 - Controller (twist handle) for tension limitation by
HAND PUMPS
means of the pressure relief valve (safety
P1 - Pump P1 „5,000 psi, Backup“,
valve), also see Chapt. 6.4.2.
P2 - Pump P2 „10,000 psi“,
- Clockwise rotation (cw), direction „+“, the
P3 - Pump P3 „10,000 psi“.
drum pull force/tension is increased.
- Counterclockwise rotation (ccw), direction „-“,
VALVE
the drum pull force/tension is reduced until it is
V1 - Compressed air main valve, charging of the
just sufficient for the drum to hold a load
pneum. pumps.
(balanced state).
V2 - Discharge valve „Dump“
DISPLAY ELEMENTS (BENCHMARK) V3 - Subsurface valve
B1 - Operator monitor, Benchmark, digital display of V4 - Lower wireline valve
pull force/tension, depth and speed, V5 - Upper wireline valve
B2 - Back-up display, digital depth display. V6 - Stuffing box
D3 - Analog hydraulic pull force/tension display,
Martin Decker PRESSURE CONTROL VALVE (air
pressure)
• For details regarding the tension, depth and speed
DRV1 - 5,000 psi pump
display, please refer to the third-party operating
DRV2 - Grease injection
manuals in „Section III“ of the technical
documentation.
OPERATING PRESSURE GAUGES
M1 - Air pressure
M2 - Grease pump/grease injection
M3 - 5,000 psi pump
M4 - Subsurface safety valve

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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M5 - Lower wireline • Read off the engine rpm at the display „9A1“,
M6 - Upper wireline adjust the engine rpm at the toggle switch „9S3“
M7 - Stuffing box for warming up if necessary.
• Do not subject the engine to load until
- the oil pressure > 0.5 bar and
6.3.4 Switching on the engine - the cooling water temperature is at approx. 87 °C.
The values are also shown on the display „9A1“,
Danger please also refer to the minimum values specified in
!
the CAT operating manual.
Never enter the hazardous area when the
engine is running! • Ensure that
- the EMERGENCY STOP buttons „4S1“ and
• To start the engine, „4S4“ are re-armed,
- Turn the toggle switch „9S1“ to IGNITION ON, - the control handles „L1“ and „L2“ (Fig. 6-4) are
- Wait until the cold start warning light has set to the center neutral position,
extinguished (if applicable), - the intended drum (rear drum or front drum) has
- Press illuminated push-button „9S2“ START. been selected with selector switch „5S1“,
• Monitor the hydraulic oil pressure (Fig. 6-1); the
! Attention unit is not ready for operation until
At atmospheric temperatures below 0 °C - the main pressure „C1“ has reached at least
(winter operation), allow the power pack to > 30 bar,
warm up at medium rpm. - the control pressure „C2“ has reached approx.
> 20 bar.

2P2 2P1

5S3 5S4 5S5 7S2

2Q1

Fig. 6-3: Electric switch cabinet with

the main switch „2Q1“ for the energy
supply from the ext. mains connection or
the hydraulically driven Dynaset
generator.
Indicating instruments for the power
supply, toggle switches for the lighting
and a signal light for malfunctions at the
Dynaset generator, as well as fuses F1
etc.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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Fig. 6-4: Pressure control equipment (PCE panel) • For the lighting, connect the external
400V power supply and switch on
with toggle switch „2Q1“.

V6 6.3.4.1 Measures in the event of a

M7
false start of the engine
• Abort the start if the engine does not
start after approx. 10 seconds,
Repeat the starting sequence after 30
seconds.
• If the starter does not turn when the
M6 V5 toggle switch is turned, or the engine
does not start up when the starter
turns, check that
- the EMERGENCY STOP buttons
„4S1“ and „4S4“ are re-armed,
- the control handles „L1“ and „L2“
M5 V4 (Fig. 6-1) are set to the center
neutral position,
• For further measures, please refer to
the engine operating manual in
„Section III“ of the technical
documentation.

M4 V3
6.3.5 Function check
• For details of a function check,
hydraulic system test, checking the
M2 drum rotational speed and direction,
M3
please refer to Chapt. 5.5 and
following chapters.
V2

DRV2

DRV1

M1
P1 P2 P3
V1

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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6.4 Operation the control panel (Fig. 6-1).

Ensure that the oil temperature does not exceed
6.4.1 Starting up the Wireline Combi 70 °C (158 °F)!
Unit PP If the oil temperature is too high, t > 70 °C:
• Thread in the wireline/cable from the drum via the - Reduce the load/tension,
measuring head to the wellhead according to the - Check the oil level and top up hydraulic oil if
„Operating and handling instructions“ to be issued necessary.
by the user/owner (Chapt. 4.2.2). - Check the oil/air cooler and return filters for
• Start the engine as described in Chapt. 6.3.4. soiling/maintenance requirement.
• Check that the wireline/cable runs correctly over
• Release the brake with brake lever „4S3“ BRAKE
the measuring head and has not run off the
RELEASE.
measuring wheels, become jammed or caught.
With respect to the other operating elements during
! Attention spooling or unspooling of the wireline at the desired
speed, the following rules apply:
Only switch on the maximum wireline/cable
• The pressure relief valve (safety valve) „R2“ limits
speed with „L1“ when pulling the wireline/
the hydraulic pressure applied to the drum drive
cable out of the borehole (Pull Out of Hole) and
motors.
spooling it onto the drum!
- Turning „R2“ clockwise, direction „+“ (cw),
If the wireline/cable runs at maximum speed
prevents valve opening at increasing pressure,
when unspooling from the drum into the
allowing the tension/pull force to be briefly (!)
borehole, this may cause problems with the
increased.
wireline/cable run in the borehole (tangling).
- Turning „R2“ counterclockwise, direction „-“
(ccw), reduces the opening pressure, limiting the
tension/pull force.
6.4.1.1 BenchMark display units
• Actuate control handle „L2“ for the drum rotational
• During operation with the Operator Monitor „B1“
direction, at the same time, the drums starts rotating
switched on and display of the tension, depth and
at slow speed,
speed, this monitor acts as a safety device. It first
- Push the control handle forward for unwinding
sounds an ALARM and then switches the winch
the wireline/cable in the direction of the wellhead/
OFF as soon as set limit values are exceeded!
borehole,
• For details, please refer to the BenchMark
- Pull the control handle to wind up the wireline/
operating manual for the Operator Monitor in
cable.
„Section III“ of the technical documentation.
The neutral/zero position is located in the center.
• Control handle „L1“ to increase the low drum
rotational speed switched on by actuating „L2“.
6.4.2 Operating the Wireline Combi With „L1“ the speed increase is independent of the
Unit rotational direction.
Whether „L1“ is moved to the front or to the rear,
! Warning i.e. is pushed or pulled, is of no relevance!
The band brake is a holding/locking brake. • When spooling or unspooling, observe the wireline/
Never actuate the hand brake lever „4S3“ cable and turn handwheel „E1“ to move the
when the winch drum is rotating! spooling mechanism back and forth from right to
If the brake is applied when the winch is left to ensure that the wireline is neatly spooled onto
rotating, overheating may occur, possibly or unspooled from the drum.
leading to flying sparks with the risk of fire/
explosion! ! Note
• During operation, check the hydraulic oil If „R2“ is set to a higher tension/pull force, the
temperature - see temperature indicator „C3“ on engine rpm will drop.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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The engine speed (rpm), thus also the engine • For operation at max. pull force/tension, control
output, is to be adjusted accordingly using the handle „L1“ is not used.
toggle switch „9S3“.
• During operation, continuously monitor the status of
6.4.3.2 Operation at high speed
the machine on the control panel.
• As soon as work has been completed, shut down
! Attention
the machine as described in Chapt. 6.5 and
following chapters. Only switch on high wireline/cable speed or
drum rotational speed when pulling the wireline/
! Note cable out of the borehole (Pull Out of Hole)!
When the rotational direction of the drum is • High wireline/cable speed,
specified with „L2“, the drum starts rotating at approx. = 400 m/min,
low speed and maximum torque. depending on the diameter of the wire/cable layers.
The drum rotational speed/wireline speed • Ensure that controller (twist handle) „R2“ and thus
increases according to the extent of movement the pressure relief valve (safety valve) is fully
of control handle „L1“ forward or back. opened.
The higher the rotational speed, the lower the Turn „R2“ counterclockwise, direction „-“ (ccw),
torque or the tension/pull force, i.e. and fully open the valve.
Low speed - high pull force • Select the drum rotational direction with control
High speed - low pull force handle „L2“ and deflect for low speed.
• Further increase the wireline/cable speed with
control handle „L1“ and spool or unspool the
6.4.3 Wireline speed, pull force/ wireline.
- Spooling - in the direction of the drum:
tension and monitoring of
Pull control handle „L1“ back or push forward,
operation irrespective of the rotational direction and speed
6.4.3.1 Operation at low speed and max. pull selected with „L2“.
force/tension The wireline/cable speed increases according to
• Low wireline/cable speed, the extent of deflection of „L1“.
approx. = 50 m/min, - Unspooling - in the direction of the wellhead:
depending on the diameter of the wire/cable layers. Pull control handle „L1“ back or push forward,
• Ensure that controller (twist handle) „R2“ and thus irrespective of the rotational direction and speed
the pressure relief valve (safety valve) is fully selected with „L2“.
closed. The wireline/cable speed increases according to
Turn „R2“ clockwise, direction „+“ (cw) and fully the extent of deflection of „L1“.
close.
• Use control handle „L2“ to spool or unspool the Attention
!
wireline/cable.
If the wireline/cable runs at maximum speed
- Unspooling - in the direction of the wellhead -
when unspooling from the drum into the
push control handle „L2“ forward. This selects
borehole, this may cause problems with the
the rotational direction, at the same time the drum
wireline/cable run in the borehole (tangling).
will run at slow speed, and the wireline/cable
Only switch on the maximum wireline/cable
speed is also slow (see above).
speed with „L1“ when pulling the wireline out
- Spooling - in the direction of the drum - pull the
of the borehole (Pull Out Of Hole) and spooling
control handle back. This selects the opposite
it onto the drum!
rotational direction, at the same time the drum will
run at slow speed, and the wireline/cable speed is
also slow (see above).

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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6.4.3.3 Operation with variable pull force/ - the engine and with it the hydraulic pump are
tension switched off.
• Regularly check the following: The external connection for the 230 V power
Ensure that the oil temperature does not exceed supply (lighting) will not be switched off.
70 °C (158 °F), see Chapt. 6.4.2.
• To increase the tension/pull force: ! Warning
- Turn „R2“ clockwise, direction „+“ (cw) for max. Only use the EMERGENCY STOP button to
tension/pull force, and fully close the valve, shut down the unit in hazardous situations. Any
- Increase the engine speed with toggle switch misuse can lead to malfunctions and damage to
„9S3“ to maximum (monitor at display „9A1“). assets!
• To reduce the tension/pull force:
- Turn „R2“ counterclockwise, direction „-“ (ccw), • After actuation of an EMERGENCY STOP button,
and open the valve until the tension/pull force has immediately shut down the unit in accordance with
reduced to cause the winch drum to come to a the shut-down routine as described in Chapt. 6.5.1.
standstill. • Further possibilities for immediately switching off
- Close „R2“ in the direction „+“ (cw) until the the unit or the control system are:
drum just starts rotating, - Switching off the control system main switch
- Close „R2“ by an additional half „2Q1“ (Fig. 6-3) or
rotation. - Turning battery main switch „4Q1“ (Fig. 6-2) to
In this operating mode, the hydraulic pump delivers the OFF position.
a slightly higher pressure than is currently required.

6.4.4.1 Automatic shut-down devices

6.4.3.4 Monitoring of operation • The engine is equipped with safety devices that
• The BenchMark Operator Monitor „B1“ or the lead to automatic shut-down, as explained in Chapt.
analog display unit „D3“ serves for monitoring the 6.4.3.4.
depth and tension of the wireline or cable (Fig. For details, please refer to the CAT operating
6-1). manuals in „Section III“ of the technical
• Regularly check the other monitoring instruments documentation.
on the control panel, see Chapter 6.3.3. Ensure that
the machine is operating in the normal operating
range and no limit values are exceeded. 6.4.4.2 Start-up after an EMERGENCY STOP
• If any limit values are exceeded, shut down the actuation
machine as described in Chapt. 6.5.1. • After hitting the EMERGENCY STOP button,
For malfunction causes please refer to Chapter 8. switch off the unit (run through the shut-down
• The engine is equipped with safety devices that routine), as described in Chapt. 6.5.1.
cause an automatic shut-down, e.g. in the event of:
- high rotational speed (rpm) ............. n > 2,250 rpm • Remedy the cause for actuation of the
- low oil pressure................. p < 0.5 bar (< 7.25 psi) EMERGENCY STOP hit button, eliminate the
hazardous situation
or
• have the cause of an automatic switch-off
6.4.4 EMERGENCY STOP switching determined by expert personnel.
device • Have any detected defects or damage to assets
• The container is equipped with two EMERGENCY rectified immediately in an expert manner!
STOP hit buttons „4S1“ und „4S4“, on the control • Rearm the EMERGENCY STOP button by turning/
panel and on the winch cab door. pulling the mushroom-type push-button and allowing
When only one of these buttons is actuated, it to unlock (Chapt. 6.4.4.3).
- the winch is shut down,
- the locking brakes are applied,

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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• Start up the unit again right from the beginning as 6.6.2 Shutting down for up to 6
described in Chapt. 6.3.4 and following chapters.
months
• Shut down the unit as described in Chapter 6.6.1.
• Drain, fill and bleed the consumables containers,
see Chapt. 6.6.2.1.
6.5 Operation of the pressure • Relubricate all grease lubrication points (drum
control equipment (PCE) bearings, spooling mechanism) as described in
• A separate control panel is installed on the left-hand Chapt. 7.5.7.
side of the control room to operate the pressure • Apply resin- and acid-free grease to bare metal
control equipment, see Fig. 6-4. For details components (except stainless steel) or spray with
regarding function and equipment, please refer to corrosion protection oil.
Chapters 4.7.5 and 4.10. • Visually inspect the container for damage/wear.
• Collect all loose objects from the winch cab and
control room/workroom and stow them away
safely.

6.6 Shutting down the machine • Check the hydraulic system, components, hose lines
and connections for damage/wear and possible
6.6.1 Brief operating interruption leaks.
• Set control handles „L1“ and „L2“ (Fig. 6-1) to the • Check the return filter of the hydraulic system for
center/neutral position. maintenance requirement, exchange the filter
• Press illuminated push button „9S4“ IDLE, the cartridge if necessary.
engine automatically goes into idle run.
• Check that the winch drums have come to a • Check the compressed air system for leaks,
complete standstill. components, hose lines and connections for
• Apply the brake with control handle „4S3“, damage/wear.
• Turn off the engine with toggle switch „9S1“ • Drain the compressed air receivers using the drain
ignition OFF. valves at the bottom of the receivers.
• Turn the main switch of the control system „2Q1“
to the position ! Warning
0 = OFF. For operation during the winter, regularly check
• Turn the main switch of the battery „4Q1“ to the engine antifreeze and the drainage of the
0 = OFF. compressed air system to prevent them from
• Check fuel (diesel oil) and the hydraulic oil level. freezing up!
Top up diesel oil and/or hydraulic oil if necessary; • Switch off the main switch of the control system
also see the CAT operating manual and Chapt. with „2Q1“.
7.7.1. • Turn off battery main switch „4Q1“ (Fig. 6-2).
• Check the engine coolant level at the cooler closure • Check the battery acid level and top up with
on top of the cooler and top up coolant if necessary. distilled water, if necessary, or remove and store
• Check the engine oil level at the dipstick, top up the battery separately, also see Chapt. 7.9.2.
engine oil if necessary
• Cover components and devices (control panel,
operator’s seat etc.) to protect them against
! Danger of crushing
moisture and dust.
Always use the door handles for closing the
doors. Never reach into the door rebate! • Move the measuring head into the left-hand park
position and secure with the locking bolt (Fig. 5-17).
• Cover the measuring head to prevent the ingress of
moisture and dust.
• Close the roof structure of the winch cab.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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• Close and lock the doors to the winch cab. 6.6.2.2 Spooling (winding up) and securing the
• Close and lock the door to the workroom, remove wireline/cable
the key and keep in a safe place. • As required, according to the owner/user’s
operating instructions (Chapt. 4.2.2): Spool the
• Take down the fencing securing the hazardous area
wireline/cable onto the drums and secure the ends
between the container and the wellhead/borehole
on the drums.
and stow it away safely.

! Danger
6.6.2.1 Removal of water from, filling and Damaged cables with ragged/broken strands
system bleeding/venting of the can cause serious hand injuries.
consumables containers Never grip the cable without wearing protective
Drain any water from, fill and vent the consumables/ gloves when spooling the wireline/cable onto or
auxiliary substance containers prior to an extended unspooling it from the drum!
shut-down of the unit in accordance with Chapt. 6.5.2,
particularly during winter operation at outside
temperatures below -15 °C. 6.6.2.3 Disconnecting the electrical connection
and grounding cables
Removal of water • Disconnect the connector for the external power
• For details regarding water removal from the supply.
containers/system, please refer to the third-party • Disconnect the grounding cable from the wellhead
operating manual in „Section III“ of the technical and wind it onto the drum on the inside of the front
documentation. door (Fig. 4-11).
• Compressed air receiver: Open the drain valve at
the bottom of the container and drain condensate.
• For draining the hydraulic oil reservoir, please refer 6.6.2.4 Winding up the PCE hoses
to Chapt. 7.7.1 • Disconnect the PCE hoses from the connection
panel (Fig. 4-24) before closing the winch cab door,
Filling wind the hoses onto drums according to the owner/
• Before shutting down the machine, fill the user’s instructions and stow away in the storage
consumables/auxiliary substance containers with the box.
respective consumables/auxiliary substances. For
details regarding filling, please refer to the third-
party operating manual in „Section III“ of the 6.6.3 Decommissioning (mothballing)
technical documentation, for the hydraulic system, • Shut down the unit as described in Chapt. 6.5.1 to
Chapt. 7.7.1. 6.5.4.
• Properly touch up any damage to the protective
Bleeding the system coat of the container.
Air humidity can lead to corrosion during long-term • Change the hydraulic oil, see Chapt. 7.7.1, fill the
storage, therefore bleed the systems before extended hydraulic oil reservoir and components, pump,
shut-down or decommissioning and completely fill with engines/motors, pipes and hose lines with fresh oil.
oil/auxiliary substance. • Remove water from and bleed the hydraulic
• For details regarding bleeding, please refer to the system.
third-party operating manual in „Section III“ of the • Check the pressure gauges, top up the glycerin
technical documentation as well as Chapt. 7.7.1. filling if necessary or replace the pressure gauges.
• Check the hydraulic hose lines carefully for damage
and aging.
• Disconnect the batteries, remove and store
separately as described in the third-party operating
manual.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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• Have a qualified electrician open any closed switch

cabinets etc. and insert silica gel. Identify switch
cabinets/electrical devices filled with silica gel with
a „Silica gel“ sticker.

6.7 Recommissioning
Should the container be decommissioned for longer
than approx. 4 years or be subject to unfavorable
storage/environmental conditions for longer than 2
years, have all components/assembly groups inspected
by expert personnel, and dismantled and replaced if
necessary.
• Check all components for further use. Renew in the
event of wear, corrosion/aging or damage!
• Relubricate all grease points as described in
Chapter 7.5.7.
• Replace all consumables, engine and hydraulic oil,
engine coolant etc., see Chapt. 7.6.2 and 7.7.1, fill
components (pumps, engines, pipework and hose
lines) with fresh oil.
• For information about further inspections, please
refer to the third-party operating manuals in
„Section III“ of the technical documentation.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

7. Service work, care and maintenance

Table of Contents 7.5.2 Maintenance intervals and
maintenance schedule .............................. 7-7
7.1 Safety information .......................... Page 7-2
7.5.3 Cleaning and care ..................................... 7-8
7.1.1 Instruction of the maintenance personnel . 7-2
7.5.3.1 Auxiliary cleaning equipment .................... 7-8
7.1.2 Necessary qualification of the
7.5.3.2 Cleaning (dry) ........................................... 7-8
maintenance personnel .............................7-3
7.5.3.3 Cleaning (wet) .......................................... 7-8
7.1.3 Permissible spare parts .............................7-3
7.5.3.4 Care measures .........................................7-8
7.5.3.5 Disposal of cleaning agents ...................... 7-9
7.2 Required tools, measuring instruments,
7.5.4 Wear/damage of components .................. 7-9
auxiliary equipment and consumables ...... 7-3
7.5.4.1 Function checks ........................................7-9
7.2.0.1 Tools ......................................................... 7-3
7.5.4.2 Repair welding .......................................... 7-9
7.2.0.2 Measuring instruments .............................7-4
7.5.5 Visual inspection of rubber and
7.2.0.3 Consumables ............................................ 7-4
plastic components ................................... 7-9
7.2.0.4 Auxiliary equipment .................................. 7-4
7.5.6 Screw/bolt connections .............................7-9
7.5.7 Relubricating grease lubrication points ... 7-10
7.3 Technical data for
maintenance work .................................... 7-4
7.6 Regular maintenance work on
7.3.1 Consumables ............................................ 7-4
components ............................................. 7-10
7.3.4.1 Fuel/diesel oil ............................................ 7-4
7.6.1 Container maintenance ........................... 7-10
7.3.4.2 Coolant .....................................................7-4
7.6.2 CAT diesel engine .................................. 7-11
7.3.2 Lubricants ................................................. 7-4
7.6.2.1 Fuel system ............................................. 7-11
7.3.2.1 Engine oil .................................................. 7-4
7.6.2.2 Engine oil system .................................... 7-11
7.3.2.2 Hydraulic oil ............................................. 7-4
7.6.2.3 Engine cooling system ............................ 7-11
7.3.2.3 Lubricating/gear oil ................................... 7-4
7.6.2.4 Intake/air filter ........................................ 7-12
7.3.2.4 Lubricating grease .................................... 7-5
7.6.2.5 Exhaust system ....................................... 7-12
7.3.2.5 Preservation oil .........................................7-5
7.6.3 Replacing the winch drums .................... 7-14
7.4 Inspections/visual inspection and
7.6.3.1 Safety fundamentals ............................... 7-14
monitoring ................................................. 7-5
7.6.3.2 Removing the winch drum ...................... 7-15
7.4.1 Regular checking of connection to
7.6.3.3 Fitting the winch drum ............................ 7-15
ground/equipotential bonding .................... 7-5
7.4.2 Compressed air vessel, regular
7.6.4 Roller chain maintenance ....................... 7-16
inspection/testing
7.6.4.1 Lubricating the roller chain ..................... 7-16
in accordance with BGR 500 ................... 7-5
7.6.4.2 Cleaning and greasing the roller chain .... 7-16
7.4.3 Pressure relief valve (safety valve)
7.6.4.3 Tensioning/slackening the roller chain .... 7-17
setting ....................................................... 7-5
7.6.4.4 Removing/fitting the roller chain ............. 7-17
7.4.4 Brake test ................................................. 7-5
7.6.5 Planetary gear unit ................................. 7-17
7.4.4.1 Establishing the free running state
7.6.5.1 Checking the oil level, topping
of the drums ............................................. 7-6
up if necessary ....................................... 7-17
7.4.4.2 Determining the main pressure at the
7.6.5.2 Changing the gear oil .............................. 7-17
point where the brakes slip ....................... 7-6
7.4.4.3 Brake holding test ..................................... 7-6
7.6.6 Band brakes ........................................... 7-18
7.4.5 Checking the max. engine speed (rpm) ...7-7
7.6.6.1 Checking the brake band pretension ...... 7-18
7.6.6.2 Resetting the brake band pretension ...... 7-18
7.5 General maintenance work ....................... 7-7
7.6.6.3 Replacing the brake band ....................... 7-19
7.5.1 Putting the machine into a safe
standstill condition ..................................... 7-7

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

7.6.7 Measuring head and spooling 7.1 Safety information

mechanism .............................................. 7-19
Always observe the regulations, warnings and
7.6.7.1 Measuring head ...................................... 7-19
information specified in Chapter 2 „Occupational
7.6.7.2 Spooling mechanism ............................... 7-20
safety and health, safety regulations and environmental
7.6.7.3 Wire oiler ................................................ 7-20
protection“2) for each maintenance measure.
7.7 Hydraulic system .................................... 7-20
7.7.0.1 Safety fundamentals ............................... 7-20
7.7.0.2 Monitoring the condition of the system .. 7-21 7.1.1 Instruction of the
7.7.1 Checking the hydraulic oil level/ maintenance personnel
topping up ............................................... 7-21 • Read the operating manual prior to starting work,
7.7.1.1 Hydraulic oil change ............................... 7-21 always perform work correctly and in a safety-
7.7.1.2 Checking the hydraulic oil condition ....... 7-21 focused manner in accordance with the regulations.
7.7.1.3 Bleeding the hydraulic system ................ 7-22 • KOLLER Maschinen- und Anlagenbau GmbH as
7.7.2 Replacing the hydraulic return filter the manufacturer of the Wireline Combi Unit PP1)
element ................................................... 7-22 accepts no liability if occupational safety and health,
7.7.3 Checking the hydraulic hoses ................. 7-22 safety regulations, hazard information/warnings and
7.7.3.1 Replacing the hose lines ......................... 7-22 relevant information in this operating manual are not
7.7.4 Oil/air cooler ........................................... 7-23 adhered to.
• The information given in this operating manual only
7.8 Compressed air system, regular refers to the KMA scope of delivery!
drainage of the compressed air vessels .. 7-23
• The handling of the wireline/cable or the tools etc. is
the sole responsibility of the user/owner, see Chapt.
7.9 Electrical equipment ............................... 7-23
4.2.2!
7.9.1 Maintenance of the battery .................... 7-23
7.9.1.1 Maintenance/replacement of the battery 7-23 Danger
!
7.10 Completion of maintenance work ........... 7-23 Contact with the running wireline/cable can
7.10.1 Visual inspection after maintenance cause serious injuries!
work ....................................................... 7-24 Prior to commencing maintenance work per-
form the necessary measures to ensure that the
Table machine is in a safe standstill condition (Chapter
7.I Screw/bolt tightening torques ................... 7-3 7.5.1)!
7.II Maintenance schedule ............................ 7-25 • It is of the utmost importance to ensure that
inadvertent or unauthorized activation of the unit is
impossible!
• Prior to all work on the hydraulic system, wait until
the individual system section is completely
depressurized, or have the system sections to be
1) The „Wireline Combi Unit PP“ is also referred to in this
operating manual as the „Container“ or „Unit“. opened depressurized beforehand by expert
2) Users located outside of the EEC should always follow the personnel - watch the pressure gauge reading!
safety practices and procedures in accordance with the • If you have to work on a running unit/group, ensure
recommendations of The Occupational Safety and Health that a second person is in the control room to take
Administration (OSHA), The National Safety Council (NSC),
The Hand Tools Institute (HTI), The International Association
over supervision and actuate the EMERGENCY
of Drilling Contractors (IADC) etc. All applicable governmental STOP „4S1“ button in an emergency!
rules, regulations or restrictions, now in effect or which may be
promulgated, take precedence over the suggestions in this
• Immediately replace any damaged components with
publication! new ones.
3) For information on the abbreviations see Chapter 1.7.1. Otherwise you will endanger your personal safety
and the operational safety of the unit!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

• Adhere to occupational safety and health 7.1.2 Necessary qualification of the

regulations when handling hazardous substances
maintenance personnel
and substances hazardous to ground water
• Please refer to Chapt. 2.2.4 regarding the required
(solvents/cleaning agents etc.). Read the safety
or prescribed maintenance personnel qualifications!
data sheet according to Directive 2006/1907/EC (or
91/155/EEC and/or 2001/58/EC), request it from the • Have work requiring trained personnel with special-
substance manufacturer if necessary. ist knowledge performed by KMA expert personnel
• Never use aggressive, easily inflammable or if possible.
hazardous solvents/cleaning agents!
• Dispose of all waste materials/used oil etc. in
accordance with the regulations, acc. to KrW-/ 7.1.3 Permissible spare parts
AbfG (Waste Avoidance, Recycling and Disposal • For reasons of operational safety (active and
Act), WHG3) (Federal Water Act) etc. Disposal is passive safety of the unit) only use original spare
the sole responsibility of the user/owner! parts tested and approved by KMA!
• Additional information for particular maintenance • The owner/user bears the full and unlimited liability
problems is available directly from KMA. for the fitting of spare parts that have not been
For the address and telephone number please see approved!
above. • If spare parts/equipment are fitted that have not
been approved, the EC Declaration of Conformity
issued by KMA as the machine manufacturer shall
become null and void!
Table 7.I: Schrauben-Anzugsmomente4)
Table 7.I: Screw/bolt tightening torques4)

Size 8.85) 10.95) 12.95) A2/A46) 7.2 Required tools, consumables

Nm Nm Nm Nm
M 6 10 13 16 8
and auxiliary equipment
M 8 23 32 39 20 Special tools for maintenance work on items of
M 10 46 64 77 42 equipment are, if applicable, also listed in the third-
M 12 80 110 135 70 party operating manuals („Section III“ of the technical
M 14 125 180 215 112 documentation).
M 16 195 275 330 170
M 18 270 390 455 240
M 20 385 540 650 340 7.2.0.1 Tools
M 22 510 720 870 • Torque wrench for 400 Nm
M 24 660 930 1,100 • 1 set each open end wrenches, ring wrenches and
M 27 980 1,400 1,650 socket wrenches
M 30 1,350 1,850 2,250 • 1 set of pin wrenches (DIN 911)
• 1 set of screwdrivers
4) Table 7.I: Richtwerte üblicher Anzugsmomente
(trocken, ungeschmiert) für Schrauben nach: • Phillips screwdriver and electric screwdriver
DIN 912 DIN 931 DIN 933 • Combination pliers, pipe wrench, circlip pliers
EN – EN 24 014 EN 24 017
Table 7.I: Guideline values for usual tightening torques
• Extractor
(dry, non-lubricated) for screws/bolts according • Punch, center punch
to: • Hammer, plastic mallet
DIN 912 DIN 931 DIN 933
EN – EN 24 014 EN 24 017 • Use separate filter pump unit with filling lance for
5) Schrauben-Festigkeitsklasse, siehe auch die Ersatz- extracting the used oil and for filling the hydraulic
teillisten im Anhang oil containers from clean and undamaged drums,
Screw/bolt strength class, also see list of spare parts in the
MRB/appendix minimum filter mesh 10 µm
6) A2/A4 - 18-8/18-10 stainless steel screws/bolts • Wire brush, dirt brush, paint brush

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

7.2.0.2 Measuring instruments 7.3.2 Lubricants

• Contact thermometer Recommended lubricants are specified in the
• Pressure gauges following, unless different information is given for
items of equipment (engine).

7.2.0.3 Consumables/auxiliary substances Lubricant procurement source:

• Hydraulic oil „HLP“, ISO VG 46 Local or regional branch of reputable oil companies.
• Gear oil „CLP“, ISO VG 150 • For extreme operating or environmental conditions,
• Grease KP2K-30 consult with the oil companies or ask the
• Approved neutral cleaning agents manufacturer/supplier, specifying the current
• Paint as priming and top coat operating conditions.
• Never mix lubricant qualities or lubricants from
different manufacturers!
7.2.0.4 Auxiliary equipment Among others, lubricants are selected according to
• Personal protective equipment (PPE) according to their oil viscosity (ISO-VG) or grease consistency
the company regulations: Hard hat, protective (NLGI class) with respect to the average ambient
gloves, safety boots, eye, hearing and respiratory temperatures at the installation site.
protection, etc., also see Chapt. 2.3.1
• Cleaning rags, sponge, pads
• Covering sheet, adhesive tape 7.3.2.1 Engine oil
• Containers/drums for separate collection of used oil, • The information given in the engine operating
solid waste etc. manual is binding!
• Lifting gear for the container, minimum load bearing Engine oils in accordance with the CAT operating
capacity 15,000 kg. manual with an SAE viscosity class corresponding to
the ambient temperature are recommended:
Factory filling:
• Engine oil ..................................................... 15W-40
7.3 Technical data for
maintenance work 7.3.2.2 Hydraulic oil
7.3.1 Consumables For the intended use of the unit in a temperate zone
7.3.1.1 Fuel/diesel oil (Central Western Europe) and at average oil
• The information given in the engine operating temperatures of approx. +40 to +70 ? the following
manual is binding! are recommended:
We recommend the use of low-sulfur diesel fuel • Hydraulic oil „HLP“ with EP, anti-oxidation and
(ULSD) according to the API specification, otherwise anti-corrosion additives acc. to DIN 51 524,
the EU exhaust values as mentioned in the engine Part 2 (VDMA 24 318).
operating manual cannot be met! • Viscosity index ...................................... ISO VG 46
• Oil volume/reservoir capacity .................... 150 liters
• In the case of extremely low/high outside
7.3.1.2 Coolant temperatures, it is necessary to contact KMA.
• The information given in the engine operating
manual is binding!
As a coolant, we recommend e.g. distilled water with 7.3.2.3 Lubricating oil
50 % ethylene glycol as an additive. As a lubricant for the planetary gear units at normal
ambient temperatures (approx. 0 ... +40 °C), an
unleaded industrial gear oil „CLP“, based on mineral
oil with EP additive according to DIN 51 517 Section
3 is used.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

• Viscosity index ...................................... ISO VG 150 following a prolonged shut-down and at regular
• Oil volume/gear box capacity ..................... 1.2 liters intervals
every 100 op.hrs.
As a lubricant for the wire oiler, the oil container (TRBS 2153).
above the measuring head, we recommend CLP or • Ensure that there is a leakage resistance of
HLP (see above) < 106 Ohm.
• Viscosity index ....................................... ISO VG 46
or engine oil 15W
• Oil volume/gear box capacity ..................... 0.5 liters 7.4.2 Compressed air vessel, regular
inspection/test in accordance
7.3.2.4 Grease with BGR 500
For relubricating grease points, we recommend: • The user/owner has to have the compressed air
• Lithium saponified grease „KP2K-30“ acc. to vessels inspected by an expert/official expert at
DIN 51 825. regular intervals acc. to DGRL and BGR 500 or
according to the regulations of the country of
destination.
7.3.2.5 Preservation oil The following inspections have to be performed:
As a corrosion protection oil for bare metal - an external inspection every 2 years,
components, we recommend: - an internal inspection every 5 years,
• Anti-corrosive oil acc. to DIN 51 359, alternatively - a pressure/strength inspection/test every 10
a multi-purpose EP lubricating oil ISO VG 46 or an years.
HD engine oil of the SAE Class 10W to 30. • Drain valves fitted underneath the vessels are used
for draining the water from the compressed air
vessel at regular intervals.

7.4 Inspections/visual inspections

and monitoring 7.4.3 Pressure relief valve (safety
• Subject the unit to a visual inspection (safety check) valve) setting
at regular intervals, also see Chapt. 6.3.2! The controller (twist handle) „R2“ on the right of the
operator’s seat for the tension/pull force limitation by
means of the pressure relief valve (safety valve) is to
7.4.1 Regular check of the grounding/ be actuated as follows:
- Turn counterclockwise, direction „-“ (ccw) to
equipotential bonding (TRBS reduce the pull force/tension,
2153) - Turn clockwise, direction „+“ (cw) to increase the
The grounding cable is located on the inside of the tension/pull force.
front door. The cable is conductively connected to the
• Pressure relief valves are safety devices. Do NOT
container and is to be connected to the wellhead, for
change the factory setting of any other pressure
example, with a screw clamp/grounding clamp.
relief valves (safety valves) in the hydraulic
Grounding points are additionally located in the
system!
container corners of the winch cab.
• Check that the lines and connections are
undamaged and perfectly fastened.
7.4.4 Brake test
• Check/test the equipment for connection to ground • Continuously monitor the band brakes and test at
prior to first start-up/commissioning, before regular intervals to ensure that they are functioning
recommissioning at different installation sites or perfectly.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

• Conduct a brake test following any work on the - Pull control handle „4S3“, BRAKE ACTIVE,
brake system or after fitting a new winch drum. • Turn controller (twist handle) „R2“ for the tension
limitation into a middle position.
• „9S3“, increase the engine rotational speed, if
7.4.4.1 Establishing the free running state of necessary, up to maximum.
the drums • Pull control handle „L2“, drum rotational direction
• If necessary, spool the wireline/cable onto the as for spooling (winding up) the wireline/cable, and
drums and secure the ends on the drums. pull „L1“ for medium drum rotational speed.
• Start the machine, see Chapt. 6.3.4, • Read off the main pressure at the pressure gauge
- Set the inside LH control handle „L2“ to the „C1“ as soon as the drum slips under the applied
center position (neutral), brake.
- push the RH control handle „4S3“ forward, • Return the control handles „L2“ and „L1“ to the
BRAKE RELEASE, neutral (center) position.
- pull „L2“ slightly back, the drum rotates as for • Press the illuminated push button „9S4“ and
spooling the wireline/cable. decelerate the engine to idle speed.
• Have a second person determine/listen to ensure • Shut down the machine, see Chapt. 6.5.1.
that the drum is rotating without contact with the
• Select the second drum with „5S1“ and conduct the
band brake and without any scraping/friction noises,
same test with this drum.
otherwise discontinue the test, adjust the brake
(Chapt. 7.6.6.2) and repeat the test.
7.4.4.3 Brake holding test
! Danger
Correctly set brakes stop the drums in a controlled,
Never touch the drum or brake when the drum uniform manner without vibrations, jolts or jerks.
is rotating! During operation the brake function is dependent on a
• If there are no scraping/friction noises between the number of factors, e.g. :
drum and brake, - The wireline/cable length spooled onto the drum
- Move control handle „L2“ in the opposite and
direction to slowly brake the drum. - the weight of the tools,
• Firmly apply „4S3“ when the drum is at a standstill. - the rotational direction of the drum etc.
• Shut down the machine, see Chapt. 6.5.1. • If necessary, spool the wireline/cable onto the
• Select the second drum with „5S1“ and conduct the drums and secure the ends on the drums.
same test with this drum. • Start the machine, see Chapt. 6.3.4,
- Set the inside LH control handle „L2“ to the
center position (neutral),
7.4.4.2 Determining the main pressure at the - Push control handle „4S3“, BRAKE RELEASE.
point where the brakes slip • Turn controller (twist handle) „R2“ for the tension
The brakes are correctly set when the drums start limitation into a middle position.
slipping at a hydr. main pressure of approx. • „9S3“, increase the engine rotational speed, if
p = 180 - 210 bar. necessary, up to maximum.
The brakes are to be adjusted (Chapt. 7.6.6.2) when • Pull control handle „L2“, drum rotational direction
the main pressure at pressure gauge „C1“ as for spooling (winding up) the wireline/cable, and
- is higher (braking force set too high) or pull „L1“ for medium drum rotational speed.
- is lower (braking force set too low). • The main pressure at pressure gauge „C1“ should
measure approx. p = 100 bar, rotating the drum at a
• If necessary, spool the wireline/cable onto the relatively high rotational speed.
drums and secure the ends on the drums. • Pull control handle „4S3“ to apply brake,
• Start the machine, see Chapt. 6.3.4, BRAKE ACTIVE.
- Set the inside LH control handle „L2“ to the The brakes must stop the drum fast and without
center position (neutral), vibration.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

! Attention 7.5 General maintenance work

Only brake the drums with „4S3“ for this brake 7.5.1 Putting the Wireline Combi Unit
holding test! PP into a stable standstill
• Return the control handles „L2“ and „L1“ to the condition
neutral (center) position.
! Warning
• „9S4“, press the illuminated push button and
decelerate the engine to idle speed. Prior to beginning any work, secure the machine
• Shut down the machine, see Chapt. 6.5.1. in a safe standstill condition. It is very important
to ensure that unauthorized/inadvertent
• Select the second drum with „5S1“ and conduct the reactivation is impossible!
same test with this drum.
• Set control handles „L1“ and „L2“ to the center/
neutral position.
7.4.5 Checking the max. engine speed • Press illuminated push-button „9S4“, the engine will
automatically operate at idle speed.
(rpm) • Check that the winch drums have come to a
• According to LRoS, the max. engine speed (rpm) complete standstill.
must be determined once per year! • Pull control handle „4S3“, apply brake,
• The factory setting of the max. rotational speed is BRAKE ACTIVE.
n = 2,250 rpm. Do NOT change this setting! • Switch off the engine, turn toggle switch „9S1“ to
• Check that „Ignition OFF“.
- control handles „L1“ and „L2“ are in the neutral • Turn the main switch of the control system „2Q1“
(center) position, to the position 0 = OFF.
- the brakes are applied, „4S3“ pulled, BRAKE • Turn battery main switch „4Q1“ OFF.
ACTIVE.
• Attach the warning sign „Machine out of operation“
• Switch on the engine as described in Chapt. 6.3.4. to the unit/to the control panel (BGV A1).
• Once the engine is operational (oil pressure and
cooling water temperature):
- turn „9S3“, toggle switch, to „+“ and increase the
rotational speed to its maximum value,
7.5.2 Maintenance intervals and
- „9A1“, read the rpm on the display, the Engine maintenance schedule
Control Center, Insufficient maintenance is deemed as incorrect
- press the illuminated push-button „9S4“ and treatment of the Wireline Combi Unit PP.
decrease the speed to idle speed. The owner/user bears the sole risk!
• Shut down the engine as described in Chapt. 6.5.1. • For the time intervals for regular maintenance work
see Table 7.II.
• Shorter maintenance intervals than those specified
may be necessary depending on operating
conditions.
• Longer time intervals are only permissible after
prior consultation with KMA and reviewing of all
operating and environmental conditions.
• An inspection or visual inspection not performed
according to schedule or not within the appropriate
period is deemed not in compliance with the
intended use. The owner/user bears the sole risk!

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

• Always record the performed maintenance work 7.5.3.2 Cleaning (dry)

and results of visual inspections/inspections in • Only remove soiling attached to the machine with a
writing! lint-free cloth (not with cleaning wool) or scrubbing
• The safety measures also include keeping the brush by hand.
installation site clean (to eliminate the risk of • If necessary, pretreat soiling
slipping/tripping), as well as ensuring free access to - with water and commercial detergent,
the unit and the operating elements. - remove grease soiling using white spirit/petroleum
ether/benzine (FAM petroleum spirit).
• It is necessary to have the machine released by the
NEVER use gasoline/petrol!
user/owner’s safety officer prior to initial start-up/
• Never apply cleaning agent/solvents, benzine, oil or
commissioning and recommissioning/starting up
other chemical substances to rubber/plastic parts
again after maintenance work/repairs etc.!
(hose lines, cable jacketing etc.). If necessary, clean
using water with commercial detergent added!
7.5.3 Cleaning and care ! Attention
• Carry out cleaning work/care of the unit after each
Have any defects/damage detected during
use and/or at time intervals to be defined by the
cleaning remedied by expert personnel prior to
user/owner depending on operation and company
starting up the machine again.
requirements.
• Cleaning of the winch, the measuring head, the oil/
air cooler etc. at regular time intervals and/or as
7.5.3.3 Cleaning (wet)
required.
• Only remove soiling from the Wireline Combi Unit
PP with a „soft“ water jet and a scrubbing brush.
• Cover or seal off all components that must not be
7.5.3.1 Auxiliary cleaning equipment
penetrated by water, cleaning agent or steam for
• Lint-free cloth, broom, hand brush, scrubbing brush
reasons of safety or due to their function.
for removing loose soiling.
High pressure and steam jet cleaners flush the roller
• Industrial vacuum cleaner for vacuuming up dust or
bearings. As a result, these will run dry and their
non-adhesive loose soiling.
longevity will be considerably limited.
• Never use aggressive cleaning agents/solvents, or
fluids which contain TRI, perchloroethylene/ ! Warning
tetrachloroethylene, carbon tetrachloride/tet/
When using high pressure cleaners or steam jet
tetrachloromethane or CFCs!
cleaners, adhere to the safety regulations
• Adhere to the safety and disposal instructions of the
specified in the operating manuals of the
respective manufacturers for solvents and cleaning
appliance manufacturers.
agents, see instructions on the package and safety
data sheet. • After cleaning, remove all temporary protective
Read the safety data sheet according to Directive covers/tape.
2006/1907/EC (or 91/155/EEC and/or 2001/58/EC), • After wet cleaning, relubricate all lubrication points
request it from the substance manufacturer if as described in Chapter 7.5.7.
necessary. • Refit/retighten any protective devices/guards/safety
• Adhere to the immission control regulations: equipment etc. removed for cleaning.
Collect loose soiling and used substances, and
dispose of according to KrW-/AbfG.
7.5.3.4 Care measures
After cleaning thoroughly and removing all residue:
• Spray bare metal components with preservation oil
(Chapter 7.3.4) or apply a thin coat of oil/grease
with a cloth.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 7 – Maintenance

• Check the protection paint of items of equipment. The welders must be employed by a company
Touch up if damaged. in possession of a manufacturer’s qualification
Class E in accordance with DIN 18 800 Part 7.
• Adhere to the safety regulations, see BGV D1.
7.5.3.5 Disposal of cleaning agents • After repair welds have been performed, the weld
• Adhere to the safety and disposal instructions of the seams must be inspected/tested by an official expert
respective manufacturers for solvents and cleaning with application of the prescribed test/inspection
agents, see instructions on the package and safety methods.
data sheet. • The test procedure is to be selected according to
the hazard potential in the event of the failure of the
respective component.
7.5.4 Wear and damage of An evaluation is to be made in accordance with EN
ISO 5817, quality level C.
components
When wear is detected, assess whether or not the part
concerned will retain its full function until the next
inspection date (Table 7.II). 7.5.5 Visual inspection of rubber and
• Repair or replace immediately if further use of
plastic components
components seems at all uncertain! ! Attention
• For information about inspecting the measuring
Never apply solvents/cleaning agents or any
head, please also refer to the Benchmark operating
other chemicals to rubber or plastic
manual in „Section III“ of the technical
components, hydraulic hose lines, cable
documentation.
jacketing etc.!
Immediately replace or repair damaged individual
Inspect all components made of rubber/plastic and
parts!
replace them if their surface reveals any damage such
as hardening/brittleness or even small cracks or signs
of porosity.
7.5.4.1 Function checks
• For function checks, also refer to Chapt. 5.5 and • For the duration of use of hydraulic hose lines,
following. please refer to Chapter 7.7.3.
• Have the hydraulic hose lines checked by qualified
expert personnel, please also refer to Chapt. 7.7.4.
• Have a qualified electrician check the electric 7.5.6 Screw/bolt connections
cables for damage and reliable fastening, and that • Retighten loose screw connections immediately, for
the cable feedthroughs are properly sealed (see tightening torques, please refer to Table 7.I.
BGV A3).
• Check the screw/bolt connections on the machine
every 1,000 operating hours or every 6
7.5.4.2 Repair welding months
If repair welding is to be performed, ensure that the for firm seating. Check that bolt/pin connections
welder’s qualifications and the joint preparation are in (e.g. on the spooling mechanism) are perfectly
accordance with the relevant regulations, as well as secured (linch pins/spring cotter pins). Retighten
EN 287-1 and EN ISO 9692-1! screws/nuts, if necessary.
In addition, adhere to the following: Check the threads of screws/nuts as well as bolts,
• The joint preparation must be performed by trained linch pins or spring cotter pins for damage.
expert personnel. • Immediately replace damaged screw-connections,
The welding work is to be performed by welders components with worn threads, as well as damaged
with valid welder approval test certification in bolts, linch pins/spring cotter pins.
conformity with DIN EN 287-1. • Always fit any screw locking devices as a new

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component meeting the original specifications for

each screw connection.

7.5.7 Relubricating grease

lubrication points
• Relubricate the grease nipples of all grease
lubrication points following (extended) shut-down,
decommissioning etc. and regularly
every 1,000 operating hours or every 6
months
as described below.
Lubrication points are:
- Flange bearings of the drums (Fig. 7-7/7-14),
Fig. 7-1: Spooling mechanism, sprocket with flange - Friction bearings at the guide axle (Fig. 7-2),
bearings and grease nipples with covers. - Flange bearings on the spooling mechanism (Fig.
7-1),
• Grease the following, i.e. apply grease with a
grease brush to:
- Guide axle of the measuring head,
- Steering column length adjustment,
- Cardan joint etc.
• Use a commercial grease gun or grease brush,
grease quality “KP2K-30”, see Chapt. 7.3.2.4.
Fig. 7-2: Measuring head friction bearing bush with • Grease nipple M6 x 1 in accordance with DIN 71
grease nipples (arrows) on the guide axle and chain 412, shape H1.
gripper. Compare to available grease gun, use matching
connection pieces.
• Relubricate the flange bearings until a slight excess
amount of grease emerges.
• Remove excess grease.
• Thoroughly clean the steering column and guide
axle, apply a thin coat of grease with a brush or a
lint-free cleaning cloth soaked in grease.
• Clean the cardan joint and apply grease with a
grease brush.

7.6 Regular maintenance work

on components
7.6.1 Container
• The container is low maintenance.
• Check the container doors, roof structure etc.
every 1,000 operating hours or every 6
months
for damage, and repair if necessary.

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• Clean or replace the filter elements as required and

7.6.2 Diesel engine described in the CAT operating manual.
• For details regarding the maintenance of the CAT
4.4 diesel engine, please refer to the CAT operating
manual “Operation and Maintenance Manual, C4.4 7.6.2.2 Engine oil system
Industrial Engine” in “Section III” of the technical • For details regarding maintenance of the lubricating
documentation. oil system, the engine oil quality and the time
intervals to be adhered to, please refer to the CAT
Warning operating manual in “Section III” of the technical
!
documentation as well as to the maintenance
Only perform maintenance work when the schedule, Table 7.II.
engine is in a safe standstill condition (secured • For the engine oil filter see Fig. 7-6.
against reactivation) and when the engine,
devices/consumables have cooled down! Checking the engine oil level
• Check the engine and the entire engine • Pull out the dipstick and check the oil level (Fig.
compartment, i.e. the fuel system, engine oil system 7-5), top up oil if necessary.
and other oil systems
DAILY Topping up with engine oil
for fluid loss / leaks. • Open the closure at the engine oil infill socket (Fig.
• Leaked fuel or oil represents a fire hazard and must 7-4), top up with oil using a funnel, if necessary.
be removed immediately. • Always check the oil level, do not overfill with
• Find the cause of the leak and remedy. engine oil.

• Check engine components or accessories that, Draining engine oil

among others, serve for sound insulation • Undo the oil drain plug (see CAT operating
every 1,000 operating hours or every 6 manual), collect and safely dispose of the old oil
months (AltölV), reinsert drain plug.
These include:
- Exhaust muffler
- Air filters 7.6.2.3 Engine cooling system
- Screw/bolt connections • For details regarding inspection/maintenance of the
- Engine fan cooling system, the coolant and its mixing ratio,
- Sound absorbing/soundproofing material. please refer to the CAT operating manual in
These components are subject to natural wear and “Section III” of the technical documentation.
are to be replaced when necessary.
! Attention
Never use waste water, brackish water or sea
7.6.2.1 Fuel system water for mixing with the coolant.
• For details regarding the fuel/diesel oil quality, the
maintenance of the fuel system and the time • Check the coolant level at regular intervals and, if
intervals to be observed, please refer to the CAT necessary, top up with coolant. Sight glass in the
operating manual in “Section III” of the technical compensation vessel at the cooler.
documentation. • Top up with coolant through the cooler closure at
the top of the cooler (Fig. 5-9).
• For details of the fuel main filter or the fuel safety
filter, please refer to Fig. 7-3. Warning
!
• Check the perfect function of the water separator,
drain condensate through the drain valve The cooling system is pressurized, open the
DAILY cooler closure carefully and wear PPE!
as described in the CAT operating manual. • For the purpose of replacing the coolant, connect a

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coolant drain hose to the socket in the engine 7.6.2.4 Intake air filter (engine)
compartment, open the drain valve, collect • Check the air filters
emerging coolant and dispose of the old coolant in DAILY.
accordance with the regulations. • Replace the air filter cartridge as required
• Close the drain valve. Open the cooler closure, depending on the amount of airborne dirt particles.
slowly top up with coolant allowing possibly trapped
air to escape.
• To vent the engine block, allow the engine to briefly 7.6.2.5 Exhaust system
run idle, shut off the engine, check the coolant level, • For details regarding the maintenance of the
and top up if necessary. exhaust system and muffler, please refer to the
third-party operating manual in “Section III” of the
• Rinse the cooling system as described in the CAT
technical documentation.
operating manual.

Air filters

Dust separation valve

Fuel filter

Engine oil filter

Hydraulic oil pressure

filter

Fig. 7-3: Hydraulic oil pressure filter,

fuel filter with water separator and oil
filter.

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Fig. 7-4: Oil filler neck at the top on the

CAT C4.4 engine.

Fig. 7-5: Engine CAT C4.4 with oil

dipstick (arrow), oil filter and air
compressor with intake air filter

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7.6.3 Replacing the winch drums Danger

7.6.3.1 Safety fundamentals regarding work on
!
the winch drums High risk of injury from moving components,
• Only perform maintenance work when the unit is in maintain a sufficient safety distance, use/wear
a stable standstill condition (secured against PPE! Secure the hazardous area with
reactivation) (Chapter 7.5.1)! barricades to prevent the access of
If it is necessary to switch on the winch during unauthorized persons!
maintenance work, only specially instructed Perform the measures to ensure that the
personnel who are familiar with the winch may machine is in a safe standstill condition (Chapter
enter the hazardous area to perform this work. 7.5.1). It is very important to ensure that
• Hazard due to carrying out work alone (without a unauthorized/inadvertent reactivation of the
second person). machine is impossible!
If maintenance work/inspections have to be • For all work involving lifting gear, the dismantling/
performed with the drums rotating/machine parts fitting of winch drums etc. observe the accident
moving, ensure that a second person is in the prevention regulations according to BGV D6 and
control room to take over supervision and actuate D8.
the EMERGENCY STOP button in an emergency.
! Danger
Never stand or work beneath suspended loads
or between a load and fixed limitations
(container/winch frame etc.).
Danger to life!

Fig. 7-6: Winch drum after removal of

cover plates, roller chain, band brake
and centering flange, lifted out of the
winch frame with a lifting beam.

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7.6.3.2 Removing the winch drum

A B • Fully open the folding roof above the winch cab.
• In preparation of exchanging a drum,
- wind up the wireline/cable and secure the ends on
the winch drums,
- Release the brake of the drum to be exchanged,
BRAKE RELEASE.
• Front/rear drum: Lower the spooling mechanism
with measuring head into the operating position and
secure (Chapt. 5.4.3.1).
The drums are lifted vertically out of the winch
frame.
• Remove the contact guard for the roller chain.
Fig. 7-7: Fastening of the drum bearings as well as • Turn the drum slightly, engine-assisted and with
grease nipple for greasing. control handle “L2” so that the connecting link of
A - Centering flange fastening in the winch frame the roller chain is accessible.
B - Flange bearing fastening on the centering flange • Shut down the machine and secure against
reactivation (Chapter 7.5.1).
• Remove the roller chain connecting chain link and
the chain. Clean the roller chain in a cleaning bath
and regrease as described in Chapt. 7.6.4.
• Release the brake band and remove as described in
Chapt. 7.6.6.
• Insert eyebolt M16 into the centering flange,
connect lifting gear/shackles.
Fig. 7-8: Winch drum with flange bearing and • Move the lifting gear with lifting beam over the
centering flange drum to be exchanged. Attach the drum to both
sides.
• Undo the centring flange fastening screws on the
winch frame while the drum is held by the lifting
gear.
• Lift the drum vertically out of the winch frame and
the container.
Deposit the drum in a prepared frame/on a suitably
prepared pallet (Fig. 7-6).
Secure the drum to prevent it from rolling!
• Remove the centring flange with flange bearing
from the drum axles.
• For storage purposes, apply grease to all bare metal
components, also see Chapter 3.4.

7.6.3.3 Fitting the winch drum

! Attention
When fitting a new winch drum, always fit a
new brake band at the same time, see Chapt.
7.6.6.

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• Prior to fitting, check the following for damage or • Fit the band brake and readjust the pretension as
wear and replace if necessary: described in Chapt. 7.6.6.
- Centering flange/flange bearings and roller • Fit the chain drive contact guard and screw tight.
bearings, • Remove all tools and auxiliary equipment from the
- chain sprocket on the planetary gear unit. operating area of the drum/brake/roller chain!
• Clean the winch frame and components located • Start up the unit as described in Chapt. 6.4.1 and
underneath the drum using a scrubbing brush and following chapters.
cloth. • Operate the newly fitted drum initially at low speed
• Fit the centering flange with flange bearing onto the in both rotational directions.
drum axles. Insert eyebolt M16 into the centering • Also test the brake function for both rotational
flange, connect lifting gear/shackles (Fig. 7-8). directions.
• Lift the drum out of its storage container. • Relubricate the roller bearings of the drum bearing
as described in Chapter 7.5.7.
• Position the drum vertically above the winch frame,
see Chapt. 7.6.3.2. Insert the drum from above.
• The centring flange guides the drum in the winch 7.6.4 Roller chain maintenance
frame. 7.6.4.1 Oiling the roller chain
• Slowly deposit the drum into the winch frame. • Lubricate the link plates of the roller chains at the
• Tighten the centring flange fastening screws, for drums and at the spooling mechanism
tightening torques see Table 7.I. every 10 operating hours or DAILY
• Fit, tension and oil the roller chain as described in with gear oil “CPL” to the inner surface using a
Chapt. 7.6.4. brush, see Chapt. 7.6.4.

7.6.4.2 Cleaning and greasing the roller chain

Fig. 7-9: Rocker with flanged-on planetary gearing, • Regularly grease the roller chain with special chain
chain tensioning device with adjusting spindle and grease
locknuts in the winch frame. every 2,000 operating hours or every 12
months,
as described in the following.
• Remove the chain guard and roller chain.
Place the chain for cleaning in a bath of petroleum
ether/white spirit/FAM petroleum spirit or diesel oil
for approx. 24 hours, NEVER in commercially
available gasoline/petrol.
• Check that all residue has been removed
and that all chain links are freely and easily
moveable.
• Heat special chain grease to approx. 120 °C,
place the chain in the hot grease for at least
2 hours.
Fit the chain after allowing the grease to drip off.
Procurement source for chain grease: Specialist
store
• Fit the chain guard.

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7.6.4.3 Tensioning/relieving the roller chain - use a straightedge to check that the chain wheels
• Check the chain pretension are flush in one level, i.e. without any offset.
every 1,000 operating hours or every 6
• Fit the roller chain so that the last links lie next to
months
each other in two chain wheel tooth gaps.
It should be possible to push in the chain between
• Connect the chain with a connecting link and secure
the chain sprocket and the drum by approx. 5 mm.
with a horseshoe clip.
• To tension/relieve the chain, undo/loosen the
• Tension the roller chain as described above.
clamping screw on the rocker (Fig. 7-9) and use the
• Fasten the chain guard and check that the chain
adjusting spindle or locknut to move the rocker up
drive runs in the guard without making contact
(to relieve the chain) or down (to tension the chain).
with it.
• Tighten the clamping screw and locknut.

! Danger
7.6.4.4 Removing/fitting the roller chain Operation of the winches without chain guard is
• Check not permitted!
- that the drum axle and gear output shaft are
horizontally aligned and axis parallel,
7.6.5 Planetary gear unit, checking
the oil level/topping up the oil or
changing the oil
When checking the oil level/changing the oil, always
Fig. 7-10: Example of the planetary gear unit with oil work with the utmost cleanliness; soiling in the
level sight glass (arrow) and infill opening. A vent planetary gear unit leads to malfunctions or at least
hose is provided at the top of the gear unit. increased wear.

7.6.5.1 Checking the oil level/topping up the

gear oil
• Check the gear oil level
every 1,000 operating hours or every 6
months

• Ensure that the oil reaches up to the middle of the

lateral oil level indicator (Fig. 7-10), otherwise top
up the gear oil.
• Top up the oil through the oil filling/vent hole on the
side or top of the gear unit.
• Oil quality, see Chapter 7.3.2.

7.6.5.2 Gear oil change

• Carry out a gear oil change 500 op.hrs. after initial
start-up, subsequently
every 3,000 op.hrs. or every 18 months.
Undo the plug of the oil infill opening, drain used oil
through the G 1/2" drain screw, on the side in the
gear unit base. Collect and correctly dispose of the
waste oil.
• Fill with approx. 1.2 liters of gear oil “CLP” ISO

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VG 150 up to the center of the oil level indicator,

see Chapter 7.3.2.

7.6.6 Band brakes

• Only perform maintenance work on the band brakes
when the machine is in a safe standstill condition
(secured against reactivation) (Chapter 7.5.1)!

! Danger
High risk of injury from moving components,
maintain a sufficient safety distance, use/wear
PPE!
Ensure that unauthorized/erroneous start-up is
absolutely impossible!

7.6.6.1 Checking the brake band pretension

Fig. 7-11: Brake band, without the drum for the
• Start up the unit as described in Chapt. 6.4.1 (for
purpose of demonstration, and pneumatic brake
operating elements see Fig. 6-2).
cylinder in the winch frame.
• Apply the brake with control handle “4S3”,
BRAKE ACTIVE.
• Run the truck engine up to maximum speed/rpm.
Turn the toggle switch “9S3” and watch the speed
on display “9A1” (Engine Control).
• Turn controller (twist handle) “R2” clockwise,
direction “+” (cw), for max. pull force/tension.
Fig. 7-12: Brake band with tensioning screw and
• Push control handle “L2” (LH, inside) forward and
pneumatic brake cylinder (the spring force applies the
try to set the drum in motion against the force of the
brake, BRAKE ACTIVE).
applied brake. Monitor the hydraulic pressure gauge
“C1 - main pressure”.

Tensioning ! Danger
screw During a brake test, the hydraulic system is
operated up to p = 200 bar. There is a risk of oil
Screw escaping at high pressure. Keep away from the
connection hazardous area!
(block) • The winch drum should not start slipping until a
hydraulic pressure of approx. p = 180 - 200 bar is
reached.
Brake lever • If the brake band loses contact with the drum at a
pressure below p = 200 bar and the drum slips, it is
necessary to readjust the brake band pre-tension.

7.6.6.2 Resetting the brake band pretension

Brake band Brake cylinder • Shut down the unit and secure in a safe standstill
condition, see Chapter 7.5.1!

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• Release the brake with control handle “4S3”, 7.6.6.3 Replacing the brake band
BRAKE RELEASE.
• Undo the tensioning screw locknut, ! Attention
• Tensioning screw nut, A new brake band has to be fitted
- is tightened to increase the band tension, - when the brake lining thickness is less than
- loosened to lower the band tension. d = 2 mm,
• Tighten the locknut. - when a new drum has been fitted, see Chapt.
• If the pretension cannot be perfectly adjusted due to 7.6.1.
wear, replace the brake band!
• Check the brake band pretension again as described • Considerable risk of injury from moving
above. components, maintain a sufficient safety distance,
use PPE!
• Remove all tools and auxiliary equipment from the • In preparation of exchanging a brake band,
operating area of the drum/brake! - wind up the wireline and cable and secure the
ends on the drums,
- apply the brakes of both winch drums, BRAKE
ACTIVE.
• Loosen the locknut.
Fig. 7-13: Bottom: Brake band tensioning screw (also • Undo the tensioning screw nut.
see Fig. 7-12). • Undo and remove the bolt fastening the tensioning
Top: Drum bearing with grease nipple screw to the winch frame and the brake band bolt
at the lever to the brake cylinder. Both bolts are
secured with spring cotter pins.
• Examine the brake band bearing surface on the
drum for wear and damage, and replace the drum if
necessary, see Chapt. 7.6.3.
• Reline the brake band or fit a completely new brake
band depending on the user/owner’s company
regulations.
• Fit a new brake band over the drum braking
surface; screw-connect the connecting block
attached to the band.
• Fit the tensioning screw to the winch frame and
brake band at the brake cylinder lever.
• Readjust the brake pretension as described above.
• Check the brake band function and pretension as
described above.
• Remove all tools and auxiliary equipment from the
operating area of the drum/brake!

7.6.7 Measuring head and spooling

mechanism
7.6.7.1 Measuring head
• For details of measuring head maintenance,
especially of the measured value transmitters,
please refer to the Benchmark operating manual in
“Section III” of the technical documentation.

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• Clean the grooves of the measuring wheels at lubricating/greasing the bearings. For cleaning and
regular intervals. Clean and, if necessary, regrease oiling the roller chain, please see Chapt. 7.6.4.1 and
the contact pressure rollers and the vertical guide following.
rollers.

7.6.7.3 Wire oiler

7.6.7.2 Spooling mechanism • Check the oil level in the oil container of the wire
• The spooling mechanism is low maintenance, please oiler and top up with oil, if necessary, see Fig. 5-8.
refer to Chapt. 7.5.7 and Fig. 7-1 and 7-2 for re-

7.7 Hydraulic system

Fig. 7-14: Hydraulic oil reservoir with oil inspection 7.7.0.1 Safety fundamentals
glasses, oil filler neck and return filter (at the top of
the reservoir); on the left in the figure, the hydraulic ! Warning
oil cooler. Prior to commencing any work on the hydraulic
system and opening individual system sections:
- Switch off the engine,
- Depressurize the hydraulic system,
- Allow the hydraulic oil to cool down.
• Ensure maximum cleanliness for all work!
Contamination in hydraulic systems leads to system
malfunctions and reduced operating life.
• Thoroughly clean the area around the oil filling hole
before refilling/changing the oil.
• In the event of extreme operating or environmental
conditions, change the oil at shorter intervals.
• Never mix lubricant qualities or lubricants from
different manufacturers, see Chapter 7.3! Never
mix mineral and synthetic hydraulic oil!
• In the event of contamination or air/water content
in the hydraulic oil, change the oil and thoroughly
rinse out the reservoir/container with fresh clean oil
or clean before refilling.
• Immediately bind any leaked oil, neutralize any
larger amounts of spilled oil. Use a cleaning rag to
carefully wipe away any oil residue (BGV A1).
• Only collect and dispose of used lubricants (waste
oil) in approved containers in accordance with the
regulations.
• Never allow leaked oil and waste oil to enter the
sewage system!

! Warning
Danger of slipping on leaked oil!

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7.7.0.2 Monitoring the condition of the system

• Check the leak tightness of all hydraulic ! Warning - Risk of scalding
components, connections and hose lines Danger of scalding while draining used oil at
DAILY operating temperature (temperature approx.
by visual inspection. 70 °C). Use/wear PPE, e.g. protective gloves
and eye protection!
• Check the condition of the hydraulic system,
every 1,000 operating hours or every 12 • Fill with new/fresh hydraulic oil from clean,
months. undamaged drums.
Check the general condition of components, - Fill with oil using a separate filter station or via a
fastening of the hydraulic motors, fastening of funnel tube with filter (10 µm),
components, fastening of valve connectors, wear/ - Oil volume/reservoir capacity 150 liters,
damage of the hydraulic connection couplings, - Oil quality “HLP”, ISO VG 46, see Chapt.
damage to hose lines/electric cables (kinked/ 7.3.2.2.
pinched or chafed etc.). • Never overfill the oil reservoir, adhere to the max.
oil level, observe the oil inspection glass!

7.7.1 Checking the hydraulic oil level

The oil level sight glasses are located on the oil 7.7.1.2 Checking the hydraulic oil condition
reservoir in the engine compartment (Fig. 7-14) • Check the hydraulic oil condition or
directly showing the actual oil level. quality,
every 2,000 operating hours or every 12
• Check the oil level months.
DAILY,
top up with hydraulic oil, if necessary. • Take an oil sample from the oil reservoir.
• Pour the hydraulic oil into a clean specimen jar or
• Topping up the hydraulic oil: test tube, and inspect.
- Thoroughly clean the surroundings of the oil filler - Color: Dark discoloration means contamination
neck, unscrew the cap, in the system or system overheated.
- top up the oil through the oil filler neck, Cloudiness (milky emulsion) indicates
Use a separate filter station or funnel tube with condensate content.
filter (10 µm), - Foam formation: Air/water content in the oil.
- firmly screw the cap onto the oil filler neck and - Water content: Over time, condensate will collect
wipe away any spilled oil, at the bottom of the test tube.
- constantly monitor the oil level while refilling, do
not overfill the reservoir. Warning
!
An oil change is overdue if free condensate is
visible in the test tube! Check all hydraulic
7.7.1.1 Hydraulic oil change
components for any damage that might have
• Change the hydraulic oil
occurred!
every 2,000 operating hours or every 12
months. - Solid matter content: Allow several drops of oil to
drip onto a sheet of blotting paper/filter
• Perform the measures to ensure that the unit is in a
paper and examine the solid matter
safe standstill condition (Chapt. 7.5.1), allow the
remaining on the surface under a
hydraulic oil/components to cool down.
microscope. This allows a rough
• Fully drain the used hydraulic oil via the drain valve.
assessment of the soiling according to the
Collect the used oil in approved used oil containers!
size distribution and type of the particles.
• In the event of discoloring, signs of contamination,
foaming, water content:

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Change the oil immediately! 7.7.3 Checking the hydraulic hose

If necessary, have a laboratory analysis performed to lines
detect the cause for the change in the oil quality, and • Perform the measures to ensure that the machine is
remedy. in a safe standstill condition (Chapt. 7.5.1).
• Check the hydraulic hoses
every 200 op.hrs. or once per month,
7.7.1.3 Bleeding the hydraulic system - check connections/hose fittings for leaks,
Prior to initial start-up/commissioning and after each - Check hose lines for externally visible damage
oil change, the hydraulic system is automatically bled (cuts/punctures, pinched, chafed points or
when the hydraulic motors are operated for a while in porosity).
idle run.
• Eliminate any hazard points at which hoses could
• Switch on the unit as described in Chapt. 6.4.1 and
become crushed/pinched, kinked or chafed.
following chapters. Allow the engine and hydraulic
system to run at idle for a while.
• Operate the front and rear drum, one after the
7.7.3.1 Replacing the hydraulic hose lines
other, in both rotational directions at different
• Replace hydraulic hoses in good time due to aging,
speeds and without load for a while.
every 4,000 operating hours or every 4 years.
• If necessary, bleeding can be accelerated by a
• Replace the hydraulic hoses,
hydraulics expert using the measuring connections
- if any damage is detected during the above
on the hydraulic pump for bleeding.
mentioned inspection,
- following a service life of more than four (4)
! Warning
years after the hoses were fitted.
Danger of injury from hydraulic oil escaping at - Do not fit unused hoses after a storage time of
high operating pressure in the event of a more than two (2) years!
malfunction!
Replace hydraulic hoses as follows:
• Operate the hydraulic system without load with
alternating switching until all functions are Warning
!
performed smoothly without any jolts.
Danger of injury from hydraulic oil escaping at
high operating pressure!
Use/wear PPE, e.g. eye protection, protective
7.7.2 Replacing the hydraulic return gloves, etc.
filter element • Prior to opening hydraulic components or
• Change the filter element of the return filter (see
disconnecting flanged hoses, always depressurize
third-party operating manual)
the system beforehand.
every 1,000 operating hours or every 6
• Watch the pressure gauge reading and have the
months
system sections to be opened depressurized by a
or as required.
hydraulics expert.
• Thoroughly clean the surroundings of the return
• Undo the hose connections.
filter with a cloth!
• Collect any emerging oil in used oil containers.
• Remove the filter cover (data sheet in the
Immediately wipe up any leaked oil!
appendix).
• Fit a new hose.
• Pull the filter element out of the housing.
- Only use original spare parts.
• Insert a new filter element,
Precisely adhere to the hose specifications, see
check the cover seal (replace if necessary) and
spare parts/hose list in the appendix.
fasten the filter cover.
- Do not twist/distort, crush/pinch or kink hoses;
• Check the hydraulic oil level,
exclude the risk of chafing.
top up oil if necessary.

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- Observe the min. bending radius of the respective 7.9.1 Battery maintenance
hose size. 7.9.1.1 Maintenance/replacement of the battery
• Always note down the date on which a hose is The batteries are located in the engine compartment
changed! (Fig. 4-9).
• Battery checks depend on requirements, however,
we recommend a check at regular intervals during
7.7.4 Maintenance of the oil/air cooler operation in the winter or following a down time or
after repairs.
• The oil/air cooler is low-maintenance, no special
• Wear the prescribed PPE, e.g. eye protection,
measures are necessary. For details, please refer to
protection gloves (corrosive substances) etc. when
the separate third-party operating manual in
performing work at the battery!
“Section III” of the technical documentation.

! Danger
Only work on the battery when the engine is
7.8 Compressed air system switched off!
Battery acid is corrosive, adhere to the safety
• The compressed air system and the equipment
instructions, wear PPE!
items are low-maintenance; no special measures
Adhere to the hazard information laid down in
are required.
the battery documentation.
• The compressed air receivers are to be drained at
regular intervals. Drain valves are located at the • Disconnect the battery connections.
bottom of the receivers and can be accessed from
underneath the vehicle frame. ! Note
• For the prescribed repeat inspection of the receivers Always disconnect the minus pole (-) first!
in accordance with the Pressure Equipment • Undo the battery mounting bracket,
Directive/BetrSichV, please refer to Chapter 7.4.2! carefully lift the battery off the holding plate.
• Clean battery, remove oxidation residue from the
connection poles (+ and - pole).
• Remove the closure caps and check the battery
7.9 Electrical equipment acid level. If necessary, top up with distilled water
Ensure that the electrical drives/devices/equipment up to the mark (on the battery housing).
are checked and maintained by a qualified electrician Replace the closure caps and tighten.
according to the implementation directives as per • Apply pole grease to the battery poles using a
BGV A3 and at the test intervals specified therein. brush.
• Reinstall the battery and secure with holding
Maintenance of the electrical equipment includes:
brackets.
• Immediately tightening any loose clamping
• Re-connect the battery.
connections.
• Immediately replacing any damaged/scorched/ Note
chafed cables. !
• Correctly drying up any moisture in the terminal Always connect the plus pole (+) first!
boxes/connections etc.
Resealing connections.
• Checking the electrical equipment, control panel
etc. for externally visible damage. 7.10 Completion of maintenance
work
• After maintenance work or repairs, have the
operational safety and operational readiness

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checked and confirmed by a safety officer.

7.10.1 Visual inspection after

maintenance work
Inspect the Wireline Combi Unit PP after maintenance
work by performing a visual inspection, as described in
the following: Check that
• the container has no externally visible damage or
defects,
• the display instruments are legible and the
panoramic window to the winch cab is clean,
• there are no loose objects in the winch cab or on
the control panel,
• there are no loose screw connections on the
winches,
• there are no visible oil leaks at hydraulic drives and
components,
• the hydraulic motors are securely fastened,
• the return filter element has been replaced,
• the consumables/auxiliary substance containers
have been filled to the specified or max. mark with
the prescribed consumables/auxiliary substances
(Chapt. 5.3).
• the battery acid level has been checked and topped
up with distilled water, if necessary.
• the air intake on the oil/air cooler is not soiled or
damaged,
• there are no leaks at the compressed air system, on
components or connections,
• hydraulic and compressed air hose lines, and
electrical cables are not kinked, pinched or chafed;
plug-connectors/sockets are not damaged.
• all protection/safety devices/guards (e.g. covers/
caps) must be securely fastened and functioning.
See Chapt. 6.3.2 for the safety inspection prior to
commissioning/starting up!

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Table 7.II: Wireline Combi Unit PP, maintenance schedule7)

Pos. Maintenance work to be performed Reference Maintenance interval

every 4,000
every 1,000

every 2,000
every 200
op.hrs.

op.hrs.

op.hrs.
op.hrs.

op.hrs.
every 50
daily
001 Visual inspection (safety check) .............................. Chap. 6.3.2....X
002 Clean the machine .................................................... Chap. 7.5.3........................ X
003 Maintenance of the diesel engine (3rd party .................OM)
- Leakages of the oil/fuel system ............................ Chap. 7.6.2....X
- Change the fuel filter cartridges ........................... Chap. 7.6.2............................................. X
- Check the engine oil level ..................................... Chap. 7.6.2....X
- Engine oil filter change .......................................... Chap. 7.6.2............................................. X
- Check the coolant level ......................................... Chap. 7.6.2....X
- Check the air filters ............................................... Chap. 7.6.2....X
004 Relubricate the flange bearings (drum shaft)9) ........... Chap. 7.5.7.................................. X
005 Relubricate the flange bearings (spooling
mechanism)9) ............................................................................... Chap. 7.5.7.................................. X
006 Check the fastening of the chain guard hoods ......... Chap. 7.5.6........................ X
007 Oil the roller chain on the inner surface ................... Chap. 7.6.2....X
008 Tension/slacken the roller chain ............................... Chap. 7.6.2.................................. X
009 Clean and grease the roller chain ............................. Chap. 7.6.2............................................. X
010 Check the fastening of the hydraulic motors
.................................................................................. Chap. 7.5.6............................................. X
011 Check the gear oil level, top up oil if necessary. ..... Chap. 7.6.3.................................. X
012 Gear oil change10) ..................................................................... Chap. 7.6.3............................................. X
013 Check the brake band fastening ............................... Chap. 7.6.4........................ X
014 Check the brake cylinder fastening .......................... Chap. 7.6.4........................ X
015 Check the brake band thickness (d > 2 mm) ........... Chap. 7.6.4........................ X
016 Check the brake pretension ..................................... Chap. 7.6.4........................ X
017 Check the sealing of the hydraulic system ............... Chapt. 7.7 ....X
018 Check the condition of the hydraulic system ............ Chapt. 7.7 .................................. X
019 Check the hydraulic oil level .................................... Chap. 7.7.1....X
020 Change the hydraulic oil ........................................... Chap. 7.7.1............................................. X

7) Maintenance intervals: - every 4,000 op.hrs. or every 2 years,

- daily, visual inspection daily/before each start-up, which ever occurs first!
during continuous operation once per shift, 9) Prior to every use, at a standstill see above
- every 50 operating hours (op.hrs.) or weekly 10) every 3,000 op.hrs. or every 18 months
- every 200 op.hrs. or once per month,
- every 1,000 op.hrs. or every 6 months,
- every 2,000 op.hrs. or every 12 months,

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Table 7.II: Wireline Combi Unit PP, maintenance schedule7), cont.

Pos. Maintenance work to be performed Reference Maintenance interval

every 4,000
every 1,000

every 2,000
every 200
op.hrs.

op.hrs.

op.hrs.
op.hrs.

op.hrs.
every 50
daily
021 Check the hydraulic oil condition, take oil samples
- Check the air/water content ................................. Chap. 7.7.1............................................. X
- Check the color/aging ........................................... Chap. 7.7.1............................................. X
- Determine the solid matter content ....................... Chap. 7.7.1............................................. X
022 Replace the return filter element ............................. Chap. 7.7.2.................................. X
023 Check the setting of the pressure relief valves
.................................................................................. Chap. 7.4.2............................................. X
024 Check hydraulic hose lines ....................................... Chap. 7.7.3........................ X
025 Replace hoses within the specified time intervals11) Chap. 7.7.3....................................................... X
026 Clean the oil/air cooler ............................................. Chap. 7.7.2........................ X
027 Check the connection to ground/equipotential
bonding8) ........................................................................................ Chap. 7.4.1........................ X
028 Check screw-connections for firm seating .............. Chap. 7.5.6.................................. X
029 Test the safety devices/safety functions ................. Chap. 5.5.5............................................. X
030 Check the electrical equipment ................................. Chapt. 7.9 ............................................. X
031 Visual inspection after maintenance work .............. Chap. 7.10.1

7) Maintenance intervals: - every 4,000 op.hrs. or every 2 years,

- daily, visual inspection daily/before each start-up, which ever occurs first!
during continuous operation once per shift, 8) every 100 op.hrs.
- every 50 operating hours (op.hrs.) or weekly 11) every 4,000 op.hrs. or every 4 years
- every 200 op.hrs. or once per month,
- every 1,000 op.hrs. or every 6 months,
- every 2,000 op.hrs. or every 12 months,

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8. Malfunctions, possible causes and remedy

Table of Contents 8.1 Malfunction causes
8.1 Malfunction causes ........................... Page 8-1 • Malfunctions of the Wireline Combi Unit PP can be
8.2 Troubleshooting .......................................... 8-1 frequently traced back to operating/maintenance
errors.
8.3 Checklist: Operating malfunctions .............. 8-3 Therefore, they are often not within the area of
8.3.1 Power pack/engine malfunctions ................ 8-3 responsibility of KMA as the machine
8.3.2 Malfunctions of the hydraulic system ......... 8-4 manufacturer.
8.3.3 Noise emissions, erratic operation .............. 8-6 Also see Chapt. 4.2.1.
8.3.4 Malfunctions in the compressed air system 8-7 • Malfunctions due to improper handling, use which is
8.3.5 Electrical malfunctions and not in compliance with the intended use or negligent
switching errors .......................................... 8-8 maintenance (not according to schedule) are not
covered by guarantee/warranty.
The owner/user bears the sole risk!

8.2 Troubleshooting
Always observe the regulations, warnings and
instructions contained in Chapt. 2 „Occupational safety
and health, safety regulations and environmental
protection“ during troubleshooting.
• For malfunctions at the power pack, generator etc.
please refer to the third-party operating manuals in
„Section III“ of the technical documentation.
During troubleshooting at the Wireline Combi Unit PP
and before any intended disassembly of components,
items of equipment, etc., first check that:
• The unit does not show any externally discernible
damage,
• it has been filled with sufficient diesel fuel,
• the EMERGENCY STOP buttons „4S1“ and „4S4“
are re-armed,
• the main switch „2Q1“ is set to the correct
operating mode,
- mains operating mode via the ext. power supply,
- emergency power mode
- for exclusive power supply by the Dynaset
generator
• there are no visible oil leaks from the hydraulic
components
• the oil level in the hydraulic oil reservoir is sufficient
• the oil temperature does not go below approx. -20
°C and does not exceed +70 °C
• the actuation of the valves is correct
- the power supply is adequate/correct
- all valve connectors are securely connected

8-1
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- the actuation corresponds to the circuit diagram/

functional diagram
• the compressed air receivers are filled and an air
pressure of p > 8 bar is provided
• there is no electrical fault and the power supply of
400V AC and 24V DC is ensured
• inspections and maintenance measures have been
performed within the specified time intervals and
worn or damaged components have been replaced.

! Danger
Insufficient technical knowledge or improper
handling of hydr./pneum./electr. devices/
equipment or non-observance of occupational
safety and health, and safety regulations (see
Chapt. 2) can result in serious damage to
health and damage to assets!
• Only permit experienced, qualified expert
personnel to perform work on hydr./pneum. units/
equipment!
• Only allow work on electrical devices/equipment to
be performed by experienced, qualified electricians
(BGV A3)!
Perform each troubleshooting measure step-by-step
and always record observations, measuring results etc.
in writing.
If you require additional information, please refer to the
third-party operating manuals or contact KMA directly.
See above for address.

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8.3 Checklist: Operating malfunctions

8.3.1 Engine/hydraulic drive (also refer to the third-party operating manual)
Malfunction Cause Remedy
- Engine does not start up - No fuel in the tank • Fill tank with diesel fuel
- Ignition not switched on • Turn on the ignition
- Shut-off valve of fuel filter • Open the fuel shut-off valve
closed • Bleed the fuel system
- Air trapped in the fuel system • Check/maintain/charge the battery
- Battery defective/discharged

- Engine starts poorly or - Engine oil is too viscous at low • Fill with the correct engine oil for the
runs irregularly ambient temperatures outside temperature
- Wrong engine oil • Check the engine oil specification, change
- Fuel is too viscous or heavily oil if necessary
soiled • Clean the fuel system, change the filter,
- Injection pipe leaking/injection change the fuel
valve defective • Check the injection pipe/injection valve
and replace if necessary

- Engine has no power - Insufficient fuel supply • Check the fuel lines for leaks
- Incorrect fuel filter • Check the fuel filter for soiling and
- Air filter/safety cartridge soiled replace if necessary
- Injection pipe leaking/injection • Bleed the fuel system
valve defective • Clean the air filter, replace the cartridge if
necessary
• Check the injection pipe/injection valve
and replace if necessary

- Engine becomes too hot - Incorrect engine oil filling • Check the engine oil level, top up engine
quantity, insufficient oil level oil if necessary
- Insufficient coolant level • Check the coolant level, top up coolant if
- Soiled cooling grid/cooling fins necessary
- Fan/V-belt defective • Clean the cooling grid and cooling fins
- Coolant thermostat defective • Check the fan/V-belt and replace if
- Wrong type of diesel fuel necessary
• Replace the thermostat
• Check the diesel fuel specification and
only use the prescribed fuel

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8.3.2 Malfunctions of the hydraulic system

Malfunction Cause Remedy
- Drums do not rotate - Pressure relief valve (safety • Increase the tension at the controller
valve) „R2“ misadjusted/open (twist handle)/pressure relief valve (safety
- Power failure/electr. fault/ valve) „R2“ if necessary by turning
control system failure clockwise (cw).
- Solenoid valves leaking/ • Relieve the drum, do not exceed max.
defective, insufficient voltage permissible load (tension)!
- Valve connector loose/defective • Have the electr. system/control system
- Hydraulic system failed checked and repaired by a qualified
electrician.
• Have the solenoid valves checked and, if
necessary, replaced by expert personnel/
KMA,
• Securely fit valve connectors.
• Have the hydraulic system checked and
repaired by expert personnel,
change the oil if necessary (Chapt. 7.7.1)
and rinse the system.

- Winches do not reach Malfunctions at the hydraulic • Top up oil, see Chapt. 7.7.1
the intended tension, group: • Have the following checked and repaired
insufficient pressure in - Insufficient oil level by expert personnel or KMA Customer
the hydraulic system, - Pressure relief and control Service:
valves misadjusted/defective, for - Pressure relief valves, control valves
adjustment of pressure relief - Hydraulic pump and motor
valve (safety valve) „R2“ see • Clean the return filter and replace the
above filter cartridge, Chapt. 7.7.3
- Hydraulic pump/motor defective, • Establish the oil condition/quality acc. to
electrical fault Chapt 7.7.1
- Return filter soiled
- Foam formation in the oil tank

- Pressure in the system - Leaks in the pipework, on hoses, • Have any leaks remedied by expert
continuously drops under connections, components etc. personnel
load, possibly due to - Pipe or hose rupture! - Replace defective pipe/hose elements
considerable oil leaks - Neutralize leaked oil (BGV A1)
• In the event of a pipe/hose rupture,
contact the KMA Customer Service.

Attention: Do not exceed the max. duration

of use of hydraulic hose lines. Replace the
hoses in time (within the specified period)!

- The winch rotates - Hydraulic pump delivery • Have the hydraulic pump checked and, if
erratically (jerkily), fluctuations, pump defective or necessary, replaced by expert personnel,
pressure fluctuations electrical fault have the electrical control cable checked
- Air in the hydraulic system by a qualified electrician.

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Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 8 - Malfunctions

8.3.2 Malfunctions of the hydraulic group, continued

Malfunction Cause Remedy
- Return filter soiled • Bleed the system, Chapt. 7.7.1
- Foam formation/soiling in the oil • Clean the return filter and replace the
tank filter cartridge, Chapt. 7.7.3
• Establish the oil condition/quality acc. to
Chapt 7.7.1

- Insufficient rotational - Hydraulic pump defective • Have the hydraulic pump checked and, if
speed / wireline/cable (insufficient flow rate) necessary, replaced by expert personnel,
speed, - Flow control valve misadjusted/ have the electrical control cable checked
pump noises defective by a qualified electrician.
- Solenoid valve defective • Have the solenoid valve replaced by
- Cable defective/electrical expert personnel/KMA Customer Service.
control cables interrupted • Have the cables/control cables checked
and repaired by a qualified electrician.

- Oil leakages at the - Shaft seals worn/defective • Have the shaft seals replaced by expert
engines/motors personnel or KMA Customer Service.

- Oil in the tank gets too - Oil cooler defective • Have the oil cooler repaired or replaced
hot, temperature above - Insufficient oil level • Check the bypass valve, readjust/replace
+70 °C - Flow control / control valves if necessary
defective • Top up hydraulic oil, Chapt. 7.7.1
- Return filter soiled • Check the valves and replace if necessary
• Clean the return filter, replace the filter
cartridge, Chapt. 7.7.3

- Foam formation in the oil - Insufficient oil level • Top up hydraulic oil, Chapt. 7.7.1
reservoir - Incorrect oil quality • Check the hydraulic oil
- Condensate (moisture) in the - oil quality acc. to Chapt. 7.3.1
system - oil level acc. to Chapt. 7.7.1,
- Shaft sealing on the suction side change the hydraulic oil if necessary.
worn • Check the shaft seals, have them replaced
by expert personnel, if necessary.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 8 - Malfunctions

8.3.3 Noise emission, erratic operation (possibly vibrations)

Malfunction Cause Remedy
- Noises, Noise emission from the hydraulic • Have the hydraulic pump checked and, if
possible signs as system: necessary, replaced by expert personnel.
described under 8.3.2 - Hydraulic pump defective • Have the solenoid valve replaced by
- Valve chatter/vibration due to expert personnel/KMA Customer Service.
soiled oil, • Check the oil level, top up oil if necessary.
defective solenoid, • Establish the oil quality acc. to Chapt
insufficient voltage, 7.7.1.
- Flow noise or air trapped in the
system
- Insufficient oil level
- Oil soiled or
foamy

- Rattling noise Screw/bolt connections loose: • Retighten screw/bolt connections, for

- Cladding and tightening torques see Chapt. 7.I.
covers/guards
- Protection devices/guards
- Other screw/bolt connections

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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8.3.4 Malfunctions in the compressed air system

Malfunction Cause Remedy
- Air escaping (leak) at - O ring/seal damaged • Check O ring/sealing, replace if necessary
the connections, etc. - Screw connections loose • Retighten screws/bolts/nuts, see third-
party operating manual

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Chapter 8 - Malfunctions

8.3.5 Electrical malfunctions and switching errors

Malfunction Cause Remedy
- Engine/motor / generator Incorrect switch position: • Set main switch „2Q1“ to mains mode
drive is not running - Main switch „2Q1“ switched to (ext. power supply) or emergency power
the wrong power supply mode mode (power supply exclusively by the
- EMERGENCY STOP button generator).
not re-armed/disengaged • Correctly remedy the cause for the
EMERGENCY STOP actuation.
Rearm the EMERGENCY STOP button.

Switches/buttons or cables • Have the following checked and, if

defective: necessary, repaired by a qualified
- Buttons/switches on control electrician:
panel - Buttons/switches
- Valve connector loose/defective - Valve connectors
- Cable loose/defective - Cables/connections
- Valve actuation does not • Have the valve actuation checked by a
correspond to the wiring dia- qualified electrician.
gram.

Drive / electrical fault/malfunction: • Have the electrical system disconnected

- Mains / phase failure (isolated) from the mains by a qualified
- Failure of the auxiliary/control electrician.
voltage, - Check the mains situation, cables and
insufficient voltage supply cable connections,
- Automatic cut-out has tripped exclude short-circuit in the supply cables
- Insufficient contact, damage to - Switch on the automatic cut-out
cables - Measure the voltage at the engine,
check the supply cable.

- No engine/motor start - Isolating switch „4Q1“ (Fig. 6-2) • Turn on isolating switch „4Q1“
possible from the control isolates the on-board electrical
panel system from the batteries.

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 KOLLER Maschinen- und Anlagenbau GmbH Operating Manual
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9. Tables of hazard analysis and risk assessment

Tables
For general safety information/instructions please refer to Chapt. 2!
9.I Hazard analysis acc. to DIN EN ISO 14121-1
9.II Risk assessment acc. to DIN EN ISO 14121-2
9.III Protection/safety devices/guards at the machine (acc. to Machinery
Directive, Annex VII, para. A1a)

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Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

01. Mechanical hazard MRL 2006/42/EC,

Annex. I, Para. 1.3,
ISO 12100-1, 4.2,
ISO 12100-2, 4.2
and 4.3, 5
01.01 Hazard emanating from shape/surface/movement/
Movement of components/tools
01.01.01 sharp points/corners/edges/protruding components Y Y Y Y Y Y Y MRL, Annex. I, 1.3.4,
(Piercing/puncture/through-puncture/cutting) ISO 12100-1, 4.2.2,
EN 13852
01.01.02 rough/cracked surface/corners and edges/ Y Y Y Y Y Y Y MRL, Annex. I, 1.3.4,
protruding components (abrasion, ripping open/getting ISO 12100-1, 4.2.2,
caught) EN 13852
01.01.03 slippery surface („no grip/hold“)
01.01.04 insufficient minimum spacing of moving components N N Y Y Y N N EN 13852, EN 13853,
(pinching/shearing/cutting) EN 13854
01.01.05 moving/rotating/oscillating components/tools N N Y Y Y Y N
(seizing/catching/pulling-in/winding up, also
sawing/cutting/pinching/shearing)
01.01.06 Moving and stationary components coming close N N Y Y Y Y N EN 13852, EN 13853,
(impact/pinching/shearing) EN 13854
01.01.07 relative arrangement of the components/tools
01.01.08 Mass and stability (potential energy of components ISO 12100-1, 4.2.2
that could move under the influence of
gravity)
01.01.09 missing stability/risk of tipping over (shifting ISO 12100-1, 4.2.2,
of the center of gravity) of machine/components ISO 12100-2, 4.6
01.01.10 kin. energy of components with controlled
or uncontrolled movement
(mass and speed)
01.01.11 tipping/reciprocating/gliding/rolling off ISO 12100-2, 4.6
machine/components
01.01.12 falling/ejected/kicking back MRL, Annex. I, 1.3.2,
/detaching/bursting/flying off 1.3.3
components

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

07.08.2010

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,

C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-1
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

01.01.13 Tight, rough surface in narrow/low-ceiling N N Y Y Y Y N

passages
01.01.14 unexpected, temporary obstacles (sudden
opening of doors and similar)
01.01.15 insufficient mechanical stability N Y Y Y Y Y N MRL, Annex. I, 1.3.2,
ISO 12100-1, 4.2.2

01.02. stored potential/kinetic energy ISO 12100-1, 4.2

ISO 12100-2, 4.3
01.02.01 Acceleration/deceleration
01.02.02 elastic elements (springs)
01.02.03 Air pressure (pneumatic) N N Y Y N Y N
01.02.04 Fluid pressure (hydraulics) N N Y Y N Y N
01.02.05 Container/pipe/hose line under high pressure N N Y Y N Y N RL 87/404/EEC,
RL 97/23/EC
01.02.06 Low pressure (vacuum)

01.03. Hazard emanating from pressurized fluid/ MRL, Annex I, 1.5.3,

air pressure systems (hydraulics/pneumatics) ISO 12100-1, 4.2,
ISO 12100-2, 4.10,
ISO 4413, ISO 4414
01.03.01 Fluid/gases under high operating pressure N N Y Y N N N
01.03.02 incorrect overpressure > operating pressure
01.03.03 in the presence of leaks/venting/bleeding, fluids N N Y Y Y Y N ISO 12100-1, 4.2.1
spurting out under high pressure
01.03.04 Pressure loss/pressure drop (e.g. „sagging“ of
cylinders) entailing mechanical hazards
01.03.05 Vacuum loss
01.03.06 Leaks N Y Y Y Y Y N
01.03.07 Leaks due to damage/ N Y Y Y Y Y N ISO 17165
Ageing of hose lines
01.03.08 incorrect pipework/hose fastening DIN 24346

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-2
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

01.03.09 Pipes/hose lines unprotected against breakage, DIN 24346,

external influences, missing cover/cladding at the MRL, Annex. I, 1.3.2
operating place/routing does not allow driving over
01.03.10 whipping hose lines (hose breakage)
01.03.11 Pressure accumulator/vessel not automatically EN 14359
pressure relieved when the machine is disconnected
from the energy supply
01.03.12 Failure of a pneumatic/hydraulic component N N N Y Y Y N

01.04. Falling on the floor/falling from an overhead

position
01.04.01 Slipping on soiling, wet treads, N Y Y Y Y Y N BGV A1, ArbStättV
slipperiness caused by the weather, loose tread
surfacing slanted treads
01.04.02 Tripping/falling due to uneven surfaces, N Y Y Y Y Y N ArbStättV, BGV A1
objects lying around, insufficient shape/
size of the tread surface
01.04.03 Risk of falling from ladders/treads/stairs/scaffolding N Y Y Y Y Y Y BGV D36
01.04.04 Falling from overhead work places ASR 12/1-3
(overhead work)
01.04.05 Risk of falling of components/machine when
installing the machine above ground/
overhead (potential energy)
01.04.06 Falling into openings/cavities

02. Electrical hazards MRL, Annex I, 1.5.1,

EN 60204, BGV A3,
ISO 12100-1, 4.3,
ISO 12100-2, 4.9
02.01. Causes of electrical hazards
02.01.01 Contact with voltage carrying components N Y Y Y Y Y N
(electrocution/electric shock leading to death)
02.01.02 insufficient spacing to components under
high voltage

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-3
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

02.01.03 Overload/overcharge N N Y Y Y Y N EN 60204

02.01.04 Components becoming live in the event N N Y Y Y Y N EN 60204
of a malfunction
02.01.05 Short-circuit, with thermal radiation/chemical
processes (combustion/poisoning)
02.01.06 Electric arc resulting from short-circuit/switching N N Y Y Y Y N EN 60204
under load (fire)
02.01.07 thermal radiation or occurrences, such as
the projection of melted particles

02.02. Electrostatic occurrences

02.02.01 Risk of fire and explosion under electro-static N Y Y Y Y Y N MRL, Annex I, 1.5.2,
charge and load disconnection EN 60079-14,
BGR 132

02.03. Electro-magnetic occurrences

02.03.01 High-frequency electro-magnetic fields/ VDE 848
direct vicinity to high voltage systems
02.03.02 Electrical effect on medical implants RL 2004/40/EC

03. Hazardous materials

See No. 08. ...

04. Thermal hazards MRL, Annex I, 1.5.5,

ISO 12100-1, 4.4
04.01.01 Naked flame, smoke formation
04.01.02 Unintended contact with components/materials N N Y Y Y Y Y EN 563/EN 13732-1
at high temperature
04.01.03 High operating temperature resulting from additional
energy input (circulation of small volumes of fluid
through return flow/bypass
04.01.04 Intended contact with hot surfaces
(adjustment components, and similar)

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-4
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

04.01.05 Direct contact with hot materials (scalding), N N Y N Y Y N

e.g. with fluids/hot steam/hot air
04.01.06 Explosion, effect of flames and shock wave EG-RL 94/9/EC
04.01.07 Splashes of hot media/materials N N N N Y Y N ISO 12100-1, 4.4
04.01.08 Refrigeration agents and coolants (death from cold)
04.01.09 Components/materials at low temperature
(cold pipework and similar)
04.01.10 Staying in refrigerated rooms
04.01.11 Heat radiation (burns)

05. Hazard emanating from sound emission/noise MRL, Annex I, 1.5.8

and 1.7.4.2, BGV B3,
ISO 12100-1, 4.5
05.01.01 Cavitation
05.01.02 Exhaust air system (exhaust system) N N N Y Y Y N
05.01.03 gases exiting at high speed,
noise of the exhaust/intake air through ventilators
05.01.04 Production process (cutting/grinding/punching,
sawing and similar)
05.01.05 Operating noise of running units (e.g. pumps, N N Y Y Y Y N BGV B3
compressors, combustion engines, etc.)
05.01.06 Rubbing/grinding/sawing surfaces of moving/
rotating/oscillating components
05.01.07 Components rotating at an imbalance
05.01.08 Whistling pneumatic systems
05.01.09 Worn components (wear/damage)
05.01.10 Insufficiently fastened components
05.02.11 Malfunction of acoustic signals/voice communication

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-5
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

06. Hazard emanating from vibration/oscillation MRL, Annex I, 1.5.9,

ISO 12100-1, 4.6
VDI 2057
06.01.01 Cavitation occurrences
06.01.02 Misalignment of moving components
06.01.03 Freely moving parts of equipment
06.01.04 Rubbing/grinding/sawing surfaces of moving/
rotating components
06.01.05 Components rotating with an imbalance/driven
by combustion engines
06.01.06 Oscillating parts of equipment
06.01.07 Worn components (wear/damage)
06.01.08 Whole body vibration including spinal
problems (e.g. seats)
06.01.09 Hand-arm vibration as a cause for neurological
diseases/damage to joints/blood
vessels (e.g. from hand-held and hand-guided
devices/tools)

07. Hazard emanating from UV, IR and laser radiation MRL, Annex I,
1.5.10,
ISO 12100-1, 4.7,
ISO 12100-2, 5.4.5
07.01.01 Ionising radiation
07.01.02 Low-frequency electro-magnetic radiation
07.01.03 Optical radiation (infra-red/visible and ultra-violet)
damaging eyes and skin
07.01.04 Laser radiation damaging eyes and skin
07.01.05 High-frequency electro-magnetic radiation
damaging eyes and skin

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-6
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

08. Hazard emanating from materials/substances

(hazardous substances) MRL, Annex I,1.5.13,
TRGS 900,
GefStoffV, BGV 1
08.01. Hazard emanating from hazardous
materials/substances
08.01.01 Materials/substances causing allergies
08.01.02 Mist/vapors/gas/exhaust gas (irritation of eyes/skin/ MRL, Annex I,1.1.7
mucous membranes/breathing difficulties/suffocation)
08.01.03 Inhaling aerosols/vapors/suspended matter/
dust (breathing difficulties/suffocation)
08.01.04 Danger of infection caused by biological and micro-
biological (viral or bacterial) substances
08.01.05 Gene manipulated organisms (GVO) BGV C4
08.01.06 Hazard emanating from carcinogenic materials/ TRGS 905
substances
08.01.07 Consumables/combustibles/fuels (irritation of eyes/ N N Y Y Y Y N
skin/mucous membranes)
08.01.08 Consumables, lubricants, e.g. transmission/hydraulic N N Y Y Y Y N PSA-BV
oil (irritation of eyes/skin/mucous membranes)
08.01.09 Topping up engine coolant (risk of scalding, N N Y Y Y Y N
irritation of eyes/skin/mucous membranes)
08.01.10 Topping up engine/hydraulic oil (risk of burns, N N Y Y Y Y N
from hot engine/hydraulic components)
08.01.11 Risk of explosion and fire caused by combustible RL 94/4/EC,
gases, vapors or mist EN 1127-1
08.01.12 Risk of fire and explosion caused by consumables VDI 2263
(fuel, oil, solvents, etc.), combustible
dust
08.01.13 Harmful dust
08.01.14 Mineral fibers (fiber dust, WHO fibers)
08.01.15 Solid matter (e.g. self-ignition of magnesium chips)
08.01.16 Fluid, e.g. cleaning agent/solvent (poisoning,
toxic reactions, swallowing)

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-7
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

08.01.17 Oxidation agents

08.01.18 Corrosion of metallic materials/ageing of N N N Y Y N N
elastomers or plastics

08.02. Hazard from hazardous substances and GefStoffV (CHV5)

mixed compounds
08.02.01 Explosion hazard through impact, friction, fire CHV5, §4, para.1
or other ignition sources (R Risk phrases R2 and R3)
08.02.02 Supporting combustion, can cause fire (R7), CHV5, §4, para.1
Risk of fire when coming into contact with
combustible substances (R8), hazard of explosion
when mixing combustible substances (R9)
08.02.03 extremely flammable
08.02.04 highly flammable
08.02.05 flammable
08.02.06 very toxic
08.02.07 toxic
08.02.08 harmful
08.02.09 corrosive
08.02.10 irritating
08.02.11 sensitizing
08.02.12 carcinogenic
08.02.13 negative reproductive effect
08.02.14 mutagenic
08.02.15 harmful for the environment

09. Hazard emanating from neglect MRL, Annex I, 1.1.6,

of ergonomic principles, e.g. in the ISO 12100-2, 4.8
work environment
09.01. Causes of hazards through the neglect
of ergonomics and the work environment
09.01.01 Limited access
09.01.02 Incorrect design/arrangement, poor visibility
of optical displays resulting in operating
mistakes/errors

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-8
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

09.01.03 Incorrect design/arrangement, poor visibility

of operating elements/adjustment elements
causing operating mistakes/errors
09.01.04 Flickering/glaring/shadow formation/stroboscopic
effects on optical displays
09.01.05 Poor local light intensity ASR 7/3, BGR 131,
ArbStättV §7
09.01.06 Mental overload/underload N Y Y N Y Y N
(Overestimation of own capabilities)
09.01.07 Poor instruction/training, insufficient N Y Y Y Y Y N
qualification of the operator
09.01.08 Physical overload (e.g. lifting/carrying
of heavy parts)
09.01.09 Human misbehaviour N Y Y Y Y Y Y
09.01.10 Unauthorized/erroneous switching of the machine by N Y Y Y Y Y N
third parties
09.01.11 Negligent, improper use of the PPE Y Y Y Y Y Y Y
09.01.12 Repetitive/monotonous actions
(tiring/negligence)
09.01.13 Stressful, unhealthy body posture (disturbance
of the body movement pattern)
09.01.14 Poor visibility of the operator

09.02. Causes of hazards through climatic ArbStättV

factors
09.02.01 Air/room temperature (discomfort/irritation of the
respiratory tract/draft)
09.02.02 Excessive/insufficient relative air humidity
09.02.03 Air change at the work place (ventilation)
09.02.04 Insufficient/excessive air speed (draft)
09.02.05 Heat radiation

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-9
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

10. Hazard emanating from the surroundings at the

place of use/work place
10.01.01 Dust/mist/darkness (poor visibility)
10.01.02 Electro-magnetic interference
10.01.03 Lightning strike
10.01.04 Humidity/moisture
10.01.05 Soiling/contamination (solid or liquid substances)
10.01.06 Ice and snow
10.01.08 Wind
10.01.09 Lack of oxygen

11. Hazard combinations ISO 12100-1, 4.11

12. Malfunction of the machine BGV A1

12.01.01 Poor attention of the operator when co-working
on the shopfloor
12.01.02 Incorrect assembly/installation of the machine/ N Y Y Y N N N MRL, Annex I, 1.5.4,
the tools
12.01.03 Operating errors due to insufficient communication N Y Y Y Y Y N
(insufficient instruction of the operator) and wrong
selection of tools/materials/operating parameters/
consumables and lubricants
12.01.04 Operating errors due to insufficient capability N Y Y Y Y Y N
lack of human characteristics
12.01.05 Software errors
12.01.06 Unexpected, automatic machine start N N Y Y Y Y N ISO 14118
12.01.07 Unexpected, automatic change of N N Y Y Y Y N
velocity/speed
12.01.08 Movement of a component/tool beyond
its stop position (overrun), brake failure
12.01.09 Failure/malfunction of the control/regulating systems N N N Y Y Y N EN 954/ISO 13849
12.01.10 Power failure N N N Y N N N
12.01.11 Sudden reinstatement of the power supply N N N Y N N N

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-10
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

12.01.12 Insufficient mechanical stability, breakage of N Y Y Y Y Y N

components due to overload

13. Hazard emanating from moving machinery

13.01.01 Machine rolling off (poor standstill
security)
13.01.02 Movement directly after engine start
13.01.03 Movement without the operator being in
the driver’s seat
13.01.04 Movement with loose objects on/in the
machine
13.01.05 Excessive speed of a pedestrian-type
machine
13.01.06 Insufficient possibility to shut-down/switch off
the pedestrian-type machine
13.01.07 Mechanical hazard by coming into contact with the
wheels or even being run over
13.01.08 Fall when approaching/leaving the work place
13.01.09 Collision/movement against a fixed obstacle
13.01.10 Incorrect loading/overload
13.01.11 Unexpected movement of the load, incorrect load
security/incorrect strapping means
13.01.12 Vibration/oscillation due to insufficient seats
13.01.13 High noise emission at the work place N N Y Y Y Y N RL 2000/14/EC
13.01.14 Exhaust gas/lack of oxygen at the work place
13.01.15 Dust emission at the work place
13.01.16 Placement/drive errors due to steep slops and
Transverse drivinig on a slope

14. Influences from the energy source/transmission

14.01.01 Hazard emanating from the combustion engine N N Y Y Y Y N
14.01.02 Hazard emanating from the hydraulic/pneumatic N N Y Y Y Y N
motor

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-11
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Hazard analysis

Table 9.I: Hazard analysis acc. to DIN EN ISO 14,121-1

Pos. Partial hazard, hazard situation Life cycle1)2) Normative

Hazard event Operating mode Protection target3),
others A B C D E F G Specifications

14.01.03 Hazard emanating from batteries N N Y Y Y Y N

14.01.04 Mechanical energy transmission through the clutch/
universal shaft
14.01.05 Energy transmission through the V-belt/chain drive N N Y Y Y Y N

15. Hazard emanating from transport/lifting action

15.01.01 Objects on traffic ways ArbStättV
15.01.02 Use of loading bridges/ramps/access planks
15.01.03 Missing optical/acoustic warning devices
15.01.04 Falling loads (loose objects)
15.01.05 Improper attachment of the machine to Y N N N N N Y BGV D6
lifting gear
15.01.06 Unsuitable attachment/load bearing means or Y N N N N N Y
means with insufficient load bearing capacity
15.01.07 Overload, representing a hazard for lifting gear, MRL, AnnexI, para.4
attachment and load bearing means
15.01.08 Exceeding the pivotal moment (lack of stability) MRL, Annex I,
e.g. when lifted with fork lift trucks, possibly para. 4.1.2.1
with forks that are too short
15.01.09 Uncontrolled movement of the load/machine DIN 75410, BGI 649,
poor strapping on the transport vehicle VDI 2700/01/02
15.01.10 Rope/cable running off the rolls/drums/
sheaves of the lifting devices/winches
15.01.11 Cable breakage/rope rupture with whipping ends N N Y Y Y Y N MRL, Annex I,
para. 1.4

1) A-Transport/storage operation G-Decommissioning/ 3) EN 12100-1, 4.2, means:

B- Assembly/installation E- Cleaning/maintenance dismantling DIN EN ISO 12100,
C-Set-up/Make-ready (Service) 2) Y = yes, applicable Part 1, Section 4.2 etc.
D-Commissioning/ F-Troubleshooting N = no, not applicable

9.I-12
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Factors for risk assessment acc. to DIN EN ISO 14121-2 Risk index
RI - 1-2 requires no further measures to be taken,
Extent of the damage - 3-4 requires measures to minimise the risk,
S1 - minor/reversible injury - 5-6 requires immediate measures to minimise the risk.
S2 - severe/irreversible injury
Principle - measures taken to minimise the risk

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98

Duration of stay in the hazardous area; exposure T - technical, mostly design-related measures

KOLLER Maschinen- und Anlagenbau GmbH

F1 - rarely to often; twice/shift or less, total time of exposure 15 min/shift O - organisational protection measures
F2 - frequently to permanently; more often than twice/shift or longer than P - personal measures, mostly by operator qualification/training.
15 min/shift

Bruchkampweg 5 • D-29227 Celle

Probability of the occurrence of a hazard
O1 - well-engineered technology, proven, known safety application,
stable/sturdy construction
O2 - one (1) technical fault in the last two years,
- a.o. caused by improper action of a trained/instructed person who
was informed about the hazards and had more than six months of
experience with the machine.
O3 - technical faults on a regular basis, one (1) fault in six months or less,
- a.o. caused by improper action of an untrained/non-instructed RI
person having less than six months experience with the machine. S1, F1, F2 O1, O2 A1, A2
1
- event of a similar nature occurred on the machine in the last 10 reversible O3
years. A1, A2
2
Start O1
A1
Possibility to minimise the hazard F1, O2 A2
3
selten
A1 - possible under certain conditions O3
A1

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
- if components move at a speed of < 0.25 m/s and if the operator S2, A2
4
knows about the risks and the indicators of a hazardous situation irreversible O1
A1
or recognises the occurrence of an impending hazard, F2, O2 A2
5
häufig O3
- depending on various conditions (temperature, pressure, noise A1
emission, ergonomics, etc.) A2
6
A2 - not possible!

Figure 9.II-1: Risk graphic to determine the risk index (RI) acc. to DIN
9.II-1

EN ISO 14121-2
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

01.01-Mechanical
hazard

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001 A-G 01.01.00 2 1 2 1 2 O-P Use/wearing of PPE, e.g. eye protection/ 2 1 1 1 2 No

KOLLER Maschinen- und Anlagenbau GmbH

face mask, hearing protection, protection
gloves,hard hat, protection shoes, regular
training of the operator

Bruchkampweg 5 • D-29227 Celle

002 D 01.01.00 1 1 1 1 1 O Hazard information (BGV A8) about 1 1 1 1 1 No
mechanicalhazards at the machine,
instruction of the operator
003 A-G 01.01.01 1 1 1 1 1 T Design-related avoidance of sharp 1 1 1 1 1 No
points/corners/edges
004 A-G 01.01.02 1 1 1 1 1 T Design-related avoidance of protruding 1 1 1 1 1 No
parts, cladding/covering of
abrasion points
005 C-F 01.01.05/06 1 1 1 2 1 O-P Cladding of rotating/moving components, 1 1 1 1 1 No
use/wearing of PPE, among others due to
risk of pinching/crushing, maintenance only
by expert personnel, instruction of the
operator
006 B-G 01.01.12 2 1 2 1 2 T-O Avoidance of components bursting due to 2 1 1 1 2 No
selection of materials, increased safety
factors for the calculation of strength/

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
stability, no access to the winch cab during
operation, instruction of the operator
007 B,C,F 01.01.13 2 1 2 2 3 O-P Work on engine/winch only when it is at a 2 1 1 1 2 No
standstill, instruction of the operator
008 A-G 01.01.15 2 1 1 1 1 T Design-related guidelines in accordance 1 1 1 1 1 No
with valid standards and long-time
experience avoid insufficient mechanical
9.II-2

stability/sturdiness
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

01.02 Stored potential/kinetic

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energy

KOLLER Maschinen- und Anlagenbau GmbH

010 C,D,F 01.02.03/04 2 1 1 1 1 T Pneumatic/hydraulic system meeting 2 1 1 1 1 No
the standards with safety equipment, such as
pressure relief valves (safety valves) etc.

Bruchkampweg 5 • D-29227 Celle

011 C,D,F 01.02.05 1 1 1 1 1 T-O Identification of containers/reservoirs, 1 1 1 1 1 No
pipes/lines Hazard warning signs in acc.
with BGV A8, instruction of the operator

01.03 Hydraulic fluid/compressed

air systems
020 C-F 01.03.01 1 1 1 1 1 T Work only by expert personnel trained and 1 1 1 1 1 No
qualified in pneumatics/hydraulics,
instruction of the operator
021 C-F 01.03.03/06/09 1 1 1 1 1 T-O Covering of exposed line sections, 1 1 1 1 1 No
wearing/use of PPE, instruction of the
operator
022 C-F 01.03.07 1 1 1 2 2 O-P Wearing/use of PPE, regular maintenance 1 1 1 1 2 No
and timely hose replacement by
expert personnel trained in hydraulics,
instruction of the operator

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
023 C-F 01.03.12 1 1 1 1 1 T Use of tested, certified 1 1 1 1 1 No
components/equipment
024 D-F 01.03.13 1 1 1 1 1 O-P Instruction of the operator 1 1 1 1 1 No

01.04 Falling
030 B-G 01.04.01/02/03 2 1 2 1 2 O-P Regular cleaning of the steps and treads, 2 1 1 1 1 No
instruction of the operator
9.II-3
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

02.01 Electrical
hazard

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98

040 D 02.01.00 1 1 1 1 1 O Hazard information (BGV A8) about 1 1 1 1 1 No

KOLLER Maschinen- und Anlagenbau GmbH

electrical hazards at the machine, instruction
of the operator
041 D-E 02.01.01/03/04/06 1 1 2 1 1 T-O Protection against contact with live 1 1 1 1 1 No

Bruchkampweg 5 • D-29227 Celle

electrical components by insulation, at least
IP 54, work on electrical equipment
exclusively by qualified electricians
042 C-E 02.01.00 2 1 2 1 2 T-O EMERGENCY STOP buttons for isolating 2 1 1 1 2 No
from energy (power) supply
043 E 02.01.00 1 1 1 1 1 O Regular inspection of the electrical 1 1 1 1 1 No
devices/equipment (BGV A3)

02.02 Electro-static
occurrences
050 C-F 02.02.01 2 1 1 1 1 T Equipotential bonding cables between 1 1 1 1 1 No
the devices, machines and frames/
containers, grounding of the unit, regular
checks of the leakage resistance

03.01 Hazardous substances

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
See No. 08. ...

04.01-Thermal
hazards
060 C-G 04.01.02 2 1 2 2 3 T-O-P Cladding of hot components, use/wearing 2 1 2 1 2 No
of PPE, instruction of the operator,
hazard information on the unit to
prevent burns
9.II-4
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

061 E-F 04.01.05/07 1 1 1 1 1 O-P Use/wearing of PPE, trained and qualified 1 1 1 1 1 No

maintenance personnel, information in the

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98

operating manual to avoid scalding

KOLLER Maschinen- und Anlagenbau GmbH

05.01 Sound emission/
noise

Bruchkampweg 5 • D-29227 Celle

070 D-F 05.01.00 1 2 1 2 1 T-O-P Sound insulation of the container, 1 2 1 2 1 No
Use/wearing of PPE, hearing protection is
mandatory, instruction of the operator
071 C,D,F 05.01.05 1 1 1 1 1 T-O Noise insulated machines, 1 1 1 1 1 No
additional insulation/damping measures
072 C-F 05.01.00 1 2 1 1 1 O Hazard information/signs (BGV A8) 1 1 1 1 1 No
is/are provided on the unit/in the control
room

06.01 Vibration/
oscillation
-/-

07.01 UV, IR,

laser radiation
-/-

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
03.01 Hazardous substances
080 D-F 08.01.07/08/09/10 1 2 1 2 1 T-O-P Wearing/use of PPE mandatory, 1 2 1 2 1 No
instruction of the operator
081 D-F 08.01.18 1 1 1 1 1 T-O Anti-corrosive agent for metallic materials,
timely replacement of plastic
components due to aging, instruction of the operator
9.II-5
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

082 A-G 08.01.00 1 2 1 1 1 O Hazard information/signs (BGV A8) regarding1 2 1 1 1 No

hazardous materials are provided on the unit

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98

KOLLER Maschinen- und Anlagenbau GmbH

09.01 Ergonomics,
workplace
090 C-F 09.01.05 1 1 1 1 1 T Light intensity at the workplace according to 1 1 1 1 1 No

Bruchkampweg 5 • D-29227 Celle

ASR 7/3, instruction of the operator
091 B-D 09.01.06/07 2 1 2 1 2 T-O-P Avoidance of operating errors by 2 1 1 1 2 No
F qualification, EMERGENCY STOP buttons
for immediate shut-down, instruction of the
operator
092 B-G 09.01.09 2 1 2 1 2 T-O Exclusion of human errors/ 2 1 1 1 2 No
faulty operation by monitoring,
qualification and repeated
training of the operator
093 B-F 09.01.10 2 1 1 1 2 T-O Work area cordoned off for unauthorized 2 1 1 1 2 No
persons, permanent monitoring,
EMERGENCY STOP buttons causing
shut-down in the event of the approach or
unauthorized/erroneous switching by
unauthorized persons, instruction of the
operator

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
094 A-G 09.01.11 2 1 1 1 2 O-P Due to negligent handling of the PPE, 2 1 1 1 2 No
frequent checks by supervisors,
repeated training of the operator

09.02 Climatic factors

100 B-F 09.02.01 1 1 1 1 1 T-O Control room air conditioned, instruction 1 1 1 1 1 No
of the operator
9.II-6
 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

10.01 Conditions at place of use/

work site conditions

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-/-

KOLLER Maschinen- und Anlagenbau GmbH

10.01 Hazard
combinations

Bruchkampweg 5 • D-29227 Celle

-/-

12.01 Malfunction of the

machine
110 B-D 12.01.02 1 1 2 1 1 O Visual inspection of the installation/ 1 1 1 1 1 No
connection prior to starting up by an expert,
will avoid assembly/installation mistakes
111 B-F 12.01.03/04 2 1 2 1 2 O-P Detailed instruction and regular 2 1 1 1 2 No
repetition of operator training
will avoid operating mistakes
112 C-F 12.01.06/07 1 1 2 1 1 T-O Control system concept avoids automatic 1 1 1 1 1 No
start-up, safe shut-down of the unit
by operating elements in their OFF position,
instruction of the operator
113 C-F 12.01.08 1 1 1 1 1 T-O-P Braking during operation by reversing the 1 1 1 1 1 No
moving direction of the winches,

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
EMERGENCY STOP buttons, instruction
of the operator
114 D 12.01.09/10/11 1 1 1 1 1 T Control concept with forced 1 1 1 1 1 No
SHUT-DOWN, see risk analysis according
to EN 954 (EN 13849)
115 B-F 12.01.12 2 1 1 1 2 O Prevention of breakage by appropriate 2 1 1 1 2 No
stress-resistant dimensioning/
9.II-7

high-quality materials/high calculated safety

 Table 9.II: Risk assessment acc. to DIN EN ISO 14 121-2
Risk Measures to minimise the risk Risk Further
Ref. Life Hazard (Table 9.I) BEFORE AFTER mea-
No. cycle Pos. S F O A RI Principle Description S F O A RI sures

factors/many years of experience

Tel. +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98

13.01 Mobile machines

KOLLER Maschinen- und Anlagenbau GmbH

120 B-F 13.01.01 1 1 1 1 1 T Chocks/wheel chocks prevent 1 1 1 1 1 No
truck from rolling out of position, instruction
of the operator

Bruchkampweg 5 • D-29227 Celle

121 D-F 13.01.13 1 1 1 1 1 T-O Insulation of the container, wearing/use of 1 1 1 1 1 No
PPE, instruction of the operator

14.01 Energy source/

energy transfer
130 D-F 14.01.01/02 1 1 1 1 1 O-P Wearing/use of PPE, instruction of the 1 1 1 1 1 No
operator
131 E-F 14.01.03 1 1 1 1 1 O-P Battery maintenance only by qualified 1 1 1 1 1 No
electricians

15.01 Transport/
lifting action
140 A, G 15.01.05/06 2 1 2 1 2 O Attachment of the container to 2 1 2 1 2 No
lifting gear, only by qualified and trained
expert personnel (personnel with training
and experience in attachment work)

Tab. 9.II-Risk assessment

Wireline Combi Unit PP
Operating Manual
141 D 15.01.11 2 1 2 1 2 O Cordoning off/barriers around the hazardous 2 1 2 1 2 No
area (Fig. 2-1), wearing/use of PPE,
instruction of the operator
9.II-8
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

01. Protection against mechanical hazards MRL 2006/42/EC, Annex I,

Para. 1.3,
ISO 12100-1, 4.2,
ISO 12100-2, 4.2
01.01. Hazard emanating from shape/surface/movement/
Movement of components/tools
01.01.02 - Separating protection devices/guards (e.g. railings/protection X MRL, Annex I, para. 1.4,
01.01.04 fence/Fencing/cladding/security glass page/covering/ ISO 12100-1, para. 3.25.4,
01.01.05 cover) ISO 12100-1, 4.2,
01.01.06 ISO 12100-2, 5.3
15.01.11 EN 14120,
BGV A1, PSA-BV
01.01.02 - baffle-type protection devices/guards (e.g. hand guard) -- MRL, Annex I, para. 1.4
01.01.04
01.01.01 - location-bound protection device/guard (two-hand control) -- EN 13851
01.01.05
01.01.06
01.01.05 - capacitive protection devices/guards (e.g. through -- MRL, Annex I, para. 1.4
01.01.06 light grids/light barriers/initiators/ultra-sound)
01.01.06 - Protection devices/guards with safety switch --
01.01.01 - Cover/cladding as touch guard X EN 13852, EN 13853,
01.01.02 EN 13854
01.01.04
01.01.05
01.01.06
01.01.05 - Protection against moving/rotating components/tools X ISO 14120
01.01.00 - Hazard information on the machine X BGV A8
01.01.00 - Use of PPE: Eye/face protection, protection gloves, X PSA-BV, BGV A1,
protection shoes, hard hat EN 397
09.01.11 - regular instruction and control/checks by the superiors, X PSA-BV
no negligent use of the PPE
01.01.04 - safety distances met by the design X EN 13852, EN 13853,
01.01.05 EN 13854
01.01.06

1) also see Pos. in Table 9.I „Hazard 2) X = applicable, on the machine

16.06.2010

analysis“ acc. to DIN EN ISO existing/to be fitted by the

14121-1 customer
- = not applicable

9.III-1
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

01.01.09 - Control of the installation surface regarding lacking stability, X ISO 12100-2, 4.6/5.2.6
(load bearing ground/foundations/steel structure), risk
of tipping of the machine, control by an expert
01.01.07 - Protection device/guard against moving components X MRL, Annex I, para. 1.3.7
01.01.11 - Protection devices/guards against rolling/gliding/reciprocating/ --
tilting materials/workpieces/tools
01.01.11 - Protection against rolling off machine by means of drag shoes --
01.01.12 - Protection devices/guards against falling/back-kicking/ -- MRL, Annex I, para. 1.3.3
detaching/bursting/flying components
01.01.12 - Collectors/baffles for ejected/ --
bursting/flying components
01.01.15 - default design parameters to prevent insufficient strength, X MRL, Annex I, para. 1.3.2
Calculation in accordance with the valid standards/long-time ISO 12100-2, 4.3
experience

01.02. Hazard from stored energy

01.02.02 - Protection devices/guards for safe reduction of --
01.02.03 stored energy
01.02.04
01.02.05
01.02.00 - default design parameters for pressure vessels/pressure X RL 87/404/EEC,
devices (fluids/gases under high pressure): Design according to 6. GPSGV,
valid standards (high nominal pressure levels)/long-term RL 97/23/EC, 14. GPSGV
experience/meets the security requirements of the pressure EN 13445-3,
vessel directive, BetrSichV

01.03. Hazard emanating from pressurized fluid/air pressure MRL, Annex I, para. 1.5.3
system (hydraulics/pneumatics) ISO 4413, ISO 4414,
ISO 12100-2, 4.10
01.03.02 - Pressure relief valve X
01.03.04 - Lowering valve/pipe rupture valve --
01.03.00 - Lockable main valve for disconnection from the hydraulic / -- MRL, Annex I, para. 1.6.3,
pneumatic the energy (power) supply EN 14118
01.03.00 - Pipe/tube routing according to standards, hose lines without X DIN 24346
kinks, punches or chafing points

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-2
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

01.03.09 - Protection from whipping movement in the event of hose --

rupture
01.03.03 - Covering/cladding to protect from oil spurting out under X MRL, Annex. I, 1.3.2
high operating pressure, e.g. as a result of damage to
hose lines
01.03.00 - Hose line checked´, inspected at regular intervals and timely X ISO 17165
replaced (not overaged)
01.03.04 - Pressure monitoring with limit-value alarm/switch off in the --
event of pressure loss/pressure drop
01.03.00 - Drain valve with control pressure gauge for full -- ISO 4413, ISO 4414,
pressure/residual energy reduction in the hydraulic/pneumatic ISO 12100-2, 4.10,
systems during maintenance work EN 14118,
BGV A1, PSA-BV
01.03.00 - Pressure accumulator with relief valve and control pressure -- EN 14359
gauge for full pressure reduction
01.03.00 - Temperature monitoring through indicator (thermometer) X
01.03.00 - Temperature monitoring with limit-value alarm/switch off, --
e.g. in the event of additional energy input (circulation of small
fluid volumes through return flow/bypass, e.g. in the hydraulic
circuit)
01.03.00 - Oil level inspection glass, manual monitoring X
01.03.00 - Oil level inspection glass with limit-value alarm/switch off in --
the event of oil shortage
01.03.00 - Protection against material/personal damage caused by fluid -- EN 60335-2-79,
jet devices (high pressure cleaners) BGV A1, BGR 500

01.04. Falling on the floor/falling from an overhead position MRL, Annex I, para. 1.5.15,
BGV A8
01.04.01 - stable/trip-free working surface/transport ways X BGI 643, ArbStättV
01.04.00 - Clean/slip-free working/installation surface (grid X BGV A1
surface and similar)
01.04.00 - Free range of movement around the machine > 1.0 m --
01.04.00 - Movement area > 1.5 m2 --
01.04.03 - stable work scaffolding -- BGV A1, DIN 4420

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-3
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

01.04.00 - Railings as side protection X ISO 14122-3

01.04.03 - ladders, stairs, treads meeting safety regulations X EN 131-1, BGV D36
ISO 14122-3
01.04.04 - guards protecting from falling/harness/safety belt/ -- ArbStättV, ASR 12/1-3,
safety harness for overhead work BGR 198
01.04.04 - access ladder with back protection --
01.04.06 - safe covering of openings/cavities in the floor --

02. Protection against electrical hazards MRL, Annex I, para.1.5.1,

ISO 12100-2, 4.9,
EN 60204-1, EN 60335
02.01.00 - Work at electrical devices/equipment exclusively by X BGV A3
qualified electricians
02.01.01 - Basic protection: against direct contact with live X
components (insulation, cover/cladding, safe distance)
02.01.00 - lockable main switch/mains circuit breaker, for isolation X MRL, Annex I, para. 1.6.3,
of the energy supply ISO 14118
02.01.00 - EMERGENCY STOP device, for all-pole disconnection from X MRL, Annex I, para. 1.6.3,
the energy supply/for shutting down combustion EN 13850, EN 60204
engines
02.01.00 - Maintenance/repair switch for all-pole isolation -- EN 60204
from the energy supply
02.01.00 - Error protection: Protection against indirect contact X
02.01.00 - Leakage current protection device --
02.01.00 - regular checks of the electrical devices/equipment X BGV A3
02.01.00 - Hazard information on the machine X BGV A8

02.02. Electrostatic occurrences

02.02.01 - Protection against electro-static charge (conductive items X MRL, Annex I, para. 1.5.2
of equipment interconnected), e.g. grounding/potential EN 60204, BGV A1,
equalisation BGR 104, BGR 132,
EN 60079-14

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-4
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

02.02.01 - Leakage resistance < 106 Ohm, tested X TRBS 2153,

EN 60079-14

02.03. Electro-magnetic occurrences

02.03.00 - Protection against electro-magnetic interference of other -- EMC-RL 2004/108/EC
equipment by electrical equipment
02.03.00 - Hazard zones with electro-magnetic fields to be -- VDE 0848
identified (e.g. high-voltage installations, very high
magnetic flow density, high frequency fields)
02.03.00 - Access to a hazard area with electro-magnetic fields forbidden --
for unauthorized persons, customer-supplied fencing
02.03.00 - Hazard information „No access“ for persons wearing -- RL 2004/40/EC
pacemakers

03. Hazardous materials, see Pos. 08!

04. Protection against thermal hazards MRL, Annex I, para. 1.5.5,

ISO 12100-1, 4.4,
DIN 33403, BGV A1,
BGI 579
04.01.02 - separating protection device/guard to prevent contact with hot/ X MRL, Annex I, para. 1.5.5,
(extremely) cold surfaces/components EN 563/EN 13732-1,
EN 14120, BGV A8
04.01.00 - Use of PPE: Eye/face protection, protection gloves X PSA-BV
(where applicable, also for work in the heat/cold)
04.01.00 - Hazard information on the machine X BGV A8
04.01.03 - Temperature monitoring with limit-value alarm/switch off, --
e.g. in the event of additional energy input (circulation of small
fluid volumes through return flow/bypass, e.g. in the hydraulic
circuit)

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-5
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

05. Protection against sound emission/noise MRL, Annex I, para. 1.5.8

and 1.7.4.2 u,
RL“Noise“ 2003/10/EC,
ISO 12100-1, 4.5,
ISO 12100-2, 5.4.2,
BGV B3, ArbStättV
VDI 2058, BGI 675
05.01.00 - Emission sound pressure level LpA < 70 dB (A) -- ISO 3744
05.01.00 - Sound power level LWA for machines operating -- RL 2000/14/EC, 9. GPSGV
outdoors < limit values according to directive
05.01.00 - PPE: Hearing protection X
05.01.05 - Sound insulation around the operating/control stand X
05.01.00 - Hazard information on the machine X BGV A8

05.01.00 - Protection devices/guards/screening due to ultra-sound --

05.01.00 - encapsulated/screen ultra-sound source --
05.01.00 - Use/wearing of special PPE, hearing protection suitable for --
ultra-sound

06. Protection against vibration/oscillation MRL, Annex I, para. 1.5.9,

RL 2002/44/EEC,
ISO 12100-2, 5.4.3
06.01.00 - Whole-body vibration: Exposure limit value A(8) < 5 m/s2 -- VDI 2057
Trigger value A(8) < 2,5 m/s2 --
06.01.09 - Hand-arm vibration: Exposure limit value A(8) < 1.15 m/s2 -- VDI 2057
Trigger value A(8) < 0.5 m/s2 --
06.00.06 - vibration reduced seats (whole-body vibration) -- VDI 2057
06.01.00 - vibration reduced operating means/tools --
06.01.00 - handles with damping/cushioning --
06.01.00 - Hazard information on the machine -- BGV A8

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-6
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

07. Protection against UV, IR and laser radiation MRL, Annex I, Para. 1.5.10
07.00.00 - Protection devices/guards/screening to protect against UV --
radiation
07.01.00 - Eye protection against UV radiation -- EN 170
07.01.00 - Eye and heat protection against strong IR radiation -- EN 171
07.01.00 - Laser systems, class 1-4, marked -- BGI 832
07.01.00 - Protection devices/guards/screening to protect from laser -- MRL, Annex I, para. 1.5.12,
radiation EN 207, EN 60825-1
07.01.00 - Danger information on the machine regarding UV, IR or -- BGV A8
laser radiation

08. Protection against dangerous materials/substances MRL, Annex I, para. 1.5.13

(hazardous substances)
08.01.00 - Safety data sheets existing at the machine X RL 2006/1907/EC
(RL 91/155/EEC)
08.01.00 - Hazard information on the machine X BGV A8
08.01.00 - PPE: Eye/face protection X PSA-BV, BGV A1,
BGR 192, EN 166
08.01.03 - PPE: Respiratory protection -- 8.GPSGV,
PSA-BV, BGV A1,
BGR 190,
RL 2004/37/EC
08.01.01 - PPE: Protective gloves X PSA-BV
08.01.08 - PPE to protect against consumables, such as transmission/ X PSA-BV, BGR 137
hydraulic oil/diesel oil, and similar
08.01.00 - Protection against the risk of fire -- MRL, Annex I, para. 1.5.6
ArbStättV, BGV A1,
BGR 133, ASR 12/1.2,
EN 13478
08.01.11 - Protection against the risk of fire/explosion (combustible gases, -- BetrSichV, 11. GPSGV,
vapors, mist) RL 94/9/EC, EN 1127-1,
EN 13463, EN 60079,
BGR 104, EN 13478,
MRL, Annex I, para. 1.5.7

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-7
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

08.01.12 - Protection against dust fires and explosions -- VDI 2263

08.01.00 - No smoking! Naked flame forbidden due to the risk of fire/ X BGV A8
explosion
08.01.00 - Protection against coolant lubricants (KSS) -- GefStoffV, BGR 143,
TRGS 611
08.01.16 - PPE to protect against cleaning agents/solvent or other -- RL 2006/1907/EC
chemical substances GefStoffV, BGI 546
BGV A1, BGR 180,
PSA-BV
08.01.06 - Protection against carcinogenic substances -- TRGS 905
08.01.14 - Protection against mineral fibers (fiber dust, WHO fibers) -- GefStoffV, BGR 190,
TRGS 521, VDI 3469,
BGI 505-31
08.01.18 - Protection of metallic materials against corrosion (anti- X
corrosion oil/grease, surface coating, etc.)
08.01.18 - Replacement of elastomers/plastics on time due to X
ageing (e.g. replacement of hydraulic hose lines)

09. Protection against neglecting basic ergonomic principles GPSG, ArbStättV, BGV A1,
or neglecting the influences emanating from the MRL, Annex I, para. 1.1.6
work environment, or caused by third-parties EN 13861, ISO 10075,
ISO 12100-2, 4.8
09.01.02 - optical transducers (signal/warning light) are noticeable --
and understandable
09.01.00 - acoustic transducers (horn) are noticeable and understandable --
09.01.00 - Information elements grouped according to function/meaning --
09.01.03 - Operating/control elements marked, assigned, switching X MRL, Annex I, para. 1.2.3
purpose and switching sequences for starting up/shutting and 1.2.4
down are clear
09.01.05 - local lighting/machine lighting is sufficient X MRL, Annex I, para. 1.1.4,
ASR 7/3
09.01.07 - qualification/instruction/training of the operators is sufficient X BGV A1
09.01.08 - Use of lifting gear for loads > 25 kg --

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-8
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

09.01.06 - mental overload/underload: Operation/control only after X ISO 10075-1

instruction/training
09.01.09 - human misbehaviour: Operation/control only after instruction/ X
training
09.01.09 - human misbehaviour: permanent monitoring --
critical parameter with compulsory shut-down/
switch-off

09.02. Climatic factors at the work place ArbStättV, BGR 121,

BGI 579, DIN 33403
09.02.00 - working climate meeting the standard, ensured by an air --
handling unit

10. Protection against the influences at the place of use/

work place
10.01.00 - Protection against lighting through grounding -- MRL, Annex I, para. 1.5.16
10.01.00 - Addition of anti-freeze in the cooling water circuits X
10.01.06 - Protection against the risk of slipping on ice and snow by --
removal

11. Hazard combinations ISO 12100-1, 4.11

12. Protection against machine malfunction

12.01.02 - Protection against faulty assembly/installation through X MRL, Annex I, para. 1.5.4
inspection by an expert prior to starting up
12.01.00 - EMERGENCY STOP switching system X ISO 12100-2, 5.5.2
ISO 13850, EN 60204-1
12.01.00 - forced safe operating condition following a control error --
12.01.00 - forcible shut-down after an interruption of -- MRL, Annex I, para. 1.2.6
the energy (power) supply
12.01.00 - No spontaneous restart following the failure and reinstatement -- ISO 12100-2, 4.11.4
of the energy supply

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-9
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

12.01.00 - No spontaneous restart following the actuation of the X ISO 12100-2, 4.11.4
EMERGENCY STOP device
12.01.04 - operating errors: Operation/control only after instruction/ X ArbSchG, BetrSichV
training
12.01.00 - operating errors: permanent monitoring of critical --
parameters with compulsory shut-down/switch-off
12.01.07 - unexpected start-up/unauthorized switching: safe -- ISO 14118, EN 60204
shut-down by lockable main switch / circuit breaker
12.01.10 - Power failure -- ISO 12100-2, 4.11.5
12.01.00 - Hazard information on the machine X BGV A8
12.01.12 - Protection against insufficient strength by the selection X MRL, Annex I, para. 1.1.3
of suitable materials, also with regard to corrosion and 4.1.2.3
abrasion, stress, temperature, fatigue

13. Protection against hazards emanating from the

mobile machine
13.01.01 - rolling off of the (shut-down) machine secured using -- BGV A1
drag shoes/rig pin
13.01.04 - loose/falling objects on to/into the machine -- MRL, Annex I, para. 3.4.4
13.01.03 - Automatic start/movement (without operator) and -- MRL, Annex I, para. 3.3.2
stopping/brakes and 3.3.3
13.01.05 - Movement of pedestrian-type machines -- MRL, Annex I, para. 3.3.4
13.01.07 - Protection against rolling over/tipping -- MRL, Annex I, para. 3.4.3
13.01.00 - PPE, protection gloves, eye and respiratory protection against X
coolant vapors when topping up engine coolant
13.01.00 - PPE, protection gloves, eye and respiratory protection against X
high surface temperatures, splashes/vapors when topping up
engine/hydraulic oil
13.01.00 - Protection against the risk of fire (fire extinguishers) -- MRL, Annex I, para. 1.5.6
and 3.5.2
13.01.00 - Hazard information on the machine X BGV A8
13.01.00 - Hazard information on the machine „Do not start in closed X BGV A8
rooms“

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-10
 KOLLER Maschinen- und Anlagenbau GmbH Operating manual
Bruchkampweg 5 • D-29227 Celle Wireline Combi Unit PP
Phone +49 (0) 51 41 / 98 98-0 • Fax +49 (0) 51 41 / 98 98 98 Tab. 9.I-Protection device

Table 9.III: Protection/safety devices/guards at the machine (MRL, Annex VII)

Pos. 1) Protection and safety devices/guards Normative protection

target
Directives,
X2) standard part, section

14. Protection against hazards emanating from the

energy source/energy transfer
14.01.05 - Coupling/universal shaft/V-belt/roller chain protection hood as X
cladding
14.01.03 - Security of the battery X MRL, Annex I, para. 3.5.1

15. Protection against hazard emanating from transport/ BGV D6, BGV D8
lifting action ArbStättV, BGV A1
15.01.01 - Traffic ways cleared, passages sufficiently --
dimensioned
15.01.02 - use of loading bridges/drive-on ramps -- BGR 500, BGR 233,
ASR 17/1.2, EN 1398
15.01.07 - load bearing capacity of lifting gear and attachment/load X MRL, Annex I, para. 4.1.2.5
suspension means, always > load and 4.3.2, DIN 15002
15.01.00 - monitoring/inspection of the load suspension means X BGR 500, DIN 15429
15.01.00 - attachment points for lifting/transporting on the machine/ X
equipment/container
15.01.00 - strapping points on the machine, for strapping on trucks -- EN 12195
15.01.08 - protection for transport on fork lift trucks -- 5. GPSGV, BetrSichV,
BGV D27
15.01.08 - fork shoes for transport by fork lift truck -- BGV D27
15.01.08 - Tilt security: the center of gravity of the load is reliably above --
the sufficient long forks
15.01.00 - Twist-lock for container security on the transport vehicle/ X EN 284
steel structure
15.01.00 - protection device/guard for the use of winches, -- 9. GPSGV, BetrSichV,
lift/towing equipment BGV D8
15.01.10 - protection device/guard against ropes/cables running off -- MRL, Annex I, para. 4.1.2.4
sheaves, drums and pulleys
15.01.11 - Protection against whipping movement in the event of rope/ --
cable rupture (e.g. through ample fence spacing around the
work area, including no entry sign)

1) also see Pos. in Table 9.I „Hazard 2) x = applicable, on the machine

analysis“ acc. to DIN EN ISO existing/to be fitted by the
14121-1 customer
- = not applicable

9.III-11