1603 Baker Hughes 270 Interactive

Baker Hughes 270 Tandem Axle Fullback Truck
SYNERGY INDUSTRIES LP
SYNERGY INDUSTRIES LP
Operations and Maintenance Manual
May 29, 2014
1
Synergy Industries
12963 Oak Grove Rd. South
Burleson, Texas 76028
[email protected]
817-295-1161 phone
Operations and Maintenance Manual
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[email protected]
817-295-1161 phone
Table of Contents
Contents
1.0 Scope 6
2.0 Safety 6
3.0 General Specifications 6
3.1 Truck Chassis and Engine Specifications 6
3.2 Logging Cabin Specifications 7
3.3 Hydraulic System 7
3.4 Electrical System 8
3.5 Pneumatic System 8
3.6 Overhead Spooler 8
3.7 Benchmark Panel 8
4.0 Starting the Unit 8
4.1 After-Start Checks 9
4.2 Overhead Spooler Setup 9
5.0 Hydraulic System Settings and Operations 10
5.1 Hydraulic Generator Settings and Operations 10
6.0 Electrical Distribution System 11
7.0 Line Oiler Operations 12

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Table of Contents
8.0 Stopping the Unit 12
8.1 Normal Stop Procedure 12
8.2 Emergency Stop Procedure 13
9.0 Drum Information 13
10.0 Cable Spooling Operation 13
11.0 Operational Check and Unit Test Procedures 14
11.1 Start Engine and Check Operation Checks 14
11.2 Hydraulic System - Drum Drive Checks 14
11.3 Hydraulic System Generator 14
11.4 Hydraulic Fluid Level 15
11.5 Hydraulic Hoses 15
11.6 Filters 15
11.7 Overhead Spooling System 15
12.0 Unit Maintenance 16
12.1 Pre-Departure Checks 16
12.2 Daily Maintenance 16
12.3 After Job Maintenance 17
12.4 General Maintenance Intervals 21
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Table of Contents
13.0 Unit Maintenance 22
13.3 Annual Maintenance 23
13.4 Level 1 Preventative Maintenance and Inspection 400 Hr Inspection Sheet 24
13.5 Preventative Maintenance Inspection Guide 400 Hr PM Inspection 26
13.6 Preventative Maintenance Inspection Annual Inspection 32
13.7 Preventative Maintenance Inspection Guide Annual Inspection 34
13.8 Preventative Mainenance Inspection Report 37
14.0 270 Tandem axle full back diagram 39
15.0 Replacement 40
16.0 Images 41
16.1 Interior Electrical 42
16.2 Interior body 86
16.3 Interior lights 100
16.4 Chassis interior 103
16.5 Underbody 106
16.6 Exterior Body and Electric 119
16.7 Exterior Lights 165
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1.0 Scope
This document provides descriptive and operational information solely for the SYNERGY
unit(s) specified. All users should familiarize themselves with the content of this manual
prior to operating or performing maintenance on the specified unit(s).
2.0 Safety
Before engaging in the operations of the unit(s) specified in this document, all users should
read and familiarize themselves with the instructions in the following document. Failure to
do so could result in damage to equipment and/or increase the danger to personnel operat-
ing the equipment.
3.0 General Specifications
3.1 Truck Chassis and Engine Specifications
Chassis Make and Model
• Peterbuilt 367
Dimensions
• Height 12’ 10” (measured from ground to top of roof mount A/C units)
• Width 8’
• Length 56.6’
• Wheel Base 22.6’
• Cab to rear axles 23.6’
Note: For more details regarding the engine, please refer to the Chassis Specifica-
tions provided.
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3.2 Logging Cabin Specifications
Exterior
• Material: Aluminum
• Construction: CNC punched, riveted, welded base
• Insulation: 2” urethane foam, .250” plywood
• Entrance(s): Single door
Interior
• Material: Brushed anodized aluminum skin
• Console: Winch operator console with Benchmark, hoist controls, gauges
• Window: One large sliding window facing reel & frame assembly
Power Distribution Panel
Direct Lights: 12 VDC LED direct lights
Floodlights: 12Volt DC LED
Air Conditioners: Two (2); 13,500 BTU cooling and 5,600 BTU heating each
Intercom Hailer
Upperbody Curbside Tool Racks (with air bags)
• Top: Capable of holding five 2-3/4” diameter tools, max length 5-1/2’
• Lower: Each capable of holding three (3), 2.5” diameter tools, max length
11’
3.3 Hydraulic System
Below are general specifications for unit hydraulics:
• Main Hoist System drives the main drum and the 3-speed funk transmission.
• Main Pump Rexroth 90cc variable displacement pump
• Motor Rexroth 80cc variable displacement motor
• Electrical Hydraulic System piggyback to main
• Pump Rexroth 56cc variable displacement pump

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• Motor Rexroth 32cc fixed displacement
3.4 Electrical System
• Electric Generator 30Kw, hydraulic driven
• Power Dist. Panel 120 VAC
• House Power Inlet Located in curbside storage compartment
• Included Cables (2) Grounding, Intercom, Wellhead pressure
• Controller High Country Tech generator speed controller, number 69.40442
3.5 Pneumatic System
Air for the pneumatic syst`em is drawn from the truck auxillary system air tanks,
which are filled by an engine-mounted compressor. The rear of the truck is mounted
on an air suspension system to reduce shock to the instrumentation.
3.6 Overhead Spooler
The support arm, for the Benchmark 3K measuring head, up and down movement
is controlled by the mini air regulator increasing air volumne to the air cylinder. The
side-to-side mivement is controlled via a joystick using the hydraulic system charge
pressure.
3.7 Benchmark Panel
• Power 12 VDC operations
• Display Depth, Line Tension, Speed
4.0 Starting the Unit
Ensure the hydraulic pump control handle is in the neutral position
Check that the drum brake is in the ON position
Put truck gear in NEUTRAL, start engine
Engage clutch and PTO drive (Do not engage PTO without a minimum of 90 PSI)
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The unit can now be controlled from the hoist cabin
4.1 After-Start Checks
The hydraulic system pressure, hydraulic charge pressure, air pressure and hydraulic
temperature are viewed on the Beijer gauge mounted in the power distribution panel.
Charge pressure should run between 350-470 PSI. Check the hydraulic pump charge
pressure.
NOTE: If the control pressure is below 200 PSI, switch the diesel engine OFF and
check the following:
Hydraulic oil level; refill if necessary
Check for leaks
NOTE: If the control pressure remains low (below 200 PSI) or high (above 500 PSI)
when the diesel engine is running and after previous checks are made, consult
SYNERGY.
4.2 Overhead Spooler Setup
The regulator joystick is located under the operator’s console. To raise the overhead
spooler, rotate the regulator clockwise, to lower the overhead spooler rotate the reg-
ulator counter-clockwise. The lift cylinder is used to balance the overhead spooler. A
hydraulic joystick (located on the operator’s console) controls side-to-side movement.
Movement is achieved by use of a hydraulic cylinder that moves in and out, causing
the arm to move left and right. The main hydraulic system charge pressure pump
supplies the necessary pressure. The steps required to set up the spooling arm are
as follows:
• Remove measuring head from transport mount.
• Adjust spooling arm to a floating position by increasing the air pressure which
pumps pressure into the system to counterbalance the arm weight.
• Insert the wireline into the spooling head and replace the second pressure wheel
assembly. Insert the pins into the head to secure the system.
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• Spool wireline out to wellhead. When adequate cable tension allows, adjust air
pressure to allow the measuring head to float on the cable. Refer to Benchmark doc-
umentation for detailed information regarding the measuring head.
5.0 Hydraulic System Settings and Operations
The hydraulic system consists of two separate closed-loop systems powered by a set of
in-line pumps. One system powers the drum motor and a cylinder for the measure head
movement; the other provides power for the generator. Before operating the hydraulics, the
following system settings should be made:
The hoist system should be in the STATIC mode with the following settings:
• Drum Brake ON
• Motor control Low
• Pump control…………………………..…..Normal (Middle Position)
• The engine should be running at 960 (PTO re-gen friendly for Peterbuilt 365).
• Set the line tension control to a low setting by turning the handle counterclockwise. This
limits the pressure that the system will apply to the winch. This control is used in the moor-
ing system to regulate the spool in tension.
• Release the hand brake.
• Select LOW gear during rig-up; HIGH gear for going in the hole.
5.1 Hydraulic Generator Settings and Operations
The unit is equipped with a 30Kw electric generator driven by a hydraulic pump
and motor with an electric control circuit to increase or decrease hydraulic system
pressure depending on power requirements. It can easily power the entire logging
system and auxiliary devices. The truck engine drives the hydraulic pump through
a PTO mounted to the transmission. Check the cables that supply power to the unit.
The cables can be used to supply power from the unit or from the rig power if de-
sired. The two plugs should be labeled “system” and “utility.” Rig power should only
be used on the utility circuit.

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Before starting the generator:
• Check the power distribution box to make sure that the 12-volt breakers are ON, all
other breakers are OFF, and that the power shut down switch is OFF.
• Press the main generator START button to start up generator. It will take about 30
seconds for the delay to enable the generator to “ramp up.”
• Check the voltage and frequency for stable operation.
• Turn ON the desired breakers. Full power is now applied to the circuits selected
above.
• Turn ON air-conditioners, lights, rig lights, etc.
• During operation monitor voltage, frequency and load meters constantly.
REMINDER: WHEN TURNING AIR CONDITIONER OFF, WAIT 3-MINUTES BE-
FORE RESTARTING.
WARNING! Be careful not to engage the power shut down switch or the engine kill
button during logging operations except in EXTREME conditions. Shut down the
electrical system in reverse order.
WARNING! When in the well, the free wheel position should NEVER be used.
6.0 Electrical Distribution System
120-Volt AC System
• The electrical system supplies 120-volt AC power to the logging system. It consists of a
30-Kilowatt power generator that runs off a hydraulic pump driven by the truck engine and
PTO.
• The power is wired directly into two quick connect cables for the “system” and “utility” cir-
cuits in the generator compartment. The “system” line provides power to the system, and the
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“utility” line provides power to the auxiliary devices such as lights, air conditioners, etc. To
enable both circuits, the generator must be switched on and started.
12-Volt System
• The main truck batteries supply power for the 12-volt DC electrical system.
7.0 Line Oiler Operations
• The cable spraying or line oiling system uses a pressurized oil tank to apply lubrication
on the cable or wireline. A drip tray is located under the drum to catch excess lubricant that
runs off. A ball valve is to be used to drain the drip tray. Follow all applicable ordinances
and laws for disposal of the excess cable lubricant.
• Tank capacity is approximately 5.3 US Gallons. Follow the cable or wireline manufactur-
er’s recommendations regarding the frequency of cable lubrication to ensure maximum life
and performance of the cable or wireline. To spray lubricant on the cable position the valve
for the appropriate reel. Activate the oiler switch on the operator’s console.
NOTE: The oiler tank is set at 20-40 PSI. Shut off air supply ball valve and vent
pressure through the top vent BEFORE removing plug to fill with lubricant.
8.0 Stopping the Unit
8.1 Normal Stop Procedure
• After rigging down tools and shutting down the computer logging system, perform
the following procedures to cut power to the unit.
• Remove the wireline from the measure head and secure the spooling arm.
• Spool up excess wireline on drum
• Turn OFF all exterior lights (if applicable)
• Turn OFF air conditioners
• Turn OFF the 110-Volt breakers located in the Power Distribution Panel
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• Turn OFF the main power switch.
• Reduce engine speed.
• Turn OFF 12V breakers (this disables any drum movement and DC lights)
• Allow engine to idle down for three to five minutes.
• Turn OFF the 12-Volt breakers.
WARNING! It is very important to allow this idle down time in order to prevent dam-
age to the turbo.
8.2 Emergency Stop Procedure
Raise protective cover and move toggle switch up.
WARNING! BE CAREFUL NOT TO ENGAGE THE EMERGENCY STOP BUTTON
DURING LOGGING OPERATIONS EXCEPT IN EXTREME SITUATIONS.
9.0 Drum Information
This unit employs a 69.30029S-WLDL split 29 welded Lebus reel.
10.0 Cable Spooling Operation
* When operating the system in a tension-controlled mode, the line tension adjustment valve
serves to limit the amount of tension being applied to the cable. The line tension adjustment
valve controls the swash plate of the pump; if set pressure is reached, the pump will de-
stroke and stop pumping. It will, however, maintain system pressure. This will prevent the
system from overheating. The operator can use the regulator to stop the system and hold the
line in place as long as required.
* Procedures for implementing tension control during normal, logging-out-of-hole operations
are as follows:
• Set the Motor ratio selector switch to the HIGH position and lock the Pump Control Joy-
stick to the MIDDLE (neutral) position.
• Turn the line tension adjustment valve to the MAXIMUM setting (clockwise fully seated).
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• SLOWLY move the Pump Control Joystick to the UPHOLE position until the desired
speed is attained.
• SLOWLY decrease the line tension adjustment valve until the cable speed begins to de-
crease.
• Turn the Line Tension adjustment valve in (knob turned to right) just enough to return to
the original logging speed, and then turn an additional quarter turn of the knob.
• This new setting will allow sufficient cable tension while logging out of the hole and pre-
vent the system from applying excessive tension to the cable.
• Repeat Steps 4 and 5 every 2000 feet as the load on the string decreases. Pay close
attention to the proper setting of the valve when approaching hazard points such as the cas-
ing shoe and wellhead.
11.0 Operational Check and Unit Test Procedures
11.1 Start Engine and Check Operation Checks
• Check gauges for normal operation
• Check throttle control by increasing and decreasing switch
11.2 Hydraulic System - Drum Drive Checks
• Check for hydraulic fluid leaks
• Apply brakes and pressure system to 5000 PSI and recheck for leaks
• Check mooring system in uphole mode. System should be able to operate from
500 to 5800 PSI
• Check mooring valve setting (700 PSI)
• Check case pressure by mounting a pressure gauge on the hydraulic pump case
• Cold not to exceed 35 PSI
• Hot (100°F) not to exceed 25 PSI
11.3 Hydraulic System Generator
• Check for hydraulic leaks

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• Check for frequency stability of 58 to 62 Hertz with load on, and load off
• Check for voltage output of 110 to 120 Volts AC
• Check for vibration of generator (should be totally free of vibration)
• Check for shaft seal leaks on motor
11.4 Hydraulic Fluid Level
• Fluid should be free of water or other contaminants
DO NOT mix fluid types, Use ATF Type F hydraulic fluid
11.5 Hydraulic Hoses
• Extreme care should be taken when installing or replacing hoses. Ensure that all
hoses match the pressure requirements and are installed correctly.
• High-pressure hose: 5000PSI
• Low pressure hose: 3000PSI
• Hoses should not be exposed to sharp surfaces
• Hoses should not be pinched or restricted
• Hoses should not hang loose or hang in a precarious position
• Use proper tie downs to secure hoses
11.6 Filters
• Change all charge filter elements prior to shipping
11.7 Overhead Spooling System
• If arm is telescopic, adjust to maximum arm extension for operation
• Check for proper pressurization of vertical system (measuring head should float
freely)
• Horizontal controller should move freely from side to side and be free floating with
joystick in the center position
• System should be bled to free trapped air in the system
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12.0 Unit Maintenance
This section provides general preventive maintenance for the Logging Unit. A table near the
end of this section lists primary maintenance intervals. Detailed maintenance instructions
and intervals specific to the Peterbuilt chassis and the Cummins engine can be located in
the documents or manuals supplied by Peterbuilt and Cummins. “Pre-departure” checks
should be done each time the truck departs to or from a job site. Maintenance expressed
as “Daily” should be performed every 24 hours the truck is in use. Maintenance listed under
“After Job” is to be performed after a wireline job is completed. The “100-Hour”, “250-Hour”,
“500-Hour” and “1000-Hour” maintenance should be performed at those respective intervals
of unit operation. Maintain and retain all maintenance records with the unit.
12.1 Pre-Departure Checks
Before leaving the base on a logging job the following pre-departure checks should
be performed.
Check engine oil level
Inspect overall condition of engine belts and pulleys
Check coolant level
Fill fuel tanks with diesel fuel
Check air pressure in tires
Start engine and check brake system air pressure
Check truck gauges for proper readings
Ensure that all equipment is secured properly before departure
Check hour meter reading and note next scheduled maintenance
12.2 Daily Maintenance
The following maintenance procedures are to be performed once every 24 hours
while the logging truck is in use.
Diesel Engine
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Check oil level
Check diesel tank and fill if necessary
Check coolant level
Hydraulic System
Check hydraulic fluid level. If necessary, fill with transmission fluid ATF Type F fluid
Check Delta P indicators on all hydraulic filters (if applicable)
Air Tank
Drain water from air tank by opening valve under tank and allowing any accumu-
lated water to drain out
Line Oiler Tank
Check level and fill as needed with recommended cable inhibitor
12.3 After Job Maintenance
The following procedures are to be performed after each job:
Thoroughly clean the entire logging truck:
Use soap and degreaser (where required) to completely remove all dirt, salt, oil, hy-
draulic fluid, etc. from the drum deck, reel and frame assembly, cabin and Line Load
Measurement System rigging components. Pull plugs and drain drip pans. Collect
fluid in containers for proper disposal. Rinse truck thoroughly with clean water.
Remove mats from inside of cabin and clean
Clean cabin interior. Use rags and appropriate cleaners for the computers, monitors,
operator’s console, etc. Mop all dirt and water from floor.
Use window cleaner to clean windows and rig lights
Replace mats in cabin
Check consumable supplies in cabin and replenish where necessary
Perform daily maintenance
Clean and service the measuring head:
Clean with soap and water

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Apply grease to all fittings
Check rollers for free movement, and check wheels and rollers for wear
Inspect all connections between pneumatic lines and devices. Apply soapy water
to each fitting and watch for bubbles indicating air leaks. Check that each fitting is
securely attached. Check fittings for corrosion.
Inspect all pneumatic devices for general condition and security of installation
Repeat above for all pneumatic lines and devices located in the reel and frame as-
sembly, in the drum deck and in the air bag deployment system on the tool racks
Replace or repair any bad lines, fittings or components
Perform hydraulic system leak and condition check:
Inspect all hydraulic lines on the truck for general condition. Look for tears, kinking,
and abrasions.
Inspect all connections between hydraulic lines and devices. Check at each fitting for
hydraulic fluid, indicating leaks. Check that each fitting is securely attached.
Check each fitting for corrosion. Inspect all devices for general condition and hy-
draulic fluid, indicating leaks. Inspect cooler for corrosion in core or fins. Check that
pumps and motors are securely fastened.
Repeat above for all hydraulic lines and devices on the drum deck
Replace or repair any defective lines or components
Inspect and lubricate reel and frame:
Ensure reel and frame mounting bolts are tight
Ensure slip ring is securely mounted to reel shaft
Check all reel and frame components for corrosion
Inspect the drum brake:
Inspect disc brake pads. Replace if worn. Remove cover under control panel to
access brake components. Check that hand brake tightens to full position before it
reaches the limit of travel.
Inspect fittings and hoses for leaks

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If needed, add regular brake fluid to the reservoir
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12.4 General Maintenance Intervals

Following is a table listing all general maintenance intervals. Refer to the legend below for an explanation of the table listings.
Legend: A=Adjust C=Clean I=Inspect L=Lubricate R=Replace
Maintenance Interval Table

Component Post Job 400 Hr Annual
Air Tanks I I I
Hydraulic Tank I I CI
Hydraulic Lines and Connections I I I
Filters, Hydraulic, High Pressure I IR IR
Hydraulic Pumps I I I
Hydraulic Motors I I I
Hydraulic Oil I CI IR
Planetary Drive I CIL CIL
Reel and Frame CI CIL CIL
Disc Brake I AI AI
Overhead Spooler C AIL AIL
Benchmark Measuring Head AIL AIL AIL
Line Oiler IL IL IL
Electrical Cables and Reels I I I
Lighting CI CI IC
Instruments CI I I
Air Conditioners I I IC
Cabin Interior I CI IC
Engine Oil Level I I I
Fuel Line Filters I I I
Engine Air Filters I I I
Engine Coolant I I I
Diesel Fuel I I I
Cabin Exterior CI CI CI
Measuring Head Components (sheave, elevator, hook) CI I I
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13.0 Unit Maintenance
13.1 400-Hour Maintenance
The following procedures are to be performed after every 400 hours of logging truck
operation, and are primarily confined to the hydraulic system.
• Hydraulic Maintenance
The Rexroth pumps and motors are relatively maintenance free. Maintenance work
is confined to the system by way of oil changes and renewal of filter elements. Mon-
itoring and periodic maintenance of the system can prevent premature breakdowns
and repairs. Under normal conditions, the following maintenance intervals are sug-
gested:
• 400 hours: First filter change, two charge pressure filters. Perform 400 hour PM
pg 22.
• 800 hours: Second filter change, two charge pressure filters
• 1200 hours: Third filter change, two charge pressure filters
• Annual: Hydraulic oil change. Fourth filter change
WARNING! Most errors during a hydraulic fluid change occur due to:
• Use of unsuitable hydraulic fluid
• Use of contaminated hydraulic fluid
• Failing to thoroughly clean the reservoir
• Performing the fluid change in a contaminated area
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13.3 Annual Maintenance
• PM form for annual maintenance
WARNING! It is of the utmost importance to ensure the area is clean and free
of contaminants when performing maintenance on any hydraulic system.
• Measure the temperature of the hydraulic fluid after the system has been operated
under pressure for approximately one hour
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13.4 Level 1 Preventative Maintenance and Inspection 400 Hr Inspection Sheet
Level 1 Preventive Maintenance and Inspection

Perform Every 400 Hyd Hours PM
SAFETY FIRST - LOCK OUT TAG OUT
REMOVE IGNITION KEYS & LOCK OUT BATTERIES
Unit No.________________________ Code ___________________ Date
Make ______________________ Serial No.
HYDRAULIC HOUR METER READING
INSPECTION CODE: √ O.K. 0 ADJUSTMENT MADE ∆ RE PAIRS X FOLLOW UP NEEDED N/A NOT APPLICBLE
Battery Inspection (Unit & Generator if applica-
ble) Insp. Code Hydraulic Systems Insp. Code
Check Cables and Terminals Clean Oil with Filter Cart
Check, Clean Hold Downs Rack & Cover Check All Hoses and Fittings
Check DC Breaker and Wiring Check Oil Level in Reservoir
Change Filters
Under Vehicle Inspection Insp. Code Check for Leakage

Check PTO’s for Leaks Check Oil Cooler Condition
Check and Grease Drivelines Check Oil Cooler for Operation
Collect Sample of Oil and Send in for Anal-
Check & Grease Direct Drive PTO & Pump Shaft ysis
Check Hydraulic Pumps for Leaks Check Charge Pressure
Check All Fittings and Hoses Check System Pressure
Check Body Hold Downs and Positions Check Auxiliary Pressure
Check Generator Compartment Mounting
Drain Air Tanks Inside Cabin Insp. Code
Check Pressure Gauge Operation
Outside Body Inspection Insp. Code Check Drum Control Operation

Check Placards and Holders Check Brake Operation
Check all Glass Check Air Conditioner Operation
Check for Physical Damage Check Heater Operation
Check Load Bearing Structural Components Check Lighting Operation
Check Cabin Step
Check Rear Step Engine Driven Generators Insp. Code
Check Compartment Doors Latch Change Air Cleaner
Check Electrical Lighting Change Crank Case Oil
Prime and Repaint any Rust Area Change Oil Filter
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Check Electrical Connections
Drum Compartment Insp. Code Check Load Operations Voltage & Freq
Check Chain Oiler
Check Line Oiler Hydraulic Generator Insp. Code
Check Tool Trays Inspect Hoses and Fittings
Inspect Spooler Hold Down Check Electrical Connections
Check Air Bags for Leaks Check Start Up and Running Steady
Inspect and Grease Spooler Arm Check System for Leaks Under Pressure
Inspect and Grease Measuring Head Check Load Operations Voltage & Freq
Inspect Mea Head Sheave Wheels for Wear Grease zert on generator shaft and Hyd mtr
Clean and Oil Mea Head Sheave Wheels
Check Drum Drive Transmission for Leaks Safety Equipment Insp. Code
Check Drum Drive Transmission Fluid Level Check Fire Extinguisher
Verify Transmission Shifts Properly if Applicable Check Hazard Triangles
Check Drum Chain For Wear & Slack Check First Aid Kit
Check Sprocket Alignment Accident Reporting Kit
Inspect & Torque All Drum Mounting Bolts
Check and Grease Brake Bearings Insp. Code
Check and Grease Drum Bearings
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13.5 Preventative Maintenance Inspection Guide 400 Hr PM Inspection
Preventative Maintenance Inspection Guide

400 Hr preventative maintenance inspection
Level 2 Inspection
Battery Inspection (Unit & Generator)
Check Cables and Terminals

Check cables for tight connection, corrosion, signs of rubbing
Check, Clean Hold Downs Rack & Cover

Check hold downs for corrosion, hold down bolts for condition,
cover for damage, missing parts
Check DC Breaker and Wiring

Check DC breaker in battery box for loose wires, damage
Under Vehicle Inspection
Check PTO’s for Leaks

Check PTO’s for leaks, mounting bolts tight
Check and Grease Drivelines

Check Slip Yoke for wear, U-joints for wear, Yoke locks screws
for tightness, lock wires in lock bolts, grease all grease fittings
Check & Grease Direct Drive PTO & Pump Shaft

Remove pump from PTO and check splines for wear, grease spline
and remount pump to PTO
Check Hydraulic Pumps for Leaks

Check for signs of leakage, mounting bolts missing or loose
Check All Fittings and Hoses

Check for signs of leakage, damaged fittings and hoses, cracking,
chafing
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Check Body Hold Downs and Positions
Check hold downs on body for looseness, check for signs of body
shifting, condition of barrier between body and chassis.

Check for signs generator compartment coming loose (door trim
not lining up), visually check compartment mounting
Drain Air Tanks

Drain all air tanks
Outside Body Inspection
Check Placards and Holders

Check condition of placards/holders
Check all Glass

Check condition of all glass
Check for Physical Damage

Check unit for physical damage
Check Load Bearing Structural Components

Check drum mounts at frame and drum cradle
Check Cabin Step

Check condition of steps to cabin for cracks, missing
parts, safe condition
Check Rear Step

Check condition of steps to back of truck for cracks,
missing parts, safe condition
Check Compartment Doors Latch

Check condition of mounting hardware, latches close securely
Check Electrical Lighting

Check all lights for operation, condition, missing or cracked lens
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Prime and Repaint any Rust Area
Sand, clean, use rust converter, prime and repaint any rusted areas
Drum Compartment
Check Chain Oiler

Check condition, operation, refill
Check Line Oiler

Check components of system for damage and functionality, refill reservoir
Check Tool Trays

Check tool racks for cracking, securely mounted
Check Spooler Hold Down

Check spooler hold down cracks, looseness, functionality
Check Air Bags for Leaks

Check air bag system for leakage, damage, function of controls
Check and Grease Spooler

Check line spooler for operation, damage and grease all fittings
Check and Grease Measuring Head

Check measuring head bearings for wear, wheels for grooving,
mechanical cables for operation, and integrity of unit, grease all fittings,
check all electrical cables and connectors for chafing, connector integrity
Check Transmission for Leaks

Check hoist transmission for signs of leakage
Check Transmission Level

Check oil level of transmission, fill to proper level
Check Drum Chain For Wear & Slack

Check drum chain and sprocket for condition and wear, tighten chain if too slack.
Check Sprocket Alignment

Check alignment of chain and sprockets
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Check and Grease Brake Bearings

Check bearings for wear and grease
Check and Grease Drum Bearings

Check bearings for wear and grease
Hydraulics
Clean oil with filter cart

Connect filter cart to unit and filter oil
Check All Hoses and Fittings

Check hoses and fittings for damage, cracking, chafing
Check Oil in Reservoir for Proper Level
Change All Hydraulic Filters
Check for leakage

Run unit and verify no leaks
Check Oil Cooler Condition

Inspect oil cooler for damage, Rusting
Check Oil Cooler Operation
Check Oil Cooler for Blockage

Inspect for bent fins, plugged up core
Check Oil For Water & Metallic Particles

Take sample of oil from bottom of reservoir and send in for analysis
Check Charge Pressure

Check and record
Check System Pressure

Check and record
Check Auxiliary Pressure

29
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Check and record
Inside Cabin
Check Pressure Gauge Operation

With unit running, verify all gauges operational, note abnormal pressures
Check Drum Control Operation

Check drum for normal operation, all speeds/ranges
Check Brake Operation

Verify parking brake and service brake operation
Check Air Conditioner Operation

Check air conditioner for proper cooling, clean filters
Check Heater Operation

Verify heater operational, all speeds
Check Lighting Operation

Verify all lights work
Engine Driven Generators
Change Air Cleaner

Replace element
Change Crank Case Oil
Change Filters

Check power cords for cracking, chafing, other damage
Check Load Operations

Using a load bank or turning on all electrical loads, note frequency and voltage
for normal readings
Hydraulic Generator
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Check power cords for cracking, chafing, other damage
Check start up and running steady

Start Generator and check for normal operation
Check system for leaks under pressure

Run unit and verify no leaks
Check Load Operations

Using a load bank or turning on all electrical loads, note frequency and voltage
for normal readings
Safety Equipment
Check fire extinguisher

Ensure extinguisher charged and inspected
Check hazard triangles

Ensure triangles in good condition
Check First Aid Kit

Ensure first aid kit stocked
Check accident reporting kit

Ensure kit is compete
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13.6 Preventative Maintenance Inspection Annual Inspection
Annual Preventive Maintenance Inspection
Equip. No.

HYD.
ENG. HOURS HOURS
INSPECTION CODE: √ O.K. 0 ADJUSTMENT MADE ∆ REPAIRS X FOLLOW UP NEEDED N/A NOT APPLICABLE
Safety Equipment Insp. Code Hydraulic Systems Insp. Code
Check Fire Extinguishers Drain Oil & Insp Hyd Reservoir For Contamination
Check Hazard Triangles Repair All Leaks
Check First Aid Kit Inspect Sight Glass For Good Condition
Accident Reporting Kit Check Filler Cap / Vent
Wheel Chocks Proper Mounting Of Hydraluic Tank
Inspect All Vacuum Gauges For Good Condition
Battery Inspection (All) Insp. Code Change All Hydraulic Filters
Cables and Terminals Fill Hydraulic Reservoir With New Oil
Clean Hold Downs Rack & Cover All Filter Indicator Circuits
Confirm Each Battery Holding Proper Voltage
Hydraulic Generator Insp. Code
Under Vehicle Inspection Insp. Code Check Electrical Connections

All Mechanical Drive Systems Are In Good
Condition Grease Mechanical Coupling
Lubricate Electrical Connectors W/ Dielectric
Inspect and Grease All Drivelines Grease
Check for All Signs of Leaks
Grease Direct Drive PTO & Pump Shaft Splines
Ensure Hoses & Fitting’s Are In Good Condition Road Power Generators Insp. Code
Verify All Body Hold Down Bolts & Brackets In
Place Check and Grease All Bearings
Component Mounting Fasteners In Place Change Belts
Drain Air Tanks Adjust Belt Tension & Alignment
Outside Body Inspection Insp. Code

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Placards and Holders Engine Driven Generators Insp. Code
All Glass In Good Condition Change Air Cleaner
Check for Physical Damage Change Oil Filter
Cabin Step Change Crank Case Oil
Rear Step Check Electrical Connections
Compartment Integrity & Door Latches Inspect & Clean Cooling System
Address Corrosion Areas
Functional Checkout - Remove Lock Out Tag Out Insp. Code
Drum Compartment Inspection Insp. Code Start Truck & Engage All Systems
Chain Oiler Inspect & Repair All Hyd / Air Leaks
Tool Storage Racks Check Oil Cooler Condition & Operation
Inspect Air Bag Assemblies Inspect All Gauges For Condtion & Operation
Inspect Mount & Grease Spooling Arm Assembly Electrical Load Operations Voltage & Frequency
Inspect and Grease Measuring Head Verify & Repair All Lighting
Change Lubricant in GFT Gearbox / Unit Specific Verify All Hoist Functions
Change Lubricant in Auburn Gearbox / Unit
Specific - Hoist Charge Pressure
Change Lubricant in Funk Gearbox / Unit Specific - System Pressure
Inspect Drum Drive Transmission for Leaks - Generator Charge Pressure
Inspect GFT Bolts - Auxiliary Pressure
Inspect & Torque All Drum Mounting Bolts Verify Functionality Of Controls & Switches
Safety Equipment Insp. Code Hydraulic Systems Insp. Code
Check Drum Chain For Wear & Slack Verify All Climate Control Functions
Verify Proper Sprocket Alignment Line Sprayer
Inspect Drum Bearings Pressurization Fan
Ensure All Lights Are Mounted Properly Spooling Arm Functionality
Inspect All Cable Reels for Mounting & Condition Hydraulic Oil Temperature
Tail Board In Good Condition Pressure Check Hydraulic Hoist System
Inspect All Hoses & Cables Grease Drum Bearings
Verify Sliding Glass Operational Verify Pressure Control System / GIT
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13.7 Preventative Maintenance Inspection Guide Annual Inspection

Annual Hoist Unit

Safety Equipment
Check fire extinguisher
Ensure extinguisher charged and inspected
Check hazard triangles
Ensure triangles in good condition
Check First Aid Kit
Ensure first aid kit stocked
Wheel Chocks
Verify wheel chocks in unit
Check accident reporting kit
Ensure kit is compete
Battery Inspection (Unit & Onan)
Check Cables and Terminals
Check cables for tight connection, corrosion,signs of rubbing
Check, Clean Hold Downs Rack & Cover
Check hold downs for corrosion, hold down bolts for condition,
cover for damage, missing parts
Confirm Each Battery Holding Voltage
Proper Voltage 12.5+
Under Vehicle Inspection
Check PTO’s for Leaks
Check PTO’s for leaks, mounting bolts tight
Check and Grease Drivelines
Check Slip Yoke for wear, U-joints for wear, Yoke locks screws
for tightness, lock wires in lock bolts, grease all grease fittings
Check & Grease Direct Drive PTO & Pump Shaft
Remove pump from PTO and check splines for wear, grease spline and remount pump
to PTO
Check Hydraulic Pumps for Leaks
Check for signs of leakage, mounting bolts missing or loose
Check All Fittings and Hoses
Check for signs of leakage, damaged fittings and hoses, cracking,
chafing
Check Body Hold Downs and Positions
Check hold downs on body for looseness, check for signs of body
34
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shifting, condition of barrier between body and chassis.
Check for signs generator compartment coming loose (door trim
not lineing up), visually check compartment mounting
Drain Air Tanks
Drain all air tanks
Outside Body Inspection
Check Placards and Holders
Check condition of placards/holders
Check all Glass
Check condition of all glass
Check for Physical Damage
Check unit for physical damage
Check Load Bearing Structural Components
Check drum mounts at frame and drum cradle
Check Cabin Step
Check condition of steps to cabin for cracks, missing
parts, safe condition
Check Rear Step
Check condition of steps to back of truck for cracks,
missing parts, safe condition
Compartment Integrity & Door Latches
Check condition of mounting hardware, latches close securely
Address Corrosion Areas
Sand, clean, use rust converter, prime and repaint any rusted areas
Drum Compartment Inspection
Check Chain Oiler
Check Tool Storage Racks
Inspect Air Bar Assembly
Inspect Mount & Grease Spooling Arm Assembly
Inspect and Grease Measuring Head
Inspect Drum Drive Transmission for Leaks
Check Transmission Level
Check Drum Chain For Wear & Slack
Verify Proper Sprocket Alignment
Inspect and Grease Brake Bearings
Hydraulics Systems
Drain Oil in Reservoir (Every 12 Months)
Fill Hydraulic Resevoir With New Oil
Repair All Leaks
Change Filters
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Hydraulic Generator
Lubricate Electrical Connectors w/ Dielectric Grease
Grease Mechanical Coupling
Electrical Load Operations Voltage & Frequency
Road Power Generators
Check and Grease all Bearings
Replace Belts and adjust Tension and Alignment
Engine Driven Generators
Change Air Cleaner
Change Crank Case Oil & Filters
Electrical Load Operations Voltage & Frequency
Function Checkout - Remove Lock Out Tag Out
Start Truck & Engage All Systems
Inspect All Guages for Condtion & Operation
Pressurization Fan
Hydraulic Oil Temperature
Pressure Check Hydraulic Hoist Systems
Grease Drum Bearings
Check Electrical Light
Check Line Oiler
Check Oil Cooler Condition
Check for Leakage
Check pressure Gauge Operation
Check Drum Control Operation
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13.8 Preventative Mainenance Inspection Report
Preventive Maintenance Inspection
List Major Repairs & Parts Required Since Last PM
List Part& Fluids Used for This PM
Comments:
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Mechanic : Date :
Designated Supervisor: Date:
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14.0 270 Tandem axle full back diagram
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15.0 Replacement
The following section provides photos and tables that identify and provide the part numbers
for replacing the given components.
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16.0 Images
Figure 3.0
Fig 3.0
# Description OEM Part # Synergy #
1 Ground plate 69.50342
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16.1 Interior Electrical
Figure 4.0
Figure 4.0
1 Monitor double arm mount 0.56014
2 SST outlet cover 0.20077S
3 15A 125V black receptacle 3232BK 0.20126B
4 Sub ram mount 0.56015
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Figure 5.0
Figure 5.0
43
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Figure 6.0
Figure 6.0
1 Pioneer 6.5 radio speakers 0.50070
2 Speaker wall plate cover 0.20021
44
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Figure7.0
Figure 7.0
1 Light SP black switch 0.20074B
2 1-Gang SST switch cover 0.20076S
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Figure 8.0
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Figure 9.0
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Figures 8.0 and 9.0

Load # To GA Col Line To
CB1-1 1 TB3 8 Red CB1-2 TB4
CB2-1 2 TB3 8 Red CB 2-2 TB9-45
CB3-1 3 TB3 10 Red CB3-2 TB10-14
CB4-1 4 TB3 8 Red CB4-2 TB9-48
CB5-1 5 TB4 10 Red CB5-2 TB9-47
CB6-1 6 TB1 10 Blk CB6-2 TB9-55
CB7-1 7 TB1 10 Blk CB7-2 TB9-56
CB8-1 8 TB1 10 Blk CB8-2 TB9-57
CB9-1 9 TB1 10 Blk CB9-2 TB9-58
CB10-1 10 TB1 10 Blk CB10-2 TB9-59
CB11-1 11 TB1 10 Blk CB11-2 TB9-60
CB12-1 12 TB1 10 Blk CB12-2 TB9-61
CB13-1 13 TB1 10 Blk CB13-2 TB9-62
CB14-1 14 TB2 10 Blk CB14-2 TB9-63
CB15-1 15 TB2 10 Blk CB15-2 TB9-64
CB16-1 16 TB2 10 Blk CB16-2 TB9-65
CB17-1 17 TB2 10 Blk CB17-2 TB9-66
CB18-1 18 TB2 10 Blk CB18-2 TB9-67
CB19-1 19 TB2 10 Blk CB19-2 TB9-68
CB20-1 20 TB2 10 Blk CB20-2 TB9-69
Figures 8.0 and 9.0 cont.

DPF/DEF light 21
From GA Color # To
DS3-1 18 Red TB9-6 13
DS3-2 18 Gry TB9-41 6
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Intercom 22
To GA Color # To
12V+ 14 Red TB9-46
12V- 14 Bkj/wht TB9-43
1C1 18 Blk TB9-79
1C1 18 WHt TB9-80
1C1 18 Red TB9-78
1C2 18 Blk TB9-82
1C2 18 Red TB9-81
AFT 18 Blk TB9-77
AFT 18 Red TB9-76

Radio 23
To GA Color # To
12V+ 18 Yel TB3
12V+ IGN 18 Red TB4
12V- 18 Blk/wht Tb5
Right+ 18 Red TB9-72
Right- 18 Blk TB9073
Left+ 18 Red TB9-74

Left- 18 Blk TB9-75
Fig 8.0 and 9.0 cont.
#24 Volts
GA Color To
18 Blk Hertz
18 Blk Amp select switch B4 2 T
18 Wht Hertz
18 Wht TB7
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#25 Hertz
To GA Color To
Volt 18 Blk Amp A
Volt 18 Wht Amp B

#26 Amps
To GA Color To
A 18 Blk Hertz
B 18 Wht Volt
CT 18 Wht TB1403
CT 18 Wht Amp select B3 1 T

Gen on 27
From GA Color # To
S5-1-3 18 Red TB9-45
S5-1-4 18 Red TB9-31
S5-2-4 18 Blu TB9-39
S52-3 18 Brn TB9-40

Gen start 28
From GA Color # To
S6-1-3 18 Blu § S5-2-4
S6-1-4 18 Orn TB9-38
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Amp select 29
From GA Color # To
S7-1-1 18 Blk § S7-1-3
S7-1-3 18 Blk TB1
S7-1-2 18 Blk TB2
S7-1-4 18 Blk S7-2-4
S7-2-2 18 Wht § Thru amp meter to TB11-3
S7-2-1 18 Wht TB11-1
S7-2-1 18 Wht TB11-2

12V Main 30
From GA Color # To
DS2-1 18 Red TB4
DS2-2 18 Gry TB5

Drum Lights 31
From GA Color # To
S80103 12 Red TB9-51
S8-1-4 12 Gry TB9-17

Deck lights 32
From GA Color # To
S9-1-3 12 Red TB9-52
S9-1-4 12 Yel TB9-19
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Rig lights 33
From GA Color # To
S10-1-3 12 Red TB9-53
S10-1-4 12 Red TB9-21
S10-2-4 12 Red TB9-53
S10-2-3 12 Red TB9-22

Quartz lgihts 34
From GA Color # To
S11-1-3 12 Blk TB9-69
S11-1-4 12 Blk TB9-25

Cell booster 34
From GA Color # To
S12-1-3 14 Blk TB9-60
S12-1-4 14 Blk TB9-71
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1 50A breaker W91X15250VDC 0.10074
2 40A breaker W91X15240 0.10071
3 30A breaker W91X15230 0.10073
4 50A breaker W91X15250VDC 0.10074
5 20A breaker S281UC-K20 0.88663
6 30A breaker 30A breaker W91X11230
8 20A breaker W91X11220 0.10049
15 20A breaker W91X11220 0.10049
21 Yellow indicator light 0.20190
22 30W black loud hailer STDVLH3000PN110288 0.83008
23 Alpine CD player radio CDE100 0.50039
24 Datel LED AC volt meter DMS20PC1LMC 0.20307
25 Datel LED frequency meter DMS20PS1FMC 0.20308
26 Datel LED amp meter ACA520PC5AC1 0.20309
27 Maintained lever switch E22V51 0.20196
30 Green 12V indicator light HW491FQDG12V 0.88590

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Figure 10.0 TB9

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Fig 10.0 TB-9
Description GA Col Jump # Description GA Col
§ 1 Ambulance lights 12 Vio
§ 2 Step lights 12 Vio
12 Brn 3 Rear horn --> 41 12 Brn
18 Red
12 Grn 4 Hyd fan gnd (relay) 12 Grn
18 Orn 5 Hydraulic oil temp 14 Orn
18 Red 6 Def/dpf light 18 Orn
14 Gry 7 Cabin pressure fan 14 Gry
12 Red 8 Engine stop
12 Orn 9 Engine stop
18 Orn 10 Throttle 5VDC supply
18 Wht 11 Throttle position supply
18 Grn 12 Throttle ECM return
18 Red 13 Ignition 12V+ 14 Blk
12 Blu 14 Line oiler 12 Blu
--> 41 18 Red
10 Red 15 Hyd fan load 10 Red
10 Red 16 Cabin pressure fan load 10 Red
12 Orn § 17 Drum lights 12 Orn
12 Orn § 18
12 Yel § 19 Deck lights 12 Yel
12 Yel § 20
12 Red § 21 Rig lights 12 Red
12 Red § 22 12 Red
14 Brn § 23 Clearance lights 14 Brn
14 Brn § 24 14 Brn
14 Blk § 25 Quartz lights 12 Blk
14 Blk § 26
18 Red 27 J-1939 tach 18 Yel
18 Blk 28 J-1939 tach 18 Grn
18 Yel § 29 Mag pickup pin A

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Fig 10.0 TB-9 cont.
18 Vio § 30 Mag pickup pin B
18 Red 31 12V+ pin C 18 Red
18 Gry 32 12V- pin D 18 Gry
18 Grn 33 Pump shield pin E Pump shield
18 Blk 34 120V+ pin F 14 Blk
18 Wht 35 120V- pin G 14 Wht
18 Blu/Wht 36 Pump + pin H Pump Blk
18 Vio/Wht 37 Pump - pin J Pump Wht
18 Orn 38 Start pin K 18 Blk
18 Blu 39 Common 18 Blu
18 Brn 40 Stop 18 Brn
18 Gry 41 TB-5 12V- 10 Grn
Def/dpf light 18 Wht
18 Gry 42 SP grn pin D
14 Blk/wht 43 Intercom
14 Blk/wht 44 Cabin pressure fan 10 Grn
18 12 Red 45 CB-2-2 interior/hyd gen on 8 Red
18 Red
14 Red 46 Intercom 10 Red
47 CB-5-2 system 8 Red
48 CB-4-2 exterior
12 Red 49 Line oiler/methanol
12 Red 50 Rear horn
12 Red 51 Drum lights
12 Red 52 Deck lights
12 Red 53 Rig lights
5 10 14 Blk 54 Front/cab. Lights
14 10 Blk 55 System rack CB-6 10 Blk
14 10 Blk 56 System rack CB-7 10 Blk
1 12 Blk 57 Printer CB-8 10 Blk
12 12 Blk 58 Monitor CB-9 10 Blk
17 12 Blk 59 120V lights/light table CB-10 10 Blk

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Fig 10.0 TB-9 cont.
2 14 Blk
12 Blk 60 Utility/cell booster CB-11 10 Blk
7 14 Blk
8 12 Blk 61 Utility outlet CB-12 10 Blk
26 10 Blk 62 A/C curbside CB-13 10 Blk
27 10 Blk 63 A/C roadside CB-14 10 Blk
9 12 Blk 64
13 12 Blk 65 Aux system CB-16 10 Blk
19 12 Blk 66 Door outlet CB-17 10 Blk
12 Blk 67 Rear outlet roadside CB-18 10 Blk
12 Blk 68 Rear outlet curbside CB-19 10 Blk
12 Blk 69 Quartz lights CB-20 10 Blk
14 Blk 70 P.E. lights 14 Blk
14 Blk 71 Cell booster 14 Blk
Speaker wire + 72 Right speaker + 18 Red
Speaker wire - 73 Right speaker - 18 Blk
Speaker wire + 74 Right speaker + 18 Red
Speaker wire - 75 Left speaker - 18 Blk
18 Red 76 PA speaker + AFT 18 Red
18 Blk 77 PA speaker - 18 Blk
18 Red 78 Front intercom + ICI 18 Red
18 Blk 79 Front intercom - 18 Blk
18 Wht 80 Front intercom sig 18 Wht
18 Red 81 Intercom reel 1C2 18 Red
18 Blk 82 Intercom reel 18 Blk
Fig 10.0
Description OEM Part # Synergy #
Medium Terminal Block 0.88672
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Figure 11.0
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Fig 11.0 TB 1-8
GA Col TB GA Col Amp
Line 1 4 Blk 1 Amp select S7-1-2 18 Blk
F-1 120V 4 Blk 80
Line 2 4 Blk 2 Amp select S7-1-4 18 Blk
F-2 120V 4 Blk 80
Battery 0/1 Red 3 Radio 12V+ (inline fuse) 18 Yel 10
F-3 12V+ 0/1 Blk 100
F-4 12V+ Heater 10 Red 30
F-5 12V+ Cab press fan (reset) 10 Red 30
F-6 12V+ hyd fan (reset) 10 Red
F-7 12V+ radio (inline fuse) 18 Yel
12V Main 4 Blk 4 Radio 12V+ ign 18 Red
Main light 12V+ DS-2-1 18 Red
KF hyd fan 86 14 Red
12V Gnd 4 Blk 5 TB-9 12V- Def/dpf light 10 Grn
Radio 12V- 18 Blk/wht
Main light 12V+ DS-2-2 18 Gry
Line 1 common 4 Blk 6 System outlet 10 Wht
System outlet 10 Wht
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Fig 11.0 TB1-8 cont.

TB11 To GA Col To
CT1 18 Blk/wht TB2
CT2 18 Blk/wht TB2
Amp select 18 Wht S7-2-1
Amp select 18 Wht S7-2-3

TB1-6 Modular marathon blocks 0.20122
TB11 Three-terminal block Synergy
9 Cell phone amplifier kit 841245AG SOHO 60Amp 0.85181
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Figure 12.0
Line 2 common 4 Blk 7 A/C 10 Wht
Utility outlet 12 Wht
Utility outlet 12 Wht
120V light 14 Wht
Safety ground 4 Blk 8 System outlet 12 Grn
System outlet 12 Grn
A/C 12 Grn
Utility 14 Grn
Utility 14 Grn
120V light 14 Grn
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Modular marathon blocks 0.20122
11 4-Hub box 0.20081
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Figure 13.0
Fig. 13.0
1 12V PotterBrumfield Fuse 80A 0.10091
2 12V PotterBrumfiled Fuse 80A 0.10091
3 100A 250V Fuse DLNR100 0.10045
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Figure 14.0
Fig 14.0
1 High country tech 40442 69.40442
2 Datel transformer 7020-01040-0 0.20316
65
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Figure 15.0
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Fig. 15.0 cont.

To Volt GA Col Amp # To
4 Line 12+ 10 Red 30 F-4 TB-3
Load 10 Red TB-10-20
5 Line 12+ 10 Red 30 F-5 TB-3
Load 10 Red KP-30
6 30 10 Red F-5 Load
85 14 Gry TB-9-8
86 14 Red F-5 Load
87 10 Red TB-9-16
85 12 Grn TB-9-4
86 14 Red TB-4
87 10 Red TB-9-15
85 12 Grn TB-9-4
86 14 Red TB-4
87 10 Red TB-9-15
Fig. 15.0 cont.

1 Cell phone amplifier kit 841245AG SOHO 60Amp 0.85181
2-4 30A reset breaker CBC30B 0.20090
5-6 Hella 12V relay w/diode 4RA933.791-091 0.85316
7 50A 12V relay R515D4012F 0.10108
8
Synergy Industries Hella 12V relay w/diode 4RA933.791-091 0.85316 67
9
Burleson, Texas 76028 Rextoth RC program controller P/N 40338 69.40338
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Figure 16.0
Fig 16.0 TB-10

GA Col Amp Jump # GA Col
1 18 Blu 1 Reel motor sig (30) 18 Red
1 18 Orn
2 18 Orn 2 Pump A uphole (15) 18 Red
1 18 Brn
2 18 Brn 3 Pump B downhole (29) 18 Red
12 Vio 4 Dump valve sig 18 Red
1 18 Red 5 Fine speed (load) 18 Red
2 18 Red
1 18 Wht 6 Pump A&B solenoid gnd (3) 18 Blk
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Fig 16.0 TB10 cont.
2 18 Wht
14 Blk/wht § 7 TB-5 12V/hyd temp 10 Grn
§ 8 Reel motor solenoid gnd 18 Blk
1 18 Blk § 9 RC cont. gnd (2 & 28) shields
2 18 Blk
10 Dump valve solenoid gnd 18 Blk
11
12 Over tension contact
18 Wht/blu 13 -31
18 Wht/blu -31
14 Red 10 § 14 CB-3-2 drawworks hyd temp 10 Red
18 Red § 15 Fine speed
18 Red § RC front/rear switch
1 18 Red 10 § 16 RC cont. (10A fuse 1,27) 1,2
2 18 Red 10 §
§ 17 Dump valve 12 Red
2 18 Wht/red 18 Rear PQ vs (36) 18 Red
2 18 Wht/grn 19 Rear PQ gnd (38) 18 Blk
2 18 Wht/brn 20 Rear PQ sig (35) 18 Wht
1 18 Wht/red 21 Front PQ vs (36) 18 Red
1 18 Wht/grn 22 Front PQ gnd (38) 18 Blk
1 18 Wht/brn 23 Front PQ sig (35) 18 Wht
Fig 13.0 TB-10 cont.
1 18 Wht/orn 24 Reel motor vs (47) 8 Red
1 18 Yel 25 Reel motor gnd (49) 18 Blk
1 18 Wht/blk 26 Reel motor sig (46) 18 Wht
1 18 Red 3 27 Front RC 12V+ (41,42)
2 18 Red 3 28 Rear RC 12V+ (41,42)
Fig 16.0 TB10 cont.

Medium Terminal Block 0.88672
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Figure 17.0
Fig 17.0
Engine Kill 1
From GA Color # To
1 14 Red 9-8
2 14 Orn 9-9
Fig 17.0 cont.

Dump valve 2
From GA Color # To
1 14 Red 10-17
2 14 Vio 10-4
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Fig 17.0 cont.
Heater 3
From GA Color # To
1-3 12 Red § 10-20 jump to 2-4
1-4 12 Red/wht 10-19
2-3 12 Orn/wht 10-18
Fig 17.0 cont.

Beijer 3cond 4
From GA Color # To
24V+ 18 Red 14-1
24V- 18 Blk 14-3
Gnd 18 Wht 14-6
Fig 17.0 cont.

Hyd temp 3cond 6
From GA Color # To
I 18 Red TB10-14
G 18 Gry TB10-7
S 18 Orn TB9-5
Fig 17.0 cont.

Fine Speed 7
From GA Color # To
1-3 18 Red 10-15
1-4 18 Red 10-5
Fig 17.0 cont.

Horn 8
From GA Color # To
1-3 12 Red 9-50
1-4 12 Brn 9-3

71
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Fig 17.0 cont.
Line oiler 9
From GA Color # To
1-3 12 Red 9-49
1-4 12 Blu 9-14
Fig 17.0 cont.

Throttle excel 8 pin 13
From GA Color # To GA Col
Pin1 18 Red 9-13 18 Red
Pin2 18 Blk 10-7 18 Gry
Pin3 18 Orn 9-10 18 Orn
Pin4 18 Wht 9-11 18 Wht
Pin5 18 Grn 9-12 18 Grn
Pin6 Yel to Pin1 Red
3cond 12 pin
Pin9 18 Blk 9-28
Pin10 18 Red 9-27
Fig 17.0 cont.

Pump
From GA Color # To
VS 18 Red TB10-021
Gnd 18 Blk TB10-22
Sig 18 Wht TB10-23
72
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1 Switch guard 55049-01 0.10041
2 Switch guard 55049-01 0.20252
4 Benchmark tension panel 69.20762
5 Air pressure gauge 1-150 0.40037
6 Hyd oil temp gauge 82740 0.10222
7 Maintained lever switch E22VG1 0.20502
8 Push button switch GA#P9CPNNG 0.20197
9 Push button switch GA#P9CPNNG 0.20197
10 Ohm meter and panel w/ 69.20939
13 Throttle Cummins ElA201-A00 0.20502
14 Air brake control valve P26715-2 0.40054
15 Spooler control valve 0.40075
16 7500 PSI gauge 213.4 0.40076
17 0-600 PSI gauge 213.40 00931F35170 0.40029
18 Pressure control valve RR DBDH R900385305 BUNA 0.40056B
19 Controller PQ M115DL15F58UNI 0.40211
20 Rexroth controller PQ M115-SL15F-58 0.42097
21 Push/pull PTO valve ACVR26LT 0.40006
73
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Figure 18.0
Fig 18.0
1 Push/pull valve 0.40006
2 Push/pull valve 0.40006
3 Air regulator 0.40223
74
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Figure 19.0
Figure 19.0
12V Main
To Jump # Volt
12V System § 1 12+
12V System § 2 12+
12V System § 3 12+
12V System § 4 12+
12V System § 5 12+
12V System § 6 12-
75
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Figure 19.0 cont.
12V System § 7 12-
12V System § 8 12-
12V System § 9 12-
12V System § 10 12-
Figure 19.0 cont.

#
1-10 Medium terminal block 70.30840
11 In differing orders see Roxtec
12 Slip ring cable
13 Backup depth cable
14 Tension load cell cable
15 Mag cable
16 Wellhead pressure cable
17 Grease cable
18 Transducer cable
19 Antenna cell booster cable
20 Intercom cable
21 Blank blank
22 Blank blank
23 Blank blank
24 Blank blank
25 Blank blank
26 Blank blank
27 Blank blank
28 Blank blank
29 Roxtec bulkhead wedge WEDGE316SS 0.42068
30 Roxtec alum stay plate 0.42069
31 Roxtec module 0.4207

76
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Figure 20.0 TB15
77
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Figure 20.0
TB15
From GA Col # To
Air gauge 12V+ 12 Red 1 TB10-16
18 Blk 2 Wellhead transducer
Air Gauge 12V- 10 Grn 3 TB5
12 Wht 4 Air heater
18 Wht 5 Grease Transducer
18 Wht 6 Wellhead transducer
TB9-81 18 Blk 7 Intercom
TB9-82 18 Wht 8 Intercom
TB9-76 18 Red 9 PX
TB9-77 18 Blk 10 PX
10 Red 11 TB4
12 Blk 12 Air heater
Figure 20.0 cont.

#
78
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Figure 21.0
Figure 21.0
2 2-Gang outlet cover SS82 0.20078S
79
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Figure 22.0
Figure 22.0
To Jump # Volt
12V System § 1 12+
12V System § 2 12+
12V System § 3 12+
12V System § 4 12+
80
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Figure 22.0 cont.
12V System § 5 12+
12V System § 6 12-
12V System § 7 12-
12V System § 8 12-
12V System § 9 12-
12V System § 10 12-
Figure 22.0 cont.

#
81
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Figure 23.0
Figure 23.0
1 Red Lion Assy 70.30445
2 Benchmark backup depth display 69.60123
82
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Figure 24.0
Figure 24.0
1 Double arm monitor mount VPTAXUL02 0.56014
2 3-Way black switch 0.20601
3 SST 1-gang plate 0.20282S
4 Sub ram mount 0.56015
83
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Figure 25.0
Figure 25.0
84
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Figure 26.0
Figure 26.0
1 Customer seat cushion 70.30181
2 Seat cushion 69.50692C
3 Bunkbed seat cushion 70.30182C
85
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16.2 Interior body
Figure 27.0
Figure 27.0
1 Bunk bed leg 69.60069
86
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Figure 28.0
Figure 28.0
1 Piano hinge A806X96 0.50052
87
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Figure 29.0
Figure 29.0
1 Mr. Coffee Coffeemaker ISTX95 0.59995
2 Microwave CSMW07B 0.59994
3 Microwave/coffee door w/70.10017 70.20075
4 Upper storage cabinet w/70.10016 70.20068
5 Adjustable black lever latch C2-32-35 0.53026
6 Southco positioning hinge G601 0.53027
88
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Figure 30.0
Figure 30.0
1 Mr. Coffee Coffeemaker ISTX95 0.59995
2 Mr. Coffee cord ISTX95 0.59995
89
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Figure 31.0
Figure 31.0
1 Prntr/light table door w/70.30234 70.30288
2 Adjustable black lever latch C2-32-35 0.53026
90
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Figure 32.0
Figure 32.0
1 Pioneer radio speaker 6.5 0.50070
2 First aid kit 240AN 0.60014
3 Bulb old #0.20084 w/0.80196 0.80198
4 Slip ring 0.88689
91
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Figure 33.0
Figure 33.0
1 Bulb old #0.20084 w/0.80196 0.80198
2 Bulb 150 W 12V Quartz Q150 118 0.20112B
3 Slip ring MXV-2WG 0.20293
4 Slip ring MXV-2WG 0.20293
5 Pioneer radio speaker 6.5 0.50070
92
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Figure 34.0
Figure 34.0
1 Access door base cabinet w/ r/s and c/s 70.30296
2 Monitor rack screws w/ 0.54041 screws
3 Hammond monitor rack RCBS1900513BK1 0.54041
93
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Figure 35.0
Figure 35.0
1 Plexiglass 69.60122
94
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Figure 36.0
Figure 36.0
1 Cat-6 cable 0.40450
2 VGA cable 0.40449
3 Coax cable 0.40451
95
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Figure 37.0
Figure 37.0
1 Synergy mat 0.59801
96
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Figure 38.0
Figure 38.0
1 Air box ceiling unit kit 3105457.018 0.50137
97
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Figure 39.0
Figure 39.0
1 Fire extinguisher ABC#5 0.60008
98
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Figure 40.0
Figure 40.0
1 Freezer door latch 503/5032 0.50005
2 9.875x23.875 Window smoked 0.60001
3 9.875x14.875 Window smoked 0.60002
4 Chrome polar hinge 0.50051
99
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16.3 Interior lights
Figure 41.0
Figure 41.0
1 3Ft radius light cover 69.50350
2 LED puck light mount 69.60123
3 LED puck light 6268 wh 0.10230
4 Cell phone amplifier kit 0.85181
100
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Figure 42.0
Figure 42.0
1 LED puck light 6268 wh 0.10230
2 LED puck light mount 69.60123
101
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Figure 43.0
Figure 43.0
1 3Ft radius light cover 69.50350
102
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16.4 Chassis interior
Figure 43.0
Figure 44.0
Figure 44.0
1 Toggle switch 683-0063 0.82216
2 Owl backup camera 0.20530
103
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Figure 45.0
Fig 45.0
1 Yellow indicator light 0.20190
104
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Figure 46.0
Fig 46.0
1 Owl backup camera 0.2053
2 Hailer STD-MLS300I 082182
105
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16.5 Underbody
Figure 47.0
Figure 47.0
1 PTO 828B-U6810-Q1CX 0.31018
2 Mooring valve 0.40074S
to Rexroth 90 Pump see Rexroth documentation
3 to X3 on pump X1
4 to X1 on pump X2
5 to Power port P
6 to tank T
106
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Figure 48.0
Figure 48.0
1 90CC Rexroth pump (reel) AA4VG90EP3DT1/32LNUF52 0.40062
2 56CC Rexroth pump (generator) AA4VG56EP3DMT1.32 0.40061
3 90 Pump solenoid override # 902603439 (EP-3) 0.42110
107
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Figure 49.0
Figure 49.0
1 Artic Fox hydraulic tank heater AFH400012 0.43020
2 Ball valve 0.85326
108
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Figure 50.0
Figure 50.0
1 Comes with chassis Peterbuilt
109
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Figure 51.0
Figure 51.0
1 Donaldson filters P163681 0.40141
110
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Figure 52.0
Figure 52.0
1 Bent axis Rexroth 80CC motor AA6VM80EP0/70WVSC520HBE 0.40064
111
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Figure 53.0
Figure 53.0
2 PTO priority pressure valve 0.40053
112
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Figure 54.0
Figure 54.0
113
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Figure 55.0
Figure 55.0
1 Bin boits Synergy
114
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Figure 56.0
Figure 56.0
1 Chassis Peterbuilt
2 Yoke end 3477211 69.50321
115
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Figure 57.0
Figure 57.0
1 Bendix tank 0.50134
116
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Figure 58.0
Figure 58.0
1 Bin boits Synergy
117
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Figure 59.0
Figure 59.0
118
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16.6 Exterior Body and Electric
Figure 60.0
Figure 60.0
1 Extension antenna 0.20009
119
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Figure 61.0
Fig. 61.0
1 14” Flexible rubber antenna 0.20801
120
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Figure 62.0
Figure 62.0
1 Dometic air conditioner 604315301 0.50136
2 Curtain strap 0.54000
121
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Figure 63.0
Figure 63.0
1 CYLINDER, HYDRLC TQ2010 P/N 639142 0.52026
2 KERR MOUNT WELDMELT BM 70.30118
3 CURTAIN, 270 206 X 72 W 45DEG 69.50186
122
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Figure 64.0
Figure 64.0
1 Air Prince cylinder .40022
2 to cooling fan cable
3 Hoffman enclosure junction box 0.10060
4 to rear lights cable
5 to clearance lights cable
6 Hydraulic cooling fan 0.88748
7 Hydraulic cooling fan bracket w/0.30374 70.30015
123
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Figure 65.0
Figure 65.0
1 160PSI Gauge 0.42013
2 Hydraulic Hose Manufacturer
3 .25 Air regulator 0.40096
4 Parker solenoid 71215SN2MN00N0C111C1 0.30251
5 In-line filter 00066X11108 0.40050
6 Line oiler tank handle 69.50024
7 Weldment line oiler tank 69.50136
8 Line oiler tank bracket 69.50054
124
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Figure 66.0
Figure 66.0
1 Split 950 reel 69.20039S-WDL
2 Sliding window 0.60023
3 Carlson brake caliper 0.85334
125
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Figure 67.0
Figure 67.0
1 Pillow block bearing 4-bolt 0.40301
2 Bolt Synergy
3 Copper tube soft 0.52062
4 Slip ring bracket 69.50268
126
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Figure 68.0
Figure 68.0
1 Pillow block bearing 4-bolt 0.40301
2 Slip ring kit 0.88689
3 Bolt Synergy
127
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Figure 69.0
Figure 69.0
1 Single fold-down step FS-200 0.54124
2 Perforated Funk cover 70.30017
128
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Figure 70.0
Figure 70.0
1 Rexroth cylinder 0.31027
2 Sheave hoses hydraulic
6 Hydraulic high pressure hoses hydraulic
7 Funk air shift cylinder 0.40004
8 Funk 3-speed transmission YZ-18165 0.40123
129
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Figure 71.0
Figure 71.0
1 Rexroth 32 bent axis motor AA6VM80EP1/70W0VSC520HBE 0.40064
2 Solenoid valve 0.85245
3 Hydraulic high pressure hoses hydraulic
4 Solenoid Rexroth pump cable 0.40432
5 Hydraylic return hose hydraulic
130
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Figure 72.0
Figure 72.0
1 Disk brake caliper 76011 0.88666
2 Pad 0.49001
131
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Figure 73.0
Figure 73.0
1 Roxtec aluminum stay plate 0.42069
2 Roxtec bulkhead wedge WEDGE316SS 0.42068
3 Roxtec module RM20 0.42070
4 1Qt oiler chain 0.42014
132
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Figure 74.0
Figure 74.0
1 Geolog Inter-com reel 69.50575
3 Wix air filter 0.50139
133
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Figure 75.0
Figure 75.0
1 Cell phone antenna 841245 AG SOHO 60 AMP W/OMNI&P 0.85181
2 Large intercom 110295 0.83006
3 Fire research intercom 69.50610
4 Ground reel, no hermenic 0.20369
7 Jumpers w/0.20369
134
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Figure 76.0
Figure 76.0
1 Body mount gusset 69.20231
2 Air bag cover 69.50451
3 Upper tool rack 69.50210
4 Air lines Synergy
5 Air lines Synergy
6 Air lines Synergy
7 Air lines Synergy
135
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Figure 77.0
Figure 77.0
1 Whitey valve 0.40060
136
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Figure 78.0
Figure 78.0
1 Water tank 70.30275
2 Galvanized cap 0.85229
137
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Figure 79.0
Figure 79.0
1 Benchmark 3K measuing head 0.20342
138
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Figure 80.0
Figure 80.0
1 Cox reel CL3505012A 0.20247
139
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Figure 81.0
Figure 81.0
1 5-Hub box WPB26 0.20080
2 Weatherproof cover 0.20123
140
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Figure 82.0
Figure 82.0
1 Gauge 446725005 0.40224
2 Chain w/snap w/0.82198 52034
4 Upper tool rack 69.50199
141
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Figure 83.0
Figure 83.0
1 Storage box in/69.50817
142
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Figure 84.0
Figure 84.0
1 Rear bumper tow pin 69.50116
143
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Figure 85.0
Figure 85.0
2 Chain w/snap w/0.82198 0.52034
144
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Figure 86.0
Figure 86.0
1 Owl backup camera SMC1086T 0.00530
2 Handrail small rear 80160 69.20501
3 Modified safety sign 70.30146
4 Grab handle 6.50025
5 Modified safety sign 70.30146
145
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Figure 87.0
Figure 87.0
1 Handrail large side 80160 69.20298
146
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Figure 88.0
Figure 88.0
1 Handrail large side 80160 69.20298
2 6” Polished hook DH6W50SS 0.50003
3 9.875x23.875 Window smoked 0.60001
4 9.875x14.875 Window smoked 0.60002
147
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Figure 89.0
Figure 89.0
1 Freezer door latch 503/5032 0.50005
2 9.875x23.875 Window smoked 0.60001
3 9.875x14.875 Window smoked 0.60002
4 Chrome polar hinge 0.50051
148
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Figure 90.0
Figure 90.0
1 Safety sign 0.60011
149
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Figure 91.0
Figure 91.0
1 Adapter 23856 0.50836
150
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Figure 92.0
Figure 92.0
1 Four folding step 69.50133
151
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Figure 93.0
Figure 93.0
1 3-Drawer tool box 70.10011
152
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Figure 94.0
Figure 94.0
1 5-Hub box WP26 0.20080
2 Weatherproof blank 0.20124
3 On/off switch 0.10024
153
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Figure 95.0
Figure 95.0
1 On/off switch WP26 0.10024
3 5-Hub box 0.20080
154
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Figure 96.0
Figure 96.0
1 Side box Synergy
155
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Figure 97.0
Figure 97.0
1 Wheel chock 0.85220
2 Triangle flare kit 9503009 0.60018
3 Pull out tray 69.50147
4 Sheave wheel holder 70.30066
5 5-Hub box WP26 0.20080
156
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Figure 98.0
Figure 98.0
1 Hydraulic generator 283PDL1766 0.20214
157
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Figure 99.0
Figure 99.0
1 Moisture separator 0.40231
2 Air lubricator 0.40230
3 50A male plug 0.20194
4 Hubble outlet .69055 0.20172
5 Hoffman enclosure 0.10060
6 On/off switch 0.20124
7 Weatherproof cover 0.20080
8 5-Hub box WP26 0.10024
9 Power shop cable 69.50443
158
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Figure 100.0
Figure 100.0
1 Hydraulic pressure hose hydraulic
2 Hydraulic return hose hydraulic
159
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Figure 101.0
Figure 101.0
1 5.0 PSI vent cap HC120PT12P5 0.30254
2 Hydraulic galvanized cap 0.85229
3 Extension handle 0.40704
4 Sight glass \ 0.35018
5 Hydraulic tank 69.50144
160
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Figure 102.0
Figure 102.0
1 Battery box cover 72.40014
161
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Figure 103.0
Figure 103.0
1 Latch assembly with lever 508 0.52011
2 CCL tray 69.20344
162
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Figure 104.0
Figure 104.0
1 Front bumper 70.30242
163
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Figure 105.0
Figure 105.0
1 Smoked window 0.60001
164
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16.7 Exterior Lights
Figure 106.0
Figure 106.0
1 36” LED light bar 0.85232
2 Hydraulic hoses 70.30236
165
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Figure 107.0
Figure 107.0
1 Evolution LED scenic light FCA570 V15DC15000 0.85337
2 LED red corner light 43252-3 0.20241
3 LED red safety 118516R00 0.20257
4 LED green safety P3624G1 0.20250
166
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Figure 108.0
Figure 108.0
1 Yellow tail board 70.30036Y
2 4” White LED light 62391 0.20012
3 Round 2” grote grommet 47112 0.20142
167
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Figure 109.0
Figure 109.0
1 White duro light 0.85206
168
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Figure 110.0
Figure 110.0
1 Rig light FCA570D15 0.20110
2 Evolution scenic lgiht FCA570V15DC 0.85337
3 Red LED clearance grote 47072 0.20139
4 Emergency vehicle 900Q65 0.80214
5 Amber LED clearance grote 47073 0.20138
6 3” Yellow grote reflector 40233 0.50019
7 3” Red grote reflector 40232 0.50018
169
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Baker Hughes 270 Tandem Axle Fullback Truck

Operations and Maintenance Manual

May 29, 2014

Operations and Maintenance Manual

3.0 General Specifications 6

3.1 Truck Chassis and Engine Specifications 6

3.2 Logging Cabin Specifications 7

3.3 Hydraulic System 7

3.4 Electrical System 8

3.5 Pneumatic System 8

3.6 Overhead Spooler 8

3.7 Benchmark Panel 8

4.0 Starting the Unit 8

4.1 After-Start Checks 9

4.2 Overhead Spooler Setup 9

5.0 Hydraulic System Settings and Operations 10

5.1 Hydraulic Generator Settings and Operations 10

6.0 Electrical Distribution System 11

7.0 Line Oiler Operations 12

8.1 Normal Stop Procedure 12

8.2 Emergency Stop Procedure 13

9.0 Drum Information 13

10.0 Cable Spooling Operation 13

11.0 Operational Check and Unit Test Procedures 14

11.1 Start Engine and Check Operation Checks 14

11.2 Hydraulic System - Drum Drive Checks 14

11.3 Hydraulic System Generator 14

11.4 Hydraulic Fluid Level 15

11.5 Hydraulic Hoses 15

11.7 Overhead Spooling System 15

12.0 Unit Maintenance 16

12.1 Pre-Departure Checks 16

12.2 Daily Maintenance 16

12.3 After Job Maintenance 17

12.4 General Maintenance Intervals 21

13.3 Annual Maintenance 23

13.4 Level 1 Preventative Maintenance and Inspection 400 Hr Inspection Sheet 24

13.5 Preventative Maintenance Inspection Guide 400 Hr PM Inspection 26

13.6 Preventative Maintenance Inspection Annual Inspection 32

13.7 Preventative Maintenance Inspection Guide Annual Inspection 34

13.8 Preventative Mainenance Inspection Report 37

14.0 270 Tandem axle full back diagram 39

16.1 Interior Electrical 42

16.2 Interior body 86

16.3 Interior lights 100

16.4 Chassis interior 103

16.5 Underbody 106

16.6 Exterior Body and Electric 119

16.7 Exterior Lights 165

prior to operating or performing maintenance on the specified unit(s).

ing the equipment.

3.0 General Specifications

3.1 Truck Chassis and Engine Specifications

Chassis Make and Model

• Wheel Base 22.6’

• Cab to rear axles 23.6’

• Construction: CNC punched, riveted, welded base

• Insulation: 2” urethane foam, .250” plywood

• Entrance(s): Single door

• Material: Brushed anodized aluminum skin

3.0 General Specifications 6

3.1 Truck Chassis and Engine Specifications 6

3.2 Logging Cabin Specifications 7

3.3 Hydraulic System 7

3.4 Electrical System 8

3.5 Pneumatic System 8

3.6 Overhead Spooler 8

3.7 Benchmark Panel 8

4.0 Starting the Unit 8

4.1 After-Start Checks 9

4.2 Overhead Spooler Setup 9

5.0 Hydraulic System Settings and Operations 10

5.1 Hydraulic Generator Settings and Operations 10

6.0 Electrical Distribution System 11

7.0 Line Oiler Operations 12

8.1 Normal Stop Procedure 12

8.2 Emergency Stop Procedure 13

9.0 Drum Information 13

10.0 Cable Spooling Operation 13

11.0 Operational Check and Unit Test Procedures 14

11.1 Start Engine and Check Operation Checks 14

11.2 Hydraulic System - Drum Drive Checks 14

11.3 Hydraulic System Generator 14

11.4 Hydraulic Fluid Level 15

11.5 Hydraulic Hoses 15

11.7 Overhead Spooling System 15

12.0 Unit Maintenance 16

12.1 Pre-Departure Checks 16

12.2 Daily Maintenance 16

12.3 After Job Maintenance 17

12.4 General Maintenance Intervals 21

13.3 Annual Maintenance 23

13.4 Level 1 Preventative Maintenance and Inspection 400 Hr Inspection Sheet 24

13.5 Preventative Maintenance Inspection Guide 400 Hr PM Inspection 26

13.6 Preventative Maintenance Inspection Annual Inspection 32

13.7 Preventative Maintenance Inspection Guide Annual Inspection 34

13.8 Preventative Mainenance Inspection Report 37

14.0 270 Tandem axle full back diagram 39

16.1 Interior Electrical 42

16.2 Interior body 86

16.3 Interior lights 100

16.4 Chassis interior 103

16.5 Underbody 106

16.6 Exterior Body and Electric 119

16.7 Exterior Lights 165