AMSLA590 Manual Orca 2021-09-28

AMSLA590 – ORCA
COMBINED DEPTH/TENSION
HEAVY DUTY SLICKLINE MEASUREMENT DEVICE
AMSLA590 ORCA SEPT 2021 Page 1 of 137

TABLE OF CONTENTS
SAFETY WARNING – TECH SUPPORT – RECOMMENDED SPARE PARTS

1.0 QUICK START GUIDE
2.0 GENERAL DESCRIPTION & FEATURES
2.2 TECHNICAL SPECS
2.3 HARDWARE FEATURES
2.4 WIRE THREADING
2.5 HAZARDOUS AREA OPERATIONS
3.0 MAINTENANCE - DRAWINGS - PARTS - LOAD PINS - ENCODERS –
ACCESSORIES
3.1 LUBRICATION
3.2 FIELD MAINTENANCE & REPAIR
3.2.1 LOAD PIN REPLACEMENT
3.2.2 TENSION WHEEL BEARING REPLACEMENT
3.2.3 TENSION WHEEL REPLACEMENT
3.2.4 HYDRAULIC LOAD CELL REPLACEMENT
3.2.5 ENCODER REPLACEMENT
3.2.6 IDLER WHEEL BEARING REPLACEMENT
3.2.7 MEASURING WHEEL BEARING REPLACEMENT
3.2.8 MEASURING WHEEL REPLACEMENT
3.2.9 BACKUP MAGNETIC DEPTH PICKUP
3.3 EQUIPMENT DRAWINGS – BILL OF MATERIALS
3.4 LOAD PINS
3.5 ENCODERS
3.6 OPTIONAL ACCESSORIES

SAFETY WARNINGS
This apparatus is suitable for use in ATEX Zone 2 Locations - PENDING
This apparatus is suitable for use in Class I, Division 2, Groups A, B, C, & D

Hazardous (Classified) or Unclassified Locations.
WARNING – EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY

IMPAIR SUITABILITY FOR ATEX Zone 2 LOCATIONS.
AVERTISSEMENT – RISQUE D’EXPLOSION – LA SUBSTITUTION DE

COMPOSANT PEUT RENDRE CE MATERIEL INACCEPTABLE POUR LES ATEX
Zone 2 LOCALES.
WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY

IMPAIR SUITABILITY FOR CLASS I, DIVISION 2;
AVERTISSEMENT - RISQUE D'EXPLOSION – LA SUBSTITUTION DE

COMPOSANTS PEUT RENDRE CE MATERIEL INACCEPTABLE POUR LES
EMPLACEMENTS DE CLASSE I, DIVISION 2
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS

POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOW TO BE NON-
HAZAROUS;
AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DECONNECTER

L’EQUIPMENT, COUPER LE COURANT OU S’ASSURER QUE L’EMPLACEMENT
EST DESIGNE NON DANGEREUX.
WARNING - PROTECTION MAY BE IMPAIRED IF THIS DEVICE IS USED IN AN

APPLICATION OR MANNER NOT SPECIFIED IN THE MANUAL
NOTE – The safe ambient temperature operating range for this equipment is -20 to 40C
or -4 to 104F.
___________________________________________________
BenchMark measuring equipment will frequently be operated in hazardous

environments. Appropriate safety precautions need to be taken.
Training - Operators shall be trained in the proper and safe use of the device.
Do not exceed the tension limit specified for this device in this manual.

SAFETY WARNINGS continued
Flammable Substances - Flammable and explosive substances are often found in the
proximity of the equipment operations. Proper venting should take place where
practicable. Avoid open flames, sparks and other ignition sources.
Electric Shock – Depending on the equipment being used, both AC and DC current
may be present. Frequently in wellsite operations conductive fluids and chemicals are
used. Use extra caution when working with BenchMark equipment and follow
manufacturer warnings to avoid electric shock.
Do not separate any electrical connector, while powered, in a hazardous area.

Separate only when power is removed, and/or in a safe area.
Safe Operating Temperatures – BenchMark Wireline equipment is designed to

operate safely within these temperature ranges. Do not try to operate this equipment in
conditions that outside these temperature limits.
The safe ambient temperature operating range for this equipment is -20 to 40C or -4 to
104F.
Hazardous Equipment Marking - See General Assembly drawings for hazardous

equipment marking.
ALL WARNING LABELS ON THE EQUIPMENT MUST BE OBSERVED AND FOLLOWED.
Installation Instructions - Install measuring device onto the spooling mechanism per
the unit manufacturer instructions. Take care to avoid pinching or cutting of electrical
cables when the measuring device moves during the spooling operation.
Take care to thread the wire through the device properly to prevent the wire from
rubbing the frame during operation. The Table of Contents of this manual will list where
the threading procedure is located.
Rotating Equipment – BenchMark Wireline measuring equipment is often attached to

rotating industrial machinery. This may include winches, pulleys, rigging, rotating drums
plus moving cable and wire. Though BenchMark’s measuring equipment does not
normally present a safety hazard when in operation provided it is used within the design
parameters of the equipment, the heavy equipment used in this type of work in proximity
to BenchMark’s equipment may. Never attempt to use BenchMark equipment in any
way or for any other purpose than for which it was designed.
Use every precaution to keep a safe distance from dangerous equipment when it is in
operation. Never approach the measuring device while the cable drum is turning.

OBTAINING TECHNICAL SUPPORT
Phone Tech Support is available to customers of BenchMark Wireline.
Prior to calling, please go through the following Checklist.
Prior to the Call, please gather this information. It will be Needed by the
Support Technician to help diagnose the problem.
 Equipment model number

o This can be found on the machine, panel, cable etc.
 Equipment serial number

o This can be found on the machine, panel, cable etc.
Contact Information
Website www.BenchMarkWireline.com
Email mail@benchmarkwireline.com
Phone +1 281-346-4300 ask for Tech Support
Fax +1 281-246-4301
Equipment may be returned for repair and maintenance, but

Please notify us prior to shipment.
Ship returned equipment to:
Benchmark Wireline Products
36220 FM 1093
Simonton Texas 77476 USA

RECOMMENEDED SPARE PARTS LIST – AMSLA590 ORCA
ITEM P/N DESCRIPTION QTY REF

1 WHEEL MEASURING 4FT 0.092-1/4 0
2 AMSLA560 WHEEL ASSY TENS 20" 5/16 MAKO 0
2 50546 WHEEL ASSY TENS 5.33FT COMPOSITE 0 OPTION
4 AM3KM040 ADAPTER ENCODER H25D/H20 MAG 0 OPTION
12 AMSLA162 WHEEL ASSY PRESS RLR 1/4 TENSN 2 OPTION
13 AMSLA163 WHEEL ASSY PRESS RLR 1/4 MEASR 1
21 AM3KM050 COUPLING ENCDR W/BKUP MAGNETS 0 OPTION
49 AM5KA058 ASSY ENCDR BACKUP MAG EEx nA 0 OPTION
51 AMS1P090 COUPLING OLDHAM ENCODER 1 OPTION
52 AMSLP040 BEARING SPHERE-ROL 50MM ID 1
52 40986 BEARING SPHERE-ROL 65MM ID 1 OPTION
53 AMSLP030 BEARING BALL 30MM 2-ROW SST 2
54 AM3KP204 BEARING BALL 20MM SST ABEC-1 8
NOTE – Depending on your location, it may be advisable to stock a spare

Encoder and Load Pin/Axle.
ONLY stock the Encoder and Load Pin/Axle used in your current Measuring
Head.
See Load Pins/Axles – starting in Section 3.4.1

See Encoders – starting in Section 3.5.1

1.0 QUICK START GUIDE
Determine wireline size to be used – .092" to 5/16”
Since the wireline wraps around the depth wheel, the circumference of the depth wheel
will change with a change in wire size. The wheel size setting needs to be set to match
the wireline size in order to accurately measure depth.
These corrections are automatically made in the BenchMark hoistman's panel by

selecting the proper cable size using the menu. If a different panel is used, the wheel
size will need to be entered at this time.

1.1 Equipment Installation Procedure
This equipment is to be installed only by personnel who are suitably trained and
qualified to local/national codes.
1. Install the measuring head on the wireline equipment.

Bolt the mounting bracket to the wireline equipment
Connect the measuring head to the mounting bracket
2. Connect the cables for to the encoder, backup and load pin to the measuring head.
Equipment Setup Procedure
1. Power up the panel connected to the measuring head and verify it is working
properly.
2. Set depth to zero “0” to enable line size selection and tension calibration.
3. Verify the panel is configured to match the system.

- Line size
- Measurement units
- Encoder settings
4. Install the line in measuring head and set the line size parameter on the panel.
Note – see Proper Wire Threading Path on next page.
5. Set Tension Alarm value.
6. Set depth adjust value if necessary.
7. Rig up through sheaves, install tool, and slack off weight.
8. Set depth to zero.
9. Press T-Zero to set tension to zero. Press T-CAL and verify that panel tension reads
correctly (depending on type of measuring head selected).
10. Pull tool to depth 0 position. Press D-Zero to reset the panel depth to 0.

1.2 WELLSITE OPERATIONING SUMMARY
Power up the panel connected to the measuring head and verify it is working properly.
Verify the panel is configured to match the system

- Line size
- Measurement units
- Encoder settings
Install the line in measuring head and set the line size parameter on the panel.
Set Tension Alarm value.
Set depth adjust value if necessary.
Ensure that memory card is installed in data recorder.

Turn power to panel off then on again.
This will write the operating parameters to the memory card.
Rig up through sheaves, install tool, and slack off weight.
Set depth to zero.
Press T-Zero to set tension to zero.
Press T-CAL and verify that panel tension reads 4,000 or 5,000 lbs (depending on type
of measuring head selected)
Pull tool to depth 0 position.

Press D-Zero to reset the panel depth to 0.

2.0 GENERAL DESCRIPTION & FEATURES
2.1 PRODUCT DESCRIPTION & INTENDED USE OF EQUIPMENT
The "Orca” Slickline Measuring Device is a heavy duty three wheeled device which accurately
measures both wireline depth, line speed and tension. It minimizes wire abrasion and fatigue by
using a non reverse bend configuration.
The device is designed to be mounted in front of the wireline drum on a spooling mechanism.
Linear bearings in the mount allow it to slide back and forth in front of the drum so the wire can
be spooled evenly. The bracket on the top of the measuring head is used to mount it to the
wireline unit. Spooling rollers and pressure wheels are provided to keep the wire in the wheels
at low or no tension.
The wireline can be removed from the measuring head without cutting off the cable head. The
guide rollers are slotted so they can be repositioned out of the way to remove the wireline.
Tension is measured from a load pin which also serves as the axle for the tension wheel. The
Orca also has a hydraulic load cell which is an independent tension measuring device. Since
the tension wheel is opposite the measuring and idler wheel, the wire completely wraps around
both wheel sets. This creates a relatively high signal at the load pin which provides a very
accurate tension measurement.
With the BenchMark Winchman's Panel, depth can be accurately measured on different sized
lines without changing wheels. This is done electronically by the panel using the depth
information provided by an encoder. Changes in wire size are accounted for by the panel
software. Wire stretch can also be automatically calculated by the panel.

2.2 TECHNICAL SPECIFICATIONS
2.2.1 DEPTH MEASUREMENT
Depth measurement is made by wrapping the wire around the measuring wheel which has a
precision machined groove. The wheel groove has a diameter of 20.06 inches. The wheel is
hardened to greater than Rockwell 58 by using a special heat treat process. This minimizes
wheel wear to maximize wheel life.
This measuring head is capable of providing two completely independent depth measurements,
an optical encoder and a magnetic pickup.
The optical encoder provides a high-resolution measurement to the BenchMark Wireline

Products hoistman’s panel. With this panel depth and line speed can be accurately measured
on different sized lines without changing wheels. This is done electronically by the panel.
Changes in wire size are accounted for by the panel software. Wire stretch can also be
automatically calculated by the panel. The panel operates on 12vdc and supplies the necessary
power to the encoder and load pin.
A backup depth system is available to provide another independent depth measurement. Depth
is measured by a frictionless magnetic pickup mounted in the measuring head. The pickup
consists of magnets imbedded in the measure wheel coupling and two hall affect devices
mounted next to the shaft. This provides a quadarature type measurement. A small display
panel is mounted inside a wireline unit. The panel is designed to be connected to an external
AC or DC supply or operate off internal batteries for up to 15 hours between charges. In the
event of an external power interruption, the unit automatically switches to battery power. The
system is designed to operate without intervention from the user. When external power fails,
the depth display is maintained by the batteries. A switch on the front of the panel allows
different sizes of wire to be measured accurately without changing the measuring wheels.

2.2.2 TENSION SPECIFICATIONS
The wheel nearest the well rotates on an axle pin that is instrumented with strain gauges.
These strain gauges produce an electrical signal proportional to the magnitude of line tension.
The wire always makes a complete 180 degree wrap around the tension wheel so rigup angle
does not affect the tension measurement.
The tension wheel is mounted on a self aligning bearing which allows the wheel to properly align
itself. This reduces any side forces that may be present which increases the tension
measurement accuracy.
Additionally, a hydraulic load cell is included which measures wireline tension

independently of the electronic load pin. It is mounted in the frame and measures the
tension differential between the measuring wheel and the tension wheel.
1. PASSIVE LOW VOLTAGE
Power Requirement - 12 vdc excitation
Interface – None – passive bridge only
2. DIFFERENTIAL VOLTAGE
Power Requirements - +/– 15 vdc input power
Interface - Proprietary circuit board which amplifies the load pin signals and provides a
1.5v differential output.
0 vdc = 0 lbs. (0 kg)

.75 vdc = 5,000 lbs. (2,268) - shunt CAL
1.5 vdc = 15,000 lbs. (6,803kg)

2.2.2 TENSION SPECIFICATIONS continued
3. 4-20MA CURRENT LOOP
Power Requirements - +24vdc input power
Interface - Proprietary circuit board which amplifies the load pin signals and provides a
4-20ma current loop output.
4 ma = 0 lbs. (0 kg)
12 ma = 5,000 lbs. (2,268) - shunt CAL
20ma = 15,000 lbs. (6,803kg)
COMMON SPECIFICATIONS
Temperature Stability
<= .015% full scale / deg F on zero
<= .02% full scale / deg F on output
Accuracy 1% full scale nominal

Maximum Rated Load 9,000 lbs. (4,082 kg)
2.2.3 HYDRAULIC TENSION SPECIFICATIONS
A hydraulic load cell is included which measures wireline tension independently of the
electronic load pin. It is mounted in the frame and measures the tension differential
between the top measure wheel and the bottom tension wheel. A second depth idler
wheel is provided to eliminate cable rub against a single wheel with the movement of
the hydraulic load cell.
Different scales are available.

2.2.4 GENERAL SPECIFICATIONS
Height: 38.01” .965 m

Length: 51.54” 1.309 m
Width: 12.86" .326 m
Weight: 310 lbs 140.61 kg
Measuring Wheel
Circumference: 5.33 feet 1.624 meters
Diameter: 20 inches .508 meters
Maximum Tension: 15,000 lbs. 6,803 kg
Line Sizes: .092" – 5/16” 2.33 mm – 7.93 mm
Operating Temperature: -40°C to +65°C -40°F to +149°F
Encoder: 1,200 PPR, others available
Backup Counter: 4 PPR Quadrature
Load Pin: Passive low voltage, Differential voltage, 4-20ma current loop
Hydraulic Load Cell Independent mechanical tension measuring device

2.3 HARDWARE FEATURES
 Cable sizes .092 to .160 slickline & 3/16” to 5/16” e-line/braided line
 Tension load axle & amplifier can be configured to different outputs
 2 fully independent depth measurements - 1. optical encoder 2. magnetic
pickup
 Backup depth system – reduces drag on measuring wheel by eliminating
mechanical drive cable
 Encoder & tension amplifier certified for Zone II/C1D2 area use
 Anodized aluminum frame – all steel parts are plated or SST
 Line removal from the side without cutting off Cable Head
 Minimizes wire abrasion & fatigue by using non-reverse bend configuration
 Separate measuring and idler wheels completely eliminates wire rub
 Large diameter wheel radius minimizes wire fatigue
 Spooling rollers and pressure wheels keep wire in wheel at low/no tension
 Sprung pressure wheel keeps wire turning with wheel even with sudden
direction change or jarring action
 Top mount configuration on a 40mm overhead spooling bar
 Hydraulic Load Cell provides second independent tension measurement

2.4 WIRE THREADING

2.4.1 SLICKLINE WIRE THREADING – OVERVIEW
This is what an Orca measuring head should look like with the wire properly threaded.
Final thread path is the same whether threaded with or without cable head attached.

2.4.2 SLICKLINE WIRE THREADING - WITH CABLE HEAD
The Orca measuring head can be threaded either with or without the cable head
attached. These images show a wire without a cable head but the same procedure can
be used for a wire with the cable head attached by threading from the side and top
around the rollers.
Loosen the screws on both sets of guide rollers only if the cable head is attached.
Swing the guide roller plate away leaving top/bottom access to the space between the
guide rollers.

2.4.2 SLICKLINE WIRE THREADING - WITH CABLE HEAD continued
Loosen the keeper roller, move it to the top of its slot and retighten the screw.
Loosen the upper pressure roller, move it to the end of its slot and retighten the screw.

Loosen the lower pressure roller, move it to the end of its slot and retighten the screw.
Thread the wire between the 1st set of guide rollers then over the top of the idler wheel.

The idler wheel is the one on the encoder side of the measuring head and lines up
directly with the gap between the guide rollers.
Feed the wire under the guide roller plate spacer.

The wire then goes over the top of the tension wheel.
It then goes around the back of the wheel under the upper pressure roller.

It continues around the bottom of the wheel under the lower pressure roller.
The wire now goes from the underside of the tension wheel to the underside of the
measuring wheel, above the lower keeper roller. The measuring wheel is the one
closed to you.

Use a ¾” open end wrench to spring the pressure roller arm away from the measuring
wheel and thread the wire between the pressure roller and the measuring wheel groove.
Note – make sure that the wire is in the groove of the measuring wheel, (the one closest
to you), and not the groove of the idler wheel.

Now thread it over the top of the measuring wheel.
Example – this is how the wire should look when properly threaded.

Run the wire out through the gap between the other guide rollers.
Now reposition the two keeper rollers and the two pressure rollers back in their slots
and tighten the screws.
Note – the two pressure rollers need to be in the slot of the tension wheel. Avoid
adjusting them with too heavy a contact with the tension wheel. If they are too close
they can bind and give false reading.

This is what the Orca should look like then properly threaded.

2.5 HAZARDOUS AREA INSTALLATION STANDARDS & REQUIREMENTS
This equipment is to be installed only by personnel who are suitably trained and
qualified to local/national codes.
1. Install the measuring head on the wireline equipment.

Bolt the mounting bracket to the wireline equipment.
Connect the measuring head to the mounting bracket.
2. Connect the cables from the panel to the encoder, backup and load pin on the
measuring head.
Make sure you use the correct cable for each connection as described in this manual.

TYPE EXAMINATION CERTIFICATES AND LABELS

3.0 MAINTENANCE - DRAWINGS - PARTS -
LOAD PINS - ENCODERS - ACCESSORIES
PRE AND POST JOB CHECKS
Between jobs, check the measuring and guide wheels for looseness, play, out-of-
roundness, worn or rough sounding bearings, or other mechanical conditions that could
affect measurement accuracy.
Visually inspect the interiors of the electrical connectors for the encoders and electronic
load axle for dirt and evidence of insulation breakdown. Clean or replace as necessary.
Install dust caps on the connectors if the cables are removed.
Manually rotate each wheel by hand to verify its condition. Inspect the depth measuring
wheel for signs of abnormal wear diameter changes, or shaft play that can affect
measurement accuracy. The wheel should be replaced if it is grooved more than .005".
Inspect the tension wheels for signs of abnormal wear, diameter changes, or shaft and
bearing play that could affect measurement accuracy. It should also be replaced if it is
grooved more than .005".
Do not pressure wash bearings or

electrical parts

3.1 LUBRICATION
Lubrication – use waterproof marine grease and a straight necked grease gun. Use
the grease nozzle that comes with the measuring head (in the small plastic bag zip-tied
to the frame).
Press the nozzle into the fitting and apply 3 squirts. Repeat same lubrication schedule
each month.
DO NOT pressure wash the machine as it will force the grease out of the bearings and
they will fail.

3.2 FIELD MAINTENANCE AND REPAIR
TENSION WHEEL MAINTENANCE

There are 4 field maintenance procedures for the Tension Wheel and Load Cell.
- Load Pin Replacement – 3.2.1
- Tension Wheel Bearing Replacement – 3.2.2
- Tension Wheel Replacement – 3.2.3
- Hydraulic Load Cell Replacement – 3.2.4
MEASURING WHEEL MAINTENANCE

There are 5 field maintenance procedures for the Measuring Wheel.
- Encoder Replacement – 3.2.5
- Idler Wheel Bearing Replacement – 3.2.6
- Measuring Wheel Bearing Replacement – 3.2.7
- Measuring Wheel Replacement – 3.2.8
- Backup Magnetic Depth Pickup – 3.2.9

3.2.1 LOAD PIN REPLACEMENT
*NOTE – maintenance on the Orca may be performed with the device clamped to a
sturdy workbench or laid horizontally on blocks.
The 1st step is to remove the spiral lock from the load pin shaft.
If the lock has not been damaged it can be used again on reassembly.
Hold the tension wheel with one hand.

3.2.1 LOAD PIN REPLACEMENT continued
Gently remove the load pin from the wheel hub.

The load pin shaft holds the tension wheel in place.
With the load pin removed gently let the tension wheel rest in the frame.
Put anti-seize compound on shaft of the new load pin.

Position the tension wheel so that the load pin can be placed through the wheel hub.
Note that the load pin has a flat notch on one side.

The flat side of the load pin will flange up to the guide plate on the frame.
Insert the load pin and rotate it so that the flat side of the pin butts up to the guide plate.

The bearing in the tension wheel has a slot for an anti-rotation screw.
*Note - depending on position of the wheel, if during this procedure the tension wheel
stays in place, there is no need to remove the anti-rotation screw.
If the wheel moves too much, the bearing may slide off the anti-rotation screw. In that
case you must remove the anti-rotation screw for proper reinstallation.

Spin the wheel until the anti-rotation slot on the bearing can be seen through the anti-
rotation screw hole.
Replace the anti-rotation screw and tighten it firmly.

Replace the spiral lock.

3.2.2 TENSION WHEEL - BEARING REPLACEMENT
For this maintenance, it is assumed that both the wheel and the bearing have already
been removed. The bearing is held in the wheel hub by 2 snap rings.
An Arbor press is being used to demonstrate this replacement.
The anti-rotation bushing will be pressed into the bearing. Place the new bearing on the
press.

3.2.2 TENSION WHEEL - BEARING REPLACEMENT continued
On the first stroke, the bushing may not go all the way into the bearing. Add a spacer
on the bottom of the bearing as the bushing will protrude below the bottom of the
bearing.
The bushing is properly installed when approximately equal amounts stick out both
above and below the bearing assembly.

Take the Tension Wheel. 2 snap rings will hold the bearing assembly in place. The
front of the wheel is the side with the grease fitting.

On the BACK of the wheel, install the 1st snap ring.
Then turn the wheel over. You should be able to simply insert the bearing assembly
into the center hub.

Install the 2nd snap ring to hold the bearing in place.
Manually tug on the bearing assembly to make sure it is firmly in place.

Lubrication – use waterproof marine grease and a straight necked grease gun. Use
the grease nozzle that comes with the measuring head (in the small plastic bag zip-tied
to the frame).
Press the nozzle into the fitting and apply 3 squirts. Repeat same lubrication schedule
each month.
DO NOT pressure wash the machine as it will force the grease out of the bearings and
they will fail.

3.2.3 TENSION WHEEL REPLACEMENT
*NOTE – maintenance on the Dolphin may be performed with the device clamped to a
heavy work bench or laid horizontally on blocks. Replacing the tension wheel is a
simple procedure that can be performed with the head in a variety of positions.
For this maintenance, we assume that the load pin has been removed. 3.2.1
Loosen and completely move the pressure roller to the end of its slot and retighten.
Unscrew and completely remove the other pressure rollers.
Pull the wheel up and out of the frame.
If bearing replacement is needed see 3.2.3
Reposition the wheel back in the frame and follow the load pin installation instructions in
3.2.1.
Then replace and adjust the pressure rollers so that the rollers fit inside the groove of
the tension wheel.

3.2.4 HYDRAULIC LOAD CELL REPLACEMENT
Note – the photos used in the Load Cell Replacement information are of the Thresher
measuring head. The Thresher and the Orca are functionally the same except for the
way that they mount to the wireline unit.
The Orca measuring head has a pivot joint that connects the measuring wheel
assembly to the tension wheel assembly. The hydraulic load cell is placed between
those two assemblies. Because of the circular wire path, as tension is added to the
wire, it will pull the tension wheel assembly towards the measuring wheel thus exerting
pressure on the load cell.
The load cell is screwed to the measuring wheel side of the frame and it rests against a
flat mounting plate on the tension wheel side.

3.2.4 HYDRAULIC LOAD CELL REPLACEMENT continued
The Hydraulic Load Cell is an additional tension measuring device independent of the
load pin.
To replace the load cell, two screws which run through the mounting plate up into the
bottom of the load cell and a deeply recessed screw need to be removed.

First remove the recessed screw. For this task a ¼ inch drive with an 8 to 10 inch
extension will work the best and a flexible connection on the extension is also helpful.
The screw is accessed by putting the extension in the position shown “between the
frame and the idler wheel” behind the encoder as shown in the picture.
Then attach a ratchet to the extension, loosen and remove the screw and remove the
extension and socket.

Now remove the other two screws that go from the mounting plate into the load cell. A
flex spring extension can be very helpful for this procedure.
As soon as the last screw is removed the load cell will usually drop from the mounting
plate.

Take the new load cell with the hydraulic hose attached and reposition it the same as
the one that was removed. Replace the three screws but do not fully tighten them.
Note that the mounting plate has a curved edge matching the radius of the load cell.

Position the load cell so that the edge of the cell aligns with the edge of the mounting
plate. Tighten the three screws to hold the load cell in place.
If necessary, use a soft hammer to nudge the cell into the proper position.

Now firmly tighten all screws

3.2.5 ENCODER REPLACEMENT
The first step is to remove the Plug.

The plug covers an access hole used to maintain the equipment.
Next remove the 4 encoder screws.

Hold the encoder as the last screw is removed or it will fall from the adapter body.

3.2.5 ENCODER REPLACEMENT continued
Carefully pull the encoder straight out avoiding contact between the couplings and the
adapter.
If the plastic coupling is attached to the coupling stack, remove it.

If it is still inside the adapter body, with a pair of needle nose pliers, reach in and extract
it.
*Note - If you drop the plastic coupling inside the adapter, you may have to remove the
adapter to retrieve it.

Carefully remove the O Ring.
Note the size of the gap between the coupling and the encoder body.

With the small Allen wrench, loosen the 2 set screws that hold the coupling on the shaft
of the encoder.
Remove the coupling stack from the shaft.

Replace the existing coupling stack on the shaft of the new encoder.
Note that the shaft has a flat side. Place the coupling on the shaft so that the tangs on
the coupling and one set screw are aligned to the flat side of the shaft.
When tightening, leave the same gap on the shaft between the coupling and the
encoder. Snug up but DO NOT fully tighten the set screw on the flat side of the shaft.

Use DC111 or equivalent and apply a thin layer to the plastic coupling.
Press the plastic on top of the coupling stack. The DC111 will temporarily hold it in
place.
The top of the encoder has the OEM labels. Rotate the coupling stack so that the slot
on the top of the plastic coupling is oriented vertically.
Look though the hole in the adapter body and you will see the coupling half.
Rotate the measuring wheel so that the tang on the coupling half is vertical.

Carefully replace the encoder watching to not jar the coupling stack.
Hold it against the adapter body.
Using a flashlight look in the hole to verify that the plastic coupling has engaged the
tang on the measuring wheel.

Temporarily replace the 2 screws to hold the encoder and coupling in place.
Place the Allen wrench in a set screw hole and exerting force, lever the encoder stack
away from you towards the measuring wheel, snug up the set screw.

Remove the temporary screws remembering to hold on to the encoder.

Carefully remove the encoder taking care to not jar the encoder stack.
Firmly tighten the 2 set crews on the coupling.
Lubricate the O ring using the DC111 and carefully replace the O ring in the adapter
body.

Position the coupling on the encoder so that the slot is vertical.
Carefully position the encoder in the adapter body.
Holding the encoder firmly in place, Rotate the measuring wheel and if properly
engaged, as you look down through the plug hole, you should see the white dots on the
coupling stack move as the coupling spins.

Replace the 4 screws and tighten them firmly.
The last step in the process is to replace the plug.

Put a half a bead of Teflon sealant on the leading threads of the plug.

Replace the plug and tighten it firmly.

3.2.6 IDLER WHEEL – BEARING REPLACEMENT
The Dolphin measuring head has a bearing in the hub of the shaft that supports both
the Measuring Wheel and the Idler Wheel. There is also a bearing in the Idler Wheel
itself. This will show how to replace the Idler Wheel Bearing.
NOTE – For information on removing the measuring and idler wheels see 3.2.7 & 3.2.8
When the wheels have been removed from the frame, the top wheel is the measuring
wheel. Notice that it has a solid hub and no bearings.
We will now replace the bearing in the center of the idler wheel.

3.2.6 IDLER WHEEL - BEARING REPLACEMENT continued
There is a shaft adapter inside the bearing. It needs to be removed.
The adapter will be pushed out from the back and it should come out very easily by
either pressing directly on it or by tapping it with a rubber hammer.

There are retainers on each side of the bearing that need to be removed.
Remove the old bearing.
The new bearing must be reinstalled with care. You cannot press on the inner race of
the bearing as it will likely bend and not work properly. You must press on the thin outer
race only.

Benchmark Wireline has developed this precision reinstallation tool that presses only on
the outer race of the bearing and seats it to the proper depth.

Replace the retainer clips that hold the bearing in place.

3.2.7 MEASURING WHEEL – BEARING REPLACEMENT
There are 2 bearings in the measuring wheel. 1 is on the shaft and the other is inside
this hub. Both will need to be replaced.
Remove the retainer clip that holds the bearing in place in the hub.
It can normally be removed and replaced with no special equipment.
Install the new bearing and the retainer clip.

3.2.7 MEASURING WHEEL – BEARING REPLACEMENT continued
The other bearing is on the shaft.

First remove the key from the shaft.
Now remove the retainer clip for this bearing.

You now need to press the shaft and the bearing out of the hub.
You will usually need a press to both remove and reinstall the bearing and shaft.
Set up your press to allow pressing the shaft and bearing out through the bottom of the
hub.
Get a punch of smaller diameter than the shaft and press out the shaft.

Be sure to catch the shaft – clean off any lubricant on the bearing and shaft.
Protect the small threaded end of the shaft by putting a nut over it to press on.
Press the shaft out of the bearing.
Place the new bearing on the shaft and snug as much as possible manually.

Place the shaft and bearing in the hub so that you can see the small end of the shaft
protruding out of the hub…this will indicate that the shaft is properly aligned in the hub.
You will now press the bearing with the shaft in it, into the hub.

Verify that the shaft is properly aligned in the hub.

If the shaft spins easily, then it is properly installed.
Now replace the key in the shaft.

The shaft is ready to be inserted in the wheel hub.
For instructions on reinstalling the shaft in the wheel, go to 3.2.8

3.2.8 MEASURING WHEEL - REPLACEMENT
NOTE – during the process of changing the wheels in this tutorial, the encoder will be
removed and then reinstalled. It is assumed that the same encoder will be reinstalled
so the process for changing the coupling stack is not shown. If you will be installing a
NEW ENCODER during this procedure, refer to 3.2.5 for details on changing the
coupling stack.
The Orca weighs approximately 350 pounds. Take extreme care in moving this device.
During this process it will be moved several times.
To begin with make sure the measuring head is lying flat on a sturdy worktable with the
encoder side up. 2x4 wooden blocks as shown in the video will hold it steady up off the
table quite well.

3.2.8 MEASURING WHEEL - REPLACEMENT continued
The first step is to remove the Plug.

The plug covers an access hole used to maintain the equipment.
Then remove the 4 screws that hold the encoder in place.
Pull the encoder straight up and try avoiding impacting the encoder coupling with the
adapter body.

Now remove the 4 screws that hold the encoder adapter in place.
You may need to tap the corner of the adapter with a hammer to loosen.
The rubber O-ring may be reused if not damaged.
Now remove the black plastic encoder adapter coupling insert.

Line up the measuring and the idler wheels and insert a wooden dowel the thickness of
a broom handle through the aligned holes and push the dowel up against the measuring
head frame.
After using a 1 ¼ inch socket on the breaker bar to remove the nut that holds the shaft
in place, remove all of the 16 screws in the hub except 2 on opposite sides which will
hold the hub in place.
Turn the orca head over with the encoder side down.
Now loosen the keeper roller and move it to the end of its slot.

We’ll now remove the pressure roller. Using a 3/8” Allen wrench and an 11/16” open
end wrench remove the nut, screw, washer, spacer and wheel.
Loosen but do not remove the 8 screws on the hub.

Align the wheels and place the wooden dowel through the holes again and push it up
against the frame.
On the underside of the wheel using a 3/16 inch Allen in a socket, remove the 2 screws
holding the lower hub in place.
The hub should easily drop out of the frame.
On the top side, slide cardboard between the wheels in preparation for removal.

Remove the already loosened screws from the top hub.
The hub and shaft should now be easily pulled out. You may have to push up on the
shaft from the bottom.
Now remove the wheels by sliding them out of the side of the frame. Both must be
removed at the same time. Note that the wheel with the raised hub is on top.

After the wheels are removed and any shaft, hub, bearing or wheel repairs have been
done, stack the wheels in the same order as when removed. Make sure that the hubs
are aligned and slide them back into the frame.
When properly installed they wheels will drop down into the frame.
Center the wheels in the frame hole.
Reinstall the hub and shaft in the center of the wheels. Locate the key on the shaft and
rotate the shaft so the key slides down into the keyway on the wheel hub. A flashlight
will help you see the relative positioning of the key and keyway.

A flat headed screwdriver will allow the shaft to be rotated precisely and the shaft and
hub to slide down into place. You may have to hold the wheel steady while turning the
screwdriver.
Rotate the hub so that the grease fitting is at the 2 o’clock position. This will help to
keep the fitting clean and dry.

Replace the 8 screws with lock washers on the hub. Do not fully tighten.
On the underside, reposition the hub over the shaft, slide the spacer on the shaft and
hand tighten the nut. The nut has fine threads so many turns will be required. Hand
tighten it until you get to the nylon threads on the nut.

Place the dowel in the holes in the wheels. Use the 1 ¼ socket and breaker bar to snug
the nut on the underside.
On the top side, tighten the 8 screws holding the hub in place. Make sure that the
measuring and idler wheels turn freely independently of each other.

Flip the measuring head over so the encoder side is on the top.
Make sure that the hub is rotated so that 2 of the inner ring screws are horizontal with
the top of the measuring head and insert 2 screws.
Now tighten up the nut with the 1 ¼ inch socket breaker bar.
After tightening, re-test the yellow wheels to make sure that they spin easily in opposite
directions without binding or touching.

Now replace the 16 screws on the hub. The long ones go on the inner ring and the
short one on the outside. Tighten them firmly.
Rotate the encoder coupling stack to vertical with the top mount and replace the black
plastic coupling insert adapter on top of the stack.

Make sure the rubber O-ring is in the groove of the encoder adapter body and is
positioned as shown. If necessary, lubricate the O-ring in DC111 or an equivalent.
Place the encoder adapter on the hub and insert the 4 screws and lock washers and
tighten.

Make sure that the encoder coupling insert is rotated to connect with coupling on the
underside of the encoder.
Replace the encoder with the cable connection facing up towards the overhead bar
connector.

Shine a light through the plug hole and rotate the measuring wheel. It the encoder is
properly connected you will see the white dot on the encoder coupling moving in the
hole.
Now replace and tighten the 4 screws on the encoder.

Now you’ll replace the plug.

Put a half a bead of Teflon sealant on the leading threads of the plug.
Replace the plug and tighten it firmly.

Now reinstall the pressure roller. Connect a ¾ inch open end wrench to the end of the
metal arm. Insert the screws and washer all the way through the hole in the control
arm. From the bottom, slide on the spacer and pressure roller with the tapered side up
and the washer and nut. Make sure the roller is in the measuring wheel groove. The
measuring wheel is the one on the bottom.
Tighten the nut and screw using a 3/8” Allen wrench and an 11/16 wrench. If done
properly the pressure wheel should turn with some effort and correspondingly the yellow
measuring wheel should also turn.

Loosen, reposition and retighten the upper keeper roller.

3.2.9 BACKUP DEPTH MAGNETIC PICKUP REMOVAL AND INSTALLATION
The backup depth magnetic pickup is mounted to the encoder adapter. It is held in
place by four screws. Remove the screws and the pickup can then be removed. The
pickup must be properly oriented to work correctly. The slot should be oriented to the
top. The top side is the encoder side. Ensure that an O-ring is inserted between the
plastic housing and the mount. An additional O-ring is used between the connector and
the housing to keep moisture out.
If the backup display is counting backward (i.e., counting negative when going down
hole), simply rotate the pickup 180 degrees to change the direction.

3.3 EQUIPMENT DRAWINGS – BILL OF MATERIALS
3.3.1 AMSLA590A ORCA – DIMENSIONS

3.3.1 AMSLA590A ORCA – SIDE 1 VIEW


3.3.1 AMSLA590A ORCA – SIDE3 VIEW


3.3.1 AMSLA590A ORCA – TOP-DOWN VIEW
3.3.1 AMSLA590A ORCA – GUIDE ROLLER

3.3.1 AMSLA590A ORCA – MEASURING & IDLER WHEELS

3.3.1 AMSLA590A – ORCA TENSION WHEEL

3.3.1 AMSLA590A – ORCA PRESSURE ROLLER

3.3.1 AMSLA590A – ORCA PRESSURE WHEEL

3.3.1 AMSLA590A – ORCA GUIDE ROLLER – TOP VIEW

3.3.2. BILL OF MATERIALS – AMSLA590 ORCA
ITEM P/N DECSRIPTION QTY REF
PARENT - COUNTER ASSY 2 WHL 20" 5/16 15,000#
AMSLA590
BASE MODEL ORCA HYBRID
1 AMSLA559 WHEEL ASSY MEAS 5.33FT ORCA .092-5/16 0
2 AMSLA562 WHEEL ASSY TENS 5.33FT ORCA .092-5/16 0
2 50546 WHEEL ASSY TENS 5.33FT COMPOSITE 0 OPTION
3 AMSLA561 WHEEL ASSY IDLER 5.33FT ORCA .092-5/16 0
3 50545 WHEEL ASSY IDLER 5.33 FT COMPOSITE 0 OPTION
4 AM3KM040 ADAPTER ENCODER H25D/H20 MAG BACKUP 0 OPTION
4 AM5KM057 ADAPTER ENCODER H37C/H25D 0 OPTION
ADAPTER COUNTER HD RT ANGL DRV 5/16 ORCA
5 AMSLM592 1
2 WHL COUNTER
5 AMSLA574 KIT 2ND ENCDR MOUNT ORCA 0 OPTION
6 AMSLM578 MOUNT GUIDE ROLR FRONT ORCA HORIZ & VERT 1
PLATE SPACER GUIDE ROLLER VERT LEVELWIND
8 AMSLM521 2
SLOTTED MAKO
11 AMSLA437 ROLLER ASSY PRS 2.10OD 12MM SS 2
11 AMSLM437 ROLLER KEEPER 2.10OD 12MM SST 0 REF
12 AMSLA162 WHEEL ASSY PRESS RLR 1/4 TENSN W/BEARING 3
12 AMSLM162 ROLLER PRESSURE TENSION 1/4 0 REF
13 AMSLM569 ROLLER SLACK HORIZ LEVELWIND MAKO 12MM 1
14 AMSLM228 NUT 7/16-14 TEE SLOT SST ECCN=EAR99 3
15 AMSLM449 GUIDE SPRING PRESS WHL 2WC MEGAMOUTH 2
16 AMSLM510 MOUNT GUIDE ROLR REAR ORCA 1
17 AMSLM257 MOUNT PIVOT PRESS WHL ORCA 3/4 WRENCH 1
SHAFT MEAS WHL 50MM ENCDR/RT ANGLE DR
18 AMSLM575 1
5/16 ORCA
19 AMSLM585 PLATE ORIENTATION L PIN MAKO 1
20 AMSLM153 SHAFT LOAD PIN REPL 1.5OD 2 WH 1
PIN LOAD 30K# 1-1/2OD 2.0mV/V 350 OHM 10-6P
20 AMSLP153 0 OPTION
TYPE C W/SHUNT
21 AM3KM050 COUPLING ENCDR W/BKUP MAGNETS 0 OPTION
BUSHING FRAME 0.406 THRU HOLE 0.75
22 AMSLM030 12
SHOULDER
23 AMSLM531 BUSHING TENS WHL 1-1/2 LP MAKO 4
BUSHING L/P 1-1/2 W/ANTI-ROT 5/16 BRAIDED LINE
24 AMSLM565 1
MAKO
25 AMSLM514 WASHER MEAS WHL SHAFT MAKO 1
26 AMSLM529 BUSHING FRAME 3/8-16 ORCA 1.25 SHOULDER 14
27 AMSLM418 SHAFT GUIDE ROLLER VERT LVLWND ORCA 4
28 AMSLM218 TBG SPACER GUIDE ROLLER LVLWND 4
29 AMSLM219 ROLLER GUIDE VERT LEVELWIND 4
30 AMSLM584 SCREW ANTI-ROTN TENS WHL MAKO 1
BUSHING FLANGE PRESS WHEL 3/8 ID X 3/4 OD
31 AMSLM053 1
SST

3.3.2. BILL OF MATERIALS – AMSLA590 ORCA continued

BUSHING FLANGE PRESS WHEL 5/16 -18 THD X 3/4
32 AMSLM555 1
OD SST
33 AMS1P072 PLUG 3/8 NPT SS 1
SPACER KEEPER ROLLER 0.70 THK 1-1/8 OD 7/16ID
34 AMSLM453 3
SST
35 AMSLM040 SPACER FRAME 2 WHEEL COUNTER 4
36 AMSLM580 SPACER PRESSURE WHEEL 1.07 THK 2
37 AMSLM080 SPACER PRESSURE WHEEL 0.32 THK 2
38 AMSLM283 SPACER KEEPER ROLLER 0.34 THK 0.69 OD SST 1
39 AMSLM583 SPACER KEEPER ROLLER 0.61 THK 0.69 OD SST 3
40 AMSLM541 SPACER PRESSURE WHEEL 1.65 THK ORCA 1
41 AMSLM590 PIVOT HINGE ORCA 1
42 AMSLM441 ANCHOR SPRING PRES WHL DOLPHIN 1
43 AMSLM566 PLATE FRAME OPEN LWR 5/8 ORCA 1
44 AMSLM567 PLATE FRAME MID LWR 5/8 ORCA 1
45 AMSLM506 PLATE FRAME OPEN UPR 5/8 ORCA 1
46 AMSLM507 PLATE FRAME MID UPR 5/8 ORCA 1
47 AMSLM508 PLATE FRAME OUTER UPR 3/8 ORCA 1
ADAPTER MEAS WHL SHAFT 50MM ENCODER SIDE
48 AMSLM596 1
ORCA
49 AM5KA055 ASSY ENCODER BACKUP MAGNETIC 0 OPTION
49 AM5KP046 PLUG FREEZE 3/4 DIA BRASS 0 OPTION
ENCODER S25HA-37F-1200-ABZC-69 -S18-15-
SPECIAL ETI HARD ANODIZED HOUSING
51 AM5KM073 COUPLING MOD ENCDR 0.250/0.375 0 OPTION
COUPLING OLDHAM ENCODER *C123 10/26/++15
51 AMS1P090 0 OPTION
DISK PN A5P15-0019 SET SCR PN A9Q17-063208
52 AMSLP213 BEARING SPHERE-ROL 65MM ID MCGILL W/SEALS 1
BEARING BALL 50MM 2-ROW 50MM ID X 110MM OD X
53 AMSLP031 2
44.4MM W
BEARING BALL 20MM SST ABEC-1 REPLACES
54 AM3KP204 8
C276P002
BEARING LINEAR 40MMID X 62MMOD X 80MM LG
55 AMSLP240 2
SELF-ALIGN COMPNSTD
BEARING BRZ FLANGED 3/8" ID X 1/4L OIL
56 AMSLP009 2
IMPREGNATED
57 AMSLP112 BEARING BALL 12MM SST 7
58 AMSLP231 BEARING BALL 2-5/16 BORE X 3-1/16 OD X 7/16 W 1
59 AMSLP501 BEARING BRZ 1.50ID X 2.00OD X 2.00 LG SAE 660 1
INDICTR WT M/D TOTCO 15K# 20FT HOSE 6" GAUGE
12SI WT IND
INDICTR WT M/D TOTCO 4K# 20FT HOSE 6" GAUGE
60 AMSLP204 0
12SI WT IND CHARGE VALVE ON CELL


61 AMSLM502-1 MOUNT HYD L/C UPR ORCA 1
62 AMSLM502-2 MOUNT HYD L/C LWR ORCA 1
WHEEL MEASURING 5.33 FT ORCA BOLT ON 0.092-
63 AMSLM504 3
5/16
64 AMSLM509 HUB TENSION WHL 5.33 FT ORCA BOLT-ON 65MM 1
65 AMSLM511 HUB MSRNG WHL 5.33 FT ORCA BOLT-ON 50MM 1
HUB IDLER WHL 5.33 FT ORCA BOLT-ON 3-1/16
66 AMSLM512 1
BRG
67 AMSLM513 BUSHING IDLER WHL 50MM SST ORC 1
HOUSING LINEAR BRG 40MM OH BAR HYBRID
68 AMSLM517 1
ORCA SST
69 AMSLM440 SPACER GUIDE OH BAR 1
70 AMSLM438 HUB GUIDE OH BAR 1
71 AMSLM444 BEARING FLANGE 2-7/8 IN ID BRZ 2
72 AMSLM241 PLATE CHAIN GUIDE ASEP OH ARM DOLPHIN 1
73 AMSLM455 SPACER GUIDE 2-7/8ID OH SPLR 2
74 AMSLM523 PIN HINGE 1-1/2 ORCA SST 1
75 AMSLM518 TBG SPACER SLACK ROLLER LVLWND 1
76 AMSLM576 MOUNT GUIDE BOTTOM ORCA 1
77 AMSLM530 BUSHING FRAME 3/8-16 MAKO 3.62 SHOULDER 2
78 AMSLM540 SPACER FRAME 2" MAKO 2
BEARING CAM FLWR 1.500 DIA X 5/8-18 THD STUD
80 AMSLP288 1
SST
BUSHING FRAME 0.406 THRU HOLE 1.25
81 AMSLM579 4
SHOULDER
99 AM5KP129 FITTING GREASE FLUSH STRAIGHT STL 7
101 AMSLA630 WEATHER SEAL ASSEMBLY 1
102 AM5KM621 LABEL MEASURING HEAD 1.38 X 3.00 SST 1
103 C276P190 SCREW 2 X 3/16 U-DRIVE SST DRILL #44 4
NOT
111 AM5KP130 NOZZLE GREASE FITTNG FLUSH 1
SHOWN
133 AMSLP244 SCREW 7/16-14 X 4 SOC HD CAP SST 2
134 C276P031 SCREW 1/4-20 X 1-1/4 SOC HD SS 2
137 AMSLP068 SCREW 3/8-16 X 4 BUT HD SS 4
138 AMS1P047 WASHER 5/16 LOCK SS 11
139 C276P039 WASHER 5/16 FLAT SST 8
140 AMSLP438 WASHER 3/8 LOCK INT STAR SST 0.7 OD X .03 THK 36
141 AM5KP011 WASHER M20 FLAT SST 4
RING RETNG INT 1.250 SHAFT SST KEEPER KEEPER
147 AMSLP412 0
WHEEL WHEEL
RING RETNG INT 4.750 LT DUTY .046 THICK SST TENSION
148 AMSLP522 2
TENSION WHEEL WHEEL


IDLER
154 AMSLP306 RING RETNG INT 3.062 LT DUTY .039 THICK SST 2
WHEEL
RING RETNG INT 2.440 MED DUTY .049 THICK SPOOLER
155 AMSLP021 1
SST ECCN=EAR99 BRG
SPOOLER
156 AMSLP287 RING RETNG EXT 2.875 SHAFT SST ECCN=EAR99 2
HUB
RING RETNG EXT 1.500 SHAFT SST LOAD PIN, LOAD PIN,
157 AMSLP105 5
HINGE PIN HINGE PIN
RING RETNG INT 4.375 LT DUTY .046 THICK SST
158 AMSLP568 2 MWHL BRGS
6011780 MWHL BRGS
SPRING COMP 2.00 OAL 1.218 OD GROUND ENDS
159 AMSLP278 1
SST
160 AMSLP015 KEY 1/4 X 7/8 WOODRUFF SST 807 1
162 C276P014 INSERT 1/4-20 HELI-COIL #R1185-4-375 25
163 C276P046 WASHER #6 LOCK SS 4
164 C276P035 WASHER #10 LOCK SS 4
165 AMS1P058 WASHER 3/8 LOCK SS 16
166 C276P513 WASHER 3/8 FLAT SST 8
167 C276P036 WASHER 1/4 LOCK SS 5
WASHER 1/4 LOCK SS HIGH COLLAR 0.363 OD X
168 AM5KP144 28
.093 THK
169 AMSLP047 WASHER 7/16 LOCK SST 2
170 AMSLP247 WASHER 7/16 HEAVY FLAT SST 1/8 THICK X 1"OD 5
O-RING 2-152 BUNA N ENC ADPTR 3-1/4 X 3-7/16 ENCODER
171 AMS1P014 1
X 3/32 ADAPTER
O-RING 2-141 BUNA N H25 ENCDR 2 5/16 x 2 1/2 x
172 AM5KP071 1 ENCODER
3/32
BACKUP
173 C276P042 O-RING 2-016 BUNA N 5/8 X 3/4 X 1/16 0
CONNECTOR
BACKUP
174 C276P041 O-RING 2-017 BUNA N 11/16 X 13/16 X 1/16 0
HOUSING
176 AMS8P024 NUT 3/8-16 ELASTIC STOP SST 4
177 AMSLP059 NUT 7/16-14 SST 2
NUT 7/8-14 ELASTIC STOP SST 1-1/4 HEX 63/64
178 C276P021 1
HIGH
AMSLM207-
179 SCREW 7/16-14 X 3.50 FLGHD SST 3
350
180 AMSLP056 SCREW 7/16-14 X 2-3/4 SOC HD CAP SST 1
AMSLM207-
181 SCREW 7/16-14 X 3/4 FLG HD SST 4
075
183 AMSLP071 SCREW 3/8-16 X 2-1/2 BUT HD SS 2


184 AMSLP241 SCREW 5/16-18 X 1 LOW HD SST HEX SOCKET 3
186 AMSLP362 SCREW 3/8-16 X 5/8 BUTTON HD 18-8 SST 36
187 AM3KP057 SCREW 5/16-18 X 1-1/4 SOC HD CAP SST 8
188 AM3KP027 SCREW 1/4-20 X 1-1/2 SOC HD SS 5
189 AMSLP025 SCREW 1/4-20 X 1 SOC HD SST 16
190 AMS5P016 SCREW 1/4-20 X 2-3/4 SOC HD SS 8
191 ACMU2P31 WASHER 1/4 FLAT 5/8OD SST 1
193 AMS4P870 SCREW 1/4-20 X 3/4 BTN HD SST 1
194 AMS1P053 SCREW 10-24 X 2 SHCS SST ECCN=EAR99 4
195 AM5KP045 SCREW 10-24 X 1/2 FH SOC SST 2
196 ALS3P025 SCREW 10-24 X 1/2 BTN HD SST 4
197 C276P331 SCREW 6-32 X 1/2 PHIL PAN SST 4
198 AMSLP023 BOLT SHOULDER 3/8 X 1-3/4 SST 5/16-18 THD 1

3.4.1 LOAD PIN – LOAD PIN - 4-20MA CURRENT LOOP - AMSLA215A
ITEM P/N DESCRIPTION QTY UNIT

1 AMS8M010 HOUSING LOAD PIN AMS80 1 EA
2 AM5KM262 LID LOAD PIN HSG BLACK WARNING 1 EA
PIN LOAD 30K# 1-1/2OD 2.0mV/V 350 OHM 10VDC EXC
4 AMSLP151 1 EA
HEADER
5 AMS7P013 CONN MS3102E-18-9P LOAD CELL 7 PIN 1 EA
6 ACMU2P09 DUST CAP MS25043-18DA RECEPT 1 EA
7 C276P040 O-RING 2-235 BUNA N L/P LID 3-1/8 X 3-3/8 X 1/8 1 EA
8 AMS8P066 O-RING 2-136 BUNA N L/P HSG 1.98ID X 2.19OD X 0.103W 1 EA
9 AM5KP118 O-RING 2-023 BUNA N L/P CONN 1-1/16 X 1-3/16 X 1/16 1 EA
10 AM5KP041 SCREW 10-24 X 1-1/4 PHIL PAN 4 EA
11 AMS8P034 SCREW 4-40 X 3/8 SOC HD SST 6 EA
13 AM5KM647 LABEL LOAD PIN Ex nA 4-20mA 09ATEX41117 1 EA
15 C276P035 WASHER #10 LOCK SS 4 EA
16 AMS8P036 WASHER #4 LOCK SST 6 EA
18 AMS1P040 SCREW 6-32 X 3/8 PHIL PAN SST 4 EA

3.4.2 LOAD PIN – DUAL PASSIVE – AMSLA252A
ITE QT UNI
M P/N DESCRIPTION Y T
1 AMSLP152 PIN LOAD 30K# 1-1/2OD 2.0mV/V 350 OHM DUAL TYPE C W/SHUNT 1 EA
2 AM5KM648 LABEL LOAD PIN Ex nA PASSIVE 09ATEX41118 1 EA
LABEL WARNING LOAD PIN ENCDR DO NOT SEPARATE WHEN
3 AM5KM650 ENERGIZED 1 EA
4 AM5KM645 LABEL LOAD PIN CAUTION AVOID MECHANICAL DAMAGE 1 EA
5 AM5KP059 DUST CAP KPT8010C CANNON MS3180-10CA 2 EA
6 ALS4P007 SCREW 4-40 X 3/4 PHIL PAN SST 2 EA

3.4.3 LOAD PIN - PASSIVE - AMSLA253A

1 AMSLP153 PIN LOAD 30K# 1-1/2OD 2.0mV/V 350 OHM 10-6P TYPE C W/SHUNT 1 EA
LABEL WARNING LOAD PIN ENCDR DO NOT SEPARATE WHEN
3 AM5KM650 1 EA
ENERGIZED
4 AM5KM645 LABEL LOAD PIN CAUTION AVOID MECHANICAL DAMAGE 1 EA

3.4.4 LOAD PIN – PASSIVE – AMSLA272A

4 AMSLP151 1 EA
HEADER
5 AMS8P055 CONN KPT02A16-8P 1 EA
6 AMS8P056 DUST CAP KPT8116C RECEPT 1 EA
12 AM5KP228 STANDOFF 4-40 X 1/2 M/F HEX 2 EA
17 AMS8P090 WASHER #4 FLAT SST 6 EA


4 AMSLP151 1 EA
HEADER
5 C276P043 CONN MS3102E-14S-6P LOAD AXLE 1 EA
6 AMS7P041 DUST CAP MS25043-14DA RECEPT POWER IN 1 EA
9 AM5KP219 O-RING 2-019 BUNA N 70D 1 EA
11 C276P047 SCREW 4-40 X 1/2 PHIL PAN SST 6 EA

3.4.6 LOAD PIN – PASSIVE – AMSLA278A

4 AMSLP151 1 EA
HEADER
5 AM5KP068 CONN 10-107218-1P BENDIX QWL COURSE THREAD 10 PIN 1 EA
6 AM5KP067 DUST CAP KPT8116C RECEPT 1 EA
18 AM5KP184 SCREW 8-32 X 3/8 PHIL PAN SST 4 EA


4 1 EA
AMSLP151 HEADER
5 AM5KP068 CONN 10-107218-1P BENDIX QWL COURSE THREAD 10 PIN 1 EA
6 AM5KP067 DUST CAP KPT8116C RECEPT 1 EA
18 AM5KP184 SCREW 8-32 X 3/8 PHIL PAN SST 4 EA

3.4.8 LOAD PIN - DIFFERENTIAL - AMSLA550

4 AMSLP151 1 EA
HEADER
5 AMS8P055 CONN KPT02A16-8P 1 EA
6 AMS8P056 DUST CAP KPT8116C RECEPT 1 EA
13 AM5KM649 LABEL LOAD PIN Ex nA 0-1.5V D 1 EA
18 AMS1P040 SCREW 6-32 X 3/8 PHIL PAN SST 4 EA

3.5.1 ENCODER - HI RESOLUTION - AM5KA068B
P/N DESCRIPTION QTY UNIT

AM5KP161 ENCODER H25D-SS-1200-ABC-4469 EEx nA 1 EA
AM5KM073 COUPLING MOD ENCDR 0.250/0.375 BORE 1 EA
AMS1P071 DUST CAP MS25043-18DA 1 EA
Specifications
1200 Pulses per revolution

+5 to +15 vdc power
Differential Quadrature output (A – A not, B – B not)
Pin Out
A - +5 to +15 vdc
B - GND
C - A\
D - B\
E - A
F - Case
G - B


AM5KP163 ENCODER H25D-SS-512/780-ABC-4469 EEx nA 1 EA
AMS4P191 DUST CAP KPT8114C 1 EA
Specifications
512/780 Pulses per revolution

+5 to +15 vdc power
Pin Out
A - A\
B - A
C - B\
D - B
G - GND
H - +5 to +15 vdc
K - SELECT
P - Case


AMSLP061 ENCODER H25D-SS-1200-ABC-4469 1 EA
ACMU2P09 DUST CAP MS25043-18DA 1 EA
Specifications

+5 to +15 vdc power
Pin Out
A - A
B - B
D - +5 to +15 vdc
F - GND
G - Case
H - A\
I - B\


AM5KP188 ENCODER H25D-SS-1200-ABC-4469 1 EA
Specifications

+5 to +15 vdc power
Pin Out
A - A
B - B
C - A\
D - +5 to +15 vdc
E - B\
F - GND
G - Case


AM5KP192 ENCODER H25D-SS-1200-ABC-4469 1 EA
Specifications

+5 to +15 vdc power
Pin Out
A - A
B - B
C - A\
D - +5 to +15 vdc
E - B\
F - GND
G - Case

3.6 OPTIONAL ACCESSORIES
3.6.1 LOAD PIN - REPLACEMENT PIN
In the event the load pin needs to be removed for calibration or repair, a pin can be
inserted in its place to support the tension wheel.
At this time a hydraulic load cell can be used to provide tension. The depth portion of
the measuring head will still function properly and accurately.
AMSLM013 ¾” pin – For measuring head – Shark
AMSLM113 1” PIN – For Measuring head – Megamouth – Bull Shark – Dolphin

– Tiger Shark
AMSLM153 – 1 1/2” PIN – For measuring heads – Mako – Orca - Thresher
LOAD PIN

3.6.2 ADD-ON ENCODER ASSEMBLY - AMSLA192
This adapter provides a means to connect a second encoder to the speedometer drive.

3.6.3 ADD-ON ENCODER ASSEMBLY WITH BACKUP – AMSLA093
This adapter is also available with a magnetic pickup sensor to drive a backup depth
panel.

3.6.4 ADDITIONAL ENCODER PARTS KIT – AMSLA574A
This optional kit provides the components to add a 2nd encoder on the measuring head.
This kit is for the Orca and Thresher measuring heads only.

3.6.4 ADDITIONAL ENCODER PARTS KIT - AMSLA574A continued
Parts for the encoder kit – for Orca and Thresher measuring heads only.
LINE P/N DESCRIPTION QTY REF

AMSLA574 PARENT - KIT 2ND ENCDR MOUNT ORCA
1 AM5KM057 ADAPTER ENCODER H37C/H25D 0 Ref
2 AM5KM073 COUPLING MOD ENCDR 0.250/0.375 0 Ref
SCREW 1/4-20 X 1-1/4 SOC HD SS ENCODER ENCODER
3 C276P031 4
MOUNT MOUNT
WASHER 1/4 LOCK SS HIGH COLLAR 0.363 OD X
4 AM5KP144 4 Nor
.093 THK
5 AMS1P052 SCREW 10-24 X 5/8 SOC HD SST ENCODER 4 ENCODER
HD
6 AMS1P053 SCREW 10-24 X 2 SHCS SST HD ENCODER HSG 4 ENCODER
HSG
7 C276P035 WASHER #10 LOCK SS ENCODER 4 ENCODER
O-RING 2-152 BUNA N ENC ADPTR 3-1/4 X 3-7/16 X

8 AMS1P014 1 Nor
3/32
O-RING 2-141 BUNA N H25 ENCDR 2 5/16 x 2 1/2 x

9 AM5KP071 1 Nor
3/32
10 AMS1P072 PLUG 3/8 NPT SS 1 Nor
SHAFT MEAS WHL 50MM ENCDR/RT ANGLE DR 5/16
15 AMSLM575 -1 REMOVE
ORCA
15 AMSLM573 SHAFT MEAS WHL 50MM ENCDR X2 5/16 ORCA 1 Nor
ADAPTER COUNTER HD RT ANGL DRV 5/16 ORCA 2
16 AMSLM592 -1 REMOVE
WHL COUNTER
ADAPTER MEAS WHL SHAFT 50MM OPEN SIDE 2ND
16 AMSLM574 1 Nor
ENCDR ORCA

3.6.5 MEASURING WHEELS
Normally, depth measurement uses an electronic counter with line size compensation
built into the panel.
These are the part numbers for the standard universal measuring wheels.
MEASURING HEAD MEASURING WHEEL P/N

SHARK AMSLM057
MEGAMOUTH AMSLM059
HAMMERHEAD AMSLM059
DOLPHIN AMSLM459
TIGER SHARK AMSLM459
MAKO AMSLM589
ORCA AMSLM504
THRESHER AMSLM504
When taking depth measurements using mechanical counters, for depth accuracy,
different line sizes require different diameter wheels.
Mechanical Counting Systems

We do not recommend using mechanical counting systems. There are many limitations
with a mechanical system and the magnetic backup system we have developed
addresses all these limitations and is a superior product.
Inherent Problems With Mechanical Systems

With a mechanical system the wheel needs to be grooved to match the wireline in order
to accurately measure depth. A 4' wheel grooved for .125 will be off about 2 or 3 feet
per thousand when you are running .108 wireline.
To measure in FEET the wheel needs to be 4' circumference including the wireline. To
measure in METERS the wheel needs to be 1.25 m circumference with the wireline
included.

To read in feet, you will need a counter with a 1:2 ratio so one turn on the input will turn
it 2 times. You will also need a 1:2 ratio right angle drive. In this configuration one turn
of a four-foot wheel will turn the counter 4 times.
To read in meters, you will need a counter with a 1:1.6 ratio, a wheel with a 1.25 meter
circumference and a 1:2 right angle drive. 4 revolutions of the wheel (5 meters) would =
2.5 turns on the counter. The 1:2 right angle drive would increase this to 5 turns.
A mechanical counter will not work with a 20" wheel because of the gear ratio. One turn
of this wheel equals 5.33 feet so the mechanical counter would be in error. You would
need to add an inline gear reducer to decrease the rotation by about 25%. A special
gear box would be needed to increase the input of the counter by about 1.33 turns per
revolution. This gear box would only be applicable for one size of wireline unless the
wheel was changed to match the wireline.
The Advantage Of Our Magnetic System

Our magnetic backup system has the ability to easily provide accurate measurements.
By simply selecting the currently used line size from a choice of standard items,
selecting the correct wheel size, enter a few other parameters and the system will
accurately measure and display the correct depth. It can handle different sizes of
wirelines and wheel sizes, without having to change the wheel on the counter head.
The system can be easily set to measure in either FEET or METERS.
In addition, the accuracy and configurability of our system eliminates the problem of
corroded counters and mechanical cables. Also, mechanical systems can require a lot
of torque to turn the cable, the right-angle drive, and counter, especially if the
mechanical cable is not run straight and is curved in places. This causes the ends of
the cables to twist off or the drive pins to shear.
BenchMark Wireline does not manufacture any of the components for the mechanical
systems and we cannot control their quality. So, with the complexity of the mechanical
setup, the likelihood of malfunctions and having to use components that we neither
engineer or manufacture, we have chosen to not offer such systems. Our view is that
you’ll have a much better result using our magnetic measuring systems.

3.6.6 COMPOSITE WHEELS
BenchMark Wireline has developed Composite Tension and Idler wheels for its
Slickline Measuring Heads. The new composite wheels deliver several advantages
over the legacy steel wheels. Only Tension and Idler wheels are offered using the
composite material.
The new Composite wheels weigh less and cost significantly less than the steel wheels.
The tension wheel assembly comes with a pressed-in bearing to simplify installation.
Steel wheels are very durable but sometimes they can cause undue wear to the coating
on the wire. The composite material in the new wheels is softer by design and absorbs
the operational wear to protect the wire.
Composite wheels also cost less than traditional steel wheels.
Accurate depth measurement requires a consistent wheel circumference so Measuring

Wheels are not offered in composite material.
PRODUCT FEATURES
 Designed for all Slickline Measuring Heads

 Wheels available in both 16 and 20 inch diameters
 Composite weigh less than steel
 Softer material protects wire from undo wear and scrubbing
 Available for both Tension Wheels and Idler Wheels
 Composite not available on Measuring Wheels
 Bearing presses directly to the wheel without additional heavy hub assembly
 Composite wheels are lower cost than traditional steel wheels
GENERAL SPECIFICATIONS
Idler Wheel 16 5.0 lbs. 2.26 kg
Tension Wheel 16 4.8 lbs. 2.17 kg
Idler Wheel 20 9.0 lbs. 4.08 kg
Tension Wheel 20 21.0 lbs. 9.52 kg

16 Inch
Composite
Wheels

20 20
Inch Inch
Idler Tension
Wheel Wheel
20 Inch
Composite
Tension
Wheel

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AMSLA590 – ORCA

AMSLA590 ORCA SEPT 2021 Page 1 of 137

SAFETY WARNING – TECH SUPPORT – RECOMMENDED SPARE PARTS

AMSLA590 ORCA SEPT 2021 Page 2 of 137

This apparatus is suitable for use in Class I, Division 2, Groups A, B, C, & D

WARNING – EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY

AVERTISSEMENT – RISQUE D’EXPLOSION – LA SUBSTITUTION DE

WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY

AVERTISSEMENT - RISQUE D'EXPLOSION – LA SUBSTITUTION DE

WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS

AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DECONNECTER

WARNING - PROTECTION MAY BE IMPAIRED IF THIS DEVICE IS USED IN AN

BenchMark measuring equipment will frequently be operated in hazardous

AMSLA590 ORCA SEPT 2021 Page 3 of 137

Do not separate any electrical connector, while powered, in a hazardous area.

Safe Operating Temperatures – BenchMark Wireline equipment is designed to

Hazardous Equipment Marking - See General Assembly drawings for hazardous

Rotating Equipment – BenchMark Wireline measuring equipment is often attached to

AMSLA590 ORCA SEPT 2021 Page 4 of 137

Prior to calling, please go through the following Checklist.

 Equipment model number

 Equipment serial number

Equipment may be returned for repair and maintenance, but

AMSLA590 ORCA SEPT 2021 Page 5 of 137

ITEM P/N DESCRIPTION QTY REF

NOTE – Depending on your location, it may be advisable to stock a spare

See Load Pins/Axles – starting in Section 3.4.1

AMSLA590 ORCA SEPT 2021 Page 6 of 137

These corrections are automatically made in the BenchMark hoistman's panel by

AMSLA590 ORCA SEPT 2021 Page 7 of 137

1. Install the measuring head on the wireline equipment.

Equipment Setup Procedure

3. Verify the panel is configured to match the system.

5. Set Tension Alarm value.

6. Set depth adjust value if necessary.

7. Rig up through sheaves, install tool, and slack off weight.

8. Set depth to zero.

AMSLA590 ORCA SEPT 2021 Page 8 of 137

Verify the panel is configured to match the system

Set Tension Alarm value.

Set depth adjust value if necessary.

Ensure that memory card is installed in data recorder.

Rig up through sheaves, install tool, and slack off weight.

Set depth to zero.

Press T-Zero to set tension to zero.

Pull tool to depth 0 position.

AMSLA590 ORCA SEPT 2021 Page 9 of 137

AMSLA590 ORCA SEPT 2021 Page 10 of 137

2.2.1 DEPTH MEASUREMENT

The optical encoder provides a high-resolution measurement to the BenchMark Wireline

AMSLA590 ORCA SEPT 2021 Page 11 of 137

Additionally, a hydraulic load cell is included which measures wireline tension

1. PASSIVE LOW VOLTAGE

Power Requirement - 12 vdc excitation

Interface – None – passive bridge only

Power Requirements - +/– 15 vdc input power

0 vdc = 0 lbs. (0 kg)

AMSLA590 ORCA SEPT 2021 Page 12 of 137

3. 4-20MA CURRENT LOOP