HYDRAULIC POWER TECHNOLOGY

60K INJECTOR HEAD 1080

SPRINT OIL & GAS SERVICES, PAKISTAN

JOB # 104550
18109 Foust Drive, Buda, Texas 78610 Phone (512) 295-4234 Fax (512) 295-3297
Website www.hpt-texas.com

Contents
HPTT RB 60K INJECTOR SPECIFICATIONS............................................................ 3
Weight: ........................................................................................................................ 3
Dimensions: ................................................................................................................ 3
Load Ratings: .............................................................................................................. 3
Tubing Size Range: ..................................................................................................... 4
Injector Drive System: ................................................................................................ 4
Injector Performance Data: ......................................................................................... 5
Injector Chains: ........................................................................................................... 6
Recommended Greases and Fluids: ............................................................................ 7
INJECTOR SYSTEM DESCRIPTION .......................................................................... 9
Chain System: ............................................................................................................. 9
Figure 1. Injector Chain Assembly ........................................................................... 10
Injector Drive System: .............................................................................................. 10
Figure 2. Injector Drive System ................................................................................ 10
Chain Tensioning System: ........................................................................................ 11
Figure 3. Chain Tensioning System .......................................................................... 11
Traction System: ....................................................................................................... 11
Figure 4. Traction System ......................................................................................... 12
Load Cell System: ..................................................................................................... 12
Figure 5. Load Cell System ...................................................................................... 13
Gooseneck: ................................................................................................................ 13
Figure 6. Gooseneck Assembly ................................................................................ 14
Stripper:..................................................................................................................... 14
Injector Legs: ............................................................................................................ 14
INJECTOR OPERATION ............................................................................................ 15
Description: ............................................................................................................... 15
Figure 7. Injector Quick Disconnect Panel ............................................................... 16
Injector Drive Circuit: ............................................................................................... 17
Figure 8. Injector Drive Circuit ................................................................................ 18
Injector Motor Displacement: ................................................................................... 19
Figure 9. Injector Motor Displacement Control ....................................................... 20
Loop Flushing: .......................................................................................................... 21
Injector Brake Circuit: .............................................................................................. 21
Figure 10. Injector Brake Control ............................................................................. 22
Injector Traction Circuit: .......................................................................................... 22
Figure 11. Injector Traction Circuit .......................................................................... 23
Figure 12. Injector Traction Circuit Control ............................................................. 24
Injector Chain Tension Circuit: ................................................................................ 25
Figure 13. Injector Chain Tension Circuit ................................................................ 26
Figure 14. Injector Chain Tension Control Circuit ................................................... 27
Injector Chain Lubrication Circuit: ........................................................................... 28
Injector Load Cell Circuit: ........................................................................................ 29
INJECTOR SETUP ...................................................................................................... 30

Introduction:.............................................................................................................. 30
Injector Hose Connections: ....................................................................................... 30
General System Component Check: ......................................................................... 30
Tubing Installation: ................................................................................................... 31
Load Cell Setup: ....................................................................................................... 32
Figure 15. Load Cell Setup ....................................................................................... 33
Transporting the Injector Head: ................................................................................ 34
SYSTEM MAINTENANCE ........................................................................................ 35
Introduction:.............................................................................................................. 35
Maintenance: ............................................................................................................. 35
TROUBLESHOOTING ................................................................................................ 38
General Troubleshooting: ......................................................................................... 38
General Troubleshooting Procedure: ........................................................................ 38
Common Injector Problems: ..................................................................................... 39
Injector Traction Circuit: .......................................................................................... 41
Injector Chain Tension Circuit: ................................................................................ 42
Injector Motor Displacement Control Circuit: .......................................................... 42
Injector Brake Circuit: .............................................................................................. 43
PARTS BREAKDOWN ............................................................................................... 44
Introduction:.............................................................................................................. 44
Figure 16. Injector Assembly.................................................................................... 45
Table 1. Injector Assembly Parts List ....................................................................... 46
Figure 17. Injector Drive Assembly.......................................................................... 47
Table 2. Injector Drive Assembly Parts List ............................................................. 48
Figure 18. Injector Traction Assembly ..................................................................... 49
Table 3. Injector Traction Assembly Parts List ........................................................ 50
Figure 19. Injector Chain Tension Assembly ........................................................... 51
Table 4. Injector Chain Tension Assembly Parts List .............................................. 52
Figure 20. Lower Idler Assembly ............................................................................. 53
Table 5. Lower Idler Assembly Parts List ............................................................... 54
Figure 21. Load Cell Pre-Load Assembly ................................................................ 55
Table 6. Load Cell Pre-Load Assembly Parts List ................................................... 56
Figure 22. Injector Interior ........................................................................................ 57
Table 7. Injector Interior Parts List ........................................................................... 58
Figure 23. Gooseneck Assembly .............................................................................. 59
Table 8. Gooseneck Assembly Parts List ................................................................ 60
Figure 24. Injector Schematic ................................................................................... 61
Table 9. Injector Schematic Parts List ...................................................................... 62

HPTT RB 60K INJECTOR SPECIFICATIONS

Weight:
Injector
With Gooseneck

8,365 lbf.
9,200 lbf.
Dimensions:

Height
Length
Width

106.75 in
67.5 in
71.75 in
Load Ratings:

Maximum Rated Pull (Continuous)

Maximum Rated Push (Snub Load)

60,000 lbf.
20,000 lbf.

Tubing Size Range:

1 Through 2-3/8

Injector Drive System:

Hydraulic Motors (2 per Injector):
Manufacturer
Type
Peak Pressure Capability
Maximum Permissible Case Pressure
Maximum Displacement
*Minimum Displacement
Pilot Pressure required to begin shifting
hydraulic motor toward minimum
displacement setting
Pilot Pressure required to obtain minimum
displacement setting of hydraulic motor

Rexroth
Variable Displacement
6500 psig
70 psig (short duration)
9.76 in^3/rev (160 cc/rev)
2.972 in^3/rev (48.7 cc/rev)
145 psig
510 psig

*Note: Maximum Injector speed is 200 ft/min. The minimum displacement setting for
the hydraulic motors is factory set assuming that a maximum of 70 gallons per minute
will be supplied to the Injector. When supplied 70 GPM, and at minimum
displacement setting, Injector speed will be approximately 200 ft/min. The minimum
displacement setting for the hydraulic motors can be adjusted to accommodate power
units that do not meet the 70 GPM flow rate requirement. Please contact HPTTs
Service department for adjustment procedures.
Planetary Gear Reducer (2 per Injector):
Manufacturer
Ratio
Type

Lantec
34:1
Two Stage planetary reducer

Modular Brakes (2 per Injector):

Manufacturer
Type
Initial Release Pressure
Full Release Pressure

Mico
Modular Multiple Disc (Dry Design)
160 psig
250 psig

Maximum Continuous Release Pressure

Volume of oil to release each brake
Brake Static Torque through Planetary

1500 psig
1.2 in^3
36,833 lbf*ft each. (New Condition)

WARNING
BRAKES BEGIN TO RELEASE AT THE INITIAL RELEASE PRESSURE
STATED ABOVE. BRAKE STATIC HOLDING TORQUE IS
PROPORTIONALLY REDUCED UNTIL THE FULL RELEASE PRESSURE
STATED ABOVE IS REACHED. BOTH BRAKES (IN NEW CONDITION) ARE
CAPABLE OF HOLDING IN EXCESS OF THE INJECTORS RATED
PULLING CAPACITY.

Injector Performance Data:

Injector Pull / Push Performance assuming 75% efficiency at lift start:

Description
Rated Pull
Pull at Minimum
Displacement (2.972
in^3/rev)
Snub Load at Full Motor
Displacement
Snub Load at Minimum
Motor Displacement (2.972
in^3/rev)

Pull / Push
60,000 lbf. Pull
25,000 lbf. Pull

Pressure Required
3700 psig
5000 psig

20,000 lbf. Push

1250 psig

20,000 lbf. Push

4000 psig

Tubing Pull to Drive Pressure Ratio (at 75% efficiency):

Motors at Full Displacement
Motors at Minimum Displacement

16 lbf/psi
5 lbf/psi

Injector speed per standard flow reference (70 GPM):

High Speed (70 GPM) (motors at minimum 200 ft/min
displacement)
Low Speed (70 GPM) (motors at full
61 ft/min
displacement)

*Note: Injector speed is infinitely variable from speeds of 1 ft/min up to a maximum of

200 ft/min.

Flow to speed Ratio:

Motors at Full Displacement (9.76
in^3/rev)
Motors at Minimum Displacement (2.972
in^3/rev)

0.87 ft/min/gpm
2.86 ft/min/gpm

Injector Chains:
Type
Pitch
Length per Side
Total Pitches per Side
Gripper Blocks per Side
Number of Roller Bearings per side
Gripper Blocks in contact with tubing per
side
Total Grip Length
Number of Roller Bearings in contact with
skate per side
Static Load Rating per Roller Bearing

ANSI 160 (Roller Back Design)

2 in.
14 ft. 4 in.
86
86
86
29
57.875 in.
30
10,800 lbf.

Chain Assembly Part Numbers for Various Sizes:

Tubing Size
1
1-1/4

(Non-Coated) Chain
Assembly Part Number
OS100-172NC
OS125-172NC

*(Coated) Chain Assembly

Part Number
OS100-172C
OS125-172C
6

1-1/2
1-3/4
2
2-3/8

OS150-172NC
OS175-172NC
OS200-172NC
OS238-172NC

OS150-172C
OS175-172C
OS200-172C
OS238-172C

* The Gripper Block faces on the Coated Chain Assemblies are coated with Tungsten
Carbide for added wear resistance.
Injector Chain Traction And Tension:
Traction:
Minimum recommended hydraulic pressure
Maximum recommended hydraulic pressure
Maximum emergency hydraulic pressure

500 psig
2000 psig
3000 psig

Tension:
Minimum recommended hydraulic pressure 100 psig
Maximum recommended hydraulic
500 psig
pressure
*NOTE: Chain Tension pressure must be adjusted to compensate for chain stretch
and Snub (Push) force.

Recommended Greases and Fluids:

Injector Chain Lubrication:
SAE 30 weight or equivalent is recommended for injector chain lubrication. For
temperatures below 30F, SAE 5 weight is recommended.
Injector Chain Bearing Lubrication:
Sealed bearings are incorporated into the chain assembly and require no further
lubrication for the life of the chain assembly.
Hydraulic System:
Hydraulic Oil (Closed Loop):
0 to 80 F
-40 to 60 F

Texaco Rando 46
Chevron Sub Zero
7

30 to 140 F

Texaco Rando 68

Hydraulic Oil (Open Loop):

0 to 100 F
-40 to 60 F
30 to 140 F

Texaco Rando 46
Chevron Sub Zero
Texaco Rando 68

Injector Planetary Reducers (Lantec):

These units should be filled with lubricating oil as per the manufacturers
recommendations as outlined in the Lantec Model D195-34 operation and maintenance
manual.
* NOTE: Many acceptable alternatives are available. However, mixing of different
brands and grades of oil is not recommended.

INJECTOR SYSTEM DESCRIPTION

Chain System:
The injector has two counter rotating chain assemblies that are supported by both the
drive and idler sprockets on the Injector. Each chain assembly, shown in Figure 1.,
incorporates gripper blocks (Item 1-) connected in series with 2.00-inch pitch chain
links (Item 2-). Traction forces are transmitted from the gripper blocks to the bearings
(Item 3-), which are mounted on the backside of each gripper block. The injector can be
fitted with chain assemblies that can accommodate tubing sizes up to 2.375 inches in
diameter.

Figure 1. Injector Chain Assembly

Injector Drive System:

Please refer to Figure 2. Injector Drive System for the following discussion. The injector
chains are driven by the drive sprockets (Item 1-), which are splined to the drive shafts
of the Lantec planetary gear reducers (Item 2-). Attached to the input flange of the
Lantec planetary gear reducers are multiple disc brakes (Item 3-) with a fail-safe feature.
Should hydraulic pressure be lost, this feature allows the brakes to set. The variable
displacement hydraulic motors (Item 4-), which are attached to the input flange of the
multiple disc brakes, are infinitely variable between maximum and minimum
displacement. This feature allows the Injector to take full advantage of the available
horsepower that will be supplied to it. Timing gears (Item 5-) that prevent gripper block
movement relative to each other link the two drive shafts. The timing gears are designed
so that in an emergency condition, operation with one hydraulic motor is possible for
short periods. In this condition, the timing gears would ensure that both injector chains
were equally loaded.

Figure 2. Injector Drive System

10

Chain Tensioning System:

The Chain Tensioning System is shown in Figure 3. The Chain Tensioning System
prevents the chains from gathering during slacking tendencies. Four hydraulic cylinders
(Item -1-) (two per side) are used to force the chain tension idler sprocket (Item -2-)
against the chain assembly to keep the chains in a constant elongation tension condition.
The chain tension idler sprockets are supported by Take-up Bearings (Item -3-), which
are supported by Take-up Rails (Item -4-) mounted to the Injector Side Plate. The
hydraulic cylinders work in conjunction with an accumulator to dampen the dynamic
effects of chain operation. The hydraulic pressure supplied to the chain tensioning
system can be varied from the control cabin.

Figure 3. Chain Tensioning System

Traction System:
The Injector Traction System is shown in Figure 4. The traction system consists of three
(3) pairs of hydraulic cylinders (Item 1-), which impart force to two (2) hardened steel
skates (Item 2-) via Traction Shafts (Item 3-) mounted in the hydraulic cylinder eyes.
Skate Holders (Item 4-) distribute the concentrated force of each Traction Shaft evenly
along the length of the Skates. As the gripper blocks pass over the hardened steel skates,
the force is transmitted to the tubing. Each set of hydraulic cylinders is free to float
horizontally on Wear Guides (Item 5-) that fit into slots designed into the injector side
11

plates. Pressure to the hydraulic cylinders is controlled from the cabin through three (3)
separate circuits, each having an accumulator to dampen the dynamic effects of the chain
during operation. The ratio of traction force to pulling force can be can be as high as 5:1
depending on many factors, including gripper block condition, tubing surface condition,
tubing wall thickness, running speed and the ovality of the tubing.

Figure 4. Traction System

Load Cell System:

The Load Cell System is shown in Figure 5. The load cell system on the injector is
designed to register both pipe light (snubbing loads) and pipe heavy loads with a single
acting hydraulic load cell (Item 1-). The Load Cell Compression member (Item 2-),
located between the injector side plates, transmits half the pipe load seen by the injector
to the hydraulic load cell. A Belleville Spring washer preload system (Item 3-) is used
to preload the single acting hydraulic load cell so that pipe light (snub) loads can be
monitored on the weight indicator. Since the hydraulic load cell and the injector pivot are
located equidistant from the centerline of the tubing, the load cell pressure must be scaled
2:1 to obtain a correct reading on the weight indicator. For example, if the Injector is
pulling a load of 60,000 lbf, 30,000 lbf will be imposed on the single acting load cell. To
isolate the load cell from the shocks that can occur from transporting the injector, the
injector can be lifted from the load cell by adjusting the transport nuts (Item 4-) under
both Preload Brackets (Item 5-) on the Injector.

12

Figure 5. Load Cell System

Gooseneck:
Figure 6. shows the Gooseneck Assembly. The Gooseneck (Item 1-) supports and
directs the tubing as it enters or exits the injector. The end of the gooseneck is flared
(Item 2-) to accommodate the tubing fleet angle. V-type rollers (Item 3-) installed in
the gooseneck can accept tubing sizes up to and including 2-3/8 diameter. The
gooseneck pins directly to the injector frame (Item 4-) and requires no further
adjustment regardless of the tubing size being run. The Gooseneck radius has a major
influence on tubing fatigue and effective tubing life. For this reason, the standard
gooseneck on the HPTT 60K injector has a radius of 8 ft. (96 in). Optional Gooseneck
configurations including different radiuses, hydraulic break over and a swivel feature are
available upon customer request.

13

Figure 6. Gooseneck Assembly

Stripper:
The stripper is a device that allows the tubing to enter the well under pressure without
well leakage. The stripper uses a wearable elastomer seal through which the coiled
tubing is passed. The stripper is bolted to the stripper base of the injector so that it is as
close to the injector chains as possible. When mounted in this manner, column buckling
of the tubing is reduced. Stripper operation is controlled remotely from the control cabin.
Hydraulic pressure is applied to the underside of a piston, forcing it upward into the
wearable elastomer seal, which compresses the seal around the coiled tubing, creating the
seal.
Injector Legs:
Aluminum telescoping legs fit into the corner sockets of the injector base to stabilize the
injector on the wellhead. If supplied, the telescoping legs are only designed for
stabilization, not to carry the tubing load.

14

INJECTOR OPERATION

Description:
The purpose of a coiled tubing injector is to supply the required effort and traction to run
coiled tubing into and out of a well. The injector head consists of several hydraulic
systems and components designed to provide the coiled tubing unit (CTU) operator a
high degree of control. An understanding of each injector function is crucial to ensure
that the equipment is operated efficiently and safely. The hydraulic circuits that are
incorporated into the HPTT RB 60K Injector can be summarized as follows:

Injector Drive Circuit

Injector Traction Circuit
Injector Chain Tension Circuit
Injector Chain Lubrication Circuit
Injector Load Cell Circuit

The control or monitoring of each of these circuits is accomplished from the control cabin
and all required hydraulic connections originate from the control cabin and power unit.
The Injector quick disconnect (Q-D) panel is located on the front left-hand side of the
injector frame as shown in Figure 7. The Injector input/output hydraulic lines are
connected to the Q-D panel by matching the hose numbers (Tag Numbers) stamped on
the hoses to the corresponding numbers on the Injector Q-D Panel.

15

Figure 7. Injector Quick Disconnect Panel

(Table 1. Q-D Panel Connections) shows the hose numbers (Tag numbers), the hose size
and the associated function of each.

Table 1. Q-D Panel Connections

Hose Number

Size

Function

53

Injector Lube

54

Traction Top

55

Traction Middle

16

56

Traction Bottom

57

Stripper Pack

58

Stripper Retract

61

Injector Brake

62

Weight Indicator

63

Well Head Pressure

64

3/8

Motor Displacement

65

Stripper Open Door

66

Stripper Close Door

70

Chain Tension

71

3/4

Injector Return

Injector Drive Circuit:

The hydraulic schematic for the Injector Drive Circuit is shown in Figure 8.

17

Figure 8. Injector Drive Circuit

The injector drive circuit is made up of an in-hole and out-hole side. Both sides of
the circuit have the same hydraulic components. By sending flow and pressure in the inhole side, the injector motors rotate in a manner that forces the tubing in an in-hole
(down) direction. The opposite is true for the out-hole side of the circuit; the injector
motors rotate in a manner that causes the tubing to run in an out-hole (up) direction.
The injector drive circuit is designed to control the overrunning loads that are present
during pipe heavy and pipe light conditions. During pipe heavy conditions, the weight of
the tubing overcomes both the pressure and frictional forces in the well. This force
attempts to cause the injector motors to rotate faster than their original speed setting. The
same is true for a pipe light condition except well pressure tries to force the injector
motors to rotate in an out-hole direction.
The following circuit description will focus on the in-hole (pipe heavy) direction for
the injector drive circuit shown in Figure 8. Hydraulic fluid enters the Injector Drive
Circuit through a 1-1/4 quick disconnect and flows through a 10-micron filter (Item 1). The filters are placed directly after the quick disconnect fittings to prevent
contamination from entering the hydraulic circuit when the fittings are attached. As the
hydraulic fluid passes through the counter balance valve (Item 2-) on the in-hole side,
it flows over a free flow check valve around the counter balance valve. With hydraulic
fluid flowing in the in-hole direction, the counter balance valve on the in-hole side of
the circuit has no influence on circuit operation. Once the fluid passes through the
counter balance valve on the in-hole side, it enters the hydraulic motors (Item 3-).
The hydraulic motors are plumbed in a counter-rotating parallel arrangement so that one

18

motors direction of rotation is opposite the other. After passing through the hydraulic
motors, the hydraulic fluid enters the counter balance valve on the out-hole side where
it is blocked by the internal check valve. Hydraulic pressure increases in the in-hole
side of the circuit until sufficient pilot pressure opens the normally closed counter
balance valve on the out-hole side of the circuit. To ensure smooth injector operation
(no jerking), dampening valves (Item 4-) are incorporated into the pilot signal lines of
each counter balance valve. The hydraulic circuit described above will prevent
overrunning loads (pipe light & pipe heavy) from occurring. During an overrunning load
condition, the hydraulic motors are being forced to act as a hydraulic pump because inlet
pressure falls off and the motors begin to suck in oil. The counter balance valves
prohibit this condition from occurring because they will prevent hydraulic flow from
passing through them until a sufficient pilot pressure (positive pressure on the motor
inlet) is present.

Injector Motor Displacement:

Variable displacement hydraulic motors are used to enhance operator control of the
HPTT RB 60K Injector. Since the hydraulic motors have variable displacement
capabilities, the operator has the ability to adjust the speed/torque ratio over a limited
range to suit the job requirement without affecting the horsepower level transmitted.
Thus, a variable displacement hydraulic motor can be considered a true torque converter.
The maximum and minimum displacement setting of the hydraulic motors determine the
range that the speed/torque ratio can be adjusted. When the hydraulic motors are at
maximum displacement, maximum torque output can be achieved at reduced speed.
Conversely, at minimum displacement setting, maximum speed output can be achieved at
reduced torque levels. By supplying hydraulic pilot pressure to Port X on the hydraulic
motors (Tag #64 (Motor Displacement), Figure 8.), the operator can reduced the
displacement setting of the hydraulic motors up to the factory set minimum displacement
setting.
NOTE:
THE MINIMUM DISPLACEMENT SETTING FOR THE HYDRAULIC
MOTORS HAVE BEEN FACTORY SET FOR A MAXIMUM INJECTOR
SPEED OF 200 FT/MIN WHEN SUPPLIED APPROXIMATELY 70 GPM.
SHOULD THE MINIMUM DISPLACEMENT SETTING OF THE
HYDRAULIC MOTORS NEED TO BE ADJUSTED, CONSULT THE
HYDRAULIC MOTOR SERVICE MANUAL OR CONTACT HPTTS
SERVICE DEPARTMENT FOR THE PROPER PROCEDURES.
Figure 9., Injector Motor Displacement Control, shows how to hydraulically control the
displacement setting of the injector motors from the control cabin.

19

Figure 9. Injector Motor Displacement Control

A Pressure Reducing / Relieving valve located in the operator panel reduces pressure
from Port 2 to Port 1 and relieves pressure at Port 1 to Port 3. For hydraulic pressures
below 145 psig at Port 1, the hydraulic motors on the injector are at maximum
displacement setting. At maximum displacement setting, the injector is capable of
maximum pull. When a hydraulic pressure of approximately 510 psig is present at Port
1, the injector motors will de-stroke to minimum displacement setting. At minimum
displacement setting, the injector is capable of maximum speed. By adjusting the
Pressure Reducing / Relieving valve between these two pressure extremes, the operator
can infinitely control the speed/torque ratio of the hydraulic motors on the injector.

WARNING!
MAXIMUM PERMISSIBLE PILOT PRESSURE FOR INJECTOR MOTOR
DISPLACEMENT CONTROL CANNOT EXCEED 1450 PSI.

20

Loop Flushing:
The hydraulic motors on the Injector are not equipped with loop flushing valves. When
the Injector is operated with a closed loop power unit, it is recommended that a loop
flushing valve (hot oil shuttle) be installed at the power unit to remove a quantity of oil
from the low side of the closed loop for cooling purposes. When operating the Injector in
a closed-loop system, the internal charge pump of the Injector supply pump should be of
sufficient size to makeup the fluid lost to the loop flushing valves.

Injector Brake Circuit:

The Injector comes supplied with multiple disc brakes, which require hydraulic pressure
to release. This can be considered a fail-safe feature because if hydraulic pressure were
to be lost for any reason, the brakes on the injector would set thereby holding the load.
A typical hydraulic circuit for Injector Brake control is shown in Figure 10.

21

Figure 10. Injector Brake Control

Figure 10, Injector Brake Control, shows a two-position three-way valve directing
hydraulic pressure either to the injector brake (full release) or to tank (brakes set). The
Injector Brakes begin to release when supplied 150 psig and full brake release is achieved
when 240 psig is reached.
Injector Traction Circuit:
The Injector Traction Circuit consists of six (6) hydraulic cylinders that are plumbed to
produce three (3) independent traction circuits; Top, Middle and Bottom. The Injector
Traction Circuit is shown in Figure 11.

22

Figure 11. Injector Traction Circuit

The desired traction pressure supplied to the injector is dependent upon the amount of
load the injector must push or pull. The higher the load, the higher the traction pressure
must be to prevent the tubing from slipping. The tubing size, condition, gripper block
condition and presence of oil between the blocks and tubing also have an influence on the
amount of traction pressure that is required for a given load. Accumulators (Item 2-),
located between the inlet connections and the hydraulic cylinders (Item 1-), cushions
any shocks or pulsations that the cylinders may experience during operation. The
accumulators for each traction circuit are pre-charged with nitrogen to 500 psig and this
pre-charge pressure should be maintained.

The HPTT 60K Injector has been designed to accept a maximum hydraulic pressure of
3000 psig to the injector traction circuit. However, during most jobs, the operator will
find that the injector traction pressure will not have to be set above 2000 psig. Since
injector traction pressure directly influences the life of the chain bearings and the coiled

23

tubing, it is advantageous to keep the traction pressure as low as possible while still
maintaining control over tubing slip.
WARNING!
NEVER ATTEMPT TO PRESSURIZE THE TRACTION CYLINDERS
WITHOUT TUBING BETWEEN THE GRIPPER BLOCKS. DAMAGE
TO THE GRIPPER BLOCKS AND CHAIN ASSEMBLY CAN RESULT.
The control valves for the injector traction circuit should be set up so that each set of
traction cylinders is independently controlled and monitored from the control cabin. A
typical hydraulic circuit that accomplishes just this is shown in Figure 12.

Figure 12. Injector Traction Circuit Control

The traction pressure supplied to the injector traction circuit is controlled by a Pressure
Reducing / Relieving valve (Item 1-). The operator can control the hydraulic pressure in
each traction circuit either individually or simultaneously by opening each traction circuit

24

Ball Valve (Item 2-) and monitoring the circuits pressure using the associated Pressure
Gauge (Item 3-). After a pressure adjustment is made, the associated Ball Valve for
each traction circuit should be closed (Traction Pressure Lock). By closing each traction
circuits Ball Valve, it will ensure that each traction circuit remains independent of the
other should a cylinder failure occur. The hydraulic circuit shown above also has
provisions for an auxiliary hand pump. This allows the operator to produce traction
pressure even if there has been a hydraulic power unit failure. Each Traction Circuit can
be completely drained of hydraulic pressure by positioning the Traction Bleed Ball
Valve (Item 5) into the Bleed position. This is required for instance when injector chain
assemblies are changed or other routine maintenance to the traction system is required.
During operation however, the Bleed position on the Ball Valve (Item -5) should be
avoided.

NOTE
PRESSURE CAN INCREASE IN THE INJECTOR TRACTION CIRCUIT
AFTER IT HAS BEEN SET DUE TO AN INCREASE IN
TEMPERATURE. THE TRACTION CIRCUITS SHOULD BE
MONITORED FOR ANY INCREASE IN HYDRAULIC PRESSURE AND
Injector
Tension
Circuit:
BLEDChain
TO THE
DESIRED
PRESSURE SETTING.
To ensure that adequate tension is maintained in the injector chain assemblies, the
injector is fitted with a hydraulic chain tension system. The hydraulic circuit for the
chain tension system is shown in Figure 13.

25

Figure 13. Injector Chain Tension Circuit

Two hydraulic cylinders (Item 1-) on each side of the injector supply the required force
necessary to keep the injector chain assemblies taught. An Accumulator (Item 2-) is
present in the circuit to remove pressure spikes that occur during dynamic operation. It is
important to maintain the 60-psig nitrogen pre-charge pressure for the Accumulator in the
Chain Tension Circuit. The Injector Chain Tension circuit is controlled from the control
cabin. Figure 14 shows a typical method for remotely controlling the Injector Chain
Tension Circuit from the control cabin.

26

Figure 14. Injector Chain Tension Control Circuit

The maximum hydraulic pressure available to the Chain Tension Circuit is 2000 psig.
The operator should limit the pressure in the chain tension circuit to no higher than 250
psig during normal operation. During maximum snub loads, the hydraulic pressure in the
circuit can reach 2000 psig. The operator should closely monitor the chain assembly
during operation and adjust chain tension pressure accordingly. The goal of the operator
should be to keep chain tension pressure as low as possible to increase the life expectancy
of the chain assembly. Failure to follow these recommendations will result in reduced
chain life expectancy and or failure. It must also be noted that the hydraulic pressure sent
to the Chain Tension circuit must be adjusted to accommodate chain stretch and injector
push (snub) load. As shown in Figure 14, hydraulic pressure can be controlled with the
pressure reducing / relieving valve (Item 1-), and monitored with a single Pressure

27

Gauge (Item 3-). As a rule of thumb, Chain Assemblies have reached the end of their
useful life, and should be replaced, when approximately 3% chain elongation has
occurred. The HPTT RB 60K Injector has been designed so that when the hydraulic
cylinders on the Chain Tension system are fully extended, 3% chain assembly elongation
has occurred.

NOTE
PRESSURE CAN INCREASE IN THE INJECTOR CHAIN TENSION
CIRCUIT AFTER IT HAS BEEN SET DUE TO AN INCREASE IN
TEMPERATURE. THE CHAIN TENSION CIRCUIT SHOULD BE
MONITORED FOR ANY INCREASE IN HYDRAULIC PRESSURE AND
BLED TO THE DESIRED PRESSURE SETTING.

Injector Chain Lubrication Circuit:

The injector has been designed for a remote air over oil lubrication system. This type of
system consists of a reservoir filled with the proper chain lubricant and pressurized with
air. This remote air over oil lubrication system should be connected to the Injector quick
disconnect panel at the appropriate location. By adjusting the air pressure (usually from
the Power Unit) present in the chain lubricant reservoir, the operator can control the
amount of chain lubricant being sent to the injector chain assemblies.

28

Injector Load Cell Circuit:

The single acting load cell (102 cc) present on the Injector should be connected, via the
Injector quick disconnect panel, to a weight indicator that has been properly scaled for
the incoming pressure it will be receiving due to the imposed load on the Injector. The
weight registered versus pressure received should be scaled 2 to 1. The weight indicator
should have a scale that registers positive 60,000-lbf for pipe heavy operation and
negative 20,000-lbf for pipe light (snub) operation.

29

INJECTOR SETUP

Introduction:
The following procedures for setting up the Injector are guidelines only. They are not
intended to be totally self sufficient as different circumstances and working conditions
may dictate different procedures.

Injector Hose Connections:

The Injector input / output hydraulic lines are connected to the Injector quick disconnect
panel by matching the numbers stamped on the hydraulic hoses with the numbers on the
quick disconnect panel on the Injector. To help minimize the inclusion of contamination,
flush face hydraulic couplings come standard on the Injector. However, the couplings
should be cleaned before connection is made. Refer to (Table 1. Q-D Panel Connections)
for a description of each connection on the Injector quick disconnect panel.

General System Component Check:

Before the Injector is set on the wellhead, various systems and components should be
examined. The General System Component Check can be summarizes as follows:

Examine all quick disconnect fittings to ensure that they are completely coupled.
Ensure that no strain, due to the weight of the hose bundle assemblies, is present
on the quick disconnect fittings.

The Injector drive chain assembly should be cleaned and lubricated.

30

Set Injector Traction pressure to 0 psig and Injector Chain tension pressure to
approximately 100 psig.

Visually check the Injector Chain assemblies for obvious signs of damage. This
is accomplished easily by slowly rotating the Injector prior to tubing installation.
Also check to make sure that all bearings in the Chain assemblies are rotating
freely.

Check the operation of all Injector functions; Injector Drive motors, Brakes,
Timing Gears, Traction cylinders, Chain Tension cylinders and lubrication flow
prior to tubing installation.

Check all bearings to ensure they have proper lubrication.

Check the Stripper for worn rubber or guide bushings before installing to the
Injector Stripper Base.

Check all mounting pins on the Gooseneck to ensure that all keepers are in place.

Tubing Installation:
The following procedures should be followed when installing tubing into the Injector. It
should also be noted that the HPTT RB 60K Injector has been designed with a gooseneck
that requires no adjustment to be made regardless of the tubing size being run. This
reduces the time and effort that would normally be required to ensure proper gooseneck
alignment.

Apply approximately 100 psig Chain Tension pressure. Ensure that the Injector
Traction Circuit has 0 psig (fully bled). This will allow the Injector Skates to be
pried open for sufficient clearance to insert the tubing.

Before inserting the tubing, rotate the Injector Chains several revolution in the
out-hole direction to check for smooth rotation and the proper amount of
tension. Adjust chain tension as required for smooth operation.

Insert the tubing from the reel and allow it to pass over the gooseneck into the
center of the Injector Chain Assemblies. The tubing must pass completely
through the chain assemblies and through the stripper. It may be necessary to
apply Traction pressure so that the Injector can pull the tubing through the
Injector.

After the tubing has been completely inserted into the Injector, increase the
Traction pressure slightly (approximately 200-500 psig).

31

Close the hold down boxes on the gooseneck were possible. The remaining hold
down boxes can be closed once the Injector has been completely rigged up and
proper reel tension has been applied to the tubing.

Load Cell Setup:

Please refer to Figure 15, Load Cell Setup for the following discussion about properly
setting up the load cell for operation.

32

Figure 15. Load Cell Setup

The following procedures should be followed to properly setup the Load Cell to accept
both pipe heavy and pipe light (snub) loads:

Remove all weight from the load cell by loosing both preload nuts and tightening
both transport nuts under the preload brackets on the injector. This will raise the
load cell compression member off of the Load Cell.

Use hand pump to force enough fluid into the Load Cell so that a gap slightly
larger than 0.625 inches exists between the upper and lower Load Cell platens.
Loosen the plug on the Load Cell to bleed the system while filling.

Once bled, tighten the plug and lower the Injector onto the Load Cell by
backing off on the transport nuts until they are approximately one inch below the
preload brackets on the Injector.

Once the weight of the Injector is resting on the Load Cell, open the plug on
the Load Cell and bleed until a 5/8 gap is present between the Load Cells upper
and lower platens.

Zero the weight Indicator in the Control Cabin.

33

Tighten each Pre Load Nut on the Injector equally (about two full revolutions per
side) until 20,000 lbf is registered on the weight indicator in the control cabin.

Zero the weight indicator. The Injector is now ready for 60,000-lbf pipe heavy
operation and 20,000-lbf pipe light (snub) operation.

NOTE
THIS PROCEDURE ASSUMES THAT A WEIGHT INDICATOR WITH A
POSITIVE 60,000 LBF AND A NEGATIVE 20,000 LBF SCALE IS
AVAILABLE FOR USE. IF NOT AVAILABLE, A WEIGHT INDICATOR
WITH A POSITIVE SCALE OF 80,000 LBF CAN BE USED AS LONG AS
THE OPERATOR REMEMBERS NOT TO ZERO THE GAUGE AFTER
THE 20,000 LBF PRE-LOAD IS PLACED ON THE LOAD CELL. IN THIS
SITUATION, AN INDICATED LOAD OF 0 LBF ON THE WEIGHT
INDICATOR WOULD REPRESENT A PIPE LIGHT (SNUB) LOAD OF
20,000 LBF AND ANY INDICATED LOAD ABOVE 20,000 LBF ON THE
WEIGHT INDICATOR WOULD REPRESENT A POSITIVE (PIPE
HEAVY) LOAD ON THE INJECTOR.

Transporting the Injector Head:

Before transporting the Injector, the weight of the Injector should be removed from the
Load Cell. The injector can be lifted from the load cell by adjusting the transport nuts
under both Preload Brackets on the Injector until a visible gap is present between the
Load Cell and the Load Cell Compression Member.

34

SYSTEM MAINTENANCE

Introduction:
The following maintenance schedules are guidelines only. The frequency of maintenance
or service operation depends on the operating conditions, environment, and age or
condition of the unit.

CAUTION
DO NOT PERFORM ROUTINE MAINTENANCE AND INSPECTIONS ON
THE INJECTOR WITH THE POWER UNIT IN OPERATION.

Maintenance:
A. Daily (Before Operation):

Grease all shaft bearings with lithium based multipurpose grease.

Inspect Timing Gears for adequate lubricant.

Check to make sure that all gauges read zero (0) pressure. Replace any
nonfunctional pressure gauges.

Check for any visible hydraulic leaks and make necessary repairs.

Check all hydraulic quick disconnects to and from the control cabin for full
engagement.

B. Daily (After Starting):

Check Injector lubricator operation.

35

Check for leaks in the hydraulic systems.

Ensure that all Injector controls are functioning properly.

With the Injector rotating, check the pressure filters that are mounted between the
main quick disconnects and the counter balance valves. These filters have an
integral bypass with a visual bypass indicator. When the bypass indicator shows
red, the filter should be replaced.

NOTE
DURING COLD WEATHER, IT IS POSSIBLE FOR THE INCREASED
VISCOSITY OF THE HYDRAULIC OIL TO CREATE SUFFICIENT
PRESSURE DROP ACROSS THE FILTER ELEMENT TO ACTUATE THE
BYPASS VALVE. FOR THIS REASON, INSPECT THE BYPASS
INDICATOR ON THE FILTER ONLY AFTER THE HYDRAULIC OIL
TEMPERATURE HAS INCREASED.
C. Daily (After Operation):

CAUTION
THE FOLLOWING MAINTENANCE MUST BE DONE WITH THE UNIT
STOPPED AND ALL SYSTEM PRESSURE RELIEVED.

Check for any external leakage on fittings and hoses. Tighten fittings and/or
replace O-rings as required.

Thoroughly clean inside and outside of the Injector and lubricate chains,
sprockets, and timing gears.

Inspect Chain assemblies for obvious signs of damage and repair as necessary.

36

Inspect Gooseneck Rollers for damage and/or seized bearings. Replace as

required.

D. Weekly (Every 60 Hours of operation):

Grease all bearings on the Injector. Tighten setscrews on all bearings set collars.

Check Injector Chains and skates for wear.

Check and drain all drip pans.

After the initial 60 hours of operation on a new Injector, replace all hydraulic
filter elements.

E. Monthly (Every 240 hours of operation):

Replace all hydraulic filter elements.

Check that the three (3) Injector Traction Accumulators maintain the required
500-psig nitrogen pre-charge pressure.

Check that the Injector Chain Tension Accumulator maintains the required 60psig nitrogen pre-charge pressure.

37

TROUBLESHOOTING

General Troubleshooting:
Most problems that occur with a hydraulic system are simple in nature. However,
because of their effect on major components in the system, they may seem
overwhelming. When attempting to troubleshoot a problem, try and remember to
eliminate the simplest possibilities first and then proceed to the more complex issues in
the circuit.

General Troubleshooting Procedure:

Operate the hydraulic circuit to identify the problem.

Check the condition of the hydraulic filters and the fluid level in the hydraulic
reservoir.

Check the circuit of the component of issue for any damage of external leaks.

Check the condition of all controls that operate the circuit under investigation.

Check to make sure that all hoses are properly connected to the Injector and
Power Unit. When making this check, be sure to see if the hydraulic quickdisconnect fittings are properly engaged. Since quick-disconnect fittings contain
a built in check valve, they will not permit flow unless they are fully engaged.

If the above procedures have not pinpointed the problem, the Power Unit or external
power source should be investigated as a possible source for the problem. This is
especially true if a loss of pressure or flow is being investigated. Proceed by
disconnecting the hoses for that system from the Power Unit and see if pressure can be
built up across the relief valve for the circuit. If full pressure can be obtained, the source
of the problem is most likely external to the Power Unit. Before attempting to trouble
shoot a Power Unit, it is recommended that the manual for the specific Power Unit at
issue be thoroughly read and understood.

38

NOTE
CARE SHOULD BE TAKEN WHEN PRESSURIZING THE POWER UNIT
CIRCUITS WITH THE HOSES CONNECTED. DUMPING FLOW OVER A
RELIEF VALVE INTRODUCES A LARGE AMOUNT OF HEAT INTO THE
HYDRAULIC FLUID.
Common Injector Problems:

Problem A: INJECTOR WILL NOT TURN.

Cause 1: Brake will not release.
a. Brake not plugged in at quick-disconnect panel.
b. Incorrect supply pressure to brake release port
Cause 2: Counter Balance Valve not opening.
a. Dampening Valve closed completely.
b. Damaged or plugged hose.
c. Damaged Counter Balance cartridge.
Cause 3: Supply Hose (Quick-Disconnect) not fully engaged.
Cause 4: Injector supply pressure is insufficient to move the load.
Cause 5: Tubing stuck in the well and weight indicator is not indicating the actual load.
Cause 6: Excess load on the Injector.
Cause 7: If the hydraulic pressure increases but the Injector will still not move the load,
check the following:
a. Check for faulty quick-disconnects on the main power hoses on the
Injector, Power Hose Reel, and Power Unit.
b. Mechanical binding in the Injector.
c. Check to see if the brakes are releasing.
d. One or more of the Injector hydraulic motors may be worn or
damaged.
e. The Counter Balance valves may not be opening because of
contamination in the dampening valve or the cartridge assembly itself.

Problem B: INJECTOR CHAINS CHATTERING.

39

Cause 1: Tubing not entering centerline of chains.

Cause 2: Damaged chain of chain bearings.
Cause 3: Improper Chain Tension Pressure of Accumulator pre-charge.
Cause 4: All chain slack not removed prior to gripping the tubing.
Cause 5: Gripper block surfaces coated with contaminates causing the tubing to slip
through the chains.

Problem C: INJECTOR SURGES GOING IN HOLE IN HEAVY PIPE CONDITION.

Cause 1: Counter Balance dampening valves need adjusting. Normal starting set point is
two (2) full turns from fully closed.

Problem D: CANNOT OBTAIN FULL SPEED FROM INJECTOR.

If Injector obtains partial speed in both directions, check the following:

Cause 1: Low engine speed.
Cause 2: Hydraulic pump(s) are not supplying the required flow.
Cause 3: System relief valve not set correctly and allowing oil to pass over it rather than
going to the Injector.
Cause 4: Worn or damaged Injector drive motors. Check for excessive case drain flow
from the hydraulic motors.
Cause 5: Hydraulic brakes may be dragging. Check brake release pressure.
Cause 6: Counter balance valves are not fully opening. Check dampening valve on pilot
line.

Problem E: INJECTOR SPEED PULSATING OR ERRATIC.

Cause 1: One or more of the Injector Drive motors may be damaged or worn causing
intermittent loss of hydraulic pressure and flow. Check case drain for an excessive
amount of hydraulic flow.
Cause 2: An Injector bearing failure.

40

Cause 3: Restriction in one or both of the pilot lines to the counter balance valves.
Problem F: INJECTOR MOTORS DO NOT COMPLETELY STOP WHEN CONTROL
VALVE IS CENTERED IN THE CONTROL CABIN.
Cause 1: Check to make sure that the hydraulic flow is not being sent to the injector
despite the control valve being centered. This may require adjustments to pumps or
valves at the Power Unit.
Cause 2: The injector motors may be worn or damaged allowing an excessive amount of
internal leakage.
Cause 3: The counter balance valves may be worn or have debris binding the main spool
causing the injector motors to creep.
Cause 4: The brakes may be damaged. The brakes must be engaged to not this problem.
The brakes should be able to hold maximum injector system pressure.

Injector Traction Circuit:

Before troubleshooting this system, it is recommended that you read the System
Operation section of this manual for a better understanding of this system. See Figures
11 & 12 in the System Operation section of this manual.

Problem A: TRACTION CYLINDERS WILL NOT INCREASE TO 2000 PSIG.

Cause 1: Pressure supply is not functioning correctly. Check all related pumps and
valves.
Cause 2: Check individual hoses to the injector to ensure that pressure is reaching the
injector quick-disconnect panel.
Cause 3: Verify proper connection to the Injector quick-disconnect panel and lines
leading to the traction cylinders.
Problem B: CIRCUIT WILL NOT HOLD PRESSURE.
Cause 1: Traction cylinder(s) leaking.
Cause 2: Traction accumulators leaking.
Cause 3: Traction supply hoses are leaking externally.

41

Cause 4: Traction supply circuit malfunctioning. Faulty pressure reducing relieving

valve.

Injector Chain Tension Circuit:

Before troubleshooting this system, it is recommended that you read the System
Operation section of this manual for a better understanding of this system. See Figures
13 & 14 in the System Operation section of this manual.
Problem A: NO PRESSURE OR UNABLE TO ADJUST PRESSURE TO CHAIN
TENSION CIRCUIT.

Cause 1: System supply pressure is not available or incorrectly adjusted.

Cause 2: If supply pressure is reaching the Injector, check tension cylinder(s) for internal
leakage and replace as necessary.
Cause 3: Air may be trapped in the Chain tension cylinders. With the pressure valve
slightly open and the bleed valve fully closed, loosen the fittings on the cap end of both
cylinders. When air bubbles cease to exit from the cylinder, tighten the fittings to prevent
air from entering the cylinders.
Injector Motor Displacement Control Circuit:
Before troubleshooting this system, it is recommended that you read the System
Operation section of this manual for a better understanding of this system. See Figure 9
in the System Operation section of this manual.

Problem A: INJECTOR WILL NOT RUN AT MAXIMUM SPEED DESPITE

RECEIVING FULL FLOW FROM THE POWER UNIT.

42

Cause 1: Injector is not receiving the correct pressure for the motor displacement circuit.
The Injector motors begin to reduce their displacement (speed up for a given flow rate)
when supplied 145 psig. The Injector motors reach minimum displacement (maximum
speed for a given flow rate) when supplied 510 psig. Maximum allowable pressure to the
circuit should not exceed 1450 psig.

Cause 2: If the correct supply pressure is being received at the Injector motor
displacement port, the displacement control on the hydraulic motor may be damaged.
Refer to the hydraulic motor service manual for repair procedures.

Injector Brake Circuit:

Before troubleshooting this system, it is recommended that you read the System
Operation section of this manual for a better understanding of this system. See Figures
10 in the System Operation section of this manual.

Problem A: INJECTOR BRAKES WILL NOT RELEASE.

Cause 1. The Injector brakes are not receiving the correct pressure from the pressure
source. The Injector brakes require 150 psig for initial release and 240 psig for full
release. Maximum continuous pressure allowable to the Injector brake circuit is 1500
psig.

43

PARTS BREAKDOWN

Introduction:
This breakdown is used for requisitioning and identifying parts for the HPT 60K Injector.
It may be used for illustrating the various assemblies and subassemblies present on the
Injector head.

44

Figure 16. Injector Assembly

45

Table 1. Injector Assembly Parts List

ITEM
1

QTY
2

10
11
12

1
1
1

DESCRIPTION
Injector Drive
Assembly
Injector Traction
Assembly
Injector Chain
Tension Assembly
Lower Idler
Assembly
Load Cell PreLoad Assembly
Gooseneck
Assembly
Main Frame
Assembly
Auxiliary Frame
Assembly
Q-D Panel
Assembly
Injector Base
Stripper Base
Stripper

PART NUMBER
See Figure 17.
See Figure 18.
See Figure 19.
See Figure 20.
See Figure 21.
See Figure 23.
INJ-60-403
INJ-60-405
INJ-60-604
INJ-60-104
INJ-60-111
Customer Specified

46

Figure 17. Injector Drive Assembly

47

Table 2. Injector Drive Assembly Parts List

ITEM
1
2
3
4
5
6
7

QTY
2
2
2
2
2
2
2

DESCRIPTION
Timing Gear
Flange Bearing
Spacer
Drive Sprocket
Planetary Reducer
Brake
Hydraulic Motor

PART NUMBER
203815
MBR-2204
INJ-60-900
INJ-60-200
D195-34
D131312D
AA6VM160/HD2/63W-VSD527B

48

Figure 18. Injector Traction Assembly

49

Table 3. Injector Traction Assembly Parts List

ITEM
1
2

QTY
12
12

3
4
5
6
7
8
9
10

6
6
6
12
2
30
30
30

DESCRIPTION
Retaining Ring
Traction Shaft
Wear Guide
Skate Holder
Traction Shaft
Traction Cylinder
Spacer
Skate
Hex Bolt
Lock Washer
Hex Nut

PART NUMBER
SH-200
INJ-60-303
INJ-60-300
INJ-60-305
B00-4174001
INJ-60-311
INJ-60-304
GR8-0.75-10-5.50LG

50

Figure 19. Injector Chain Tension Assembly

51

Table 4. Injector Chain Tension Assembly Parts List

ITEM
1

QTY
2

2
3
4
5
6
7

8
8
32
32
4
4

DESCRIPTION
Chain Tension
Sprocket
Take Up Rail Base
Take Up Rail
Cap Screw
Lock Washer
Bearing
Hydraulic Cylinder

PART NUMBER
INJ-60-202
INJ-60-203
INJ-60-204
SHCS-0.625-11-3.00LG
5/8
MT7-2204
B00-5055001

52

Figure 20. Lower Idler Assembly

53

Table 5. Lower Idler Assembly Parts List

ITEM
1
2
3
4

QTY
2
4
16
16

DESCRIPTION
Idler Sprocket
Flange Bearing
Lock Washer
Hex Bolt

PART NUMBER
INJ-60-201
MBR-2204

0.5-13-1.50LG

54

Figure 21. Load Cell Pre-Load Assembly

55

Table 6. Load Cell Pre-Load Assembly Parts List

ITEM
1
2

QTY
1
1

5
6

2
24

DESCRIPTION
Load Cell
Load Cell
Compression
Member
Load Cell PreLoad Bracket
Load Cell PreLoad Bolt
Pre-Load Nut
Belleville Spring
Washer
Injector Transport
Nut

PART NUMBER
CC102
INJ-60-206

INJ-60-207
INJ-60-208
1-1/8
B2250-073
1-1/8

56

Figure 22. Injector Interior

57

Table 7. Injector Interior Parts List

ITEM
1

QTY
16

3
4
5

1
2
1

6
7
8
9

6
6
2
2

DESCRIPTION
Intermediate
Spacer
Chain Tension
Sprocket
Load Cell
Injector Side Plate
Load Cell
Compression
Member
Traction Shaft
Skate Holder
Drive Sprocket
Injector Skate

PART NUMBER
INJ-60-205
INJ-60-202
CC102
INJ-60-103
INJ-60-206

INJ-60-305
INJ-60-300
INJ-60-200
INJ-60-304

58

Figure 23. Gooseneck Assembly

59

Table 8. Gooseneck Assembly Parts List

ITEM
1

QTY
2

2
3
4

2
1
1

5
6

1
1

7
8

1
1

9
10

14
1

11

12

13

14

15

14

16
17
18
19
20
21
22

8
17
17
8
34
3
2

23

DESCRIPTION
8ft. Gooseneck
Side Plate
Dovetail Side Plate
Dovetail Roller #1
Dovetail Roller
Shaft #1
Dovetail Roller #2
Dovetail Roller
Shaft #2
Dovetail Roller #3
Dovetail Roller
Shaft #3
Gooseneck Roller
Dovetail Roller
Shaft #4
Dovetail Roller #1
Axle
Dovetail Roller #2
Axle
Dovetail Roller #3
Axle
Dovetail Roller #4
Axle
Gooseneck Roller
Axle
Bevel Spacer
Lock Washer
Hex Nut
Snap Ring
Bearing
Hold Down Box
Dovetail Retaining
Pin
Dovetail Retaining
Pin Retainer

PART NUMBER
INJ-60-501
INJ-60-512
INJ-60-502
INJ-60-503
INJ-60-504
INJ-60-505
INJ-60-506
INJ-60-507
INJ-60-508
INJ-60-509
INJ-60-513
INJ-60-514
INJ-60-515
INJ-60-516
IN10-6041
BS100-1-1

10 UNC.
SR075
BE2000-0013C3
INJ-60-517
INJ-60-518
RP-0.125

60

Figure 24. Injector Schematic

61

Table 9. Injector Schematic Parts List

ITEM
1
2

QTY
2
2

3
4
5
6
7
8

2
2
1
6
4
4

DESCRIPTION
Filter (10 micron)
Counterbalance
Valve
Hydraulic Motor
Needle Valve
Check Valve
Hydraulic Cylinder
Accumulator
Hydraulic Cylinder

PART NUMBER
HPK04-W6RB-0804-N
CBIH-CJV-ZFD/S
AA6VMHD2
NV8000-0009
CV2000-0001
B00-4174001
AM9031003
B00-5055001

62