1080 Manual

7/26/2019 1080 Manual

1/63

HYDRAULIC POWER TECHNOLOGY

60KINJECTOR 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

7/26/2019 1080 Manual

2/63

1

Contents

HPTT RB 60K INJECTOR SPECIFICATIONS ............................................................ 3Weight: ........................................................................................................................ 3

Dimensions: ................................................................................................................ 3Load Ratings: .............................................................................................................. 3

Tubing Size Range: ..................................................................................................... 4Injector Drive System: ................................................................................................ 4Injector Performance Data: ......................................................................................... 5Injector Chains: ........................................................................................................... 6Recommended Greases and Fluids: ............................................................................ 7

INJECTOR SYSTEM DESCRIPTION .......................................................................... 9Chain System: ............................................................................................................. 9Figure 1. Injector Chain Assembly ........................................................................... 10Injector Drive System: .............................................................................................. 10

Figure 2. Injector Drive System ................................................................................ 10

Chain Tensioning System: ........................................................................................ 11Figure 3. Chain Tensioning System .......................................................................... 11Traction System: ....................................................................................................... 11Figure 4. Traction System ......................................................................................... 12Load Cell System: ..................................................................................................... 12Figure 5. Load Cell System ...................................................................................... 13Gooseneck: ................................................................................................................ 13Figure 6. Gooseneck Assembly ................................................................................ 14Stripper:..................................................................................................................... 14Injector Legs: ............................................................................................................ 14

INJECTOR OPERATION ............................................................................................ 15

Description: ............................................................................................................... 15Figure 7. Injector Quick Disconnect Panel ............................................................... 16Injector Drive Circuit: ............................................................................................... 17Figure 8. Injector Drive Circuit ................................................................................ 18Injector Motor Displacement: ................................................................................... 19Figure 9. Injector Motor Displacement Control ....................................................... 20Loop Flushing: .......................................................................................................... 21Injector Brake Circuit: .............................................................................................. 21Figure 10. Injector Brake Control ............................................................................. 22Injector Traction Circuit: .......................................................................................... 22

Figure 11. Injector Traction Circuit .......................................................................... 23

Figure 12. Injector Traction Circuit Control ............................................................. 24Injector Chain Tension Circuit: ................................................................................ 25Figure 13. Injector Chain Tension Circuit ................................................................ 26Figure 14. Injector Chain Tension Control Circuit ................................................... 27Injector Chain Lubrication Circuit: ........................................................................... 28Injector Load Cell Circuit: ........................................................................................ 29

INJECTOR SETUP ...................................................................................................... 30

7/26/2019 1080 Manual

3/63

2

Introduction: .............................................................................................................. 30Injector Hose Connections: ....................................................................................... 30General System Component Check: ......................................................................... 30Tubing Installation: ................................................................................................... 31Load Cell Setup: ....................................................................................................... 32

Figure 15. Load Cell Setup ....................................................................................... 33

Transporting the Injector Head: ................................................................................ 34SYSTEM MAINTENANCE ........................................................................................ 35

Introduction: .............................................................................................................. 35Maintenance: ............................................................................................................. 35

TROUBLESHOOTING ................................................................................................ 38General Troubleshooting: ......................................................................................... 38General Troubleshooting Procedure: ........................................................................ 38Common Injector Problems: ..................................................................................... 39Injector Traction Circuit: .......................................................................................... 41Injector Chain Tension Circuit: ................................................................................ 42

Injector Motor Displacement Control Circuit: .......................................................... 42

Injector Brake Circuit: .............................................................................................. 43PARTS BREAKDOWN ............................................................................................... 44

Introduction: .............................................................................................................. 44Figure 16. Injector Assembly .................................................................................... 45Table 1. Injector Assembly Parts List ....................................................................... 46Figure 17. Injector Drive Assembly.......................................................................... 47Table 2. Injector Drive Assembly Parts List ............................................................. 48Figure 18. Injector Traction Assembly ..................................................................... 49Table 3. Injector Traction Assembly Parts List ........................................................ 50Figure 19. Injector Chain Tension Assembly ........................................................... 51Table 4. Injector Chain Tension Assembly Parts List .............................................. 52Figure 20. Lower Idler Assembly ............................................................................. 53Table 5. Lower Idler Assembly Parts List ............................................................... 54Figure 21. Load Cell Pre-Load Assembly ................................................................ 55Table 6. Load Cell Pre-Load Assembly Parts List ................................................... 56Figure 22. Injector Interior ........................................................................................ 57Table 7. Injector Interior Parts List ........................................................................... 58Figure 23. Gooseneck Assembly .............................................................................. 59Table 8. Gooseneck Assembly Parts List ................................................................ 60Figure 24. Injector Schematic ................................................................................... 61Table 9. Injector Schematic Parts List ...................................................................... 62

7/26/2019 1080 Manual

4/63

3

HPTT RB 60K INJECTOR SPECIFICATIONS

Weight:

Injector 8,365 lbf.With Gooseneck 9,200 lbf.

Dimensions:

Height 106.75 in

Length 67.5 in

Width 71.75 in

Load Ratings:

Maximum Rated Pull (Continuous) 60,000 lbf.

Maximum Rated Push (Snub Load) 20,000 lbf.

7/26/2019 1080 Manual

5/63

4

Tubing Size Range:

1 Through 2-3/8

Injector Drive System:

Hydraulic Motors (2 per Injector):

Manufacturer Rexroth

Type Variable Displacement

Peak Pressure Capability 6500 psig

Maximum Permissible Case Pressure 70 psig (short duration)

Maximum Displacement 9.76 in^3/rev (160 cc/rev)*Minimum Displacement 2.972 in^3/rev (48.7 cc/rev)

Pilot Pressure required to begin shiftinghydraulic motor toward minimumdisplacement setting

145 psig

Pilot Pressure required to obtain minimumdisplacement setting of hydraulic motor

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 minimumdisplacement 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 Lantec

Ratio 34:1

Type Two Stage planetary reducer

Modular Brakes (2 per Injector):

Manufacturer Mico

Type Modular Multiple Disc (Dry Design)

Initial Release Pressure 160 psig

Full Release Pressure 250 psig

7/26/2019 1080 Manual

6/63

5

Maximum Continuous Release Pressure 1500 psig

Volume of oil to release each brake 1.2 in^3

Brake Static Torque through Planetary 36,833 lbf*ft each. (New Condition)

Injector Performance Data:

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

Description Pull / Push Pressure Required

Rated Pull 60,000 lbf. Pull 3700 psig

Pull at MinimumDisplacement (2.972in^3/rev)

25,000 lbf. Pull 5000 psig

Snub Load at Full MotorDisplacement

20,000 lbf. Push 1250 psig

Snub Load at MinimumMotor Displacement (2.972in^3/rev)

20,000 lbf. Push 4000 psig

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

Motors at Full Displacement 16 lbf/psi

Motors at Minimum Displacement 5 lbf/psi

Injector speed per standard flow reference (70 GPM):

High Speed (70 GPM) (motors at minimumdisplacement)

200 ft/min

Low Speed (70 GPM) (motors at fulldisplacement)

61 ft/min

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.

7/26/2019 1080 Manual

7/63

6

*Note: Injector speed is infinitely variable from speeds of 1 ft/min up to a maximum of200 ft/min.

Flow to speed Ratio:

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

0.87 ft/min/gpm

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

2.86 ft/min/gpm

Injector Chains:

Type ANSI 160 (Roller Back Design)

Pitch 2 in.

Length per Side 14 ft. 4 in.

Total Pitches per Side 86

Gripper Blocks per Side 86

Number of Roller Bearings per side 86

Gripper Blocks in contact with tubing perside

29

Total Grip Length 57.875 in.Number of Roller Bearings in contact withskate per side

30

Static Load Rating per Roller Bearing 10,800 lbf.

Chain Assembly Part Numbers for Various Sizes:

Tubing Size (Non-Coated) ChainAssembly Part Number

*(Coated) Chain AssemblyPart Number

1 OS100-172NC OS100-172C

1-1/4 OS125-172NC OS125-172C

7/26/2019 1080 Manual

8/63

7

1-1/2 OS150-172NC OS150-172C

1-3/4 OS175-172NC OS175-172C

2 OS200-172NC OS200-172C

2-3/8 OS238-172NC OS238-172C

* The Gripper Block faces on the Coated Chain Assemblies are coated with TungstenCarbide for added wear resistance.

Injector Chain Traction And Tension:

Traction:

Minimum recommended hydraulic pressure 500 psig

Maximum recommended hydraulic pressure 2000 psig

Maximum emergency hydraulic pressure 3000 psig

Tension:

Minimum recommended hydraulic pressure 100 psig

Maximum recommended hydraulicpressure

500 psig

*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):

0to 80F Texaco Rando46

-40to 60F Chevron Sub Zero

7/26/2019 1080 Manual

9/63

8


Hydraulic Oil (Open Loop):


-40to 60F Chevron Sub Zero30to 140F Texaco Rando68

Injector Planetary Reducers (Lantec):

These units should be filled with lubricating oil as per the manufacturersrecommendations as outlined in the Lantec Model D195-34 operation and maintenancemanual.

* NOTE: Many acceptable alternatives are available. However, mixing of different

brands and grades of oil is not recommended.

7/26/2019 1080 Manual

10/63

9

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 chainlinks (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 befitted with chain assemblies that can accommodate tubing sizes up to 2.375 inches indiameter.

7/26/2019 1080 Manual

11/63

10

Figure 1. Injector Chain Assembly

Injector Drive System:

Please refer to Figure 2. Injector Drive System for the following discussion. The injectorchains are driven by the drive sprockets (Item 1-), which are splined to the drive shaftsof the Lantec planetary gear reducers (Item 2-). Attached to the input flange of theLantec 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 variabledisplacement hydraulic motors (Item 4-), which are attached to the input flange of themultiple disc brakes, are infinitely variable between maximum and minimumdisplacement. 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 blockmovement relative to each other link the two drive shafts. The timing gears are designedso that in an emergency condition, operation with one hydraulic motor is possible forshort periods. In this condition, the timing gears would ensure that both injector chainswere equally loaded.

Figure 2. Injector Drive System

7/26/2019 1080 Manual

12/63

11

Chain Tensioning System:

The Chain Tensioning System is shown in Figure 3. The Chain Tensioning Systemprevents 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-), whichare supported by Take-up Rails (Item -4-) mounted to the Injector Side Plate. Thehydraulic cylinders work in conjunction with an accumulator to dampen the dynamiceffects of chain operation. The hydraulic pressure supplied to the chain tensioningsystem 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 steelskates (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 evenlyalong 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 floathorizontally on Wear Guides (Item 5-) that fit into slots designed into the injector side

7/26/2019 1080 Manual

13/63

12

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 chainduring operation. The ratio of traction force to pulling force can be can be as high as 5:1depending 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 isdesigned to register both pipe light (snubbing loads) and pipe heavy loads with a singleacting 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 injectorto 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 bemonitored on the weight indicator. Since the hydraulic load cell and the injector pivot arelocated equidistant from the centerline of the tubing, the load cell pressure must be scaled2:1 to obtain a correct reading on the weight indicator. For example, if the Injector ispulling a load of 60,000 lbf, 30,000 lbf will be imposed on the single acting load cell. Toisolate the load cell from the shocks that can occur from transporting the injector, theinjector can be lifted from the load cell by adjusting the transport nuts (Item 4-) underboth Preload Brackets (Item 5-) on the Injector.

7/26/2019 1080 Manual

14/63

13

Figure 5. Load Cell System

Gooseneck:

Figure 6. shows the Gooseneck Assembly. The Gooseneck (Item 1-) supports anddirects 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 inthe gooseneck can accept tubing sizes up to and including 2-3/8 diameter. Thegooseneck pins directly to the injector frame (Item 4-) and requires no furtheradjustment regardless of the tubing size being run. The Gooseneck radius has a majorinfluence on tubing fatigue and effective tubing life. For this reason, the standardgooseneck 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 areavailable upon customer request.

7/26/2019 1080 Manual

15/63

14

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 coiledtubing is passed. The stripper is bolted to the stripper base of the injector so that it is asclose to the injector chains as possible. When mounted in this manner, column bucklingof 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 thewearable elastomer seal, which compresses the seal around the coiled tubing, creating theseal.

Injector Legs:

Aluminum telescoping legs fit into the corner sockets of the injector base to stabilize theinjector on the wellhead. If supplied, the telescoping legs are only designed forstabilization, not to carry the tubing load.

7/26/2019 1080 Manual

16/63

15

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.

7/26/2019 1080 Manual

17/63

16

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

7/26/2019 1080 Manual

18/63

17

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.

7/26/2019 1080 Manual

19/63

18

Figure 8. Injector Drive Circuit

The injector drive circuit is made up of an in-hole and out-hole side. Both sides ofthe circuit have the same hydraulic components. By sending flow and pressure in the in-hole 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 injectormotors 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 presentduring pipe heavy and pipe light conditions. During pipe heavy conditions, the weight ofthe tubing overcomes both the pressure and frictional forces in the well. This forceattempts to cause the injector motors to rotate faster than their original speed setting. Thesame is true for a pipe light condition except well pressure tries to force the injectormotors to rotate in an out-hole direction.

The following circuit description will focus on the in-hole (pipe heavy) direction forthe injector drive circuit shown in Figure 8. Hydraulic fluid enters the Injector DriveCircuit 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 preventcontamination from entering the hydraulic circuit when the fittings are attached. As thehydraulic 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 hydraulicfluid flowing in the in-hole direction, the counter balance valve on the in-hole side ofthe circuit has no influence on circuit operation. Once the fluid passes through thecounter 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

7/26/2019 1080 Manual

20/63

19

motors direction of rotation is opposite the other. After passing through the hydraulicmotors, the hydraulic fluid enters the counter balance valve on the out-hole side whereit is blocked by the internal check valve. Hydraulic pressure increases in the in-holeside of the circuit until sufficient pilot pressure opens the normally closed counterbalance 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 ofeach counter balance valve. The hydraulic circuit described above will preventoverrunning loads (pipe light & pipe heavy) from occurring. During an overrunning loadcondition, the hydraulic motors are being forced to act as a hydraulic pump because inletpressure falls off and the motors begin to suck in oil. The counter balance valvesprohibit this condition from occurring because they will prevent hydraulic flow frompassing through them until a sufficient pilot pressure (positive pressure on the motorinlet) is present.

Injector Motor Displacement:

Variable displacement hydraulic motors are used to enhance operator control of theHPTT RB 60K Injector. Since the hydraulic motors have variable displacementcapabilities, the operator has the ability to adjust the speed/torque ratio over a limitedrange 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 therange that the speed/torque ratio can be adjusted. When the hydraulic motors are atmaximum displacement, maximum torque output can be achieved at reduced speed.

Conversely, at minimum displacement setting, maximum speed output can be achieved atreduced torque levels. By supplying hydraulic pilot pressure to Port X on the hydraulicmotors (Tag #64 (Motor Displacement), Figure 8.), the operator can reduced thedisplacement setting of the hydraulic motors up to the factory set minimum displacementsetting.

Figure 9., Injector Motor Displacement Control, shows how to hydraulically control thedisplacement setting of the injector motors from the control cabin.

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 THEHYDRAULIC MOTOR SERVICE MANUAL OR CONTACT HPTTS

SERVICE DEPARTMENT FOR THE PROPER PROCEDURES.

7/26/2019 1080 Manual

21/63

20

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.

7/26/2019 1080 Manual

22/63

21

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.

7/26/2019 1080 Manual

23/63

22

Figure 10. Injector Brake Control

Figure 10, Injector Brake Control, shows a two-position three-way valve directinghydraulic pressure either to the injector brake (full release) or to tank (brakes set). TheInjector Brakes begin to release when supplied 150 psig and full brake release is achievedwhen 240 psig is reached.

Injector Traction Circuit:

The Injector Traction Circuit consists of six (6) hydraulic cylinders that are plumbed toproduce three (3) independent traction circuits; Top, Middle and Bottom. The InjectorTraction Circuit is shown in Figure 11.

7/26/2019 1080 Manual

24/63

23

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 of3000 psig to the injector traction circuit. However, during most jobs, the operator willfind that the injector traction pressure will not have to be set above 2000 psig. Sinceinjector traction pressure directly influences the life of the chain bearings and the coiled

7/26/2019 1080 Manual

25/63

24

tubing, it is advantageous to keep the traction pressure as low as possible while stillmaintaining control over tubing slip.

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

WARNING!

NEVER ATTEMPT TO PRESSURIZE THE TRACTION CYLINDERSWITHOUT TUBING BETWEEN THE GRIPPER BLOCKS. DAMAGE

TO THE GRIPPER BLOCKS AND CHAIN ASSEMBLY CAN RESULT.

7/26/2019 1080 Manual

26/63

25

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.

Injector Chain Tension Circuit:

To ensure that adequate tension is maintained in the injector chain assemblies, theinjector is fitted with a hydraulic chain tension system. The hydraulic circuit for thechain tension system is shown in Figure 13.

NOTE

PRESSURE CAN INCREASE IN THE INJECTOR TRACTION CIRCUITAFTER IT HAS BEEN SET DUE TO AN INCREASE IN

TEMPERATURE. THE TRACTION CIRCUITS SHOULD BE

MONITORED FOR ANY INCREASE IN HYDRAULIC PRESSURE AND

BLED TO THE DESIRED PRESSURE SETTING.

7/26/2019 1080 Manual

27/63

26

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.

7/26/2019 1080 Manual

28/63

27

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

7/26/2019 1080 Manual

29/63

28

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.

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.

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.

7/26/2019 1080 Manual

30/63

29

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.

7/26/2019 1080 Manual

31/63

30

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 presenton the quick disconnect fittings.

The Injector drive chain assembly should be cleaned and lubricated.

7/26/2019 1080 Manual

32/63

31

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

Visually check the Injector Chain assemblies for obvious signs of damage. Thisis accomplished easily by slowly rotating the Injector prior to tubing installation.

Also check to make sure that all bearings in the Chain assemblies are rotatingfreely.

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

Check all bearings to ensure they have proper lubrication.

Check the Stripper for worn rubber or guide bushings before installing to theInjector 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. Itshould also be noted that the HPTT RB 60K Injector has been designed with a gooseneckthat requires no adjustment to be made regardless of the tubing size being run. Thisreduces the time and effort that would normally be required to ensure proper gooseneckalignment.

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

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

Insert the tubing from the reel and allow it to pass over the gooseneck into thecenter of the Injector Chain Assemblies. The tubing must pass completely

through the chain assemblies and through the stripper. It may be necessary toapply Traction pressure so that the Injector can pull the tubing through theInjector.

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

7/26/2019 1080 Manual

33/63

32

Close the hold down boxes on the gooseneck were possible. The remaining holddown boxes can be closed once the Injector has been completely rigged up andproper 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.

7/26/2019 1080 Manual

34/63

33

Figure 15. Load Cell Setup

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

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

Use hand pump to force enough fluid into the Load Cell so that a gap slightlylarger 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 bybacking off on the transport nuts until they are approximately one inch below thepreload brackets on the Injector.

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

Zero the weight Indicator in the Control Cabin.

7/26/2019 1080 Manual

35/63

34

Tighten each Pre Load Nut on the Injector equally (about two full revolutions perside) 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 heavyoperation and 20,000-lbf pipe light (snub) operation.

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 nutsunder both Preload Brackets on the Injector until a visible gap is present between theLoad Cell and the Load Cell Compression Member.

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 THEWEIGHT INDICATOR WOULD REPRESENT A POSITIVE (PIPE

HEAVY) LOAD ON THE INJECTOR.

7/26/2019 1080 Manual

36/63

35

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.

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 anynonfunctional pressure gauges.

Check for any visible hydraulic leaks and make necessary repairs.

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

B. Daily (After Starting):

Check Injector lubricator operation.

CAUTION

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

7/26/2019 1080 Manual

37/63

36

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 anintegral bypass with a visual bypass indicator. When the bypass indicator showsred, the filter should be replaced.

C. Daily (After Operation):

Check for any external leakage on fittings and hoses. Tighten fittings and/orreplace 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.

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.

CAUTION

THE FOLLOWING MAINTENANCE MUST BE DONE WITH THE UNIT

STOPPED AND ALL SYSTEM PRESSURE RELIEVED.

7/26/2019 1080 Manual

38/63

37

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

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 hydraulicfilter elements.

E. Monthly (Every 240 hours of operation):

Replace all hydraulic filter elements.

Check that the three (3) Injector Traction Accumulators maintain the required500-psig nitrogen pre-charge pressure.

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

7/26/2019 1080 Manual

39/63

38

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 hydraulicreservoir.

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 andPower Unit. When making this check, be sure to see if the hydraulic quick-disconnect fittings are properly engaged. Since quick-disconnect fittings containa 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 isespecially true if a loss of pressure or flow is being investigated. Proceed bydisconnecting the hoses for that system from the Power Unit and see if pressure can bebuilt up across the relief valve for the circuit. If full pressure can be obtained, the sourceof the problem is most likely external to the Power Unit. Before attempting to troubleshoot a Power Unit, it is recommended that the manual for the specific Power Unit atissue be thoroughly read and understood.

7/26/2019 1080 Manual

40/63

39

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 theInjector, 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.

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.

7/26/2019 1080 Manual

41/63

40

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 slipthrough 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 istwo (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 thangoing to the Injector.

Cause 4: Worn or damaged Injector drive motors. Check for excessive case drain flowfrom 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 pilotline.

Problem E: INJECTOR SPEED PULSATING OR ERRATIC.

Cause 1: One or more of the Injector Drive motors may be damaged or worn causingintermittent loss of hydraulic pressure and flow. Check case drain for an excessiveamount of hydraulic flow.

Cause 2: An Injector bearing failure.

7/26/2019 1080 Manual

42/63

41

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 CONTROLVALVE IS CENTERED IN THE CONTROL CABIN.

Cause 1: Check to make sure that the hydraulic flow is not being sent to the injectordespite the control valve being centered. This may require adjustments to pumps orvalves at the Power Unit.

Cause 2: The injector motors may be worn or damaged allowing an excessive amount ofinternal leakage.

Cause 3: The counter balance valves may be worn or have debris binding the main spoolcausing 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 SystemOperation section of this manual for a better understanding of this system. See Figures11 & 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 andvalves.

Cause 2: Check individual hoses to the injector to ensure that pressure is reaching theinjector quick-disconnect panel.

Cause 3: Verify proper connection to the Injector quick-disconnect panel and linesleading 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.

7/26/2019 1080 Manual

43/63

42

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

Injector Chain Tension Circuit:

Before troubleshooting this system, it is recommended that you read the SystemOperation section of this manual for a better understanding of this system. See Figures13 & 14 in the System Operation section of this manual.

Problem A: NO PRESSURE OR UNABLE TO ADJUST PRESSURE TO CHAINTENSION 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 internalleakage and replace as necessary.

Cause 3: Air may be trapped in the Chain tension cylinders. With the pressure valveslightly open and the bleed valve fully closed, loosen the fittings on the cap end of bothcylinders. When air bubbles cease to exit from the cylinder, tighten the fittings to preventair 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.

7/26/2019 1080 Manual

44/63

43

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 pressuresource. The Injector brakes require 150 psig for initial release and 240 psig for fullrelease. Maximum continuous pressure allowable to the Injector brake circuit is 1500psig.

7/26/2019 1080 Manual

45/63

44

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 theInjector head.

7/26/2019 1080 Manual

46/63

Figure 16. Injector Assembly

7/26/2019 1080 Manual

47/63

46

Table 1. Injector Assembly Parts List

ITEM QTY DESCRIPTION PART NUMBER

1 2 Injector DriveAssembly

See Figure 17.

2 1 Injector TractionAssembly

See Figure 18.

3 2 Injector ChainTension Assembly

See Figure 19.

4 2 Lower IdlerAssembly

See Figure 20.

5 1 Load Cell Pre-

Load Assembly

See Figure 21.

6 1 GooseneckAssembly

See Figure 23.

7 1 Main FrameAssembly

INJ-60-403

8 1 Auxiliary FrameAssembly

INJ-60-405

9 1 Q-D PanelAssembly

INJ-60-604

10 1 Injector Base INJ-60-104

11 1 Stripper Base INJ-60-111

12 1 Stripper Customer Specified

7/26/2019 1080 Manual

48/63

Figure 17. Injector Drive Assembly

7/26/2019 1080 Manual

49/63

48

Table 2. Injector Drive Assembly Parts List


1 2 Timing Gear 2038152 2 Flange Bearing MBR-2204

3 2 Spacer INJ-60-900

4 2 Drive Sprocket INJ-60-200

5 2 Planetary Reducer D195-34

6 2 Brake D131312D

7 2 Hydraulic Motor AA6VM160/HD2/63W-VSD527B

7/26/2019 1080 Manual

50/63

Figure 18. Injector Traction Assembly

7/26/2019 1080 Manual

51/63

50

Table 3. Injector Traction Assembly Parts List


1 12 Retaining Ring SH-2002 12 Traction Shaft

Wear GuideINJ-60-303

3 6 Skate Holder INJ-60-300

4 6 Traction Shaft INJ-60-305

5 6 Traction Cylinder B00-4174001

6 12 Spacer INJ-60-311

7 2 Skate INJ-60-304

8 30 Hex Bolt GR8-0.75-10-5.50LG

9 30 Lock Washer

10 30 Hex Nut

7/26/2019 1080 Manual

52/63

Figure 19. Injector Chain Tension Assembly

7/26/2019 1080 Manual

53/63

52

Table 4. Injector Chain Tension Assembly Parts List


1 2 Chain TensionSprocket

INJ-60-202

2 8 Take Up Rail Base INJ-60-203

3 8 Take Up Rail INJ-60-204

4 32 Cap Screw SHCS-0.625-11-3.00LG

5 32 Lock Washer 5/8

6 4 Bearing MT7-2204

7 4 Hydraulic Cylinder B00-5055001

7/26/2019 1080 Manual

54/63

Figure 20. Lower Idler Assembly

7/26/2019 1080 Manual

55/63

54

Table 5. Lower Idler Assembly Parts List

ITEM QTY DESCRIPTION PART NUMBER1 2 Idler Sprocket INJ-60-201

2 4 Flange Bearing MBR-2204

3 16 Lock Washer

4 16 Hex Bolt 0.5-13-1.50LG

7/26/2019 1080 Manual

56/63

Figure 21. Load Cell Pre-Load Assembly

7/26/2019 1080 Manual

57/63

56

Table 6. Load Cell Pre-Load Assembly Parts List


1 1 Load Cell CC1022 1 Load Cell

CompressionMember

INJ-60-206

3 2 Load Cell Pre-Load Bracket

INJ-60-207

4 2 Load Cell Pre-Load Bolt

INJ-60-208

5 2 Pre-Load Nut 1-1/8

6 24 Belleville SpringWasher

B2250-073

7 2 Injector TransportNut

1-1/8

7/26/2019 1080 Manual

58/63

Figure 22. Injector Interior

7/26/2019 1080 Manual

59/63

58

Table 7. Injector Interior Parts List


1 16 IntermediateSpacer INJ-60-205

2 2 Chain TensionSprocket

INJ-60-202

3 1 Load Cell CC102

4 2 Injector Side Plate INJ-60-103

5 1 Load CellCompressionMember

INJ-60-206

6 6 Traction Shaft INJ-60-305

7 6 Skate Holder INJ-60-300

8 2 Drive Sprocket INJ-60-2009 2 Injector Skate INJ-60-304

7/26/2019 1080 Manual

60/63

Figure 23. Gooseneck Assembly

7/26/2019 1080 Manual

61/63

60

Table 8. Gooseneck Assembly Parts List


1 2 8ft. GooseneckSide Plate INJ-60-501

2 2 Dovetail Side Plate INJ-60-512

3 1 Dovetail Roller #1 INJ-60-502

4 1 Dovetail RollerShaft #1

INJ-60-503



INJ-60-505


8 1 Dovetail Roller

Shaft #3

INJ-60-507

9 14 Gooseneck Roller INJ-60-508


INJ-60-509

11 1 Dovetail Roller #1Axle

INJ-60-513


INJ-60-514


INJ-60-515

14 1 Dovetail Roller #4

Axle

INJ-60-516

15 14 Gooseneck RollerAxle

IN10-6041

16 8 Bevel Spacer BS100-1-1

17 17 Lock Washer

18 17 Hex Nut 10 UNC.

19 8 Snap Ring SR075

20 34 Bearing BE2000-0013C3

21 3 Hold Down Box INJ-60-517

22 2 Dovetail Retaining

Pin

INJ-60-518

23 2 Dovetail RetainingPin Retainer

RP-0.125

7/26/2019 1080 Manual

62/63

Figure 24. Injector Schematic

7/26/2019 1080 Manual

63/63

Table 9. Injector Schematic Parts List


1 2 Filter (10 micron) HPK04-W6RB-0804-N2 2 Counterbalance

ValveCBIH-CJV-ZFD/S

3 2 Hydraulic Motor AA6VMHD2

4 2 Needle Valve NV8000-0009

5 1 Check Valve CV2000-0001


7 4 Accumulator AM9031003


1080 Manual

Documents

Transcript of 1080 Manual