COPYRIGHT NOTICE

This manual is copyrighted as an unpublished work.

This manual contains the confidential and proprietary information of Yantai Jereh

Petroleum Equipment and Technologies Co., Ltd.

Neither this document nor any information contained herein may be reproduced or

redistributed in any form whatsoever without the express, written consent of an

authorized agent of Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.

Any attempt by any person other than an authorized agent of Yantai Jereh Petroleum

Equipment and Technologies Co., Ltd. to alter the contents of this manual in any way

shall be construed as copyright infringement, punishable by all applicable laws.

All vendor literature contained in this manual is the copyrighted property of the

respective vendors, protected by the same laws governing this operation and

maintenance manual.

© Copyright 2014 by Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.

All rights reserved.

© Copyright Yantai Jereh Petroleum Equipment and Technologies Co., Ltd. 2014
 FOREWORD

Thank you for choosing JEREH products. We will provide you with professional and

timely after-sales service.

This equipment is independently developed by JEREH. It is an ideal product with high

intelligence and automation and it has been widely applied in both domestic and

overseas oilfields.

This operation and maintenance manual consists of introductions regarding to

equipment structure, operation, safety and maintenance.

Read this manual carefully before operation. It will help you:

a) Understand the structure and performance of the equipment better.

b) Avoid any improper operation that will cause equipment failure.

c) Enhance the reliability of the equipment.

d) Extend the life of the equipment.

e) Reduce maintenance cost.

Please be informed that though contents of this manual are correct, our product is

subject to constant change and such change will not be notified.

Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.

Injector Foreword 1
 WARNING, CAUTION, NOTE

There are kinds of potential hazards in oilfield operation. It’s necessary for the

operators of the equipment to be familiar with all relevant safety regulations and

preventive measures. Nonobservance of the safety regulations in this chapter or the

warning/caution in other chapters may cause damage or failure to the equipment, or

injury or in some cases lost of life. Operators shall read the following safety regulations

before operation.

SAFETY SYMBOLS

Look for these symbols that point out items of importance to the safety of the

individual and group.

The safety warnings and cautions contained in this manual are typical, and are not the

only types of general precautions that should always be observed during all phases of

operation and maintenance. Actions during any unusual circumstances should be

directed by common sense.

Warnings and cautions within this manual should be learnt by heart. But it should also

be pointed out that these warnings and cautions do not cover everything, which should

be noticed to ensure personal safety and long equipment lifetime.

WARNING

WARNING: A comment pertaining to an operation or maintenance action, procedure,

practice condition, or statement that, if not strictly observed, will result in injury or

death to personnel and/or damage to equipment.

2 Foreword Injector
 CAUTION

CAUTION: A comment pertaining to an operation or maintenance procedure, practice,

or condition that, if not strictly observed, can result in injury or death to personnel

and/or damage to equipment.

NOTE

NOTE: An essential comment pertaining to the highlighting of a specification,

procedure, practice, or condition that aids in the maintenance or operation of the

equipment function involved or described.

SAFETY ALERT

a) Protect the equipment from being impacted during transportation to avoid any

possible accident.

b) Check the status of all valves before running the unit. Make sure the pressure of

the safety valve is set correctly and adjust if necessary.

c) Check the lube oil level each time before operation.

d) DO NOT let equipment running pressure go beyond maximum permissible value.

Injector Foreword 3
 UNIT CONVERSION

Conversion Between Metric Units

Unit
and Imperial Units
L
1 bbl=42 gal=158.76 L;
bbl
1 gal=3.785 L
gal

g/cm3

kg/L 1 g/cm3=1 kg/L=8.35 lb/gal

lb/gal

kg
1 kg=2.205 lb
lb

MPa

kPa
1 MPa=1000 kPa=10 bar=145 psi
bar

psi

ft

m 1 ft=12 in=0.3048 m

in（″）

°C
℃=(℉-32)×5/9
℉

m3/min

m3/h 1 m3/min=60 m3/h=264.172gpm

gpm =2118.88SCFH

SCFH

4 Foreword Injector
 TABLE OF CONTENTS

CHAPTER 1……………………………………………..………………..…………..…....ABOUT THIS MANUAL

CHAPTER 2…………………………………………………………………………..………SAFETY AND HEALTH

CHAPTER 3…………………………………………………………………….….....………………….…....INJECTOR
 CHAPTER 1 ABOUT THIS MANUAL

1.1GENERAL USE

The manual provides sufficient descriptive material and illustrations to enable the

operator and maintenance personnel to understand the fundamentals of successful

operation. This manual is intended only as a guide and not as a substitute for

mechanics, electronics, or hydraulics training. No liability, either expressed or implied, is

given for any information contained herein.

This manual does not intend to illustrate all possible situations. Study this manual

carefully before making any attempt to operate this equipment. Pay special attention to

CHAPTER 2—SAFETY AND HEALTH outlined herein.

Yantai Jereh Petroleum Equipment & Technologies Co., Ltd. assumes no

responsibility for improper use of equipment, improperly trained personnel, improperly

maintained equipment, or failure to follow normal safety precautions outlined here, in

the manufacturer literature, or by properly trained personnel.

Use of this manual for any purpose other than for the safe and proper operation and

maintenance of the equipment and all its components constitutes misuse. If there is any

discrepancy between information contained in this manual and the manufacturer

literature, the manufacturer literature is assumed correct.

Please use standard parts and materials provided by JEREH. Should any damage occur

Injector Chapter 1 About This Manual 1

due to application of parts and materials not provided or not proved by JEREH, JEREH

will automatically terminate its quality warranty and all damages incurred shall be

borne by the user.

All information in this manual is based on the latest product information available at

the time of publication. If you have any unsolved problem or any question concerning

the contents or format of this manual, please contact our after-sales service at:

Yantai Jereh Petroleum Equipment & Technologies Co., Ltd.

Add: No. 27 Jereh Road, Laishan District, Yantai, Shandong, China.

P.C.: 264003

Tel: +86-400-816-2161

Fax: +86-535-672-3171

2 Chapter 1 About This Manual Injector

1.2 WARRANTIES OF QUALITY

A. Yantai JEREH warrants that on the date of acceptance and for one year thereafter,

the Goods shall be free from defects in JEREH’s materials and workmanship and

shall meet the additional express written statement of quality, if any, made by

JEREH in connection with the Sale of Goods and signed by an officer of JEREH. This

Express Warranty set forth in the immediate preceding sentence shall apply ONLY

in favor of the User and shall be subject to the following limitations:

a) The Express Warranty of quality shall apply only if:

1) The goods have been exposed to normal use and service, have been

reasonably maintained, and otherwise used in accordance with JEREH’s

instructions,

2) The Goods are returned to JEREH’s factory in Yantai, China (or such other

place closer to the location of the equipment, goods or parts as may be

designated by JEREH) within ten days after User first discovers a claimed

defect with transportation costs prepaid by User; and

3) JEREH’s examination upon the return of such Goods satisfies JEREH that

such are in fact defective.

b) The Express Warranty of quality shall not apply:

1) To Goods that have been rebuilt (whether by JEREH or by any other

entity)， so as in JEREH’s judgment to affect the stability, reliability, or

performance of the Goods.

2) To Goods not manufactured entirely by JEREH (however, JEREH shall

assign to User, to the extent the same assignable, whatever warranty

JEREH has received from the manufacturer of such Goods).

3) To Goods that have passed the quality assurance period and have not

Injector Chapter 1 About This Manual 3

 been in quality assurance time range.

4) To Goods which have been misused or not been used within the designing

functions.

5) to Goods that have been unreasonably used by User or any other entity

after User or such entity knew or should have known of the defect in the

Goods, Or which have been damaged due to unreasonable sue,

negligence, or accident of User or any other entity, or

6) The operation and maintenance manual shall prevail for the Goods and

their uses, any advisory services and/or recommendations provided by

JEREH with respect to the Goods and their uses are not warranted. Any

reference by JEREH to User’s specifications and similar requirements are

made only to describe the Goods in general, and no warranties or other

terms therein shall any force or effect. The operation and maintenance

manual is for general information purposes only and shall not be deemed

to constitute express written statements of quality, and items mentioned

in the manual have no legal effect.

7) Main components of the unit (such as chassis, engine, transmission and

pump) are operated improperly or are not maintained according to the

operation and maintenance manual of the original manufacturer.

B. Other than the express written statements of quality made in paragraph one above,

all express warranties，engineering drawings, samples, models, or actions with

respect to the sale of goods without JEREH’s approval have no legal effects.

C. What is called implied warranties existing under the law with respect to the sale of

Goods’ particularly the implied warranty of merchantability and the implied

warranty of fitness for a particular purpose ， we JEREH hereby negates and

4 Chapter 1 About This Manual Injector

 disclaims.

D. In addition, all other liability that may arise with respect to the sale of Goods, either

in contract or tort, statutory or otherwise, including without limitation, strict

liability and liability based upon the negligence of JEREH, are expressly disclaimed

and negated.

E. No representative of JEREH, other than an officer of JEREH, has authority to alter or

increase this Express Warranty in may manner whatsoever, and no attempt to repair

or promise to repair, replace, or improve the Goods covered by this Express

Warranty of representative of JEREH shall waive, change, or extend this Warranty in

any manner whatsoever, unless such action, promise or other representation is in

writing and signed by an officer of JEREH.

F. User warrants through the purchase of the Goods that User is familiar with its

correct application and the proper use thereof. Before using the Goods hereunder,

User shall give the Goods reasonable and prudent examination and/or tests to

determine the suitability of said Goods for User’s intended use.

G. After acceptance of Goods, User’s sole remedy and JEREH’s sole liability for any

failure of the Goods to conform with the Express Warranty of Quality or for any

breach by JEREH for any obligation pertaining to the quality of the Goods (even if

such nonconformity results from the negligence of JEREH, shall be limited to one of

the following at JEREH’s option:

a) Repairing or replacing (whichever JEREH shall elect) at JEREH’s factory in

Yantai, China (or such other place closer to the location of the Goods as may be

designated by JEREH) the Goods whereby they comply with the Express

Warranty of quality, or

b) Paying User an amount equal to the cost (to User at the original time of sale) of

Injector Chapter 1 About This Manual 5

 the part of the Goods which does not comply with the Express Warranty of

quality. In no event shall JEREH be required to repair, replace or reimburse User

for more than the part of the Goods that is found to be not in compliance with

the Warranty of quality. Any Goods or parts thereof that are repaired or

replaced by JEREH pursuant to this paragraph shall be arranged as of their date

of delivery in accordance with the terms and conditions of this Agreement.

H. The remedies provided herein shall be the sole and exclusive remedy of User for

JEREH’s breach of warranties or for any breach of any contractual or legal duty or

obligation arising out of the sale of the goods by JEREH to User.

I. JEREH shall not under any circumstances be responsible or liable to User or to any

user or to any third party for any economic loss or physical harm, incidental,

consequential punitive, or special damages (including without limitation downtime,

loss of profits and/or loss of business opportunities) arising from any defect in the

goods or services or any failure of the goods or services to conform with the

warranties made herein or any failure of JEREH to meet any obligation or duty

existing and applicable under the law with respect to the sale of the goods whether

such defect in goods or failure of the goods to conform with the warranty or failure

of JEREH to meet its obligations or duties result in damage or harm only to the

goods or to other property.

J. Except to the extent such obligation is inconsistent with JEREH' s obligation to User

under the terms of the Limited Express Warranty stated above in Paragraph A, User

agrees to defend, indemnify, and hold JEREH harmless from and against any and all

claims, liabilities, loss, costs (including without limitation, the cost of litigation and

attorney's fees), and expense made against or incurred by JEREH on account of

death or bodily injury to persons or injury to property or loss, damage or expense

6 Chapter 1 About This Manual Injector

 (including without limitation, subsurface damage, subsurface trespassing, or

damage to the well or reservoir), which relates to or results from, or is in any way

attributable to the sale, handling, use or operation of the Goods or any device,

material, or thing which the Goods are made a part or to which the Goods are

attached or within which the Goods are enclosed (while in User's possession or

subsequent to any transfer of possession to any other entity) or which related to or

results from, or in any way attributable to, the Goods or services provided by JEREH

to User hereunder.

K. User’s obligations to defend and indemnify and hold JEREH harmless shall apply

and be fully enforceable, irrespective of whether such death of bodily injury to

persons or injury to property or loss, damage or expenses is caused by or results

from the sole or concurrent negligence or other fault of JEREH or any agent or

employee of JEREH or any independent contractor who is directly responsible to

JEREH.

L. Due to a policy of continuous product improvement, JEREH reserves the right to

change designs, materials, or specifications and to discontinue product without

notice.

M. No credit will be given on items returned without prior approval and written

instructions accompanying the items stating the reasons for return and the name of

JEREH’s representative who authorized the return. Only the Officers of JEREH may

authorize return of items for credit. JEREH cannot be responsible for holding or

accounting for items returned without prior approval and proper written

instructions being shipped with the returned items. If freight is not prepaid on the

items returned for credit, the cost of freight will be deducted from the credit issued.

Non-standard items which are manufactured at the request of User cannot be

Injector Chapter 1 About This Manual 7

 returned for credit.

N. An action for breach of any provision herein contained must be commenced within

one year after the cause of action has accrued or such cause is forever barred.

O. All terms contained herein are separable and the invalidity of any part hereof shall

not affect the validity of any other part.

P. The rights and remedies herein reserved to JEREH shall be cumulative and in

addition to other rights and remedies provided by law. The failure of JEREH to insist

upon strict performance hereof in any one instance shall not constitute a release of

its right to require such performance in the future with respect to such incidence or

with respect to any later breach of the Agreement by User.

WARNING

Any one or User shall not disassemble or surveying and mapping the products

privately, and shall not behavior violating the patent rights. Otherwise, he shall be

responsible for the violation and compensate for all loss JEREH bears.

WARNING

All related copyrights, patents, trademarks, business secrets and all other ownership

or rights belong to JEREH. This Manual shall only be used as a reference of unit

operation and maintenance, User shall not copy, reprint, modify or edit any

information contained, use it for any other commercial use or provide it to any third

party without the written permission of JEREH. Otherwise, he shall be responsible for

all legal responsibility related.

All rights reserved by JEREH.

8 Chapter 1 About This Manual Injector

 WARNING

Under no circumstance shall JEREH be responsible for any special, incidental, indirect

and subsequent damage and any loss of profit, data, goodwill or expected economy.

WARNING

If the product (including but not limited to the software and technical data) covered

by this Manual needs to be exported, re-exported or imported, User shall follow the

applicable laws and regulations. User shall not export, re-export or import the product

to any country that sanctioned by USA, otherwise, the User shall be responsible for all

responsibility and loss.

WARNING

User’s rights and obligations under this Agreement may not be assigned or

transferred without the express written consent of JEREH.

Injector Chapter 1 About This Manual 9

 Chapter 2 SAFETY AND HEALTH

2.1 SAFETY AND HEALTH ........................................................................................................1

2.1.1 QUALIFIED PERSONNEL ..........................................................................................1

2.1.2 PERSONAL PROTECTIVE EQUIPMENT ..................................................................1

2.1.3 SAFETY PRACTICE .....................................................................................................2

2.1.4 UNAUTHORIZED PERSONNEL................................................................................2

2.1.5 HIGH PRESSURE ........................................................................................................2

2.1.6 UNAUTHORIZED MAINTENANCE .........................................................................2

2.1.7 LIFTING .......................................................................................................................2

2.1.8 MOVING PARTS ........................................................................................................2

2.1.9 VISIBILITY ...................................................................................................................3

2.1.10 PRE-START ...............................................................................................................3

2.1.11 WORK AREA.............................................................................................................3

2.1.12 EQUIPMENT TRANSPORTATION.........................................................................3

2.2 SAFETY OPERATION GUIDELINE......................................................................................3

2.2.1 SAFE EQUIPMENT .....................................................................................................4

2.2.2 SAFETY PROCEDURE ................................................................................................6

 CHAPTER 2 SAFETY AND HEALTH

The users shall always abide by all related procedures and standards, and wear personal

protective equipments when working around the unit. When the unit is running, please

pay attention to all the moving parts and all unauthorized personnel shall be away from

the unit.

2.1 SAFETY AND HEALTH

This chapter intends to introduce to you the general safety and health, as well as safety

operation guidance. Personnel must understand and apply these precautions during all

phases of operation and maintenance of this equipment. For specific hazardous

operations, this manual introduces some detailed caution measures in forms of

WARNING. Some WARNING has been mentioned in this manual and they are stressed

hereinafter.

2.1.1 QUALIFIED PERSONNEL

Only qualified personnel shall be authorized to operate and maintain the equipment.

2.1.2 PERSONAL PROTECTIVE EQUIPMENT

Personnel operating and performing maintenance on the equipment must wear

appropriate Personal Protective Equipment.

Injector Chapter 2 Safety and Health 1

2.1.3 SAFETY PRACTICE

Good overall safety practices must be adhered to at all times when setting up,

operating, shutting down and maintaining this equipment. It is the equipment

owner’s/operator’s responsibility to ensure that good safety practices, personnel

training programs, and safety practices are maintained.

2.1.4 UNAUTHORIZED PERSONNEL

Keep unauthorized personnel away from the unit when operating, servicing or

performing maintenance.

2.1.5 HIGH PRESSURE

Make sure the pressure of the pipeline connecting with the equipment is released

before any disassembly operation.

2.1.6 UNAUTHORIZED MAINTENANCE

DO NOT attempt unauthorized disassembly or maintenance of components. Contact

your JEREH representatives for further information.

2.1.7 LIFTING

Equipment used for lifting and moving the unit must be of sufficient rating to handle

the weight involved.

2.1.8 MOVING PARTS

Keep hands, hair, clothing, jewelry, rags and tools away from moving parts.

2 Chapter 2 Safety and Health Injector

2.1.9 VISIBILITY

DO NOT attempt to operate equipment with obstructed visibility. This includes before

sunrise and after sunset unless suitable lighting provisions are available.

2.1.10 PRE-START

Ensure all the operation controls are in correct position before startup.

2.1.11 WORK AREA

Keep work areas clean and clear of obstructions, hand tools and other objects when

operating the unit.

2.1.12 EQUIPMENT TRANSPORTATION

Ensure that all components are secured before transporting the unit to another

location.

2.2 SAFETY OPERATION GUIDELINE

This guideline is to ensure the safe operation of this unit. The following are the

suggested standards with respect to training, equipment safety and procedures relating

to equipment operation.

Injector Chapter 2 Safety and Health 3

2.2.1 SAFE EQUIPMENT

a) Install a wind vane which can be seen from all directions on location for wind

direction visibility in the event of H2S exposure or any other potential breathing

hazard.

b) Equip everyone with appropriate Personal Protective Equipment (PPE).

c) Set an emergency area at least 60m (200feet) away from the upwind of well site and

equip it with the following

1) Three SCBAs (for H2S or any breathing hazard);

2) Fire extinguisher suitable for flammable liquid;

3) First-aid kit;

4) Eyewash device;

5) Stretcher;

6) Transmitter-receiver or cell phone for emergency call.

d) Emergency well pressure control equipment shall at least include the following:

1) Well killing manifolds;

2) Disabling valve of the remote controlling and hydraulic systems shall be

installed on the manifolds between the tube killing valve and pump.

3) Pumping equipment;

4) Well killing fluid tank;

5) Well killing fluid;

e) For possible H2S exposure, H2S detector with an audible alarm shall be installed in

the following positions:

1) The ground near to the well-head；

2) 30m (100feet) away from downwind of the well site;

4 Chapter 2 Safety and Health Injector

 3) Round wellhead.

f) Prepare emergency transportation vehicle that must be equipped with the

following facilities as a minimum.

1) First-aid kit;

2) Eyewash device;

3) Fire extinguisher suitable for flammable liquid;

4) Transmitter receiver for emergency call.

g) For H2S circumstance or other potential breathing hazard, SCBAs should be in

places:

1) Emergency response and first-aid area;

2) Control Cabin of Coiled Tubing Unit；

3) Operation platform of the unit;

4) Liquid pumping equipment.

h) The following measures shall be taken regarding use of acids or any other harmful

chemicals: Clean (counteract) the area that has been polluted by harmful chemicals

to minimize physical or breathing impact;

i) Mobile communication devices on the same channel/frequency are required

equipment for the following personnel including site owner’s supervisor, service

company’s field supervisor and equipment operator.

Injector Chapter 2 Safety and Health 5

2.2.2 SAFETY PROCEDURE

a) Set up a detailed equipment layout in a conspicuous visible position on site that

clearly indicates dangerous area and emergency escape route.

b) Only authorized personnel shall operate the well-head valves and any related

equipment.

c) Control entrance to the site by keeping a signature record.

d) Set up a large waterproof safety label on site if any hazardous material is in use and

it should at least include the following information.

1) Chemical type and composition;

2) Related preventive actions of each chemical in place;

3) Emergency countermeasures for chemical spill;

4) First-aid countermeasures;

5) Other related information such as emergency telephone number.

e) It is recommended to conduct a safety meeting before operation which should

include at least the following.

1) Operating plan introduction;

2) Risk analysis;

3) Emergency plan and procedure;

4) Demonstrate t of special safety devices usage;

5) Distribution of tasks and responsibilities;

6) Confirmation of procedure communication.

6 Chapter 2 Safety and Health Injector

 CHAPTER 3 INJECTOR

3.1 INTRODUCTION ............................................................................................ 1

3.2 SPECIFICATIONS ............................................................................................ 2

3.3 INJECTOR SYSTEM INTRODUCTION ......................................................... 4

3.3.1 DRIVE SYSTEM ................................................................................................... 4

3.3.1.1 HYDRAULIC MOTORS .......................................................................... 5

3.3.1.2 BRAKE ......................................................................................................... 5

3.3.1.3 GEAR BOX ................................................................................................. 5

3.3.1.4 CHAIN SPEED .......................................................................................... 5

3.3.1.5 RATED TUBING PULL ........................................................................... 6

3.3.1.6 RATED TUBING SNUBBING FORCE ................................................ 6

3.3.2 TRACTION SYSTEM .......................................................................................... 6

3.3.3 TENSION SYSTEM ............................................................................................. 8

3.3.4 FRAMEWORK AND PROTECTION.............................................................. 8

3.3.5 LOAD CELL SYSTEM ......................................................................................... 9

3.3.6 LUBRICATION SYSTEM ................................................................................. 11

3.4 OPERATING INSTRUCTIONS .....................................................................12

3.4.1 SYSTEM PRESSURE ADJUSTMENT .......................................................... 12

3.4.1.1 CHAIN TENSION .................................................................................. 12

3.4.1.2 CHAIN TRACTION ............................................................................... 14

3.4.1.3 SYSTEM PRESSURE.............................................................................. 15

3.4.2 GOOSENECK INSTALLATION ..................................................................... 16

 3.4.3 LUBRICATION ................................................................................................... 21

3.4.4 COUNTER INSTALLATION (OPTIONAL) ................................................ 26

3.5 PARTS INFORMATION ...............................................................................29

3.5.1 GOOSENECK ASSEMBLY .............................................................................. 32

3.5.2 FRAME ASSEMBLY .......................................................................................... 35

3.5.3 GOOSENECK SLIDING BOTTOM ASSEMBLY ....................................... 37

3.5.4 DRIVE SYSTEM ASSEMBLY .......................................................................... 38

3.5.5 TRACTION SYSTEM ASSEMBLY ................................................................ 40

3.5.6 TENSION SYSTEM ASSEMBLY ................................................................... 43

3.5.7 LOAD CELL SYSTEM ASSEMBLY ................................................................ 44

3.5.8 LUBRICATION SYSTEM ASSEMBLY ......................................................... 49

3.5.9 HYDRAULIC SYSTEM ASSEMBLY.............................................................. 52

3.5.9.1 INJECTOR MOTOR ASSEMBLY ....................................................... 54

3.5.9.2 FILTER ASSEMBLY ................................................................................ 58

3.5.9.3 BRAKE CARTRIDGE VALVE ASSEMBLY ....................................... 60

3.5.9.4 ACCUMULATOR ASSEMBLY ............................................................ 62

3.5.9.5 OIL DRAIN VALVE ASSEMBLY......................................................... 64

3.5.9.6 TENSION CYLINDER ASSEMBLY .................................................... 65

3.5.9.7 TRACTION CYLINDER ASSEMBLY ................................................. 66

3.6 MAINTENANCE ...........................................................................................68

3.6.1 MOTOR ................................................................................................................ 68

3.6.2 FILTERS ................................................................................................................ 68

3.6.3 COUNTERBALANCE VALVES ...................................................................... 69

 3.6.4 CYLINDERS......................................................................................................... 69

3.6.5 ACCUMULATORS............................................................................................. 70

3.6.6 CHAIN .................................................................................................................. 71

3.6.6.1 CHAIN WEAR ELONGATION MEASUREMENT ........................ 74

3.6.6.2 LINKPLATE INSPECTION ................................................................... 78

3.6.6.3 PIN INSPECTION .................................................................................. 78

3.6.6.4 ROLLER INSPECTION.......................................................................... 79

3.6.6.5 CHAIN DISTORTION AND SIDE BEND INSPECTION ............ 80

3.6.7 GRIPPER .............................................................................................................. 81

3.6.7.1 GRIPPER RADIUS WEAR INSPECTION........................................ 82

3.6.7.2 CARRIER EAR INSPECTION.............................................................. 83

3.6.8 GRIPPER CARRIER .......................................................................................... 84

3.6.9 DRIVE SYSTEM ................................................................................................. 85

3.6.10 SPROCKET INSPECTION ............................................................................ 86

3.6.11 CHAIN BEARING ........................................................................................... 87

3.6.12 SKATE................................................................................................................. 88
3.7 DAILY CHECK................................................................................................89

3.7.1 BEFORE OPERATION ...................................................................................... 89

3.7.2 AFTER STARTING ............................................................................................ 90

3.7.3 AFTER OPERATION......................................................................................... 91

3.7.4 WEEKLY (EVERY 72 HOURS OF OPERATION) ..................................... 91

3.7.5 MONTHLY (EVERY 300 HOURS OF OPERAITON) ............................. 91

3.7.6 LUBRICATION (DAILY) .................................................................................. 91

 3.7.7 PROCEDURE FOR RESURFACING OF GRIPPERS ................................ 92

APPENDIX 1 INJECTOR DRIVE SYSTEM MAINTENANCE FORM .............93

APPENDIX 2 RECOMMENDED INJECTOR PERIODICAL MAINTENANCE

SCHEDULE ...........................................................................................................95

APPENDIX 3 PARTS ORDER FORM...............................................................97

 CHAPTER 3 INJECTOR

3.1 INTRODUCTION

The coiled tubing injector is used to supply power to snub and pull the tubing into and

out of the well. The injector consists of the framework, drive system, hydraulic system,

lubrication system, tension system, traction system, tubing weight measuring system,

gooseneck and protection devices.

1 Chapter 3 Injector ZRT-80K

3.2 SPECIFICATIONS

Shown in inches:

Figure 3-1 ZRT-80K （With 100” Gooseneck）

2 Chapter 3 Injector ZRT-80K

Specification as follows:

Model ZRT-80K

Overall Dimensions 67.1/8×61.3/5×104.4/5 in

Injector(Ref, Only) 10,800lb

Weight
With 100”Gooseneck (Ref, Only) 12,560lb

Continuous Pulling Capacity 80,000 lb

Continuous Snubbing Capacity 40,000 lb

Max. Speed 190ft/min

Applicable Tubing Size 1 1/4～3 1/2 in

ZRT-80K Chapter 3 Injector 3

3.3 INJECTOR SYSTEM INTRODUCTION

3.3.1 DRIVE SYSTEM

The drive system consists of motors, brakes and gearboxes.

The chains are driven by gearboxes. The hydraulic motors allow the injector to take

maximum advantage of available horsepower. When set at maximum displacement the

injector is in low speed “gear” and the injector can generate its maximum pulling

force. When set to minimum displacement the injector is in high speed “gear” and the

pulling force is reduced and running speed capabilities are maximized.

Attached between the motors and the gearboxes are brakes with a fail-safe feature.

NOTE

a) See Figure 3-2, 3-3 and 3-4 for injector performance curves.

b) Please refer to Figure 3-13 for the illustration of gear drive system.

WARNING

Opening of the drive system by anyone other than a JEREH service technical personnel

shall void all warranties. Exception may be granted (in writing) by JEREH service

manager on an emergency basis.

4 Chapter 3 Injector ZRT-80K

3.3.1.1 HYDRAULIC MOTORS

Max. Displacement 105 ml/r

Max. Working Speed (at Max. Displacement) 3,500 r/min

Max. Working Speed (at Min. Displacement) 4,100 r/min

Shell Allowable Temperature 90 ℃

Weight 86lb

3.3.1.2 BRAKE

Brake Release Pressure 250 psi

Static Brake Torque 904 Nm

NOTE

The brake is a wear-out part, so please check regularly to ensure the the wear-out of

the brake is within normal range.

3.3.1.3 GEAR BOX

Gear Ratio 64.8:1

Oil Capacity About 13.8 L

3.3.1.4 CHAIN SPEED

Min. Chain Speed 0.6 ft/min

Max. Chain Speed (High Gear) 190 ft/min

Max. Chain Speed (Low Gear) 75 ft/min

ZRT-80K Chapter 3 Injector 5

3.3.1.5 RATED TUBING PULL

Low Gear (4,600 psi drive pressure) 80,000 lb

3.3.1.6 RATED TUBING SNUBBING FORCE

Low Gear 40,000 lb

3.3.2 TRACTION SYSTEM

The traction system consists of three pairs of cylinders which act on two skates, between

which the chain carriers are clamped as they pass through grip zone. Each pair of

cylinders reacts against one another through inner support plate of the injector.

Pressure to the hydraulic cylinders is controlled from the cabin through three separate

circuits, each having an accumulator to dampen the dynamic effects of the chain during

operation and to provide pressure in the event of hydraulic pressure loss. The injector

pulling force is directly related to the traction force applied. The ratio of traction force to

pulling force varies depending on many factors, including gripper condition, oil or other

substances on the tubing surface, tubing wall thickness, running speed and tubing

ovality.、

WARNING

a) DO NOT add pressure to the traction hydraulic cylinders when there is no tubing

inside to avoid damaging the gripper, gripper carrier, pins and cylinders.

b) The three pairs of traction cylinders have to be operated in turn. Make sure the

pressure has an adjustment within 200psi to reduce the damage of the skates.

6 Chapter 3 Injector ZRT-80K

 NOTE

a) See Figure 3-14 for traction system.

b) See Figure 3-15 for chains assembly.

c) See Figure 3-3 for traction system pressure requirements.

d) Apply spray lubrication to chain assembly before each job, after each chain

cleaning, and every 500 running meters at a maximum. Make sure entire chain has

been lubricated before turning spray lubricator off.

e) If the tubing slips during operation, do not increase traction pressure greatly in a

short time. Please increase traction pressure slowly to reduce the damages to the

tubing.

Skate Reversible

Quantity of Traction Cylinders 6

Max. Traction Pressure 3,000 psi

Accumulator 3; 1 quart

Tubing Sizes 1.1/4 in. ~ 3.1/2 in.

Total Carriers 60

Total Bearings 120

Inserts Screw
Total Inserts 60

Total Elastomers 60

ZRT-80K Chapter 3 Injector 7

3.3.3 TENSION SYSTEM

The chains are kept in constant tension by the forces generated by the tension cylinders.

This tension prevents the chains from becoming slack and possibly damaging the

tubing. The chain tension pressure can be varied from the control cabin.

NOTE

a) See Figure 3-2 for proper chain tension pressure requirements.

b) See Figure 3-16 for Injector Tension System.

c) The tension generated by tension cylinders prevents the chains from becoming

slack and damages to the tubing and grippers caused by the slack chains.

Cylinders 4

Min. Operating Pressure 500 psi

Max. Operating Pressure 3,000 psi

3.3.4 FRAMEWORK AND PROTECTION

The outer frame of the injector mounts the gooseneck and incorporates a four-point lift

for handling the injector during transport and operation. Shackle mounts are provided

for anchor points and harness tie-off at the job site.

Lift Capacity over Frame 95,000lb

Rated Capacity of Sling 35,270lb

Maximum Arresting Force for Fall-safe Brake 900lb

8 Chapter 3 Injector ZRT-80K

3.3.5 LOAD CELL SYSTEM

The load cell system has three optional configurations: two hydraulic load cells; one

electronic load cell; two hydraulic load cells and one electronic load cell. To isolate

transport shock loads from the load cell, the load cell system is designed with tie-down

bolts that must be engaged when moving from site to site.

NOTE

a) See Figure 3-11, 3-12, 3-13 for the load cell system.

b) The injector can be tilted forward or backward but along the direction of the

gooseneck for transportation, but it is forbidden to transport the injector with it

tilting to one side.

c) Make sure that the locknuts are loose for operation and tight for transportation.

d) Regarding to the electronic load cell system, there is center load cell nut which

should be tight against the load cell support for operation or loose for

transportation.

e) Check whether the hydraulic load cell repair kit (P200018579) inside the hydraulic

load cell leaks or not. If any leakage is found, replace it in time.

Hydraulic Load Cells (Two-each)

Type Mechanical

Outputs 0～1,250 psi

Tubing Load Range -80,000 to +80,000 lb

Operational Temperature Range -29℃～65℃

ZRT-80K Chapter 3 Injector 9

Electronic Load Cell (One)

Type Strain Gauge

Outputs 4-20 mA

Tubing Load Range -80,000 to +80,000 lb

Operational Temperature Range -40℃～85℃

Load Cell(s) Set-Up Options

 Hydraulic Load Cell

a) Using the adjustable lock out screws, adjust the injector until it is parallel to the

injector seat.

b) Bleed any entrapped air from both pipe-light and pipe-heavy load cells and

hydraulic pipes by pumping lube oil (W-15) into the load cells.

c) Once the air has been purged, pump W-15 into the pipe-heavy and pipe-light load

cells until load cell gaps are 11±0.5mm. (Note: Excessive pumping pressure against

load cells can cause erroneous weight indicator indications.)

d) Loosen the lock out screws and allow the weight of the injector to weigh onto the

pipe-heavy load cell. An increase in load should be noted "pipe-heavy" on the

weight indicator. This is the weight of the injector except for the frame on the load

cell.

e) Set the weight indicator(s) pipe-heavy scales to "0".

 Electronic Load Cell

a) Loosen the lock out screws and allow the weight of the injector to weigh onto the

pipe-heavy load cell. An increase in load should be noted "pipe-heavy" on the

10 Chapter 3 Injector ZRT-80K

 weight indicator. This is the weight of the injector except for the frame on the load

cell.

b) Set the weight indicator(s) pipe-heavy scales to "0".

NOTE

a) The alignment between gooseneck and chains is critical to the correct readout of

load cell and success operation of chains system.

b) The readout of hydraulic load cells will increase with the ambient temperature, so

please pay close attention to the effect to the load cell readout caused by ambient

temperature.

c) Insufficient or excessive pumping pressure to the load cells will lead to

misalignment of the gooseneck and erroneous weight indicator indications.

3.3.6 LUBRICATION SYSTEM

The injector lubrication system is specially designed spray type system that ensures

complete coating of the chains and its components. Additionally, the spray lubrication

system prolongs the service life of the chains, skates and traction bearings to the

maximum.

ZRT-80K Chapter 3 Injector 11

3.4 OPERATING INSTRUCTIONS

3.4.1 SYSTEM PRESSURE ADJUSTMENT

3.4.1.1 CHAIN TENSION

The tension cylinders are installed at the bottom of the injector. Keep their tension

pressure at 500 psi to the minimum to ensure the stable rotation of the chains.

During a pipe-light application, keep proper tension pressure will prevent the chains

from slack. If the wellhead pressure is too high, it will produce an upward force trying to

push the tubing out of the well. If no tension force is applied, the upward force will lead

to chain slack. Operators should increase the chain tension to make up the force that

wellhead applies to the injector chain. Please refer to Figure 3-2 Chain Tension Pressure

vs. Snubbing Force below.

12 Chapter 3 Injector ZRT-80K

 Figure 3-2 Chain Tension Pressure vs. Snubbing Force

High tension pressure will shorten the service life of chains and grippers. If the tension

pressure exceeds 3,000 psi, it is higher than the designed tension force of the injector.

NOTE

a) The chart is developed from measurements made in good condition. Since the job

conditions vary the actual value could have a certain difference with the chart.

Please adjust the tension pressure according to the actual job conditions.

b) When the pressure of the tension cylinder is set, the actual pressure in the tension

cylinders will increase with the temperature rising. Please pay close attention to

the pressure and adjust it to needed value in time.

ZRT-80K Chapter 3 Injector 13

3.4.1.2 CHAIN TRACTION

See Figure 3-3 for relationship between injector pull and traction pressure.

Figure 3-3 Traction Pressure vs. Injector Pull

NOTE

Operate the injector traction between the minimum and maximum lines in Figure 3-3.

The chart is developed from measurements made in good condition. Since the job

conditions vary the actual value could have a certain difference with the chart. Please

adjust the traction pressure according to the actual job conditions.

14 Chapter 3 Injector ZRT-80K

 The following conditions will influence the value:

a) Tubing ovality;

b) Tubing surface conditions such as oil, grease, paraffin and dirt;

c) Gripper conditions such as worn, scarred and polished smooth.

When the pressure of the traction cylinder is set, the pressure will increase with the

temperature. Please pay close attention to the pressure and adjust it to needed value in

time.

3.4.1.3 SYSTEM PRESSURE

See Figure 3-4 for the relationship between injector pull and system pressure:

Figure 3-4 Injector Pull vs. System Pressure

ZRT-80K Chapter 3 Injector 15

 NOTE

a) The chart is developed from measurements made in good condition. Since the job

conditions vary the actual value could have a certain difference with the chart.

Please adjust the pressure of the drive system according to the actual job

conditions.

b) Be aware of the maximum anti-break load and the circulation pressure of each job.

The pressure of the injector drive system should be set lower than the pressure

needed to be generated to avoid break the tubing inside the well.

3.4.2 GOOSENECK INSTALLATION

The injector is equipped with a foldable gooseneck and is easy for transportation.

The alignment of the gooseneck can be achieved through nut 1 and 2. The main

purpose is to ensure the tubing can stay in the center of the injector when it enters the

injector. Even though the tubing is flexible, it cannot be bent sharply. If the tubing is not

in the center of the injector, the gripper cannot hold the tubing correctly.

Observe the chains from the top of the injector to tell whether the gooseneck is aligned

from the position where the tubing begins contacting the chains.

16 Chapter 3 Injector ZRT-80K

 Incorrect Correct
Figure 3-5 Injector Gooseneck Installation

NOTE

Improper alignment adjustment will cause damage to the tubing, grippers or bearing.

When adjusting the gooseneck, operators should make sure that the personnel

protective equipment such as safety belt and lifting device are all in place.

Setting Gooseneck Alignment:

a) Ensure the traction pressure is shut off to the traction circuits and there is no

additional force.

b) Apply 300~500 psi to the chain tension circuit.

ZRT-80K Chapter 3 Injector 17

c) Rotate chains at least ten revolutions in in-hole/out-hole direction and inspect

chains visually to ensure chains rotate smoothly in correct direction and the size of

the grippers is consistent with that of the tubing.

d) Release tension pressure and ensure the chains and grippers are at floating status

when inserting the tubing in.

e) Insert the tubing into the gooseneck. And the tubing runs into the chains at the

outer tangent line direction of the gooseneck.

f) When inserting the tubing into the injector, apply a pressure less than 100psi to the

traction circuit if necessary and then drive the injector in-hole to pull the tubing

through the injector. Please make sure the tubing is in the middle part of the injector

before applying the traction pressure. A stabbing device is very helpful for this

purpose.

g) Once the tubing is completely through the injector and into the stripper, increase

traction pressure to at least 500psi.

h) If the wellhead pressure is smaller than 1,000psi, adjust the tension pressure to

500psi. If the wellhead pressure is bigger than 1,000psi, then adjust the pressure

according the table above.

i) The chains must be at the center of the injector. Observe whether the clearances are

the same after the tubing runs into the stripper.

j) If the chains are bent, please check the position of the gooseneck. The tubing should

enter the center of the injector chains evenly and there shouldn’t be any S bents or

too short bents.

k) Proper maintenance will help save a lot of time in troubleshooting. The visual

18 Chapter 3 Injector ZRT-80K

 inspection of the rotary/moving parts and the in-time replacement of worn parts will

help reduce the failure rate.

Always tilting the gooseneck following correct procedures will help reduce the

ineffective time caused by damages of rollers and the tubing.

Some Symptoms of A Gooseneck Alignment Problem are:

a) Chains do not run in the center of the skate.

b) Traction system closes more on one side than it does on the other.

c) Excessive chain noise during operation.

d) Marking or damaging tubing.

e) Excessive wear on one side of stripper bushing.

f) Excessive motion of the top or bottom traction set.

NOTE

If the damage of the injector leads to the tilt or serious misalignment of the core frame

and outer frame, it cannot be corrected with the gooseneck adjustment. This type of

misalignment can and will cause serious damage to the injector chain and traction

system as well as the tubing itself. Please contact Jereh Service personnel for help for

this circumstance.

ZRT-80K Chapter 3 Injector 19

Setting position of the roller:

The set-up position of the roller should be changed with the different tubing sizes:

20 Chapter 3 Injector ZRT-80K

3.4.3 LUBRICATION

Injector System Lubricants and Lubrication Points (Figure 3-6)

No. Description Oil

1 Gooseneck Metal Roller 2EP Grease

2 Gooseneck Guide Roller 2EP Grease

3 Gear Box Omala S2 G220 (Fill oil to the middle of gear box)

4 Chains and Bearings 15W/40 (-20~+45℃)

5 Tension Bearings 2EP Grease

ZRT-80K Chapter 3 Injector 21

 Figure 3-6 Oils Filling and Lubrication Points

22 Chapter 3 Injector ZRT-80K

Other Recommended Lube Oils for Gear Box

Supplier Lube Oil

Mobil gear 630

Mobil
Mobil gear 600 XP 220

NOTE

a) Please ensure the consistency of oils filled.

b) Replacement Requirement of Gear Box Lube Oil: Replace lube oil for the first time

after 150 hours of operation or 100 hubodometer mile (readout of odometer) for

the first time; check the oil condition every half a year; replace the lube oil annually

or every 1,500 hours of operation.

ZRT-80K Chapter 3 Injector 23

Other Recommended Lube Oils for Chains

Recommended Lube Oils

Ambient Temperature
SAE ISOVG
-10℃-0℃ 20 68

0℃-40℃ 30 100

40℃-50℃ 40 150

50℃-60℃ 50 220

Lube oils used in low temperature environment are as shown below. For other brands,

please use the same grade oil.

Ambient Temp. Supplier Brand

-60℃-150℃ Castrol Optileb CH 32

-54℃-90℃ Anderol Royco 756A

-45℃-150℃ Kluber 4 NH1-32

-30℃-200℃ Castrol Optileb CH 150

-30℃-200℃ Castrol Optileb CH 280

NOTE

a) Lubricate the chain every time before operation or after the chain cleaning or

running 500m at most. Make sure the chain has been fully lubricated before

stopping the chain lubrication.

b) The injector chain operation will produce noise if not fully lubricated, which will

speed up the chain wear.

c) DO NOT feed the injector lubrication system with slop oil; DO NOT use hydraulic

24 Chapter 3 Injector ZRT-80K

 oil as replacement; DO NOT clean the chain with steam.

d) Please use tarpaulin for outdoor storage since oil loss caused by rain and snow will

produce detrimental corrosion.

e) Please wipe off the moisture and apply WD-40 antirust agent and then lube oil if

the chain gets wet in rainy or snowy day. For long-term storage, please coat

VpCI-322 antirust oil.

f) It is recommended to dip the chains in lube oil for lubrication before installing it to

the unit.

ZRT-80K Chapter 3 Injector 25

3.4.4 COUNTER INSTALLATION (OPTIONAL)

Figure 3-7 Counter Installation Ⅰ

NOTE

a) The tubing counter properly installed can measure the downhole tubing depth

accurately.

b) Adjust the bolt as shown in figure 3-7 to make the front end of the counter against

the right middle of the tubing.

c) If the pressing force is not enough, please adjust the spring tension adjustment

screw as shown in figure 3-8.

d) Check whether the chains and gears are greased.

26 Chapter 3 Injector ZRT-80K

e) Check the wear condition of the tubing counter wheel. Replace it if the diameter

abrasion loss reaches 96.95mm.

f) Check whether the coupling gets loose.

Figure 3-8 Counter Installation Ⅱ

NOTE

a) Please ensure the consistency of oils filled.

b) Replacement Requirement of Gear Box Lube Oil: Replace lube oil for the first time

after 150 hours of operation or 100 hubodometer mile (readout of odometer) for

the first time; check the oil condition every half a year; replace the lube oil annually

ZRT-80K Chapter 3 Injector 27

 or every 1,500 hours of operation.

c) DO NOT add waste oil to the lubrication system of the injector. It is not

recommended to use hydraulic oil as lube oil.

d) It is recommended to dip the chains in lube oil for lubrication before installing it to

the unit.

28 Chapter 3 Injector ZRT-80K

3.5 PARTS INFORMATION

This list is used to identify the parts when using or ordering spare parts. It can also be

used to indicate the assembling relationships between parts during disassembly and

assembly.

NOTE

The assembly drawing may be not the latest version. Please provide the product

number of the unit when ordering spare parts.

ZRT-80K Chapter 3 Injector 29

 Figure 3-9 Injector System

30 Chapter 3 Injector ZRT-80K

Components List:

No. Description Qty. Remark

1 Gooseneck Assembly 1
2 Injector Protection Frame Assembly 1
3 Drive System 1
4 Traction System 1
5 Tension System 1
6 Load Cell System 1

ZRT-80K Chapter 3 Injector 31

3.5.1 GOOSENECK ASSEMBLY

Figure 3-10 72”Gooseneck Assembly

32 Chapter 3 Injector ZRT-80K

Components List:

No. P/N Description Qty. Remark

1 E020008148 Grease Nipple 24

2 D060009980 Bearing 18

3 D060009216 Bearing 18

4 D030006643 Nut 37

5 D040008005 Plain Cushion 92

6 3810009291 Stud I 1

7 3810009292 Roller I 1

8 3810009290 Stud H 1

9 3810009293 Roller H 1

10 3810009289 Stud G 1

11 3810009294 Roller G 1

12 3810009288 Stud F 1

13 3810009295 Roller F 1

14 3810009287 Stud E 1

15 3810009296 Roller E 1

16 3810009286 Stud D 1

17 3810009297 Roller D 1

18 3810009285 Stud C 1

19 3810009298 Roller C 1

20 3810009284 Stud B 1

21 3810009299 Roller B 1

22 3810009283 Stud A 1

23 3810009300 Roller A 1

ZRT-80K Chapter 3 Injector 33

 No. P/N Description Qty. Remark

24 3810008537 Stud 2

25 3810008538 Guide Pulley 2

26 3810098609 Hinge Pin 1

27 E020005325 Shackle 2

28 0301005162 Chain 1

29 E020012234 O Pin 2

30 2409019800 Steel Wire 2

31 E020012281 Buckle 4

32 B040010223 Cylinder 2

33 3810009302 Bolt 15

34 3810008553 Axle Sleeve 8

35 D060009769 Bearing 30

36 3810009304 Roller 15

37 3810008559 Axle Sleeve 22

38 3810072408 Hinge Pin 1

39 3810009315 Hinge Pin 1

40 D080012302 Split Pin 3

41 B040010220 Cylinder 1

42 3810009316 Bolt 1

43 D040007893 Plain Cushion 2

44 D030006705 Nut 1

45 D080013099 Hinge Pin 1

34 Chapter 3 Injector ZRT-80K

3.5.2 FRAME ASSEMBLY

Figure 3-11 Injector Frame Assembly

ZRT-80K Chapter 3 Injector 35

Components List:

No. P/N Description Qty. Remark

1 E020014495 Fall-safe Brake 1

2 3801008670 Fall Protection Frame 1

3 3801009146 Footboard A 2

4 3801009154 Leading Screw 2

5 D030006705 Nut 4

6 D040007893 Plain Cushion 4

7 3801009156 Pin 4

8 D030012644 Nut 4

9 3801009867 Stripper Carrier 1

10 3801008698 Stripper Fixed Pin 2

11 3801010940 Pin 2

12 3801008616 Holder 4

13 E020015264 Pin with Chain 4

14 3801008708 Gooseneck Sliding Bottom 1

15 3801009127 Footboard B 1

16 3801009145 Pin 2

17 3801008614 Baffle Plate 2

18 D010006420 Bolt 4

19 3801017806 Footboard C 1

36 Chapter 3 Injector ZRT-80K

3.5.3 GOOSENECK SLIDING BOTTOM ASSEMBLY

Figure 3-12 Injector Gooseneck Sliding Bottom Assembly

Components List:

No. P/N Description Qty. Remark

1 D020012309 Screw 24

2 3801009123 Cushion 4

3 3801009115 Gooseneck Carrier 1

4 D030006693 Nut 4

5 D040007879 Plain Cushion 2

6 3801009160 Screw 1

7 D080008084 Pin 2

8 3801009122 Fixed Sleeve 2

9 3801009121 Pin 1

ZRT-80K Chapter 3 Injector 37

3.5.4 DRIVE SYSTEM ASSEMBLY

Figure 3-13 Drive System Assembly

Components List:

No. P/N Description Qty. Remark

1 B020009705 Motor 2

2 G030010858A Brake 2

3 3803009950 Flange A 2

4 D060009890 Bearing 2

5 3803009952 Flange B 2

6 3803008230 Drive Sprocket 2

7 3803010390 Drive Shaft 2

8 3803008232 Flange 2

9 G030008389 Gear Drive 2

10 D010011626 Bolt 4

38 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

11 D040010596 Plain Cushion 8

12 D030011661 Nut 4

13 D020012861 Screw 60

14 B050011034 Seal Ring 2

15 B050012272 Seal Ring 2

16 3803008229 Retainer Ring 2

17 D040012326 Retainer Ring 2

18 D040012348 Retainer Ring 2

19 D990009851 Oil Cup 2

20 D990012367 Seal Ring 2

21 D040012348 Retainer Ring 2

22 D020010622 Screw 80

Repair Kit:

P/N Description Qty.

3899102854 The repair kit of the brake (NO.2) 2

B030033144 Balance value of motor 2

ZRT-80K Chapter 3 Injector 39

3.5.5 TRACTION SYSTEM ASSEMBLY

Figure 3-14 Traction Assembly

Components List:

No. P/N Description Qty. Remark

1 D020015804 Screw 24

2 3806008239 Base Plate 6

3 B040012448 Cylinder 6

4 D020012369 Screw 24

5 3806008240 Pin 8

40 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

6 3806008241 Sleeve 8

7 D030009207 Nut 8

8 D060009342 Bearing 8

9 3806096096 Skate 2

10 D020037636 Shoulder Screw 8

Repair Kit:

P/N Description Qty.

3899102844 The seal kit of the cylinder (NO.3) 6

Chain Assembly

Figure 3-15 Chain Assembly

ZRT-80K Chapter 3 Injector 41

Components List:

No. P/N Description Qty. Remark

1 A020012519 M-Link 60

2 A020012520 Roller Link 120

3 A020012522 Center Plate 120

4 A020012508 Cover Plate 60

5 A020012530 Z Pin 60

6 3806053257 Gripper Carrier 60

7 D060017901 Bearing 120

8 3806009870 Hinge Pin 60

9 D040007910 Elastic Collar 120

10 Gripper 60
11 3806009872 Gripper Gasket 60

12 D020015676 Blot 60

According to different requirements, the Grippers have the following different sizes:

No. P/N Description Qty. Remark

1 3806018268 1.25" Gripper 60

2 3806052996 1.5" Gripper 60

3 3806052997 1.75" Gripper 60

4 3806052994 2" Gripper 60

5 3806052995 2.375" Gripper 60

6 3806095433 2.625" Gripper 60

7 3806052993 2.875" Gripper 60

42 Chapter 3 Injector ZRT-80K

3.5.6 TENSION SYSTEM ASSEMBLY

Figure 3-16 Tension Assembly

Components List:

No. P/N Description Qty. Remark

1 3801008222 Steel Wire 4

2 B040012359 Cylinder 4

3 3805008223 Cylinder Baffler 4

4 3801008224 Steel Wire 4

5 D010010867 Bolt 3

6 D040007958 Spring Washer 3

7 D040007977 Plain Cushion 3

8 3805053475 Baffler 3

ZRT-80K Chapter 3 Injector 43

 No. P/N Description Qty. Remark

9 D060009841 Bearing 4

10 3805008225 Baffler 8

11 2501113066 Bolt set 8

12 3805008219 Slideway 8

13 3805008220 Slave Sprocket 2

14 D070028395 Flat Key 2

15 3805008221 Idler Shaft 2

16 A990010419A Milometer 1

Repair Kit:

P/N Description Qty.

3899102845 The seal kit of the cylinder (NO.2) 4

3.5.7 LOAD CELL SYSTEM ASSEMBLY

The injector can be equipped with hydraulic load cell or electronic load cell or a

combination of both hydraulic and electronic cells according to the requirements.

44 Chapter 3 Injector ZRT-80K

 Figure 3-17 Electronic Load Cell System Assembly

Components List:

No. P/N Description Qty. Remark

1 C050024513 Load Cell 1

2 D010006348 Bolt 8

3 D040007991 Elastic Washer 8

4 D040007906 Plain Cushion 8

5 3801043763 Screw 1

6 D030023108 Center Nut 1

7 3801043762 Gasket 1

8 3801043761 Gasket 1

9 3801043764 Gasket 1

10 3801043765 Gasket 1

ZRT-80K Chapter 3 Injector 45

 Figure 3-18 Hydraulic Load Cell System Assembly

Components List:

No. P/N Description Qty. Remark

1 D010006360 Bolt 4

2 D040007918 Elastic Washer 4

3 D040007912 Plain Cushion 4

4 C050012523 Hydraulic Load Cell 2

Repair Kit:

P/N Description Qty.

P200018579 The repair kit of the Hydraulic Load Cell (NO.4) 2

46 Chapter 3 Injector ZRT-80K

 Figure 3-19 Combination of Electronic and Hydraulic Load Cells

Components List:

No. P/N Description Qty. Remark

1 C050012523 Hydraulic Load Cell 2

2 D010006360 Bolt 4

3 D040007918 Elastic Washer 4

4 D040007912 Plain Cushion 4

5 D010019020 Nut 1

6 3801035775 Center Screw 1

7 D010011626 Bolt 8

8 D040007944 Elastic Washer 8

ZRT-80K Chapter 3 Injector 47

 No. P/N Description Qty. Remark

9 D040010596 Plain Cushion 8

10 C050024513 Sensor 1

11 3801035776 Support 1

Repair Kit:

P/N Description Qty.

P200018579 The repair kit of the Hydraulic Load Cell (NO.1) 2

48 Chapter 3 Injector ZRT-80K

3.5.8 LUBRICATION SYSTEM ASSEMBLY

Figure 3-20 Hydraulic Lubrication System Assembly

ZRT-80K Chapter 3 Injector 49

Components List:

No. P/N Description Qty. Remark

1 B070008123 Connector 1

2 B070004356 Connector 1

3 B070012268 Connector 1

4 B010012518 Pneumatic Pump 1

5 B070008885 Connector 1

6 B080012503 Filter 1

7 B070008468 Connector 1

8 B030000535 Throttle Valve 1

9 B070004780 Straight Connector 1

10 B070008817 Tee 1

11 B070003763 Connector 1

12 B070008861 Connector 2

13 B070008841 Tee Connector 2

14 B030014498 Bulkhead Connector 4

15 B070009044 45°Connector 4

16 B030014318 Adjustable Ball Joint 4

17 B030014319 Fan-shaped Nozzle 4

18 B080012515 Filter 1

19 B070004402 Connector 2

20 E030005472 Ball Valve 2

21 3801018999 Transparent Hose 1

22 3812009949 Lube Oil Tank 1

23 B070009007 Plug 1

50 Chapter 3 Injector ZRT-80K

Repair Kit:

P/N Description Qty.

3899102848 The seal kit of the Pneumatic Pump (NO.4) 1

3899102856 The repair kit of the Filter (NO.6) 1

ZRT-80K Chapter 3 Injector 51

3.5.9 HYDRAULIC SYSTEM ASSEMBLY

Figure 3-21 Hydraulic System Schematic

52 Chapter 3 Injector ZRT-80K

Components List:

No. Description Qty. Remark

1 Injector Motor Assembly 1 1

2 Injector Motor Assembly 2 1

3 Upper Filter Assembly 1

4 Lower Filter Assembly 1

5 Cartridge Valve Assembly 1

6 Accumulator Assembly 3

7 Oil Drain Valve Assembly 1

8 Bulkhead Connector Assembly 1

9 Tension Cylinder Assembly 1

10 Traction Cylinder Assembly 1

ZRT-80K Chapter 3 Injector 53

3.5.9.1 INJECTOR MOTOR ASSEMBLY

Figure 3-22 Injector Motor Assembly 1 Schematic

Components List:

No. P/N Description Qty. Remark

1 B070010887 Flange Joint 2

2 B050000688 O-ring 2

3 B070004752 Flange 2

4 D020013480 Bolt 8

54 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

5 D040007969 Elastic Washer 8

6 B070005871 Connector 1

7 B070008595 Tee Joint 3

8 B070005859 Connector 1

9 B050007897 Sealing Washer 1

10 B070012357 Connector 1

11 B070008726 Tee Joint 1

12 B070008893 Connector 1

13 B070005328 Connector 1

14 B030013896 Safety Valve 1

15 B070005326 Connector 2

16 B050007934 Sealing Washer 2

17 B070005549 Connector 1

18 B070005877 Connector 1

19 B080034579 Pressure Gauge 1

ZRT-80K Chapter 3 Injector 55

 Figure 3-23 Injector Motor Assembly 2 Schematic

Components List:

No. P/N Description Qty. Remark

1 B050007897 Sealing Washer 1

2 B070005859 Connector 1

3 B070004652 Connector 1

4 B050007934 Sealing Washer 1

5 B070005326 Connector 1

6 B070005871 Connector 1

56 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

7 B070012455 Connector 1

8 B050000688 O Ring 2

9 B070004752 Flange 2

10 D040007969 Elastic Washer 8

11 D020013480 Bolt 8

12 B070010887 Flange Joint 2

ZRT-80K Chapter 3 Injector 57

3.5.9.2 FILTER ASSEMBLY

Figure 3-24 Filter Assembly Schematic

58 Chapter 3 Injector ZRT-80K

Components List:

No. P/N Description Qty. Remark

1 B070004380 Flange Joint 2

2 B070005730 Flange 4

3 B050000730 Seal Ring 5

4 D020016224 Bolt 8

5 D040007938 Gasket 16

6 B070009035 Connector 2

7 3804009764 Flange Block 2

8 D020014052 Bolt 8

9 D040007888 Gasket 8

10 B080009658 Filter Element 2

11 D010006382 Bolt 8

12 D040007881 Gasket 8

13 B070009058 Plug 2

14 D020019690 bolt 8

15 B080043760 Pressure Gauge 2

16 B030014566 Connector 2

17 B070013229 Connector 1

18 B080011217 Dust Cap 1

19 B070010886 Connector 2

20 B050000730 Seal Ring 5

21 B070013229 Connector 1

22 B080011208 Dust Plug 1

ZRT-80K Chapter 3 Injector 59

Repair Kit:

P/N Description Qty.

P200024151 The seal kit of the filter (NO.10) 2

3.5.9.3 BRAKE CARTRIDGE VALVE ASSEMBLY

Figure 3-25 Brake Cartridge Valve Assembly Schematic

Components List:

No. P/N Description Qty. Remark

1 B070003876 Connector 1

2 B030011214 Control Valve 1

3 B070009031 Connector 2

60 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

4 B070004103 Connector 1

5 B070008935 Connector 2

6 B080043780 Pressure Gauge 1

7 B070005840 Connector 3

8 B070005549 Connector 1

9 B070008889 Connector 1

10 B020012502 Control Valve 1

11 B070009005 Connector 2

ZRT-80K Chapter 3 Injector 61

3.5.9.4 ACCUMULATOR ASSEMBLY

Figure 3-26 Accumulator Assembly Schematic

Components List:

No. P/N Description Qty. Remark

1 B070003876 Connector 1

2 B030011214 Control Valve 1

3 B070008468 Connector 1

62 Chapter 3 Injector ZRT-80K

 No. P/N Description Qty. Remark

4 B070005871 Connector 1

5 B030009214 Control Valve 1

6 B070003887 Connector 1

7 B070012544 Connector 1

8 B070005282 Connector 1

9 B080012528 Accumulator 1

10 B070012549 Connector 1

11 B080043609 Pressure Gauge 1

12 B070008594 Connector 1

13 B070005869 Connector 1

14 B070008804 Connector 1

Repair Kit:

P/N Description Qty.

P200048258 The bladder kit of the Accumulator (NO.9) 1

ZRT-80K Chapter 3 Injector 63

3.5.9.5 OIL DRAIN VALVE ASSEMBLY

Figure 3-27 Oil Drain Valve Assembly

Components List:

No. P/N Description Qty. Remark

1 B070008732 Connector 1

2 B030013896 Relief Valve 1

3 B080043761 Pressure Gauge 1

4 B070005510 Connector 1

5 3804039288 Discharge Manifold 1

6 B070009005 Connector 1

7 B070005840 Connector 2

8 B070008890 Connector 1

64 Chapter 3 Injector ZRT-80K

3.5.9.6 TENSION CYLINDER ASSEMBLY

Figure 3-29 Tension Cylinder Assembly Schematic

Components List:

No. P/N Description Qty. Remark

1 B080043609 Pressure Gauge 1

2 B070008935 Connector 1

3 B070003876 Connector 1

4 B070008934 Connector 1

ZRT-80K Chapter 3 Injector 65

 No. P/N Description Qty. Remark

5 B070010619 Connector 1

6 B070005804 Connector 2

7 B070008594 Connector 1

8 B070012457 Connector 2

9 B070009035 Connector 2

10 B070005840 Connector 2

3.5.9.7 TRACTION CYLINDER ASSEMBLY

Figure 3-30 Traction Cylinder Assembly Schematic

66 Chapter 3 Injector ZRT-80K

Components List:
No. P/N Description Qty. Remark

1 B070012534 Connector 6

2 3804009668 Steel Tube 1

3 B070012556 Connector 3

4 B070008963 Connector 3

ZRT-80K Chapter 3 Injector 67

3.6 MAINTENANCE

3.6.1 MOTOR

Internal leakage is usually seen at the high-speed cycle. Initial start-up during cold

weather requires the system to warm up and the motor rotates at low speed.

WARNING

DO NOT allow case drains to be restricted or blocked during operation of the injector.

3.6.2 FILTERS

The filter element needs to be replaced when the indicator on the filters warns. Once

the indicator warns, impurities can enter the motor through the filter bypass. So, check

the filter indicator daily and immediately after each start-up. Replace elements every

300 hours of operation.

NOTE

Dirty hose couplers are a progressive source of contaminants. Use coupling protectors

when couplings are not in use. Clean couplers before every connection.

68 Chapter 3 Injector ZRT-80K

3.6.3 COUNTERBALANCE VALVES

These valves act as retarders to runaway conditions at the motor caused by the weight

loads on the injectors.

WARNING

DO NOT adjust the counterbalance valves. Due to their distinctiveness, they are not

within the scope of service. Any damage to the counterbalance valves may lead to

operation function confusion. Therefore, all warranties related to the counterbalance

valves are not within the warranty scope of this unit.

3.6.4 CYLINDERS

The circuits are controlled through the control panel inside the operation cabin. Leakage

in these cylinders can occur at the rod seals and piston seals. Check for abrasive material

on the rods or loose mechanical connections that cause rod deflection. If cylinder is in

good shape, only the packing need to be replaced. If the cylinder is not in good shape,

for example, pitting of cylinders and connectors, leaking from rod end at wiper seals,

replace it.

NOTE

Vent accumulator pressure before attempting to service cylinders by turning the

handle of ball valve at the outlet of accumulator to the direction which is parallel to

corresponding pipe direction. This ball valve must be closed during normal operation.

ZRT-80K Chapter 3 Injector 69

Anytime a connection on a hydraulic hose is disconnected for maintenance or is

damaged, air can enter the hydraulic cylinder. Air should be bled from the cylinders

before each operation. The following procedures should be implemented to bleed off

pressure:

a) Ensure the injector is not working.

b) Ensure the injector clamps tubing so that the traction cylinders can be opened.

c) Open all traction cylinder supply valves to supply a traction pressure of 200~300psi.

d) Slowly loosen the hose fitting closest to the cylinder until air bubbles disappear and

a steady steam of hydraulic fluid is flowing from the f ittings. If there is no

flow/bleeding when hose fitting is loosened, increase traction pressure slowly until

flow/bleeding occurs.

e) When solid fluid stream appears (no air bubbles) re-tighten the hose fitting.

3.6.5 ACCUMULATORS

The accumulators on the injector act as pressure compensation and pressure storage

devices. The set pressure of the accumulators in the hydraulic system is 550 psi.

NOTE

a) Check the pre-charged nitrogen pressure of the accumulator.

b) Bleed off all hydraulic pressure before doing ANY service work by turning the

handle of ball valve at the outlet of accumulator to the direction which is parallel to

corresponding pipe direction. This ball valve must be closed during normal

operation.

70 Chapter 3 Injector ZRT-80K

 Figure 3-31 Accumulator

NOTE

DO NOT attempt to remove accumulators while injector is connected to the power

pack. Bleed all pressure from line and accumulators before attempting service work.

Bleed nitrogen before dismantling accumulators.

3.6.6 CHAIN

Regular inspection and maintenance is necessary to achieve the longest service time.

It is recommended to maintain one time every year or every 100 reading (as per

odometer).

ZRT-80K Chapter 3 Injector 71

Please carry out regular maintenance in a much shorter cycle in case of the following

situations.

a) Poor lubrication;

b) Bad environment, such as ocean and desert area;

c) Emergent stop when running at high speed;

d) Suspension/intermittent operation

WARNING

a) Avoid contacting the running chain before the inspection and maintenance.

b) Please wear the qualified safety glasses, protective clothing, safety helmet, gloves

and safety boots.

c) Use the tools in the correct working conditions and in the right way.

d) DO NOT disconnect or reconnect the chain before being fully aware of the chain

structure.

e) Fix the chain before disconnecting to avoid the sudden moving of the chain or the

chain components.

f) DO NOT reuse the damaged chain or chain components or individual component.

72 Chapter 3 Injector ZRT-80K

Inspection Procedure

Procedure Methods Item

a) Check the chain running for abnormal noise.

Visually check the b) Check the chain for slackness.

chain running c) Check whether chain lubrication system oil

Step 1
condition for path is smooth.

abnormity. d) Check whether the chain interferences with the

surrounding object.

a) Remove the collected oil sludge or foreign

materials.

b) Check the chain appearance for corrosion, and

check the side and end face of linkplate, pin

surface and roller surface for damage.

c) Check the pin rotation and the interval

Stop running to check
between the linkplate and pin. Check whether the
Step 2 the chain parts in
roller rotation is smooth.
detail.
d) Check the chain for distortion and side bend.

e) Measure the wear elongation.

f ) Check the teeth face and side of the sprocket

for damages.

g) Check the lubricant and replace the lube oil

filter element.

ZRT-80K Chapter 3 Injector 73

3.6.6.1 CHAIN WEAR ELONGATION MEASUREMENT

The surface wear on the pins and bushings cause the larger interval. As material is worn

away from these surfaces, the chain will gradually elongate.

Measure the elongation of the roller chain regularly can calculate the chain service time.

When measuring the elongation, stretch the chain to a certain degree to eliminate the

interval of the whole roller chain. Use a force of 500PSI to tension the chain.

The following two ways can be used measure the elongation of the chain.

1) Refer to 0005152347-Chain Inspection Fixture (Chinese and English) for chain wear

measurement. The maximum allowable wear elongation is 3%.

It means severe wear of the chain when the pin center reaches the indication points and

the chain should be replaced.

Procedures are as follows:

74 Chapter 3 Injector ZRT-80K

ZRT-80K Chapter 3 Injector 75
2) Measure with vernier caliper

Specific method is as shown below:

Measure multiple chain links to reduce the measuring error. Use the tapeline as

replacement when the vernier caliper is not available. Multiple chain links also should be

measured to reduce the measuring error.

Roller

As shown in picture, measure L1 and L2 to calculate the measured chain length L.

The chain length is:

L=（L1+L2）/2

76 Chapter 3 Injector ZRT-80K

The chain elongation is:

Elongation=(L-Datum Length)/ Datum Length ×100%

Where:

Datum Length=Chain Pitch×Chain Link Qty.

Replace the chain if the calculated elongation reaches 3%.

Follow chart is avilable to be used judge if elongation reaches 3%

Chain Wear Elongation Limits

Chain Pitch Measured Length

ANSI Chain
Nominal At 3% Wear
No. in mm Pitches
in mm in mm

25 0.25 6.35 48 12 305 12.375 314

35 0.375 9.52 32 12 305 12.375 314

41 0.5 12.7 24 12 305 12.375 314

40 0.5 12.7 24 12 305 12.375 314

50 0.625 15.88 20 12.5 318 12.875 327

60 0.75 19.05 16 12 305 12.375 314

80 1 25.4 12 12 305 12.375 314

100 1.25 31.75 20 25 635 25.75 654

120 1.5 38.1 16 24 610 24.719 628

140 1.75 44.45 14 24.5 622 25.25 641

160 2 50.8 12 24 610 24.719 628

180 2.25 57.15 12 27 686 27.812 706

200 2.5 63.5 10 25 635 25.75 654

240 3 76.2 8 24 610 24.719 628

ZRT-80K Chapter 3 Injector 77

3.6.6.2 LINKPLATE INSPECTION

Imposing load which is much greater than the maximum allowable tension on the chain

repeatedly will cause chain fatigue failure, thus result in early crack of linkplate.

The linkplate will produce stress corrosion cracks due to rust and corrosion in marine

environment and situations accompanied with acid-base interaction.

Generally the crack occurs on the edge or at side of the linkplate hole. Replace the

whole chain if the linkplate has cracks.

Cracks-prone Area Cracks Example

3.6.6.3 PIN INSPECTION

There will be abnormal friction between pins and bushings due to the poor lubrication

during high-load operation where the pins will rotate in a moment as shown below.

Replace the whole chain in this case.

Remove the other connecting parts and check the pin surface for mechanical damage or

obvious wear. Replace the whole chain in such case.

Check the pin surface for corrosion. Remove the rust and coat lube oil or replace the

chain in such case.

78 Chapter 3 Injector ZRT-80K

 Normal Rotation

3.6.6.4 ROLLER INSPECTION

Imposing load which is much greater than the maximum allowable tension on the roller

will cause fatigue failure since the repeated impact load with sprockets will increase.

Check for cracks in such case.

Roller Crack

There will possibly be cracks on the roller when engaging with sprockets, especially

when foreign materials are involved. In addition, during high-load operation, cracks will

also appear even if there is no foreign materials since the rollers will impact with the

ZRT-80K Chapter 3 Injector 79

sprocket teeth faces.

Poor lubrication will also cause roller cracks.

Replace chain whose roller has fatigue failure since all the parts shall bear the uniform

repeated load.

Check the roller for poor rotation.

3.6.6.5 CHAIN DISTORTION AND SIDE BEND INSPECTION

Replace the whole chain in case of local distortion and side bend.

80 Chapter 3 Injector ZRT-80K

 Side Bend Distortion

3.6.7 GRIPPER

Grippers are available in various sizes corresponding to tubular diameters. Improper

gooseneck alignment can add unwanted wear on the gripper and skate system. The

gripper inspection includes gripper radius wear inspection and gripper carrier ear

ZRT-80K Chapter 3 Injector 81

dimension measurement.

3.6.7.1 GRIPPER RADIUS WEAR INSPECTION

Use matched inspection tool to inspect the gripper radius wear.

Replace the gripper if the measured value L is less than the corresponding value in the

table below. Otherwise tubing slippage will occur.

Gripper Spec. (in) L Min. Value/mm

1.25 69.68

1.5 72.85

1.75 76.03

82 Chapter 3 Injector ZRT-80K

 Gripper Spec. (in) L Min. Value/mm

2 79.20

2.375 83.96

2.625 87.14

2.875 90.31

Tool P/N:

Tool Size P/N Remarks

1.25 M400012951 Measure shaft (1.25”)

1. 5 M400012948 Measure shaft (1. 5”)

1.75 M400012952 Measure shaft (1.75”)

2 M400012950 Measure shaft (2”)

2.375 M400012949 Measure shaft (2.375”)

2.875 M400012947 Measure shaft (2.875”)

NOTE

Contact Jereh sales personnel to order testing tool if necessary.

3.6.7.2 CARRIER EAR INSPECTION

Gripper inspection includes the following dimensions. Replace the gripper if L and h is

greater than the values in the table below.

h/mm L/mm

0.38 10.6

ZRT-80K Chapter 3 Injector 83

3.6.8 GRIPPER CARRIER

Gripper carrier inspection includes the following dimensions. Replace the gripper carrier

if L1, L2 and L3 are less than the values and Φ is greater than the value in the table

below.

L1/mm L2/mm L3/mm Φ/mm

2.5 100.4 6.22 25.55

84 Chapter 3 Injector ZRT-80K

3.6.9 DRIVE SYSTEM

Check the gearbox lube oil level before each job. If the level is too low, it will damage

the drive system.

Inspection procedures:

a) Drain the lube oil inside the gearbox to check for metal flecks.

b) Remove the motor and brake to check all splines for damage.

c) Lay down the injector on its side and make the gearboxr facing up.

d) Remove the gearbox covers and check whether the gear faces and bears are

damaged. The first stage is visible once the covers is removed. The second stage is

made visible once the first stage is removed.

ZRT-80K Chapter 3 Injector 85

e) Fill the Injector Drive System Maintenance Form (Appendix 2) and send to Jereh

After-sale service technicians.

f) Lubricate motor splines with 2EP Grease.

g) Re-assemble the drive system.

h) Fill gearboxes to the proper level with recommended oil.

NOTE

Inspect the injector drive system according to the maintenance form regularly. Contact

Jereh after-sale service technical personnel to determine the maintenance time.

3.6.10 SPROCKET INSPECTION

Check the engaging status between roller chain and sprocket according to collision

status between the roller and the tooth face. The right status is A.

Poor installation of sprockets or roller chain distortion may cause deviation as B or the

teeth sides being colliding and grinding. Please check again and correct it.

86 Chapter 3 Injector ZRT-80K

DO NOT use the sprocket when the high-frequency quenching layer of teeth faces is

worn out, otherwise the chain wear will be accelerated. Please replace the sprocket.

3.6.11 CHAIN BEARING

Bearings on the injector chain are special heavy duty type which needs no lubrication.

Carry out visual inspection before and after operation as following:

a) Whether injector chain bearing rotates flexibly;

b) Whether the bearing seal is damaged and has grease leakage;

c) Whether bearing inner ring and outer ring are fixed;

d) Whether the bearing is broken.

NOTE

a) DO NOT wash the bearing with high-pressure water to avoid bearing seal damage.

b) Skate surface wear and improper gooseneck alignment can influence the bearing

service life.

ZRT-80K Chapter 3 Injector 87

3.6.12 SKATE

Visual inspection before and after operation and annual flaw detection is recommended

since skates are the critical bearing parts of the injector.

Annual flaw detection:

a) Disassemble the chain and wash the skate. Check the skate surface for cracks and

replace it if so.

b) Ultrasonic flaw detection and magnetic particle inspection are necessary if no

cracks via visual inspection. Replace the skate that fails the magnetic particle inspection.

Please contact JEREH after-sale service engineers for flaw detection standards.

88 Chapter 3 Injector ZRT-80K

3.7 DAILY CHECK

3.7.1 BEFORE OPERATION

a) Grease all the idler sprocket bearings with lithium based multi-purpose grease.

b) Grease all the gooseneck rollers and guide pulleys with lithium based

multi-purpose grease.

c) Check whether the lube oil inside the gearbox is invalid or insufficient.

d) Check whether the gooseneck is aligned by observing the position where the chains

first contact the tubing from the top of the injector.

e) Check whether the lockout screws of the load cells are loose to a safety distance to

avoid affecting the measurement.

f) Check whether all controls are at safe startup positions.

g) Check for any externally visible leaks.

h) Check to see that all gauges read zero (0) pressure (shift the control valve on the

circuit to bleed gauge pressures). Replace all bad gauges.

NOTE

a) Before starting power unit, be sure that all controls are in a safe, start-up position

and that no one is working on injector or has his hands in the injector.

b) Even surface wear of 0.5mm will lead to the failure of traction bearings. Both sides

of the skates can be used and the other side can be used if necessary.

c) Only tubing right for in-hole operation can be used to align the gooseneck. If the

outer diameter or wall thickness changes, the gooseneck needs to be re-aligned.

ZRT-80K Chapter 3 Injector 89

 Check the alignment of the gooseneck before each operation.

3.7.2 AFTER STARTING

a) Check all functions of the injector.

b) Check all connectors of the hydraulic and pneumatic systems for leaks. Tighten the

leaking position or replace seal (connector).

c) Check the injector spray lubrication operation.

d) Check running condition of the traction cylinders, tension cylinders, motors, brakes

and gearboxes.

e) With the injector rotating, check the filters mounted on the main pressure manifold.

These filters have an integral bypass valve and a visual bypass indicator. When the

filter condition indicator shows red the elements need to be replaced.

f) Visually check whether the chains and grippers have obvious damages.

g) Visually check if all roller bearings of the chains work smoothly.

NOTE

a) Set the traction pressure to 0 psi and chain tension pressure at 500psi, and rotate

the chains slowly will help to finish the above inspections.

b) Check the running status of the injector when the downhole tubing depth is 60m.

if the traction cylinder jumps or injector chains generate abnormal noise, check the

alignment of the gooseneck

90 Chapter 3 Injector ZRT-80K

3.7.3 AFTER OPERATION

a) Tidy all spare parts of the unit.

b) Lubricate chains and roller bearings.

c) Check for any externally visible leaks.

NOTE

The following maintenance must be done with the power unit engine stopped and the

hydraulic system relieved of pressure completely.

3.7.4 WEEKLY (EVERY 72 HOURS OF OPERATION)

a) Grease all idler sprocket bearings and gooseneck rollers on injector.

b) Check injector chains, grippers and skates for wear.

c) Check to make sure all fastening parts such as screws, bolts and pins are secure.

Retighten as required being careful not to over torque.

d) Check whether the inner ring of the tension bearing is loose.

3.7.5 MONTHLY (EVERY 300 HOURS OF OPERAITON)

a) Clean or replace the two hydraulic filter elements located on the power pipeline of

the injector.

b) Check the injector traction accumulators for proper nitrogen pre-charge.

3.7.6 LUBRICATION (DAILY)

a) Coat all exposed threaded bolts and rods with anti-seize.

b) Lubricate all hinge pins with spray lubricant.

ZRT-80K Chapter 3 Injector 91

c) Lubricate chains and traction bearings.

3.7.7 PROCEDURE FOR RESURFACING OF GRIPPERS

a) Remove grippers from injector and clean.

b) Sandblast grippers with #1 or #2 (60 to 120 grit) sandblasting media in radius area

until an even surface roughness is achieved. This may happen with very few passes,

depending on the coarseness of grit and the sandblasting equipment.

c) Clean all grit off the grippers.

NOTE

If the gripper has been used for a long time and has serious wear which lead to tubing

slipping. Please handle the surface of the gripper according to the above procedures

or replace the grippers.

92 Chapter 3 Injector ZRT-80K

APPENDIX 1 INJECTOR DRIVE SYSTEM MAINTENANCE FORM

Form to be completed every 200 running meters (Hubodometer reading) of the injector.

Gearbox Model:

Injector Product No.：

Injector Hubodometer reading:

Gearbox Lube Oil Condition

Largest Metal Fleck Size:

□ Contaminated Oil □ Burned Oil Smell

□ Moisture Present □ Normal Oil smell

Note

Many minute metal flecks are normal.

Spline condition Wear Pattern Step Depth

Motor Output Flat/Hourglass

Brake Input Flat/Hourglass

Brake Output Flat/Hourglass

Driveshaft Input Flat/Hourglass

Driveshaft Output Flat/Hourglass

Note

ZRT-80K Chapter 3 Injector 93

Step depth over 0.35mm is worn out. If so, please contact Jereh after-sale service

technician.

Gear Condition

First Stage (check all that apply):

□ Chipped Teeth □ Spalling

□ Rough Finish □ Machined Finish □ Mirror Finish

Second Stage (check all that apply):

□ Chipped Teeth □ Spalling

□ Rough Finish □ Machined Finish □ Mirror Finish

Third Stage (check all that apply):

□ Chipped Teeth □ Spalling

□ Rough Finish □ Machined Finish □ Mirror Finish

94 Chapter 3 Injector ZRT-80K

 APPENDIX 2 RECOMMENDED INJECTOR PERIODICAL MAINTENANCE

SCHEDULE

Time Intervals
Running Running Maintenance
BJ AJ M Y
Time/h Miles/m
● 1. Check lube oil level of the gearbox.

● 2. Check the alignment of the gooseneck.

● 3. Check if all gooseneck rollers work smoothly.

4. Check whether the lockout screws of the load
cells are loose to a safety distance, whether the
●
hydraulic load cell leaks or electronic load cell is
used well.
5. Check whether all controls are at safe startup
●
positions.
● 6. Check for any externally visible leaks.
7. Check the traction cylinders, tension cylinders
●
for leaks.
8. Check whether the retaining screws of the
● gripper are loose and whether grippers are
damaged.
9. Check whether the chain bearings are
● damaged and whether there is grease leaking
from the seal.
● 10. Check whether the skates are damaged.
11. Check whether the chains are damaged or
●
lost.
12. Check the injector spray lubrication
●
operation.
● 13. Check whether the sprockets are damaged.

ZRT-80K Chapter 3 Injector 95

 Time Intervals
Running Running Maintenance
BJ AJ M Y
Time/h Miles/m
14. Check the filters mounted on the main
●
pressure manifold.
15. Check whether the inner ring of the tension
●
bearing is loose.
● 16. Tidy all grippers.

● 17. Lubricate chains and bearings.

18. Check the injector traction accumulators for
●
proper nitrogen pre-charge.
19. Check if lifting lugs and pins are worn or
●
damaged
20. Make flaw detection for skates after
●
disassembling chains
100 21．Measure chain wear elongation

● 1500 22. Replace the lube oil of the gearbox.

23. Clean or replace the hydraulic filter elements
300
located on the power pipeline of the injector.
200 24. Replace the grease of the tention bearing.
25. Replace the lube oil of the gearbox for the
150 100
first time.
200 26. Check the drive system.

800 27. Repair the drive system.

KEY:
BJ—Before Job; AJ—After Job; W—Weekly; M—Monthly;Y-Yearly;m-Hubodometer reading

Note: Please subject to time and mileage, whichever comes first.

96 Chapter 3 Injector ZRT-80K

APPENDIX 3 PARTS ORDER FORM

（When ordering parts, please be sure to include the product number located on the

front cover of this manual.）

Customer: Date:

Contact: Product No.:

P/N
Description Qty.

ZRT-80K Chapter 3 Injector 97

 P/N
Description Qty.

Note: Please contact Jereh sales personnel to order the whole set of equipment

repair package.

JEREH Tel: +86-400-812-9130 Fax: +86-535-672-3171

98 Chapter 3 Injector ZRT-80K

 Clarification

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