Grease Injection Head

Assembly Instructions

6 ASSEMBLY INSTRUCTIONS

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH THE PRODUCT
SPECIFIC ASSEMBLY DRAWINGS AND BEFORE CARRYING OUT ANY OF THE FOLLOWING
ACTIONS

6.1 Tools List

- Clean work surface;
- Airline;
- Clean rags;
- Vice;
- O-ring pick;
- Grease brush;
- Grease; L-881720
- PTFE thread tape; L-861900
- Loctite 577 thread sealant;
- Plastic hammer;
- 5/16" Allan key (for manifold block screws);

REMEMBER...”SAFETY IS EVERYONE'S RESPONSIBILITY”

• Do use eye protection when using power tools.
• Do wear gloves or use barrier cream to protect your hands.
• Do wear protective footwear.
• Do keep loose clothing and long hair well out of the way of moving mechanical
parts.
• Do remove rings, wristwatch etc, before working.
• Do change out of oil-soaked clothes and do not keep oily rags in your pocket.
• Do ensure that any lifting or jacking equipment has a safe working load rating
adequate for the job.
• Do get someone to check periodically that all is well when working alone.

Section 6 - Page 1
 Copyright 2002 Elmar
 Grease Injection Head
Assembly Instructions

6.2 Assembly Instructions

NOTE: The following assembly instructions are for concentric type flow tubes.

CHECK VALVE
CIRCLE SEAL
CHECK VALVE
HOUSING

O-RING
BACK-UP
RING
BACK-UP O-RING 5/16” SH
RING SCREWS
O-RING
MANIFOLD
BLOCK QC HUBER
M- HEX
1/8” NPT NIPPLE HEX
THREAD PLUG

COUPLING FLOWTUBE

O-RINGS

Step Action

1 Ensure all components are clean and in good order.

Check note after Step 11 for required quantity.
2 Fit O-rings into couplings.
NOTE: O- Rings and Back-ups
Probably the best way to avoid damage to O-rings during installation is:
(a) Check all components for cleanliness before installation
(b) Tape all threads over which o-rings will pass. O-rings should never be forced over
unprotected sharp edges.
(c) Use an O-ring lubricator.
(d) Double check O-ring to ensure correct size
(e) Don’t over stretch the O-ring.
(f) Prevent the O-ring from rolling or twisting during assembly.
(g) Where only one back-up ring is used, it must be placed between the O-ring and the
pressure face.

BACK-UP RING O-RING

PRESSURE DIRECTION

PRESSURE FACE

3 Insert injection coupling (bottom coupling) in vice and coat threads with grease.
4 Fit O-rings and back-ups to check valve housing and install into manifold block, tap
home with plastic hammer.

Section 6 - Page 2
 Copyright 2002 Elmar
 Grease Injection Head
Assembly Instructions
NOTE: Check the orientation of the back-ups i.e. both back ups nearest the centre.
Ensure the correct seals are located in each groove. Ensure that smaller end is
installed into the manifold block
5 Fit O-ring to check valve.

Step Action

6 Fit the check valve into the leading edge of the check valve housing ensuring that the arrow
stamped on the circle seal points out of the port in the manifold block i.e. 1/8”NPT port
outermost.
7 Drive the check valve down into the housing until home.
8 Grease the coupling check valve housing port and fit the manifold block assembly to the
injection coupling.
9 Put thread sealant on manifold block 5/16" cap screws and screw manifold block to
coupling. Apply 10 lbf ft (13.5 Nm) torque
10 Tape and Loctite male hex nipple to QC Huber. Ensure that the QC Huber is assembled
with the internal O-ring facing away from hex nipple. Tighten down the hex plug while
holding the QC Huber. Tape and Loctite assembly into manifold block.
11 Connect flotubes and remaining couplings as required.
NOTE: Locate flotube into coupling and screw flotube sleeve into coupling. Screw next coupling
onto flotube sleeve ensuring that flotube locates into coupling correctly. This is often best
achieved vertically to prevent the flotube falling one way. If desired the assembly can be
completed as the wireline is fed through, much like threading beads on a necklace.
NOTE: It is very important to use the correct number of flow tubes as well as the correct size. A
single flow tube of the correct size can hold approximately 2,000 psi, Below is a table of the
number suggested. Remember it is safer to have too many than too few.

Well Pressure Type Number of Flow Tubes

(concentric type)
0-5,000 psi Liquid 4
0-5,000 psi Gas 5
5-10,000 psi Liquid 6
5-10,000 psi Gas 6+
10-15,000 psi Liquid 6+
10-15,000 psi Gas 7 or more

NOTE: For high pressure gas work it might be necessary to use more than one grease injection
point to maintain the seal and lubricate the wireline.

Section 6 - Page 3
 Copyright 2002 Elmar