© 2003 Stewart & Stevenson Services, Inc.

Chapter 2

CHAPTER 2
OPERATION

2.1 PRELIMINARY CHECKS

; Check all operating fluids, such as engine oil, engine coolant, etc.

; Grease all bearings and drivelines.

; Check all connections. Make sure all fittings are tight, and that all hoses are
connected properly. If any leaks are found, repair immediately.

Before using this equipment, any operator should carefully read

the operation instructions in this section, review the safety sum-
mary, and conduct a pre-operation safety inspection of the equip-
ment.

If the operator has ANY QUESTIONS about the safe use or mainte-
nance of the unit, ASK THE SUPERVISOR - NEVER GUESS -
ALWAYS CHECK.

2.2 OPERATION
2.2.1 FLUID CONNECTIONS PANEL FUNCTIONS (REFER TO FIG 2.1)
1. HYDRAULIC INPUT FORWARD DIRECTION Connector. Allows input of hy-
draulic fluid to motor(s) for forward direction (into well).

2. HYDRAULIC INPUT REVERSE DIRECTION Connector. Allows input of hydrau-

lic fluid to motor(s) for reverse direction (out of well).

3. SPARE Connectors.

4. SPEED Connector. Allows control motor displacement which increases and

decreases speed.

5. OILER Connector. Allows input of chain lubricant to chain oiler nipples

in top of frame over chains.

6. CHAIN TENSION Connector. Allows control of amount of tension

applied to chain to keep chain tight.

7. TRACTION - END Connector. Allows control of amount of pressure

that chain (gripper blocks) applies to tubing at ends of chain.

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8. STRIPPER PACK Connector.

Used to energize packing
element to prevent well pres-
sure from venting past tubing.

9. TRACTION MIDDLE Connec-

tor. Allows control of amount of
pressure that chain (gripper
blocks) applies to tubing in
middle of chain.

10. STRIPPER RETRACT Con-

nector. Removes pressure 1 2
from packing element to
facilitate changing of
packing elements.

11. WELL PRESSURE Connec-

tor. Connection to optional
debooster.

12. RETURN Connector. Allows

hydraulic fluid to return to tank. 3

13. WEIGHT INDICATOR Con-

nector. Connection toLOAD
CELL (see 4 5
index 17).

6 7

8 9

10 11

12 13

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2.2.2 MOTOR SIDE GAUGE PANEL

1. CHAIN TENSION. Measures and displays input hydraulic pressure from CHAIN
TENSION Connector.

2. SNUBBING. Measures and displays hydraulic pressure being applied to valves

applying tension to chain.

3. TRACTION MIDDLE. Measures and displays hydraulic pressure being applied to

tubing in middle of chain.

4. TRACTION END.
Measures and
displays hydraulic
pressure being
applied to tubing at
ends of chain.

5. END TRACTION
BLEED VALVE
Handle. Used to
relieve hydraulic
pressure from
system to allow
system to be
worked on.

6. MIDDLE TRAC-
TION BLEED
VALVE Handle.
Used to relieve
hydraulic pressure
from system to allow
system to be
worked on.
Figure 2.19, Motor Side Gauge Panel
7. TENSION BLEED
VALVE. Used to relieve hydraulic pressure from system to allow system to be
worked on.

8. ACCUMULATORS. Used to store hydraulic pressure and help maintain pressure

in the system

9. HYDRAULIC FLUID FILTER (2 each). Used to filter impurities from hydraulic

fluid. One filter for each input.

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2.2.3 VBII PRESSURE RECOMMENDATIONS

2.2.3.1 VBII CHAIN TENSION

Minimum operating pressure for chain tension is 500 psi (3447.5 kPa). Pressures over 500 psi
(3447.5 kPa) when not in snubbing mode increase friction in the joints of the chain causing exces-
sive wear and decreasing the longevity of the chain.

Pressures in the shaded area exceed the 20,000 lb snubbing de-

sign limitation of the injector head.

If any wellhead pressure is present consult the above chart for minimum tension setting. Above chart
does not account for stripper and pipe friction. Leave the hydraulic pressure on the tension circuit during
setup. When ready to run the job, dump the hydraulic pressure at the control panel. This will set the
check valve locking fluid in the cylinders.

2.2.3.2 VBII CHAIN TRACTION

Chain traction is used to ensure that the tubing doesn’t slip between the gripper blocks. The
following chart indicates the recommended traction pressure for a given tubing string weight.

Tubing String Weight Traction Pressure

lb kg psi kPa
5,000 2,265 950 6,550.25
10,000 4,530 950 6,550.25
15,000 6,795 950 6,550.25
20,000 9,060 1,075 7,412.13
25,000 11,325 1,200 8,274.00
30,000 13,590 1,300 8,963.50
35,000 15,855 1,425 9,825.38
40,000 18,120 1,550 10,687.25
45,000 20,385 1,675 11,549.13
50,000 22,650 1,800 12,411.00
55,000 24,915 1,925 13,272.88
60,000 27,180 2,025 13,962.38
65,000 29,445 2,150 14,824.25
70,000 31,710 2,275 15,686.13
75,000 33,975 2,400 16,548.00
80,000 36,240 2,500 17,237.50

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2.2.4 VBIII PRESSURE RECOMMENDATIONS

2.2.4.1 VBIII CHAIN TENSION

Chain Tension

Later Stewart & Stevenson injector heads have tension cylinders with 2.25″ diameter pistons.
These injector heads can snub 20,000 lb (9071.85 kg) with 2,515 psi (17.34 mPa) tension
pressure and 40,000 lb (18143.69 kg) with 5,030 psi (34.68 mPa) tension pressure. Operating
pressure for chain tension should be 500 psi (3447.5 kPa). At that pressure, the chain tension
allows the chain to move smoothly through the injector head. When the chains are slack, the
block ears that engage the chain can be broken. When the chain tension pressure exceeds 500
psi (3447.5 kPa), the chain joints wear quicker, decreasing the chain’s longevity without improv-
ing the performance of the injector head.

A tension circuit holds tension on the lower shafts with low hydraulic pressure whenever the
tension cylinder pressure drops below 500 psi (3447.5 kPa). The principle behind this circuit is
the incompressibility of hydraulic fluid, which if locked in the tension cylinders would cause the
cylinders to act as solid supports for the lower shafts. A pilot-operated check valve is used to
hold hydraulic pressure in the tension cylinders. As the snub load increases, on the lower shaft
the hydraulic oil can’t move out of the cylinders and holds the lower shafts in place. To set the
hydraulic pressure in the tension cylinders, increase the pressure to 750 psi (5171.07 kPa) to
900 psi (6205.28 kPa), and then quickly dumps the tension pressure to the tank. The flow out of
the cylinders must pass through an orifice to the tank, while the check valve pilot pressure goes
directly to the tank. The check valve closes before the hydraulic pressure in the tension cylin-
ders is decreased. A pressure gauge in the tension cylinder manifold shows the pressure in the
tension cylinders, but the pressure gauge on the control panel shows 0 psi.

Well pressure exerts a force on the tubing to push the tubing out of the well which causes slack
in the chains unless the chain tension pressure is increased to compensate for this force. The
operator must compensate for well pressure by adding to the recommended chain tension
pressure an additional pressure which produces in the chain tension cylinders a force equal to
the force produced on the tubing by the well pressure. To find the pressure to add to the recom-
mended operating pressure go to the Varia-Block III Snubbing Table on the next page. Locate
the well pressure on the right side column and follow the bottom row across to the tubing size
and read the pressure at the intersection. The table only considers well pressure on the tubing
and does not consider stripper and pipe friction.

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2-6
Varia-Block III Snubbing Table
Chapter 2

Tubing Siz e 1 1.25 1.5 1.75 2 2.375 2.875 3.5

Wellhead
Pressure Read In Control Cabin In PSI
Pressure

1,000 599 654 722 802 895 1,057 1,316 1,710

2,000 698 809 944 1,105 1,290 1,614 2,133 2,920
3,000 796 963 1,167 1,407 1,685 2,171 2,949 4,130
4,000 895 1,117 1,389 1,710 2,080 2,728 3,765 5,340
5,000 994 1,272 1,611 2,012 2,475 3,286 4,582 6,549
6,000 1,093 1,426 1,833 2,315 2,870 3,843 5,398 7,759
7,000 1,191 1,580 2,056 2,617 3,265 4,400 6,215 8,969
8,000 1,290 1,735 2,278 2,920 3,661 4,957 7,031 10,179
9,000 1,389 1,889 2,500 3,222 4,056 5,514 7,847 11,389
10,000 1,488 2,043 2,722 3,525 4,451 6,071 8,664 12,599
11,000 1,586 2,198 2,944 3,827 4,846 6,628 9,480 13,809
12,000 1,685 2,352 3,167 4,130 5,241 7,185 10,296 15,019
13,000 1,784 2,506 3,389 4,432 5,636 7,742 11,113 16,228
14,000 1,883 2,661 3,611 4,735 6,031 8,299 11,929 17,438
15,000 1,981 2,815 3,833 5,037 6,426 8,857 12,745 18,648

Pressures up to 3,000 psi can be achieved by control from the cabin. To reach pressures above 3,000 psi (in the lightly shaded area),
the hydraulic pressure must be dumped at the control panel to lock the fluid in the cylinders. Pressures in the dark shaded area exceed
the snubbing design of the injector head (35,000 lb).

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2.2.4.2 VBIII CHAIN TRACTION

Chain traction is used to ensure that the tubing doesn’t slip between the gripper blocks. The
following chart indicates the recommended traction pressure for a given tubing string weight.

VBIII Chain Traction Table

Tubing String Weight Recommended Traction Pressure

PSI

LB MODEL

400 800 800L 1100

5,000 700 700 400 400
10,000 700 700 400 400
15,000 800 800 500 500
20,000 900 900 550 550
25,000 1,100 1,100 700 700
30,000 1,300 1,300 800 800
35,000 1,400 1,400 900 900
40,000 1,600 1,600 950 950
45,000 1,700 1,000 1,000
50,000 1,800 1,100 1,100
55,000 1,900 1,150 1,150
60,000 2,000 1,200 1,200
65,000 2,100 1,300 1,300
70,000 2,200 1,350 1,350
75,000 2,300 1,400 1,400
80,000 2,400 1,450 1,450
85,000
90,000
95,000
100,000
105,000
110,000

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VBII and VBIII Chain Snubbing

Chain snubbing is used to control the forces on the tubing as it is forced into the wellhead.

VBII and VBIII Snub Chart

Tension Required Negative Pipe Weight

6 0 0 p si -1580 lb
7 0 0 p si -3180 lb
8 0 0 p si -4780 lb
9 0 0 p si -6360 lb
1 0 0 0 p si -7960 lb
1100 psi -9540 lb
1 2 0 0 p si -11,140 lb
1 3 0 0 p si -12,720 lb
1 4 0 0 p si -14,388 lb
1 5 0 0 p si -15,900 lb
1 6 0 0 p si -17,500 lb
1 7 0 0 p si -19,080 lb
1 8 0 0 p si -20,680 lb
1 9 0 0 p si -22,260 lb
2 0 0 0 p si -23,860 lb
2 1 0 0 p si -25,440 lb
2 2 0 0 p si -27,040 lb
2 3 0 0 p si -28,628 lb
2 4 0 0 p si -30,220 lb
2 5 0 0 p si -31,800 lb
2 6 0 0 p si -33,400 lb
2 7 0 0 p si -35,000 lb
2 8 0 0 p si -36,580 lb
2 9 0 0 p si -38,180 lb
3 0 0 0 p si -39,760 lb

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2.3 TUBING GUIDE GENERAL INFORMATION

Each injector comes equipped with an adjustable tubing guide. It detaches from the injector
and folds in half for transport. Tubing guides come in a variety of configurations for varying
applications. Options are listed below.

y 72-, 90-, or 120-inch radius (1.82, 2.29, or 3.05 meters respectively)

y Urethane, aluminum, or steel tubing rollers
y Variable or two-speed motor control
y Manual or automatic brakes
y Hydraulic or electric load cell
y Collapsible crow’s nest, fold-up workboards, or below-head tubing counter
y May come with support as well as extension legs

2.4 ADJUSTMENTS
2.4.1 CENTERING ADJUSTMENT

The centering adjustment is used to adjust the tubing to fall from the tubing guide (gooseneck)
into the center of the injector head. Even though the steel tubing is “flexible,” it does not bend
sharply. If the tubing does not fall into the center of the injector head, the gripper blocks will not
grip the tubing properly. Refer to Figures 1 and 2 during the adjustment procedure.

Figure 1
Incorrect Correct
Abnormal bending As little tension
causes excessive on this roller as
force on chain possible.
bearings.

Premature
Equal
tubing
mating of
contact with
chain blocks.
chains.

NOTE: Some drawing details have been omitted for clarity.

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Improper centering adjustment could cause damage to the gripper

blocks and/or the tubing.

Individuals performing this procedure should use a safety belt, ap-

proved lifting devices, and any other necessary precautions to pre-
vent personal injury. In addition, make sure all protective guards
are in place.

Centering Adjustment procedures are as follows:

1. Ensure that all inside traction cylinder valves are in the OPEN position. Ensure that
pressure to the traction cylinders is OFF and any excess pressure is released.
2. Apply 300 to 500 psi to the outside chain tension cylinders.
3. Rotate the injector chains a minimum of 10 revolutions OUT-HOLE. Visually inspect
chains for proper tension and smooth rotation. Make sure that all inserts are the same
size as well as the proper size for the tubing.
4. Release pressure on the tension cylinders. This will allow the chain and block assem-
bly to float while aligning the pipe.
5. Insert tubing into the guide and allow it to pass around the guide radius into the center
of the injector chains.
6. While inserting tubing, it may be necessary to apply a minimal amount of inside
traction pressure to let the injector pull the tubing through. However, ensure that the
tubing has passed beyond the center of the traction cylinder before applying pressure.
7. Once the tubing extends completely through the injector and stripper, adjust the inside
traction cylinder pressure to 800 psi which is the minimum operating pressure.
8. Apply a tension cylinder pressure of 500 psi if the wellhead pressure is below 1,000
psi. If the wellhead pressure is above 1,000 psi, refer to the chain tension chart.
9. Injector chains and skates must be on the center line of the injector. To determine
this, observe the tubing exiting the chains prior to entering the stripper. The tubing
should be equal distance between the inserts.
10. If the main body of the chain does not appear straight, check the position of the tubing
guide. The tubing should arc naturally into the center of the chains. There should be
no “S” bending or shortened arc. This arc is adjusted with the rear centering roller
(see Figure 2). The centering roller should press against the tubing with enough force
to cause the tubing to enter the centerline of the chains. Straight tubing must not be
used for this adjustment or the roller will not be adjusted correctly.

Proper tubing guide alignment is critical for proper unit perfor-

mance. If not aligned correctly, the tubing can suffer premature
failure which can cause a hazardous condition to exist, especially
if dangerous chemicals are being pumped down well. Improper
alignment can also cause excess wear on the injector head. Refer
to Figure 1 as a guide.

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There are two phases to the adjustment that centers the tubing in the injector head. The first
phase is a coarse adjustment that moves the gooseneck to the center of the injector head. The
second phase is a fine adjustment that moves the final guide rollers of the gooseneck. These
rollers should be positioned so that the arc of the tubing from the gooseneck into the injector head
is smooth and not abrupt or distorted.

1- Centering Roller 2 - Fine Adjustment Jam Nuts 3 - Coarse Adjustment Jam Nuts

2.4.2 COARSE ADJUSTMENT

1. See which direction the tubing and gooseneck needs to be moved for centering.

2. Loosen the jam nuts of the coarse adjustment bolts opposite to the direction the
gooseneck needs to be moved

3. Again on the coarse adjustment bolts, tighten the jam nuts (3) that will move the
gooseneck in the desired direction.

4. Once the gooseneck is in the desired position, tighten the jam nuts (3) loosened
in Step 2, above.

5. See if the final guide rollers (1) need to be moved to ease the arc of the tubing.

2.4.3 FINE ADJUSTMENT

6. Determine which direction the tubing needs to be moved to ease the arc.

7. On the fine adjustment bolts (both sides of the gooseneck) of the adjustable
roller (1) loosen the jam nuts (2) on the side of the bolts opposite to the direction
the roller needs to be moved.

8. Again on the fine adjustment bolts of the roller (1) identified in Step 7, tighten the
jam nuts (2) that will move the roller in the desired direction.

9. Make sure that all jam nuts (2 & 3) are properly tight.

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2.4.4 SWIVEL ANGLE ADJUSTMENT

These injector heads can be used with various specific flow rates. Each specific flow rate
requires a minimum swivel angle adjustment. The angle determines the maximum motor speed.

Formula: Displacement (in3) = [(0.5 gpm) (231)] ÷ rpm

If the swivel angle adjustment is performed incorrectly, a possible

overspeed condition could occur, resulting in damage to the mo-
tor.

1. Using the minimum displacement or minimum swivel angle from the table below,
determine what dimension “X” should be. Refer to “Hydraulic Motor” illustration,
next page. Measure dimension “X”, the exposed length of the limiting screw (1),
from the top of the hex head seal nut to the top of the limiting screw.

2. With a 19 mm wrench, loosen the seal nut.

3. With a 6 mm Allen wrench, adjust the limiting screw in or out as necessary.

4. Tighten the seal nut before checking dimension “X”.

5. Repeat steps 1 through 4 until the correct setting is obtained.

Minimum Angle (Degrees)

Size S p e cs 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3 1.35 1.62 1.88 2.15 2.42 2.69 2.95 3.21 3.48 3.73 4.00 4.26 4.52 4.77 5.03 5.28 5.53 5.79 6.03 6.28
in
D i sp .
cm3 22.1 26.5 30.9 35.2 39.6 44.0 48.3 52.6 57.0 61.2 65.5 69.8 74.0 78.2 82.4 86.6 90.7 94.9 98.9 103.0

107 Limiting
M12X70 M12X80 M12X90 M12X100
Scr. Size

Dim. in 0.75 0.67 0.59 0.51 0.43 0.35 0.67 0.59 0.51 0.43 0.75 0.67 0.59 0.51 0.43 0.75 0.67 0.59 0.51 0.45
X mm 19.0 17.0 15.0 13.0 11.0 9.0 17.0 15.0 13.0 11.0 19.0 17.0 15.0 13.0 11.0 19.0 17.0 15.0 13.0 11.0
3 2.01 2.42 2.81 3.22 3.61 4.01 4.41 4.80 5.20 5.59 5.98 6.36 6.75 7.14 7.52 7.90 8.28 8.65 9.02 9.40
in
D i sp .
cm3 33.0 39.6 46.2 52.7 59.2 65.7 72.2 78.7 85.2 91.6 98.0 104.3 110.7 117.0 123.3 129.5 135.7 141.8 147.9 154.0

160 Limiting
M12X80 M12X90 M12X100 M12X110
Scr. Size

Dim. in 0.75 0.65 0.57 0.47 0.37 0.69 0.61 0.49 0.41 0.71 0.63 0.53 0.43 0.75 0.65 0.55 0.47 0.37
X mm 19.0 16.5 14.5 12.0 9.5 17.5 15.0 12.5 10.5 18.0 16.0 13.5 11.0 19.0 16.5 14.0 12.0 9.5

Minimum Swivel Angle Adjustment (Maximum Speed)

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Hydraulic Motor

1 - Limiting Screw

2.4.5 HYDRAULIC LOAD CELL ADJUSTMENT

Using the following procedure will adjust the hydraulic load cell for use in the injector head.
Refer to “Hydraulic Load Cell”, next page, during the adjustment procedure.

1. Place a spring in each spring cup (1).

2. Fill the load cell (2) and connecting hoses with hydraulic fluid and bleed the air
from the load cell.

3. Dump the hydraulic fluid from the load cell back to the tank so that the load cell is
in the fully lowered position against the “C” mounting plate.

4. Zero the WEIGHT INDICATOR gauge.

5. Pump up the load cell (2) until the injector is parallel with the base.

6. Measure the gap that has opened between the “C” mounting plate (3) and the
load cell (2). The opening should be from 3/16 in to 3/8 in.

NOTE: If the gap is not correct, go to step 7. If the gap is correct, go

to step 10.

7. Adjust the load cell mounting assembly to obtain the proper gap.

8. Dump the hydraulic fluid from the load cell (2) back to the tank.

9. Repeat steps 3 through 8 of the adjustment procedure until the gap is correct.

10. With the injector parallel to the base, turn the spring lock nuts one turn each to
compress the springs in the spring cups equally until the WEIGHT INDICATOR
gauge reads 18,000 lb for the Series 800.

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11. Dump the hydraulic fluid from the load cell (2) back to the tank. The WEIGHT
INDICATOR gauge should again read “O” again.

12. Pump the load cell (2) up until the injector is parallel with the base. The WEIGHT
INDICATOR gauge should again read 18,000 lb for the Series 800.

NOTE: The weight reading will vary with temperature.

1 - Spring Cup 2 - Load Cell 3 - “C” Mounting Plate

Hydraulic Load Cell

2.4.6 ELECTRONIC LOAD CELL ADJUSTMENT

Do not attempt to adjust the electronic load cell. When adjustments are necessary, adjust the
instruments used to record or display the load cell’s readings. For further information, refer to
the Sensotec information in Chapter 5 of this manual.

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2.5 INSPECTIONS AND PROCEDURES

2.5.1 OVERVIEW
2.5.1.1 MAINTENANCE BENEFITS

Your injector head is ensured of its best performance and reliability when a scheduled mainte-
nance program is followed. A small cost and effort expended for a maintenance program yields
improved performance and efficiency. For more maintenance information, such as recom-
mended lubricants, maintenance schedules, etc., refer to chapter three.

2.5.2 NATURE OF MAINTENANCE

The nature of maintenance demands operator awareness of the injector head’s operation. Aware-
ness demands consciousness of abnormalities such as leaks, knocks, or smoke. Awareness
demands knowing the injector head’s equipment capabilities and perceiving the equipment’s ser-
vice needs. Being aware can also be described as being watchful, or being alert.

Regardless of the method or manner of detection, the potential failure should be promptly
corrected, in order to help avoid a shutdown or a breakdown. The corrective actions taken or
the service rendered constitute maintenance.

2.5.3 SCHEDULED MAINTENANCE

Scheduled maintenance is intended to ensure satisfactory operation and economical main-
tenance costs. The table on the following page lists operator level inspections. The desig-
nated intervals for scheduled maintenance are for normal operation under usual conditions.
Scheduled maintenance should be conducted more frequently if operating under unusual
conditions. The designated intervals are:

1. BEFORE (B) Inspections, adjustments, and services performed before putting

the injector head into operation.

2. AFTER (A) Inspections, adjustments, and services performed immediately after

the completion of a job.

3. MONTHLY (M) Inspections, adjustments, and services performed once every 30

consecutive days.

4. SEMIANNUALLY (S) Inspections, adjustments, and services performed every

six months.

5. YEARLY (Y) Inspections, adjustments, and services performed every twelve

months.

Clean or service only when the equipment is shut down, isolated,

and tagged “out of service.”

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2.5.4 OPERATOR LEVEL INSPECTIONS

INT ERVALS Area to be What to Corrective

B A M S Y Inspected Inspect for Action

Use Accumulator
Proper pre-charge
X Accumulators
pressure
Pre-charge Check
in this section

Replace hydraulic
Leaks, cuts,
hoses as
Hydraulic hoses breaks, damage
X X and piping and wear Loose or
necessary. Tighten
or reseal loose or
damaged fittings
damaged fiftings.

Pressure wash
chains and re-
Drive chain/ gripper lubricate. Replace
Dirt and debris
X blocks Chain
Damage and wear
chain or insert
inserts according to the
procedures in this
chapter.

Replace chain or
Damaged, wom,
Chain insert locking insert according to
X X pins
loose, and missing
the procedures in
pins.
this chapter.

Loose or broken
Frame, base, and fasteners, cracks, Tighten, replace,
X other welded breaks, gaps, repair, or re-weld
structures chipped or peeling as required.
paint, and rust

Hydraulic fluid filter Change the fifter

X inspection ports
Visibly dirty fluid
element.

X Drive gearbox(es) Proper level Add oil.

X Drive gearbox(es) Dirty oil Change oil.

X Timing box Proper level Add oil.

Timing box oil

X change
Dirty oil Change oil

External evidence
X Zerk fittings
of grease
Grease fitting

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2.5.5 ACCUMULATOR PRE-CHARGE CHECK/RECHARGING

A gaseous pre-charge maintains the pressure in the accumulators. The following procedure is
used to check and recharge the nitrogen gas as necessary. Refer to the illustration below.

1. Unlock and open hydraulic pressure bleed valves (see items 5, 6, & 7; “Motor
Side Gauge Panel”) to bleed pressure from accumulators (6) and chain tension
circuits.

2. Turn off power.

3. Tag and lock out all controls “Out of Service.”

4. Remove gas valve guard and gas valve cap from accumulator (6).

5. Back gas chuck (item 4, illustration below) “T” handle (3) all the way out (counter
clockwise) before attaching charging/checking assembly to accumulator gas
valve.

1 - Pressure Gauge

2 - Bleed Valve

3 - “T” Handle

4 - Gas Chuck

5 - Swivel Nut

6 - Accumulator

7 - Filler Connection

Charging/Checking Assembly

6. Close bleed valve (2).

7. Attach swivel nut (5) to accumulator (6) gas valve and tighten (10-15 in-lb with a
torque wrench).

8. Turn gas chuck (4) “T” handle (3) all way down, depressing core in gas valve.

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9. Check pressure reading on pressure gauge (1). The gauge should read 500 ±
20 psi (3,477.5 ± 137.9 kPa).

10. If accumulator (6) requires charging, proceed with Step 11. If accumulator does
not require charging, proceed with Step 20.

11. Back gas chuck (4) “T” handle (3) all the way out.

12. Open bleed valve (2) to release pressure. Close bleed valve again.

13. Ensuring there are no loops or twists in hose from nitrogen bottle, attach hose
swivel nut to filler connection (7) and tighten to 10-15 in-lb (0.11 - 0.165 kgm)
with a torque wrench.

14. Turn gas chuck (4) “T” handle (3) all the way down.

15. Crack open nitrogen bottle valve and slowly fill accumulator (6).

16. Close nitrogen bottle valve when gauge has reached 500 ±20 psi (3,447.5 ±
137.9 kPa).

17. Let pre-charge set for 10 to 15 minutes to allow gas temperature to stabilize.

18. Again check gauge (1).

19. If gauge (1) reading exceeds 500 ± 20 psi (3,447.5 ± 137.9 kPa), slowly open
bleed valve (2) to lower pressure to 500 psi. If gauge reading is less than 500
psi, repeat steps 15 through 18 until pressure is correct.

20. Back gas chuck (4) “T” handle (3) all way out.

21. Open bleed valve (2).

22. If necessary, remove nitrogen bottle hose.

23. Hold gas chuck (4) while loosening swivel nut (5).

24. Remove charging/checking assembly.

25. Replace and tighten gas valve cap to 10-15 in-lb (0.11 - 0.165 kgm) with a torque
wrench.

26. Replace valve guard.

27. Close and lock hydraulic pressure bleed valves (see items 5, 6, & 7; “Motor Side
Gauge Panel”) in operational position.

28. Remove tags and unlock all controls.

29. Turn on power.

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2.5.6 FILTER ELEMENT REPLACEMENT

Each filter has a visual indicator to signal when the filter element needs to be changed. The
following procedure is used to change the element when signalled by the visual indicator.

1. Unlock and open the hydraulic pressure bleed valves (see items 5, 6, & 7;” Motor
Side Gauge Panel”) to bleed pressure from the accumulators and chain tension
circuits.

2. Turn off power. Lock out all controls and tag them “Out of Service.”

Exercise extreme caution when performing maintenance on the

hydraulic system. Fluid escaping under pressure can cause seri-
ous personal injury. Face shield and protective clothing must be
worn.

Hydraulic fluid can become very hot. Always wear protective

equipment to prevent burn injuries.

3. Check the input gauges (see items 3 & 4,” Motor Side Gauge Panel”) to ensure
that hydraulic pressure is at zero.

4. Place a container under the filter housing to catch the hydraulic fluid.

5. Remove the drain plug from the bottom of the filter housing.

6. After the hydraulic fluid drains, unscrew the filter housing from the filter head.

7. Dispose of the drained hydraulic fluid in accordance with local regulations.

8. Remove the element from the filter housing.

9. Clean the filter housing with clean hydraulic fluid.

10. Install a new, clean element in the filter housing.

11. Screw the filter housing back into the filter head.

12. Install the drain plug in the drain hole at the bottom of the filter housing.

13. Close and lock the hydraulic pressure bleed valves (see items 5, 6, & 7; “Motor
Side Gauge Panel”) in the operational position.

14. Remove tags and unlock all controls.

15. Turn on power.

16. Check for leaks. If any leaks are found, repair as necessary.

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2.5.7 VBII AND VBIII CHAIN REMOVAL

Visual inspection of the chain can locate wear and damage to the drive chain or the gripper
blocks before such wear or damage can cause a breakdown. Removing a damaged chain can
be accomplished by using the following procedure and by referring to “Drive Chain Section”,
next page.

Do not wear loose clothing, unbuttoned shirts, or neckties while

working on moving equipment.

1. Remove the chain guards.

2. Remove the inserts (see Insert Removal/installation also in this chapter).

3. Unlock and open the hydraulic pressure bleed valves (see items 5, 6, & 7; “Motor
Side Gauge Panel”) to bleed the pressure from the accumulators and the chain
tension circuits.

4. Turn off power.

5. Tag and lock out all controls “Out of Service.”

6. Locate the chain link with a groove etched (3) in the link pin heads (2). This is the
master link (1).

7. Remove the R pins (4) from the inside of the link pins of the master link (1).

8. Remove the master link (1) from the chain.

9. Repeat steps 6 through 8 for the other side of the chain.

10. Remove the chain from the injector head.

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2.5.8 VBII CHAIN INSTALLATION

Refer to illustrations below during the installation procedure.

1. Install the chain on the injector head.

2. Insert the master link (item 1, “Drive Chain Section”) into the chain.

Master Link

3. Install new R pins (4) into the inside of the link pins of the master link (1).

Do not reuse R-pins. Reusing R-pins can cause serious damage to

the machinery.

4. Close and lock the hydraulic pressure bleed valves (see items 5, 6, & 7;” Motor
Side Gauge Panel”) in the operational position.

5. Remove tags and unlock all controls.

6. Turn on power.

7. Install inserts according to the Insert Removal/Installation Procedure also in this

chapter.

Drive Chain Section

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2.5.9 VBII INSERT REMOVAL/INSTALLATION

During this procedure, refer to the illustration below.

Check the insert locking pins for damage, wear, looseness, and
missing pins before and after every job.

1. Remove the chain guards.

2. Remove the 3/8″ cap screw opposite the motor.

3. Slide the insert until it clears the gripper block channel and can be removed.

4. Install the 3/8″ cap screw in one side of the new insert using Blue LOCTITE
#242 and torque the screw 25 ft-lb to 40 ft-lb.

5. Install the new insert into the gripper block channel and slide it until the cap
screw contacts the block. Install the second cap screw with Blue LOCTITE #242
and torque the screw 25 ft-lb to 40 ft-lb.

There are two sizes of inserts; the Standard Insert, and the Ex-
tended Insert. Intermixing the two sizes on the injector head can
damage the tubing and/or the chains.

6. Move the chain as necessary to continue changing inserts.

7. After all the inserts have been changed, reinstall the chain guards.

Capscrews once removed must be replaced with new capscrews.

Chain Insert
Removal/Installation

1 - Insert

2 - Locking Pin

3 - Gripper Block

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2.5.10 VBIII CHAIN INSTALLATION

Refer to illustrations below during the installation procedure.

1. Install the chain on the injector head.

2. Insert the master link (item 1, “Drive Chain Section”) into the chain.

Master Link

3. Install new R pins (4) into the inside of the link pins of the master link (1).

Do not reuse R-pins. Reusing R-pins can cause serious damage to

the machinery.

4. Close and lock the hydraulic pressure bleed valves (see items 5, 6, & 7;” Motor
Side Gauge Panel”) in the operational position.

5. Remove tags and unlock all controls.

6. Turn on power.

7. Install inserts according to the Insert Removal/Installation Procedure also in this

chapter.

Drive Chain Section

1 2 3 4

1 - Master Link 2 - Etch Mark 3 - Link Pin Head 4 - R-Pin

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2.5.11 VBIII CHAIN INSERT REMOVAL/INSTALLATION

During this procedure, refer to the illustration below.

To remove the chain inserts:

1. Remove the chain guards.

2. Remove and discard the insert retaining capscrew.

3. Slide the insert out of the gripper block channel.

To install a new insert:

1. Slide a new insert into the gripper block channel.

2. Install a new insert retaining capscrew and torque it to 59 ft-lb.

3. Move the chain as necessary to continue changing inserts.

4. After the last insert has been changed, reinstall the chain guards.

Capscrews once removed must be replaced with new capscrews.

Insert Retaining Capscrew

Figure 3.4, Insert Removal/Installation

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2.5.12 ZERK FITTINGS

There are 44 zerk fittings on the injector head that require attention. There are 36 fittings, 18 for
each chain, accessible from the timing box side of the injector head beside the chains on the roller
block yokes; these fittings are not illustrated in any of the figures. On the same side of the injector
head (the timing box side) are four more zerk fittings (item 1; “Timing Box Side of Injector Head”,
next page). There are two fittings (item 1; “Hinge Side Zerk Fittings”, below) on the hinge side of
the injector head. The final two fittings (item 1; “Motor Side Zerk Fittings”, below) are located on
the motor side of the injector head, behind the Snubbing Pressure Gauge (2) and the Traction
Middle Gauge (3).

Hinge Side Zerk Fittings

1 - Zerk Fittings

2 - Snubbing Pressure Gauge

3 - Traction Middle Gauge

Motor Side Zerk Fittings

1 - Zerk Fittings

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2.5.13 TIMING BOX

The timing box houses the timing gears
that keep the two drive chains synchro-
nized. The oil in this box lubricates the
gears and keep them running smoothly.
During the following procedures, refer
to the illustration at right.

Timing Box Side of Injector Head

1 - Zerk Fittings

2 - Timing Box Filler Plug

3 - Timing Box Level Plug

4 - Timing Box Drain Plug

2.5.13.1 ADDING OIL

1. Remove the timing box

filler plug (2).

2. Remove the timing box

level plug (3).

3. Pour oil into the timing box through the hole left by the removal of the filler plug
(2) until the oil begins to leak out of the hole left by the removal of the level plug
(3).

4. Replace the timing box level plug (3).

5. Replace the timing box filler plug (2).

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2.5.13.2 CHANGING OIL

1. Remove the timing box filler plug (2).

2. Remove the timing box level plug (3).

3. Place a container under the timing box drain plugs (4) to catch the oil.

4. Remove the drain plugs (4).

5. When the oil has finished draining, replace the drain plugs (4).

6. Dispose of the dirty oil in accordance with local regulations.

7. Pour new oil into the timing box through the hole left by removing the filler plug
(2) until the oil begins to leak out of the hole left by removing the level plug (3).

8. Replace the timing box level plug (3).

2.5.14 CHAINS
The Series 800 injector head has two chains. The chains require constant lubrication during
operation. The standard means of lubrication is through a set of spray heads above each
chain that drops oil directly onto the chains. The spray heads are fed through the Oiler Con-
nector on the hydraulic connections panel, see item 5 of “Connections Panel”. Oil is supplied
to this connection from an external oil pump and tank, both supplied by the user.

2.5.15 GEARBOXES

The Series 800 injector head has two gearboxes. The gearboxes are between the motors and
the chain head. The gearbox filler plug is on top of the injector head frame. Although the filler
plug is not shown, it is connected by hose to the filler hole shown in the gearbox illustration. The
first oil change should be done 50 hours after commissioning. All subsequent oil changes
should be performed yearly. Refer to the gearbox illustration during the following procedure.

2.5.15.1 ADDING OIL

1. Remove the gearbox filler plug from the port in the top of the frame.

2. Remove the gearbox level plug (2).

3. Pour oil into the gearbox through the filler hole (1) through the port in the top of the frame
until the oil begins to leak out of the level hole.

4. Replace the gearbox level plug (2).

5. Replace the gearbox filler plug in the port in the top of the frame.

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1 - Gearbox Filler Hole 2 - Gearbox Level Plug 3 - Gearbox Drain Plug

Gearbox

2.5.15.2 CHANGING OIL

1. Remove the gearbox filler plug from the port in the top of the frame.

2. Remove the gearbox level plug (2).

3. Place a container under the gearbox drain plug (3) to catch the oil.

4. Remove the drain plug (3).

5. When the oil has finished draining, replace the drain plug (3).

6. Dispose of the dirty oil in accordance with local regulations.

7. Pour new oil into the gearbox through the hole (1) left by removing the filler plug
from the port in the top of the frame until the oil begins to leak out of the hole left
by removing the level plug (2).

8. Replace the gearbox level plug (2).

9. Replace the gearbox filler plug in the port in the top of the frame.

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2.6 INJECTOR HEAD TROUBLESHOOTING

The following troubleshooting charts provide information for diagnosing and correcting problems
with the Series 800 Injector Head. This information will help you to quickly identify the problem
and to make the necessary repairs to bring the unit back into service. The categories covered
with these charts are:

Injector Running Without Control Signals - Flow Chart 1

Injector Will not Operate - Flow Chart 2

Injector Head not Operating Smoothly; Erratic - Flow Chart 3

Injector Speed Does not Change - Flow Chart 4

Injector has no Power - Flow Chart 5

For troubleshooting of a more general nature, consult the troubleshooting tables that follow.
These tables cover the following topics:

General Hydraulic Problems

Transmission Problems

Brake Problems

NOTE: Remember, troubleshooting charts can only indicate problem

areas. They are not a substitute for the knowledge of a licensed
mechanic. Two completely different problems can have similar symp-
toms. Only qualified individuals should attempt repairs.

Flow Chart 1 Injector Running Without Control Signals

Check null adjust on main Readjust null on main Repair or replace.

N.G.
injector pump. injector pump.
o.k.

Check position of all injector N.G. Control valves leaking Repair or replace.
controls. internally.

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Flow Chart 2 Injector Will Not Operate

Check for proper PTO
& gear ratio.
1:1
o.k.
Check main injector pump Dead head main injector
output pressure in control N.G. hoses & dial pressure up Repair or replace.
panel (note 1). (note 1).

o.k.

Check injector control pilot N.G. Check pressure at outlets of Repair or replace
pressure joystick (note 2). joystick. It should be injector control
variable. joystick.

o.k.

Check injector pressure N.G. Contaminates in poppet & Clean, repair, or

adjust in control cabin seat assembly replace valve panel
(note 3). mount cabin.

o.k.

Check auto and/or manual N.G. Low brake pressure, or air in No Frozen water in
braking system (note 4). braking system. hydraulic lines.
Yes
o.k. Bleed air from braking Defrost, drain water.
system

Repair or replace. Repair or replace.

Check quick disconnects on N.G. Tighten if loose.

main power hoses.

o.k.

Case leakage should not

Check hydraulic motors. N.G. exceed 1.5 gpm under full Repair or replace.
load.

o.k.

Check counter balance N.G. Repair or replace.

setting (note 5).

Note 1: Max pump output pressure:LOW PRESSURE SYSTEM-3500 psi; HIGH- PRESSURE SYSTEM 5000 psi
Note 2: Injector control pilot pressure 0 - 1000 psi
Note 3: Injector pressure adjust:LOW PRESSURE SYSTEM 0 - 3500 psi; HIGH PRESSURE SYSTEM 0 - 5000 psi

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Flow Chart 3 Injector Head Operating Erratically

Check charge pressure at Repair or replace.

N.G.
main pump.
o.k.
Check brake system circuit N.G. Air in brake system. Bleed air from brakes.
(note 2).
o.k.

Check counter balance N.G. Repair or replace.

setting (note 3).

o.k.
Chain tension pressure too N.G. Repair or replace.
low (note 4).

o.k.

Chains slipping. N.G. Traction pressure too low. Check gauges and readjust.

o.k.
Call Service Department (281) 345-5100

Check stripper. N.G. Stripper pack pressure too Check gauges and readjust.
high.

o.k.
Check for broken or Remove load and operate Repair or replace damaged
N.G.
damaged bearings. injector or broken bearings.

Note 1: Charge pressure is 350 psi

Note 2: Brake release pressure; Manual - 350 psi, Automatic - 750 - 800 psi
Note 3: Counter balance setting 500 - 600 psi
Note 4: Chain tension not to exceed 400 to 500 psi with no well pressure.

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Flow Chart 4 Injector Speed Does Not Change

Check speed control in Check reducing relieving Repair or replace.

N.G. N.G.
control cabin (note 1). valve.
o.k. o.k.

Check speed control

quick disconnect on N.G. Repair or replace.
injector head.

Check system supply N.G. Check hoses for pinched N.G. Repair or replace.
pressure (note 2). or damaged supply line.
o.k.

Check for air in hydraulic Bleed air from speed

N.G.
lines. circuit.

Note 1: Speed control 0 - 400 psi

Note 2: System supply pressure 3000 psi
Note 3: Main injector supply pump 350 - 5000 psi

Flow Chart 5 Injector Has No Power

Check brakes. Low brake pressure, or air Repair or replace

N.G. in braking system.
o.k.

Check main injector pump N.G. Check charge pressure or

(note 1). system output pressure.
o.k.

Check speed control N.G. Ensure tubing weight not Lower speed control
pressure (note 2). too heavy for high speed. pressure in control
cabin.

o.k.
Check hydraulic motors on Case leakage should not
injector. N.G. exceed 1.5 gpm N.G. Repair or replace.
per motor.

Note 1: Main injector supply pump 350 to 5000 psi

Note 2: Speed control 0 to 400 psi

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2.7 GENERAL TROUBLESHOOTING

This section is intended to locate problems of a general nature. Only a licensed mechanic should
attempt in-depth diagnosis. Remember, more than one problem can have the same symptoms.
Eliminate the obvious, first. The problem may be bad wiring, blown fuse, etc.

2.7.1 GENERAL HYDRAULIC PROBLEMS

PROBLEM CAUSE ACTION

Components not cleaned properly after
Service unit again; clean components
servicing.

Inadequate screening in fill pipe Install proper screens in fill pipe

Air breather left off (insufficient Install air filter element in the air
protection of air breather). breather.

Proper gaskets not installed in tank. Install correct gaskets in tank.

Dirty oil
Hydraulic lines (pipes, hoses, etc.) not Install clean plugs in ends of hydraulic
covered or protected during servicing. lines during servicing.

Improper tank baffles not providing

Install proper baffles in tank.
settling basin for heavy materials

Oil filter elements not replaced at Change oil filter elements in a timely
proper intervals or when indicated. manner.

Fluid return line to tank not below fluid Fill tank to full line. Lengthen fluid
level. return line to bottom of tank.

Broken hydraulic line (pipe, hose, etc.). Repair broken line.

Line between bulkhead coupling and Install line between bulkhead coupling
bottom of tank not installed. and bottom of tank.
Foaming Oil
Inadequate baffles in tank. Install proper baffles in tank.

Fluid contaminated with incompatible Drain contaminated oil, purge system,

foreign material. fill with new oil.

Air leak in pump suction line. Repair pump suction line.

Lack of anti-foaming additives. Add anti-foaming additives to tank.

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2.7.1 GENERAL HYDRAULIC PROBLEMS (Cont)
P ro b le m C ause
F luid le ve l b e lo w c o o ling c o ils .
F ill p o rt le ft o p e n.
W a te r in o il
R e p la c e m e nt fluid c a ns c o nta in w a te r.
E xtre m e te m p e ra ture d iffe re ntia l in
g e o g ra p hic a l a re a .
N o w a te r d ra in in ta nk .
H e a t e xc ha ng e r c lo g g e d .
C o ntinuo us o p e ra tio n a t re lie f va lve
s e tting .
E xc e s s ive s lip p a g e o r inte rna l
le a k a g e .
Ta nk to o s m a ll.
S ys te m O ve rhe a ting Ta nk a s s e m b le d w ith ins uffic ie nt o r no
b a ffling .
Ins id e D ia m e te r (ID ) o f hyd ra ulic line s
(p ip e s , ho s e s , e tc .) to o s m a ll.
Ins uffic ie nt a ir c irc ula tio n a ro und ta nk .
S ys te m re lie f va lve s e t to o lo w.
P ip e s c a le no t p ro p e rly re m o ve d .
S e a ling c o m p o und (p ip e d o p e , Te flo n
ta p e ) a llo w e d to g e t ins id e fitting s .
Im p ro p e rly s c re e ne d fill p o rts a nd a ir
F o re ig n m a tte r in the b re a the rs .
c irc uit
B urrs ins id e hyd ra ulic line s .
C o m p o ne nts a nd o p e n line s
unp ro te c te d d uring re p a irs (the hum a n
e le m e nt).
R e p a ir p a rts a nd re p la c e m e nt
c o m p o ne nts no t p ro p e rly p ro te c te d
w hile s to re d in p a rts c o nta ine r.
C o m p e ns a to r a nd re lie f va lve s e t
P re s s ure s urg e s
inc o rre c tly.
2-34
A c tio n
A d d hyd ra ulic fluid to b ring the fluid to
the p ro p e r le ve l.
D ra in w a te r fro m ta nk .
C lo s e a nd s e a l fill p o rt.
D ra in w a te r fro m ta nk .
G e t ne w o il d rum s .
E nc lo s e ta nk in e nviro nm e nta lly s ta b le
e nc lo s ure .
Ins ta ll w a te r d ra in in lo w e s t p o int o f
ta nk .
C le a n a nd unc lo g he a t e xc ha ng e r.
R e s e t re lie f va lve hig he r tha n o p e ra ting
p re s s ure .
R e p a ir o r re p la c e m o to rs a nd /o r
p um p s .
Ins ta ll a la rg e r ta nk .
R e c o ns truc t the ta nk w ith the c o rre c t
b a ffling .
R e -p lum b s ys te m w ith la rg e r ID
hyd ra ulic line s .
M o ve ta nk to a llo w a ir to c irc ula te
fre e ly a ro und it.
R a is e the s e tting o f the s ys te m re lie f
va lve to the p ro p e r s e tting .
R e m o ve p ip e hyd ra ulic line s , c le a n the
p ip e p ro p e rly, re -ins ta ll p ip e hyd ra ulic
line s .
D ra in hyd ra ulic fluid fro m s ys te m , flus h
s ys te m to re m o ve c o nta m ina nts , re -
m a nufa c ture jo ints to re m o ve s o urc e o f
c o nta m ina nts (s ta rt p ip e c o m p o und o r
Te flo n ta p e a b o ut tw o thre a d s fro m the
o p e ning ), re fill hyd ra ulic fluid .
Ins ta ll p ro p e r s c re e ning in fill p o rts a nd
a ir b re a the rs .
D ra in hyd ra ulic fluid fro m s ys te m , flus h
s ys te m to re m o ve b urrs , re -
m a nufa c ture jo ints to re m o ve b urrs ,
re fill hyd ra ulic fluid .
K e e p c o m p o ne nts a nd o p e n line s fre e
fro m d irt a nd m o is ture .
K e e p re p a ir a nd re p la c e m e nt
c o m p o ne nts p ro te c te d fro m d us t, d irt,
a nd m o is ture to p re ve nt c o nta m ina tio n
fro m rus t, e tc .
R e s e t the c o m p e ns a to r to 2 8 0 0 p s i;
s e t re lie f va lve to m a xim um a nd b a c k
o ff o ne turn.
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2.7.2 TRANSMISSION PROBLEMS

Problem Cause Solution

Go through the General Hydraulic
There is a problem in the hydraulic system (a
Troubleshooting table and take the appropriate
broken line, filter clogged, no hydraulic fluid, etc.)
action.
Does not drive with The engine clutch is not engaged. Engage the clutch.
the hydraulic motor
turning in either The brake is engaged. Release the brake.
direction.
Setup for maximum displacement on hydraulic Reset the displacement of the motor(s)
motor(s) is incorrect. according to the directions in this section.

Leakage in the hydraulic motor(s). Repair or replace the hydraulic motor(s).

There is a problem in the hydraulic system Go through the General Hydraulic

(pump not able to keep up, a broken line, filter Troubleshooting table and take the appropriate
Drive is sluggish or clogged, no hydraulic fluid, etc.) action.
erratic
Air in hydraulic pilot pressure lines. Bleed the air and resume operation.

The brake is not fully released. Release the brake and proceed.

There is a problem in the hydraulic system (relief Go through the General Hydraulic
valve not working, a broken line, filter clogged, Troubleshooting table and take the appropriate
no hydraulic fluid, etc.) action.

Pilot pressure line for opposite direction plugged

Drives in one Clean or repair pilot line and reinstall the line.
or leaking.
direction, only
Setup for maximum displacement on hydraulic Reset the displacement of the motor(s)
motor(s) is incorrect. according to the directions in this section.

Quick disconnect connectors on main hoses not

Tighten quick disconnect connectors.
completely tightened.

Drives in wrong
Pilot pressure lines reversed at pump. Reconnect pilot pressure lines properly.
direction

The fluid in the gearboxes is low or of incorrect Fill the gearboxes and/or change the fluid to
grade. the correct grade.

The drive coupling is not installed or aligned Correct the installation and/or alignment of the
Drives at high noise properly. drive coupling.
level
Remove the air from the fluid and determine
Air in the hydraulic fluid.
cause of air induction.

Motor(s) operating at excessive speed. Check motor displacement for correct setting.

Shaft seal ruptured Emergency pop off set incorrectly. Set emergency pop off to 50 psi.

The operating temperature is above 195ºF

Check the hydraulic fluid cooler.
(90.6ºC).
Operates at higher
than normal Hydraulic motor(s) stalling intermittently. Shut down system and correct stalling problem.
temperature
Check the case (leakage at the motor drain
Internal leakage.
should not exceed 1.5 gpm at full load).

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2.7.3 BRAKE PROBLEMS

PROBLEM CAUSE ACTION

Check filters, piping/hose size, and
Excessive pressures in hydraulic
restrictions in other hydraulic
system return.
components.

Replace fluid seal in brake; check

Fluid designed for dry use.
Slipping motor(s) seal; check piston seals.

Check disc thickness and replace if

Disc plates worn.
necessary.

Springs broken or have taken Check release pressures; replace

permanent set. springs as necessary.

Check pressure with gauge in bleed

Low actuation pressure. port and system on; correct fluid flow
problem.

Drags or runs hot Bearing failure. Replace bearings.

Excessive fluid Drain fluid and refill as specified.

Counterbalance valves adjusted Readjust counterbalance valves to

incorrectly. proper setting (500 - 600 psi).

Clean, repair, or replace the defective

Stuck valve or clogged line.
line or component.

Bad o-rings. Replace the o-rings.

Will not release
Discs frozen. Replace the disc stack.

Reset release pressure to correct

Release pressure incorrect.
setting (100 - 500 psi).

2-36 230606-001/8334PM