PSB Product Bulletins

PRODUCT SERVICE BULLETINS
PSB # Product Subject Date

101 Coiled Tubing Power Auto Driller Aug 11, 1992
102 Coiled Tubing Reel Valve Adjustments Dish Type Reel Aug 20, 1992
103 Tubing Reel Levelwind Arms Reinforcement Oct 22, 1992
104 90K & 180K Nitrogen Unit Dynometer Modifications Oct 22, 1992
105 Coiled Tubing Tubing Reel Directional Control Valve Nov 30, 1992
106 HR-480 Injector Gripper Insert Retainer pn CB310067-rev A Dec 13, 1993
Retention of Outside Chain Tension and
107 HR-480 Injector Jan 01, 1994
Bottom Idler Shaft
108 HR-480 Injector Retraction System Apr 12, 1994
109 HR-480 Injector Traction Tie Rods Apr 12, 1994
110 HR-480 Injector Gooseneck Mount Apr 14, 1994
111 HR-480 Injector Gripper Block Elastomers Jul 19, 1994
112 HR-480 Injector Gooseneck Mount Additional Support Aug 03, 1994
113 Coiled Tubing Reel Right Angle Gear Drive Reels May 15, 1996
Needle Valve (Counterbalance Dampener
114 HR-440 / HR-480 Injector May 07, 1996
Valve)
115 HR-480 Injector Injector Drive Case Oct 01, 1996
116 HR-440 Injector Drive Case Assembly Mar 04, 1997
117 HR-440 Injector Inside Traction System Mar 10, 1997
118 HR Injectors Retrofit Electronic Load Cells Mar 10, 1997
High Pressure Open Loop
119 Directional Control Spool 1998
Power Pack
120 HR 400 Series Injectors High Pressure Applications Apr 23, 1998
121 Tubing Reel Right Angle Drive Cargo Handling Aug 12, 1998
122 HR-480 Injector Retainer Bar CB370266 May 20, 1999
123 HR-480 Injector Traction Retrofit Kit CC365636
124 HR-440 Injector Brake Spacer Spool Plumbing Dec 15, 1999
125 HR-440 Injector Rail Type Inserts and Carriers Feb 10, 2000
Coil Tubing and Nitrogen
126 Hydraulic Tank Assembly Mar 21, 2001
Units
HR-560, HR-580, HR-5100 Variable Speed Injectors, Maximum
127 Sep 17, 2001
Injectors Allowable Speed
128 180K Nitrogen Units Denison P-16 Hydraulic Pumps Oct 22, 2002
129 HR500 series injectors Input Pinion Bearing Operating Temperature Sep 14, 2004
PSB # Product Subject Date
CT power pack & N2 units

130 3 and 4 Butterfly Valve Sep 2, 2004
supplied by HR-UK
HR580, 560, & 440G
131 Gearbox Bearings Oct 26, 2004
Injectors
132 All Tubing Reels Reel Swivel Bolted Joint Connections Feb 18, 2005
133 All 6-Series Injectors Chain Tension Installation Jan 2, 2007
All 440G, 560, 580 & 5100
134 Proper Gearbox Oil Level Clarification May 1, 2009
Injectors
135 All Trailer Mounted Injector Safety Latch on Injector Tilt Stands July 7, 2009
HR680 & HR6100 Injector Pressure June 11,
136 HR680 & HR6100 Injectors
Balance Line 2012
137 HR580 & HR680 Injectors HR580 & HR680 Injector Traction Cylinders April 25, 2013
Hydra Rig, Inc.
6000 East Berry Street
Fort Worth, Tx 76119
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT SERVICE BULLETIN

RECEIPT ACKNOWLEDGEMENT
Customer Name ______________________________
Date of Response _____________________________
PSB Number you are responding to _______________
Name, Phone number, and Fax number of person responding
Send response by e-mail or fax to:

E-mail: hriservice@hydrarig.com
Fax: (817) 457-1472
Approved by: Drawings included: PSB Number:

Date:
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT SERVICE BULLETIN # 101
PRODUCT: Coiled Tubing
REFERENCE: Power Auto Driller (P.A.D.)
SCOPE:
To advise field locations of operational rig-up error that is commonly being made in
conjunction with P.A.D. system.
Hydra Rig is issuing this P.S.B. in an effort to help prevent this rig-up error.
Furthermore, we are providing a recommended modification to help keep this human
error from occurring.
OPERATION:
There have been recent field service reports made to Hydra Rig about injector motor
case drains leaking and injectors locking up. Hydra Rig has found after investigating
these reports that the auto driller hoses (#70 and #97) in the side of the hose reel have
been left disconnected during operation. These hoses must be connected up whenever
the injector is used, even if auto driller is not going to be used.
RECOMMENDED MODIFICATIONS:
Presently, auto driller hoses #70 and #97 have to be connected on the side of the power
hose reel after the injector is rigged up. Hydra Rig has made up a modification parts kit
to allow the auto driller hoses to be routed through the reel swivel hose replacing #2
stripper hoses. The #2 stripper hoses will be connected on the side of the reel. See
illustration on pg. 4 for swivel port numbers and location.
Approved by: Drawings included: PSB Number: 101

Date: August 11, 1992
Greg Todd
Page 1 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
MODIFICATION INSTALLATION INSTRUCTION:
STEP 1
Remove hose #9 from housing of hose swivel replace and replace fitting with item (1)
90 degree adapter and move #70 auto driller control hose into its place.
STEP 2
Remove #94 hose from housing of hose swivel and move #9 hose (remove from step 1)
into its place.
STEP 3
Remove #9 hose from rear of bulkhead panel and move hose #94 from bulkhead to
hose swivel and install it in #9 bulkhead location.
STEP 4
Remove existing fitting and adapters from old #9 connection on mandrel of hose
swivel and replace it with item 1 90 degree adapter. This will be new #70.
STEP 5
Drill out #94 hole in bulkhead panel to and install item #2, bulkhead adapter
fitting. Also, label bulkhead with #70 and install Q.D. removed from side of hose reel to
bulkhead adapter.
STEP 6
Install NE hose, item # 3, from #70 port on mandrel of hose reel installed in steps to #
70 of bulkhead adapter installed in step 5.
STEP 7
Remove # 95 hose from housing of hose swivel and move # 97 hose from side of reel in
its place.
STEP 8
Label old # 95 connection on bulkhead to # 97.
STEP 9
Move # 95 hose removed in step 7 to the side of hose reel where # 97 was.
STEP 10
Take # 94 hose removed in step 2 and, using adapters required, install it on side of
hose reel where # 70 was or if a spare is located on reel it may be used.
Greg Todd
Page 2 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PARTS REQUIRED FOR MODIFICATION:
CA5600023
CONVERSION KIT HOSE SWIVEL (PAD) SYSTEM
BILL OF MATERIAL
ITEM # QUANTITY DESCRIPTION HR PART #
1 2 ADPTR MNPT X MJIC BHD HHB10015
2 1 ADPTR MOR X MJIC 90 HHA20025
3 1 HOSE ASSEMBLY CA400021
4 2 ADPTR MNPT X FNPT HHA10021
5 1 ADPTR MNPT X MNPT 90 HHA20002
6 1 ADPTR MJIC X MNPT 90 HHA20028
7 1 ADPTR MJIC X MNPT 45 HHA30013

Greg Todd
Page 3 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Greg Todd
Page 4 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: COILED TUBING REEL
REFERENCE: VALVE ADJUSTMENTS FOR DISH TYPE REEL
SCOPE:
To advise field operations of correct valve adjustment. These adjustments need to be

checked on existing and newly received reels.
OPERATION:
Recent field reports indicate that some reel manifold relief and back press valves
(mounted on reel skid behind Q.D. bulkhead panel ) have been readjusted. This
readjustment is happening after HR testing and not noted until the first well operation.
The most likely reason for these valves being readjusted is to facilitate tubing spooling
with equipment not set up to operate with these newer reels. It is imperative that these
valves are reset to their original settings. Failure to do so can cause problems in the
reel circuit, i.e. the levelwind metering valve (chain driven) locking up, excessive drag
(back pressure) on reel while spooling off, or reel will not keep up with injector while
pulling out of hole at a high rate.
If at any time any of these situations are encountered follow the procedures outlined in
this bulletin.
PROCEDURE FOR REEL MANIFOLD ADJUSTMENT (Ref. Drawing Pg. 3)
1. SECURE REEL WITH CHAIN BINDERS TO INSURE REEL DOES NOT ROTATE.
2. DISCONNECT HOSE FROM REEL SUPPLY HOSES (IN # 46 AND OUT # 45) TO
TUBING REEL. DIAL IN ON REEL PRESSURE ADJUSTMENT IN CONTROL
CONSOLE TO INSURE POWER PACK REEL RELIEF IS SET FOR 2500 PSI. IF
PRESSURE IS TOO HIGH OR TOO LOW, SET ACCORDINGLY.

Greg Todd
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
3. ONCE REEL CIRCUIT PRESSURE IS VERIFIED, CONNECT REEL SUPPLY

HOSES TO TUBING REEL. ONCE AGAIN, DIAL IN REEL PRESSURE FROM
CONTROL CONSOLE. INSURE PRESSURE IN BOTH DIRECTIONS (REEL
DIRECTIONAL VALVE IN CONSOLE) ADJUSTED TO A MINIMUM OF 2450 PSI.
IF PRESSURE IS BELOW MINIMUM PRESSURE SETTINGS, TURN IN TO
INCREASE ON THE IN OR OUT HOLE CROSSOVER RELIEF VALVES (ITEM
5 & 8) ADJUST SCREWS. ONCE CORRECT PRESSURE IS OBTAINED SECURE
ADJUSTMENT BY TIGHTENING ADJUST LOCKNUT.
4. REMOVE 2 EA. MOUNTING BOLTS FROM REEL MOTOR FLANGE. REMOVE

MOTOR SO THE MOTOR SHAFT IS EXPOSED.
5. TO CHECK SETTINGS ON BACK PRESSURE VALVES SIMPLY INSTALL A 0 TO

1000 PSI GAUGE IN THE PRESSURE LINE TO THE LEVELWIND VALVE.
INSTALL THE GAUGE AT THE LEVELWIND VALVE. (THE VALVE HAS A P
FOR PRESSURE STAMPED IN THE CASTING OF THE VALVE.) INCREASE
PRESSURE IN REEL CIRCUIT FROM CONTROL CONSOLE. NOTE THE
PRESSURE AT THE LEVELWIND VALVE THE INSTANT THE REEL MOTOR
SHAFT STARTS TO ROTATE. PRESSURE SHOULD BE 300 + 25 PSI. NOTE:
THERE IS A SLIGHT ROTATION OF THE MOTOR SHAFT INITIALLY. THIS
ROTATION IS CAUSED BY NORMAL COMPONENT LEAKAGE.
IF PRESSURE IS INCORRECT, SET VALVES IN HOLE (#3) OUT HOLE ( # 10)

(BACK PRESSURE VALVES) ACCORDINGLY FOR THE DIRECTION SELECTED
(SCREW IN TO INCREASE OR OUT TO DECREASE).

Greg Todd
Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
NOTE:
REEL MOTOR AS NO SHAFT SEAL. CASE OIL IS USED TO COOL AND
LUBRICATE THE BREVINI GEAR BOX. WHEN REMOVING MOTOR SMALL
QUANTITIES OF OIL SHOULD BE EXPECTED TO SEEP OUT OF THE GEARBOX.
RUNNING MOTOR WEN REMOVED FROM GEARBOX WILL ALSO HAVE LEAKAGE
THROUGH SHAFT END OF MOTOR.
FACTORY PRESET:
A QUICK OBSERVATION OF THE AMOUNT OF EXPOSED THREADS ON THE
BACK PRESSURE (#3 & #10) AND RELIEF VALVES (#5 & #8) CAN DETERMINE IF
VALVES HAVE BEEN MANIPULATED. AFTER PRESSURES ARE SET AT THE
FACTORY BACK PRESSURE RELIEF VALVES HAVE APPROXIMATELY 10 TO 11
THREADS EXPOSED AND THE RELIEF VALVES HAVE APPROXIMATELY 5 TO 6
THREADS EXPOSED.

Greg Todd
Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: New Style Tubing Reel

Ref.: Part Nos. CE00009, CE400010, CE400014,
CE400018, CE400015, CE460009, CE400026, CE400009,
CE400019
REFERENCE: LEVELWIND ARMS, REINFORCEMENT
SCOPE:
The above mentioned part no. reels have a knee brace type support for the levelwind
arms. This support is mounted off of the reel drum pedestal. There is a single tie in
weld between the support arm and top support plate of the pedestal.
There has been field reports of this weld point cracking, and in some cases, failing.
The primary cause for this failure is the tubing oiler packing causing excessive tubing
drag. This drag resultant forces are reacted by the levelwind support arms. The
excessive drag through the oiler is caused by excessive oiler packing or tightening of
the packing.
Observation of the tubing passing through the oiler is all that is required to determine if
the packing is excessively tight. The tubing oiler will chatter and jump if the packing is
excessively tight. Typically, there will be audible chattering or squeaking noise. This
jumping action can cause the support arm weld to fatigue and ultimately, cause weld
failure.
Reduction of the amount of packing or loosening of the brass guide/packing

compression end pieces will prevent this problem.
Hydra Rig is issuing the P.S.B. to advise of this potential problem and to supply a repair
procedure.
Hydra Rig also recommends this as a modification to all indicated part no. reels. This
should be done even if there is no apparent problem. This will help ensure oiler drag or
other sources of levelwind loading will not cause support arm weld failure.

Date: October 22, 1992
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REPAIR AND MODIFICATION:
Reinforce levelwind support arm with angular gusseting.

This is accomplished by adding a gusset to the upper levelwind arm. The gusset
attachment is at the point where the levelwind arm meets the bearing mount on the
pedestal. This requires a piece of 4 x 4 square plate thick. Cut the plate diagonally
forming two triangular gussets. Install them as the following drawings show. (see
drawing on page 3)
The original weld area and box tubing structure should be visually inspected for signs of
fatigue (i.e. paint cracking), box tubing indentions, cracked welds, etc. If there are signs
of fatiguing of damage, doubler plates should be added. The doubler plates should
extend 2 above and below the damaged point(s) on both sides of each arm upright. a
4 x 4 x plate is utilized for this purpose. This doubler plate would be added prior to
adding the gusset. A quantity of four (4) doubler plates would be required. (see
drawing on page 3)

Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: DYNOMOMETER, STUSKA 400D & 800D UTILIZED ON HYDRA RIG

90K AND 180K N2 PUMPING UNITS
REFERENCE: DYNO MODIFICATIONS
SCOPE:
Stuska engineering, through research and testing, have recently made improvement to the 400D and
800D dynos. The improvements are now standard on dynos being installed on new Hydra Rig N2 Units.
Hydra Rig feels that these improvements are very beneficial to field operations. Therefore, we are issuing
this Product Service Bulletin with the information required for the field operations to make these
upgrading modifications.
MODIFICATION PROCEDURES:
The dyno modification consists of adding two (2) ports on each side of dyno housing. These ports are
added to help the dyno maintain a constant torque for sustained operation. An added benefit with these
additional ports is overall better response and control of the dyno.
These additional ports on new dynos are SAE no. 6 O-Ring ports. The ports should be fitted with 45
SAE
O-Ring by no. 6 JIC fittings. Two (2) 3/8 100R2 hoses should be connected to two (2) 3/8 NPT ports
added to the coolant fluid tank. These ports must be above water level, preferably on the top of the tank.
On dynos that do not have this modification, it is recommended the field add these ports. Page 2 defines
and illustrates these modifications. You will note that added ports are called out to be 3/8 NPT, not SAE
no. 6 O-Ring. This is done to simplify field modification. However, due to the nature of the tapered NPT
thread, caution should be used when installing the NPT fittings. These fittings, if over torqued, could
potentially cause the aluminum housing to crack.
As there are four (4) additional ports (two on each side of dyno), the two (2) correct ports to utilize are the
two on the same side as the bottom plate discharge outlet port. (These ports are actually catching the
coolant water prior to it exiting the normal discharge port.)
The fixed 1/16 orifice fitting for cooling/lubrication flow must be directed into the top vent and load port.
This must be located so flow enters the dyno. It is possible to have the 1/16 fitting orientated such that
the fluid jet stream would pass out the vent line with little water entering the dyno. Both sides (vent and
load ports) must have 1/16 orifice water flow going into their applicable port.
The preceding described the modification for 400D dyno with a single rotor housing. The 800D has two
rotor housings, thus the porting and hosing described will be double. All other information is the same for
either dyno.

Greg Todd
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Greg Todd
Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Dynamometer - Waterbrake
Manu. - Stuska Engineering Corp.

Denver, Colorado 303-762-0553
Model No. - 400-D With Modifications Listed

Max. Horsepower - 250 HP
Max. RPM - 3,000 RPM
Modifications/Options Required
1. Fill ports to be (-12) SAE straight thread.
2. Torque arm mount bolt pattern to be for model 800; (on side opposite input
shaft).
3. No other ports or mount holes required.
4. Input shaft flange for spicer 1350 series (ship loose).
5. Grease zerts and grease reliefs to be installed in all applicable openings.
6. Plug standard seal cooling ports.
7. Do not supply any parts associated with seal cooling system.
8. Drill and tap 4 each (total) #6 SAE straight thread drain ports (2 per cover).
Location as per Stuska recommendation of 35o off of drain vertical center-
line on both sides of vertical centerline. (For use with either rotation.) Plug all
holes.
Specification, Dynamometer
Stuska Model #400-D 250 HP @ 3,000 RPM
DRAWING NO. A00040 D CHANGES

DRAWN BY T. Preston ECN 6415, 6855, 6951, 7483
CHECKED BY K.B.
9-29-89
Greg Todd
Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: COILED TUBING
REFERENCE: TUBING REEL DIRECTIONAL CONTROL VALVE
SCOPE:
The evolution of the tubing reel drive system has made it mandatory that the load check valve in
the tubing reel directional control valve be removed.
On new units, it is necessary for the load check to be removed to allow reverse flow through the
P or pressure port of the directional control valve. On the older units, the flow went across a
relief mounted on the reel skid base.
These load check valves have been removed from the new units. However, all units should be
inspected as a precautionary step. The possibility exists that a valve change has taken place
without load check removal.
OPERATION:
There have been recent field service reports about tubing reels locking up when the injector is
pulling pipe from the tubing reel. Also, the reel drive motor has been getting very hot and
making noise. This normally happens when a new style reel (see model reference numbers) is
run with an older style coiled tubing unit if the load check has not been removed.
RECOMMENDED MODIFICATIONS:
There are 2 different valves used for the directional control of the tubing reel.
1) Husco 6000 series - This valve was used in only a few units from 1980 thru 1984.
2) Commercial shearing A 20 - This valve was used widely from 1980 thru the present and
is the valve in all new units.
The modification is to remove this load check valve from the directional control valves. Some of
the units may have two or three banks or control sections, i.e. tubing reel direction, levelwind
override, reel pivot. Remove the load check from the tubing reel direction section or bank only!
The load check can be found in the particular valve as shown on page 3.
Approved by: Drawings included: PSB Number: 105 rev A

Date: November 30, 1992
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
The following reel part numbers are reel designs that will not work with a load check installed in
the directional control valve:
CE400002 CE460006
E14HS4050 E14HS4056
E14HS4074 E14HS4082
E19HS4028 E19HS4042
E20HS4022 E20HS4027
E20HS4034 E20HS4045
E20HS4048 E20HS4049
CONCLUSION:
1. If there is any doubt whether there is a load check installed or not, the customer should
make a physical inspection of the valve.
2. Removing a load check from a directional control valve used with an old style reel not
requiring load check removal, will not cause a problem.
3. Inspect and remove load check(s) from any reel directional control valve installed as a
replacement of original equipment.
NOTE: The bank valve handles have been mounted upside down from the following parts
breakdown (see page 3). This has located the load check on top of the valve, and it is
not accessible unless the valve is unbolted from the control panel.

Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR-480 INJECTORS
REFERENCE: GRIPPER INSERT RETAINER PART NUMBER CB310067 REV. A

.
SCOPE:
TO ADVISE OF A MODIFICATION MADE TO CORRECT A WELDING PROCEDURE

FAULT ON THE PART NUMBER CB310067 RETAINER, USED ON HR 480
INJECTORS.
REASON FOR MODIFICATION:

THE ORIGINAL DESIGN WAS MEANT TO HAVE THE RETAINER PINS WELDED TO
THE RETAINER PLATE WITH A FILLET WELD.
HOWEVER, RETAINERS WERE MANUFACTURED WITH A FLUSH, FUSION TYPE
WELD. THIS FLUSH, FUSION WELD HAS PROVEN TO BE A WEAK POINT.
IT WAS NOTED BOTH AT NEW ASSEMBLY AND IN THE FIELD THAT THE PIN CAN
SEPARATE FROM THE RETAINER PLATE.
THIS TYPICALLY HAPPENS DURING INSTALLATION, WHEN THE RETAINER IS
TAPPED WITH A HAMMER. THE TAPPING CAN CAUSE THE PLATE TO SHEAR
THE FUSION WELD AND SEPARATE FROM THE PIN.
MODIFICATION:
THE RETAINER MODIFICATION HAS BEEN MADE IN TWO (2) STEPS:
STEP 1
HYDRA RIG TOOK THE EXISTING STOCK AND REWELDED THE PIN TO THE
PLATE. THE NEW WELD MORE SECURELY BONDS THE PLATE TO THE PIN.
THE WELD AREA WAS ALSO BUILT UP OVER THE PIN. THIS WAS DONE TO
TRANSMIT THE TAPPING OR HAMMERING FORCE DIRECTLY INTO THE PIN.
THE INSTALLER SHOULD STRIKE THE WELDED AREA AND NOT THE PLATE.
DOING THIS SHOULD ELIMINATE PLATE TO PIN SHEAR.
STEP 2
HYDRA RIG MODIFIED THE DESIGN TO HAVE THE PIN EXTEND THROUGH THE
PLATE AND WELD THE TWO TOGETHER WITH A 1/8 FILLET WELD. ALL NEW
RETAINERS ARE MAKE TO THIS DESIGN (SEE ATTACHED DRAWING). DURING
INSTALLATION, THE INSTALLER SHOULD STRIKE THE PIN/WELD AREA, AND
NOT THE PLATE. THIS SHOULD PREVENT WELD SHEAR ON THE RETAINERS.

Date: December 13, 1993
CB310067
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
WARRANTY:
HYDRA RIG WILL SEND WARRANTY REPLACEMENT RETAINERS TO
CUSTOMERS SUPPLIED WITH THE DEFECTIVE PARTS. HYDRA RIG REQUESTS
CUSTOMERS RECEIVING THE REPLACEMENT RETAINERS TO SEND THE
DEFECTIVE RETAINERS BACK TO HYDRA RIG. THIS IS DONE IN AN EFFORT TO
INSURE DEFECTIVE PARTS ARE NOT REUSED.
CUSTOMERS THAT HAVE MANUFACTURED THEIR OWN RETAINERS ARE

REQUESTED TO REPLACE THEM WITH THE HYDRA RIG PARTS.
THE ABOVE STEPS ARE NECESSARY TO MAINTAIN CUSTOMER WARRANTY ON

THEIR INJECTORS.
RETURN OF FAULTY RETAINERS:

PLEASE RETURN THE FAULTY RETAINERS TO:
HYDRA RIG, INC.

6000 E. BERRY STREET
FORT WORTH, TEXAS 76119
USA
ATTN: SERVICE DEPT.
ALONG WITH THESE RETAINERS, PLEASE INCLUDE A NOTE WITH THE

INJECTOR SERIAL NUMBER AND QUANTITY OF PINS RETURNED. IF ALL 144
PINS ARE NOT RETURNED, PLEASE ADVISE STATUS OF UNRETURNED PINS
(I.E. LOST, DISCARDED, ETC.).
SUMMARY:
PLEASE CONTACT HYDRA RIG SALES OR SERVICE DEPARTMENTS IF YOU
HAVE ANY QUESTIONS.
TELEPHONE: (817) 457-3825

FAX: (817) 457-3897, 5237, 1472

CB310067
Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

CB310067
Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR-480 INJECTOR
REFERENCE: RETENTION OF OUT SIDE CHAIN TENSIONING AND BOTTOM IDLER

SPROCKET SHAFTS, SEE CBPSB107 MODIFICATION DRAWING
ATTACHED.
SCOPE:
To advise users of the HR-480 injectors of the potential for the outside chain tensioning
and lower idler sprocket shafts to walk out of their support bearings.
To walk means that shafts will rotate or slide within the inner race of the support
bearings. The shafts can move enough to be completely disengaged from the bearing.
The resulting disengagement can cause severe damage to the injector.
The injector damage may also result in secondary equipment and/or well damage.
MODIFICATIONS AND PREVENTIVE MEASURES:
The following describes immediate field prevention measures, permanent field

modifications, and new injector changes.
IMMEDIATE PREVENTATIVE MEASURE:
The following is designed as a temporary means to help secure the sprocket shafts until
a permanent repair can be made:
A. Inspect both outside chain tensioning and bottom idler sprocket shafts to see if
they are walking. If they have moved, loosen the locking set screws on both the
inner and outer locking ring of each bearing. Reference the attached bearing
information, which clearly shows these set screws. Using a rubber mallet or
brass drift, drive the shaft back into the correct position. Care needs to be used
to prevent damage to the end of the shaft.
Once the shafts are in the correct position, remove the lock collar set screws, and, using
a drill and drill bit slightly smaller than the set screw (approximately .38 dia.), drill into
the shaft 1/8. Then, install and torque the set screws to 30 to 35 ft./lb.

Date: January 1, 1994
CBPSB107
Page 1 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
If it is not possible to drill the shaft, the shaft should be correctly positioned, as
previously mentioned, and the set screws torqued to 30 to 35 ft./lb.
In either case, the shaft should be regularly monitored to ensure it is not walking out of
the bearing.
PERMANENT REPAIR MODIFICATION (REF. ATTACHED DRAWING NO.

CBPSB107 AND BEARING INFORMATION SHEET):
A permanent repair should be made as soon as possible. Drawing No. CBPSB107

illustrates a simple means to affect a permanent repair. The repair is straight forward
and requires little, if any, disassembly of the injector.
The following is a step by step procedure to accomplish what the drawing illustrates:
A. Center the shaft if it has moved in the bearing. Be sure to loosen both inner and
outer collar set screws on both bearings prior to centering the shaft. A rubber
mallet or brass drift should be used to drive the shaft to the center position to
prevent shaft damage.
B. Once the shaft is centered, the locking collar set screws should be torqued to 30
to 35 ft./lb. Be sure and torque both inner and outer lock collar set screws.
C. With the shaft centered and secured by the set screws, the half keys* (Items 1, 2,
and 3 on drawing CBPSB107) are ready for installation. Prior to installation of
the half keys, a small diameter rod (I.E. 1/8 welding rod) should be inserted into
the key way to determine actual length required for each individual half key.
When determining this dimension, the half key length should leave enough room
to make a full 3/16 fillet weld within the confines of the key way.
*The above described half keys are actually mild steel flat bar. The CD1018 in
the drawing description is referring to cold drawn ASTM A108 OR UNS G10180
material.
These half keys should be precut to the individual key way required dimension. The
dimensions shown on the drawing are for reference only. Sharp corners and edges
should be removed to allow easy installation.

CBPSB107
Page 2 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
The half key should be tapped into the slot with a small hammer. It is recommended
that the key be lubricated to aid installation. Care should be taken not to damage the
half key or key way. A small round punch may be utilized to drive the key the last 1 or
so to prevent damaging the key or key way. The half key, when installed correctly,
should rest against the original full key and have about 1/4 open key slot between it
and the end of the shaft.
With the half key installed, 3/16 fillet weld is applied, welding the half key to the shaft.
This weld area should be cleaned (residual lubrication removed) prior to welding. The
weld must be kept below the top of the key way to allow bearing removal. A low
hydrogen (7018-7020) type welding rod should be utilized for the weld. Both the shaft
and half key are mild steel so no special welding procedures are required. During the
welding process, the ground lead of the welding machine should be connected to the
sprocket/shaft that is being welded on. This will prevent ground arcing damage to
critical components (I.E. bearings, cylinders, and motors).
NEW INJECTOR AND REPLACEMENT SHAFTS:
On the new injectors or replacement shafts, the key way will be milled into the shaft only
in the area the key way of the sprocket and shaft line up. This will eliminate any future
necessity of installing the half keys.
SUMMARY:
The preceding outlines a temporary measure to help prevent shaft walking and a
permanent repair. The temporary measure should be monitored regularly to ensure that
the shaft is staying secured. The permanent repair should be conducted at the first
opportunity possible.
If there are any questions about this PSB or other areas of the HR-480 injector, please
contact Hydra Rig Service or Sales Departments with your inquiry.
PHONE: (817) 457-3825

FAX: (817) 457-5237, 1472

CBPSB107
Page 3 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

CBPSB107
Page 4 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

CBPSB107
Page 5 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REFERENCE: RETRACTION SYSTEM
SCOPE:
RELIEF VALVE INSTALLATION FOR HR480 INJECTOR HAND PUMP

RETRACTION CIRCUIT.
OPERATION:
A RELIEF VALVE IS BEING INSTALLED ON OUR 480 INJECTORS TO

REDUCE THE POSSIBILITIES OF HUMAN ERROR IN THE OPERATION OF
THE RETRACTION HAND PUMP CIRCUIT.
IF THE HAND PUMP SELECTOR VALVE, FOR ONE REASON OR ANOTHER,
HAD BEEN LEFT IN THE RETRACT POSITION AND INSIDE TRACTION
PRESSURE WAS APPLIED, THE RELIEF VALVE WOULD PROTECT THE
HYDRAULIC AND MECHANICAL ELEMENTS OF THE RETRACTION CIRCUIT
FROM PREMATURE FAILURE.

Date: April 12, 1994
Bradley J. Hastad CV1001
Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Bradley J. Hastad CV1001
Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REFERENCE: TRACTION TIE RODS
SCOPE:
On some of our earlier model 480 injectors, there may have been a tolerance problem
between the chain links and the traction tie rods.
During dynamic conditions, the chains may be contacting these rods, which in turn
creates a groove in the tie rod.
To inspect these rods, simply loosen rod end retainer bolts. Rotate rod (item #1 on the
drawing) and inspect for any noticeable wear patterns. If rods are undamaged, ensure
to retorque retaining bolts to minimum 350 ft. lbs.

Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: 480 INJECTOR
REFERENCE: GOOSENECK MOUNT
SCOPE:
Being that the upper frame weldment for the gooseneck mount is symmetrical, we wish
to emphasize that the swivel mount can be installed backwards. Inspect gooseneck
mount to ensure bearing swivel is mounted correctly. Refer to attached page for details.
Note: Ensure Item 2, which is a 5 width plate, is facing the reel (item 1 is a 3
plate).
OPERATION:
Proper adjustment of gooseneck should include adjustment of item 3, which will include
adjusting your bearing carrier either forward or backward, depending on the pipe size.
Item 4 is to adjust the gooseneck forward or backward, once again, depending on pipe
size. Centerline of the swivel bearing should be set forward (toward reel) slightly off the
centerline of the injector chain. When gooseneck is adjusted properly, the tubing will
pass through the center of the swivel bearing, and the natural arc of the tubing will
contact both sets of chains at the same time.

CV1000
Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

CV1000
Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REFERENCE: GRIPPER BLOCK ELASTOMER
SCOPE:
The present black elastomer being used in the 480 injector gripping system is being
discontinued. The reason for this discontinued use is the development of a more
durable clear urethane compound. The urethane compound has better wear
characteristics, and is more tolerable to extreme conditions.
WARRANTY:
The new urethane elastomer part number is CC310193. Please inspect the injector
gripping system and inform the Hydra Rig Service Department if you have the black
elastomers. The new urethane elastomers will be supplied at no cost. Please continue
to use the black elastomers until the urethane elastomers become available.
The following information must be received with each request for urethane elastomers:
1. Company Name and Location

2. Shipping Address
3. Hydra Rig Serial Number of Injector Head
4. Name of Person Making Request

Date: July 19, 1994
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

REFERENCE: GOOSENECK MOUNT ADDITIONAL SUPPORT

For tubing through 3.5, under normal working conditions the gooseneck mounts should
never exceed their rated capacity of 3000 lb. Line pull using a 100 gooseneck. Should
the line tension exceed 3000 lb. pull, the gooseneck mount becomes the forgiving point
within the injector structure.
In cases where line tension exceeds 3000 lb. pull, intermittently or continuously, Hydra Rig
has designed a support structure for the gooseneck mount. This structure, if applied and
properly adjusted, will increase the load capacity of the gooseneck mount from 3000 lb. to
7500 lb. of line pull.
The following pages include dimensional drawings of the goose neck mount support to aid
in the fabrication of the components.
INSTALLATION:
1. Assemble upper and lower mounts prior to installing them into position (fig. 4 and 5).
2. Weld upper mount into position (fig. 1A).
3. Hang two (2) struts from upper mounts by using two (2) 1 diameter 2.5 long pins (fig.
1A).
4. Attach bottom mount to both struts.
5. Position bottom mount between each frame uprights (fig. 1A) and weld into place.
NOTE: INSURE ROD ENDS (FIG. 1, ITEM 7 AND 8) ARE SCREWED IN PRIOR
TO WELDING BOTTOM STRUT SUPPORT.
6. Once all weldments are complete, extend struts approximately 0.5 to provide and
ensure support to the gooseneck mount tail section. Lock into position (fig. 1A, item 3).
Using rod ends as shown (fig. 1, items 7 and 8) would allow you to maintain maximum
swivel capabilities of the gooseneck mount.
Any questions concerning this application should be forwarded to the Hydra Rig Service
Department.
CB360212, RCP00011, Date: August 3, 1994
RCP00012, CC380043, Page 1 of 5
CC380044
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

RCP00012, CC380043, Page 2 of 5
CC380044
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

RCP00012, CC380043, Page 3 of 5
CC380044
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

RCP00012, CC380043, Page 4 of 5
CC380044
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

RCP00012, CC380043, Page 5 of 5
CC380044
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT:
REFERENCE: Coiled Tubing Right Angle Gear Drive Reels
SCOPE: It has come to Hydra Rigs attention that during Coiled Tubing Operation
that the drive sprocket fell off the 90 reel drive. This was caused by the
sprocket retaining bolt working loose, allowing the sprocket to walk off the
end of the splined drive shaft and possibly a misalignment of the drive and
driven sprocket.
REPAIRS REQUIRED:
1. Remove sprocket retaining bolts, clean bolts and drive shaft bolt holes threads.
2. Reinstall bolts using retainer (P/N CB460219) and locktite to 18 ft. lbs. of torque.
3. Tighten all angle drive mounting bolts to 55 ft. lbs. of torque. Insuring lock
washers are in place.
4. Check the sprockets alignment. Align by adjusting the mounting plate and at the
same time adjust proper chain tension.
5. Rotate reel without guard on to insure alignment and chain tension is correct.
This procedure should be performed on an annual bases after initial inspection.
See Attached Drawing.
Please contact Hydra Rig Service if you have any questions on this P.S.B..
Tel. # (817) 457-3825 Fax # (817) 457-1472

E-Mail # HRISERVICE@WHYNET After Hours Cell Phone # (817) 475-4324

Date: May 15, 1996
CB930005
Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
RETAINER
CB460219
TORQUE TO 200 FT LBS
TORQUE TO 18 FT LBS TORQUE TO 55 FT LBS

VIEW WITH LOCKTITE

Date: May 15, 1996
CB930005
Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: 440/480 INJECTOR
REFERENCE: Needle Valve (Counterbalance Dampener Valve)
SCOPE: The needle valves, part number HVF0005, used on early models of
the 440/480 injectors are being discontinued and replaced by part
number HVF00312.
The new valve is stainless steel and has hardened seat and
needle.
This provides corrosion protection and better wear characteristics.
WARRANTY: The new stainless steel valve, P/N HVF00312, is available under
warranty. Please inspect the injector counterbalance dampener
valves and inform the Hydra Rig Service Department if you
presently do not have stainless steel valves. New valves will be
supplied at no cost.
The following information must accompany requests for warranty:
1. Company name and location.

2. Shipping address.
3. Hydra Rig serial number of injector head.
4. Name of person making request.
Supplied replacement parts: 2 HVF00312 - Needle valves

2 HHA20341 - NPT adaptors
2 HHA10254 - 37 JIC adaptor

Date: May 7, 1996
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR480 Injector
REFERENCE: Injector Drive Case
SCOPE:
Hydra Rig has made various improvements to the design of the 480 Drivecase since its
inception in 1993. This PSB is intended to communicate potential problems and
recommended upgrades to prevent these problems.
BACKGROUND:
It has been observed during field service that some of the earlier design drivecases can
experience excessive case deflection under high tubing loads, causing motor
misalignment. This condition sometimes causes high drive motor case leakage,
resulting in diminished slower speed control. Later designs use a new symmetrical
valve motor, which eliminate the problems associated with preferred rotation. However,
the new motor is more sensitive to alignment and deflection, so case leakage is more
pronounced. The current drive case design addresses these problems and minimizes
internal motor leakage, providing smoother, more controlled operation at high tubing
loads, especially at slow speeds.
UPGRADE:
Hydra Rig is offering a one-time exchange program through April 1, 1997, through
which the customer can upgrade their injector drivecase to the latest design, and in
some cases, Hydra Rig will credit the customer for returned cores.
Following are the three different drivecase configurations, and how they will be
addressed.

Brad Hastad
Page 1 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
TYPE A DRIVECASE SERIAL NUMBERS:
3223/9693 1225/10172 1232/11054 1234/12162

1237-1/12451 1238/12498 1240/13230 301087/13417
1242/13422 301098/16365 1249/17172 1251/17174
2254/17616 1224/9842 3231/11053 1233/11058
301078/12429 1237-2/12451 1239/12499 1241/13233
1243/13421 301092/13622 1248/17171 1250/17173
301103/17396 1256/18265
The original 480 drivecases built until mid 1994 used a non-symmetrical Poclain motor
with an internal valve design which would tolerate greater misalignment, thus motor
case leakage under high loads was less apparent. These early motors were also a
hydrabase design with the sealing plate built into the drivecase. To upgrade to current
drivecase design using existing motors, shipping seal plates are required. This upgrade
package, including remanufactured drivecase, gears, shafts, sprockets, new bearings,
new seals, shipping plates, and associated hardware is available at a cost of $32,000
F.O.B. Fort Worth, TX. Type A cores are not rebuildable and no credit will be issued
for returned cores.
TYPE B DRIVECASE SERIAL NUMBERS:
1261/18031 1275/25474 1262/18427 1263/18428

1281/25475 1264/18429 1265/18430 1286/26537
301117/18630 1266/19201 1287/26564 1270/21447
1272/22231 3284/26101 301153/23960 301164/24613
3276/25204 3278/25320 3293/27848 1277/25354
These cases were similar to Type A cases, and were built from mid 1994 to late 1995.
The Type B case also used non-symmetrical motors, but had shipping seal plates and
reinforced drivecase structures. The shipping seal plate permits the motor to be
delivered from Poclain as an assembly and permits easier field removal and servicing.
This upgrade package does not require shipping seal plates, and includes
remanufactured drivecase, gears, shafts, sprockets, new bearings, new seals, and
associated hardware for a cost of $32,000 F.O.B. Fort Worth, TX. A credit of $8,000 will
be issued upon return of Type B cores.

Brad Hastad
Page 2 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
TYPE C DRIVE CASE SERIAL NUMBERS:
1300/28234 301224/29647 301249/30809 301226/29818

301060/9648 1306/29936
The Type C drivecases utilize the new symmetrical valve motor, and were built
between late 1995 and mid 1996. These drivecases are more sensitive to misalignment
and may experience excessive case leakage under high load. Hydra Rig will provide
the upgrade package for the Type C drivecase at no cost F.O.B. Fort Worth, TX, with
a core charge of $32,000 refundable upon receipt of core.
CURRENT DRIVECASE:
If your injector is one of the following serial numbers, be advised that all upgrades have
been completed. All injectors built since July 1996 have been upgraded to the current
design. If you are in doubt or if your injector serial number is not listed below, contact
Hydra Rig Service to confirm the status of drivecase.
SERIAL NUMBERS:
301231/30193 301272/32099 301077/12428 1310/30236
301273/32100 301123/19109 1307/30631 301292/32450
3296/28060 301267/31738 301252/30182 301288/32519
301276/32025 301288/32520 1322/30182 301297/32761
1320/33022 1323/33578
TERMS:
1. This offer is valid for orders placed before April 1, 1997, and orders will be filled
on a first-come first-serve basis.
2. All prices are F.O.B. Fort Worth, Texas, USA. Cores to be returned at
customers expense.
3. Service technicians will be available at a normal day rate plus incurred expenses
to assist with the installation and testing of the drivecase.
4. Detailed installation instructions will be provided at the time of order, and Hydra
Rig Service staff will be available to answer questions.

Brad Hastad
Page 3 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REPLY FORM RETURN IS MANDATORY:

Please fill out attached form and return to the Hydra Rig Service Department at fax
number (817) 457-1472 or E-mail address hriservice@why.net. Please respond to
accept or reject this offer as soon as possible.
RESPONSE FORM
HR480 INJECTOR HEAD DRIVE CASE
Date of Response: ___________________________________
Customer Name: _____________________________________
Equipment Location: _________________________________
HR 480 Serial Number: _______________________________
Date of Manufacture: _________________________________
Customers Unit Number: ______________________________
Type of Drive Case: Type A
Type B
Type C
Not Listed
Please check one of the following:

Yes, I would like a new Drive Case.
No, I do not require a new Drive Case.
I require a service technician to assist with installation.

Yes No
Please return to Hydra Rig Service Department as soon as possible.

6000 E. Berry St.
Ft. Worth, TX 76119 USA
Phone Number: 817-457-3825
Fax Number: 817-457-1472
E-mail address: hriservice@why.net __________________

Brad Hastad
Page 4 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR 440 Injector
REFERENCE: Drivecase assembly
Through ongoing studies of the 440 injector and related problems in the field HRI has
made several design upgrades to the drivecase that will prevent any potential future
problems. If you wish to have these upgrades performed on your injector please
complete the attached form and return it to HRI. Expenses for this upgrade will be
handled case by case. HRI would prefer to do the upgrades in Fort Worth, but if this is
not possible one of our Technical support personnel will be made available to assist you
at your location at our regular daily rate, again this will be handled on a case by case
basis. If the upgrades are done at your location a complete drivecase will be sent on an
exchange basis. This offer is valid until August 15, 1997. All upgrades will be handled
on a first come first serve basis. Following is a list of affected injectors. If the serial
number for your injector is not listed then please disregard this PSB.
22976/301142 28248/2298
17403/301131 28242/2299
19695/3267 35155/2326
21095/301133 35157/2327
21096/301134 35159/2328
23642/301149 35161/2329
23777/301152 35163/2330
25047/1274 30239/1310
25749/301175 30282/301230
26920/356192 30589/301239
27348/1288 30807/301250
1285 30912/301250
28010/1290 30808/301250
28010/1291 31126/301257
28023/1292 31355/1314
28006/301204 31347/1316
30802/1311 31839/1317
29151/28046 32052/1318
29188/27640 32388/301287
30743/3305 33221/3321
29973/301227 34761/1325
28240/2297

Date: March 4 1997
Richard Russell
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR440 injector
REFERENCE: Inside traction System
It has come to HRIs attention that the traction system used on some 440 injectors is
much too sensitive to being adjusted properly. To the point that only minor
maladjustment will greatly reduce the systems ability to grip tubing properly.
To correct this potential problem, HR has designed a traction system that is more user
friendly in that adjustments are not needed after initial setup. This upgrade is not
applicable to all 440 injectors. To find out if your injector is affected, complete the
attached response form and return it to HR. We will contact you upon receipt of the
response form. Kit #CA360022

Date: March 10, 1997
Terry Watts
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: All Hydra Rig Injectors
REFERENCE: Retrofit to electronic load cells
In keeping up with the electronic age, many Hydra Rig customers are replacing existing
hydraulic load cells with electronic load cells. This does not present any problems as
long as it is done correctly.
When you install the electronic load cell, you must ensure that the vertical center line of
the chains is perpendicular to the injector base when the load cell is at its zero position.
This will ensure that the tubing will pass through the injector in a straight line.
If you do not do this, not only will the weight readings you get be inaccurate; you also
run the risk of severely damaging the injector. If you have any questions or would like to
discuss your retrofit with us please contact us at:
Hydra Rig
PO Box 15951
Fort Worth, Texas 76119
Phone 817-457-3825
Fax 817-457-1472 or 817-457-3897
E-Mail hriservice@why.net

Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Product Service Bulletin

Response Form
Customer Name ______________________________
Equipment Location ___________________________
Equipment Serial Number ______________________
Date of Response _____________________________
Date of Manufacture ___________________________

Hydra Rig
P.O. Box 15951
Fax: (817) 457-1472

Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

PRODUCT: High pressure open loop power packs
REFERENCE: Directional control spool

We have learned that due to conditions beyond our control the spool used in the
Denison directional control valve utilized on this type power pack is not configured as
we intended. The spool should be configured so that ports A and B are drained to port
T through orifices when the injector control in the operators cabin is shifted to the
neutral position.
We now are aware that some spools were installed that blocked ports A and B causing
a condition where there would be trapped pressure between the injector and the power
pack. It is not known exactly what this will cause, but it could increase the chances of a
run away condition occurring. To check the spool in your power pack quickly and easily
the following can be done.
1. Connect the control cabin to the power pack as normal.

2. Do not connect the 1 inch hoses to the injector. Instead install a 5000 psi
gauge in the end of each of the hoses.
3. Start the power pack and pressure up the hydraulics.
4. From the control cabin shift the injector directional control to the in-hole position.
5. Dial in on the injector motor pressure control until 3000 psi is reached
6. After the injector system has 3000 psi on it shift the injector directional control
back to the neutral position.
7. The 3000 psi should begin to bleed off. If after 20 seconds the hoses are still
pressured up the spool must be changed.
If you discover that you have the incorrect spool in your power pack, if you will contact
us we will supply you with the correct spool at no cost to you, provided that you send
the incorrect spool back to us. When we supply you with the correct spool we will supply
you with the information needed to complete the change out. The change out of the
spool is very simple and can be done in a hour or less.
Following is a list of power pack serial numbers that this PSB may affect.
3284 1335 355750 1310 1309
3293 1285 1336 1324 1307
1306 1282 1286 1325 301235
1322 1308 1300 301192
If you determine that you need a new spool please fill out the attached form and return it
to us by fax at 817-457-1472 or by email at hriservice@hydrarig.com
Date: 1998
Richard Russell
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: Hydra Rig 400 Series Injectors
REFERENCE: High Pressure Applications
Introduction
Coiled tubing is being used more and more in high pressure well applications. Coiled
tubing and associated service equipment was designed for this application, but it must
be operated within its design limits for successful results. Many new coiled tubing
operators are being trained and are entering the workforce. As the high pressure trend
progresses, it is imperative that both coiled tubing job planners and coiled tubing
operators fully understand issues concerning:
Coiled tubing mechanical strength and burst / collapse ratings

Injector operation
Maintenance
Complex jobs
If these issues are not fully understood and addressed, the consequences could be
catastrophic.
Coiled tubing strength limitations:

In a high pressure or live well application, coiled tubing can be subject to collapse
pressure. Allowable collapse pressure decreases as the pipe is worked through the reel
and gooseneck causing it to become more oval in cross section. Normal operating
procedures call for pressure to be applied inside the coiled tubing at the reel so that
rated collapse pressure is never approached. If a collapsed section of pipe ever
reaches the injector in a pipe light situation, the injector can loose grip and the pipe will
blow out of the well.
Injector operation:
In typical no or low pressure applications, standard operating procedure is to minimize
chain tension and traction pressure which maximizes chain and injector life. However,
in a high pressure (snub or pipe light) application, the primary consideration is to hold
onto the pipe and safely complete the job. Chain tension recommendations for a snub
situation as found in operating manuals must be followed. A safety factor should be
applied to recommended traction pressure for pull to insure that pipe is never allowed to
slip under any conditions. The coiled tubing operator should never adjust traction
pressure in a pipe light situation by allowing pipe to slip and then adjusting traction
pressure.
Terry Watts
Page 1 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Charts addressing traction pressure specifically for a snubbing situation are being
distributed for the 440 and 480 injectors as part of Product Service Bulletin # 120.
These charts are based on new injector inserts on new, oiled pipe. As pipe and other
components wear or as foreign material such as grease or spherical frac sand is
introduced, coefficients of friction change. It is the operators responsibility to insure
that sufficient traction pressure is utilized to prevent any slippage under actual operating
conditions.
Maintenance:
Proper coiled tubing equipment maintenance is important in any operation, but it is
absolutely critical in a high pressure application. Stretched or worn out injector chains
that allow the chain tensioning cylinders to bottom out cannot be tolerated. Seal
components in the BOPs must be functional and tested at least to maximum pressure
anticipated on the job. In short, the injector, BOPs, and hydraulic system controlling
them must be maintained in top condition. Hydra Rig service technicians are available
to assist in this effort.
Complex jobs:
Some coiled tubing jobs can become complex and difficult to understand either in the
planning or execution stage. Various combinations of forces or pressures can interact
to create uncertainty. Any high pressure coiled tubing job should be planned and
executed with the same care and attention to detail as a snubbing job. Hydra Rig
service technicians or engineers can assist with information regarding Hydra Rig
equipment. Hydra Rigs sister company, CTES, L.C. (Coiled Tubing Engineering
Services) can assist with engineering services related to the combined effects of ovality,
fatigue, buckling, burst, collapse, and tensile loadings.
Attached are packets to be added to your 440 and 480 manuals. The packet contains a
snub vs. traction pressure chart and an example of how to read the chart. If you have
any questions or need further assistance, please contact the Service Department at
Hydra Rig.
Hydra Rig CTES, L.C.

6000 East Berry Street P.O. Box 2178
Fort Worth, Texas 76119 Conroe, TX 77305-2178
Phone: (817) 457-3825 Phone: (409) 756-4800
Fax: (817) 457-1472 Fax: (409) 756-5175
E-mail: hricsc@flash.net
After hours: 1-888-517-8904
Mobile: (817) 475-4324
Terry Watts
Page 2 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
High Pressure Well Applications

WARNING
THE FOLLOWING ISSUES MUST BE FULLY UNDERSTOOD AND

ADDRESSED BY COILED TUBING OPERATING PERSONNEL
Coiled tubing mechanical strength and burst/collapse ratings
Injector operation
Maintenance
Complex jobs
Coiled Tubing Strength And Burst/Collapse Ratings

In a high pressure or live well application, coiled tubing is or can be subject to
collapse pressure. Normal operating procedures call for pressure to be applied
inside the coiled tubing at the reel so that rated collapse pressure is never
approached.
WARNING
IF A COLLAPSED SECTION OF PIPE EVER REACHES THE

INJECTOR, IN A PIPE LIGHT SITUATION, THE INJECTOR WILL
LOSE GRIP AND THE PIPE WILL BLOW OUT OF THE WELL

Terry Watts
Page 3 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Traction Pressure Settings for HR 440 - Pipe Heavy

This recommended traction pressure chart shows a range of pressures for a
given tubing load. This chart does not imply that it is possible to pull at the top of
the band for a given pressure. The chart indicates a range of values
corresponding to varying conditions such as.
Tubing Ovality
Tubing Surface Conditions

Oil Grease
Frac Dirt
Sand
Insert Conditions
Worn Scarred
The chart denotes that at a given traction pressure the injector should pull
somewhere in the band depending upon the above conditions. The values found
by using the chart are adequate under most conditions. It should be noted,
however, that conditions for each job are unique and deviations from the chart
values may be required.

Terry Watts
Page 4 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Pull vs. TractionPressure

HR440B
3000
Tra c tio n Pre s s u re (p s i)
2500
B
2000
1500
1000
500
A
0
InjectorPull (lbs)

Terry Watts
Page 5 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Pull Vs. Traction Pressure
Example:
To obtain a tubing pull of 24,000 lb locate the injector pull on the bottom of the
chart, read the corresponding traction pressure on the left side of chart. Traction
pressure should be between 1000 psi (A) and 1475 psi (B) depending upon
operating conditions.
Injector Operation For HR 440 - Snub

In no or low pressure application, standard operating procedure is to minimize
chain tension and traction pressure to maximize chain and injector life. In a high-
pressure (snub or pipe light) application, the primary consideration is to hold onto
the pipe.

Terry Watts
Page 6 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Snub vs. Traction Pressure

HR440
2500
2000
Tr actio n Pr e s s u r e (ps i)
1500
1000
500
0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
Snub Load (lbs)
Traction Pressure w/ 20% S.F. Traction Pressure w/ 50% S.F.
Snub vs Traction Pressure

Terry Watts
Page 7 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Traction Pressure Settings for HR 480 - Pipe Heavy

This recommended traction pressure chart shows a range of pressures for a
given tubing load. This chart does not imply that it is possible to pull at the top of
the band for a given pressure. The chart indicates a range of values
corresponding to varying conditions such as.
Tubing Ovality
Tubing Surface Conditions

Oil Grease
Frac Dirt
Sand
Insert Conditions
Worn Scarred
The chart denotes that at a given traction pressure the injector should pull
somewhere in the band depending upon the above conditions. The values found
by using the chart are adequate under most conditions. It should be noted,
however, that conditions for each job are unique and deviations from the chart
values may be required.

Terry Watts
Page 8 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Pull vs. Traction Pressure

HR480
2500
Tr action Pr e s s u r e (ps i)
2000
1500 B
1000
500
A
0
Injector Pull (lbs)

Terry Watts
Page 9 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Pull Vs. Traction Pressure
Example:
To obtain tubing pull of 40,000 lb locate the injector pull on the bottom of the chart, read
the corresponding traction pressure on the left side of chart. Traction pressure should
be between 750 psi (A) and 1000 psi (B) depending upon operating conditions.

Terry Watts
Page 10 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Injector Operation For HR 480 - Snub

In no or low pressure application, standard operating procedure is to minimize
chain tension and traction pressure to maximize chain and injector life. In a high-
pressure (snub or pipe light) application, the primary consideration is to hold onto
the pipe.

Terry Watts
Page 11 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Snubvs. TractionPressure
HR480
3000
2500
2000
1500
1000
500
SnubbingLoad(lbs)
TractionPressure w/20%S.F. TractionPressure w/50%S.F.
Snub Vs Traction Pressure

Terry Watts
Page 12 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Maintenance
Proper equipment maintenance is important in any operation and is critical in a
high-pressure application.
WARNING
DO NOT OPERATE THE INJECTOR WITH STRETCHED OR

WORN CHAINS, THIS CAN CAUSE THE TENSIONING
CYLINDERS TO BOTTOM OUT AND WILL CAUSE DAMAGE TO
THE EQUIPMENT OR PERSONNEL
Complex Jobs
Some coiled tubing jobs can become complex and difficult to understand either in
the planning or execution stage. Various combinations of forces or pressures
can interact to create uncertainty. Any high pressure coiled tubing job should
be planned and executed with the same care and attention to detail as a
snubbing job. Hydra Rig service technicians or engineers can assist with
information regarding Hydra Rig equipment. Hydra Rigs sister company, CTES,
L.C. (Coiled Tubing Engineering Services) can assist with engineering services
related to the combined effects or ovality, fatigue, buckling, burst, collapse, and
tensile loadings.

Terry Watts
Page 13 of 13
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: Tubing Reel, right angle drive
REFERENCE: Cargo handling
Purpose:
This PSB provides inspection, protection, and upgrading of Hydra-Rigs 4000
series tubing reels.
Introduction/History:
There has been an incident of a tubing reel drive failure on a 4000 series-tubing
reel. The failure occurred because the load binders supplied on the reel were not
used to mechanically lock the reel to the frame during transportation. As the reel
rocked back and forth, shock loads from the rotational inertia acted through the
reel drive chain and caused the right angle drive to fail at the output housing. This
failure caused the drive to lock up and fail the drive chain.
This reel is designed so that the spring-actuated brake is supplied with no hydraulic
pressure in the system. It is either on or off. The brake is a parking brake used to
hold the reel from rotating when the injector is stopped during the coiled tubing
operation. It is not a dynamic brake and was not designed for shock loading as
encountered during transport.
Safeguards:
1- Ensure that the load binders are in use and tightened correctly for
transportation or storage. The rear load binder should be tightened first
to take the load off the drive and brake and then the front binder should
be secured to prevent reel rotation during transport.
2- Visually inspect the output housing of the reel drive prior to operation.
3- Perform periodic NDE (magnetic particle inspection) to prove structural
integrity on the output housing.

H. Barzin
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Upgrade:
An upgraded right angle drive may be purchased to provide increased
safety factor in the right angle drive out put housing. This kit will not
eliminate the need for use of load binders during transport, but will increase
overall fatigue life of the assembly.
Recommended 4000 series Tubing Reels for upgrading:

Job Number Part Number
29558 CD400013
29559 CD400013
35608 CD400041
35616 CD400041
25204 CE400114
27847 CE400114
29533 CE400114
30144 CE400114
38717 CE400114
39117 CE400114
39175 CE400114
28854 CE400124-0001
31019 CE400124-0003
31020 CE400124-0003
31721 CE400124-0004
32446 CE400124-0004
37023 CE400124-0006
38162 CE400124-0007
38170 CE400124-0007
27611 CE400131
To order contact:
Please contact inside sales group,
Phone #: 817-446-2326 and ask for Bernie Smith.
E-mail: bernies@mail.net
H. Barzin
Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Upgrade to drawing number CB412688 Rev. 0

1 EA CC462634, mount drive machining
1 EA TGR00022, reducer gear angle right
10 EA BFC00070, HHCS
10 EA BFW00005, washer lock split
10 EA BFN00033, nut hex STD
1 EA CC472635, sprocket drive weldment

H. Barzin
Page 3 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR480 Injectors (all versions)
REFERENCE: Retainer Bar CB370266
The retainer bar was originally designed into the 480 injector as an aid in assembling
the skate system. The intention was for the retainer to hold the skate hangers in place
so that the skate could be lowered into place between the hangers. As an assembly aid,
this feature is not really necessary, and for field redress, the change-out of the skates
would occur with the drive case mounted to the injector and the retainer bars would
have to be removed.
There can also be clearance problems between the retainer bars and the hydraulic
fittings that transmit hydraulic pressure to the traction cylinders. Notches in the retainer
bars are designed to provide clearance between the fittings and the retainer bars. If
improper assembly occurs, the fittings can contact the retainer bar and cause the fitting
to fail upon the application of pressure to the traction system. This interference could
also cause the traction cylinder to cock that could cause uneven loading to the skate.
The retainer bars add no structural integrity, and have proven not to be useful as an
assembly aid. Additionally, if assembled incorrectly, the retainer bars could cause
problems in the traction system. Therefore, Hydra Rig recommends that the retainer
bars be removed from all 480 injectors as soon as possible.
There are four retainer bars on each injector. One attached at each skate hanger area.
(see illustrations). There are four half-inch bolts attaching each retainer bar. Remove all
four bolts and discard the retainer bars.
If your injector is currently working on a job a quick inspection will determine if there is
interference between the retainer bar and the hydraulic fittings. If there is no
interference continue the job as you are and remove the retainer bars at your earliest
opportunity.
If you are unsure about where the retainer bars are on the injector or have any
questions regarding the removal of the retainer bars please contact us before you
proceed.
Hydra Rig, A Tuboscope Company

6000 East Berry Street ph: 817-457-3825
Fort Worth, Texas, USA ph: 817-457-1521 (24 hour emergency)
PO Box 15951 hriservice@hydrarig.com

Date: May 20, 1999
Richard Russel
Page 1 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: May 20, 1999
Richard Russel
Page 2 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: May 20, 1999
Richard Russel
Page 3 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: May 20, 1999
Richard Russel
Page 4 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
RECEIPT ACKNOWLEDGEMENT
Customer Name ______________________________
Date of Response _____________________________

Fax: (817) 457-1472

Date: May 20, 1999
Richard Russel
Page 5 of 5
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT:
REFERENCE: HR480 TRACTION RETROFIT KIT CC365636
As a result of recent developments and widespread use of higher strength, heavier wall
large diameter coiled tubing, Hydra Rig has developed an improved traction beam
system to handle the increased loads imposed by this pipe. For those operating
HR480s, a kit has been designed to retrofit existing injectors.
The new traction system consists of newly designed traction beams (CC365287) and tie
rods (CC375252). These new traction system components are designed as a single unit
and are thus required to be used together for proper functioning (mixing of old traction
system components with new is prohibited). Additionally, all six sets of beams and rods
must be replaced. The traction beams are of a cast design that maximizes the bending
strength of the beam and minimize the defections under load. The tie rods are
constructed of high strength steel and are designed to maximize the clearance between
the tie rod and chain assembly while providing the structural strength required for this
service.
This system will retrofit all HR 480 injectors built after October 1993.
The kit part number CC360075 consists of:
(12) Traction Beams (CC365287)

(12) Traction Rods (CC375252)
(24) Nylock Nuts (BFN00041)
(24) Tube Bushings (CB360137)
(12) HHCS 0.50 x 6.0 Lg. (BFC00607)
(12) 0.50 Lock Washer (BFW0005)
(12) 0.50 Washer PL Type B Series R STL (BFW00035)
(1) Installation blueprint (CC365636)
The list price for the kit is 3400.00USD, but until November 30, 1999 the kit will be sold
at half price 1700.00USD. Any kits ordered after December 1, 1999 will be at full price.
To get this price reduction you must supply Hydra Rig with the serial number of the
injector that you are planning on using the kit on. If you are purchasing the kit for spares
we also need that information.

Date:
Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Orders for the kit will be accepted now with the estimated delivery time of eight weeks.
Again, to take advantage of the half price offer you must supply the serial number of the
injector the kit is intended for at the time the order is placed.
Any questions regarding this PSB or any other PSB can be directed to the Field Service
department at Hydra Rig.
Hydra Rig
A Tuboscope Company
Fort Worth, Texas, USA 76119
P.O. Box 15951
Phone (817) 457-3825

Fax (817) 457-1472
E-mail hriservice@hydrarig.com

Date:
Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REFERENCE: Brake spacer spool plumbing

All HR440 injectors built prior to December 1, 1999 were built plumbed so that the motor
case drain is routed into the spacer spool between the brake and the drivecase. This
was done to allow leakage from the brake seal to make its back to the hydraulic tank
through the case drain hose. Plumbing the spool in this manner made it necessary to
seal the area between the drive shaft and the brake shaft. Because of very low pressure
and the design of the joint this area is very difficult if not impossible to seal and to make
the seal last for an extended length of time. There are two major disadvantages of
plumbing the injector in this manner.
1. The seal between the drive shaft and the brake shaft fails frequently which gives
the appearance that the injector brake shaft is leaking large quantities of oil and
is on the verge of failure, when actually the case drain oil is what is leaking.
2. There is no physical evidence that can be seen by the operator that the brake
shaft seal is leaking and is in need of attention.
To correct both of these problems we have changed the way we plumb the 440 injector.
The spacer spool between the brake and the drivecase is no longer plumbed into the
case drain of the motors. It is now plumbed to atmosphere via stainless steel tubing.
The tubing is formed so that the end is inside the injector center section. A flow of
hydraulic fluid coming from these tubes indicates that the brake shaft seals are leaking
and are in need of maintenance.
To make this modification to heads already in the field the following steps should be
taken.
Locate the .25 inch case drain hose that connects to the spool. It will be about halfway
between the brake and the drivecase on the top side of the spool. Remove this hose
and the adapters that are screwed into the spool. Trace this hose to find the other end.
Remove this end of the hose as well from its fitting and replace it with a .25 inch JIC
cap. A brass or steel cap can be used as this will always be low pressure. Connect one
of the formed tubes to each spool using the required adapters. Discard the hose that
was removed.
See the illustrations for instruction on how to form the tubes and for how to install the
tubes.
Date: 12-15-1999
Richard Russell
Page 1 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: 12-15-1999
Richard Russell
Page 2 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: 12-15-1999
Richard Russell
Page 3 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
If you wish to order the required parts from HR you need to order one CC365966 per
HR440 injector.
If you have questions about this or any other PSB please contact the Field Service
Department.
Hydra Rig
A Varco Company
PO box 15951
817-457-3825 phone
817-457-1472 fax
hriservice@varco.com

Date: 12-15-1999
Richard Russell
Page 4 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
REFERENCE: Rail type inserts and carriers
As of January 1, 2000 HR discontinued production of the rail type carrier for the 440
injector. Our intention is to standardize on one style, the clip style of insert and carrier.
This will eliminate confusion when ordering parts from the field and insure correctness
of spare parts shipments as well as reduce inventory for those locations that run both
rail and clip style.
Rail type inserts will remain available until June 30, 2000.
If your injector utilizing rail type carriers is less than six months old, or if you have
purchased a replacement rail type chain assembly in the past six months, we offer the
following two plans to get you converted over to clip type inserts and carriers.
1. We will provide you with a blue print that will enable you to modify the rail type
carrier to accept clip type inserts. Note that when this machining process is
completed, the carrier will accept both rail and clip type inserts. The first set of clip
type inserts that you order will be reduced in price by 600.00$ to offset the cost of
this modification.
2. We will send you a set of modified carriers in exchange for your rail type carriers.
HR will modify the carriers and continue the exchange program. Note that the
carriers sent back must be in good condition and are subject to inspection. Any
carriers that are not usable will be returned to the supplier.
If your injector is older than six months we will supply you with a blue print that will
enable you to modify your rail type carriers to accept the clip type inserts. You can
disassemble your chains and send the carriers to HR and we will modify them to accept
the clip type inserts for a cost of $8.50 each. If the entire chain is sent you will be
charged labor for disassembling and reassembling the chain.
After June 30, 2000 Hydra Rig will no longer manufacture rail type inserts. Please take
advantage of this offer and allow yourselves time to prepare for this discontinuance.

Date: 2-10-00
Richard Russell
Page 1 of 1
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: Hydra Rig Coiled Tubing units and Nitrogen units
REFERENCE: Hydraulic Tank Assembly
Over the past several years HR has been incorporating the Denison P-16 pump into the
design of our Coiled Tubing units as well as our Nitrogen units. One of the problems
that exist with using this pump is that they must be supercharged with oil because of
their inability to suck oil from the hydraulic tank.
To correct this Hydra Rig uses a check valve and a relief valve that are mounted inside
the hydraulic tank. Oil is returned into the P-16 from other circuits to produce this
supercharge pressure. The relief valve in the tank keeps the supercharge pressure from
over pressurizing the system and the check valve is arranged so that if the pump needs
to suck oil momentarily it can do that.
We have been made aware of two instances where this plumbing inside the hydraulic
tank has come off or was found to be loose. When this occurs the supercharge pressure
is lost and pump cavitates. This being a piston pump even slight cavitation will cause
damage.
HR is taking measures on future units to see that this problem is not encountered. To
see that units currently in the field do not develop this problem, we ask that all locations
that have a unit using a P-16 inspect the unit to ensure that the valves in the tank are
still tight.
There are two drawings attached to this PSB. They depict the most common
arrangement for the relief valve and check valve that are mounted inside the hydraulic
tank.
N2 hydraulic tank: 180K units using a single P-16 pump.

CTU hydraulic tank: Coiled Tubing Power Pack.
If either of the valves is found to be loose they must be tightened to ensure that they do
not come completely off during operations.

Date: 3-21-01
Richard Russell
Page 1 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
To correct loose valves the hydraulic tank must be drained to a level below the valves
and fittings that the valves are threaded on. After the tank level is lowered remove the
valves and clean both the internal and external threads to remove all oil. The relief valve
can be replaced using pipe sealant that you would normally use for any other pipe
connection. Remember that this connection will be below the oil level in the tank and
cleanliness is a must. After the sealant is applied tighten the relief valve as tight as
possible using a pipe wrench on the lower part of the valve. Do not use the hex on the
cap to tighten the entire valve. If the check valve is loose, remove it from the pipe nipple
it is mounted on and clean both the internal and external threads. On the end of the
valve that the pipe nipple threads into drill and tap a hole for a -20 set screw or
equivalent on three of the wrench flats. Again use pipe sealant before reinstalling the
check valve. After the valve is tight on the pipe threads tighten the three setscrews.
Refill the hydraulic tank and resume operations.

Date: 3-21-01
Richard Russell
Page 2 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: 3-21-01
Richard Russell
Page 3 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472

Date: 3-21-01
Richard Russell
Page 4 of 4
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: HR560, HR580 and HR5100
REFERENCE: Maximum Allowable speed of variable speed injectors
Hydra Rig has a new line of injector that incorporates a variable displacement motor into
the drive system. In the past all HR injectors have used motors that have a high gear
and a low gear.
The drive system for the new design injector is a variable displacement piston motor
through a sandwich type brake into a deep reduction gearbox. The maximum speed for
the new design HR440G and the HR560 is 200 feet per minute. Over speeding will
cause damage to the brake and drive system.
There are some HR Coiled Tubing units that are capable of over speeding the injectors.
For instance, If you had one of the variable speed injectors that was set up to run 200
FPM with a supply of 90GPM and you coupled this injector to a closed loop power pack
that uses a Denison P-14, that is capable of supplying 120 GPM to the injector you
would have the capability to over speed the injector by a great deal.
Because of this possibility, we suggest that anytime the variable speed injector is
moved from one unit to another or to a power unit that is not manufactured by HR, that
a test be run to determine if the unit is capable of running the injector at speeds in
excess of maximum.
To test the injector, first connect it to the CTU. Plug in all hoses. Paint or otherwise mark
one chain pin so that each revolution of the chain can be counted when running at
maximum speed. Start the engine and increase the RPM to 1800. Make certain that the
chain traction circuit is bled off to 0-PSI. Apply 150-PSI chain tension pressure. Shift the
injector directional control all the way in either direction. Screw in the injector motor
pressure control until the chains stop increasing in speed. With a stop watch, measure
the amount of time it takes to turn 10 complete revs. If this time is less than 34 seconds,
the injector is over speeding. Repeat the procedure only shift the injector in the other
direction. The speed should be the same in both directions.
The Rexroth motors used on the injectors have adjustments on them that allow the
minimum and maximum displacement to be set so that the motor will operate in a
specific range. These adjustments cannot be made in the field. The adjustment will
come with a factory-installed cap on them. The cap cannot be removed without damage

Date: 9-17-01
Richard Russell
Page 1 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
to the cap. Any warranty claims on injectors with this cap removed or damaged will be
denied.
Although the speed of the injector can be limited by the amount that you shift the
injector directional control, we recommend that you limit the amount of flow that the
hydraulic pump is capable of sending to the injector. All hydraulic pumps that we have
used that are capable of 5000-PSI have flow limiters on them. If you find that you have
the capability to over speed your injector contact HR service department for instruction
on how to limit the flow your pump is capable of sending to the injector. Please have the
serial number of your power pack handy before you contact us.
We can be reached by any of the following means

8:00 AM to 5:00 PM Monday through Friday 817-457-3825
After hours 817-457-1521
Fax during normal hours 817-457-1472
e-mail hriservice@varco.com

Date: 9-17-01
Richard Russell
Page 2 of 2
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
PRODUCT: 180 K nitrogen pumping units
REFERENCE: Denison P16 H Hydraulic Pumps

It has been brought to our attention that this hydraulic pump may overheat during long
periods of idling. For 180 K nitrogen units, this pump is configured such that it is not a
pressure compensated pump, which means that there is very little flow through the
pump case when the pump is idling for extended periods or when not driving the triplex
pump.
Denisons solution to this problem is to add a flushing and cooling circuit that consists of
a .25-inch hose from port AG to port DG on the pump. A kit will be sent to every
location where one of our 180K nitrogen units are located.
This kit will consist of:

Qty. 1 - .25 inch hose 15 inches long straight on one end 90 degree on the other end
Qty. 1 - .25 o-ring X .25 MJIC 90 degree fitting
Qty. 1 - .25 inch o-ring by .25 MJIC tee.
These parts are to be installed as per the attached illustration and the unit may be
placed back in service.

Date: 10-22-02
Richard Russell
Page 1 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Port DG
Port AG

Date: 10-22-02
Richard Russell
Page 2 of 3
Hydra Rig, Inc.
Ph: 817-457-3825
Fx: 817-457-1472
Port DG Port AG
.25 Hose

Date: 10-22-02
Richard Russell
Page 3 of 3
Hydra Rig
1020 Everman Parkway
Fort Worth, TX, USA 76140
817-985-5000 Phone
817-985-5282 Fax
PRODUCT: Hydra Rig 500 series injectors

HR560, HR580, and HR5100
REFERENCE: Input pinion bearing operating temperature

A catastrophic failure has occurred with an HR580 injector. Control of the tubing was lost due to a
failed gearbox input pinion bearing allowing the input pinion to disengage from the first driven gear.
The motor and brake on the 500 series injectors are connected to the inputs of the gearbox and thus
are connected to the chain through the gearbox. The injector can and will freewheel if gear
engagement is lost.
As on most coiled tubing rig-ups these days, this injector was rigged up fairly high and there was
other equipment such as cranes and pump units sitting next to the CT unit operating, making it nearly
impossible for the operator to hear the injector running. In this failure, there was an area of charred
paint in the bearing housing, but this area is situated 90 degrees from the operators line of view to
the injector.
The cause of this bearing failure has not yet been determined, but studies into this are ongoing at
Hydra Rig, the gearbox manufacturer, and at the bearing manufacturer. While this injector had
several million feet on it, the bearing use before failure was only a portion of what its full life should
have been.
In an effort to keep this from happening on other injectors, Hydra Rig is supplying a stick on
temperature indicator for every 500 series injector in the field.
This temperature sticker is to be placed on the gearbox close to the input pinion bearing. If this
sticker changes colors it indicates that the bearing has failed and the injector should be shut down
immediately. At that point, Hydra Rigs Service department should be notified by phone, fax, or
email.
Phone: 817-985-5000 Ext 5115

Fax: 817-985-528
E-mail: rrussell@varco.com
gbrewer@varco.com
tbarnes@varco.com
Enclosed is a drawing of the temperature sticker itself and a label explaining the temperature sticker
as well as proper placement of the sticker and installation instructions.

Date: 09/14/04
Page 1 of 3
Hydra Rig
817-985-5000 Phone
817-985-5282 Fax
Injector Serial number ________________________________________________
Hubometer reading ________________________________________________
Company and Location _______________________________________________
Mailing Address ________________________________________________
Shipping Address ________________________________________________
Contact Name _____________________________________________________
Contact Phone Number ______________________________________________

Date: 09/14/04
Page 2 of 3
Hydra Rig
817-985-5000 Phone
817-985-5282 Fax

Date: 09/14/04
Page 3 of 3
Hydra Rig
Boundary Road
Harfreys Industrial Estate
Great Yarmouth
Norfolk
NR31 OLW
United Kingdom
Tele: 44-1493-651-801
Fax: 44-1493-651805
service@hydrarig.co.uk
PRODUCT: Coiled Tubing Power Packs and Nitrogen Units Supplied by HRUK
REFERENCE: 3 and 4 Butterfly Valves
It has come to our attention that in some instances the 3 and 4 inch butterfly valves
used to isolate the suctions on hydraulic tanks on some Coiled Tubing Power Packs
and Nitrogen Units may have been inadvertently supplied with the incorrect seal or seat
material. When exposed to hydraulic oil the seal or seat material can prematurely
deteriorate and cause failure.
We recommend that the seal or seat material be checked as soon as possible.

The seal or seat material can be identified by checking the tag on the stem of the valve.
The seal or seat material should be noted as NBR on the tag. If the tag has NBR on it
no further action is required. If the seal or seat is noted as EPDM on the tag or cannot
be identified please contact Hydra Rig UK Service Department with the size and
quantity of the valves you have with the incorrect seal or seat material. A replacement
valve will be supplied to you.
Hydra Rig UK Service Department

service@hydrarig.co.uk
Tele: 44-1493-651801
Fax: 44-1493-651805

Date: 9-2-04
None
Page 1 of 1
Hydra Rig
PH: 817-985-5000
Fax: 817-985-5282
PRODUCT: HR580, HR560, and HR440G injectors
REFERENCE: Gearbox bearings
A problem has been discovered in Hydra Rig HR580 injector gearboxes manufactured
by one of our suppliers. The problem results in inadequate lubrication to the bearing on
the input pinion opposite the drive motor and brake. In operation, the bearing can
literally pump itself dry. This condition can eventually cause failure of the bearing
depending on many factors, including speed, gearbox footage, loading, temperature,
lube oil level, and maintenance. If left unattended the bearing failure can cause the input
shaft to disconnect from the secondary gears, which will allow the injector to
freewheel.
Although each individual gearbox has the possibility of this bearing failing, field
history of the injectors has shown that damage progresses slowly, and is in fact
uncommon. For these reasons we are not recommending that the injectors be taken out
of service. However, we are recommending that the following actions be taken as soon
as possible.
First Priority: HR580 Gearboxes
Injector Information & Inspection Survey

It is imperative that the survey (enclosed) be completed for every HR580 injector
in your fleet. The completed forms should be sent to Hydra Rig following the
instructions on the form. These forms will be used to produce a schedule to get
your injector inspected and/or upgraded. After receipt of your form, we will
contact you and arrange for a technician to come to your location. We may also
ask that you make simple modifications that will help with the bearing lubrication
until we can get there.
Hydra Rig will inspect and/or upgrade the bearing lubrication on all HR580 injectors in
the field that we have an information form on. Completing the information form on your
injector is the most reliable means to be sure your injector is scheduled. All of the
inspections/upgrades combined will take about 8 hours once the injector is in a location
where we can work on it. To complete the work, we must remove the outer protection
frame, drain the gearbox, and lay the injector on its side. The serial number of the
gearbox and injector will determine what needs to be done to make sure your injector
has all the upgrades. These actions will be taken under Hydra Rig warranty. All injectors
with a ship date after the published date of this PSB will have all the latest upgrades.
Page 1 of 5
Hydra Rig
PH: 817-985-5000
Fax: 817-985-5282
Second Priority: HR440G and HR560 Gearboxes
We have not experienced any freewheel type failures with the HR560 or HR440G
injectors in the field. HR440G injectors have been in service since January 1999 and
HR560 injectors have been in service since January 2001. However, a similar bearing
problem could exist with these injectors. Once the HR580 injectors are inspected and
upgraded, Hydra Rig will inspect all HR560 and HR440G injectors in the field. If the
bearing lubrication problem exists with these injectors, Hydra Rig will cover warranty
costs on these upgrades as well. At the same time an overall maintenance survey will
be performed on these injectors to produce a condition report versus total footage (from
the hubometer readings) to give both Hydra Rig and users base line data for future
maintenance or rebuild programs versus total footage.
Therefore, we request that the Injector Information & Inspection Survey be

completed for HR560 and HR440G injectors as above.
The Injector Information & Inspection Survey on the next page can be returned to
one of the email addresses listed below or faxed to the number listed below.
Email:
rrussell@varco.com
hriservice@varco.com
hrisales@varco.com
Fax:
817-985-5282
Attention: Service Department

Page 2 of 5
Hydra Rig
PH: 817-985-5000
Fax: 817-985-5282
Injector Information & Inspection Survey

CLICK INSIDE SHADED AREA TO FILL IN INFORMATION
Injector model number (HR440G, HR560, or HR580):
Injector Order Number:

(Found on Stainless Steel plate mounted to the front of the outer protection frame)
Gearbox serial number:

(Found on plate mounted to the side of the gearbox opposite the drive motor)
Hubometer reading:
Pinion shaft end play (See the enclosed end play measuring procedure)
Input Pinion:
First Reduction:
Second Reduction:
First Output:
Second Output:
Spline Visual inspection (new condition, very little wear, normal wear, excessive wear)
Please include digital photos
Pinion internal splines:
Brake external splines:
Brake internal splines:
Motor external splines:
Location of Injector (Country, State, and city):

Contact Person:
Phone number:
Fax number:
Email address:

Page 3 of 5
Hydra Rig
PH: 817-985-5000
Fax: 817-985-5282
End Play Measurement Procedure

TOOLS REQUIRED:
Standard allen wrench set
Dead blow mallet
One -13 UNC bolt 2.5 inches long
inch end wrench
Dial indicator
Magnetic base for dial indicator
Crowbar
1. Remove the outer protection frame from the injector.

2. Drain the oil out of the injector gearbox.
3. Remove the motor and brake. Visually inspect and take pictures of all splines.
The pictures need to be sent in with the Injector Information & Inspection Survey
4. Very carefully lay the injector on its side with the motor and brake side down.
5. On the cover of the gearbox, which is now pointed up, are five 3/8 inch pipe
plugs. The plugs are the center of each shaft in the injector gearbox. Remove all
of the pipe plugs and save for reuse when this procedure is complete.
6. Start on the input shaft in the gearbox. (Same shaft the brake mates up with)
7. Thread the -13 UNC bolt into the end of the shaft through the hole where the
pipe plug was. This bolt does not have to be extremely tight but does need to be
snug.
8. With the mallet hit the head of the bolt to ensure that the shaft being measured is
completely bottomed out in the bearing race on the opposite side of the gearbox.
9. Set up the dial indicator attached to the magnetic base on the head of the -13
bolt, tighten all the connections on the dial indicator and base.
10. Zero the dial indicator
11. Place the crowbar under the head of the -13 bolt and pry upwards firmly but not
excessively. (See detail A)
12. Record the amount of travel in the shaft on the survey sheet.
13. Repeat this procedure for each shaft.
14. When complete reinstall the pipe plugs.
15. Refill gearbox
16. Reinstall outer protection frame.

Page 4 of 5
Hydra Rig
PH: 817-985-5000
Fax: 817-985-5282
FIGURE A

Page 5 of 5
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282

PRODUCT: All Tubing Reels
REFERENCE: Reel Swivel Bolted Joint Connections
It is important that the fasteners that attach the swivels to the reel stub shafts be
installed and kept tight to assure maximum life and safety of the connection. It has
come to our attention that some information supplied in our manuals is incomplete or in
some cases inaccurate. It is necessary, therefore, to immediately check the condition of
your Hydra Rig reel(s) using the following guidelines.
Reels with 1.25, 1.5, and 2 bore swivels rated at 10,000 psi working pressures use
13 UNC studs and nuts. The studs should be Hydra Rig part number BFA00009 which
is an L-7 grade stud identified with L-7 stamped on the end. These should be checked
to be in good condition and tightened using Torque Specification P/N CA420369, copy
attached. The nuts and washers are P/N BFN00033 and BFW00005, respectively. A
complete fastener kit for mounting the swivel, including Loctite, anti Seize, and face seal
for the 1.25 swivel is CA420374. The fastener kit for the 1.5 is CA420370 and for the
2 it is CA420372.
Reels with 1.5 bore swivels rated at 15,000 psi working pressures use 5/8 11 UNC
studs and nuts. The studs should be Hydra Rig part number BFA00069 which is an L-7
grade stud identified with L-7 stamped on the end. These should be checked to be in
good condition and tightened using Torque Specification CA420368, copy attached.
The nuts and washers are P/N BFN00086 and BFW00007, respectively. A complete
fastener kit for mounting the swivel, including Loctite, Anti Seize, and face seal is
CA420371.
Note: If there is any doubt that the fasteners are not genuine Hydra Rig components in
good condition, we recommend replacing them. A click type micro adjustable open end
torque wrench for applying proper torque to both of these stud sizes is available from
Hydra Rig by ordering P/N CA420373.
The fasteners attaching the swivels to the reel stub shaft should be checked periodically
for proper tightness as outlined above. Any time the swivels are removed and
replaced, it is important to follow the tightening procedures above.
If there are any questions, please contact Hydra Rig Service Department.

Date: February 18, 2005
Page 1 of 3
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282

Swivel Bolted Joint Torque Procedure
The nuts attaching the swivel to the reel shaft should be tightened according to the following
procedure.
1. Inspect the studs and nuts for condition and to make sure that they are the correct
fasteners called out on the assembly print.
2. When installing or replacing the studs into the reel stub shaft, anchor the studs with
Loctite.
3. Clean the mounting faces and packing bore of any loose debris.
4. Coat the face seal and mounting faces with grease.
5. Lubricate the threads with Anti Seize.
6. Tighten the nuts with an open end torque wrench like a Kell Strom Sturtevant Richmont
micrometer adjustable torque wrench or equivalent evenly, following the sequence
below. First snug the joint up by applying 20 foot-pounds, then torque each nut to 80
foot-pounds.
7. Any time the swivel is removed and/or replaced, it is important to follow these
installation procedures.
2 10,000 psi Bolt Pattern 1/ and 1 10, 000 psi Bolt Pattern
DESCRIPTION:
TORQUE SPECIFICATION 1.25, 1.5" & 2" 10K SWIVEL
PRODUCT LINE: CTU
DATE: 2/16/5 NEXT ASSEMBLY:

REVISION: .

Page 2 of 3
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282

PAGE 3 OF 3 ENGINEER: DWM PART NUMBER: CA420369
Swivel Bolted Joint Torque Procedure
The nuts attaching the swivel to the reel shaft should be tightened according to the following
procedure.
1. Inspect the studs and nuts for condition and to make sure that they are the correct
fasteners called out on the assembly print.
2. When installing or replacing the studs into the reel stub shaft, anchor the studs with Loctite.
3. Clean the mounting faces and packing bore of any loose debris.
4. Coat the face seal and mounting faces with grease.
5. Lubricate the threads with Anti Seize.
6. Tighten the nuts with an open end torque wrench like a Kell Strom Sturtevant Richmont
micrometer adjustable torque wrench or equivalent evenly, following the sequence below.
First snug the joint up by applying 20 foot-pounds, then torque each nut to 150 foot-pounds.
7. Any time the swivel is removed and/or replaced, it is important to follow these installation
procedures.
1 15,000 psi Bolt Pattern
DESCRIPTION:
TORQUE SPECIFICATION 1.5" 15K SWIVELS
PRODUCT LINE: CTU
DATE: 2/16/5 NEXT ASSEMBLY:

REVISION: .
PAGE 3 OF 3 ENGINEER: DWM PART NUMBER: CA420368

Page 3 of 3
CLARIFICATION
The fastener kits referenced on page one of PSB 132 include studs, nuts, washers,
Loctite, anti seize, and a face seal.
The torque wrench referenced, P/N CA420373, includes crows feet or wrench adapters
for both size nuts 3/4 and 15/16.
The PSB as it appears on the website www.hydrarig.com includes these clarifications.

Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
PRODUCT: All 6-Series Injectors
REFERENCE: Chain Tension Installation

This PSB is a follow up to PIB 14, issued at the beginning of October 2006.
A retrofit kit has been designed and tested to correct the problem of the tension shafts
walking out on the 6-Series injectors. For every injector in the field, Hydra Rig will
supply a retrofit kit containing two replacement tension sprockets, two tension shafts,
and four tension bearings. This kit will be pre-assembled and have step by step
instructions for proper installation included.
The original connection between the shaft and sprockets, and the connection
between the shaft and bearings, were a slip fit. Starting mid-November 2006, both
of these connections were changed to a press fit.
In addition to the retrofit kits, Hydra Rig will supply a Technician to remove the original
parts, install the retrofit kit, test the assembly, and return the original idler sprockets to
Hydra Rig. However, there are a limited number of technicians. The technicians will be
dispatched in an order to ensure that the total down time for all our customers is kept to
a minimum. Technicians will not be dispatched until the retrofit parts are verified to be
where the work is to be completed.
Hydra Rig will also assist our customers to install the retrofit kit themselves if a
technician is not available in the time frame needed by the customer. The supplied
retrofit kit includes a drawing with step by step instructions and Hydra Rig Service will
support questions by e-mail or phone during the installation. Once the retrofit kit is
installed, the idler sprockets are to be returned, at Hydra Rigs expense, through
Hydra Rig Service. Any warranties on the injector will not be affected by customer
installation as long as the step by step instructions are followed.

Page 1 of 2
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
Please complete the form below for every injector to begin the retrofit process, then fax
or email it to the following:
Email: Richard.Russell@nov.com Fax 817-985-5282
Customer: _________________________________________
Location: _________________________________________
Bill To Address: _________________________________________
_________________________________________
_________________________________________
_________________________________________
Location: _______________________________________
Ship To Address: _______________________________________
(Physical Address) _______________________________________
_______________________________________
_______________________________________
_______________________________________
Contact at Ship To Address: _________________________________________

Phone Number: _________________________________________
Fax Number: _________________________________________
Email Address: _________________________________________
Injector Part Number: _________________________________________

Injector Order Number: _________________________________________
Date of Manufacture: _________________________________________
Does this injector show signs of any tension shafts having moved horizontally? _
________________________________________
Suggested Means of Shipment:_______________________________________

Page 2 of 2
Fort Worth, Texas, USA 76140
Phone 817-985-5000
Fax 817-985-5282
Product Service Bulletin

PSB # 133
Product Line: All 6-Series Injectors
Reference: Chain Tension Installation
This PSB is a follow up to PIB 14, issued at the beginning of October

2006.
A retrofit kit has been designed and tested to correct the problem of the
tension shafts walking out on the 6-Series injectors. For every injector in
the field, Hydra Rig will supply a retrofit kit containing two replacement
tension sprockets, two tension shafts, and four tension bearings. This kit
will be pre-assembled and have step by step instructions for proper
installation included.
The original connection between the shaft and sprockets, and the
connection between the shaft and bearings, were a slip fit. Starting mid-
November 2006, both of these connections were changed to a press fit.
In addition to the retrofit kits, Hydra Rig will supply a Technician to
remove the original parts, install the retrofit kit, test the assembly, and return
the original idler sprockets to Hydra Rig. However, there are a limited
number of technicians. The technicians will be dispatched in an order to
ensure that the total down time for all our customers is kept to a minimum.
Technicians will not be dispatched until the retrofit parts are verified to be
where the work is to be completed.
Hydra Rig will also assist our customers to install the retrofit kit
themselves if a technician is not available in the time frame needed by the
customer. The supplied retrofit kit includes a drawing with step by step
instructions and Hydra Rig Service will support questions by e-mail or
phone during the installation. Once the retrofit kit is installed, the idler
sprockets are to be returned, at Hydra Rigs expense, through Hydra Rig
Service. Any warranties on the injector will not be affected by customer
installation as long as the step by step instructions are followed.
Please complete the form below for every injector to begin the retrofit
process, then fax or email it to the following:
Email richard.russell@nov.com
Fax 817-985-5282
Customer __________________________________________
Location: ________________________________
Bill To Address ________________________________
________________________________
________________________________
________________________________
Location: ________________________________
Ship To Address ________________________________
(Physical Address) ________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Contact at Ship To Address ____________________________

Phone Number ______________________________________
Fax Number ______________________________________
Email Address ______________________________________
Injector Part Number __________________________________

Injector Order Number ________________________________
Date of Manufacture _________________________________
Does this injector show signs of any tension shafts having moved
horizontally? ________________________________________
Suggested Means of Shipment ___________________________
Approved by Drawings included PSB # 133
None
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
PRODUCT: All 440G, 560, 580 and 5100 Injectors
REFERENCE: Proper Gearbox Oil Level Clarification
All Hydra Rig injectors listed above use PEM purpose built gearboxes to drive the
injector chains. There may be some confusion in the field about where the gearbox oil
level should be maintained. Each model of the gearboxes listed above has a different
full level, and needs to be checked and maintained carefully. The purpose of this PSB is
to inform everybody in the field operating a 440G or 500 series injector how to properly
maintain the gearbox oil level, and to make any modifications to their gearbox
necessary to maintain the gearbox oil level at the proper level.
Following, there are illustrations of each gearbox. Each illustration will show the proper
location of the sight glass and all related placards. Each gearbox will also be identified
by the Hydra Rig gearbox part number. This same part number is cast into the cover of
each gearbox. If there is doubt about what gearbox you actually have, you can identify it
by matching part numbers. Regardless of the orientation of the sight glass on your
gearbox now, the illustrations in this PSB indicate where the sight glass needs to be, to
properly check for the correct oil level in the gearboxes.
If you determine that your sight glass is not in the location on the following illustrations,
it should be moved to the location pointed out in the illustration.
To successfully accomplish this, the following procedure should be followed
1. Remove the outer protection frame from the injector

2. Drain the oil from the gearbox
3. Lay the injector on its side with the cover up, and the drive motor down.
4. At this point it would be a good idea to check the end play on all the shafts in
the gearbox per the instructions in your manual. These instructions are found in
the maintenance section of the manual referred to as external gear drive
inspection recommended every 2 million running feet. If the bearing end play
needs attention, you can adjust it while the cover is off to move the sight glass.
5. Break the silicone seal on the gearbox cover
6. Lift the cover off of the gearbox and move it to the location where you will drill
and tap the cover
7. Cover the gearbox still attached to the injector with a tarp, or other material to
keep foreign matter out of the gearbox while the cover is being modified

Date: May 1, 2009
Page 1 of 7
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
8. Lay out the desired location for the sight glass using the dimensions on the
illustrations
9. Drill a hole in the cover of the gearbox in the desired location 29/32 (.906)
inches in diameter
10. Tap the hole inch national pipe thread.
11. Clean the inside of the gearbox cover of any drill or tap shavings
12. Clean old silicone off of the cover sealing flange
13. Clean the old silicone off of the mating flange of the gearbox itself.
14. If the end play on the gearbox shafts needed no attention, apply new silicone to
the sealing flange of the gearbox
15. Lower the gearbox cover onto the gearbox using the dowel pins to line it up.
16. Install and tighten all cover bolts.
17. Move the sight glass to the desired location.
18. Install a inch NPT plug in the now open hole.
19. Stand the injector upright
20. Refill gearbox to proper oil level
21. After the gearbox is sealed up if there are numbers on the outside of your gear
box indicating an amount of oil capacity, grind these numbers off. Only grind
deep enough to get the number off.
22. Touch up paint as needed
23. Reinstall outer frame
If your sight glass is found to be in the proper position per the illustrations you then
need check to see if there are numbers cast into the gearbox cover indicating a
specific amount of oil to be filled into the gearbox. If these numbers are present they
should be ground off; in doing this, only grind deep enough to remove the numbers.
Also, you need to check to see if you have the correct oil fill label in the correct
position. If the labels are not correct, you need replace these. Following is a list of
the oil fill label part numbers for each model gear box.
HR440G Oil Fill Label CB312018

HR560 Oil Fill Label CB312018

Date: May 1, 2009
Page 2 of 7
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
Hydra Rig will supply the oil fill label needed for your gearbox free of charge.
When contacting us please have the serial number/order number of your injector
and the serial number of your gearbox available so we can record what labels were
shipped for what injectors. We would also like to have the hubometer reading from
your injector. To obtain this label contact us by any of the following means.
HRIserivce@nov.com
HRIsales@nov.com
Richard.Russell@nov.com
Fax # 817 985-5282
If you need a replacement sight glass it can be ordered using part number HRS00029
If you need to replace the lubricant label it can be ordered using part number CC300755
If you need to replace the heat dot on your gearbox it can be ordered using part
number CD300494.
Some HR5100 injectors may have been shipped without sight glasses. If you
determine that your 5100 injector does not have a sight glass Hydra Rig will supply
one to you to be installed in the location indicated on the illustration free of charge.
To obtain these and the fittings needed to install them please contact us by the
same means as above. When you contact us to obtain these please have the
serial/order number of your injector and the serial number of your gearbox available
so that we can record what parts were shipped for what injector. Although it is not
required we would also like the have the hubometer reading from your injector
If at any time during the execution of the steps to complete this PSB you have any
questions, you can direct those questions to any of the service department
personnel at our Hydra Rig, Fort Worth, Texas office via email, or phone. When
calling by phone between the hours of 8:00 am and 5:00 pm Monday through Friday,
please call 817-985-5000 and ask to speak to a Service Technician. At any other
time please call 817-985-5221 and let the operator know you need service. The
proper email addresses to use are as follows:
Richard.Russell@nov.com Mark.Basham@nov.com
Steve.Dawson@nov.com Bobby.Price@nov.com
Robert.Skinner@nov.com Brad.Brandenberg@nov.com
Jay.Light@nov.com HRIservice@nov.com

Date: May 1, 2009
Page 3 of 7
Approved by:
CAUTION
IF CENTER OF INDICATOR LABEL TURNS
BLACK, STOP RUNNING INJECTOR DRIVE CASE LUBRICANT
IMMEDIATELY AND CALL: (817) 985-5521 AMBIENT TEMPERATURE LUBRICANT
15F - 120F HEAVY DUTY GEARLUBE 85W - 140
-30F - 80F SYNTHETIC HEAVY DUTY GEARLUBE 75W - 90
Drawings included:
Page 4 of 7
PSB Number: 134
Date: May 1, 2009

Hydra Rig
Fx: 817-985-5282
Ph: 817-985-5000
Approved by:
CAUTION
BLACK, STOP RUNNING INJECTOR
IMMEDIATELY AND CALL: (817) 985-5521
DRIVE CASE LUBRICANT

AMBIENT TEMPERATURE LUBRICANT
Drawings included:
Page 5 of 7
PSB Number: 134
Date: May 1, 2009

Hydra Rig
Fx: 817-985-5282
Ph: 817-985-5000
Approved by:
CAUTION

Drawings included:
MODEL 580
CE310364
Page 6 of 7
PSB Number: 134
Date: May 1, 2009

Hydra Rig
Fx: 817-985-5282
Ph: 817-985-5000
Approved by:
CAUTION
IF CENTER OF INDICATOR LABEL TURNS MODEL 5100
IMMEDIATELY AND CALL: (817) 985-5521 CE317789
Drawings included:
Page 7 of 7
PSB Number: 134
Date: May 1, 2009

Hydra Rig
Fx: 817-985-5282
Ph: 817-985-5000
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
PRODUCT SERVICE BULLETIN # 134 Addendum 1
PRODUCT: All 440G, 560, 580 and 5100 Injectors
REFERENCE: Proper Gearbox Oil Level Clarification
After issuing PSB 134, we received customer comments that we considered. As a

result, we are approving an alternative method to check and maintain the proper oil
level in these injector gear drives without relying on the sight glasses.
Remove the oil level sight glass in the gear box and replace with a standard plug.
Then, properly fill the gearbox by removing the fill to plug identified on the attached
drawings (also indicated on the gear cases with the oil level fill to arrow label). With the
injector sitting level, fill the oil into the gearbox to the recommended level. Replace the
fill port plug and fill to port plug (if separate). Proper oil level can then be checked
during subsequent operation intervals by removing the oil level fill to plug and checking
to make sure that the oil level is there.
If you have questions about this PSB, please contact the service department personnel
at our Hydra Rig, Fort Worth, Texas office via email, or phone. When calling by phone
between the hours of 8:00 am and 5:00 pm Monday through Friday, please call 817-
985-5000 and ask to speak to a Service Technician. At any other time please call 817-
985-5221 and let the operator know you need service. The proper email addresses to
use are as follows:
Approved by: Drawings included: PSB Number: 134-1

Date: June 15, 2009
Page 1 of 5
Approved by:
CAUTION
BLACK, STOP RUNNING INJECTOR DRIVE CASE LUBRICANT
IMMEDIATELY AND CALL: (817) 985-5521 AMBIENT TEMPERATURE LUBRICANT
Drawings included:
Page 2 of 5
Hydra Rig
PSB Number: 134-1

Date: June 15, 2009
Fx: 817-985-5282
Ph: 817-985-5000

Approved by:
CAUTION

Drawings included:
Page 3 of 5
Hydra Rig
PSB Number: 134-1

Date: June 15, 2009
Fx: 817-985-5282
Ph: 817-985-5000

Approved by:
CAUTION

MODEL 580
CE310364
Drawings included:
Page 4 of 5
Hydra Rig
PSB Number: 134-1

Date: June 15, 2009
Fx: 817-985-5282
Ph: 817-985-5000

Approved by:
CAUTION
IF CENTER OF INDICATOR LABEL TURNS MODEL 5100
IMMEDIATELY AND CALL: (817) 985-5521 CE317789
Drawings included:
Page 5 of 5
Hydra Rig
PSB Number: 134-1

Date: June 15, 2009
Fx: 817-985-5282
Ph: 817-985-5000

Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
PRODUCT: All Trailer Mounted Injectors
REFERENCE: Safety Latch on Injector Tilt Stands
During a recent unit test here, a safety latch on an injector tilt failed to catch an injector
being tilted with the injector mounting pin missing. Although we recommend always
installing the pin before tilting, the safety latch should restrain the injector to the tilt
stand. Investigation determined that the tip of the latch lever on the safety latch hung
on a weld preventing the latch from closing properly. In order to prevent this from
occurring in the future, we recommend that the tip of the latch be removed by cutting
and grinding smooth as shown in the attached illustration.
Furthermore, we encourage the installation of a warning label next to the injector tilt
control valve warning the operator that the pin must be installed between the injector
base and the injector tilt before the injector is tilted over for transport. This label is
available at no cost to owners of trailers with injector tilt systems by ordering label part
number CB063884.
Once the lever is modified and checked for proper operation as outlined, we
recommend that you test the tilt safety latch by installing a Grade 8 bolt that is 8
long in place of the standard injector tilt pin. With the bolt installed and secure, carefully
tilt the injector over making sure the latch does not open. If the latch does not stay
closed during this operation, please contact our service department. Presuming a
successful test, stand the injector to its upright position and reinstall the permanent pin
for continued operation.
If you have questions about this PSB, please contact the service department personnel
at our Hydra Rig, Fort Worth, Texas office via email, or phone. When calling by phone
between the hours of 8:00 am and 5:00 pm Monday through Friday, please call 817-
985-5000 and ask to speak to a Service Technician. At any other time please call 817-
985-5221 and let the operator know you need service. The proper email addresses to
use are as follows:

Date: July 7, 2009
Page 1 of 3
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
Modification to Latch
Date: July 7, 2009
Page 2 of 3
Hydra Rig
Ph: 817-985-5000
Fx: 817-985-5282
Test to Make Sure Latch Holds

Date: July 7, 2009
Page 3 of 3
Hydra Rig
Fort Worth, TX 76140
Phone: 817-985-5000
Fax: 817-985-5282
PRODUCT SERVICE BULLETIN #136

PRODUCT: HR680 & HR6100 Injectors
REFERENCE: HR680 & HR6100 Injector Pressure Balance Line
We have experienced failures in some installations of the special stainless steel

pressure balance lines fitted to both the HR680 and HR6100 injectors. These failures
occurred in field retrofits as well as in newly built injectors. Although the number of
failures is small, no failures can be tolerated. All of the reported failures of the balance
line kits were in the special fittings used with the stainless steel line, although some lead
to a failure of the stainless line itself.
Failures of this connection in the injector hydraulic drive circuit are disabling and
potentially dangerous. The new design, without the special fittings, is to be installed
immediately to avoid possible balance line failures. This design employs proven
hydraulic hose and high pressure split flange fittings already used in the injector drive to
make a highly reliable balance line. Hydra Rig will supply the upgrade kits free of
charge.
The new injector counterbalance jumper kits should be installed per the attached
procedure using parts called out on the correct kit. The HR680 kit is CC332230 Hose
CB Valve Jumper Mod and the HR6100 kit is CD332245 Hose CB Valve Jumper Timed
Mod. These kits can be installed without Hydra Rig assistance.

Date: 6/11/12
Richard Russell CC332230 & CD332245
Page 1 of 6
Hydra Rig
Phone: 817-985-5000
Fax: 817-985-5282

Requirements:
One CC332230 or CD332245 installation kit
CC332230 or CD332245 drawing print, below
HR680 or HR6100 injector with room to work on the drive side
Basic mechanic and hydraulic tools
Installation Steps:
1. Verify all plugs are properly installed and tight on the new sandwich plates.
2. Verify the injector is disconnected from hydraulic power and all pressures are removed.
3. Place catch buckets below injector motor ports for hydraulic oil.
4. If installed, disconnect and discard the stainless steel balance line.
5. Disconnect the motor end of all four drive hoses.
6. Remove counterbalances and set aside protecting the counterbalances from
contamination.
a. Optionally, Remove horizontal outer frame cross bar if more room is desired.
7. If installed, disconnect and discard the original sandwich plates with the special fitting
ports.
8. Grease and install O-rings into the grooves of the new sandwich plates made with 4-
bolt flange connections.
9. Assemble the new sandwich plates, counterbalances, split flange halves, and drive
hoses. The sandwich plates go between the motors and the counterbalances with the
O-ring side of the sandwich plates and counterbalances facing upwards, toward the
motors.
a. Verify the front sandwich plate, labeled with an F, is installed on the motor
toward the filters and the rear sandwich plate, labeled with an R, is installed on
the motor furthest from the filters.
10. Lubricate then tighten the bolts on the motor split flanges to 81 ft. lbs.
11. Grease and install O-rings into the jumper hose flanges.
12. Install the jumper hose to the sandwich plates using the split flange kits in the
installation kit.
13. Lubricate then tighten the bolts on the jumper hose split flanges to 53 ft. lbs.
14. Verify all connections are tight that may have loosened during the assembly process.
15. Install the outer frame cross bar, if removed in step 6.a.

Date: 6/11/12
Page 2 of 6
Hydra Rig
Phone: 817-985-5000
Fax: 817-985-5282

Test Installation:
1. Close injector brake locking valve with 0 psi on brakes. This will lock the injector brakes
engaged.
2. Connect injector In-Hole, Out-Hole, and Case Drain.
3. Engage injector pump, allowing charge pressure to go to the injector drive.
4. Verify/correct any leaks.
5. Wait for 2 minutes with charge pressure engaged to allow the motor cases to fill.
6. Increase drive pressure gradually to 5,000 psi or the power supply maximum, whichever
is lower, in the Out-Hole direction.
7. Observe/correct any leaks.
8. Disengage the drive pressure.
9. Repeat steps 6-8 in the In-Hole direction.
10. Shut down the injector drive and then open brake locking valve.

Date: 6/11/12
Page 3 of 6
Hydra Rig
Phone: 817-985-5000
Fax: 817-985-5282
HR680

Date: 6/11/12
Page 4 of 6
Hydra Rig
Phone: 817-985-5000
Fax: 817-985-5282
HR6100

Date: 6/11/12
Page 5 of 6
Hydra Rig
Phone: 817-985-5000
Fax: 817-985-5282

Hydra Rig will supply the Hose CB Valve Jumper Modifications, part number CC332230
or CD332245, free of charge. To order, provide the information requested below for
each injector that requires a kit. Only one kit per injector will be supplied. Please print
this PSB and send this last sheet with the information filled in, either by scanning and e-
mailing, or by fax, to any of the following:
E-mail Fax
Richard.Russell@nov.com 817-985-5282
HRIservice@nov.com 817-985-5297
Customer
____________________________________________________
Physical Ship to Address

____________________________________________________
____________________________________________________
____________________________________________________
Contact Name
____________________________________________________
Contact Phone Number

____________________________________________________
Injector Order Number from ID Plate on the Injector

____________________________________________________
Assembly Number from ID Plate on the Injector (i.e. CC30XXXX)

___________________________________________________
Hubometer Reading on the Injector and Date of Reading

___________________________________________________
Best Means of Shipment

___________________________________________________

Date: 6/11/12
Page 6 of 6

PSB Product Bulletins

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

PSB Product Bulletins

Hochgeladen von

Copyright:

Verfügbare Formate

PRODUCT SERVICE BULLETINS

PSB # Product Subject Date

CT power pack & N2 units

PRODUCT SERVICE BULLETIN

Customer Name ______________________________

Date of Response _____________________________

PSB Number you are responding to _______________

Name, Phone number, and Fax number of person responding

Send response by e-mail or fax to:

Approved by: Drawings included: PSB Number:

PRODUCT SERVICE BULLETIN # 101

PRODUCT: Coiled Tubing

REFERENCE: Power Auto Driller (P.A.D.)

Approved by: Drawings included: PSB Number: 101

PRODUCT SERVICE BULLETIN # 101

MODIFICATION INSTALLATION INSTRUCTION:

PRODUCT SERVICE BULLETIN # 101

PARTS REQUIRED FOR MODIFICATION:

Approved by: Drawings included: PSB Number: 101

PRODUCT SERVICE BULLETIN # 101

Approved by: Drawings included: PSB Number: 101

PRODUCT SERVICE BULLETIN # 102

PRODUCT: COILED TUBING REEL

REFERENCE: VALVE ADJUSTMENTS FOR DISH TYPE REEL

To advise field operations of correct valve adjustment. These adjustments need to be

PROCEDURE FOR REEL MANIFOLD ADJUSTMENT (Ref. Drawing Pg. 3)

Approved by: Drawings included: PSB Number: 102

PRODUCT SERVICE BULLETIN # 102

3. ONCE REEL CIRCUIT PRESSURE IS VERIFIED, CONNECT REEL SUPPLY

4. REMOVE 2 EA. MOUNTING BOLTS FROM REEL MOTOR FLANGE. REMOVE

5. TO CHECK SETTINGS ON BACK PRESSURE VALVES SIMPLY INSTALL A 0 TO

IF PRESSURE IS INCORRECT, SET VALVES IN HOLE (#3) OUT HOLE ( # 10)

Approved by: Drawings included: PSB Number: 102

PRODUCT SERVICE BULLETIN # 102

Approved by: Drawings included: PSB Number: 102

PRODUCT SERVICE BULLETIN # 103

PRODUCT: New Style Tubing Reel

REFERENCE: LEVELWIND ARMS, REINFORCEMENT

Reduction of the amount of packing or loosening of the brass guide/packing

Approved by: Drawings included: PSB Number: 103

PRODUCT SERVICE BULLETIN # 103

REPAIR AND MODIFICATION:

Reinforce levelwind support arm with angular gusseting.

Approved by: Drawings included: PSB Number: 103

PRODUCT SERVICE BULLETIN # 103

Approved by: Drawings included: PSB Number: 103

PRODUCT SERVICE BULLETIN # 104

PRODUCT: DYNOMOMETER, STUSKA 400D & 800D UTILIZED ON HYDRA RIG

REFERENCE: DYNO MODIFICATIONS

Approved by: Drawings included: PSB Number: 104

PRODUCT SERVICE BULLETIN # 104

Approved by: Drawings included: PSB Number: 104

PRODUCT SERVICE BULLETIN # 104

Manu. - Stuska Engineering Corp.

Model No. - 400-D With Modifications Listed

1. Fill ports to be (-12) SAE straight thread.

3. No other ports or mount holes required.

4. Input shaft flange for spicer 1350 series (ship loose).

5. Grease zerts and grease reliefs to be installed in all applicable openings.

6. Plug standard seal cooling ports.

7. Do not supply any parts associated with seal cooling system.

DRAWING NO. A00040 D CHANGES

PRODUCT SERVICE BULLETIN # 105