*READ CAREFULLY BEFORE OPERATION*

INSTRUCTIONS

TO

ZYT5402TZJ （（（（350HPP）））） MOBILE DRILLING

RIG

SM-C0.249D

ZYT Petroleum Equipment Co., Ltd.

Sep, 2009

TO THE USER

Established in 1980, ZYT Petroleum Equipment Co., Ltd. is one of the largest special

vehicle manufacture bases of SINOPEC and China Petroleum in China. Under large clients and

leaders' support, Our Company has designed and manufactured series of drilling rigs which is

from 30 T to 120 T so far. Besides we have also developed lots of following petromechanism

produces: Cement special vehicle, hot washing special vehicle, dewaxing special vehicle,

drilling rigs, diesel engine generator, etc. By this time, our products are used in land oil field all

over the country; moreover, we have exported various products to many countries and regions

like Russia, Turkmenistan, Iraq, Peru and U.S.A.

In May 1996, we gained ISO 9001 certificate. And some products like wellhead equipment,

mast, rotary table, hook and so on, have API certificate of American Petroleum Institute.

Furthermore, in 1998 our company had been named “high- new technology enterprise”.

ZYT Petroleum Equipment Co., Ltd., Its tenet is oriented to meet the demand of

consumers, and strive for subsistence with quality, development with science and technologies,

good reputation with good service. Introduce willingly advanced technology overseas, which

will be improved, absorbed and developed. We are making our great efforts to create more

economic benefit for our clients with our products.

We are doing our best to provide products and service, creating opportunity and fortune for

all of you!

APPLICATION MANUAL

� Read and understood INSTRUCTIONS TO ZYT5402TZJ DRILLING RIG carefully

before operation.

� It introduces the application range, technical standard, operation maintenance and handles.

� It doesn’t consist of the manual for special carrier, CAT diesel engine , Allison gearbox

and some purchased parts ,their use and maintenance please refer to the relative data along with

the equipment.

� Signs in this article show the dangerous state of the operation staff:

Danger! ―― heavy danger, the persons can die or the operation can cause

grievous bodily harm.

Warning! ―――――――― middle danger, the unsafe operating can make the personal die

or injured.

Attention! ―――――――― light danger, the unsafe operating can make the personal

injured or the machine damaged.

� It consist of the following contents:

� Product brief introduction

� Main parts and technical specification

� Using manual and operation program

� Inspection and maintenance

� Main standard part、quick-wear part list

� After service connect with us

� ZYT5402TZJ DRILLING RIG is still in the development. Contact us for the latest

information about the product.

Contents

Chapter 1: Product Brief Introduction

Chapter 2: Main Components And Technical Requirement

Chapter 3: Operation Instruction & Routine Practice

Chapter 4: Check, Lubrication And Maintenance

Chapter 5: Package And Transportation

Chapter 6: Appendix

Chapter 7: Quality assurance

Chapter 1

Product Brief Introduction

Summarization

Model Introduction

Technical Index

ⅠⅠⅠⅠ.Summarization ZYT5402TZJ truck-mounted drilling rig is self-propelled drilling equipment with double

drums. It mainly consists of parts as follows:

� Carrier: ZYT5402TZJtruck-mounted special carrier

� Engine: CAT C-9

� Gear-box：ALLISON 4700 OFS_R

� Double drums drawworks

� Mast assembly

� Drawworks drive gearbox

� Rotary table drive gearbox

� Transmission system

� Traveling system

� Hydraulic、air system

� Lighting system

� Water-cooling system The drilling rig has a 8×8 type self-propelled carrier. And the carrier frame is welded to be strengthen beam by wide wing H steel. The diesel engine is CAT C-9 made in USA, and the transmission box is ALLISON 4700 OFS hydraulic made by USA GE company. The design of ZYT5402TXJ drilling rig absorbs the advanced technology from home and abroad, and it is made by mature manufacture technology. This rig is used for small workover in 4000m(2 7/8" EU oil tube), and big workover in 3200m(2 7/8" DP), 2500m(3 1/2" DP).

ⅡⅡⅡⅡ. Model and code introduction

Model: ZYT5402TZJ DRILLING RIG

ZYT—corporation code, ZYT

5—special truck code

40—overall fixed weight 40×1000kg

2—design ordinal number

T—Special using vehicle

XJ—drilling rig

ⅢⅢⅢⅢ. Main technical data

NO Item Technical data

1 Drilling

depth

Big workover depth 4000m(2 7/8"DP)

Small workover depth 3200m(2 7/8"oil tube)

2 Maximum static load 900 KN

3 Traveling system form 3×4

4 Line diameter φ26 6×19S+RL+IWRC IPS wire line

5 Mast

Mast form Double sections, telescopic

Clear height 29.5m

Working obliquity 3.5°

Maximum static load 900KN

Racking board height 17.2m, 18.7m, 21.5m

Racking board capacity 4000m(2-7/8" DP)

6

Drawwork

s

Input power 350 HP

Main drum

Max. Pull of fast line 180 KN (secondary layer)

Drum diameter×length 450mm×912mm

Brake rim diameter×length 1070mm×310mm

Wire line diameter 26mm

Max. rotate speed 450rpm

Brake rim cooling form Forcible water circulation cooling

8 Hydraulic system

Rated pressure 14MPa

Rated flow 165L/min

Oil tank cubage 0.85m3

9 Air system Pressure 0.85MPa

Flow 670L/min

10 Power transmission form Hydraulic & mechanism

11 Engine Engine rated power 350HP/2100rpm

Engine maximum torque 1557 N.m/1400rpm

12 Torque

Type With lock clutch, hydraulic reducer

Torque 2.05

Ratio 5 Forward 1 Rear

13 Drive type of carrier 8×8

14 Max speed 45 km/h

15 Environment Max wind speed 110 km/h

Temperature -20℃～50℃

16 Dimension（L×W×H） 19060×3400×4400

ⅣⅣⅣⅣ. Main drum hook load、、、、hook speed character graph

VVVV Solid moving condition graph：（：（：（：（mm））））

VVVVIIII Working condition figure：（：（：（：（the slant angle of mast is 3.50 ））））

12

VII. Layout of guy lines, deadman hole and groundwork

RRRRECOMMENDED GUYLINE SIZES:ECOMMENDED GUYLINE SIZES:ECOMMENDED GUYLINE SIZES:ECOMMENDED GUYLINE SIZES: A: WIND GUYS TO DEADMAN, 5/8 PREFORMED 6×19S+IWRC EEIPS CLASS WIRE LINE B: RACKING BOARD WIND GUYS TO DEADMAN, 5/8 PREFORMED 6×19S+IWRC EEIPS CLASS WIRE LINE C: LOAD GUYS TO UNIT, 3/4 PREFORMED 6×19S+IWRC EEIPS CLASS WIRE LINE D: PREVENT TURN-OVER GUYS TO UNIT, 5/8 PREFORMED 6×19S+IWRC EEIPS CLASS WIRE LINE E: FRONT END HOLDDOWN TO DEADMAN, 5/8 PREFORMED 6×19S+IWRC EEIPS CLASS WIRE LINE GROUNDWORK:GROUNDWORK:GROUNDWORK:GROUNDWORK: THE MINIMUM SAFETY LOADING CAPACITY IS 39T/M3, REQUIRE DRAINAGE MANAGEMENT; THE SPOTTING SURFACE: THE GRADE OFF THE WELL HEAD 4m IS 1:20, THE MINIMUM SAFETY LOADING CAPACITY IS 29T/M3

Chapter 2

Main Components And Technical Requirement

Drawworks Assembly

Mast Assembly

Angle Gear Box

Substructure Assembly

Hydraulic System

Air Pressure System

Water cooling system

- 1 -

JC21B Double-Drum Drawworks

���� . Technical Parameters

Model JC18/11

Type Double-drum

Rated power 350HP

Technical Parameters Main drum Sand drum

Drum

Diameter

mm 450 345

Length

mm 912 912

Brake

rim

Diameter

mm 1070 970

Length

mm 310 210

Cooling Type Forced circulation water

cooling

Envelope angel of brake

strap 345° 345°

Drum capacity

m 500mφ26 wireline 2800mφ9/16” wireline

Allowable Max. rotary

speed

rpm

450 450

Fast tension 210kN (the second layer) 110kN (the second layer)

Clutch ATD-324H ATD-124H

Assist brake WCB224

ⅡⅡⅡⅡ. Contents

� Main drum assembly

� Brake system for main drum

� Sand drum assembly

� Brake system for sand drum

� Drawworks frame

� Cooling system

� Lubrication system

� Auxiliary brake assembly

- 2 -

MMaaiinn ddrruumm aasssseemmbbllyy

Fig 1-1 Main drum assembly

- 3 -

Main drum assembly list

Item Part Number Description Qty. Material Remark

1 WCB224 Water cooling disc assist brake 1

2 XJC21A.04-04 Attachment flange 1 Steel plate Q235A t55

3 GB286-64 Bearing 3528 1

4 XJC21A.04-05 Left bearing base 1 ZG270-500

5 XJC21A.04.02 Brake hub assembly 2

6 C0.229.03.04-01 Shaft 1 Steel strip 42CrMo φ220

7 XJC21A.04.03 Drum assembly 1

8 XJC21A.04-09 Key 45×25×240 2 Steel plate 45 t30

9 XJC21A.04.04 Cooling water pipe assembly 1

10 Q/ZB286.2 Screw plug R3/8 2

11 XJC21A.04-21 Key 36×36×233 2 Steel plate 45 t40

- 4 -

12 GB286-64 Bearing 3003730 1

13 XJC21A.04-11 Right bearing base 1 ZG270-500

14 XJC21A.04-12 Middle flange 1 Steel plate Q235A t40

15 XJC21A.04-13 Intermediate flange 1 Steel plate Q235A t20

16 XJC21A.04-15 Chain wheel case 1 ZG270-500

17 C0.229.03.04-04 Chain wheel 1 ZG35CrMo

18 XJC21A.04-18 Gear rim 1 ZG200-400

19 500703000003 Thrust disc clutch 1 ATD324-H

- 5 -

� Drum assembly

Fig 1-2

Attention! ◆◆◆◆ Tighten torque for bolts should be 487N.m. ◆◆◆◆ Fastening glue applies to all bolts for locking. ◆◆◆◆ Pay attention on the alignment of cooling water ports with relation to each other.

- 6 -

� Brake rim

Attention! ◆◆◆◆ Check the wear of brake rim timely during running, otherwise it will result in the

equipments trouble and the Human body hurt because of excessive wear, mechanical

strength reducing and rapid falling of brake ability. ◆◆◆◆ Allowable min. diameter of brake rim is 1045mm. ◆◆◆◆ Change brake rim at once if there exists crocodile stripe with length over 100mm on the

surface of brake rim. ◆◆◆◆ The brake rims should be changed for pairs and should be the product of the same

manufactory and the same batch to make sure of brake function.

- 7 -

� Change brake rim

Measure method of brake rim:

Measure tool: Depth scale, Rectilinear scale, Steel tape, Caliper, fine thread etc.

A Depth scale measure method

Lay vernier tightly against non-wearing surface of brake rim and staff gauge against

wearing surface. Calculate single-side wear value of brake rim according to the reading on the

staff gauge. The quantity of measuring points should be no less than 6 and the measuring points

should be distributed evenly on the circle. Replace the brake rim once one of the values reaches

12.5mm.

B Caliper measure method

Use caliper to measure the wear diameter of brake rim directly and then use steel tape to

measure the distance between the two feet of caliper. The reading on the steel tape is the wear

diameter of brake rim. The quantity of measuring points should be no less than 3 and the

measuring points should be distributed evenly on the circle. Replace the brake rim once one of

the values reaches 1045mm.

C Fine thread measure method

Use thin steel wire or copper wire(φ1mm or so), or a little bit thick fiber rope as fine thread

to measure. Wrap the surface of brake rim with fine thread for one turn and mark on the joins of

the fine thread. And then measure the length between the two marks. The number obtained by

dividing the length by 3.14 is the wear diameter of brake rim. The quantity of measuring points

should be no less than 3 and the measuring points should be distributed evenly on the circle.

Replace the brake rim once one of the values reaches 1045mm.

- 8 -

Disassembly of brake rim

Attention! ◆◆◆◆ Make sure that the equipment keeps still and safe before repairing, otherwise it would

result in the equipments trouble and the Human body hurt. ◆◆◆◆ The repairman must be specially trained and be authorized, otherwise it would result in

the equipments trouble and the Human body hurt. ◆◆◆◆ Carefully read operation procedure and be familiar with the steps of changing parts

before repairing, otherwise it would result in the equipments trouble and the Human body

hurt.

1. Remove wireline. Slowly reverse the drum, pull out the wireline which coils around the

drum and take out rope end from the slot on the drum.

2. Remove drawworks frame guards, chain case and clutch guards.

3. Using chain tightener remove chain.

4. Remove brake system.

5. Remove lubrication system of drawworks.

6. Remove air line and air connector which are linked with air-operated rotary connector.

Remove air-operated rotary connector.

7. Hang up the main drum from drawworks frame. The weight of main drum is 4100kg.

8. Remove dual passage rotorseals on both ends of main drum. Remove cooling water line

connectors on main drum and assist brake.

9. Remove sprocket( see Fig 1-1, part 6, part 20)

10. Remove transition flange ( see Fig 1-1, part 17)

11. Remove brake rim.

- 9 -

Assembly of brake rim

1. Prepare

a Clear oil dirt, clean brake rim surface, and clear the burr of key and key slot.

b Check consumable accessory for damage. Repair when being hurt or replace when being

destruction.

c Check brake rim surface, cooling water port thread and exhaust bolt.

2. Install brake rims on both ends and the alignment of gas vent on the brake rim with relation

to the hole on the drum must be maintained. Install the connecting screws which hold brake rim

to the drum and evenly tighten the nuts one by one to prevent brake rim from turning off center

with relation to drum.

3. Install water line connectors on both brake rims.

Attention!

The connectors should be spread with sealing film or gasket to avoid leaking.

4. Install transition connecting plate.

5. Install sprocket.

6. Install dual passage rotorseals on both ends of main drum. Install cooling water line

connectors on main drum and assist brake.

7. Using hoist install main drum on the drawworks frame.

8. Install air line and air connector which are linked with air-operated rotary connector on the

main drum shaft end. Install air-operated rotary connector.

9. Install lubrication system of drawworks.

10. Install brake system.

11. Using chain tightener install chain.

12. Install drawworks frame guards, chain case and clutch guards.

13. Install wireline

- 10 -

� Line clamp mount

Fig 1-4

Attention!

1. Make the interspaces among three slips evenly when assemble.

2. The tighten torque of retaining nut should not less than 350N····m.

3. Test tension after mounting the line clamp. Forbid slipping when testing tension of

wireline is 50kN.

4. Check the clip state invariably when working, to avoid it shake off.

- 11 -

� Dual passage rotorseal

Fig.1-5

Item Part Number Description Qty. Material

1 XJC21A.04.01-01 Nut M68×2 2 45

2 XJC21A.04.01-02 Washer 68 1 Steel plate Q235A t1.5

3 GB13871-92 Gasket Model B 80×100×10 2

4 XJC21A.04.01-04 Bearing cover 2 Q235A

5 XJC21A.04.01-09 Washer 2 Asbestos rubber plate

6 GB276-79 Bearing 214 (70×125×24) 2

7 XJC21A.04.01-08 Backing plate 2 Steel plate Q235A

8 HG4-337-66 V-Gasket (A) 70×95 2 Ⅰ-1

9 XJC21A.04.01-06 Spring seat 2 Q235A

10 XJC21A.04.01-07 Compression spring 1 Spring steer line φ6 65Mn

11 XJC21A.04.01-05 Housing 1 HT200

12 XJC21A.04.01.01 Overflow nozzle 2

- 12 -

13 XJC21A.04.01-10 Spindle 1 35

14 GB3452.1-82 O-ring 69 X5.3 1 Ⅰ-2

- 13 -

Thrust disc clutch

- 14 -

Check air clutch

Check the wear of the driving plate and check the diaphragm timely during running,

otherwise it would result in the equipments trouble and body hurt because of over-wear, rapid

reducing of brake ability and dropping of mechanical strength. ● Make sure the clearance among driving plates is 1.5~2mm. ● Allowable max. wear value of driving plate is 3mm. 1、、、、Wear meterage

1) Measure tool: Clearance gauge, Steel tape, Slide caliper rule

2) Prepare for measure

Remove air-operated rotary connector.

Remove the clutch outer and inner guards.

3) Measure clearance

Measure the clearance among driving plates with clearance gauge under the condition that

there is no compression gas in the diaphragm. If the clearance is too small, remove safety steel

line and fixed screws, and then add adjusting gaskets. Measure the clearance again after

remounting. If the clearance is excessively large, reduce the adjusting gaskets quantities.

When the clearances among driving plates are different, check all springs stiffness and

change all fatigue springs.

IF the clearance is still large when removing all adjusting gaskets, some driving plates must

be fatigued and should be replaced in time.

4) Measure driving plate

Dismount the clutch.

Measure the thickness of driving plates one by one. And replace it when the thickness is less

than 19mm because of excessive wear.

Check the driving plates for crack and nick. Otherwise replace it.

- 15 -

2、、、、Disassembly the diaphragm and driving plates

1) Prepare

A、Stop the engine, keep the gear box idle and cut off the current of the carrier before

dismounting the clutch.

B、New diaphragm and driving plates are at the ready.

C、Provide with installation platform, support and steel pipes with the length of 800 mm and the

diameter of φ80mm。

2) Remove the whole clutch from drum shaft

Mark on the shaft end before removing the entire clutch. Using puller remove the clutch.

Attention!

Fitting marking must be made on the shaft end to make sure of drum dynamic balance

when removing the clutch .

3) Remove the clutch

A、Place the clutch on the installation platform , backplate down and connecting bolts up.

B、Make fitting marks on backplate, center plate, pressure plate and clamp ring to avoid being

misplaced and unbalanced when remounting.

C、Dismount the safety steel wire.

D、Loosen fixed screws evenly one by one. When all screws have been loosened for 30mm,

remove three alternate screws and remount three long screws(the length is 30mm longer than

that of primary ones ) to hold the clamp ring. Remove the remained screws, and then loosen the

long screws evenly one by one to remove them.

E、Remove the diaphragm, clamp ring, pressure plate ,spring, driving plate and center plate sets.

3、、、、Change the diaphragm and driving plates, reassemble the clutch

1) Prepare

A、Clean the clutch. Clear backplate working surface and the burr of gear slot.

B、Clean pressure plate and check the spring. Repair it when being hurt or change the damage

parts.

C、Clear the diaphragm and driving plates.

D、Lubricate the gear slot of backplate. And the lubrication can not be excessive, grease spot

can not be allowed on the rest part of backplate, otherwise it would influence assembling

quality and the clutch would slip.

- 16 -

E、Assemble the springs in groups, each group is made up of six pieces of springs and free

height error margin is 0.5 mm.

2) Assemble and adjust the clutch

A、Measure the thickness of all driving plates, center plate and pressure plate to determine the

regulating gasket thickness and the number of regulating gaskets.

B、Place backplate flatly with tooth upward.

C、Place six springs in the spring seat of the backplate and lay a piece of driving plate on the

backplate upward surface. Place center plate on the springs to pay attention on the alignment of

the marks with relation to that on the backplate. Then install remaining driving plates in the

proper order.

D、Install the pressure plate to keep the alignment of the marks with relation to the one on the

backplate.

E、Install regulating gaskets with desired quantity.

F、Place the diaphragm on the clamp ring to keep the alignment of air-operated connector of the

diaphragm with relation to the hole of clamp ring. And then put the clamp ring on the backplate

to keep the alignment with relation to the marks on the backplate.

G、Insert three long screws alternately into the holes on the clamp ring. Screw them down into

the screw holes of the backplate one by one to make sure of clamp ring balance. When the long

screws being screwed for 30mm, install three fixed screws into the remaining screw holes and

tighten them. Replace the three long screws with fixed screws, and then tighten them evenly

one by one to keep the clamp ring balance.

3) Adjust the clearance

Place the clutch upright, insert a steel pipe into the center hole, and then support the clutch

with bracket.

Measure the clearance among driving plates with clearance gauge. If the clearance is

excessive small, remove safety steel line and fixed screws, and then add adjusting gaskets.

Measure the clearance again after remounting. If the clearance is too large, reduce the adjusting

gaskets quantities.

When the clearances among driving plates are different, check all springs stiffness and

replace all fatigue springs.

4、、、、Install the clutch

1) When installing the clutch, pay attention on the alignment of marks and tighten the nuts

which hold the clutch backplate to sprocket sleeve.

- 17 -

2) Install hose connector which is connected with air-operated rotary connector on the main

drum shaft. The connectors should be spread with sealing film or gasket to avoid leaking.

5、、、、Running-in

The friction contact area of the clutch is smaller and would influence driving ability after

changing diaphragm and driving plate. So carry on running-in before normal operation.

Running-in load：It should be carried on under the condition of half of rated load.

Running-in time：It should be carried on for four hours at least.

Running-in speed：It should be carried on under the condition of 60% of rated speed. That

means the max. lifting speed of travelling hook is no more than 0.6m/s. If running-in speed is

too high, it would cause partial overheating and deterioration of friction material to influence

drive ability.

The only difference between the main drum clutch and the sand drum clutch is the quantity

of driving plates and their structures are similar.

- 18 -

BBrraakkee ssyysstteemm

- 19 -

Item Part Number Description Qty Material Remark

1 XJC21A.06-06 Brake block 18

Asbestos copper wires

basketwork

2 XJC21B.06.01 Brake strap assembly 2

3 XJC21B.06.01-01 Brake shaft 1 Round steel 45 φ65

4 XJC21A.06-08 Screw 120 Copper stick H62 φ20

5 XJC21A.06-09 Self-lock nut 120 Round steel 45 φ20

6 XJC21A.06-11

Brake block on dead

end 2

Asbestos copper wires

basketwork

7 XJC21A.06-27 Bearing box 2 Round steel Q235A φ190

8 GB/T 281-1994 Bearing 1212K 2

9 XJC21A.06-26 Bearing cover 2 Round steel Q235A φ190

10 XJC21A.06.03 Crank 2

11 XJC21A.06.01 Balance block 2

12 XJC21A.06-24 Balance beam 1 Steel plate Q235A t25

13 XJC21A.06.04 Anti-knock crank arm 1

14 XJC21A.06-12 Connecting arm 2 Steel plate Q235A t30

15 XJC21A.06-21 Right-hand screw rod 2 Round steel 35 φ65

16 XJC21A.06-03 Adjusting nut 2 ZG270-500

17 XJC21A.06-05 Left-hand screw rod 2 Round steel 35 φ65

- 20 -

� Adjustment and maintenance

Adjust

Adjust brake system in time to make sure of good brake function after the drum brake strap

being used for a period. Otherwise, the wearing of brake strap would influence the brake

function.

1、、、、 Adjust the brake strap clearance

Adjust the brake straps clearance in time. The method is as following, firstly brake the brake

strap tightly and tighten all roller as shown, then loosen bolts for three turns to make sure the

clearance between brake strap and brake rim is about 5 mm.

- 21 -

2、、、、 Adjust brake strap active end

With brakes on tight and flanges at ambient temperature , the offset of center pin in the

toggle ( the distance of point O to line AB) should be is 30mm or the angle ∠A0B is 150°as

shown

All subsequent operations as position of brake lever working height will be accomplished

with the brake adjusted as per above.

- 22 -

3、、、、 Adjust the balance of brake strap

Adjust the balance of brake strap: with brakes on tight, the equalizer beam should be as

shown, with brakes disengaged the equalizer rod should swing freely

4、、、、 Adjust the height of brake handle

When brake block becomes thin and the wrap angle of brake strap becomes larger because

of wear, which results in inconvenient operation and excessive low of brake handle, the

adjustment should be done in time to keep the suitable height of brake handle.

Replace brake blocks

Replace brake block. All brake blocks should be changed before the retaining bolts heads

touch the brake rim, which means the remained thickness of brake block is about 15 mm.

1. Prepare ● Stop engine, keep gear box idle and cut off the current of carrier. ● Place traveling hook on the rig floor, release the wireline and the number of wireline coiling

layers would not be more than two turns. ● No mast above the drawworks.

2. Remove brake strap ● Make marks on brake straps of both sides. ● Remove bracket of anti-knock valve, anti-knock valve and air line.

- 23 -

● Remove connecting bolts on top guards of both sides. ● Remove adjusting bolts on top guards of both sides. ● Remove top guards. ● Loosen roller assembly. ● Remove reset spring. ● Remove connecting pins at the lugs of brake straps on both sides. ● Remove brake straps. Adjust brake straps to keep split downward. Using hoist lift it slightly

and using crow bar force brake strap to leave off brake rim and move toward drum. When

brake strap reaches the center of drum, lift up it.

Attention!

When removing brake strap, be careful of operation to avoid distortion of brake strap

which would influence brake function.

3. Replace brake block ● Remove old brake strap, loosen retaining locknuts which hold brake block to the back of

brake band, remove brass screws and old brake block. ● Check and adjust brake band, clean foreign matter and burr on the surface of brake band,

and check pinhole on the lug of brake band for damage. Repair it when being damage. ● Check locknut and brass screws. Change it when being damaged and repair it when being

hurt. ● Install brake block. Eighteen pieces of braided brake blocks and two pieces of cast brake

blocks are at the ready. Cast brake blocks are fixed on the dead end of brake band and

braided brake blocks are fitted at the remaining parts of brake band. Tighten self-locking

nuts on each brake block evenly. Tighten torque for nuts is 16.7～22.3N·m.

Attention!

Blocks of brake straps on both sides should be manufactured by the same factory to

avoid different brake capability and non-synchronous wear. ● Check brake straps for fitting. Brake blocks should be fixed tightly and no looseness is

permitted. Brass screws should be screwed in under the surface of brake block. No incline ,

no looseness and no outcrop are permitted. The inner surface of the whole brake block

should be flat and trim warp parts.

- 24 -

Attention!

When fitting brake straps, pay attention on differentiating the fitting positions of

brake straps. No confusion of position is permitted and forbid pulling brake straps in a

sudden to avoid influencing brake function.

Running-in

The friction contact area of brake block must be small after changing the brake block, which

will influence brake ability. So it must carry on running-in before normal running of the

equipment. ● Running-in load

It should be carried on under the condition of half of rated load, and that mean the max.

hook load is no more than 400kN. ● Running-in time

It should be carried on for four hours at least. ● Running-in speed

It should be carried on under the condition of 60% of rated speed. That means the max.

falling speed of traveling hook is no more than 3m/s. If running-in speed is too high, it would

cause partial overheating and deterioration of friction material to influence brake ability. Change brake rim

Attention! ◆◆◆◆ Check the wear of brake rim timely during running, otherwise it will result in the

equipments trouble and the Human body hurt because of excessive wear, mechanical

strength reducing and rapid falling of brake ability. ◆◆◆◆ Allowable min. diameter of brake rim is 1045mm. ◆◆◆◆ Change brake rim at once if there exists crocodile stripe with length over 80mm on the

surface of brake rim. ◆◆◆◆ The brake rims should be changed for pairs and should be the product of the same

manufactory and the same batch to make sure of brake function.

The installation of the brake rim

1、The preparing work

a Clean the oil dirt, clean the surface, connection key and burr of the brake drum；

- 25 -

b Inspect whether there are damages , and repair or change；

Attention!

Put airproof glue or enlaced seal film to prevent leaking.

2、Fit brake rim of two ends

3、Fit transition connected plate；

4、Fit chain wheel；

5、Fit clutch ring

6、Fit main drum, auxiliary brake bearing swivel, and cooling pipes connection, and auxiliary

brake pipes connection.

7、Fit the main drum on the drawwork frame by suspending equipment；

8、Fit the air connection and pipeline of the pneumatic circling connection on the main drum；

9、Fit lubrication system of dramwork ；

10、Fit brake system；

11、Fit chain and use chain tighten；

12、Fit the frame cover and chain box and clutch cover；

13、Fit steel wire.

- 26 -

AAuuxxiilliiaarryy bbrraakkee aasssseemmbbllyy

Model S122 Auxiliary brake technical parameters

Model S122

Wheel Dia. 22″

Stator Dia. 22″

Max. temperature of output water 82℃

Max. pressure of output water 0.175Mpa

Max. rotary speed 2200r/min

Max. braking power 1192kW

Max. braking torque 12880N.M

Lubrication system

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 GB1152-74 Oil cup M10×1 6

2 YB448-71 Copper pipe φ8×1 7m

3 QJKT-2J3-Z6 Connector 6

Lubricant------Molybdenum bisulfide extreme-pressure Lithium-based grease

Lubrication intervals------every shift and add lubricant when working.

Trouble-shooting

NO. Fault Cause Remedy

1 Brake

handle

Press it to the lowest

position, the drum not

braked

Brake block wore

Both brake straps unbalanced

Brake rim polluted

Too low the position of brake handle

Brake strap active end incorrectly adjusted

Change brake block

Adjust balance

Clear oil dirt

Adjust brake handle height

Adjust brake strap active end

Lift to the highest

position, the hook

stops falling or falls

slowly.

Too small the clearance between brake

strap and brake rim

Friction between brake strap and brake rim

Brake handle incorrectly adjusted

Adjust brake strap clearance

Change clutch friction disc

Adjust brake handle

2 Drum

clutch

The drum clutch not

engaged, the drum

keeps running

Too small the clearance of clutch friction

discs

clutch friction disc sintered

Adjust the clearance of

clutch friction disc

Change clutch friction disc

The drum keeps

running after the

clutch being

unengaged.

Too small the clearance of clutch friction

disc

clutch friction disc sintered

Air pipeline broken not thoroughly

Adjust the clearance of

clutch friction disc

Change clutch friction disc

Check air pipeline and valve

Slip when the

traveling hook lifting.

The clutch polluted

Not enough gas supply

Too large the clearance of clutch friction

disc

The clutch friction disc worn badly

Clear oil dirt

Adjust gas pressure

Adjust the clearance of

clutch. Friction discs

Change clutch friction disc

3 Brake of

drum

Insufficient brake

force

Not enough gas supply

Too large the clearance of brake rim

Bad wear

Brake rim polluted.

Both brake straps unbalanced with each

other

Increase gas pressure

Check and adjust

Check and change

Check and clear

Check and adjust

Brake strap wore too

quickly

Too fast the falling speed of the hook

The clearance of brake rim is excessively

small

Control the hook speed

suitably

Check and adjust

Tighten torque for bolts see as following table

Thread

diameter

d (mm)

Screw pitch

S（mm）

Performance grade of bolts

4.8 5.8 8.8

Tighten

torque

N.m

Pre-tighten

force N

Tighten

torque

N.m

Pre-tighten

force N

Tighten

torque

N.m

Pre-tighten

force N

6 1 3.5 2894 4.3 3617 6.9 5788

8 1.25 8.4 5270 10.2 6588 16.3 10537

10 1.5 16.6 8349 20.6 10434 33 16691

12 1.75 29 12135 36 15165 58 24259

14 2 46 16555 57 20689 92 33095

16 2 72 22602 90 28245 143 45182

18 2.5 99 27641 124 34542 198 55254

20 2.5 141 35271 176 44077 281 70507

22 2.5 191 43621 239 54512 383 87198

24 3 243 50819 304 63508 487 101587

27 3 356 66079 445 82578 713 132092

30 3.5 484 80763 605 100929 968 161446

33 3.5 661 9991 826 124857 1321 199722

Mast assembly

No Name Code Qty Remark 1 Mast C0.162A.02 1 2 Y-support CO.162A.07 1 3 Rear support C0.162A.08 1

No Name code Remark 1 crownblock C0.249.02 2 Sub mast C0.162A.02.01 3 Up-mast C0.162A.02.02 4 The racking board C0.162A.02.08

Mast Technical data:

Item Data

Mast model JJ900/32-K

Mast form double sections 、 telescopic

Maximum static load 900KN

Working inclined angle 3.5°

Clear height 32m

Racking board height 17m,18.5m,20m

Maximum anti-wind capacity 96km/h

weight 11250

� Anchor line and positon

Anchor line:

Item Position for anchor line Anchor line specification Qty. Length

1 crown block to deadman φ16 6×19S+IWRCEEIPS grade wire

line

4 L=55

2 racking board to deadman φ16 6×19S+IWRCEEIPS grade wire

line

2 L=38

3 crown block to the front

support

φ19 6×19S+IWRCEEIPS grade wire

line

2 L=35

4 the top of mast lower

section to the front support

φ16 6×19S+IWRCEEIPS grade wire

line

2 L=23

GGGGuyline loopuyline loopuyline loopuyline loop No Spec Qty

1 ST 3/4 2

2 ST 5/8 6

3 GB5926-86 16KTH 6

Guyline clamp installation

Carry on the pulling test after installation, make sure not have the surge phenomenon when

the pull is 80KN.

� Test and assessment of the mast Periodically

The mast is the key equipment of the oil drilling exploitation, it is very important to insure

its integrality and security. So, in order to make sure the security during working of the

long-term serving mast, please carry on the integrated testing assessment.

The range of the testing assessment:

(1) The mast that have the accident of falling down, collide the crown block, bumping severely

or have the record of over load heavily

(2) The mast that have the partial or unitary distortion, fracture or crack and have being

repaired heavily.

(3) The mast that have been on serve over 5 years or rusted seriously.

(4) The mast that should be assessed by relative standard and regulations.

Organization and assessment of the testing:

(1) The test should commission the professional testing institution having quality certificate. It

should accord with the operation ranges that have been authorized by superior department.

(2) The using on、repair or abandonment of the mast should according to the conclusion of the

test and assessment.

(3) The task should be under the charge of professional technical personnel according to SY/T

6326 strictly.

Maintenance of the mast:

(1) Consult with the manufactory before repairing or modifying in order to affirm the raw

material and the method. When disagree with the manufactory, the operators and technics

should be confirmed by the mechanical engineer.

(2) Repairing or modifying mast should comply with SY/T6326.

(3) The mast should be maintained annually. In common instance, each sections of the bottom

section of the main body of the mast should carry on antirust-anticorrosive disposal at least one

time every year, the bottom section of the main body of the mast should carry on

antirust-anticorrosive disposal one time six years. The sections that have been corrupted by

drilling liquid、oil、natural gas、saturated brine and sulfureted hydrogen, etc, should be carry on

antirust-anticorrosive disposal before moving after drilling a well.

The crown block

Technical parameter:

1、wire line diameter 26mm

2、Maximum load 900KN

3、overall dimension: 2358×1510×1300mm mm

Item Name Code Qty. Remark

1 Guardrail 1

2 Bearing 352028 GB299-86 4

3 Deadline pulley C0.162A.01-01 1 Dia.760mm

4 Crown block sheaves C0.162A.01-01 2 Dia.760mm

5 Fastline pulley C0.162A.01-07 1 Dia.915mm

6 Crown block base C0.162A.01.01 1

The winding Method of Traveling System:

Drawworks

Fastline pulley

Deadline pulley

Back fixed pulley

Front fixed pulley

Traveling block

Reeving method to racking board：：：：

Note: The same as right side and left side

Troubleshooting

No. Phenomenon Cause Method

1 Crown block pulley

axle heating

Lubricate ill

Bearing conjugate loosely

Sealing ring damaged

Clean、check lubricate system

Adjust or replace bearing

Replace hermetic ring

2 Crown block pulley

running noisily

Bearing damaged heavily

Pulley、axle frayed

Pulley running interferentially

Replace bearing

Check or replace

Adjust、check

3 Crown block pulley

running

interferentially

Axial clearance small

Pulley friction

Adjust clearance

Check

4 Edge of the crown

block pulley frayed

Fast line pulley eccentric wear

Traveling pulley speed

differently

Periodically adjust fast line

pulley inversely

Exchange traveling pulley

periodically

5 Crown block pulley

locked

Impurity

Bearing damaged

Check、clean

Replace

Y- support :

Rear support :

Power transmission system

No. Code Name Qty. Remark

1 C0.249B.06 jackshaft 1

2 GB243-83 Chain 28A-2-110 90 links

3 GB243-83 Chain 28A-2-156 156links

4 GB243-83 Chain 20A-3-126 126links

Check chain or chain wheel damaged：

Check chains for the crack、fracture、distortion、dead link or the rotation of the axle pin. If

find any question, check out the cause and eliminate it, then replace the whole chain. Even if

the rest part of the chain looks fine, it may be damaged and breakage invalidation takes place at

once possibly.

Check chain wheel for the rupture、damage and distortion. If problem happens, check out

the cause and eliminate it, then replace the chain wheel. Compared with the chain, the chain

wheel has more high intensity and be damaged difficultly, but when meshed with the attrite

chain it will be damaged soon.

Check chain abrasion：

Mostly in the running of the chains, when the stretch measure reaches 3%, the chain is

considered disabled.

Notice!

Forbid to use the new chain linked with the attrite chain and the attrite

chain equipped with the new chain wheel.

No. Chain pitch Measure length

Link qty. Nominal length Chain length (3% damaged)

140 44.45mm（1.75’） 14 622.3mm (24.5’) 640.97mm (25.235’)

Check chain wheel abrasion：

Check the joint and roughness of the surface when the new chain divorced from the chain

wheel, check it for gear thick and the disfigurement of the meshed surface. If the disfigurement

can be found without templet, the chain’s longevity of service will be reduced obviously,

replace the chain wheel.

Notice!

Forbid to use new chains with the damaged chain wheel.

The damaged chain wheel

Check chains tightening:

Check the whole displacement of the chains’ midpoint, if it exceeds the range of the list;

adjust the centre-to-centre distance to make sure the degree of tightness. If the displacement

exceed the range of adjustment, and that the wear abrasion don’t exceed 3% or limits of validity,

disconnect two links of the chain and fit it on again. If the minimum adjustment capacity don’t

allow to shorten two links, use the transition chain to shorten one link.

Notice!

Check sag of the chains frequently, avoid it knock on the body of the

chain box.

Driving equipment

Central position

Level ～45° 45°～aplomb

mm in mm in

Tangent line length

of the two chain

wheels

cm (in)

25 (10) 10～15 0.4～0.5 5～8 0.2～0.3

51 (20) 20～30 0.8～1.2 10～15 0.4～0.6

76 (30) 30～45 1.2～1.8 15～23 0.5～0.9

127 (50) 51～76 2.0～3.0 25～38 1.0～1.5

178 (70) 71～107 2.8～4.2 36～53 1.4～2.1

254 (100) 102～152 4.0～6.0 51～76 2.0～3.0

C

B

A

紧边 tension side

Right angle gear box

technical parameter：

number items technical parameter

1 Maximum output torque 10kN·m

2 Gear ratio 1.857

3 Maximum input rotate speed 1800rpm

� Maintenances

1、Inspect the oil level of gear box .add or reduce the oil after inspection.

Attention!

The place around the oil sump should be clean when inspect oil level，，，，prevent dust or

foreign matter fall into the gear box。。。。

2、A full inspection and maintenance should be given every 1000 hours。Inspects various

fasteners , connect parts，the lubrication pipe，and change the lubricating oil.

3、Inspecting the condition of gear.

4、Recommended lubricating oil：heavy-duty gear oil 80W/90 GL-5

5、Standard parts and quick-worn parts table：

No. code model Qty.

1 GB9877.1-88 Oil blanket B120×150×12 1

2 GB9877.1-88 Oil blanket B110×140×12 2

3 GB283-87 Bearing 32321 1

4 GB299-86 Bearing 97524 1

5 GB299-86 Bearing 97520 1

6 GB2283-87 Bearing 32317E 1

Drilling floor assemble

Main technical parameters

No. Item Technical parameters Remarks

1 Height 4.5m

2 Headway between rotary table beam to

ground

3.6m

3 Max. rated net load of rotary table 900kN

4 Max. rated thribble load 1200kN

5 Setback capacity 4000m 2-7/8＂DP

6 Drilling floor area 4.9m×6.6m Maintance of drilling floor

1. Dress the work clothes and take on safety helmet when go up to drilling floor, and

forbid smoke or fire, and be careful dropping, hanged equipment, stumbling,

electric shock, falling, injury by machine etc. Forbid non-operating personnel to

move the brake handle or driller accessories on condition of no allowance.

2. The base of rig substructure should be solidly, base is higher than ground

150~200mm in order that there is advisable slope gradient around base to drain

away water.

3. When finding the base of rig substructure downwelling, should take the remedial

measures on time.

4. When using the rig substructure, should check whether bolt or pin flexible, weld

line chinking, banisters are dependable, safety exit is expedite, to make sure that

the rig substructure is used safely.

5. When finding the paint of metal components fall off, should repaint it on time in

order to reduce corruption and extend the service life of metal components.

6. When finding the components deformed or damaged for collision, should calibrate

or change it to make sure the safety of using.

7. Check oil level and temperature of climbing chain box regularly. Change a new

chain on time when the chain links length are pulled more than 3%.

8. Check the opposing movement components such as pin shaft, chain box bearing,

oil seal, drive axle, pulley, rolling bar, and fill lubricant on time. When finding

wear seriously or damaged, should change it on time.

9. Check the rig substructure regularly, and clear the hidden danger on time in order

to avoid great mishap and extend the service life of equipment.

Air controlled system

Air controlled system schematic diagram

Main technological parameter：：：：

No. Item Model / Parameter

1 Compressor Model Bendix(BA-921)

Discharge capacity l/min 444

2 Air treatment

model

Filtration reducing valve FRC-3/4-D-MIDI-A

Atomized lubricator

3 Desiccator IDG50-30

3 System working pressure 0.85MPa

4 Air tank cubage 0.2m3

5 ambient temperature -20℃～50℃

Air controlled box

Trouble shooting

No. Fault Cause Elimination methods

1 Air compressor Fault Refer to engine operation

manual

2

Air

pressure

system

The pressure

is low

The pressure is adjusted by

the adjustable valve is too

low

The air compressor have

fault

Adjust the pressure adjusting

valve

Check the air compressor

The pressure

is not stable

The pressure-adjusting valve

have fault.

The pipeline leakage is too

big

Check the pressure adjusting

valve

Check the pipeline

3

Pressure

adjusting

valve

Pressure is not

stable

Valve is choked and sealing

ring is damaged

Overhaul, clean and replace it

The pressure

is not adjusted

high

The spring is tired and get

soft.

Replace the spring.

4

Dryer Not exhaust Signal circuit is short

The discharge valve is

blocked

The drying agent is not

effective.

Check the signal circuit

Overhaul and clean the

discharge valve

Replace the drying agent

5

Control

pipeline

The dirty

liquid is much

The drying agent is not

effective

The filter is not effective.

The dirty liquid in air storage

is not discharged in time

Check

Check

Emit in time

Dreezing in

winter

The drying agent is not

effective

The filter is not effective

The dirty liquid in air storage

is not discharged in time

The antifreezing device is

not filled with anti-freeze

fluid in time.

Overhaul

Overhaul

Discharge in time

Overhaul the anti-freezing

device and add the

anti-freezing fluid

6

Rotational

junction

Gas leakage The sealing ring is damaged

Spring is tired and get soft

Replace

Replace

Block The bearing is worn

The lubrication is not enough

Replace

Lubricate in time

7 Gas

cylinder

Gas leakage The sealing rings for cylinder

head and cover are damaged

Replace

The force is

small

The inner is leakage

The piston sealing ring is

damaged

The inner wall of air cylinder

has trace.

The sealing ring of piston

rod is damaged

Replace

Replace

Delivery to be repaired

Replace

8

Diaphragm

Cylinder

Leakage The diaphragm is damaged

The back cover connect is

loosen

Replace

Adjust to be fixed

Push is small The diaphragm is damaged Replace

Return to

position

slowly

The spring get tired or

damaged

Replace

9

Emergency

brake valve

Control

failure

The valve core is blocked Overhaul and clean

leakage The sealing ring is damaged

The valve body has crack

Replace

Replace the valve assembly

Brake and

release brake

is slow

The piston is blocked

The sealing ring of piston

The valve core is blocked

Overhaul, clean and lubricate

Replace

Overhaul, clean and lubricate

10

Quick-disc

harge valve

Failure The diaphragm is damaged Replace

Leakage The sealing ring is damaged

The valve body has crack

Replace

Replace the assembly

11

Shuttle

valve

Failure The sealing ring is damaged Replace

Leakage The sealing ring is damaged

The valve body has crack

Replace

Replace the assembly

Hydraulic system

Hydraulic principle

Control valve inst.

System parameters:

System pressure MPa 14

System flow L 165

Brand of hydraulic oil

Summer：L-HM 68；

Winter：L-HM 46(0～-10）℃ L-HV

46D（lower than-30℃）

Volume of hydraulic oil tank m3 0.9

Main oil pump

Model P25X378BEIU257

Type Gear pump

Rated pressure MPa 14

Flow L/min 165（Oil pump speed is 1800rpm）

Oil suction filter

Model TF-400×80F-C

Type Box outside self-sealing, suction

filter

Flow L/min 400

filtering accuracy μm 80

Oil return filter

Model LXZS-400×30

Type Box outside self-sealing, suction

filter

Flow L/min 400

filtering accuracy μm 80

Raising cylinder

Model 3# hydraulic pressure lift cylinder

Type Three-grade combinated cylinder,

equipped with single choke valve

Total stroke mm 5300

Telescopic

cylinder

Model Y3030

Type Single-action plunger cylinder

Total stroke mm 300

Hydraulic small

winch Model YJ-3

Type Epicyclical reduction gear and brake

System operating rules

1、、、、Preparation work：：：：

(1) Move the power devider hand lever to “OFF ROAD” position，and take off the front axle

driving;

(2) Inspect oil level from hydraulic oil tank. And make it reach oil level upper line position；

(3) engage pump。Move the oil pump air control valve hand lever to “ENGAGE” position；The oil pump air control valve is on the console

(4) move lock hook between the mast upper section and lower section (at the bottom of the

mast lower section）；

(5) Move shift valve hand lever of the operating box to “N” position；

(6) Put the lever of all the hydraulic valve to middle position；Put all the air valve to the middle

position too。

2、、、、Mast raising

Attention

Raising mast need two worker at least , one operating ,one inspecting.

prepare

(1) Start engine, engage hydraulic pump；

(2) Raise the lever of hydraulic valve, leveled the drilling rig by four hydraulic support legs. Do

not raise the wheels off the ground. Relieve some weight from the wheels by lifting

approximately one to two inches (25-50mm)

Attention！！！！

Tighten all the locknut after the drilling rig being leveled .

(3) Open valve "C" counter-clockwise ，raising the handle of change direction valve "B" 5

minutes to put out the air of hydraulic system；

(4) Open the bleeder of two hydraulic raising cylinders , raising the handle slowly ,put out the

air in the raising cylinders , close bleeders；

(5) Rotate clockwise to close valve "C"

(6) raising the handle of valve "B" and raise mast off front mast support approximately

200mm,stop mast raising momentarily and inspect system .sponginess or mast settling

should not be noticeable；

(7) Stop mast at the breakover point , if excessive sponginess is observed ,lower the mast and

bleed the ram on the pull back side of the rams；

(8) Pull raising valve control handle out slowly to ease mast over center ,seat mast lower

section front legs onto "Y" type base front legs and secure with two locknuts.

(9) Leveled the drilling rig and locked all locknut of the support leg

Attention!

When cylinder raising mast the biggest ram should be stretched first and the pistion

rod last. If stretch order is wrong ,some measure should be adopt to let cylinder return its

initial status , or will damage equipment and injure personal .

Warning!

Check to be certain that mast will be clear all electric power lines by at least 10’(3m)

to avoid hazard of electrocution!

3、、、、Mast extending:

(1) Release main drum brake and make traveling hook close to ground；

(2) Open valve "D" counter-clockwise ，raising the handle of change direction valve "A" 5

minutes to put out the air of hydraulic system；

(3) Close valve "D" clockwise. If there's air in the cylinder, a worker should climb up to the

mast and loose the bleeder, raising the handle of valve "A" a bit to push the air out until

clear oil come out，close bleeder；

(4) Raising the handle of valve "A”, make mast upper section extending. see that the extending

ram stabilizers operate properly as mast upper section pass them；

(5) Observe the mast upper section pawls extend as they pass above the pawl seats in the mast

lower section. Stop extending movement. push control valve "A" handle to "retract"

position and seat pawls firmly into pawl seat；

(6) Open the valve "D" counter-clockwise, insert the safe pin behind the mast pawl；

(7) Connect the lighting wire；

(8) Be sure to mast tilt indicator is set to the proper tig up distance as indicated on the tilt

indicator plate.

(9) Install mast load guys and pull tight to achieve a 3″ to 4″ in （75-100mm）sag in the

cable from a straight line；

(10) Attention!

Be certain that the mud boat under the mast base are level within 1/8”(3mm)on mast

base diameter to assure that mast base do not slip on mud boat.

Attention！！！！

When the mast upper section extending .observe racking board for proper

manipulation, see that the extending ram stabilizer fully grip the ram as the upper section

passes them so that the ram is supported horizontally. Otherwise, the ram may buckle

causing the derrick upper section to drop.

4、、、、Mast withdraw:

(1) Engaged oil pump , put out the air in hydraulic system ；

(2) Remove the safety pin behind the mast upper section pawl and the connect of lighting wire；

(3) Inspect the status of ram stabilizer , keep all line clear of mast；

(4) Close valve "D”, raising the handle of valve "A " to extend mast, unseating pawls and

forcing

(5) Them into the pawl retractor lock. this require approximately 6" of extending mast travel

(6) Open valve "D", let mast down slowly. close the valve when mast retract fully

Attention！！！！

Safety pin and lighting socket should be removed before telescope mast upper section,

otherwise will cause equipment damage or personal injure.

5、、、、lowering mast

(1) Remove the connection between the mast lower section and the "Y" type base；

(2) If there is air in hydraulic system , do step 2,3 of mast raising

Danger！！！！

If there is the air in the raising cylinder, the mast may fall down when it past the

perpendicular line and damage equipment and/or injure personal.

(3) Push in slowly on the handle of valve "B”, set mast on front mast support

Attention！！！！

When lowing the mast the ram rod should be retract first, the second ram, the

biggest ram finally。。。。If retract order is wrong, some measure should be adopt to let

cylinder return its initial status, or will damage equipment and injure personal.

Danger！！！！

If the lifting cylinder retracts abnormal, take appropriate measure to make it

restoration. Otherwise, it may result in damage to equipment and/or human injury.

Attention！！！！

The hook should be keep on the hook rack when lowing the mast

(4) Retract Y type base support legs and tighten the lockhook between mast upper and lower

section

(5) Retract four hydraulic support legs.

(6) Disengage pump

Using the system correctly:

1) Reasonable adjust the working pressure and speed of hydraulic system, the

over-pressure and over-load is prohibited.

2) According to the oil brand stated in the manual, chose suitable hydraulic oil for the local

condition, when adding oil to the oil tank, it will be filtered by the hydraulic air filter, it is

prohibited from opening manhole to adding oil directly.

3) The working Temp. of hydraulic system is 35～65℃,in the hard condition area, the oil

temp. must be less than 25℃. When the oil temp. is over the decided temp., please stop

working to check, after the fault is got rid of or the hydraulic oil is cooled, the work can be

continued.

4) When the equipment is running, please check the liquid level and oil temp. of hydraulic

tank.

5) The pressure gauge is damaged or failure, please replace it in time and do not continue

working reluctantly.

6) Periodically fix. because the hydraulic equipment has shake, hydraulic impaction and

pipeline self-shake, the pipe connection and fastening bolt is loosen, please fix them

periodically. The period is once one month.

7) Periodically clean and replace filtering element. under the normal condition, clean once

three months, if the dust is too much, the period should be shorten. When clean the filtering

element, please using the diesel or kerosene, the gasoline is prohibited; after being blowed

clean with the compressed air, the filtering element should be replaced in time.

8) Periodically clean the hydraulic tank. When the hydraulic system is working, the partial

dirt deposited and collected at the bottom of oil tank should be cleaned periodically. under the

normal condition, clean six months once, if the dust is too much, the period should be shorten.

9) Periodically force to filtrate and replace the hydraulic oil. under the normal condition,

replace the oil once after the equipment works for continuous six months, if the dust is too

much, the period should be shorten. in north area, the temp. difference between winter and

summer is great, the lowest temp in winter is less than-25℃, the max. temp in summer is over

35℃, the equipment must use the winter and summer hydraulic oil, according to the temp. to

replace it.

10) Periodically check the sealing unit. Generally, the sealing unit material of hydraulic

equipment is oil-proof nitrile-butadient rubber or polyurethane rubber, it will get natural aging

because of long being used, and the sealing unit gets forever distortion and lose the sealing

performance, please replace it periodically. Generally, the using life for sealing unit is about

half and one year.

TTTTrouble shootingrouble shootingrouble shootingrouble shooting::::

No. Fault Cause Trouble shooting

1 Hydraulic

oil tank

The oil is

polluted

The tank cover is not sealed well and

have water leakage

The oil is not replaced for long time

The oil tank is cleaned for long time

The filter is plugged and filtering

element is cracked.

The suction pipe of hydraulic pump has

leakage

Check and replace sealer

Replace the oil

Clean the oil tank

Check the filter and replace the filtering

element

Check and replace

The Temp.

is high

The oil level is low

The oil viscidity is too much

No-work run for long time

Add the hydraulic oil

Replace the hydraulic oil

The oil pump is off under the condition of

no-work period.

Abnormal

voice in the

tank

The oil level is low and the oil pump is

intaked empty

The oil return pressure is high

Add the hydraulic oil

Check and eliminate fault

2 Hydraulic

pump

Hot

The bearing is worn

The hole in pump body is worn

The gear end surface and side plate is

worn

The oil viscidity is high

Replace the bearing

Replace

Overhaul, rubbing and replace

Replace the hydraulic oil

The

pressure is

low

The oil viscidity is little

Hydraulic oil is polluted seriously

Oil pump is worn

The overflow valve is adjusted

wrongly

Replace the hydraulic oil

Replace the hydraulic oil

Replace oil pump

Adjust the overflow valve

The flow is

small

The oil viscidity is low

Hydraulic oil is polluted seriously

Empty-suction is serious

Valve and pipe have leakage

Replace the hydraulic oil

Replace the hydraulic oil

Add the hydraulic oil

Overhaul the valve and pipe

Leak Sealing ring is damaged

The pump body has crack

Replace

Replace the oil pump

Noise is

loud.

Installation and adjustment is wrong

Bearing is worn

The resistance in oil tank is large

Check and adjust

Replace

Check the oil viscidity.

3 Overflow

valve

Adjustment

failure

Main valve cup and cone valve cup is

blocked

The adjusting spring is cracked

The damp hole of main valve core is

blocked

Overhaul and clean

Replace

Overhaul and clean

No pressure

The damp hole of main valve core is

blocked

Reset spring of valve core is cracked

Hydraulic oil is polluted seriously

Overhaul and clean

Replace

Replace

The

pressure can

not be

adjusted

highly

The adjust spring is tired and get soft

Main valve core is blocked

The cone valve core is worn

The oil viscidity is low

Oil pump is damaged

Replace

Overhaul and clean

Replace

Replace

Check, grind and replace

Librations

and noise

The valve core is attached dirt

Fitting precision of valve core is bad

The cone valve and valve cup is

matched not very well

The installation of adjust spring is not

vertical

Overhaul and clean

Check, grind and replace

Overhaul and grind

Overhaul and emend

4

Oil

suction

and filter

Oil suction

is not

smooth

The hydraulic oil is polluted seriously

The oil tank is not clean when being

disassembled

The filter core is plugged

Replace

Clean

Check、clean

The filtering

core is

distorted

The loading and unloading is wrong

The filtering element is polluted

seriously

Pay attention to the assembling quality

Check and clean filtering element in time.

Filtering

core is

cracked

The loading and unloading is wrong

The valve core is polluted seriously

The quality of filtering core is bad.

Pay attention to the assembling quality

Check and clean filtering element in time

Replace

Self-sealing

is bad

The check valve and valve cup touch

badly

The check valve is wore and get soft

Overhaul and replace the sealing ring of

valve cup

Replace

5 Oil-return

filter

Oil return is

not smooth

The hydraulic oil is polluted seriously

The oil tank is not clean when being

assembled

The filtering element is blocked

Replace the hydraulic oil

Clean oil tank

Check and clean the filtering element

The filtering

element is

cracked

The loading and unloading is wrong

The hydraulic oil is polluted seriously

The quality of filtering core is bad.

Pay attention to the assembling quality

Check and clean the filtering element

Replace

6 Legging

cylinder

The pushing

force is not

enough

O-shaped ring in Piston outer cycle is

damaged

O-shaped ring in Piston inner cycle is

damaged

The system pressure is not enough

Replace

Replace

Adjust the system pressure

Oil leakage

The leakage exists in trapezoidal screw

rod

O-shaped ring of copper sleeve outer

inner cycle are damaged

Cylinder sealing ring is damaged

The leakage exists in cylinder body

Replace

Replace

Replace

Replace

7 Raising

cylinder

The push

force is not

enough

The system pressure is not enough

Adjustment pressure the eight-unite

valve is too low

The gland nut of sealing ring is too

tight.

Adjust the system pressure

Adjust the pressure of eight-unite valve

Overhaul and fasten the gland nut properly.

Retraction is

not strong

The system pressure is not enough

The third-stage retraction is not strong

and piston O-shaped ring is damaged

Adjust the system pres sure

Adjust the eight-unite valve pressure

Overhaul and fasten the gland nut properly.

Leak oil

The outer surface of plunger has oil

leakage and the relating plunger

sealing ring is damaged

Welding seam of cylinder head has

leakage

The connection of oil vent has leakage

Overhaul and rotate the gland nut of sealing

ring properly.

Overhaul and patching

Overhaul and replace connection

The

telescopic

order of

every

cylinder is

wrong

The gland nut of sealing ring is too

tight

The plunger is distorted

The air exists in the cylinder

Overhaul and rotate the gland nut of sealing

ring properly.

Check and repair

Discharge the air

8 Cat head cylinder

The pull is

not enough O-shaped ring in Piston inner or outer

cycle is damaged

The system flow is too low

Replace Adjust the system pressure Protruding

slowness The system flow rate is not enough

Multi-way valve has fault Adjust the engine rotate speed

Replace or overhaul Leak oil Piston rod part leak oil

Cylinder lid, cylinder head, cylinder

surface leak oil

Replace sealing ring or copper bush

assembly

Replace the O-shaped ring

9

Hydraulic

small

winch

The lift is

not enough

The system pressure is too low

The oil Temp. is too high

The pulley of wireline is blocked

The hydraulic motor is worn and leak

in inner of motor

Adjust the system pressure Reduce the oil Temp. Check pulley and lubricate it Overhaul and replace The

libration

exists under

the

condition of

rated load

The system pressure is too low

The system flow is too low

The hydraulic oil has high viscidity

Adjust the clearance or replace

Replace

Overhaul or replace

Suspending

stop and

skid

The brake friction disc is worn

The brake spring is worn and get soft

Clutch failure

Adjust the clearance or replace

Replace

Overhaul or replace

Suspending

weight can

not dropped

or stable

The brake is blocked

The oil pipe of brake cylinder is

blocked

Damp hole of brake valve is blocked

Overhaul and clean up

Overhaul and cleanout

Overhaul and cleanout

The wireline

arrangement

is not good

Overload

The pulley of wireline is blocked

Overload is not permitted

Overhaul and lubricate it.

Cooling system

main drum cooling system

No. Code Name Qty. 1 JH-100 Heat sink assemble 1 2 C0.249B.09-01 2" Nipple L=320 1 3 Q/ZB230-77,QT7 Swivel connection RC2 4 4 ISG50-125 Upright clear water pump 1 5 430560016450 Bolt GB/T5781-2000 8 6 435020000160 Backing ring GB/T93-1987 8 7 431030000160 Nut GB/T41-2000 8 8 C0.249A.02.02 Water in-out flange 2 9 C0.110A.08.02.01.01 Filter cleaner bleed hole joint 1 10 460104260 Stainless steel ball valve Rc2 1 11 Q/ZB246-77,QT4 Inside joint R2×135 3 12 475261 Normal bend DN50 2 13 C0.249B.09.01 Water tank assemble 1 14 460104135 Female screw ball valve DN25 1 15 C0.249B.09-02 Backwater nipple L=405 2 16 475264 Normal bend DN25 1 17 Q/ZB230-77,QT7 Swivel connection RC2 2 18 C0.249A.02-06 2" Nipple L=400 1 19 47625H201800 Hydraulic capsuleφ25-H-Ⅱ 1 20 ZCY/B-01.05.18E Joint R1-M39×2 4 21 C0.249A.02.04 Pipe clamp assemble 4 22 430560008500 Bolt GB/T5781-2000 8 23 435020000080 Backing ring GB/T93-1987 8 24 460109012 Z15T-10 Brake valve 2" 1 25 Q/ZB246-77,QT4 Inside joint R2×60 3 26 C0.249A.02-08 Water brake backwater joint 1 27 C0.249A.02-07 2" Nipple L=1000 1 28 E122 122 type water brake 1 29 C0.249B.09.02 Water brake water intake multiport 1 30 47651H201000 Hydraulic capsule φ51-H-Ⅱ 2 31 C0.249B.09/03 Water brake support leg 4

32 475261 Normal bend DN50 4 33 ZCY/B-01.05.25E Joint R2-M64×2 2 34 47651H201400 Hydraulic capsule φ51-H-Ⅱ 1 35 Q/ZB230-77,QT7 Swivel connection RC2 4 36 C0.249B.09-04 2" Nipple L=600 1 37 Q/ZB246-77,QT4 Inside joint R1×75 1 38 475264 Normal bend DN25 2 39 Q/ZB242-77 QT6 Reducer tee RC2×RC1 1 40 Q/ZB246-77,QT4 Inside joint R2×60 1 41 460104260 Stainless steel ball valve 1 42 460104135 Female screw ball valve DN25 1 43 C0.249B.09-05 2" Nipple L=850 1 44 C0.249A.02.05 Pipe clamp assembleⅡ 4 45 430560010600 Bolt GB/T5781-2000 8 46 435020000100 Backing ring GB/T93-1987 1 47 ZCY/B-01.05.25E Joint R2-M64×2 1 48 47651H201500 Hydraulic capsule φ51-H-Ⅱ 1 49 C0.249B.09-06 2" Nipple L=100 1 50 475261 Normal DN50 2 51 430560008400 Bolt GB/T5781-2000 4 52 435020000080 Backing ring GB/T93-1987 4 53 431030000080 Nut GB/T41-2000 4

System parameter:

No. Item Technical parameter

1 Water box useful volume m3 1.52

2 Recycle water flow rate L/S 3.47

3 System working pressure MPa 0.3

4 Radiator

Recycle water flow rate L/S 3.83

Matching motor power kW 2.2

Radiator fan diameter mm 760

5

Water

pump

Model SLR50-100

Flow rate 3.47

Matching power kW 1.1

Cooling medium:

The cooling medium should be selected suitably，or else begetting cauterization

and scaling， Make the winch and auxiliary brake elimination of heat bad , causes the

parts get hot damage excessively. Cooling water should choose litmusless soft fresh

water，first choose distilled water、softened water、mollifiable water，cannot choose

seawater、alkali water、riverwater without processing、brine and industrial waste water.

In the cooling water to forestall .Adding antirust additive in the cooling water to

prevent rustiness in the water tank，water pipe and penstock. Adding antifreeze fluid

when temperature is low comparatively.

Attention!

Not using antirust and antifreeze at the same time. Draining the former

cooling liquid off and cleaning the penstock and water cavity before change the

cooling fluid.

Inspecting the antifreeze fluid efficiency and liquid level height . after using

antifreeze fluid, especially inspecting the antifreeze fluid efficiency carefully

when temperature near critical temperature to prevent equipment crack as a

result of freezing. Please not adding the antifreeze excessively to prevent

reducing the effect.

Antifreeze fluid：

Can use ethylene glycol as a substitute for antifreeze，confecting as follows：

No. Minimum surroundings

temperature ℃ antifreeze % Purity soft water %

1 -10 20 80

2 -20 34 66

3 -30 44 56

4 -40 50 50

Chapter 3

Operation Instruction & Routine Practice

The deportation of drilling rig

Preparation before Operation

Operating stage

End of Operation

Summarization:

It is necessary for customer to completely comprehend its characteristic、structure、service range and be familiar with relative matters of the operation

instruction and routine practice before operating, thus live up to safe operation、rational use、 natural maintenance to prolong its operating life. The ability of the

drilling rig should be exerted sufficiently to avoid the unnecessary major mechanical

and personnel accident.

Caution!

Before anyone who is not trained and familiar with the technology

performance、、、、the structure features、、、、notice and the strict demand and operation

steps of the instructions, should be forbid to operate the drilling rig. The

operator must obey routine practice and carry out maintenance periodically and

repair. In case of some anomalies are spotted and suspected, the rig must be shut

down immediately to troubleshoot and repair them before its continuation of

operation.

Danger!

The vent-pipe of the engine must load fire-resisting cover ( Do-it-yourself )

when the drilling rig repair gas well or petro-gas well. Do fire fighting yourself

according to the actual fact.

The deportation of drilling rig:

1、、、、 Preparation before deportation

1.1 Check item

(1) Check whether the water in the engine cooling water tank is sufficient;

(2) Check whether the fuel oil mass in the engine is sufficient;

(3) Check whether the mobile oil of the engine is under the specified oil level;

(4) Check whether the oil mass in the hydraulic tank is sufficient

(5) Check whether the water flow of water circulation in the cooling water tank is

sufficient；

(6) Check the cleanness of each packed bed filter;

(7) Check the oiliness and oil level in each gear case and each chain case;

(8) Check whether each valve in the driller case is on the meso-position and whether

the gear-shifting is on the free position;

(9) Inspect whether the controlling handle of differential box is on “ driving” position;

(10) Check the tire pressure

1.2 Start up the engine. When the engine works normally and the pressure live up to

up 0.6MPa, it can work in accordance with the operating order

Caution!

The max. speed of ZYT5402TZJ DRILLING rig can’t exceed 50 km/h,

emergency brake is forbidden to avoid accident.

Warning！！！！

The shift-changing handle of transmission must be put on the empty

position before starting engine, otherwise the starting of engine will lead to the

moving of vehicle and influence the safety of people.

Preparation before operation

1.Ground preparation

1.1 The well area

(1) The area of well :The recommendation area of well which includes anchor tunnel

of the line is 46m ×46m;

(2) Mounting area of the equipment: Taking the mouth of the well position as the

center, the drilling rig about the width is 6.5m;

(3) Deadman hole: strike six anchor tunnels, the depth of anchor tunnel is 1.8m,

above long 1.3m, above extent 0.8m, down long 1.6m down extent 0.8m;

(4) Install deadman: the ability pull of each deadman should be not less than 98KN;

1.2 Basic requirements:

Select the rig’s parking place in accordance with the actual working condition on

the well site, convenient operation、parking the drilling rig steadily. Mast substructure

and floor base must be higher than well surface and dig barrel-drain to avoid the

gathering water after raining. Pay attention to the wind direction of the well site and

avoid the mast laterally to endure wind power as far as possible when determining

foundation position to prevent the drilling rig from overturning.

(1) Basic condition: Use different ground in accordance with different well yard

ground condition,

A、The ground for rock、dry and mass clay should adopt natural foundation and tamp

ground;

B、The ground for moist clay、desert、beach spreads and so on the soft ground region

should adopt manual foundation , which includes permanent foundation and

deportable foundation. Permanent foundation adopts the sand and crushed stone

concrete to pour; Deportable foundation adopts concrete to prefabricate, which forbids

using metal foundation.

C、Ground should carry out digging operation and tamp ground

(2) Groundwork load bearing

A、Drilling rig foundation: Install it in the ground directly, the groundwork must have

a load capacity no less than 3m/KN390 . If it matches with carrier matting plate, the

groundwork must have a load capacity no less than 3m/KN290 ;

B、The drill rod discharging area must have a load capacity no less than 3m/KN290 ;

C、Mast foundation must have a load capacity no less than 3m/KN390 ;

D、The mast floor must have a load capacity no less than 3m/KN390 .

(3) Groundwork level:

Around the fore-and-aft direction of the carrier is somewhat low and the slope can

not exceed 1:20; mast foundation、mast floor foundation、the level warp of the

right-and-left direction can not exceed 3m/mm1 , the level warp of the fore-and-aft

direction can not exceed 3m/mm4 . If it matches with the hull shape foundation, the

level warp of the right-and-left direction can not exceed 3m/mm2 .

1.3 drilling rig spotting

Spot rig so that its longitudinal center line intersects well center .the mast tilt plate

specifies the tilt angle is 3.5o.

(1) The distance from the center of rear beam of carrier to the center of hook (well

center) is 2600mm.

(2) Switch the power: transmission in neutral position, push the handle of power

divider box to “ROAD OFF”, engage pump which control valve on console of

rear.

(3) Bleed the gas of the hydraulic system according to the hydraulic system operation.

(4) Test the pressure of the hydraulic system: Control throttle and make it run at

600 ～ 800rpm. Uplift one leg of the cylinder slowly and retract to the

extremeness. Observe the pressure gauge should be 14MPa.

(5) Install the Y type base matting plate、cylinder、mast support;

Warning!

Support legs of carrier、、、、Y type base support legs must set on the

reinforcement plate of the matting plate, or the danger will occur!

(6) Level rear end of unit with rear support legs using bed level for check. The

support legs should take some of the load off of the rear wheels but not raise the

rear wheel off of the road. Don’t raise the rear wheel off the ground. The same for

the front support legs. If drilling rigs need long time to run, the extended screw of

support legs should be greased.

Caution:

To avoid excessive frame vibration and possible from frame cracking ,don’t

raise rear wheels off ground with support legs.

(7) Adjust well frame: Adjust the Y type bracket jack and put down the jack branch

leg of two trapezium screw threads, tightly riveted, the moment of 600N.m(±20N.M)

(8) Fix the walkway. Guardrail and the ladder.

(9) Fix others accessory.

1.4 Debug the equipment

1、Preparation

Inspect each propeller shaft、pins、locknuts for tightening

Inspect each lubricate part and add lubricant、lubricant grease in time.

Inspect the height of each lubricant; check the height of each water rank; check

the height of each gasoline tank.

Inspect each control handle and set it in suitable position.

Inspect each fluid and gas system、tube line and tie-in and assure each pressure

table in good condition and all ready; check each tube line reliable、unbroken

phenomena、aging fault and so on; Check each tie-in that has no phenomena of

loosened and leaked out.

Inspect the drum brake system.

Inspect each cables, without break thread、stave phenomena and instead the

disqualification steel wire in time.

2、Debug

1) Start engines:

A、Check the cooling liquid level: If the cooling fluid is not enough, add cooling

fluid. It is forbid to add cooling fluid in hot condition to prevent sudden change and

shatter economy. Permit to add an upper cooling fluid slowly if the condition is

emergent. Stop adding it until it overflows

B、Check the level of oil、oiliness; the liquid level of oil is between upper limit and

lower limit, if necessary, add oil. The oiliness should be cleanness and unpolluted.

C、Check the level of fuel; Turn on the switch of electrical source and check the

liquid level of fuel from fuel table or turn on the oil box cover directly and check the

height of fuel.

2) Hydraulic torque converter:

A、Check the liquid level、oiliness;

B、Check the oil temperature、oil pressure;

3) Liquid and gas system tests run. Each pressure is normal and doesn’t leak out.

4) The drawworks test. Adjust the clearance of brake strip, the balance of brake

strip, the height of brake handle; Operate the drum clutch, the hook rise normally and

brake firmly

5) The crown block saver test. Move the handle of toggle valve at the course of

tripping, the drawworks should be brake and the power put into the drawworks should

be cut off immediately.

2、、、、Mast raising

2.1 Notes:

(1) Each connected and tightened part of mast is all ready、steady and standard

accords with requirement.

(2) Each part of mast is all ready、in good condition、reliable and clears up easy

fallen thing; Check the mast and guarantee the mast cleanness.

(3) Inspect the lines of traveling system .utility winch .racking board .rod basket

should not blend each other.

(4) Inspect each line, including the guy line. If lines have rupture、wrest kink、stave

or others shatter which results in steel wire frame distortion and exceeds the related

order of ST/T5170、GB/T5972 should exchange.

(5) Inspect the clamp of fast line and deadline, should be tighten

(6) Inspect the mast pawl and the actuating linkage, properly lubrication should be

given.

(7) Move out the guy lines from the side hook of mast

(8) Inspect whether the lighting line、lamps are all ready and in good condition;

Disconnect the link of light socket on the top of the mast upper section;

(9) Inspect hydraulic system to guarantee without leakage phenomena before one

tripping the mast;

(10) All the air in the cylinder must be put out before operate mast .

(11) Remove all the obstruction, which may disturb the sight of driller

Warning!

When the wind speed exceeds four-stage (contain four-stage) the landing and

the flexing of the mast can not be carried out. After the mast rise up, the branch

leg of the mast can’t move.

2.2 mast raising program:

(1) Before raising cycle, grease mast hinges at rear support, and pins in each end of

raising cylinders. At least weekly prior to raising mast, grease pivot pins in racking

board and rod board and all sheave pins in racking board and rod board raising system

(2) Engage hydraulic pump drive at control console, raising “MAST RAISING”

lever and raise mast off front support approximately 200mm. raising pressure should

not exceed 1800psi(12.4MPa). Stop mast raising momentarily and inspect system.

Sponginess in raising cylinders or settling should not be noticeable .If sponginess or

mast settling is noticed, the raising cylinder should be bled using the procedure

outlined. （3）Raising the mast by lifting the handle of hydraulic cylinder, in this period ,

observe the order of cylinder raising carefully, and the order is one grade piston,

two grade piston, three grade pistion.

Note:

All the hydraulic operation see “HYDRAULIC SYSTEM OPERATE

PROGRAMS” （4）The operation of per grade should be slowly and prevent pounching. Reduce

the opening degree of handle and close valve of piston pole when the mast is close

to plumb position. And locate the mast at the Y-shaped support by controlling the

handle and opening degree when the mast over 90 degree, fix bolts well and

gugline at last. （5）get the control handle to the middle position and open the switch of

exhausting and discharge the pressure of cylinder. （6）Release the brake in time when raising

（7）Fix bolts between the mast and Y-shaped support. And fit the 4 pieces

guyline well of down-section mast, the beginning train is 4450N( suspending

droop is 150mm).

Attention！！！！

Forbid long time-raising , spread lubrication grease on the surface of

piston and cover it with jacket.

Attention！！！！

The raising should be clam, forbid brake and add speed suddendly.

2.3 mast extending program

（1）Discharge the telescopic cylinder before extending the mast. Close the needle

valve and open the discharge hat on the top of the hydraulic cylinder, lift up the

operation handle of cylinder slowly and do keep the pressure of gauge below the

1Mpa, discharge the air in cylinder, the handle go back to the original position and

fixed the discharge hat well. （2）Lifting up the handle of cylinder to keep the mast raising slowly, inspect

whether there is creeping phenomena, if there is, it proves that there is air in

cylinder, please operate (1) repeatly. （3）Reduce the opening degree of handle and lower the speed of mast when the

up-mast is closed to the working position. When the height of up-mast is higher

than the bearing block, get the handle go back to the middle position and open the

swith of needle valve, lie down the up-mast , make the block on the loaing seat and

close the needle valve at last. （4）Fix the guylines well. The beginning tensile force is 4450N(overhang degree

is 150mm), the guyline of racking board, the beginning tensile force is

2220(overhang degree 300mm) （5）Release brake to make the hook closed to grlund when extending the mast. （6）Worker with safety belt clambs to the mast, lock the loading structure and

knock into the pin of electricity to make the illumination connected well. （7）Fit the guard of racking board.

Warning!

Do no people beside the mast whtn lifting, lying and telescoping mast.

Warning!

The centralizer must be opened when raising the mast.

Danger!

Fix the guyline by using the grips. And disammble the grips when it gets to the

tensile force.

3 Installation of the water cooling system

Lay the cooling tank (radiator included) at the side of assist brake and parallel

with the carrier, connect the input and output hose, add soft water to tank.

Before one tripping the pipe, first switch the electrical source, and then startup the

water pump.

Attention!

Clear all obstruction before start the motor of pump and radiator, which

may be sucked into the radiator by the fan and make radiator damaged.

Operation

1、、、、 Drawworks operation

1.1 Main drum Operation

Engage main drum clutch to hoist blocks and load. The control unit is a composite

lever operated directional valve consisted of two 3-way directional valves and a

3-way pressure regulating portion. Each unit has its own OUT port.

The lever of control valve move upward 10°the clutch will be full engaged ,then

with the lever moving forward ,the throttle of the engine will be increased.

The lever of control valve move downward will increase the throttle of engine.

1.2 The main drum brake control

Operation regulations of the brake hold:

The brake framework is the manual mechanical structure. The brake power

increases the right and left power through the lever passing structure, push the

crooked crutch which pulls the movement of the brake strip, embrace the brake drum

to make the main drum decelerate or stop. Realize the intention of controlling the

hook speed、hanging the hook .

The brake hold has the safety chain, after pressing the brake hold tight, be able to

lock the position of the brake.

(1) Make a pull. Right hand controls brake hold and left hand controls the

control valve of the main drum, push up the control valve of the main drum, engage

the clutch. Continue to push up the control valve handle of the main drum and

enhance the engine rotate speed step by step. The main drum starts to rotate, at the

same time right hand loosens the brake hand properly, and swarm vehicle hook

ascends slowly. After the hook spring is pressed, increase the gun. Control the engine

speed at 1200～1800rpm, the hook ascends and suspends the vitta pole. Before the

hook ascends up to the vertex, reduce the ascending speed and prepare for the braking.

When braking, the control valve handle of the main drum lies in neutral position and

the main drum clutch breaks away. Right hand press the brake hand properly and the

swarm vehicle hook stop slowly。

(2) Going down. Right hand controls brake hand and left hand controls the

control valve handle of the main drum. When the hook load is less than 300KN, not

use the auxiliary brake and set the control valve handle of the main drum in neutral

position. The main drum clutch breaks away, right hand loosens the brake hand

properly, control the lower speed of the hook. When the hook load exceeds 300KN,

use the auxiliary brake and engage the control valve of the auxiliary brake, at the

same time adjust the brake pressure to attain the proper auxiliary brake power.

Corporate with the brake hand to reduce the lower speed of the hook, when the staff

pole tie-in passes the turntable, press the brake hand to ease the impact. When the

single radix leaves 3～4m, reduce the lower speed and press the brake hand step by

step to make condole block seated on the turntable balanced.

Caution!

Crown saver system should be inspected before tripping, the action

of brake should sensitive and credible

The operation should be steady and should not dash pull or down.

Prohibit brake failure suddenly and cause cable drilling.

1.3 The cooling circulate system of the main drum brake hub

The cooling circulate system of the main drum brake hub and the water cooling

circulate system of the auxiliary brake which use the one and the same cooling water

tank are set in the same system, but the circulate path is different. The electrical

engine drives the centrifugal pump which transports a certainty pressure circulate

water which circulates in the two brake hub water jackets to another end the head

cock of the main drum. After circulating, reflow to the water tank cooling from

another one end head water of the main drum axes.

Caution!

Startup the circulate water to cool the system electrical engine when

operating

Pay attention to the circulate water pressure in the operation. Prevent water

pressure too higher or too lower and the pipe line being short of water.

2、、、、 The control of the rotary drive box

The function of the rotary dive box transmits the power for the rotary table, by

way of the control frame of the turntable. Its operation goes along through the

turntable control valve of the head driller box. The turntable control valve is a

three-position four-way valve. The handle of the valve pulls forward, and then the

clutch of the rotary table box engages and drives the turntable circumvolving. Push

back the handle of the valve, the clutch comes away; the turntable brake cylinder

starts to work, and then the turntable stops circumvolving.

Otherwise, the rotary table box still sets up the hand positive and reverse unit,

push forward the putting up and hanging handle, and then engage the positive. Pull

back the putting up and hanging handle, and then engage the reverse to be convenient

for using the positive and negative button drill pipe.

Warning!

Gear changing is forbidden when the clutch of rotary box engaged, or will

damage the clutch or the other parts

The rotary table box still sets up the drill pipe reverse distortion and the energy

released unit. Its operation is carried through the turntable brake control valve of the

head driller box. The turntable brake control gas circuit is made up of a three-position

four-way valve and a handle pressure regulating valve. When the rotary

boring operation stops, push the handle of the turntable control valve from up to down.

The main gas gets through three-position four-way valve, supplies the gas to the brake

cylinder by hand wheel pressure regulating valve. Prevent the drill pipe distortion and

the energy released which causes the turntable and the transmission parts reverse by

the brake cylinder, avoid shattering the transmission parts. The higher of the handle

comer which rotates clockwise, the bigger of the braking force. Reverse turning hand

wheel can release the distortion energy of the dill pipe. The hand wheel pressure

regulating valve sets in open state in normal.

Caution!

Don’t operate the rotary brake control valve if the rotary table runs or the

clutch doesn’t come away, or it will spoil the clutch or the braking device.

3、、、、 Hydraulic air course and electrical system

3.1 Hydraulic system

The hydraulic system of the drilling rig adopts air control mode. The hydraulic

winch、the cathead control measure of oil tank adopts the air control. Because

operation of rig up and flex hydraulic tank has been described, only describes the

operation system.

A、Engage oil pump, derive the hydraulic oil pump.

B、The hydraulic winch control valve adopts the pneumatic mode, the control air

valve is three-position

four way valve. The control valve upper hydraulic winch drum revolves in clockwise,

upgrade the clog and stop in neutral position; lower hydraulic winch drum revolves in

anticlockwise and the clog.

C、The oil tank control valve adopts gas mode, The control air valve is made up of

two three-position

four way valve. The oil tank realizes load and unload operation when the control

valve lies in the lower position. Relieve it in the upper position.

D、The hydraulic clamps oil inlet is controlled by the change-over valve. When the

valve handle lies in the oil tank the hydraulic system carries through operation of the

mast raising and mast down. Meet with the hydraulic clamp while lying in the

hydraulic clamps.

The pressure of the overflow cock of the hydraulic pressure system and other

pressure regulator site has been adjusted before ex-works, so it is unnecessary to be

adjusted in use. The packed bed filter should be inspected and cleaned periodically to

ensure the working reliability of the liquor passage system. The replacing of the

hydraulic oil should refer to its pollution level. if the moisture limit ratio by weight

exceeds 0.05 ％ and the grime degree exceeds 7-10mg／100ml, the hydraulic oil

should be replaced.

3.2 The air passage system

The compressed air of the air passage system is d by an air compressor locates in

the nearside of the engine and has a pressure control valve on its side, supplies the

compressed air to the air passage system, whose limited pressure has been adjusted

before ex-works. If the pressure is set too low, user could adjust it using this method:

unburden the end cover and rotate the inner stud anticlockwise to adjust upwards the

pressure，contrarily depressurize. An automatic unloading gear has been fixed in the

air compressor. Once the pressure in the air pocket reach standardized value, this

pressure would be feed back to the air compressor interior via pressure control valve

and then the compressed air will be passed between the two cylinders, which results in

no-load working of the air compressor.

The safety valve pressure regulating pressure of the gas is 1.1MPa (160Psi). A

water drain valve has been set in the lower part of the air pocket to drain once a day

and twice in the winter. Three elements for compressed air disposing has been set on

the main air passage, the erection sequence should take turns in air filter, then the

pressure control valve, and at last the oil mist generator. An anti-frozen pump has

been fixed behind the oil mist generator. The pressure control valve have been

adjusted to specified working air pressure before ex-factory，user need not to adjust

generally.

The work pressure of the air filter is 1 MPa and the maximum working

temperature is 52 . An outlet valve, for automat℃ ic drain or manual drain, has been

located at the bottom of the air filter. Manual drain need to be drained periodically.

When the filter is repairing，shut down the air inlet first which leads to the pressure in

the container and pipeline decrease to zero. The plastic container could only be

cleaned with warm water while other parts could be flushed with warm water or suds.

The filtering element could be huffed from then reverse direction of the airflow to

remove surface impurity. Through hole of the part and shell interior could be

blow-dried with clean and dry compressed air.

In order to make the air passage system of the drilling rig work normally, the

anti-frozen pump was used. Airflow passed by alcohol anti-congeal implement，so the

vaporized alcohol is carried away, which avoids the freezing of pipeline and

pneumatic component.

Caution!

Before adding alcohol, the ball valve before the anti-frozen pump should be

shut down to disconnect the air passage of anti-frozen pump. Alcohol could not

be charged until there is no air pressure in the anti-frozen pump when the filling

opening could be opened.

All of the pneumatic control valves are centered on the driller case and each

function shows as follows：

A、 The main drum control combination pressure regulating valve

This valve, possesses the function of three-position four-way valve and two-way

pressure adjustment, controls the main drum on-off movement and the opening of the

engine throttle. When the handle of the valve put at the mid position, the disc type

clutches of the main drum disengages and the engine throttle works in the idle speed.

Push towards for 10o，the disc type clutches of the main drum will integrate. Keep on

pushing towards，the opening of engine throttle and the engine speed could be

augmented. Drag the handle down to control engine throttle, by this time it possesses

the function of hand throttle.

When it was working，first to engage gear, and then push towards for 10o， the

main drum will integrate, which main drum will not rotate if it is loading weight, by

this time, the torque converter, like a master clutch, departs from the operating mode.

Keep on pushing towards, the engine speed could be augmented and the main drum

begins to roll which leads to rising of the hook.

When the hook is expected to rest down，loosen the handle, which is clasp by the

left hand of the main drum control combination valve. The handle will automatically

get back to mid position and the engine returns to tick over. Impact brake handles

with the right hand to rest hook down.

The hook falls down by dint of the deadweight. Operate the tightness of the brake

handle to control the velocity the hook falls

B、 The gear shifting valve of the gear-box

The gear shifting valve of the hydrodynamic drive case controls the gear shifting

of gear-box, which has six droves, a neutral and a reverse gear. When it begins to drill,

it is strictly prohibited to use the reverse gear in case of spoiling the gear-box.

Gear shifting should be performed at the condition of off-load. Making a pull at

the surcharge in each gear is strictly prohibited. Instead, select an adequate gear

according to the weight of upright post.

In the period of working，engine speed can not fall below 1200r／min to ensure

sufficient lubricating oil were stored in the gear-box.

The drilling rig adopts hydromechanical drive, the output torque of the torque

converter should be greater than the engine moment in zero condition, which enables

the drill to have the excellent starting characteristic. Because the engine and the

compound box adopts non-rigid link, which can lighten the mutual attack and improve

drive characteristic. At the same time the engine doesn’t have the function of reverse

brake, so when it begins to drill, it is strictly prohibited to use the reverse gear in case

of spoiling the torque converter and the engine.

Warning!

When it begins to drill, using the reverse gear will spoil the torque

converter and the engine.

C、 Crown saver valve

Crown saver valve is a three-position four-way directional control valve. when

the drilling rig works well ，move handle upwards to anti-clash site. When hook up

run up to the specified alert site at the bottom of overhead traveling crane, anti-clash

elbow valve, locate on the winch, is opened by steel wire rope. The compressed air

enters into the brake cylinder and the drum brakes. Here now the compressed air shut

down the Normal open post-gasses ware, Cut off the passage of the compressed air to

the drum control valve, at the same time the compressed air in the drum clutch are

quickly exhausted from the rapid delivery valve. The air cylinder of the throttle stop

to be offered with the air as the drum clutch loosens and the engine returns to tick

over.

Here, operating the driller control valve would not react. After the failure cleaned,

anti-clash elbow valve follower should be reseated. Move the anti-clash reseat valve

handle to the reset position, the brake cylinder would involute and release skid. At this

point，the control valve handle should be moved to the anti-clash position to ensure

the security of next use.

Caution!

This system should only be used in emergency

situation ,often use could bring excessive impact to mast and other

parts .

The emergency braking control valve is a two-position three way directional

control valve. In the general situation, the emergency braking dam situates on the

normally off. Once the skid poaptor begin to be out of control and the hazardous

condition appears, push the emergency braking control valve handle upwards. The

compressed air would transport to the brake cylinder and the drum is braked firmly

and quickly. Then the hook would be rested on the security position. The working

principle of the air passage system is the same as the Anti-clash reset control system.

After the failure cleaned, the handle should be reseated. The brake cylinder deflates

and release skid. Push the anti-clash reseat valve handle to the reset position, the

brake cylinder would draw back. At this point，the control valve handle should be

moved to the anti-clash position to ensure the security of next use.

Caution!

After the toggle valve of crown saver system actuated, should let

the brake cylinder reset by opetate “CROWN SAVER RESET” . That is turn

the lever of CROWN SAVER valve to “SAVER”

D、 Flameout pneumatic control valve

There is pneumatic control valve for engine flameout in the digger control case，so

the transmission case must be put in the neutral position when flameout is required.

Then put the flameout valve in the flameout position. Flameout valve will issue the

pneumatic signal to the flameout air cylinder，then pull the drawbar of the flameout air

cylinder into the flameout position，engine will flameout. Flameout air valve should

be put in the disconnection position when wanting to start up the engine.

E、 The turntable brake control valve

The turntable brake control valve is made up of the combination valve of the

control valve、two-position three-way valve、hand pressure regulating valve. The

combination valve is used to control the turntable clutch and the engine gun. The

two-position three-way valve is used to control the torque released of the turntable.

When the rotary boring operation stops, the handle of the two-position three-way

valve pushes back, through applying the brake cylinder to prevent the turntable on

account of the drill pipe releasing the energy which causes the turntable and

corresponding transmission part to overturn rapidly in order to spoil the driving

medium. As the brake force becomes bigger, the hand wheel’s corner of the hand

wheel pressure valve whirls clockwise bigger. At first it needs to relieve the brake and

revolve the handle of the hand wheel pressure valve, the turntable revolves slowly and

releases the energy. The hand wheel pressure valve sets the opening maximum

position.

F、 The cathead cylinder control valve

This valve is a self-resetting three-position four-way valve. This valve controls the

slave valve to realize the on-off operation;

G、 The hydraulic winch control valve

This valve is a three-position four-way valve. This valve controls the slave valve

to realize the yo-yo rotation.

3.3 Electrical system

The electrical system which adopts the mains supply of 220V and 50HZ is made

up of lightening and signal system、auxiliary brake and brake hub cooling water

circulation and the water pump electric motor circuit .

The lightening and signal system is made up of an explosion prevention and

waterproof connector of 220V and 50HZ、explosion prevention lamps and lanterns、flame retardant cable. All of the lightening and switching facilities settle for the

outdoor conditions. A strip of the spur track controls the mast lightening and signal

lamp and the other spur track controls the lightening of the rig floor, another spur

track controls the vehicle lightening.

The auxiliary brake and brake rim cooling water circulation and the water pump

electric motor circuit is made up of a two-way jack box of 220V and 50HZ、explosion

prevention electric motor、flame retardant cable. Two-strip spur tracks are controlled

by the electric motor. The water pump electric motor should be in normal condition

when the drill works well.

3.4 Regulations operation of the hoisting system

3.4.1 Gear selecting

When it was working, it should select the gear of the gear-box and the ascending

speed properly according to the hook loads. Assure the equipment runs safely while

increasing the working efficiency; the hook should be in unload while shifting the

gear and the engine returns to tick over; In normal condition, the hoisting working

gear of the gear-box should be the second gear、 the third gear、the forth gear. The

first gear should be used to deal with the underground accidents and the fifth gear

hoisting the idle hook.

3.4.2 Operation of the engine throttle

The opening magnitude of the gun controls the main engine rotate speed, realize

to control the hoisting speed of the hook. The main drum control valve may control

the engine gun in the rig floor. Operating the engine gun should accelerate steadily,

which is prohibited to accelerate the gun in case of spoiling the engine.

No Working condition Rotational speed of

engine rpm

1 idle running speed 500～600 2 hoisting of hook 1200～2100 3 drilling of rotary table 1200～2100 4 support cylinder 600～1000 5 lifting cylinder 600～1000 6 cathead cylinder 800～1200 7 hydraulic drilling tongs 1200～2100 8 lifting of hydraulic winch 800～1600

End of Operation:

Rig down:

1. preparation:

a. prior to each rig down, grease rear mast support hinges and mast raising ram

pins, both at mast end and at vehicle end . at each rig down or at a minimum of one

rig down per week , grease pivot pins at racking board and rod board and all sheave

pins in racking board and rod board raising system

b. remove the safety pins behind the automatic pawl

c. disconnect air lines and electrical connection between upper and lower section of

mast

d, loosen wind guys at guyline anchors ,pull all guylines clear from the mast

2. telescoping mast:

a, close manual bypass valve “D”at hydraulic valve group

b. engage hydraulic pump at hydraulic valve group

Caution!

Retract both hydraulic catworks cylinders before lowering mast

Caution!

Before any hydraulic pressure is applied to telescope

mast ,operator must see that all extending ram stabilizers are fully

extended so that the ram is supported horizonally .otherwise , a

“buckling” of the ram may occur dropping the mast upper section.

c. extend mast, unseating pawls and forcing them into the pawl retractor lock . this

require approximately 150mm of extending mast travel .

Attention!

Water pressure gauge .if upper section is slow in raising or raising with above normal

pressure , indications are air in the extending cylinder .in this event ,it may require

bleeding at the upper pawls .if the upper section raises and retracts the pawls , it is

safe to telescope the mast and bleed when the upper section is fully retracted.

d. move control valve to “retract” position and telescope the upper section into the

lower section . pay attention to the following items:

� keep all lines clear of the mast .

� watch racking board for proper manipulation .

� take in line on drilling drum as required to keep traveling block above the ground

and well head

� take in line on utility winch as required .

� lower upper section until pawls automatically release and section stops at bottom

of travel.

� If desired , hydraulic pump may be disengaged after clearing pawls during

telescoping operation .

e. after telescoping ,place manual bypass valve at control valve group in

“OPEN :position

f.. disengage hydraulic pump

3. lowering the mast

(1) Preparation

a. Hang traveling block on block hook and lower against block cradle.

b.Release drum brakes and put deadline, fast line and sand line behind the tie back

spool. Take slack out of the cable and apply drum brakes.

c. Set main drum brake safety latch at bell crank at rear of rig and remove control

rod from manual brake lever to rear of unit.

CAUTION:

Be sure to remove control rod from derrick mounted brake lever to bell

crank at rear of unit before lowering derrick to prevent possible bending or

breaking of control rod.

d.Shut off air supply to operator’s control console at supply shut off valve at rear of

unit and by placing transmission control position in cab to “ON” position.

e. Remove tilt screw lock plates or pins between derrick lower section front legs and

split base.

f. Check support legs to see that they are in working position and tight in the base

plates.

g.Check hydraulic rams for external leakage. Of noted, bleed rams.

h.Wipe off exposed chromed cylinder sleeve surfaces prior to lowering derrick to

avoid pulling dirt into cylinder packing.

i. Engage hydraulic pump at hydraulic valve group.

j. Check to determine that hydraulic pressure is available in “RAISE” direction by

slight control valve manipulation.

(2) Lowering Derrick

a. push in slowing on derrick “LOWER” lever. Build up pressure slowly and pull

mast back over center slowly. When derrick breaks center toward the rig, stop.

Ease handle on in to “LOWER” position and let derrick come down gently. Do not

exceed 500psi (35kg/cm2) hydraulic pressure.

CAUTION!

If any external leakage has been observed or if derrick has been

standing for a long period of time or for any other suspicion of air in the

system, bleed rams prior to this lowering sequence

ATTENTION!

Always keep hydraulic pump engaged when lowering the derrick so

that the top side of the raising cylinder pistons can be replenished with

hydraulic fluid as derrick lowers.

ATTENTION!

Avoid abrupt control valve movement and control pressure by amount of

valve manipulation.

b.Clear all lines from derrick to keep them from hanging up. Guylines may be

pulled into guyline hooks alongside derrick as derrick is lowering to expedite

guyline storage later.

c. Seat derrick on front derrick support.

d.Disengage hydraulic pump.

e. Attach front derrick support tie down.

f. Stow control box and operator’s platform.

g.Wrap guyline hook and stow loose items.

WITH HYDRAULIC PUMP DISENGAGED, move hydraulic valve handle to

both “RAISE” and “LOWER” position. This will relieve any pressures in the raising

cylinders.

Chapter 4

Check, Lubrication And Maintenance

Check Period And Check Item

Lubrication

Maintenance

Using In Winter

Parking And Storage

]

Termly check and maintenance is important to avoid possible injury and/or

damage to the equipment as well as to assure the rig works effectually and to prolong

the service life.

1、、、、 maintenance Period Table

No Check Lever Running Interval Remarks

1 Break-in check 80～100h DIY

2 Routinely check 250～300h DIY

3 Ⅰ-lever maintenance 500h DIY

4 Ⅱ-lever maintenance 1000h DIY

5 Ⅲ-lever maintenance 2000h Repair

6 Mid-repair 4000h Repair

Note:

(1) The upper table is made for drilling rig whose running time per year is 1500h.

If running time is less than 500h, the maintenance period should be short

appropriately.

(2) “Routinely check” means: the check period and check items should be done

per 80～100h running time after the new equipment or the repaired one is in service.

2、、、、 Check Period and Check Item

2.1 Shift Check Table

No Position Temp. Pressure oil lever running Remarks

1 Engine

Oil √ √ √

Fuel √ √ Engine speed

Water tank √ √

2 Hydraulic transmission

oil √ √ √ working pressure1172-1275kPa（170-180Psi）

3 Air- pressure system √ √ working pressure 0.833-0.931MPa(85-95kgf/cm2

4 Hydraulic system √ √ √ √

5 Angle transmission √ √ √

6 Rotary table √ √

7 Chain cases √ √

8

Drawworks

Cooling

water tank √ √ √

Main drum √

Crown

block

protect

√

Main drum

brake system √

Auxiliary

brake

system

√

Sand drum √

Sand drum

brake

system

√

9 Hydraulic cathead √

10 Hydraulic winch √

Note!

Stop the equipment immediately for check once any problem occurs. Do

not work with trouble.

2.2 Check Table per 100h, 300h and 1000h (on the base of shift check)

No Check Item Check Period

The100th hour The 300th

hour The 1000th

hour

1 Engine fuel √ √ √

2 Oil filter √ √ √

3 Fuel filter √ √ √

4 Pre-fuel filter √

5 Air cleaner core √ √ √

6 Engine idle √ √

7 Transmission oil √ √ √

8 Transmission oil filter √ √ √

9 Propeller shaft’s link and lubrication √ √ √

10 Chain case √ √ √

11 Lubrication for winch √ √ √

12 Lubrication for mast √ √ √

13 Lubrication for hook √ √ √

14 Rotary table transmission oil √ √ √

15 Lubrication for rotary table √ √ √

16 Hydraulic & air system work condition √ √ √

17 All control rods’ work condition √ √

18 Loose condition of tightening

parts (keys, pins, bolts) √ √

19 Abrasion condition for brake block √

20 Appearance condition of brake hub √

21 Chain abrasion condition √

22 Gear joggle condition √

23 Wireline working condition √

24 Hydraulic winch √ √ √

25 Instruction meter Replace immediately once instruction failure

26 Weight instrument √ √

27 Fuel & air pipe Replace immediately once damaged

Note!

1．hydraulic oil is quality criterion of hydraulic system：

The moisture limit ratio by weight exceeds 0.05 ％ and the grime degree exceeds

7-10mg／100ml, the hydraulic oil should be replaced.

2．When chain link is lengthen is more then 3%, it should be change chain

3．Radius of travel block and crown wheel rope groove are more than

R13.97mm, it should be replaced or change wheel.

4．Radius of bailing wheel is more than R7.85mm, is should be replaced or

change wheel.

3、、、、 Lubrication

1、 A good lubrication for every needed position is very important for the equipment, not only for the normal working but for prolonging

service life, or it may result in abnormal damage. So, the customer should pay specially attention to the lubrication condition and strictly follows

the following table to lubricate.

No Lubrication Position Lubricant

Points Period Remarks Summer Winter

1

Two sides lubrication

point of drawworks

support

Molybdenum bisulfide

extreme-pressure Lithium-based grease 12 Every shift Oiling before working

2 Auxiliary brake 3# Lithium-based grease 4 Every Oiling before working

3 Brake control system 3# Lithium-based grease 8 Every Oiling before working

4 Drawworks brake bracket 3# Lithium-based grease 6 Every Oiling before working

5 Input-output chain case Mechanism oil

N32

Mechanism oil

N22 3 Every 6 month

Putting in new lubricant to oil

lever pointer after emptying the

old one and cleaning the case

6 Crown block Molybdenum bisulfide polar-pressureed

Lithium-based grease 6 Every shift

7 Hoisting cylinder pins 3# Lithium-based grease 4 Every serving 1 oil

well

8 Guiding wheel device for

take-off cylinder 3# Lithium-based grease 4 Every shift

9 Telescopic cylinder

centralizer 3# Lithium-based grease 16

Every serving 1 oil

well

No Lubrication Position Lubricant

Points Period Remarks Summer Summer

10 Angle gear box Heavy-duty gear oil 80W/90 GL-5 1 Every 6 month

11 Rotary table transmission Heavy-duty gear oil 80W/90 GL-5 1 Every 6 month

12 Transmission shaft 3# Lithium-based grease 20 Every shift

13 Engine 15W/40CD 10W/40CD(0～-25℃）

5W/30CD（-30℃以下） 1 Every 6 month

14 Transmission ALLISION C4 Certificated 1 Every 6 month

15 Bearing block shaft 3# Lithium-based grease 4 Every serving 1 oilwell

16 Hydraulic winch 3# Lithium-based grease 1 Every

17 Hydraulic winch wheel 3# Lithium-based grease 2 Every

18 Guiding wheel 3# Lithium-based grease 2 Every shift

19 Hydraulic system 15W/40CD L-HM 46(0～-10℃）

L-HV 46D（-30℃以下） 1 Every 6 month 900L

Note!

The oil type of upper table is only for reference. The user should choose the appropriate oils for lubrication according to the

region and ambient temperature.

4、、、、 Maintenance

4.1 Periodically clean the oil filter once every 2 months.

4.2 Periodically clean the air cleaner once every 2 month.

4.3 Periodically check, clean and maintain other units. Replace them once there is any

badly abrasion or damage.

4.4 Maintenance for mast

A. Putting lubricant in the all opposite moving units on time.

B. Forbid drilling hole or welding in the mast.

C. Paint after derusting once the paint on the mast is broken off.

D. Periodically check the wire lines and line clip, make sure that the lines are in

good condition and the clips are tightened effectively.

E. Maintenance period should be modified according to actually conditions,

generally done along with normally check.

5、、、、 Using in the winter

Generally, winter running begins when the ambient temperature is under 5℃.

Before the winter, the season-changing maintenance should include the items below:

A Check the pre-heater of engine and assure that it’s in good condition.

B Putting ethanol in antifreezing device for air system (do if the ambient

temperature is below 0℃).

C Make sure that the warmer is in good condition.

D Replace the anti-freeze fluid using in winter for engine.

E Use the anti-freeze fluid for the water circle system.

6、、、、 Parking and Storage

Lubricate the related transmission units and periodically maintain the engine if the

rig will not work for a long time. Cover the power settings with canvas and hold out

the cylinder leg to support the equipment weight in order not to press the tires for

long.

Warning!

Have the cylinder leg hold out if the equipment will be parked for a long time,

or, the frame may be anamorphic timelessly.

Chapter 5

Package And Transportation

1、Three different types of transportation

ZYT5510TZJ DRILLING Rig mainly composes two parts, that is main vehicle

and assembly units. There are three different types of transportation to choose. The

user should choose an economical one to meet needs.

1.1 Road Transportation

Recommend use the self-walk type transportation to arrive the destination if the

whole mileage is about 500 kilometer and the main road is in good condition. In this

case, no need to pack, the hook and mast can be carried along with vehicle. the

vehicle’s driving speed is between 30 kilometer and 50kilometer.

The overall transportation dimension of ZYT5510TZJ DRILLING Rig is:

18950x3000x4400mm, the minimum turning radii is 17meter, the maximum

climbable gradient is 25%.

1.2 Train Transportation

This type is suit for long transportation. Generally have the equipment divided

into three parts: main vehicle (carrier and special device of vehicle included), mast

and accessories. In this case 3 carriers are needed. Naked lading is adapted for mast,

main vehicle and mass accessories (to avoid damaging or losing the units, the key

units can be packed with packing board), there, the remarkable slinging signs are

painted in these parts. Wood box is suit for small accessories. Make the main vehicle

drive into the loading area, the main vehicle is 42 tons and the mast (including crown

block, hook, Y-type bracket, etc.) is 14 tons.

1.3 Ship Transportation

It is typically used for oversea transportation, generally shipping on the board in

the inland port, transiting to destination via international liner through inshore port.

When loading, divide the equipment into three parts: main vehicle (including carrier

and special devices of its), mast and accessories (hook, lighting system, etc). The mast,

main vehicle and mass accessories are packed with packing board and the remarkable

signs are painted separately; besides that, the small accessories are packed with wood

boxes. For the main vehicle, it can be driven into loading area. The main vehicle and

mast (including crown block, hook, Y-type bracket, etc) is 42 tons and 14 tons

separately.

2、Transportation of the main vehicle in the Oil field

Oil field transportation is generally same as road transportation. Because of the

complex oil field road, it’s necessary to pay attention to following conditions.

2.1 The driver should read the Using Manual of ZYT5580TZJ Carrier carefully to

assure that the vehicle will be driven rightly and safely.

2.2 Do not drive or park at the softly road, especially not drive or park at the edge of

softly road. otherwise, it may result in vehicle slanting, even overturn because of

the heavy weight of vehicle (see the following figure).

2.3 Drive slowly if the road condition is not good.

2.4 Check the air pressure of tires before driving, make sure that the pressure is

conformed to standard.

Chapter 6

Appendix

Appendix Table 1: the Attached Document List

No Name Remarks

1 the User Manual to CAT C-16 Engine

2 the User Manual to Allision S6610HR Hydraulic

Transmission

3 the User Manual to ZYT5580TZJ Drilling Rig

Carrier

4 the User Manual toZYT5510TZJ DRILLING Rig

5 the Product Certification of ZYT5510TZJ

DRILLING Rig

6 the instruction of YG160B Hook

7 The instruction of XSL135 swivel

7 the instruction to ZX110A Rotary Table

Transmission

8 the instruction for JZ serial Weight Instrument

Appendix Table 2: the Attached Tool List

No Item Code Quant. Remarks

1 chain-tightener 28A-2 CS0.110.01 1

2 tire nut wrench 1

3 lever ruler 600 1

4 needle clamp 8″ 1

5 grease gun 200ml 1

6 metric box spanner 1set

7 box spanner 1set

8 open-ended spanner 1set

9 ring spanner 1set

10 monkey wrench 12″ 1

11 monkey wrench 8″ 1

12 steel wire clamp 8″ 1

13 screw driver 8″ 1

14 screw driver 6″ 1

15 jack 20t 1

16 Phillips screw driver 10″ 1set

17 locksmith hammer 2 pounds 1

18 crowbar 2

19 crowbar 2

20 tire air pressure meter 1MPa

21 air-charge manifold φ10 L=12m 1set

22 carp clamp 8″ 1set

23

Appendix Table 3: the Main quick-wear parts List

No Item Code Name Qty.

1

double-dr

um

drawwork

s

Main drum

GB13871-92 seal ring B-160×190×15 3

GB1235-76 O-type rubber barφ3.5O 5

GB13871-92 seal ring B-180×210×15 1

GB13871-92 seal ring B-170×200×15 1

GB13871-92 seal ring B-160×190×15 3

Main drum brake

XJC21A.06-06 intertexture brake block 18

XJC21A.06-11 dead-end brake block 2

XJC21A.06-08 bolt 20

XJC21A.06-09 lock nut 20

Clutch

m a t c h e d 2 4 t y p e c l u t c h friction plate 4

m a t c h e d 2 4 t y p e c l u t c h air chamber 2

m a t c h e d 2 4 t y p e c l u t c h pushing plate 2

c o o l i n g p i p e a s s e m b l y GB1235-76 O-ring 24X2.4 10

dual passage

rotorseal

5321000530069002 O-ring 69X5.3 1

5323100080001002 B seal ring 80X100X10 2

HG4-337-66 V type seal ring (A)70X95 2

XJC21A.04.01-07 packing spring 4

Sand drum

GB/T 13871-1992 B typ e seal ring 130x160x12 3

GB1235-76 O-type rubber barφ3.5 2

GB/T 13871-1992 B typ e seal ring 220x250x15 1

Brake system

C0.229.03.03-01 molten brake block 2

C0.229.03.03-03 intertexture brake block 18

XJC21A.06-08 bolt 20

XJC21A.06-09 Lock nut 20

2 Angle transmission GB9877.1-88 oil seal B120×150×12 1

GB9877.1-88 oil seal B110×140×12 2

3 Hydraulic system

GB1235-86 O-ring 11X1.9 30

GB1235-86 O-ring 12X1.9 50

GB1235-86 O-ring 16X2.4 50

GB1235-86 O-ring 30X3.1 60

GB1235-86 O-ring 35X3.1 10

GB1235-86 O-ring 40X3.1 5

ZX-400×180 filter core 1

ZX-160×100 filter core 1

ZSX-400×30-CZ filter core 1

ZSX-160×10 filter core 1

4 cooling system

FX.BH-515×80 filter core 1

RQDF-15 electromagnetism valve 1

YBLT-EKW/5A/B foot pedal switch 1

5 transmission system 28A-2 transition chain link 3

6 rotary table clutch

matched ATD218 friction plate 2

matched ATD218 air chamber 1

matched ATD218 pushing plate 1

4N-2531 air compressor strap 2

Appendix Table 4: the Standard Units List of Main components:

No Item Code Name Qty. Remarks

1 double-drum

drawworks

Main

drum

GB286-64 bearing 3528 1

GB276-82 bearing 228 2

GB286-64 bearing 3003730 1

Brake

system

GB/T

281-1994 bearing 1212K 2

dual

passage

rotorseal

6214 bearing GB/T276-1994 2

Sand

drum

22222 bearing GB/T288-1994 2

N221 bearing GB/T283-1994 2

Brake

1308 bearing GB/T281-1994 2

1212 bearing GB/T281-1994 2

2 Angle Transmission

GB283-87 bearing 32321 1

GB299-86 bearing 97524 1

GB299-86 bearing 97520 1

GB2283-87 bearing 32317E 1

3 Crown block

GB299-86 bearing 2097128 5

GB299-86 bearing 2097722 1

4 mast centralizer GB281-86 bearing 1206 8