*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
Ⅰ.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).
Ⅱ. 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
Ⅲ. Main technical data
NO Item Technical data
Big workover depth 4000m(2 7/8"DP)
Drilling
1
depth 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
Mast form Double sections, telescopic
Clear height 29.5m

5 Mast
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)
Input power 350 HP
Max. Pull of fast line 180 KN (secondary layer)
Drum diameter×length ×
450mm 912mm
Brake rim diameter×length 1070mm×310mm
Drawwork
6
s
Main drum
Wire line diameter 26mm
Max. rotate speed 450rpm
Brake rim cooling form Forcible water circulation cooling
Rated pressure 14MPa
8 Hydraulic system Rated flow 165L/min
Oil tank cubage 0.85m3
Pressure 0.85MPa
9 Air system
Flow 670L/min
10 Power transmission form Hydraulic & mechanism
Engine rated power 350HP/2100rpm
11 Engine
Engine maximum torque 1557 N.m/1400rpm
Type With lock clutch, hydraulic reducer
12 Torque Torque 2.05
Ratio 5 Forward 1 Rear
13 Drive type of carrier 8×8
14 Max speed 45 km/h
Max wind speed 110 km/h
15 Environment
Temperature -20℃～50℃
16 Dimension （L×W×H） 19060×3400×4400
Ⅳ. Main drum hook load、
、hook speed character graph
V Solid moving condition graph：
：
（mm）
（ ）
VI Working condition figure：
：
（the
（ slant angle of mast is 3.50 ）
VII. Layout of guy lines, deadman hole and groundwork

RECOMMENDED 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:
3
THE MINIMUM SAFETY LOADING CAPACITY IS 39T/M , REQUIRE DRAINAGE MANAGEMENT; THE SPOTTING
SURFACE: THE GRADE OFF THE WELL HEAD 4m IS 1:20, THE MINIMUM SAFETY LOADING CAPACITY IS
29T/M3

12
 Chapter 2

Main Components And Technical Requirement

Drawworks Assembly
Mast Assembly
Angle Gear Box
Substructure Assembly
Hydraulic System
Air Pressure System
Water cooling system
 JC21B Double-Drum Drawworks

. Technical Parameters

Model JC18/11
Type Double-drum
Rated power 350HP
Technical Parameters Main drum Sand drum
Diameter 450 345
Drum mmLength
912 912
mm
Diameter
1070 970
mm
Brake Length
310 210
rim mm
Forced circulation water
Cooling Type
cooling
Envelope angel of brake
345° 345°
strap
Drum
m
capacity
500m φ26 wireline 2800m φ9/16” wireline
Allowable Max. rotary
speed 450 450
rpm
Fast tension 210kN (the second layer) 110kN (the second layer)
Clutch ATD-324H ATD-124H

Assist brake WCB224

Ⅱ. 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

-1-
Main drum assembly

Fig 1-1 Main drum assembly

-2-
 Main drum assembly list

Item Part Number Description Qty. Material Remark

WCB224 Water cooling disc 1

1
assist brake
XJC21A.04-04 Attachment flange 1 Steel plate Q235A
2
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
C0.229.03.04-01 Shaft 1 Steel strip
6
42CrMo φ220
7 XJC21A.04.03 Drum assembly 1
XJC21A.04-09 Key 45×25×240 2 Steel plate 45
8
t30
XJC21A.04.04 Cooling water pipe 1
9
assembly
10 Q/ZB286.2 Screw plug R3/8 2
XJC21A.04-21 Key 36×36×233 2 Steel plate 45
11
t40
-3-
12 GB286-64 Bearing 3003730 1
13 XJC21A.04-11 Right bearing base 1 ZG270-500
XJC21A.04-12 Middle flange 1 Steel plate Q235A
14
t40
XJC21A.04-13 Intermediate 1 Steel plate Q235A
15
flange 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

-4-
  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.

-5-
  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.

-6-
  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.

-7-
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.

-8-
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

-9-
  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.

- 10 -
 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

- 11 -
13 XJC21A.04.01-10 Spindle 1 35
14 GB3452.1-82 O-ring 69 X5.3 1 Ⅰ-2

- 12 -
Thrust disc clutch

- 13 -
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.

- 14 -
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.
- 15 -
 、
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.

- 16 -
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.

- 17 -
Brake system

- 18 -
Item Part Number Description Qty Material Remark
Asbestos copper wires
1 XJC21A.06-06 Brake block 18 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

Brake block on dead Asbestos copper wires
6 XJC21A.06-11 end 2 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

- 19 -
  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.

- 20 -
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.

- 21 -
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.
- 22 -
● 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.

- 23 -
 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 ；
- 24 -
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.

- 25 -
Auxiliary brake assembly

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

- 26 -
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

Press it to the lowest Brake block wore Change brake block
position, the drum not Both brake straps unbalanced Adjust balance
braked Brake rim polluted Clear oil dirt
Too low the position of brake handle Adjust brake handle height
Brake
1 Brake strap active end incorrectly adjusted Adjust brake strap active end
handle
Lift to the highest Too small the clearance between brake Adjust brake strap clearance
position, the hook strap and brake rim
stops falling or falls Friction between brake strap and brake rim Change clutch friction disc
slowly. Brake handle incorrectly adjusted Adjust brake handle
The drum clutch not Too small the clearance of clutch friction Adjust the clearance of
engaged, the drum discs clutch friction disc
keeps running clutch friction disc sintered Change clutch friction disc
The drum keeps Too small the clearance of clutch friction Adjust the clearance of
running after the disc clutch friction disc
Drum clutch being clutch friction disc sintered Change clutch friction disc
2
clutch unengaged. Air pipeline broken not thoroughly Check air pipeline and valve
Slip when the The clutch polluted Clear oil dirt
traveling hook lifting. Not enough gas supply Adjust gas pressure
Too large the clearance of clutch friction Adjust the clearance of
disc clutch. Friction discs
The clutch friction disc worn badly Change clutch friction disc
Insufficient brake Not enough gas supply Increase gas pressure
force Too large the clearance of brake rim Check and adjust
Bad wear Check and change
Brake rim polluted. Check and clear
Brake of
3 Both brake straps unbalanced with each Check and adjust
drum
other
Brake strap wore too Too fast the falling speed of the hook Control the hook speed
quickly The clearance of brake rim is excessively suitably
small Check and adjust
Tighten torque for bolts see as following table

Performance grade of bolts

Thread Screw pitch 4.8 5.8 8.8
diameter
d (mm)
（ ）
S mm Tighten Pre-tighten Tighten Pre-tighten Tighten Pre-tighten
torque force N torque force N torque force N
N.m N.m N.m
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 C0.162A.02.08

board
 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 φ 16 6 × 19S+IWRCEEIPS grade wire 4 L=55
line
2 racking board to deadman φ 16 6 × 19S+IWRCEEIPS grade wire 2 L=38
line
3 crown block to the front φ 19 6 × 19S+IWRCEEIPS grade wire 2 L=35
support line
4 the top of mast lower φ 16 6 × 19S+IWRCEEIPS grade wire 2 L=23
section to the front support line

Guyline 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:

Fastline pulley
Drawworks

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 Lubricate ill 、
Clean check lubricate system
axle heating Bearing conjugate loosely Adjust or replace bearing
Sealing ring damaged Replace hermetic ring

2 Crown block pulley Bearing damaged heavily Replace bearing

running noisily 、 Check or replace
、
Pulley axle frayed
Pulley running interferentially Adjust check
3 Crown block pulley Axial clearance small Adjust clearance
running Pulley friction Check
interferentially
4 Edge of the crown Fast line pulley eccentric wear Periodically adjust fast line
block pulley frayed Traveling pulley speed pulley inversely
differently Exchange traveling pulley
periodically
5 Crown block pulley Impurity 、
Check clean
locked Bearing damaged 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 （ ） 14
44.45mm 1.75’ 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.

紧边 tension side

C
B
A

Driving equipment Level ～45° ～

45° aplomb
Central position
mm in mm in
Tangent line length 25 (10) 10～15 0.4～0.5 5～8 0.2～0.3
of the two chain 51 (20) 20～30 0.8～1.2 10～15 0.4～0.6

30～45 1.2～1.8 15～23 0.5～0.9

wheels
76 (30)

51～76 2.0～3.0 25～38 1.0～1.5

cm (in)
127 (50)

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
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 3.6m
ground
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

Model Bendix(BA-921)
1 Compressor
Discharge capacity l/min 444
Air treatment Filtration reducing valve
2 FRC-3/4-D-MIDI-A
model 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

Air compressor Fault Refer to engine operation
1
manual
Air The pressure The pressure is adjusted by Adjust the pressure adjusting
pressure is low the adjustable valve is too valve
system low
The air compressor have Check the air compressor
2 fault
The pressure The pressure-adjusting valve Check the pressure adjusting
is not stable have fault. valve
The pipeline leakage is too
big Check the pipeline
Pressure is not Valve is choked and sealing
Pressure stable ring is damaged Overhaul, clean and replace it
3 adjusting The pressure The spring is tired and get Replace the spring.
valve is not adjusted soft.
high
Dryer Not exhaust Signal circuit is short Check the signal circuit
The discharge valve is Overhaul and clean the
4 blocked discharge valve
The drying agent is not Replace the drying agent
effective.
Control The dirty The drying agent is not Check
pipeline liquid is much effective
The filter is not effective. Check
The dirty liquid in air storage Emit in time
is not discharged in time
Dreezing in The drying agent is not Overhaul
5 winter effective
The filter is not effective Overhaul
The dirty liquid in air storage Discharge in time
is not discharged in time
The antifreezing device is Overhaul the anti-freezing
not filled with anti-freeze device and add the
fluid in time. anti-freezing fluid
Rotational Gas leakage The sealing ring is damaged Replace
junction Spring is tired and get soft Replace
6
Block The bearing is worn Replace
The lubrication is not enough Lubricate in time
Gas Gas leakage The sealing rings for cylinder Replace
7
cylinder head and cover are damaged
 The force is The inner is leakage Replace
small The piston sealing ring is Replace
damaged
The inner wall of air cylinder Delivery to be repaired
has trace.
The sealing ring of piston Replace
rod is damaged
Diaphragm Leakage The diaphragm is damaged Replace
Cylinder The back cover connect is Adjust to be fixed
loosen
8 Push is small The diaphragm is damaged Replace
Return to The spring get tired or Replace
position damaged
slowly
Emergency Control The valve core is blocked Overhaul and clean
brake valve failure
leakage The sealing ring is damaged Replace
9 The valve body has crack Replace the valve assembly
Brake and The piston is blocked Overhaul, clean and lubricate
release brake The sealing ring of piston Replace
is slow The valve core is blocked Overhaul, clean and lubricate
Quick-disc Failure The diaphragm is damaged Replace
10 harge valve Leakage The sealing ring is damaged Replace
The valve body has crack Replace the assembly
Shuttle Failure The sealing ring is damaged Replace
11 valve Leakage The sealing ring is damaged Replace
The valve body has crack Replace the assembly
Hydraulic system
Hydraulic principle
Control valve inst.
System parameters:
System pressure MPa 14
System flow L 165
：
Summer L-HM 68 ；
Brand of hydraulic oil ： ～ ）℃ L-HV
Winter L-HM 46(0 -10
46D（lower than-30℃）
Volume of hydraulic oil tank m3 0.9
Model P25X378BEIU257
Type Gear pump
Main oil pump
Rated pressure MPa 14
Flow L/min 165（Oil pump speed is 1800rpm）
Model TF-400×80F-C
Box outside self-sealing, suction
Type
Oil suction filter filter
Flow L/min 400
filtering accuracy μm 80

Model LXZS-400 ×30

Box outside self-sealing, suction
Type
Oil return filter filter
Flow L/min 400
filtering accuracy μm 80
Model 3# hydraulic pressure lift cylinder
Three-grade combinated cylinder,
Raising cylinder Type
equipped with single choke valve
Total stroke mm 5300
Model Y3030
Telescopic
Type Single-action plunger cylinder
cylinder
Total stroke mm 300
Hydraulic small
Model YJ-3
winch
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.
 Trouble shooting:
shooting:
No. Fault Cause Trouble shooting
The tank cover is not sealed well and Check and replace sealer
have water leakage
The oil is not replaced for long time Replace the oil
The oil is The oil tank is cleaned for long time Clean the oil tank
polluted The filter is plugged and filtering Check the filter and replace the filtering
element is cracked. element
The suction pipe of hydraulic pump has Check and replace
Hydraulic
1 leakage
oil tank
The oil level is low Add the hydraulic oil
The Temp. The oil viscidity is too much Replace the hydraulic oil
is high No-work run for long time The oil pump is off under the condition of
no-work period.
Abnormal The oil level is low and the oil pump is Add the hydraulic oil
voice in the intaked empty
tank The oil return pressure is high Check and eliminate fault
The bearing is worn Replace the bearing
The hole in pump body is worn Replace
Hot The gear end surface and side plate is Overhaul, rubbing and replace
worn
The oil viscidity is high Replace the hydraulic oil
The oil viscidity is little Replace the hydraulic oil
The Hydraulic oil is polluted seriously Replace the hydraulic oil
pressure is Oil pump is worn Replace oil pump
low The overflow valve is adjusted Adjust the overflow valve
Hydraulic
2 wrongly
pump
The oil viscidity is low Replace the hydraulic oil
The flow is Hydraulic oil is polluted seriously Replace the hydraulic oil
small Empty-suction is serious Add the hydraulic oil
Valve and pipe have leakage Overhaul the valve and pipe
Sealing ring is damaged Replace
Leak
The pump body has crack Replace the oil pump
Installation and adjustment is wrong Check and adjust
Noise is
Bearing is worn Replace
loud.
The resistance in oil tank is large Check the oil viscidity.
 Main valve cup and cone valve cup is Overhaul and clean
blocked
Adjustment
The adjusting spring is cracked Replace
failure
The damp hole of main valve core is Overhaul and clean
blocked
The damp hole of main valve core is Overhaul and clean
blocked
No pressure
Reset spring of valve core is cracked Replace
Hydraulic oil is polluted seriously Replace
Overflow The The adjust spring is tired and get soft Replace
3
valve pressure can Main valve core is blocked Overhaul and clean
not be The cone valve core is worn Replace
adjusted The oil viscidity is low Replace
highly Oil pump is damaged Check, grind and replace
The valve core is attached dirt Overhaul and clean
Fitting precision of valve core is bad Check, grind and replace
Librations The cone valve and valve cup is Overhaul and grind
and noise matched not very well
The installation of adjust spring is not Overhaul and emend
vertical
The hydraulic oil is polluted seriously Replace
Oil suction
The oil tank is not clean when being Clean
is not
disassembled
smooth
The filter core is plugged Check 、clean
The filtering The loading and unloading is wrong Pay attention to the assembling quality
Oil core is The filtering element is polluted Check and clean filtering element in time.
4 suction distorted seriously
and filter Filtering The loading and unloading is wrong Pay attention to the assembling quality
core is The valve core is polluted seriously Check and clean filtering element in time
cracked The quality of filtering core is bad. Replace
The check valve and valve cup touch Overhaul and replace the sealing ring of
Self-sealing
badly valve cup
is bad
The check valve is wore and get soft Replace
The hydraulic oil is polluted seriously Replace the hydraulic oil
Oil return is The oil tank is not clean when being Clean oil tank
not smooth assembled
Oil-return
5 The filtering element is blocked Check and clean the filtering element
filter
The filtering The loading and unloading is wrong Pay attention to the assembling quality
element is The hydraulic oil is polluted seriously Check and clean the filtering element
cracked The quality of filtering core is bad. Replace
 O-shaped ring in Piston outer cycle is Replace
The pushing damaged
force is not O-shaped ring in Piston inner cycle is Replace
enough damaged
The system pressure is not enough Adjust the system pressure
Legging
6 The leakage exists in trapezoidal screw Replace
cylinder
rod
O-shaped ring of copper sleeve outer Replace
Oil leakage
inner cycle are damaged
Cylinder sealing ring is damaged Replace
The leakage exists in cylinder body Replace
The system pressure is not enough Adjust the system pressure
The push Adjustment pressure the eight-unite Adjust the pressure of eight-unite valve
force is not valve is too low
enough The gland nut of sealing ring is too Overhaul and fasten the gland nut properly.
tight.
The system pressure is not enough Adjust the system pres sure
Retraction is
The third-stage retraction is not strong Adjust the eight-unite valve pressure
not strong
and piston O-shaped ring is damaged Overhaul and fasten the gland nut properly.
The outer surface of plunger has oil Overhaul and rotate the gland nut of sealing
Raising leakage and the relating plunger ring properly.
7
cylinder sealing ring is damaged
Leak oil
Welding seam of cylinder head has Overhaul and patching
leakage
The connection of oil vent has leakage Overhaul and replace connection
The The gland nut of sealing ring is too Overhaul and rotate the gland nut of sealing
telescopic tight ring properly.
order of The plunger is distorted Check and repair
every The air exists in the cylinder Discharge the air
cylinder is
wrong
O-shaped ring in Piston inner or outer Replace
The pull is
cycle is damaged
not enough The system flow is too low Adjust the system pressure
Cat head
8
Protruding The system flow rate is not enough Adjust the engine rotate speed
slowness Multi-way valve has fault Replace or overhaul
cylinder
Piston rod part leak oil Replace sealing ring or copper bush
Cylinder lid, cylinder head, cylinder assembly
Leak oil
surface leak oil Replace the O-shaped ring
 The system pressure is too low Adjust the system pressure
The lift is
The oil Temp. is too high Reduce the oil Temp.
not enough
The pulley of wireline is blocked
Check pulley and lubricate it
The hydraulic motor is worn and leak
in inner of motor
Overhaul and replace
The The system pressure is too low Adjust the clearance or replace
libration The system flow is too low Replace
exists under The hydraulic oil has high viscidity Overhaul or replace
Hydraulic
the
small
condition of
winch
9 rated load
Suspending The brake friction disc is worn Adjust the clearance or replace
stop and The brake spring is worn and get soft Replace
skid Clutch failure Overhaul or replace
Suspending The brake is blocked Overhaul and clean up
weight can The oil pipe of brake cylinder is Overhaul and cleanout
not dropped blocked
or stable Damp hole of brake valve is blocked Overhaul and cleanout
The wireline Overload Overload is not permitted
arrangement The pulley of wireline is blocked Overhaul and lubricate it.
is not good
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
Filter cleaner bleed hole
9 C0.110A.08.02.01.01 joint 1
Stainless steel ball valve
10 460104260 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
Water brake water intake
29 C0.249B.09.02 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

Recycle water flow rate L/S 3.83

4 Radiator Matching motor power kW 2.2

Radiator fan diameter mm 760

Model SLR50-100
Water
5 Flow rate 3.47
pump
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：
Minimum surroundings
No.
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 390KN / m 3 . If it matches with carrier matting plate, the
groundwork must have a load capacity no less than 290KN / m 3 ;
B 、The drill rod discharging area must have a load capacity no less than 290KN / m 3 ;
C、Mast foundation must have a load capacity no less than 390KN / m ; 3

D、The mast floor must have a load capacity no less than 390KN / m . 3

(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 1mm / m 3 , the level warp of the fore-and-aft
direction can not exceed 4mm / m 3 . If it matches with the hull shape foundation, the
level warp of the right-and-left direction can not exceed 2mm / m 3 .
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
、 、locknuts for tightening
Inspect each propeller shaft pins
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.
、tube line and tie-in and assure each pressure
Inspect each fluid and gas system
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 automatic 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
～100h running time after the new equipment or the repaired one is in service.
per 80
2、 Check Period and Check Item
2.1 Shift Check Table

No Position Temp. Pressure oil lever running Remarks

Oil √ √ √
1 Engine 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 √ √
Cooling
water tank
√ √ √
Main drum √
Crown
block √
protect

8
Drawworks
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)
Check Period
No Check Item
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.

Lubricant
No Lubrication Position Points Period Remarks
Summer Winter
Two sides lubrication
Molybdenum bisulfide
1 point of drawworks 12 Every shift Oiling before working
extreme-pressure Lithium-based grease
support
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
Putting in new lubricant to oil
Mechanism oil Mechanism oil
5 Input-output chain case 3 Every 6 month lever pointer after emptying the
N32 N22
old one and cleaning the case
Molybdenum bisulfide polar-pressureed
6 Crown block 6 Every shift
Lithium-based grease
Every serving 1 oil
7 Hoisting cylinder pins 3# Lithium-based grease 4
well
Guiding wheel device for
8 3# Lithium-based grease 4 Every shift
take-off cylinder
Telescopic cylinder Every serving 1 oil
9 3# Lithium-based grease 16
centralizer well
 Lubricant
No Lubrication Position 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
～ ℃）
10W/40CD(0 -25
13 Engine 15W/40CD
（ ℃以下）
5W/30CD -30
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

～ ℃）
L-HM 46(0 -10
19 Hydraulic system 15W/40CD
（ ℃以下）
L-HV 46D -30
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

the User Manual to Allision S6610HR Hydraulic
2
Transmission
the User Manual to ZYT5580TZJ Drilling Rig
3
Carrier
4 the User Manual toZYT5510TZJ DRILLING Rig
the Product Certification of ZYT5510TZJ
5
DRILLING Rig
6 the instruction of YG160B Hook

7 The instruction of XSL135 swivel

the instruction to ZX110A Rotary Table
7
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.

GB13871-92 seal ring B-160×190×15 3
GB1235-76 O-type rubber barφ3.5O 5
Main drum 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
XJC21A.06-06 intertexture brake block 18
XJC21A.06-11 dead-end brake block 2
Main drum brake
XJC21A.06-08 bolt 20
XJC21A.06-09 lock nut 20
matched 24 type clutch friction plate 4
double-dr Clutch matched 24 type clutch air chamber 2
um matched 24 type clutch pushing plate 2
1
drawwork co oli ng pi pe assem bl y GB1235-76 O-ring 24X2.4 10
s 5321000530069002 O-ring 69X5.3 1
dual passage 5323100080001002 B seal ring 80X100X10 2
rotorseal HG4-337-66 V type seal ring (A)70X95 2
XJC21A.04.01-07 packing spring 4
G B /T 1 38 7 1 - 1 99 2 B t yp e seal ring 130x160x12 3
Sand drum GB1235-76 O-type rubber barφ3.5 2
G B /T 1 38 7 1 - 1 99 2 B t yp e seal ring 220x250x15 1
C0.229.03.03-01 molten brake block 2
C0.229.03.03-03 intertexture brake block 18
Brake system
XJC21A.06-08 bolt 20
XJC21A.06-09 Lock nut 20
GB9877.1-88 oil seal B120×150×12 1
2 Angle transmission
GB9877.1-88 oil seal B110×140×12 2
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
3 Hydraulic system
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
FX.BH-515×80 filter core 1
4 cooling system RQDF-15 electromagnetism valve 1
YBLT-EKW/5A/B foot pedal switch 1
5 transmission system 28A-2 transition chain link 3
matched ATD218 friction plate 2
matched ATD218 air chamber 1
6 rotary table clutch
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

GB286-64 bearing 3528 1

Main
GB276-82 bearing 228 2
drum
GB286-64 bearing 3003730 1
Brake GB/T
bearing 1212K 2
system 281-1994
dual
double-drum
1 passage 6214 bearing GB/T276-1994 2
drawworks
rotorseal
22222 bearing GB/T288-1994 2
Sand
drum
N221 bearing GB/T283-1994 2

1308 bearing GB/T281-1994 2

Brake
1212 bearing GB/T281-1994 2

GB283-87 bearing 32321 1

GB299-86 bearing 97524 1

2 Angle Transmission
GB299-86 bearing 97520 1

GB2283-87 bearing 32317E 1

GB299-86 bearing 2097128 5

3 Crown block
GB299-86 bearing 2097722 1

4 mast centralizer GB281-86 bearing 1206 8