山东科瑞石油装备有限公司

Shandong Kerui Petroleum Equipment Co., Ltd.

ZJ30/1800CZ Truck-mounted Drilling Rig

Maintenance Manual

KR013.00SM

版本：2010-A KR200.14.00WH

中国•东营 Edition：2014-A

Dongying, China
 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

Preface

Thanks for choosing the truck-mounted drilling rig manufactured by Shandong Kerui
Machinery Manufacture Co., Ltd.
Maintenance manual of ZJ30/1800CZ truck-mounted drilling rig is a complete set of
truck-mounted drilling rig maintenance document, drawn up by the technical personnel
according to product design manufacture and oil field service experience; and the manual is
mainly used as reference when operator and maintenance personnel maintain the equipment,
to operate the truck-mounted drilling rig in good working condition for a long term.
Please read this manual carefully for the reliable and steady running of the product. This
manual only provides part instruction of the whole rig due to too many mating components of
the rig; and for other parts which are not mentioned, or just make a brief introduction, please
refer to their own service manuals and maintenance manual or its related technical
information in details.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Important Safety Statement

All the personnel who operates, manages, maintains and repairs the rig shall be
familiar with the related content in this manual, and obey related regulations for the
usage, management, operation, maintenance and repair of the rig. In addition, pay
special attention to the safety warnings, notes, etc., and national laws, professional
rules and common safety rules, to avoid personal accident and equipment damage.
This manual cannot list all of the safety warning information, so please make sure
that the method will not endanger personal safety, or damage the equipment when any
method is selected to operate.

Right maintenance is an important factor to keep product running reliably and

safely, and maintainer shall maintain in accordance with the method mentioned in this
manual.

Please read the explanation of the following warning signs carefully when they appear.

Warning！It will cause possible injury or loss of life to person & serious damage to

equipment if not following relevant regulations.

Attention！It will cause any injury to person & damage to equipment if not observing

operating procedure and method strictly.

Note！It is used for providing notes or and instruction condition independently.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Contents
Preface ....................................................................................................................................................... I
Important Safety Statement ................................................................................................................... II
Chapter 1 Summary ................................................................................................................................. 1

1.1. Operation and maintenance regulations .................................................................... 1

1.2. Periodical maintenance regulations ............................................................................ 2

Chapter 2 Periodic Check and Maintenance ......................................................................................... 5

2.1. Check and maintenance of carrier .............................................................................. 5

2.1.1. Check table of per shift ---------------------------------------------------------------- 5

2.1.2. Check table for per operating 80～100h -------------------------------------------- 6
2.1.3. Check table per operating 500h ------------------------------------------------------- 7
2.1.4. Check table per operating 1000h ----------------------------------------------------- 7
2.1.5. Usage and maintenance during arctic period --------------------------------------- 8
2.2. Check and maintenance of mast and substructure..................................................... 8

2.2.1. Routine check items -------------------------------------------------------------------- 8

2.2.2. Matters needing attention when check----------------------------------------------- 9
2.3. Check and maintenance of raising system .................................................................. 9

2.3.1 Maintenance and check items per shift ---------------------------------------------- 9

2.3.2 Maintenance and check items per week ------------------------------------------- 10
2.3.3 Maintenance and check items per week ------------------------------------------- 10
2.4. Check and maintenance of transmission system ...................................................... 10

2.4.1. Maintenance and check items per shift -------------------------------------------- 10

2.4.2. Maintenance and check items per week ------------------------------------------- 10
2.4.3. Maintenance and check items per month ------------------------------------------ 11
2.5. Check and maintenance of pneumatic system ......................................................... 11

2.5.1. Maintenance and check items per shift -------------------------------------------- 11

2.5.2. Maintenance and check items per week ------------------------------------------- 11
2.5.3. Maintenance and check items per month ------------------------------------------ 11
Chapter 3 Maintenance of Rig Transmission Equipment .................................................................. 12

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3.1. Maintenance of power take-off case ........................................................................ 12

3.1.1. Check gear oil mass ------------------------------------------------------------------ 12

3.1.2. Check fasteners ----------------------------------------------------------------------- 12
3.1.3. Check items after open the cover of power take-off case ----------------------- 12
3.1.4. Check working condition of power take-off case -------------------------------- 12
3.1.5. Maintenance --------------------------------------------------------------------------- 12
3.1.6. Lubrication----------------------------------------------------------------------------- 13
3.1.7. Common faults and solutions of power take-off case --------------------------- 13
3.2. Angle transmission box maintenance ....................................................................... 14

3.2.1. Check ----------------------------------------------------------------------------------- 14

3.2.2. Maintenance --------------------------------------------------------------------------- 15
3.2.3. Lubrication----------------------------------------------------------------------------- 15
3.2.4. Common faults and solutions ------------------------------------------------------- 15
3.3. Rotary table transmission box maintenance ............................................................. 16

3.3.1. Check and maintenance -------------------------------------------------------------- 16

3.3.2. Chain change -------------------------------------------------------------------------- 17
3.3.3. Lubrication----------------------------------------------------------------------------- 18
3.3.4. Rotary table maintenance ------------------------------------------------------------ 19
Chapter 4 Maintenance of Mast and Other Parts ............................................................................... 20

4.1. Mast maintenance ..................................................................................................... 20

4.1.1. Appearance inspection at regular intervals---------------------------------------- 20

4.1.2. Inspection and assessment under particular condition -------------------------- 21
4.1.3. Lubrication----------------------------------------------------------------------------- 22
4.1.4. Repair and maintenance of mast ---------------------------------------------------- 22
4.1.5. Other matters needing attention ---------------------------------------------------- 23
4.2. Crown block maintenance ......................................................................................... 23

4.2.1. Maintenance before operation ------------------------------------------------------ 23

4.2.2. Maintenance during operation ------------------------------------------------------ 24
4.2.3. Lubrication----------------------------------------------------------------------------- 25

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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4.2.4. Common faults and solutions of crown block ------------------------------------ 25

4.3. Maintenance of travelling hook ................................................................................ 26

4.3.1. Inspection ------------------------------------------------------------------------------ 26

4.3.2. Maintenance --------------------------------------------------------------------------- 26
4.3.3. Lubrication----------------------------------------------------------------------------- 26
4.3.4. Common faults and solutions ------------------------------------------------------- 27
4.4. Swivel maintenance................................................................................................... 30
Chapter 5 Drawworks Maintenance..................................................................................................... 31

5.1. Dairy inspection, repair and maintenance for drawworks ........................................ 31

5.1.1. Per shift inspection items ------------------------------------------------------------ 31

5.1.2. Other inspection items --------------------------------------------------------------- 31
5.1.3. Regular inspection -------------------------------------------------------------------- 32
5.1.4. Annual inspection items ------------------------------------------------------------- 33
5.2. Lubrication of drawworks transmission system ........................................................ 33

5.2.1. Lubrication of lube ------------------------------------------------------------------- 33

5.2.2. Lubrication of lubricating grease --------------------------------------------------- 34
5.2.3. Replacement cycle of lube ---------------------------------------------------------- 34
5.3. Maintenance of draw work pneumatic control system ............................................ 35

5.3.1. Inspection before usage -------------------------------------------------------------- 35

5.3.2. Clean and replacement of pipeline ------------------------------------------------- 35
5.3.3. Faults treatment of pneumatic elements ------------------------------------------- 36
5.4. Maintenance of other equipment ............................................................................. 36

5.5. Common faults and solutions of drawworks system ................................................ 37

Chapter 6 Substructure Maintenance .................................................................................................. 41

6.1. Substructure usage .................................................................................................... 41

6.2. Inspection for substructure ....................................................................................... 42

6.2.1. General principle---------------------------------------------------------------------- 42

6.2.2. Inspection category ------------------------------------------------------------------- 43
6.2.3. Inspection cycle ----------------------------------------------------------------------- 44
6.3. Maintenance and repair of substructure .................................................................. 44

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6.3.1. Substructure maintenance ----------------------------------------------------------- 44

6.3.2. Substructure repair-------------------------------------------------------------------- 45
6.3.3. Methods applied to structure repair for substructure: --------------------------- 45
6.3.4. Corrosion------------------------------------------------------------------------------- 45
6.3.5. Announcements for maintenance --------------------------------------------------- 46
6.4. Package and transportation ...................................................................................... 47

6.4.1. Package --------------------------------------------------------------------------------- 47

6.4.2. Transportation ------------------------------------------------------------------------- 47
6.4.3. Storage --------------------------------------------------------------------------------- 48
Chapter 7 Lubrication and Common Faults for Drilling Rig ............................................................ 49

7.1. Lubrication ................................................................................................................. 49

7.1.1. Lubricating oil ------------------------------------------------------------------------- 49

7.1.2. Fuel oil --------------------------------------------------------------------------------- 50
7.1.3. Cooling liquid ------------------------------------------------------------------------- 51
7.1.4. Lubricating grease -------------------------------------------------------------------- 52
7.2. Common faults for truck-mounted drilling rig .......................................................... 56
Chapter 8 Attached drawings ............................................................................................................... 61

8.1. Lubrication drawing of equipments installed on ZJ30/1800CZ ................................. 61

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Chapter 1 Summary

Periodical check, repair and maintenance of the truck-mounted drilling rig can reduce the
possibility of accident in time, which not only can avoid happening tremendous accident,
decrease repair cost, but also can improve the equipment utilization factor greatly, prolong the
service life of the truck-mounted drilling rig. Therefore, please maintain and manage the rig
frequently according to the technical condition and working status of the drilling rig during the
whole usage period of the drilling rig.
The maintenance of ZJ30/1800CZ truck-mounted drilling rig shall be conducted according
to a certain cycle. The periodic maintenance can be divided into shift maintenance, weekly
maintenance, monthly maintenance, half a year maintenance and annual maintenance. The
problems, which are found in the process of maintenance, shall be solved by operator or
professional technicians. The repair working (such as changing bearing, etc.), which is difficult
to repair and large to work on site, shall be submitted to the rig maintenance station or factory for
solution.
For the parts or equipment that is not introduced in detail or introduced briefly, please refer
to their service manuals, maintenance manual, or other technical documents for their
maintenance instruction.

Warning：Please turn the power off when the rig is maintained, and there should be
a locking device and evident warning mark for wrong operation, in order to avoid causing
safety accident of person and equipment injury.

1.1. Operation and maintenance regulations

 Mechanical, electrical and instrument technicians shall be arranged at the drilling rig site to
operate and maintain the rig.
 If the truck-mounted drilling rig breaks down or works abnormally, stop operating the
drilling rig, then maintain it in time.

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 It is forbidden to operate the rig with over speed, over-high temperature, over-high pressure,
over load or other violation of operation regulations.
 Periodical check and maintenance are required during the whole usage period of the drilling
rig.

Note：The problems found during maintenance shall be solved by operator or

professional personnel on site. If the repair work is huge, please send the rig to the nearest
rig repair station or repair factory to solve.

1.2. Periodical maintenance regulations

Mandatory and periodical check and maintenance of the drilling rig will eliminate the
possibility of accidents, and avoid accident happening, to keep the normal running of the rig and
prolong the service life of the rig.
As the working environment and condition for the drilling rig are various, the periodical
check and maintenance take common working condition as reference. Therefore, the users shall
consider the actual condition and working environment on site according to own working
experience to update and perfect the check and maintenance content, to keep the drilling rig in a
good condition.

 Check
Table 1-1
No. Check grade Rig running period /h Remark
1 Rig running check 80～100 Self maintenance
2 Routine check 250～300 Self maintenance
3 Grade 1 maintenance 500 Self maintenance

4 Grade 2 maintenance 1000 Self maintenance

5 Grade 3 maintenance 2000 Send to the factory

6 Medium maintenance 4000 Send to the factory

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Note：The above maintenance periodic table is drawn up according to the

working time of 1500h per year. If the drilling rig works less than 500h per year, the
maintenance period can be shortened. If the drilling rig works less than 1500h per year, the
maintenance period can be prolonged.

Routine check refers to the periodical check after new equipment of drilling rig or repaired
equipment begins to work. Check content can refer to the periodic check content according to
80-100h operating period of the drilling rig.

 Shift maintenance
The shift maintenance items of the drilling rig includes routine check, commissioning,
lubrication, fastening, cleaning, anti-corrosion and other routine operating content; in
addition, it also includes shift maintenance operating items specified by each system and
parts.
The shift maintenance operation shall be completed by operators independently, and it is the
routine check work of operators.

Note: When the mechanical or electrical equipment is working, all installing

equipment must be in good condition, including the crown-o-matic, safety valve, overflow
valve and engine alarm, etc. All safety equipment shall be conducted the shift check, to
ensure that they can work normally.

 Weekly maintenance
Weekly maintenance shall include items of shift maintenance.
The routine check of weekly maintenance will be completed by operators independently;
part of the work can be done with the help of other people when the work is too much.

 Monthly maintenance
Monthly maintenance shall include items of weekly maintenance.

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The items, which include too much workload or a lot of difficulties (e.g. replacing band
brake or friction plate of the clutch, etc), can be done by relevant people or technicians to
solve.

 Half a year and annual maintenance

After half a year or a whole year of working, all running parts must have certain damage or
abrasion, so do other non-running parts. Therefore, proper adjustment, maintenance and
replacement shall be done. All above work shall be done at a professional station or factory
by professional people, and the drilling rig should be checked and maintained
comprehensively according to the suggestions of the equipment management technicians.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Chapter 2 Periodic Check and Maintenance

2.1. Check and maintenance of carrier

2.1.1. Check table of per shift

Liquid
No. Check position Temp Pressure Remark
level
Engine oil √ √ √
Check running of the
1 Engine Fuel oil √ √
engine
Radiation water tank √ √
Check the running of the
2 Hydraulic speed changing box √ √ √
box

3 Power take-off case √ √

Discharge the wasted liquid
4 Pneumatic system √
in air tank

5 Hydraulic system √
6 Hydraulic oil tank √ √
7 Electrical control system Control and check
Differential box/Speed changing
√
box
Steering mechanism √ Check during driving
8 Carrier
Brake mechanism √ days

Control mechanism √
Tire/ air bag of floating axle √
Angle transmission box √
Chain box √
Draw Check during drilling
9 Cooling water tank √ √
works days
Crown-o-matic √

Braking system

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Air control system √

10 Rotary table transmission box + chain box √ √
11 Climbing chain box √ √
12 3T Hydraulic winch √ √
13 5T Hydraulic winch √ √

14 5T air winch √ √
15 0.5T air winch √ √
16 Raising oil cylinder √ √
Temperature is not higher
17 Accumulator √
than 45℃

Attention：Stop to check, and do not operate with faults if there is anything abnormal
found.

2.1.2. Check table for per operating 80～100h

No. Check position Content Remark

1 Check necessarily per shift Check term by term
2 Transmission shaft Fastening bolt, lubrication
3 Pneumatic system filter Check and clean
4 Hydraulic system filter Check and clean
5 Fuel oil system filter Check and clean
Check oil mass, oil quality, change the oil if
Engine oil
6 the oil quality exceeds standard
Engine oil filter Check and clean
Speed changing box filter Check and clean
7 Speed changing box Check oil mass, oil quality, change the oil if
hydraulic oil the oil quality exceeds standard

8 Power take-off case filter Check and clean

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Check oil mass, oil quality, change the oil if
9 Gearbox lubricating oil
the oil quality exceeds standard
Check oil mass, oil quality, change the oil if
10 Chain case lubricating oil
the oil quality exceeds standard
11 Water circulation filter Check and clean
Check oil mass, oil quality, change the oil if
12 Hydraulic oil
the oil quality exceeds standard
Check liquid level, water quality, change the
13 Circulating water
water if the water quality exceeds standard
Electric quantity, liquid level, conductor
14 Accumulator
jointing

2.1.3. Check table per operating 500h

No Check position Content Remark

1 Check necessarily per shift Check term by term

2 80～100h Check table Check term by term

3 Brake hub of main drum Attrition rate and surface quality
4 Engine Change lubricating oil
5 Brake block Attrition rate and surface quality
6 Transmission chain Attrition rate and chain quality
7 Transmission gear Attrition rate and tooth form quality

8 Brake hub of each axle Attrition rate and surface quality

2.1.4. Check table per operating 1000h

No Check position Content Remark

1 Check table per shift Check term by term

2 80～100h check table Check term by term

3 500h check table Check term by term
4 Speed changing box Change lubricating oil
Attrition rate of brake block, change the brake
5 Braking system
block near to screw surface.

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Attrition rate, change when the chain stretches
6 Transmission chain box
3%, change lubricating oil.
Attrition rate of gear and bearing, change
7 Transmission gear box
lubricating oil.
8 Operating handle Operate flexibly, and act reliably.
 Please stop the engine until it cools down before change lubricating oil, otherwise,
lubricating oil is easier to flow out.
 When adding lubricating oil, the liquid level should be kept at the top position between
the two graduation of vernier scale, it is proper at about 2/3 position.
 Please stop running until it cools down before change lubricating oil in the speed
changing box, otherwise, lubricating oil is easier to flow out.
 When add lubricating oil into the speed changing box, the liquid level should be kept at
the top position between the two graduation of vernier scale, it is proper at about 2/3
position, according to heat condition（71～90℃）

2.1.5. Usage and maintenance during arctic period

The water tank of the engine and the water circulating system of the drawworks must add
antifreezing solution according to low temperature requirements.
Before starting the engine, it is required to check whether the water tank of the engine
and the water circulating system of the drawworks are frozen.
When the temperature is lower than -20℃, it is required to take protective measures to
protect the main bearing components such as chassis, mast, substructure and others from
being damaged.
Liquid, gas, water, electrical system and relevant control element should be protected to
take necessarily antifreezing measures.

2.2. Check and maintenance of mast and substructure

2.2.1. Routine check items

Whether the rising components crack and deform or not.

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Whether rope ring and bail rust or not, and whether there is any corrosion near the end
part.
Whether the steel wire rope is in perfect condition without any broken wire.
Attrition rate of sheaves, and whether it is required to change or not.
The lubricating status of sheaves system.
Whether all pins are in place, and safety pins are all in readiness.
Whether connections of all bolts are tight or not.
With load, measure straightness error of the mast gin poles in the full length rang, and the
perpendicularity error between the mast front & side face and the horizon.
Before raising and lowering, check the buffer device.

2.2.2. Matters needing attention when check

Don’t dismantle any transverse brace, diagonal brace or other component in any
condition.
Don’t drill hole, cut hole or weld on component of steel structure.
Check mast and substructure monthly and every time before bearing special load such as
casing.

2.3. Check and maintenance of raising system

2.3.1 Maintenance and check items per shift

The connection, working performance and brake performance of brake apparatus and
crown-o-matic.
Sealing property and operation reliability of driller’s console, electrical, liquid, gas
components.
Tightness of dead line and fast line end parts
Fix rack, bearing pedestal and protective device.
Lubricating property and sealing property of each bearing.
Earring bolts on the hook and stop pins should be fastened, the hook should be rotated

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flexibly and the spring can be telescopic freely.

Sealing parts of swivel, rotary table, drawworks should be in good condition, the oil mass
and temperature of the oil-bath should conform to requirements.
Whether stop pin of the rotary table should be flexible and reliable or not.

2.3.2 Maintenance and check items per week

Abrasion and clearance between brake block and brake hub.

Whether the oil supply condition of drawwork lubricating oil way is normal or not.
Whether the swivel bail and pin roll is flexible or not.
Fixing condition of traveling block axle.
Abrasion condition of sheave groove for crown block and traveling block.
Sealing condition of swivel washing pipe packing.
Tightness condition of universal shaft flange on the rotary table.

2.3.3 Maintenance and check items per week

Crack condition of brake hub.

Connection and abrasion condition of clutch and universal shaft cross joint.
Whether there is any crack on the bail, pin and sheave.

2.4. Check and maintenance of transmission system

2.4.1. Maintenance and check items per shift

Check tensity of chain and the temperature of the transmission parts.

Check the quality, oil mass, oil pressure and oil temperature of transmission lube.
If the noise is too loud and chain or sprocket is abrasive, etc., it should be handled in
time.

2.4.2. Maintenance and check items per week

Check operation condition of oil pump, and clean filter.

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Check abrasion condition of clutch.

2.4.3. Maintenance and check items per month

Check abrasion of chain and sprocket comprehensively.

Measure oil quality in the oil-bath.

2.5. Check and maintenance of pneumatic system

2.5.1. Maintenance and check items per shift

There is no abnormal of air compressor starting and stopping, and oil quality, oil mass
and oil temperature should conform to regulations.
Check the auto pressure regulating device and safety valve.
Check working pressure of air storage cylinder, and discharge water and pollution.
Whether the pipeline is smooth and sealing is in good condition or not.
Temperature raising condition of air swivel.

2.5.2. Maintenance and check items per week

Check safety valve and sequence valve.

Check sealing property of brake cylinder.

2.5.3. Maintenance and check items per month

Clean filter, dehydrator and safety valve of air storage tank.

Check control valves of air compressor.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Chapter 3 Maintenance of Rig Transmission Equipment

3.1. Maintenance of power take-off case

3.1.1. Check gear oil mass

Please check after stopping the equipment for few minutes.

First of all, check whether there is any oil leak appearance of oil seal, do well the clean
work, take off the plug screw of temperature indicator, check the oil level, to keep oil level
not lower 10~15mm than the oil plug hole. Supplement the gear oil to the specified standard
according to requirements after check.

3.1.2. Check fasteners

Check whether the external fasters and adapting pieces are loose or not. If necessary, it
can be changed and tightened.

3.1.3. Check items after open the cover of power take-off case

Open the cover plate of the case, to check wear pattern of gear and spline in the case, and
whether the fastener is loose or not.
Check whether shifting fork deforms or not with sample plate.
Check the spring force of ball nut, and adjust or repair as required.

3.1.4. Check working condition of power take-off case

Road test can be used to adjust the working condition of the power take-off case, and
generally the sound is normal without engaging automatically or difficultly; otherwise it is
required to open the cover to maintain.

3.1.5. Maintenance

During check, it is required to maintain, repair or change parts.

Gear oil is changed usually in level 3 maintenance. The waste oil should be discharged
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while the equipment is still hot, and make sure there are no metal fragments. If any metal
fragment is found, open the cover of transfer case to check.
After the waste oil is discharged, plug the oil plug back, add light diesel oil equal to 1/3
oil mass in the power take-off case oil-bath, or kerosene mixed with 5% engine oil into the
transfer case, and then start the engine.
Work in low speed for several minutes (don’t engage the front axle at this time), stop the
engine, discharge the cleaning oil, then add new gear oil to standard rate. It can also clean
using air pressure spray gun to eject cleaning fluid into the transmission.

3.1.6. Lubrication

80W/90（API GL-5）heavy load gear oil is used by power take-off case，and fuel charge
is about 43L.
Oil change period:
The first time after 300 working hours.
From the second time, change oil every 1000 working hour.
Change oil after every overhaul

3.1.7. Common faults and solutions of power take-off case

Table 1 Common faults and solutions of power take-off case

Fault Reason Solution

Oil leak Oil seal is damaged Change new oil seal

Bearing is worn and loose. Change new parts

Abnormal Gear mesh clearance is large, or gear groove hub Change new parts or bead weld
and spline are worn and loose. to repair spline shaft.
sound
Lubrication is not enough due to oil leakage of Fill in or change the lube which
bearing, or lube viscosity is improper. conforms to specification.
Spline gear on shaft and spline of sliding gear Bead weld to repair shaft or
sleeve are abrasive, and clearance is too large. change new parts.
Trip stop
Uneven abrasion of bearing is heavy. Change new parts.

Shifting fork is worn to deform. Weld to rectify.

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Mesh sleeve cannot be separated completely. Adjust

Difficult to
Lube is not enough or improper. Fill in or change lube.
shift
Mesh sleeve assembly is worn. Change
Bolt of shifting handle is worn to loosen or
Abnormal Change new parts.
broken.
shifting Working surface of shifting fork is worn
Weld
excessively.

Note: Please pay attention to the sound character of the power take-off case
so as to solve it correctly. If there is noise in neutral gear, it could be bearing
looseness. If there is metal grating sound and the temperature of power take-off box is
overheating, it could be oil lacking or bearing tightness. If there is periodic noise
during working, gear could be partly damaged or gear axis is deflected. If the noise is
slight, it can still work, but if there is sharp noise, gear could be broken or metal
pieces get into the box, and it should be maintained immediately.

3.2. Angle transmission box maintenance

3.2.1. Check

Gear oil check: It should be taken after stop the machine for several minutes. First of all,
check whether there is any oil leakage appearance of oil seal, do well cleaning work, take
off the plug screw of temperature indicator, and check the oil level. The oil level should
be not lower 10~15mm than the oil plug hole. Fill in the gear oil up to standard rate after
check.
Fastener check：Check whether every external fastener and adapting pieces are loose or
not, and change or fasten them if necessary.
Case internal check: Check whether the gear attrition rate, gear tooth mesh and tightness
of fasteners meet the operating requirement or not.

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3.2.2. Maintenance

During check, it is required to maintain, repair or change parts.

Gear oil is changed usually in level 3 maintenance. The waste oil should be discharged
while the equipment is still hot, and make sure there are no metal fragments. If any metal
fragment is found, open the cover of power take-off case to check.
After the waste oil is discharged, plug the oil plug back, add light diesel oil equal to 1/3
oil mass in the power take-off case oil-bath, or kerosene mixed with 5% engine oil into
the power take-off case, and then start the engine.
Work in low speed for several minutes (don’t engage the front axle at this time), stop the
engine, discharge the cleaning oil, then add new gear oil to standard rate. It can also clean
using air pressure spray gun to eject cleaning fluid into the transmission.

3.2.3. Lubrication

80W/90（API GL-5）heavy load gear oil is used by angle transmission case，and fuel
charge is about 16L.
Oil change period:
The first time after 300 working hours.
From the second time, change oil every 1000 working hour.
Change oil after every overhaul.
Lubrication grease, No.1 lithium-based, there is a lubricating point, and the lubricating
parts need to be lubricated per week.

3.2.4. Common faults and solutions

No. Reason Solution

1 Gear attrition rate is heavy Butt weld to repair or change gear.
2 Oil leakage Change seal element.
3 Uneven attrition rate of bearing is heavy Change bearing
Make a Gear is abrasive and loose. Change gear.
4
sound Backlash in circular tooth fixes or Repair or change gear.
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there is clearance between gear

hub and key on the shaft
Oil mass is not enough or oil
Fill or change lube.
viscosity is improper

3.3. Rotary table transmission box maintenance

3.3.1. Check and maintenance

Rotary table transmission box should keep clean so as to check.

On the basis of cleaning work, check whether any spring washer cracks or not, whether
bolts and nuts are loose or not, whether the oil pipe is broken or leaks oil or not; and change
them if necessary.
Meanwhile, check whether the engagement and disengagement operating device is
flexible or not, repair or change it if there is any problem. Check whether the oil level of
lubricating oil tank is normal or not before every shift.

Note：Before check the oil level and disassemble the oil pipe, please clean the
end of the oil pipe firstly to prevent dust or other thing falling into the oil-bath,
Otherwise it may cause that the parts inside the transmission box are worn excessively
or the oil pipe is blocked. After check, please add or reduce the oil mass in time.

There should be a complete maintenance of rotary table transmission box after every
1000 working hours.
It is required to check whether fasteners and joint levers are loose or not.
Whether the operating system is flexible, and the lubricating system is
unobstructed.
Change the lubricating oil. Discharge the waste oil while the temperature of the
equipment is high, and pay attention that whether there are metal particles in the oil. If
any metal particle is found, it is required to open the cover of the transmission box to

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check, in order to find out the reason and handle the problem.
After the waste oil is discharged, plug the oil plug back, add light diesel oil equal
to 1/3 oil mass of transmission box or kerosene mixed with 5% engine oil into the box,
then start the engine, to work in low speed for several hours, stop the engine, discharge
the cleaning oil, then add the same gear oil up to standard rate.
While changing the lubricating oil, open the cover of the box, check the wear
pattern of the gears and splines inside the box, and check whether each fastener inside
loosens or not, and fasten it if necessary.
Check if the shifting fork of the engagement & disengagement operating device
is deformed or not; please repair or replace it as required. At the same time, check and
maintain the other parts; if it finds damage or serious abrasion, please repair or replace it
in time.
For the working condition of transmission case, it can be judged according to drilling &
workover operation; and it should be no abnormal noise, no automatic or difficulty to
disengage & engage. Otherwise, please demount the cover to maintain and repair it.

3.3.2. Chain change

After working for every 1000 hours, it is required to check the wear condition of chain at
regular intervals; If it finds serious wear or the length of each section chain has exceeded
52.5mm (elongation exceeds 1.524mm), please change the chain; and it is required to dismount
the transmission shaft, and demount the chain case, then place it on the platform horizontally to
make it set up, and keep the shield of clutch upwards, and open the rear cover plate and end cap
on the box body, drain the oil in it, and demount the chain and replace new chain; Before
replacing, press the new chain on the chain wheel at the upper end opening, to check if it is
fitted well with the roller of the chain; If it finds there is looseness on the chain link on the chain
wheel, it indicates that the chain wheel has been worn and the tooth becomes sharp; Then,
measure the tooth thickness, if the size is less than 28.5mm, please replace a new pair of chain
wheel.

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3.3.3. Lubrication

When transmission case transmits torque, the lubricating system of transmission

case can ensure that there’s still oil film between gears, to reduce the abrasion of gear and
bearing; meanwhile, take away heat generated by the gear and bearing running, to
increase the transmission efficiency and service life of the gear and bearing and ensure
the transmission case can run normally.
The lubricating oil in transmission case should have high viscosity and good
performance; at low temperature, it is easy to flow, and at high temperature, it is easy to
keep oil film. It is recommended to adopt 80W/90（API GL-5）heavy load gear oil for
angle gear transmission case on the truck-mounted drilling rig. Quantity of lubricating oil:
gear box uses 18L, chain box uses 4L.
The oil changing cycle of transmission case’s lubricating system is related to
local environmental condition, operation condition and circulating condition of load.
Generally, please change oil once after the transmission box has been worked for 300h at
first time; After then, please change oil once after it has been worked for 1000h, after
each overhaul and heavy repair, please change the oil. If the oil is polluted, such as oil
temperature is increased, oil has peculiar smell or oil has problem through the oil quality
analysis, please replace the lubricating oil.
The lubricating grease is No.1 lithium base, there are 2 lubricating points, and
the lubricating parts need to be lubricated per week

Note: Keep the lubricating oil filled into lubricating oil tank absolutely clean;
please use clean vessel and oil injector to prevent dirt getting into the lubricating oil
tank.

Rotary table transmission case adopts two kinds of lubricating way, which includes
oil filling lubrication and splash lubrication. The gear lubrication of transmission case
adopts splash lubrication; the oil splashed into the case flows into oil collecting box, and

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lubricates the bearing through oil duct, meanwhile takes away the heat generated by
bearing.

Note: Clutch annular gear bearing of rotary table transmission box must be
lubricated by grease.

3.3.4. Rotary table maintenance

Rotary table maintenance can refer to ZP275 Rotary Table Service Manual in
detail.

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Chapter 4 Maintenance of Mast and Other Parts

4.1. Mast maintenance

Mast is the key equipment of petroleum drilling rig & truck-mounted drilling rig, so it
is significant to ensure mast’s integrality and security. Therefore, to ensure the safety of
well drilling operation, mast must be maintained well and taken comprehensive inspection.
During the operating process of mast, it should avoid loading suddenly, to prevent the
mast from heavy impact; Especially under the large hook load, such as running technical
casing, drilling maximum well depth and handling down hole jamming of drilling tools,
please load slowly, and avoid loading suddenly and emergency brake, to ensure mast
security.

4.1.1. Appearance inspection at regular intervals

At well site, mast should be taken regular appearance inspection by operator (or
appointed representative) at regular intervals. The operator (or appointed representative)
should report the inspection result. In general, check the mast once every drilling cycle,
and check it once again after drilling or workoverk and before transporting. During the
daily drilling & workover process, if it finds any looseness, damage and other
abnormalities, please take actions in time, to avoid accidents.
For the inspection report format, inspection program, scope, specified items and flaw
of mast’s appearance, please refer to appendix in JJ180/38 Mast Service Manual.
Inspection purpose and scope
In order to ensure the inspection work can be carried out fully and completely, and
make sure that the report format is uniform, inspection procedure and report format are
compiled.
American petroleum institute (API) has taken it as reference document and listed it
into the API 4E Appendix A Recommended Regulation for Maintenance and Usage of

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Drilling Rig and Truck-Mounted Drilling Rig. As long as the listed inspection content
meets the needed inspection condition, all of them can be applied to this regulation. If the
mast is used under the condition that the load is close to its load upper limit, or used under
the limited conditions hindering safety operation, please carry out some more detailed and
strict inspection at regular intervals, or supplement some regulations for this recommended
regulation.
Marks on the damaged parts
When inspection, please make obvious marks on the damaged parts or on mast so as
to carry out necessary repair work. It is recommended to use bright and distinct paint to
make marks. After repair, cover marks on the damaged part by painting. If there is no
damage on the inspected part, the inspector should write “No damage” on it to indicate that
this inspection item has passed the inspection. When inspecting, it had better to refer to the
final assembly drawing and service manual provided by manufacturer. For the inspection
item that could not be inspected and not be inspected, please draw a line after this item in
the table.

4.1.2. Inspection and assessment under particular condition

Scope of inspection and assessment

 The mast happens with major accidents, such as collapse or crashing into the crown
block or serious damage after being collided, or the mast with serious overload record
when handling down hole accidents.
 During using, there is serious partial or overall deformation, and serious flaws, such as
fracture and crack, or the mast through overhaul.
 The mast has serviced for more than five years or with serious corrosion.
 The mast is required to be taken comprehensive inspection and assessment according
to relevant standard and regulations.
Organization and assessment of inspection work
 The comprehensive inspection & assessment for mast should be done by quality
certified or recognized professional test agency. The agency responsible for testing

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should meet the business scope authorized by the superior competent department.
 The continued usage, repair or abandonment of mast should be in accordance with
inspection & assessment result.
 The comprehensive inspection for mast should be done by qualified technician strictly
according to SY/T6326.

4.1.3. Lubrication

The good lubrication for each rotary part of mast is significant to ensure mast’s
normal running and prolong its service life. Otherwise, it may cause abnormality and
damage. Therefore, the user should pay attention to the lubricating condition of mast.
Please refer to table 2 to lubricate it in time.
Table 2 Reference table for mast main lubrication points

Lubricating Oil filling

No. Lubrication part Lubricant specification Remark
point cycle
1 Crown block No.1 lithium base grease 11 Per shift
Connecting pin between lower
2 No.1 lithium base grease 4 Per month
section and Y type bracket
3 Sheave shaft of tong cylinder No.1 lithium base grease 1 Per month
4 Roller of tong cylinder No.1 lithium base grease 6 Per month
Centralizer of telescopic Per raising
5 No.1 lithium base grease 16
hydraulic cylinder mast
Per raising
6 Pin roll of bearing mechanism No.1 lithium base grease 8
mast
Per raising
7 Pin roll of raising cylinder No.1 lithium base grease 4
mast
8 Brake in high position No.1 lithium base grease 2 Everyday
4.1.4. Repair and maintenance of mast

Before repairing or modifying mast, please contact and negotiate with manufacturer to
confirm the raw material and modifying method of mast. Without permission of
manufacturer, the operator and construction technology should be approved by mechanical

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chief engineer, and then the operator can repair or modify the mast.
The repairing and modifying for mast should be in accordance with the relevant
regulation of SY/T 6408.
During normal usage period, the mast should be maintained once every half a year.
Generally, mast main body and Y type bracket should be taken rust removal and
anti-corrosion treatment at least once every half a year.
For the serious corrosion parts or positions eroded by drilling fluid, petroleum, natural
gas, saturated salt water and hydrogen sulfide, all of them should be taken rust removal and
anti-corrosion treatment after drilling a well and before moving or transporting to another
well.

4.1.5. Other matters needing attention

As the mast is the main load bearing component part of drilling rig, without
permission, it is not allowed to weld and drill hole on the mast.
Any damaged or missing components during transportation and using cannot be
substituted randomly; please contact with the manufacturer for technical consulting.
When storing the mast, please stack it neatly, and keep it flat; all pin holes of pad eye
should be coated with antirust grease. All guy lines should be bundled into a roll and stored
at a dry place after coated with anti-rust grease.
The maximum bearing capacity of mast means that the mast can bear the maximum
load at normal environment temperature. At the other temperature, the bearing capacity of
mast will decline; especially when it works below -20℃, the operator must confirm the
materials’ low temperature performance and take necessary protective measures.

4.2. Crown block maintenance

4.2.1. Maintenance before operation

In order to ensure the crown block works for a long time without fault, please adopt
correct measures to maintain it in time.

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Before mounting crown block, if there is abnormal condition, please find the fault and
handle it.
 Each sheave should be rotated flexibly, and there should be no jamming or blocking
and no abnormal noise; it is qualified that the sheave can be rotated flexibly by hand.
 When rotating a sheave, the neighbored sheaves shall not be rotated with it.
 Check if the locking nut at the shaft end of crown block sheave and sand sheave can
work reliably; lubricate grease nipple of the crown block’s sheave block at regular
intervals.
 All connections must be fixed well; there should be no looseness.

Fig.1 Crown block structure diagram

1. Crown block base 2. Fast line sheave 3. Main pulley assembly 4. Sand sheave 5. Dead line sheave

4.2.2. Maintenance during operation

Fill lubricating grease at regular interval according to lubrication maintenance rule.

When the temperature rise of bearing is more than 40℃ of environment temperature,
or the bearing has noise or sheave is not stable to shakes, please find reason, and
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change lubricating grease or replace the worn bearing.

When the bearing temperature exceeds 70℃，grease will lose its lubricating function,
please take action to eliminate in time.
When the sheave has crack or the hub is damaged, don’t use it anymore and replace it
in time.
Because the shape of sheave groove is significant for the service life of wire line,
please check the wearing condition of sheave groove frequently, and use specialized
samples to inspect at regular intervals. For making and using of samples, please refer
to API Spec 8C. For repaired groove bottom radius of sheave, please refer to table 6.
When there is major accident, such as jamming of a drilling tool or breaking of drilling
tools, please check carefully if each connecting part of each position is loosened or not
or check if the wire line is out of the rope groove.

4.2.3. Lubrication

Before using and during operation, each sheave bearing should be filled with a certain
amount of lubricating grease twice every week.
Lubricating grease: No. 0 extreme pressure lithium grease.
Table 3 repaired sheave groove bottom radius
Groove bottom sample dimension
Wire line nominal
diameter Min groove Max groove Min groove bottom radius of
bottom radius bottom radius worn sheave groove
32mm ( 1-1/4) 16.84mm 17.48mm 16.28mm
4.2.4. Common faults and solutions of crown block

Temperature of sheave shaft raises (the temperature raises to more than 70℃).
Reason: oil pipeline is blocked, lacks oil, lubricating oil is not clean, bearing inner
&outer ring are loosened.
Bearing has noise.
Reason: bearing is worn severely; and bearing bracket is loosened.

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4.3. Maintenance of travelling hook

4.3.1. Inspection

Lubricate each lubrication point.

Inspect whether all cotters are fastened well.
Inspect whether each locking unit is flexible and reliable.
Inspect whether the intermediate body can be rotated flexibly.
Inspect whether the sheave of traveling block can be rotated flexibly and there is no
blocking
Inspect whether the buffer device leaks; check whether the oil filling port screw plug
is in good condition and tightened firmly or not.

4.3.2. Maintenance

Check the intermediate body of traveling hook and each bearing hand wheel of hook
body at regular intervals. When necessary, please take nondestructive test. If it finds
crack or excessive wear, please stop using it.
Check the sheave, bearing and rope groove at regular intervals.
 Under the condition that the sheave edge is worn and it is easy to be out of the rope
groove and wear or damage the wire line, please replace the sheave in time.
 When the sheave cannot rotate steadily or the bearing has abnormal noise caused by
the increased bearing clearance, please replace the bearing in time.
 When the surface of sheave rope groove has corrugated groove or the groove bottom
radius of rope groove has worn to be less than the value (in table 6), please replace the
sheave in time or re-process it.

4.3.3. Lubrication

Lubricating point
 Grease nipple at the shaft end of traveling block’s sheave.
 Grease nipple on the brake at the side of hook barrel.

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 Main bearing and spring inside hook barrel.

 Grease nipple at the end of hook body supporting pin.
 Contact surface between hook body and elevator link or swivel’s bail and each surface
of each sheave rope groove.
Lubrication cycle
 Each rolling bearing and hook body supporting pin should be filled with lubricating
grease once every 150 hours;
 Main bearing inside hook barrel and brake should be filled with lube or lubricating
grease once every 150 hours;
 Each working contact surface of sheave rope groove and hook body should be coated
with lubricating grease once every 8 hours.
Lubricating grease (oil)
 Lubricating grease: No.1 lithium grease
 Lubricating oil: 80W/90（API GL-5） heavy load gear oil.

4.3.4. Common faults and solutions

Common faults and solutions of travelling hook refer to table 4.

Table 4.Common faults and solutions of travelling hook

No. Faults Reason Solution

1○. Oil duct is blocked,
Sheave is heating or cannot 1○.○
1. Clean and fill oil
1 and lacks oil
rotate 2○. Change bearing
2○. Bearing damages
1○. Spring is fatigue and
Spring has no enough stroke 1○. Replace spring
2 relaxed or broken
or cannot return back 2○. Inspect to repair
2○. It is blocked insides.
1○. Oil lacks 1○. Fill oil
Hook cannot rotate flexibly
3 2○. Bearing damages. 2○. Replace spring
or blocked
3○. It is blocked insides. 3○. Inspect to repair
The brake device of hook 1○. Be jammed 1○. Repair
4
cannot work normally 2○. Spring is damaged 2○. Replace spring
Safety locking device of hook
5 Spring is damaged Replace spring
mouth cannot work normally

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Inspection and maintenance

For the hook which has been used, it must be taken periodical inspection &
maintenance and be made related record, which ensures the equipment can be used safely,
to avoid equipment damage &human injury.
Table 5 Inspection item & inspection cycle table for traveling hook

Items Position Cycle

During the running of
equipment, observe if the
Appearance of each equipment Per 8 hours
performance meets the
requirement
Each position of connecting thread; each
Inspect, and adjust the
bearing pin; The contacting position of
corrosion, deformation,
hook body’s main hook & auxiliary hook
looseness or falling off, Every week
and lifting bail &elevator link; Rope
damage and visible surface
groove surface of sheave, locking arm
crack.
and crescent locking arm.
Main hook, auxiliary hook, and
connecting position between both and
Surface nondestructive test and
the hook body; Connecting pin hole Semiannually
abrasion inspection
position of hook level and hook body;
Rope groove surface of sheave
Main hook, auxiliary hook, and
connecting position between both and
It should be no inner flaw
the hook body; Connecting pin hole
through ultrasonic or radio Every year
position of hook level and hook body;
test.
Main bearing mounting position of hook
level
The manufacturing and repairing of traveling hook should be in accordance with API
SPEC 8A. For new & repaired sheave and drum groove bottom radius, please refer to
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figure 2 and table 6.

Note: Inspection, maintenance and repair of hook should conform to 2

standards, including SY/T 6357-1998 Inspection, Maintenance, repair and Restore
Procedure for Raising Equipment and SY/T 6100-1994 Petroleum Drilling Usage
and Maintenance.

1.75dMax

1.33d Min

Fig.2 Sheave used for wire line of drilling and casing

Table 6 New and repaired sheave and drum groove bottom radius

Nominal Nominal
Min groove Max groove Min groove Max groove
diameter of diameter of
bottom radius bottom radius bottom radius bottom radius
wire line wire line
in mm in mm in mm in mm in mm in mm

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0.250 6.5 0.134 3.40 0.138 3.51 2.375 60 1.259 31.98 1.306 33.17
0.313 8 0.167 4.24 0.172 4.37 2.500 64 1.325 33.66 1.375 34.93
0.375 9.5 0.199 5.05 0.206 5.23 2.625 67 1.391 35.33 1.444 36.68
0.438 11 0.232 5.89 0.241 6.12 2.750 71 1.458 37.03 1.513 38.43
0.500 13 0.265 6.73 0.275 6.99 2.875 74 1.524 38.71 1.581 40.16
0.563 14.5 0.298 7.57 0.309 7.85 3.000 77 1.590 40.39 1.650 41.91
0.625 16 0.331 8.41 0.344 8.74 3.125 80 1.656 42.06 1.719 43.66
0.750 19 0.398 10.11 0.413 10.49 3.250 83 1.723 43.76 1.788 45.42
0.875 22 0.464 11.78 0.481 12.22 3.375 86 1.789 45.44 1.856 47.14
1.000 26 0.530 13.46 0.550 13.97 3.500 90 1.855 47.12 1.925 48.89
1.125 29 0.596 15.14 0.619 15.72 3.750 96 1.988 50.50 2.063 52.40
1.250 32 0.663 16.84 0.688 17.48 4.000 103 2.120 53.85 2.200 55.88
1.375 35 0.729 18.52 0.756 19.20 4.250 109 2.253 57.23 2.338 59.39
1.500 38 0.795 20.19 0.825 20.96 4.500 115 2.385 60.58 2.475 62.87
1.625 42 0.861 21.87 0.894 22.71 4.750 122 2.518 63.96 2.613 66.37
1.750 45 0.928 23.57 0.963 24.46 5.000 128 2.650 67.31 2.750 69.85
1.875 48 0.994 25.25 1.031 26.19 5.250 135 2.783 70.69 2.888 73.36
2.000 52 1.060 26.92 1.100 27.94 5.500 141 2.915 74.04 3.025 76.84
2.125 54 1.126 28.60 1.169 29.69 5.750 148 3.048 77.42 3.163 80.34
2.250 58 1.193 30.30 1.238 31.45 6.000 154 3.180 80.77 3.300 83.82
Notes: As for the wire line whose diameter is over 0.375in (9.5mm) not list in the
table, calculate the groove bottom radius according to following formula:
Min new worn radius = nominal diameter of wire line + 6%
Max worn radius = nominal diameter of wire line + 10%

4.4. Swivel maintenance

Swivel maintenance refers to XSL225 Swivel Service Manual in detail.

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Chapter 5 Drawworks Maintenance

5.1. Dairy inspection, repair and maintenance for drawworks

5.1.1. Per shift inspection items

Fast line clamp pressing plate should be complete and tight.

The brake is flexible and reliable.
Whether brake block is worn excessively and has cracks.
Whether clearance between brake hub and brake band is uniform.
Whether brake device, and emergency brake are normal.
There is no oil leakage for any of shaft end, bearing cap, chain case, and others, and
bearing temperature rise is normal.
There is no air leakage in pneumatic control system.
There is no oil leakage in lubricating system.
There is no abnormal noise of each transmission.

5.1.2. Other inspection items

Replacement cycle of lubricating oil in chain case: The circle should be over 2000h,
when there are few impurities in oil, no severely deterioration, and no leakage.
Inspect, adjust and tighten adopting piece of all transmissions, and inspect whether
chains are damaged, if necessary.
Inspect wear pattern of clutch and brake block at any time, and adjust or replace them
promptly.
Inspect wear pattern of fast line; replace them if excessive abrasion, or strand and wire
broken is found.
In general, inspect wear pattern of chain wheel, bearing, seal and others for
semi-annually, and replace them timely if necessary. Inspect lubricating system, and
inspect whether pneumatic control system hoses or all connections are loose.

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Contents not listed in inspection items should be also noted in the back and forth
inspection, and eliminate equipment hidden dangers at any time to keep equipment run
normally.

5.1.3. Regular inspection

After drawworks runs for a period of time, the running parts will be worn in varying
degree, and the connection parts shall be loosened, pipeline may be blocked, and sealing
elements get aged. If it keeps going like this, the normal use of equipment will be affected.
Therefore, regular inspection and repair should be adopted except daily inspection and
general maintenance mentioned above. There should be professional personnel engaging
into the regular inspection, and the large-scale maintenance should be carried on in
maintenance station or machine repair workshop.
Inspection item of drawworks semiannually:
 Inspect wear condition of brake hub, and replace it if necessary. Commonly, the
factory abrasion loss of brake block is 10mm. When the abrasion loss ≤
X1mm, brake
block should be replaced. The brake block abrasion loss diagram refers to figure.3.
 Inspect whether pneumatic tube clutch air bag is aging,
and inspect the abrasion degree of friction block,
replace it if necessary.
 Inspect following components of lubricating system,
and replace, overhaul, or adjust the components
according to the situation.
Chain case and lubricating oil Countersunk bolt
Oil pipeline
Fig.3Brake block wear mass loss diagram
Sealing element

Warning: As any brake block wears and leads to the fixed bolt head touching
the brake hub, all brake blocks should be replaced, to avoid brake block and brake hub
slipping, and equipment trouble and personal casualty.
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5.1.4. Annual inspection items

Brake mechanism works well.

Inspect bolts and nuts of all connecting pieces, fasten them when loosening; and
replace cotters and pins when lost or damaged.
Inspect the wear patterns of bearing, seal and others; replace it if excessive wearing.
Inspect the leakage and blockage of all pipelines of lubricating oil and lubricating
grease.
Inspect clutch, and replace wear-out part.
Inspect wear pattern of chain case, drawworks chain wheel, and chain.
Inspect wear pattern of brake hub.
Clean oil pool.
Check pneumatic control system.
Check all oil seals.
After checking, determine the components and parts which should be overhauled or
replaced, and the ones settled hard on site should be overhauled or replaced in a
professional maintenance station or a machine repair workshop.

5.2. Lubrication of drawworks transmission system

JC28/11 drawworks lubricating system adopts engine oil bath lubrication and grease
lubrication.

5.2.1. Lubrication of lube

Lubrication principle
 Lubricating method of drawworks chain adopts engine oil bath lubrication.
 Oil pointer is equipped at the lower part of the chain case. Pay attention to oil pointer
when drawworks starts to use and is in process of using, and keep the oil level in the
middle.
Oil added in the chain case

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 Recommend to use 80W/90（API GL-5）heavy load gear oil.

 Oil level should be in the middle of oil pointer when adding oil. As the oil level is still,
observe the oil pointer, add oil in time when oil lever is lower than oil pointer.
Lubricating oil should be filtered as adding oil, and each well must replace lubricating
oil once. Oil should be replaced according to the actual conditions if polluted.

5.2.2. Lubrication of lubricating grease

Main lubricating position of drawworks includes axial bearings of both sides of drum，
clutch bearing, dual-purpose swivel, brake mechanism connecting rod, pin shaft, crank
throw, spline, bearing, etc.
Apart from the part adding grease of drum shaft axial bearing locating on rack side
plate, other lubricating points are all located at positions required to be lubricated.
When adding in grease, it should pay attention that if there is oil chamber filler
connected with copper pipe in the middle, disassemble the oil cup, connect the grease
machine joint, and then add in grease by grease machine.
For oil cup connecting to lubricating grease cavity directly, add grease into cavity
with grease gun or with grease machine.
Lubricating grease: recommend to use No.1 lithium grease.

5.2.3. Replacement cycle of lube

Replacement cycle of lubricating oil relates to service conditions, maintenance, clean

and other factors, and it’s difficult to provide exact value. Following values provided based
on experience are for reference only.
 After a new truck-mounted drilling rig is put into use, the first oil replacement cycle is
2000h from operating (quality of lubrication oil products reduces fast during run-in
period).
 Under conditions of corrective usage and maintenance, oil replacement cycle is
2000h~4000h or even more from running.

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5.3. Maintenance of draw work pneumatic control system

Pneumatic control system of drawworks is mainly composed of clutch control,

crown-o-matic, and brake device, etc.
Faults in pneumatic control system will severely affect production of truck-mounted
drilling rig. Therefore, maintenance of pneumatic control system is of vital importance for
normal operating of truck-mounted drilling rig.

5.3.1. Inspection before usage

 Inspect whether instrument in the driller control box is right, whether the inside and
outside of box are clean, and whether air leakage exists.
 Inspect whether each control valve works reliably.
 Inspect crown-o-matic: crown-o-matic should be tested before round trip every time,
to ensure it’s safe and reliable.
 Inspect whether the exhaust valve and air supplier are in good condition.
 Inspect whether each pipeline leaks air or not.
 Adjust the pressure of reserve tank on the truck-mounted drilling rig to 0.8MPa。
 Add lubricating grease into air swivel.
 Check whether the clutch works reliably.
 Check whether the brake cylinder works reliably.

5.3.2. Clean and replacement of pipeline

Pipeline polluted will cause pipeline blocked, valves failure even damage, and
security incidents will occurs. Thus it should keep the pipelines clean, and replace them if
necessary.
 When moving truck-mounted drilling rig, the disassembled pipeline joints should be
protected, and the opening of pressed hose should be wrapped with clean cloth, and
the opening of metal pipeline should be blocked or wrapped with cork.
 Pipeline should be clean with compressed air before installed, and connect the pipes

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after clearing dirt.

 When it disassembles the plastic fast air pipe, it should press the check washer with
one hand, and pull out plastic pipe with the other hand.
 After plastic pipe is repeatedly assembled, deformation at the front of plastic pipe
should be cut off, then connect into the joint. Otherwise air leakage will occur
probably because of untight seal.

5.3.3. Faults treatment of pneumatic elements

When operation of pneumatic control elements is wrong or failed, it should not take the
valves apart casually. As there are many reasons for valve faults, and the faults are not
always caused by valves sometimes, it’s probably due to air circuit pipeline jam or low air
pressure. So don’t take pneumatic control elements apart casually when meeting this kind of
faults. The treatment method: firstly, confirm the position of fault according to pneumatic
control schematic diagram; then check per section (check the control gas circuit at first, open
the air connector in sections, and then check the venting condition), if the control air circuit
is unblocked, and then check the working air circuit. Disconnect the air outlet pipeline of
valves, and check the venting condition. If it’s blocked, check the intake pipeline. If intake
pipeline is unblocked, it shows that there’s something wrong with valves, and open valves to
repair. Commonly, replace the problematic valves with the emergency valves, and then
check faults of the replaced valves, in order to ensure that the drilling work can operate
normally.
After well drilling or a period of time (not more than three months), take a maintenance
for whole air system, inspect the easily damaged parts conditions completely, and replace
and clean them promptly, to avoid valves running in abnormal state.

5.4. Maintenance of other equipment

Details about thrust disc clutch maintenance refer to relevant service manual.
Details about auxiliary brake maintenance refer to relevant service manual.

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5.5. Common faults and solutions of drawworks system

No. Fault Reason Solution

Brake block is worn
Replace the brake block
excessively.
Brake band is unbalance. Adjust balance.
When pressing
Clear oil stain and paint
to the lowest Brake hub gets oil stain
rosin powder.
position, brake Brake handle is adjusted Adjust height of brake
fails. too low handle.

Brake Running end of brake band Adjust the running end of

1 is adjusted improperly brake band.
handle
When brake Clearance between brake
Adjust brake band
band and Brake hub is too
handle reaches clearance
small.
highest position, There is friction between Repair brake band and
hook cannot go brake band and brake hub brake hub
down or go Brake handle is adjusted
Adjust brake handle
down slowly. improperly

Clutch friction disc Adjust friction disc

Drum runs
clearance is too small. clearance.
before the clutch
Clutch friction disc
is disengaged Replace fiction disc.
sinterings.
Clutch friction disc Adjust fiction brake

Drum clearance is too small clearance

2 After removing
Clutch Clutch friction disc
clutch, drum Replace fiction disc
sinterings
still runs.
Control gas circuit is not Overhaul gas circuit and
shut off completely relevant valves

Slip when Clutch is polluted by oil Clear oil stain

Lifting traveling Air pressure of clutch is Adjust air pressure

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hook. not enough.

Clutch friction disc Adjust fiction brake

clearance is too big clearance
Clutch friction disc is
Replace fiction disc
worn excessively.
Air pressure of clutch is
Adjust air pressure
too low
Brake hub clearance is too
Adjust brake hub clearance
big
Brake band is worn
Overhaul and replace
excessively.
Brake force is Brake hub is polluted by
Clear oil dirt
not enough oil

Left and right brake bands

Adjust balance.
are unbalance
Cooling water temperature
Drum Adjust water temperature
3 is too high
brake
Increase cooling water
Brake hub is too hot
quantity.

Hook lowers too fast Control speed properly

Do not engage auxiliary Engage brake by rule in

brake time.
Brake hub cooling isn’t Adjust temperature and
Brake band is
enough. flow of cooling water.
worn too soon.
Brake hub clearance is too
Adjust brake hub clearance.
small.
Air pressure of clutch is
Adjust air pressure.
too high.

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Resistance of
no-load running Brake is not adjusted well. Readjust brake.
is big.
Clearance between brake
band and brake hub is too Readjust clearance.

Sand big.
4
drum Running end of brake isn’t Readjust running end of
Brake failure adjusted well. brake.
Brake block is worn
Replace brake block.
excessively.

Surface of brake hub gets Clear oil stain and paint

oil stain. rosin powder
Chains fracture Replace chains
Brake isn’t disengaged. Adjust brake.

Air pressure is insufficient. Adjust air pressure.

Air bag burst Replace air bag

Pressing plate is damaged Replace pressing plate
Tension force is
Intermediate fluted disc
Main insufficient. Readjust clearance
5 clearance is too big.
drum
Surface of friction plate Clear oil stain and paint
gets oil stain. rosin powder
Friction plate is worn
Replace friction block.
excessively.

Readjust brake or
Brake failure Brake system failure
maintenance
Air pressure of clutch is
Adjust air pressure
Auxiliary Brake force is too low
6
brake not enough. Brake hub clearance is too
Adjust brake hub clearance
big

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Brake band is worn

Maintenance and replace
excessively.
Brake hub is polluted by
Clear oil dirt
oil
Cooling water temperature
Adjust water temperature
is too high
Rotary speed of using is
Control speed properly
too high.
Cooling water temperature Adjust temperature and
Get hot is too high. flow of cooling water.
Cooling water inlet and
Water outlet is on 12
outlet lines are connected
o'clock view
error
Rotary speed of using is
Control speed properly
too high.
Cooling water temperature Adjust temperature and
Burn is too high. flow of cooling water.
Friction plate is worn
Replace friction plate.
excessive.
Air pressure is too high Adjust pressure
Lack lubricating oil Add lubricating oil
Lubricating oil is
Replace lubricating oil
Get hot partly contaminated
Maintenance and replace
Chain Bearing is worn
bearing
7 transmission Maintenance and replace
Bearing is worn
box bearing
Abnormal noise Maintenance and replace
Chain is worn
when running chain
Maintenance and replace
Chain link is lengthened
chain

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Chapter 6 Substructure Maintenance

6.1. Substructure usage

Ambient temperature is not lower than -20℃, when substructure bears loads such as the
largest hook load of mast, the largest load of rotary table and others. If the operating
ambient temperature is lower than -20℃, the heat equipment must be started to make
heat protection for substructure in order to avoid lowering greatly performance of
components’ material under low-temperature environment, which results in damage of
components even dangerous accident and other aftermath.
The base of drilling rig substructure should be firm and reliable, and the base is above
ground for 150~200mm so that there is appropriate slope for nearby ground of base,
which is convenient to drain away water and keep the soil stability
When the base of drilling rig substructure is found to sink unevenly during operating,
the remedial measures should be taken without delay.
When substructure bears the load, it is not allowed to disassemble any load-bearing
components and adapting pieces of the main body.
In the course of using, substructure should avoid loading suddenly to prevent from
occurring excessive impact load.
In the course of substructure using, check regularly whether all bolts loosen or not,
whether pin roll and safety pin fall off or not ,whether welding lines crack or not,
whether railing fixture is reliable or not, and whether the safety exit is clear or not, etc.,
to make sure that substructure works normally.
If paint film of metal components is found to fall off, it needs to paint in time, to reduce
rusting and prolong the service life of metal components in the process of usage.
If the structural components are deformed or damaged due to crash in the course of
usage, it should be corrected or changed timely, to ensure to use safely.
Check oil level and oil temperature of the climbing chain box periodically. When the

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length of chain link is more than 3%, it should be changed in time.

Check relative running components periodically, such as pin roll, chain box bearing, oil
seal, transmission shaft, sheave, roller and others; and fill lube in time. If there are some
badly damaged parts, change timely.
Check and maintain substructure periodically and eliminate the possible problems
timely, which not only can avoid the tremendous accidents, reduce downtime, lower the
repair and other cost; but also can improve the utility factor of equipment greatly, and
prolong service life of equipment.
When substructure is operated under its limiting condition or the factors influencing its
structural performance, it needs to check and maintain periodically in accordance with
the more detailed and higher requirements.
Therefore, the important significance of regular inspection and maintenance is equal to
that of the normal operation.

Note: If ambient temperature is lower than -40℃, the operation for

substructure is forbidden.

6.2. Inspection for substructure

6.2.1. General principle

The crack or mechanical damage will badly damage equipment and cause failures
immediately. The aim of inspection is to eliminate the defects of substructure. If there are
some defects on substructure, it should stop using or to repair at once.
The regular inspection should be taken periodically during the usage of substructure,
and the inspection results are recorded in the document and diagram of equipment.
Inspect the contact condition between substructure and its base.
Inspect if there are cracks or breaks for the all welding lines.
Inspect if all components have obvious deformations.
Inspect if stairway, handrail and railing of all parts are complete, fastened and in good

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condition.

6.2.2. Inspection category

Class Ⅰ
The rig personnel should check visually if substructure performance is in good
condition during operation.
Class Ⅱ
Based on class Ⅰ, inspect thoroughly (but not limited to) if the load-bearing area
and sheaves have crack, damage, corrosion, loosing or missing of spare parts. Take
class Ⅱ inspection when truck-mounted drilling rig is installed
Class Ⅲ
Based on class Ⅱ, check visually and thoroughly all bearing spare parts and
components to ensure the substructure condition is normal, and record the well site
inspection report with uniform format. It should be considered to check in accordance with
the more detailed and higher supplement program when substructure is used under its
limiting condition or structure is in critical condition which influences the structural safety
performance.
Class Ⅳ
Besides class Ⅲ inspection, it still needs to disassemble and clean all critical
regions which the equipment shall take nondestructive test. All the pipe (or enclosed
type) components should adopt ultrasonic section test to inspect if there is no corrosion
inside. It can also adopt inner camera controlled by cables to inspect visually the inner
corrosion condition.
The damage found in the inspection can be divided into three types: severe
damage, moderate damage and slight damage according to the following principles.
 Severe damage: The main bearing components have the obvious geometry deformation
or structural damage.
 Moderate damage: Non-main bearing components have obvious damage or
deformation.

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 Slight damage: the damage or deformation of auxiliary equipment, such as stairway

railing, etc.
Check visually all welding lines（100%）.
All welding lines of critical region should conduct nondestructive test according to
Chapter 6 in AWS D1.1.

6.2.3. Inspection cycle

Users determine the category or cycle of inspection according to the criterion in

the table 7.
Table 7 Category or cycle of inspection

Drilling rig 20 drilling 100 drilling Document

Category Daily
installation wells wells record

Ⅰ √ Select

Ⅱ √ Select
Drilling rig
Ⅲ √
document
Drilling rig
Ⅳ √
document

The cycle mentioned above is used in the regular service life of equipment. It should be
considered to increase the amount of inspection under the corrosion environment, such as
wet, saliferous, sulfuretted hydrogen and so on.

6.3. Maintenance and repair of substructure

6.3.1. Substructure maintenance

The maintenance for substructure mainly includes adjusting, clean, lubrication, test and
changing quick-wear parts and other actions.
During the normal service life of substructure, it needs to maintain once a year and
antirust and anticorrosion treatment should be conducted once every six months.
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The severe corrosion parts, which immerse into drilling fluid, petroleum, natural gas,
saturated salt water, and sulfuretted hydrogen and others, should conduct antirust and
anticorrosion treatment thoroughly after drilling the well and before transportation.

6.3.2. Substructure repair

If substructure needs to be repaired, consult manufacturer in order to get the

agreement about used material and repair method.
Without the agreement of manufacturer, the qualified personnel should be employed,
and the admitted engineering method is adopted to supervise the requested repair.

6.3.3. Methods applied to structure repair for substructure:

Repair or change damaged components.

Use the welding method approved by manufacturer or qualified personnel, to guide
repair or renovate.
The severe damage should be repaired in the workshop according to OEM technical
specification.
The moderate and slight damage can be repaired on site.
The substitution material, pin and bolts should be satisfied with OEM technical
specification.

Warning: It is forbidden to punch, cut hole or weld for rotary beam and
setback beam of substructure and the relative components without the
allowance of specialized management institution.

6.3.4. Corrosion

It should be repaired when the rusted damage of components’ cross section is more
than 10%. The rusted area should be bright and clean (close to metal color) after abrasive
blasting and mechanical cleaning. The assessments and repair methods are as follows:
 Repair to weld the rusted area and burnish smoothly.
 Seal weld the damaged area of connecting plate.

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 Eliminate the damaged area and be smooth again.

 Change the whole component.
The whole area should be painted again after repair.

6.3.5. Announcements for maintenance

Pay attention to protect coat of painting for component surface, to avoid causing severe
corrosion of components in the course of disassembling and transportation for
substructure.
During disassembling and transportation, prevent substructure from strength loss
caused by colliding and others, and avoid disassembling powerfully and deforming
components when using.
During installation and operation, substructure should be operated within the safety load
range, to avoid overload use according to Service Manual for DZ180/6 Substructure.
It is forbidden to punch hole, cut and weld and so on casually on substructure. If it is
necessary, the relative department or personnel should agree with it. Constructors
should be professionals with the relative work certification.
The relative personnel should conduct basic safety check for substructure per day. It
should be eliminated and rectified in time if there are some problems or abnormity for
substructure.
In the course of normal usage, prevent substructure from corroding due to soaking in the
acid, alkali corrosion materials and others, check the painting of substructure surface at
regular intervals (per running 800~1500h), and make up painting in time at place of the
paint falling off , which reduces corrosion and prolong the service life of components.
The section where substructure contacts with the ground should conduct antirust and
anticorrosion treatment at regular intervals (per running 1500h).

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6.4. Package and transportation

6.4.1. Package

The procedure for substructure disassembling is in opposite of the installation

procedure. That is to say, the last installed part should be disassembled first, vice versa.
And it shall obey such disassembling procedure, which disassembles from up to down, and
accessories first and then main body.

After disassembling, assort and pack the small pieces, including adjustable lead screw,
bolt, nut, axis pin, safety pin, electrical appliance and others; furthermore, place them in
the fixed location. When disassembly is finished, count the quantity, and pack them in the
box to avoid losing. Railings, pedals, walkway and other parts required to be disassembled
and structural rod should be tied up with washer to avoid damaging the painting and
components. Besides, use label to mark and record. For the large parts of main body, they
can be packed in nude and taken necessary protection treatment.

6.4.2. Transportation

When substructure needs to transport after packing, it should be tied up firmly with
washer whatever long-distance or short-distance transportation, to avoid damaging the
painting or components.
In the course of lifting transportation for substructure, strictly prevent components
from colliding or deforming. If such conditions happen, it should be corrected and changed
in time. When substructure is transported after disassembling, it should pay attention to
safe keep for axis pins, bolts, safety pins, electrical parts, railings and other accessories. It
should paint lubrication grease to avoid corrosion for the fastening connection pieces and
nude metal machining surface such as the metallic pin hole, thread and others.
All the transportation parts are only allowed to hoist, and it is required to hoist the
reliable part, such as special lug.

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6.4.3. Storage

Substructure should be located at the dry horizontal plane where is smooth and has
enough support points, to avoid deformation for components when storage.
When substructure is out of use for a long time, it should clean with hot water and
store in the open-air warehouse. If it is limited by condition, substructure should be put in
the dry and ventilated place to avoid direct sunlight, and take the rain-proof action. The
disassembled small parts and components should be lubricated in order to store for a long
time, to avoid rusting, damaging or affecting requirements for usage safety performance.
Besides, electrical parts should be taken anti-aging action.

Note: When substructure is stored, sleepers can be increased under

components, to avoid accelerating component corrosion due to humid
or immersing in water and other factors.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
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Chapter 7 Lubrication and Common Faults for Drilling

Rig

7.1. Lubrication

The good lubrication for every running parts of drilling rig ensures that the rig can be
operated smoothly and prolonged the service life; otherwise, it will cause damage
abnormally.
Therefore, user should pay attention to the lubrication condition frequently, choose the
proper brand of lube according to the local ambient temperature, and lubricate in time, in
order to adapt to the working environment of truck-mounted drilling rig.

7.1.1. Lubricating oil

The usage recommendation of the drilling rig refers to table 8.

Table 8 Lubricating oil recommended table of drilling rig

In summer In Summer
Fuel
and Winter and
No. Part Summer charge
-25～49℃ Winter >
（L）
-35℃

SAE30 10W/40 5W/30

1 CAT engine 26.5×2
CG-4/CH-4 CG-4/CH-4 CH-4

Hydrodynamic
2 Allison C-4 special hydraulic oil 70×2
transmission

3 Main hydraulic oil tank L-HM-N68 L-HM-N46 YC-N46D 1460

4 Power take-off case （API GL-5）80W/90 heavy load gear oil 43

5 Angle transmission box （API GL-5）80W/90 heavy load gear oil 16

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Chain cover for main

6 （API GL-5）80W/90 heavy load gear oil 10
drum input end

Chain cover for main

7 （API GL-5）80W/90 heavy load gear oil 10
drum output end

Rotary table
8 transmission box（gear （API GL-5）80W/90 heavy load gear oil 18
box）

Rotary table
9 transmission box（chain SAE30 4
box）

10 Climbing chain case SAE30 4

11 Rotary table （API GL-5）80W/90 heavy load gear oil 65

12 3t hydraulic winch （API GL-5）80W/90 heavy load gear oil 5.7

13 5t hydraulic winch （API GL-5）80W/90 heavy load gear oil 6.65

14 Main reducer （API GL-5）80W/90 heavy load gear oil 20×4

15 Wheel-side reducer （API GL-5）80W/90 heavy load gear oil 2.25×8

Note: The lubes in the table are for reference, and customers adjust lubes
according to the different operation environment and temperature difference.

7.1.2. Fuel oil

The recommended usage for engine fuel oil sees in the table 9.
Table 9 Fuel list

Climate Temperature Fuel brand

Summer Above 4℃ No. 0 light diesel oil

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No. 10 light diesel oil

-5℃～-15℃ No. -20 light diesel oil

Winter -15℃～-29℃ No. -35 light diesel oil

-30℃ below No. -40 light diesel oil

Note：fuel tank capacity：500L×2=1000L

7.1.3. Cooling liquid

Selection
The cooling fluid should be chosen properly. Otherwise it may cause corrosion and
scale buildup for the cooling circulatory system chamber, which affects the heat emission
of the diesel engine, draw works and other equipment, and leads to some components
overheated and damaged in the severe condition.
 The cooling circulatory system water should be neutral soft water, and the distilled
water, deionized water and softened water should be adopted firstly. It is forbidden to
use seawater, saline water, and industry wastewater.
 The proper amount of anti-rust additive should be added into circulation water so as to
prevent the water tank, pipe and equipment from rusting.
 When the temperature is lower, the antifreeze fluid should be added according to the
local ambient temperature.
Matters needing attention
 It is forbidden to use the anti-rust additive and antifreeze additive at the same time.
When the cooling fluid needs to be changed, it should be drain away the original cooling
fluid, and clean circularly the pipeline, water tank and other circulatory equipment.
 After using the antifreeze fluid, it should check the antifreeze fluid energy efficiency
and level condition regularly to avoid lowering antifreeze fluid energy efficiency and
equipment frost crack.
 The ratio should be proper between antifreeze fluid and circulatory water under the
low-temperature environment; otherwise, the circulatory water is hard to satisfy the
antifreeze energy efficiency.

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Usage amount
 Cooling system for engine: 40L×2
 Independent cooling system for draw works:8m³
 Cooling system for sand drum：340L
 Antifreeze for air control system
 The proper amount of ethanediol should be added into anti-freezer for air control system
under the low-temperature environment, to prevent air pipeline, valves and others from
freezing.
 When anti-freezer is added, the engine should stop working, to prevent pressure of
anti-freezer from hurting people.
 Anti-freezing solution
 The American Extended Life Coolant is recommended to use.
 It can be replaced by using glycol, and the ratios see the table 9:
Table 9 glycol ratio table for anti-freezing coolant

Temperature /℃ Anti-freezing coolant//% Pure potable water /%

-10 20 80

-20 34 66

-30 44 56

-40 51 49

 It is not allowed to add too much anti-freezing additive. And if the ratio of
anti-freezing additive is excessive, it will reduce the anti-freezing effect.

7.1.4. Lubricating grease

Lubrication points for drilling rig running parts and the period for filling and changing
grease sees in the table 10.
Table 10 Lubricating points of ZJ30/1800CZ

Lubricating Recommended Filling and changing

No. Lubricating parts
point lubricant oil period

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Transmission shaft (6pcs No.1 lithium

1 1×6 Every month
totally) base grease

No.1 lithium
2 Output bearing of angle case 1 Every month
base grease

No.1 lithium
Bearing 1×2 Every day
base grease

Clutch air No.1 lithium

1 Every day
swivel base grease

Bearing for No.1 lithium

1×2 Every day
brake shaft base grease

Brake balanced No.1 lithium

1×2 Every day
block base grease

Intermediate
No.1 lithium
base for brake 1×2 Every day
base grease
shaft
3 Main drum
Bearing for
No.1 lithium
brake 1×2 Every week
base grease
transition shaft

No.1 lithium
Swivel 1×2 Every day
base grease
Low-position No.1 lithium
2 Every day
brake base grease

No.1 lithium
Bearing 1×2 Every day
base grease
Clutch air No.1 lithium
1 Every day
swivel base grease

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Bearing for No.1 lithium

1×2 Every day
brake shaft base grease

No.1 lithium
Brake 1×2 Every day
base grease
No.1 lithium
Bearing 1×2 Every day
base grease
Clutch air No.1 lithium
1 Every day
swivel base grease

Bearing for No.1 lithium

4 Sand drum 1×2 Every day
brake shaft base grease

Brake balanced No.1 lithium

1×2 Every day
block base grease

Bearing for No.1 lithium

1 Every day
brake base base grease

Clutch air No.1 lithium

1×2 Every month
swivel base grease

Input
No.1 lithium
transmission 3×4 Every month
base grease
shaft
Rotary table
Bearing for No.1 lithium
5 transmission 1×2 Every month
chain box base grease
system
Output
No.1 lithium
transmission 1×3 Every month
base grease
shaft

Copper sleeve No.1 lithium

1 Every day
for rotary table base grease

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shaft

Anti bouncer No.1 lithium

1×3 Every day
bearing base grease

Main No.1 lithium

2×2 Every mast raising
connection pin base grease

Tong
No.1 lithium
hydro-cylinder 1×1 Every day
base grease
sheave shaft

Tong cylinder No.1 lithium

1×6 Every day
roller base grease

Telescopic
No.1 lithium
cylinder 4×4 Every mast raising
base grease
centralizer

upper and
6 Mast No.1 lithium
lower locking 4×2 Every mast raising
base grease
block pin roll

tong cylinder No.1 lithium

1×2 Every day
sheave shaft base grease

crown block No.1 lithium

1×7 Every shift
sheave shaft base grease

Pull rope shaft

No.1 lithium
on racking 1×2 Every mast raising
base grease
board

High position No.1 lithium

2 Every day
brake base grease

7 Travelling Travelling 2×2 No.1 lithium Every week

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

block block shaft base grease

&hook Intermediate No.1 lithium
2 Every day
body base grease

No.1 lithium
Hook body 3 Every day
base grease

No.1 lithium
Lifting bail 2×2 Every day
base grease

No.1 lithium
Seal ring seat 1 Every month
base grease
8 Swivel
Upper bearing No.1 lithium
1 Every six months
seat base grease

No.1 lithium
Oil pitch 1 Every six months
base grease

No.1 lithium
9 Lifting cylinder 2×2 Every six months
base grease

No.1 lithium
10 3T hydraulic winch 1 Every day
base grease

No.1 lithium
11 5Thydraulic winch 1 Every day
base grease

7.2. Common faults for truck-mounted drilling rig

The common faults for carrier of truck-mounted drilling rig refer to the abnormities in
the process of normal operation, which needs to pay more attention, to avoid any possible
unnecessary damage due to any negligence.
The common faults and corresponding solution can refer to the following table 11, as
user’s reference. And common faults and corresponding solution of other components can

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

refer to the service manual and user’s manual of other components.

Table 11 Common faults and solutions list

No. Part Faults Reason Check and solution

○
1 Oil pump is not
engaged
Hydraulic ○
1 Check and engage oil pump
○
2 Oil pump damages or
system has ○
2 Replace or maintenance oil
leaks insides terribly.
no pressure pump
○
3 The locked part of ○
3 Maintenance or replace
or pressure
overflow valve is in overflow valve
is too low. ○
4 Add hydraulic oil
normal open condition.
○
4 Liquid level is too low
○
1 Same check and solution as
the above.
Hydraulic ○
1 No pressure
1 ○
2 Same check and solution as
system ○
2 System pressure is too
the above.
low
○
3 Check and change the
○
3 Control valve leaks
Hydraulic control valve.
insides.
actuators do ○
4 Maintain the corresponding
○
4 Actuator is jammed.
not work. actuators.
○
5 Hose is broken
○
5 Replace hose
○
6 Oil level is too low.
○
6 Add hydraulic oil
○
7 There is air in hydraulic
○
7 The hydraulic system
system
exhaust air with idle
circulation.

○
1 Compressor works ○
1 Maintain or change air
The system
improperly. compressor.
Pneumatic has no
2 pressure or ○
2 Pressure regulating ○
2 Maintain or change
system pressure is
valve does not work. pressure regulating valve.
too low
○
3 Pipeline is broken. ○
3 Change pipeline.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

○
4 The system pressure is ○
4 Adjust pressure regulating
too low. valve.
○
1 Pointer of pressure
gauge does not work ○
1 Change pressure gauge.
normally. ○
2 Same check and solution as
○
2 The system has no the above.

Actuators pressure or pressure is ○

3 Maintain or change the
do not work too low. corresponding pneumatic
○
3 Pneumatic control control valve.
valve damages. ○
4 Change pipeline and air
○
4 Pipeline and air bag are bag.
broken.
○
1 The engagement and
Compound
disengagement device ○
1 Maintain the engagement
case has no
does not work. and disengagement device.
power to
○
2 Gear is blocked or ○
2 Maintain or change gear.
Compound output.
3 damaged.
case
Compound
○
1 Clearance between
case has ○
1 Adjust the clearance of gear.
gears is large.
abnormal ○
2 Maintain and change gear.
○
2 Bearings are damaged.
noise.

No power Gear is blocked or

Maintain or change gear.
outputs. damaged.
Angle Angle
4 transmission transmission ○
1 Clearance between
○
1 Adjust the clearance of gear.
case case has gears is large.
○
2 Maintain or change gear.
abnormal ○
2 Bearings are damaged.
noise.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

○
1 Chain is broken.
○
2 The brake is not
○
1 Change the chain.
loosened.
○
2 Loosen the brake and the
○
3 The pressure is not
brake spring goes back in
enough.
position.
○
4 Air bag is broken.
○
3 Regulate the air pressure.
○
5 . Pressed plate is
Roller does ○
4 Change the air bag.
5 Draw works damaged.
not rotate. ○
5 Change the pressed plate.
○
6 Clearance of
○
6 Adjust again according to
intermediate gear disc is
requirements.
too large.
○
7 Clean oil dirt and coat the
○
7 Surface of friction
colophony powder
block has oil dirt.
○
8 Change friction block.
○
8 Friction block is worn
severely.
RT
○
1 Gear is blocked or
transmission ○
1 check or replace gear
case has no damaged.
RT power ○
2 replace clutch
○
2 Clutch is broken.
output
6 transmission
RT
○
1 Clearance of gear is ○
1 Adjust the clearance of
case transmission
case has large. gears.
abnormal
○
2 Bearings are damaged. ○
2 Change bearings.
sound
○
1 Air pressure is not ○
1 Adjust air pressure.
RT
enough. ○
2 . Change air bag.
transmission
○
2 . Air bag is damaged. ○
3 Change press plate.
Transmission case
7 ○
3 Press plate is damaged. ○
4 Adjust the clutch clearance
system transmitting
○
4 . Clutch clearance is again.
torque is not
large. ○
5 Clean oil dirt and coat
enough.
○
5 Fiction block surface colophony powder.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

has oil dirt. ○

6 Change fiction block
○
6 Fiction block is
damaged severely.
○
1 Clearance between ○
1 Adjust clearance between
brake band and brake brake band and brake hub.
hub is large. ○
2 Adjust brake running end.
Brake
○
2 Brake running end is ○
3 Change brake block.
failure
adjusted improperly.
Draw works ○
3 Brake block is
8
brake system damaged severely.
○
1 Clearance between ○
1 Adjust clearance between
Hook brake band and brake brake band and brake hub for
lowers hub is small. 3～5mm；
difficultly. ○
2 The travelling system ○
2 Check and eliminate the
is blocked. blocking phenomenon.
○
1 Ex-proof switch does ○
1 Open ex-proof switch
not open. ○
2 Fasten firmly ex-proof plug.
Lighting
○
2 Ex-proof plug is not ○
3 Change lamps
Lighting system does
9 fastened firmly. ○
4 Change cables or electric
system not work
○
3 Lamps are damaged. wire.
normally.
○
4 Lighting circuit is
disconnected.

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

Chapter 8 Attached drawings

8.1. Lubrication drawing of equipments installed on ZJ30/1800CZ

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 ZJ30/1800CZ Truck-mounted Drilling Rig Maintenance Manual
Shandong Kerui Machinery Manufacture Co., Ltd.

Rotary table

Base pin roll on

Pull line sheave on racking board racking board

Guide line sheave on racking board Guide sheave Centralizer bearing case Buckle cylinder sheave Raising cylinder base

Legend Climbing chain box

Oil gun

Transmission shaft
Oil level

Add grease (by

hand)

Qty of each lubricating point

RT transmission case
Crown block
Drawwork Connection rod of drawwork brake
Qty of lubricating part Angle transmission case

Attached drawing: Lubrication drawing of equipments installed on ZJ30/1800CZ

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