JC50D Drawworks

December , 2008
Table of Contents

General ................................................................................................................................................................ 1
1 Safety warning ............................................................................................................................................... 2
2. Introduction ................................................................................................................................................... 2
2.1 Purpose and application........................................................................................................................... 2
2.2 The DW is designed and manufactured as per following standards and specifications ....... 3
2.3 Brief operational principle ...................................................................................................................... 3
2.4 DW technical parameter .......................................................................................................................... 3
2.5 DW speed and hoisting capacity ........................................................................................................... 4
3. DW structure ................................................................................................................................................. 5
3.1 DW transmission system drawing ........................................................................................................ 5
3.2 Major components..................................................................................................................................... 6
3.3 Power and transmission system ............................................................................................................ 6
3.4 DW frame .................................................................................................................................................... 7
3.5 Drum Shaft Assembly .............................................................................................................................. 7
3.6 Transmission shaft assembly.................................................................................................................. 8
3.7 Intermediate shaft assembly ................................................................................................................... 8
3.8 Rotary Drive shaft Ass ............................................................................................................................. 9
3.9 Rotary Intermediate Shaft Assy ............................................................................................................ 9
3.10 Output Shaft Assy ................................................................................................................................. 10
3.11 Crown-block Saver (CBS).................................................................................................................. 10
3.12 Hydraulic disc brake ............................................................................................................................ 11
3.13 Pneumatic control system ................................................................................................................... 12
4 Lubrication .................................................................................................................................................... 12
4.1 Grease ......................................................................................................................................................... 12
4.2 Lubricating oil .......................................................................................................................................... 13
5 Installation of drawworks ......................................................................................................................... 14
5.1 Inspection before installation ............................................................................................................... 14
5.2 Installation and fixation of drawworks ............................................................................................. 14
5.3 Installation of pneumatic control system and lubrication system pipelines ........................... 14
5.4 Installation of motors and electrical lines ........................................................................................ 14
5.5 Cooling device of Eaton disk brake ................................................................................................... 14
5.6 Guard .......................................................................................................................................................... 14
5.7 Lubricant filling ....................................................................................................................................... 14
6. Operation of drawworks .......................................................................................................................... 15
6.1 Manipulating Control Handle .............................................................................................................. 15
6.2 Trial run of the drawworks ................................................................................................................... 16
6.3 Pressure Setting for Oil and Pneumatic Systems ........................................................................... 19
6.4 Safety operation regulations................................................................................................................. 19
7 Drawworks maintenance .......................................................................................................................... 20
7.2 Items for weekly inspection and maintenance: ............................................................................... 21
7.3 Items for monthly maintenance ........................................................................................................... 21
8 Frequent faults and eliminating .............................................................................................................. 22
9 Maintenance and adjustment ................................................................................................................... 23
9.1 Maintenance and adjustment of pneumatic tube clutch ............................................................... 23
9.2 Maintenance and adjustment of chain drive .................................................................................... 24
10 Disassembly and assembly of shaft assemblies of drawworks ................................................... 27
10.1 Dismantling, disassembly and assembly of drum shaft assembly .......................................... 27
10.2 Disassembly and assembly of transmission shaft assembly ..................................................... 28
10.3 Disassembly and assembly of intermediate shaft assembly ..................................................... 29
10.4 Removing, dismantling and assembling of rotary drive shaft ................................................. 29
10.5 Removing, dismantling and assembling of rotary intermediate shaft ................................... 30
10.6 removing, dismantling and assembling of rotary output shaft ................................................. 30
10.7 Assembly and commissioning of drawworks ............................................................................... 31
11. Dismantling and transportation of drawworks main body .......................................................... 32
11.1 Dismantle drawworks from substructure ....................................................................................... 32
11.2 Transportation of drawworks ............................................................................................................. 33
12 Chains list for JC50D drawworks ........................................................................................................ 33
13 Bearings list for JC50D drawworks.................................................................................................... 33
14 Recommended spare parts list of JC50 drawworks (one year) ................................................... 34
 OPERATION MANUAL OF JC50D DRAWWORKS

General
JC50D drawworks is one of the main components for ZJ50D drilling rig. It is designed and

constructed as per related standards of SY/T5523-2002 “Drawworks for Petroleum Drilling rig” and API

Spec 7K "Specification for Drilling and Well Servicing Equipment", and can satisfy the requirement of

ZJ50D drilling rig.

The manual has described the technical parameters, drive principle, structure, installation, operation,

maintenance and repair, adjustment, disassembly and transportation etc of the drawworks.

The drawworks operators should read this manual carefully before installing, and operation,

maintenance upon the manual. Without understanding related content, wrongly processed installation,

operation or maintenance may lead to personnel injury or equipment damage.

The left and right side of the drawworks is defined as when you face the drum and look from drum to

the main motor.

A matched spare parts list and a recommended spare parts list are attached to the manual for users to

order spare parts. If the spare parts required by users are not included in the list, please refer to drawworks

parts list.

Each drawworks has its own SN, customers need to point out the model and SN, when ordering spare

parts and inquire about the equipment.

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 OPERATION MANUAL OF JC50D DRAWWORKS

JC50D Drawworks

1 Safety warning
z The personnel who are engaged in installation, operation and maintenance of the system should be
trained and qualified, and do the work with qualification certificate.
z Before installation, operation or maintenance, related workers shall read this manual and manuals
of all the other equipments of the drilling rig carefully, and perform upon the manuals.
z There must be a chief principal for installation, operation and maintenance and persons in charge
of each work, and detailed and reliable safety measures should be taken.
z All the equipments should be used strictly in accordance with their operation rules and related
safety regulations.
z When the system is running, it’s forbidden to perform maintenance and repair.
z It’s forbidden to overload the equipment.

2. Introduction

2.1 Purpose and application

JC50D drawworks is one of the essential components of ZJ50D drilling rig, which is principally
applied in works of tripping, running-in casing, WOB control during drilling, eliminating accident, as
well as for hoisting and lowering of mast. It shall mainly consist of the main body and the power system
of drawworks, see figure 1 for its overall dimensions and main structure.

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 OPERATION MANUAL OF JC50D DRAWWORKS

1. Main power system 2. DW main body 3.auxiliary drive device

Figure1 . JC50D Drawworks

2.2 The DW is designed and manufactured as per following standards and

specifications
2.2.1 Design of the drawworks is conformable to the requirement of SY/T5532 of “Drawworks for
Petroleum Drilling rig”.
2.2.2 Design of the main components of the drawworks conforms to the requirement of API Spec 7k
“Specification for Drilling and Well Servicing Equipment”.

2.3 Brief operational principle

This drawworks is a 4-shaft integral chain drawworks consisting of transmission shaft, intermediate
shaft, drum shaft, drawworks frame, power system, hydraulic disc brake, Eaton disk brake and driving
box body, etc.
The DW is driven directly by two 800kw DC motors via coupling. Two gears are formed by two sets
of chains between transmission shaft and intermediate shaft, another two gears are formed by two sets of
chains between intermediate shaft and drum shaft via engagement and disengagement of high/low speed
clutch. The total gears of drawworks have 4 forward gears and 4 reverse gears. Drawworks could realize
the stepless speed regulation due to the use of the DC motor drive. It increases the power efficiency and
drawworks operation.
The change of gears between the transmission shaft and the intermediate shaft is done by toothed
shift fork. The change of gears between the intermediate shaft and the drum is done by the means of
pneumatic tube clutch.
The drawworks adopts the electric pump forced oil spraying lubrication, and the RT driving box
body is lubricated by force by the oil pump.
The drawworks brake system consists of hydraulic disc brake and Eaton disk brake. The hydraulic
disc brake is the main brake with double-disk water cooling mode. The inside and outside gears of the
Eaton disk brake are joined at the high speed end to the drum shaft with keys; the brake disk of the
hydraulic disc brake is connected as a whole with the drum.

2.4 DW technical parameter

Input power 1600kW

Max. pull of fast line 340kN

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 OPERATION MANUAL OF JC50D DRAWWORKS

Diameter of wireline Φ35mm

Gearshift 4 forward and 4 reverse, stepless speed

regulation

Size of grooved drum (diameter× length) Φ685×1245mm

Main brake hydraulic disc brake

Brake disc dimension (outer diameter× thickness) Φ1600×75mm

Auxiliary brake 336WCB2 Eaton Disk Brake

Main motor (power×number) 800kw×2

Overall size (Length×width×height) 6900mm×3285mm×2985mm

Weight 38560kg

2.5 DW speed and hoisting capacity

2.5.1 Lifting condition (dual motors)

DW lifting parameters（dual motors, 12 lines system）

Motor Gear Gear
speed r/min GearⅠ Gear Ⅱ Ⅲ Ⅳ
Hook Hook Hook Hook
Hook speed Hook speed Hook speed Hook speed
r/min load kN m/s load kN m/s load kN m/s load kN m/s
750 3152 0 .3 6 2010.7 0 .5 9 1356.8 0 .8 8 824.9 1 .4 5
787 3152 0 .3 8 1916.2 0 .6 2 1293 0 .9 2 786.1 1 .5 2
850 2918 0 .4 1 1774.2 0 .6 7 1197.2 1 727.9 1 .6 4
900 2756 0 .4 3 1675.6 0 .7 1 1130.7 1 .0 6
940 2639 0 .4 5 1604.3 0 .7 4 1082.6 1 .1
970 2557 0 .4 7 1554.7 0 .7 7 1049.1 1 .1 4
1000 2480 0 .4 8 1508.1 0 .7 9 1017.6 1 .1 7
1050 2362 0 .5 1 1436.3 0 .8 3 969.1 1 .2 3
1100 2255 0 .5 3 1371 0 .8 7 925.1 1 .2 9
1150 2157 0 .5 5 1311.4 0 .9 1 884.9 1 .3 5
1200 2067 0 .5 8 1256.7 0 .9 5 848 1 .4 1

2.5.2 Lifting curve (12 lines, dual motors)

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 OPERATION MANUAL OF JC50D DRAWWORKS

Lifting curve

3500
3000
Hook load kN

2500 GearⅠ
2000 Gear Ⅱ
1500 Gear Ⅲ
1000 Gear Ⅳ
500
0
0 0.5 1 1.5 2
Hook speed m/s

3. DW structure
The DW is driven directly by two 800kw DC motors via coupling. Two gears are formed by two sets
of chains between transmission shaft and intermediate shaft, another two gears are formed by two sets of
chains between intermediate shaft and drum shaft via engagement and disengagement of high/low speed
clutch. The total gears of drawworks have 4 forward gears and 4 reverse gears. Drawworks could realize
the stepless speed regulation due to the use of the DC motor drive. And the brake system of DW consists
of hydraulic disc brake and Eaton disk brake. The hydraulic disc brake is the main brake with
double-disk water cooling mode, and can carry out the service braking, parking brake and emergency
brake. The inside and outside gears of the Eaton disk brake are joined at the high speed end to the drum
shaft with keys; the brake disk of the hydraulic disc brake is connected as a whole with the drum.

3.1 DW transmission system drawing

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 OPERATION MANUAL OF JC50D DRAWWORKS

Figure 2 DW transmission system

3.2 Major components

The DW mainly consists of the following parts: see figure 3

1）Transmission shaft assembly

2）Intermediate shaft assembly

3）DW frame

4）power system: consists of two 800kw DC motors

5) Brake system: consists of hydraulic disc brake and Eaton disk brake.
6) Drum shaft assembly: consists of drum, high drum clutch and low drum clutch.
7) RT driving body: consists of input shaft, intermediate shaft, output shaft and casing.

1.Power system 2. Driving shaft assembly 3.Intermediate shaft assembly 4.Drum shaft
assembly 5.Drawworks frame 6. Brake system 7/8. Rotary drive shaft assembly
9.RT driving intermediate shaft assembly 10.Output shaft assembly
Figure 3 DW structure

3.3 Power and transmission system

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 OPERATION MANUAL OF JC50D DRAWWORKS

The DW is driven directly by two 800kw DC motors via coupling. Two gears are formed by two sets
of chains between transmission shaft and intermediate shaft, another two gears are formed by two sets of
chains between intermediate shaft and drum shaft via engagement and disengagement of high/low speed
clutch. The total gears of drawworks have 4 forward gears and 4 reverse gears.

3.4 DW frame
The JC50D drawworks framework is of wallboard welded structure. All driving chains of this
drawworks are enclosed drive. Auxiliary drive shaft and the transmission shaft assembly are installed and
fixed from one end of the drawworks framework. The drum shaft and middle shaft assembly are
respectively installed and fixed from one end of the gap of the wall.
There’s oil tank in the skid not only for the storage of lubricating oil of the whole drawworks but also
for heat dissipation.

3.5 Drum Shaft Assembly

The drum shaft assembly is the key component of the drawworks, it consists of drum body, hub,
brake hub, bearing seat, shaft, chain wheel and ventilation type pneumatic tube clutch etc. The idle chain
sprocket and bearings of main bearing seat should be greased and oil sealed, see figure 4.
During operation, the drum is wound with the drilling line of the traveling system, through the
positive and negative rotation of this shaft, the drilling line is wound or unwound from the drum, in this
way the drilling tools are hoisted or lowered .
The drum shaft assembly is fixed by bolts and bearing housings on main wall plates. While the
power is inputted from left low-speed chain sprocket, the left low-speed air clutch is engaged and the
drum rotates in low-speed; whereas, while the power is inputted from right high-speed chain sprocket, the
right high-speed air clutch is engaged and the drum rotates in high-speed, and supply power to the RT
driving body as well.
Warning: Upon operation, it is not allowed to charge the drawworks high and low speed air clutches
simultaneously.
The drum is a cast-welded structure and provided with ‘Lebus’ grooving which enables the wire-line
(Φ35mm) to be wound on the drum in order and properly so as to avoid the pressed force and extend the
service life of the wire-line. There is a socket on the right side of the drum, fastline clip can be put into the
socket, for convenient disassembly.
When the traveling block is lowered down to the lowest height required, the circle number of initial
wireline winding on the drum should not be less than 9.
Emergency bolts are provided on low-speed clutch end; when the airlines or clutches are failing, set
the emergency bolts in and connect the clutch to friction hub as a rigid unit to transfer the power.

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 OPERATION MANUAL OF JC50D DRAWWORKS

The Eaton disk brake is provided on the right end of the drum shaft. During going down, the
running speed may be controlled with opposing torque produced by the Eaton disk brake so as to reduce
the main brake weight.

1.Air guide faucet（Low speed end） 2. Emergency bolt 3.Low speed clutch (LT1170/250T)
4. Low speed chain wheel 5. Bearing seat 6.Brake disc 7.Drum 8.Drum shaft 9. High speed chain
wheel 10. High speed clutch (LT1070/200T) 11. Eaton disk brake
Figure 4 Drum shaft assembly

3.6 Transmission shaft assembly

Transmission shaft assembly consists of transmission shaft, chain sprocket, left and right bearing
seats, bearing, coupling etc. Bearing should take forced lubrication and clearance seal. See figure 5.

1.Crown toothed coupling 2.Oil slinger 3.Bearing seat 4.Chain wheel 5.Transmission shaft
6.Crown toothed coupling
Figure 5 Transmission shaft assembly

3.7 Intermediate shaft assembly

Intermediate shaft assembly consists of left and right bearing seats, high/low speed chain wheel,
gear-shifting toothed clutch etc. See figure 6.
This shaft is the intermediate part to connect transmission shaft, auxiliary drive shaft and drum
shaft, which can transmit the power from transmission shaft and auxiliary drive shaft to drum shaft.
Engage high/low speed idle chain wheel via gear-shifting toothed clutch, so that intermediate shaft can
transmit the power from transmission shaft to drum shaft at high or low speed.

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 OPERATION MANUAL OF JC50D DRAWWORKS

1.Chain wheel Z=22 2.Bearing 3.Intermediate shaft 4.Idle chain wheel Z=50 5.Idle chain
wheel Z=38 6.Chain wheel Z=22
Figure 6 Intermediate shaft assembly

3.8 Rotary Drive shaft Assy

The rotary drive shaft assy consists of left and right bearing seat, chain sprocket and the coupling
flange of universal shaft, etc. (See Fig. 7)
This shaft is the intermediate part for connecting the drum shaft and the rotary drive shaft, and may
transmit the power from the drum shaft to the driving device of the rotary table.

1. Bearing Seat, 2. Chain Sprocket, 3. Coupling Flange of Universal Shaft, 4. Driving shaft
Fig. 7 Rotary drive shaft Assy

3.9 Rotary Intermediate Shaft Assy

The rotary intermediate shaft assy consists of left and right bearing seat, chain sprocket,
intermediate shaft and belt pulley, etc. please see Fig. 8.
The shaft is the intermediate part for connecting the rotary drive shaft and the rotary output shaft,
and may transmit the power from the rotary drive shaft to the rotary output shaft.

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 OPERATION MANUAL OF JC50D DRAWWORKS

1. Belt Pulley, 2. Bearing seat, 3. Chain sprocket, 4. Intermediate shaft, 5.Chain

sprocket
Fig. 8 Rotary Intermediate Shaft Assy

3.10 Output Shaft Assy

Output shaft assy consists of left and right bearing seat, idler chain sprocket and pneumatic tube
clutch, etc. please see Fig. 9.
The output shaft is the intermediate part for connecting the rotary intermediate shaft assy and the
rotary table and may transmit the power from the rotary intermediate shaft assy to the rotary table via
the universal shaft.

1. Pneumatic tube clutch 2. Bearing seat 3. Idler chain sprocket 4. Output shaft 5. Pneumatic tube
clutch
Fig. 9 Output Shaft Assy

3.11 Crown-block Saver (CBS)

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 OPERATION MANUAL OF JC50D DRAWWORKS

The role played by the crown block saver is that while the traveling system is going up to a preset
limit position, through its limiting device, it exerts an emergency brake to stop lifting of the traveling
system so as to avoid collision with crown block to ensure safety. The dual-insurance is used in crown
block saver for ZJ50D series drilling rig. One is an electronic saver device realized via the coder on drum
shaft combined with the electric control system for operation. The other is drawworks saver toggle valve
device. And besides we can install a steel wireline saver device on the mast upper section. This device can
limit the rising position of the traveling block. Combined usage of the three devices can ensure the safety
during the drilling.
The toggle valve of JC50D drawworks is installed above the drum and adjustable left and rightwards
axially. Its deflector rod’s length depends on how many wire-lines are wound on the drum while the
traveling block reaches the preset limit height and could be adjusted (generally, 6-7 m from raising
traveling block to the bottom of crown block beam). When the traveling block reaches the preset height
limit, the wire-line on the drum touches the deflector rod of the toggle valve, which discharges the drum
clutch and exerts, by enclosed disc brake calipers, an emergency brake to stop the drum deadly. After the
troubleshooting, turn the disk brake working clamp hand lever to the Max. brake position to lock the load,
then release the emergency brake and reset the deflector rod of the toggle valve.
Warning: Before each duty-shifting, check the sensibility of the toggle valve deflector rod，make sure
it works correctly.
After use of each time and before engagement of drum, push on the anti-collision release valve and
make the disc brake calipers be loosened, and turn the toggle valve deflector rod to vertical position.

Figure 10 Toggle valve anti-bumping device schematic

3.12 Hydraulic disc brake

3.12.1 Main technical specification

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 OPERATION MANUAL OF JC50D DRAWWORKS

Brake disc diameter: Φ1600 mm

Number of working clips 4
Number of safety clips 2
Brake disc thickness 76 mm
Rated working pressure of the system 8Mpa
Rated single-side total working positive pressure 480KN
Rated single-side working brake torque 120KN.m
Rated emergency brake torque 240KN.m

3.12.2 Main structure

The hydraulic disc brake mainly consists of clip holders, brake clips and hydraulic source system.
Please see “Operation Manual or Operation Instructions of Hydraulic Disc Brake” for the detailed
structure of it.

3.13 Pneumatic control system

The pneumatic control system for the drawworks shall mainly consist of the control for the
following: the control of the anti-bumping toggle valve, the control of gear shifting and the control of
engagement and disengagement of pneumatic tube clutch for the drum shaft and the RT driving output
shaft.

4 Lubrication

4.1 Grease lubrication

Gear coupling and supporting bearing of drum shaft adopt grease lubrication. Before leaving
factory, each lubrication point of the drawworks is lubricated. When drawworks works on the well site
or during maintenance period, lubricate each point of crown gear coupling and supporting bearing of
drum shaft every100 hours per time, and the filling quantity is about 0.7~1.0kg.
Check the VF motor user manual for detailed information on lubrication of VF motor.
Check the hydraulic disc brake device user manual for lubrication of hydraulic disc brake.
All lubrication points of drawworks are set on necessary points, and each grease cup should be
filled with lithium base grease.
Ambient temperature above﹣20℃, NLGI 2 extreme pressure lithium base grease
Ambient temperature above﹣25℃, NLGI 1 extreme pressure lithium base grease
When filling grease, for oil cups which connect to grease pocket directly, grease gun or grease
station is adopted. Check figure 10 for grease lubrication points.

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 OPERATION MANUAL OF JC50D DRAWWORKS

4.2 Lubricating oil

Electric gear oil pump is set on the drawworks skid. The oil tank is placed in the skid of the
drawworks，and every oil nipple is at the relative positions of the chains, gears and bearings. This pump
can transfer lubricating oil from oil sump under the skid to each lubricating point.
The normal oil pressure of the oil passage is 0.08～0.3MPa.with the electric contact pressure
gauge, and with the control of the driller ’s control console, when the oil pressure is very lower, an
automatic alarm will be triggered. Every shift needs to check the pressure gauge once.
The suction filter is set at the oil pump inlet，and the discharge filter at the outlet. The filter in the oil
passage should be cleaned often to guarantee smooth oil sucking process.
Notice: it’s not allowed to run the drawworks when the oil pipe pressure is abnormal.

The oil in oil sump： ISO VG220 industrial gear oil or Mobil SHC630 used in summer;，ISO

VG220 synthesis gear oil or Mobil SHC630 used in winter，the oil level must be at the level between

those two marks (upper mark and lower mark) of the oil dipstick.
Caution: When the drawworks is running, it’s forbidden to lubricate. Do it only when the
drawworks stops.

Fill once per shift Fill once per week

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 OPERATION MANUAL OF JC50D DRAWWORKS

Figure11 Grease lubricating points

5 Installation of drawworks

5.1 Inspection before installation

5.1.1 Check fastening condition of installation bolts for main motor, auxiliary motor, reducer,
Eaton disk brake and disc brake device etc. Fasten them again as per the required torque when
necessary.
5.1.2 The required torque for installation bolts are as follows: (bolt strength is grade 8.8)

Bolt nominal diameter/mm 16 20 24 27 30 36

Pretension torque/N.m 189-252 369-492 638－850 933－1244 1267-1689 2214-2952

5.1.3 Check the condition of oil and air pipelines and oil nipples. Repair or replace, if any
damage is found.

5.2 Installation and fixation of drawworks

Install and locate the drawworks onto skid as per the positioning blocks, and fasten the fixing bolts
between them. The pretension torque should follow the requirement of item 5.1.2.

5.3 Installation of pneumatic control system and lubrication system pipelines

Connect the pipelines of pneumatic control system and lubrication system correctly as per marks.

5.4 Installation of motors and electrical lines

Connect the lines of motors and electrical system correctly as per marks.

5.5 Cooling device of Eaton disk brake

For water cooling type Eaton disk brake adopted by this draw, the cooling water inlet and outlet
pipelines shall be connected properly (for the forced air cooling type of Eaton disk brake, there is no
such requirement).

5.6 Guard
Deformation is easily caused by collision and impact during transportation and hoisting, so protect
them carefully. Perform repairing before installation if necessary.

5.7 Lubricant filling

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 OPERATION MANUAL OF JC50D DRAWWORKS

When the equipment leaves factory, lubricating oil in drawworks is drained, so after installation fill
each lubrication point with lubricating oil of proper quantity as per “4 lubrication” of this manual.
For grease points (except 800kw main motor), perform inspection for quality and quantity of
grease, feed some if the grease is not enough and replace it if the grease is polluted.

6. Operation of drawworks
Safety warnings!

To prevent personal injury, the power supply should be cut off while conducting
maintenance etc. and locking apparatus for preventing misoperation and apparent
warning signs should be available as well.

Safety warnings!

While mechanical and electric equipments are running, all safety apparatus
should be kept in good condition, including: crown block savor, safety valve of
pneumatic , hydraulic and oil system, alarm of power machine, cut-off device for
safety and brake system etc in the air, liquid and oil systems, all these safety
apparatus should be inspected in every shift to assure that they can work normally.

6.1 Manipulating Control Handle

All manipulating handles, buttons and switches of the drilling rig are located in the driller control
room. The main manipulating handles of drawworks and other controlling components are located on a
manipulation board on the front left of the main control console. There’re descriptions of the functions of
all manipulation components, and the effects of each turning destination are indicated as well（see manual
of driller control room for details）.
1) Gear change switch
This switch has three gears: gear I, neutral position, gear II. When the switch is put at the neutral
position, the drawworks transmission shaft will be disconnected with the intermediate shaft, and the
intermediate shaft is at the halted state. Gear I and II combined with the high/lower speed clutch to
respectively create four different rotary speeds for the needs of drilling. Choose gears as per well
drilling technology and hook load, and according to item 3.1 lifting parameter list and item 3.2 lifting
curve. Overloading is not allowable.

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 OPERATION MANUAL OF JC50D DRAWWORKS

Notice：Changing gears is strictly forbidden when the drawworks has load! Stop
running on changing gears.
2) gear lock switch
Put the operation lock gear/ unlock gear knob (or handle) to the unlock position, the pressure of the
lock gear gauge is 0, it is ok to change gear. Put the operation lock gear/ unlock gear knob (or handle) to
the lock position，observe the lock gear pressure gauge on the operation panel, when the pressure is the
same as the air source pressure, it means gear changing is completed；if the lock gear pressure is 0, it
means gear changing failed, then just release main brake a bit, lower down the empty traveling hook a
little, actuate intermediate shaft or start motors to have a lower speed running(the speed of the main
motor should be no more than 10r/min), after mobilizing the intermediate shaft or transmission shaft,
then change gears again.
3) With electric drive system, have an inter-lock check at starting bit-feed clutch and
auto-bit-feeding program.

6.2 Trial run of the drawworks

The trial run shall be applied to those brand new drawworks installed for the first time or the
drawworks to be used for the first time after being overhauled before being put into practical operation.
6.2.1 Inspection before Test-run
The drawworks that has been installed and connected should be inspected again:
1) Connection bolts of various parts should be all ready and be fastened.
2) After being connected, the labels on both ends of oil and air pipelines should be exactly same.

Misconnection may lead to function failure or accident.

3) To inspect if there’s any foreign materials in various places (especially in cavity), especially pay
attention to inspect whether there’s any tool left at certain place in the drawworks.
4) To inspect the lubricating oil level and refill anytime when it’s necessary.
6.2.2 Hydraulic disc brake running-in
Running in for brake disc and friction pad of new drawworks hydraulic disc brake have been
performed and tested qualified, but after overhaul, the running-in and fitting running for brake disc and
friction pad must be performed again and tested qualified then the hydraulic disc brake can be put into use.
6.2.2.1 Initial running-in
1) Adjusting the clearance of normally opened calipers
Adjust the clearance between friction pad and brake disc. Test it with feeler gauge, it should be
0.5mm (one side); then tighten the locknut properly.

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 OPERATION MANUAL OF JC50D DRAWWORKS

2) Adjusting the clearance of normally closed caliper

Adjust the clearance between the friction pad and brake disc, test the clearance with feeler gauge, it
should be 0.5mm (one side).
3) Run in initially
If there is a little nonuniform in the clearance between friction pad and brake disc, it can only be
run in with very little braking force in a short time. The running in pressure and time should be
controlled according to actual condition. The recommended pressure is 0.5MPa ~ 0.8MPa in 1~ 2
minutes. Observe frequently the running in heating and wearing conditions during running in period.
Over running in or burnt phenomenon is not allowed. Keep the temperatures of the brake disc and brake
pad within 200℃.
6.2.2.2 Fitting running (running in completely) between brake pad and brake disc
If it is normal in running in test, carry out fitting run by increasing braking pressure respectively to
1.0MPa, 1.2MPa, 1.5MPa, 1.8MPa and 2.0MPa in sequence, each one takes about 3 minutes, time
interval is 3 to 5 minutes. The time can be regulated according to actual fit run and heating condition.
Control the drum rotation speed in the range of 50 to 80 rpm.
After fitting run operation, check the fit area between the brake pad and brake disc, it should be
above 75%; test the clearance between the brake pad and brake disc, it should be 0.5mm (one side). If it
can not meet the above requirements, increase the braking pressure properly to 2.5 MPa and repeat the
procedure until the requirements are met.
Precaution for operation: when carrying out fitting run operation and pressurize the brake,
operate the handle with care; don’t be too rough and violent in order to avoid over-wearing and getting
burnt of brake disc and brake pad.
After everything goes well, switch the gear change switch to neutral position and lock, then operate
as following steps.
6.2.3 Check under no load
Following checks shall be made under the terms of no power input:
1) Open the air source valve to introduce the compressed air into the system and check for pressure
of each working point.
2) Check for the working order of each control valve and the relative actuating device (please refer
to the Operation Manual of pneumatic control system):
a) Operate the gear shifting switch, make sure each gear operate properly and be agile and reliable.
b) Put the high and low clutch lever to any speed position (high speed or low speed position) and
hold for 3 to 5 seconds before release, the related clutch controlled shall be charged with air; then put
the lever to the opposing position (also hod for 3 to 5 seconds), the previous charged clutch shall be

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 OPERATION MANUAL OF JC50D DRAWWORKS

discharge. Repeat the aforesaid process to charge the other clutch with air after a certain time interval,
the transfer between the two clutches will have an effect of the " time lag ".
c) Operate the brake handle to check for operation state of the working clips and safety clips in
accordance with the Operation Manual of disc Type Brake, and the running-in of the friction plates and
the brake disc shall conform to the requirements.
d) Manually handle with toggle valve of the crown-block saver (just right upper the main drum of
drawworks), at the time all the brake clips of the disc type brake shall participate in and hold tightly the
brake disc, and the main motor shall stop running.
e) Straighten the anti-bumping toggle valve and press the anti-bumping release button to make the
system be back to normal.
After the completion of all the above checks, if every actuating component controled by air valve
fulfils the action as per the requirement, it shows that the air circuit is connected properly and the valve
and its actuating component work normally.
6.2.4 Test run without load
1) Before conducting this task, inspection should be undertaken as per manuals of 800kw main
motor and electrical control system, after it’s confirmed that all things are in proper situation then the
power supply may be turned on for operation of the drawworks.
Note: during the running of drawworks, lubricating oil flows into various lubricating points
and it won’t return immediately, therefore the oil level will go down. If the oil level is lower than the
lowest limit of the oil pointer, you need to refill proper amount of lubricating oil, please note not to
let the oil level to go down too low.
2) Start the diesel engine, turn the drum high/speed clutch handle to the low speed position
(whatsoever position the handle is turned to previously, you need to turn the handle to the lower speed
position once more, this process should not be omitted).
3) Stop the machine, turn the gear shifting handle to gear I(of course you need to turn the gear lock
switch to the unlock position to release the gear lock mechanism first, after shifting you need to turn it to
locking position again to lock the gear lock mechanism).
4) After the drawworks ran for 10 to 20 minutes at the lowest speed of gear I, conduct the following
inspections:
a) If there’re phenomena like rubbing, colliding, interference etc. during the running of drawworks.
b) The pressure of lubricating oil should be stable, the lubricating effect should be fine.
c) Conduct engagement of high-speed clutch & low-speed clutch of drum respectively to inspect
conditions of running and braking.
5) Shift to gear II and reverse gear respectively, repeat the processes mentioned above.
6) Brake test: test braking as per disc brake device manual.

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 OPERATION MANUAL OF JC50D DRAWWORKS

7) The requirement of adjustment of drawworks:

a) All manipulation should be accurate, reliable and flexible.
b) Each part should be sealed well, there should not be effusion and leaking of oil.
c) Lubricating oil pressure should be stable, there should be appropriate amount of lubricating oil at
lubricating points.
d) Machine should run smoothly, and there should not be abnormal vibration and noise.
e) Temperature rise of bearings of various parts should be normal.
8) If the results of all the experiments mentioned above turned out to be normal, tasks like
installation of fast line clip and winding fast line etc can be conducted for hoisting the mast and
substructure.
6.2.5 Setting of crown block saver
1）Adjust the toggle valve located above the drawworks to the correct position before tightening the
clamp.
2) Set the correct position of the toggle valve to ensure it can disconnect the power supply and stop
moving when the traveling block top reaches the position 6m beneath the water table bottom.
3) Set the electronic impact-prevention device to ensure it to alarm and turn off power and start the
disc brake when the traveling block top reaches the position less than 6m beneath the bottom of the
water table.

6.3 Pressure Setting for Oil and Pneumatic Systems

Pressures of lubrication oil and compressed air should be checked before putting into operation,
adjust them to the normal range if necessary; please see the following data list
Air pressure
Pressure MPa
Parts
M ax . Norm. Min.
General pipe line of control
1 .0 0 .8 0.80
panel
Low speed clutch 1 .0 0 .8 0 .7
High speed clutch 1 .0 0 .8 0 .7

Lubrication system
Pressure MPa
Parts
M ax . Norm. Min.
Every lubrication oil
0 .3 0.15 0.08
working point

6.4 Drawworks operation regulations

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 OPERATION MANUAL OF JC50D DRAWWORKS

6.4.1 Operation requirements

Drawworks operators and maintenance personnel should pass on-the-job training and be examined
qualified, work with their certificates.
Drawworks safety operation regulations must be made by drilling crew, which should be followed
by drawworks operators.
Running speed and max hoisting capacity of drawworks should not exceed regulated values in “2.5
Drawworks speed and hoisting capacity”.
1) The JC50D drawworks has 4 gears forward+4 gears in reverse, that consist of mechanical gear
shifting and pneumatic tube clutch gear shifting. The reverse gears are produced by main motor
reversing. During hoisting of drilling tools or in the process of drilling, mechanical gear shifting should be
conducted firstly, then effect the drum high/low speed clutches to get the gear needed, the motor should be
stopped while conducting mechanical gear shifting.
2) When braking is needed during the process of hoisting of tools, the low-speed or high-speed
clutch must be released firstly, then braking should be conducted promptly.
3) During tripping in the hole especially at high speed and heavy load situations, controlling the
tripping speed of the drilling tools in half-brake situation for a long time is strictly forbidden to prevent
premature damage of the braking blocks and the braking discs.
4) If the length of drilling tool trip in exceeds 700m, auxiliary brake must be used.
5) Oily and hard objects must be prevented from entering the space between the brake disc and the
brake block, for preventing it from causing slippage or damaging the brake disc.
a. Pay attention to keep the system pressure of compressed air at 0.8-1.0 Mpa; if it is too high, shock
may be caused; if it is too low, sliding may be caused.
b. Every shift must carefully inspect the oil passage and the chains once to assure all transmission
chains and lubricating pipelines are working under the smooth and fine condition. The lubricating oil
pressure should be within the range of 0.08～0.15Mpa, otherwise the reasons must be figured out and the
failure should be solved in time.
c.During the operation of the drawworks, the guards and covers should be installed properly.
Filling lube oil or grease during operation is strictly prohibited to avoid personal injury.
6.4.2 Following operations are strongly forbidden
Drawworks runs overload, overspeed, or runs over temperature.
Maintain the drawworks without cutting off the power or control supply.
Adjust the hydraulic disc brake when the drilling wire line has load.
Water the surface of brake disc or clutch friction hub.

7 Drawworks maintenance

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 OPERATION MANUAL OF JC50D DRAWWORKS

Daily inspection, repair and maintenance are the important contents of maintenance. Keep safe
when you do inspection, stop running when you do repair. The following recommendations are just the
inspection items in normal conditions.
7.1 Items of inspection and maintenance for each shift
(1) Connecting pins and bolts between the drawworks and substructure should be complete and
tightened
(2) The fast line clamp seat should be tightened
(3) The fixing bolts for braking mechanism should be complete and tight.
(4) The connecting pins lock devices and split pins should be complete.
(5) The lube oil level of the gear speed reducer should be within the normal scope, lubrication oil
pump pressure conforms to requirements and all places are lubricated properly.
(6) Lubrication and temperature rising of all bearings shall be normal. Temperature rising should
not be higher than 45℃, the bearing housing temperature measured really should not be higher than 90
℃.
(7) The connection and operation of electric, pneumatic and hydraulic elements and pipeline from
the driller cabin to drawworks should be reliable.
(8) All transmission pairs should be without any abnormal noise or vibration.
(9) Check all sealing positions; there should be no seepage and leakage.
(10) Check all guards, they should be tight and reliable.
(11) The reliability test of crown block saver:(it is required to test before each shift starts).
(12) Check the clearance between brake pad and brake disc, adjust it if necessary.

7.2 Items for weekly inspection and maintenance:

The items of inspection and maintenance of shift are included and the follows:

（1）Check the oil supply condition of the lubrication oil pump, if the lubrication oil is clean and if

it is necessary to replace the element of filter.

（2）Check the wearing conditions of the braking pad of the disc brake. When the thickness of the

brake pad reduces to minimum thickness regulated by disc brake manual or some other reason makes it
ineffective, it is necessary to replace the whole set of the brake pad. The newly replaced brake pad
should be fitting run (running in completely) and make its contacting area above 70%, then it can be
used.

7.3 Items for monthly maintenance

The items for weekly inspection and maintenance are included and the follows:

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 OPERATION MANUAL OF JC50D DRAWWORKS

（1）Check for the engagement of chain sprockets for the main driving box and the transmission

box of rotary table..

（2）Test the quality of the lubricating oil.

（3）Check for the abrasion and cracking of brake disc and the friction hub of pneumatic tube

clutch of the RT driving boxes.

（4）Check the mesh condition of the crown gear coupling.

（5）Check the working condition and wearing condition of the bearing at each position.

8 Frequent faults and eliminating

Trouble Reasons Eliminating method

Adjust the system pressure (refer to
A. Low pressure in lubrication system the “Operation and maintenance
manual of gear speed reducer”)
Find out the piping related to the
B. Lubrication pipeline blocked temperature rising, and eliminate the
blockage, clean oil filter.
High C. Deteriorated and contaminated Clean and replace the bad grease or
temperature lubrication grease or oil oil.
rising Add or reduce lubrication oil to the
D. Too low or high of lube oil level.
stipulated level.
E. Too much or too less lubrication
Reduce or add lubrication grease
grease.
F. The technical specification of
Replace the grease or oil with
lubrication grease or oil, such as
required one.
viscosity can not meet the requirement
A. Damaged bearing Replace the damaged bearing.
B. Loose connecting or lock accessories Tighten it.
Change the operation rotation speed;
C. System resonance
keep away from the resonance zone.

Abnormal
noise and D. Foreign matter or fallen off part in Clear out the foreign matter or
vibration machine reinstall and retighten the fallen part.

Oil steam pressure is too high in the

chamber-- breathing valve is blocked,
clean the valve;
Oil leakage A. . Leaking oil from journal
Oil seal damaged—replace it
Lubrication oil is too dilute, select
the proper oil according to season.

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 OPERATION MANUAL OF JC50D DRAWWORKS

Cover plate deformed-- rectify it to

flat.
B. leaking oil from cover plate
Poor seal--replace the sealing gasket
or besmear it with sealing glue.
A. faults of brake, pneumatic control, Refer to the related operation
Others
electric and hydraulic system manuals.

9 Maintenance and adjustment

9.1 Maintenance and adjustment of pneumatic tube clutch

The balance test and accuracy adjustment of alignment have been conducted for the clutch assembly
when the product was delivered.
After the machine has been used for a period of time, the components of friction pair have been
ceaselessly abraded, this leads to reduction of the capability of transferring torque, the friction plate must
be replaced when its thickness is reduced to 2/3 of original thickness, the friction hub must be replaced
when its wear extent in diameter (measured according to the difference between the present diameter and
the original diameter) exceeds 4~6mm.
If any component of clutch pair has been dismantled, the alignment must be adjusted as per the
following method after assembly (see figure 12)

B C
Figure 12 Correction of positional accuracy of clutch

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 OPERATION MANUAL OF JC50D DRAWWORKS

According to figure 9A, one dial gauge should be installed, then rotate right part of the pair, read the
meter once after the interval of every 90°, the radial offset should not exceed 0. 5mm.
According to figure 9B, rotate left part of the pair, read the meter once after the interval of every 90°,
the axial offset should not exceed 0.2mm.
According to figure 9C, measure the vertical degree between friction hub outer round surface and
connection disc end surface. Error in full range of circle should ≦0.1mm.
Note: Materials like grease, liquid etc must not be allowed to enter the friction surface of clutch,
liquid such as grease etc shall reduce the coefficient of friction and the transferring torque, it must be
cleaned with solvent and then dry off.

9.2 Maintenance and adjustment of chain drive

The center distance of chain wheels of the chain drive system of this drawworks can not be adjusted
and there’s no tension pullling structure. All driving parameters have been adjusted well before delivery
of the machine and positioning device is also equipped to assure there won’t be any variation of driving
accuracy after many times’ repeated dismantling and installation. If there’re phenomena such as increased
noise and vibrations during usage, there might have been serious abrasion of chain and chain wheels or
positions of chain wheels have been changed, the inspection should be conducted then.
Open the cover board of shaft end or box cover of drawworks frame to inspect the lube condition of
chain or chain wheels, then check if there is overwearing of chain sleeve, if chain plate is distorted or
eroded, if it is blocked or if pins are turning in chain holes, if there are problems turned out, replace the
whole piece of chain. If chain wheel position is changed, align it; if the working surface of chain wheel
is overworn, replace chain wheel.
9.2.1 Check of chain abrasion
To conduct the following procedures if the chain is in good condition: to measure the part of chain
indicated in figure 13 and the table, taking the table blow as the reference, if the elongation at abrasion
exceeds 3% or the regulated limit, the whole chain should be replaced.
Measured Length

Figure 13 Measurement of abrasion elongation of chain

Table I Measurement of abrasion elongation of chain (set chain pitch as 38.1, 50.8 for example)

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 OPERATION MANUAL OF JC50D DRAWWORKS

Measured Length
Chain Pitch Nominal Value of Length of Chain when
Number Length of Chain Abrasion Rate is 3%
of Links
mm (in) mm (in) mm (in)
38.10 1.500 16 609.6 24.00 627.86 34.719
50.80 2.000 12 609.6 24.00 627.86 24.719
The chain is allowed to be used if the abrasion elongation does not exceed the limit. Due to the
increase of the length of chain, the sagging rate is too high, 2 chain links must be removed then the chain
shall be linked again. The possible condition is: the chain cannot be linked after removing 2 links, or the
chain is too tight after being linked (without sagging rate or sagging rate is low), one transition link is
needed under this kind of circumstance; however what we need to explain in particular is that you should
do all you can to avoid the usage of transition link. The reason is that the bearing capacity of the transition
link is much lower than that of other links of the chain. If it’s really needed, the transition link with
interference fit pin should be the choice.
9.2.2 Inspection of degree of tightness of chain
To brake one chain wheel shaft and rotate the other chain wheel shaft manually to tighten the chain,
as shown in figure 14, then measure the sagging rate, please see table II for its data. (Values of tangent
length between 2 chain wheels listed in the table are not the parameters of this drawworks)
Table II Recommended value AC of displacement of midpoint of chain
Midpoint of Driving Horizontal ~ 45° Vertical ~ 45°
Device mm in mm In

250(10) 10~15 0.4~0.5 5~8 0.2~0.3

Tangent 510(20) 20~30 0.8~1.2 10~15 0.4~0.6

Length
Between 760(30) 30~45 1.2~1.8 15~23 0.5~0.9
2 Chain
Wheels 1270(50) 51~76 2.0~3.0 25~38 1.0~1.5
mm (in)
1780(70) 71~107 2.8~4.2 36~53 1.4~2.1

2540(100) 102~152 4.0~6.0 51~76 2.0~3.0

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 OPERATION MANUAL OF JC50D DRAWWORKS

Figure 14 Displacement of midpoint

9.2.3 Inspection of abrasion of chain wheel
Inspect the joint condition of driving fittings and the surface roughness of sprocket gear with the
eyes, check if the thickness of sprocket gear has been reduced (the maximum reduction rate of thickness is
5%) and if there’re depressed pit in the meshing areas of sprocket, if abrasion of sprocket can be clearly
seen even without sample (see figure 15), the chain wheel should be replaced.

Figure 15 Abraded Chain Wheel

New chain should not be used on the abraded chain wheel; otherwise the chain shall be abraded
quickly.
9.2.4 Repair of chain wheel
During the process of repairing, if there’s any chain driving shaft which has been once dismantled
(replacement of any component of this assembly, such as bearing, chain wheel, gear wheel etc.), the
accuracy of parallel degree and coplanarity of chain wheels must be re-checked after installation.
Please see figure 16 for inspection:
The coplanarity of one chain wheel can be measured by putting a long flat ruler (or tightened thin
steel wire) against the side of the other chain wheel; its permissible error is 0.045P, correction and
improvement must be conducted if the result exceeds the permissible error, the chain wheel between the
transmission shaft and the intermediate shaft can be adjusted by using the adjusting nuts on both ends of

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 OPERATION MANUAL OF JC50D DRAWWORKS

the chain wheel on the transmission shaft; as for the section between the intermediate shaft and the drum
shaft, number of spacers can be added or reduced at the appropriate section of the intermediate shaft
assembly (or change the size of distance sleeve) to move the shaft horizontally to improve the coplanarity.

Figure 16 Correction of Positional Accuracy of Chain Drive

10 Disassembly and assembly of shaft assemblies of drawworks

When the maintenance of larger scale has to be conducted for the drilling rig for it has been used for
a long time, or because there has been serious abrasion of internal components or occurrence of failure,
the maintenance should be conducted in professional machine maintenance stations or mechanical plants.
The chapter contains important instructions about how to dismantle the assembly from drawworks, how
to disassemble the assembly to replace components and then assemble again.
The machine should just be dismantled to the extent that the maintenance can be conducted, the
dismantling process can be stopped once the components which are to be maintained or replaced (e.g.
bearing, seal etc.) be taken off, it's not necessary to thoroughly dismantle the machine as mentioned in this
article.

10.1 Dismantling, disassembly and assembly of drum shaft assembly

10.1.1 Dismantling of drum shaft assembly
See drawworks drum shaft assembly in figure 4 while manipulating
1）All components related to the drum assembly should be dismantled first:
a)Air pipeline
b)Auxiliary braking system
c)Relevant shield, cover board, insert
d)Driving chain
e)Relevant fittings of disk brake system
2）After dismantling all connecting bolts on left and right bearing seats of drum shaft assembly
and inserts, screw the connecting bolt into the threaded hole of bearing seat to jack up the bearing seat

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 OPERATION MANUAL OF JC50D DRAWWORKS

away from the drawworks framework, and it's being hoisted slowly by the crane.Once the bearing seat is
completely detached from the drawworks framework, the drum shaft assembly shall be moved out from
the opening.
After being dismantled from the drawworks the drum shaft assembly shall be put on a timber floor,
and spacer should be added at proper place (it's strictly prohibited to support the drum shaft assembly
with air tube clutch).
Inspect the damaged component to determine the extent of dismantling, those parts irrelevant to this
component should be carefully protected to avoid damage and prevent foreign materials from entering.
10.1.2 Dismantling of pneumatic tube clutch
1) Dismantle pipeline and relevant fittings (pneumatic hoist etc.)
2) Dismantle connecting bolt
3) Take off the external components
4) Directly take off the friction hub
10.1.3 Dismantling of chain wheel
Chain wheel is connected to shaft by two groups of bearings, all connections between bearings and
relevant fittings are of transition fit which can be easily dismantled by using 2-jaw (or 3-jaw) screw puller
(its popular name is puller), or it can be dismantled by even knocking of wooden hammer or copper bar.
10.1.4 Dismantling of left and right bearing seats
1) Dismantle the screws on the cap of bearing seats, then by knocking with copper hammer the
bearing seats can be dismantled.
2) If the bearing or oil seal is to be replaced, the bearing should be dismantled from the shaft. The
connection between bearing and journal is of transition fit. It's recommended to use puller to dismantle it.
Bearing must be replaced if it has been damaged, and it can be dismantled by any means provided the
journal is not to be damaged; if heating is to be adopted, the speed of heating should be swift and even,
temperature at the location of installation should be checked by using temperature meter anytime, it
should not exceed 120°C, it's strictly prohibited to dismantle bearing by using gas cutting.
Caution: The connection between drum and drum shaft is tight interference fitting connection,
so it can not be dismantled.
10.1.5 Re-assembly
All components should be cleaned before assembly, fitting surface should be applied with lubricating
oil, and procedures are same as above but reversed

10.2 Disassembly and assembly of transmission shaft assembly

See drive shaft assembly in figure 5 while manipulating.
10.2.1 disassembling transmission shaft assembly from casing

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 OPERATION MANUAL OF JC50D DRAWWORKS

1) Disconnect chain.
2) Dismantle coupling connected to motor (connecting bolts between inner teeth sleeves),
dismantle bolts connected to casing.
3) The transmission shaft assembly can be pushed out toward right with wireline
10.2.2 Disassembling, dismantling
1) Dismantle outer teeth sleeve, bearings, chain wheel etc.
2) Dismantle drawworks input chain wheel, right bearing cover and bearing, dismantle chain wheel.
The chain wheels and bearings are installed by the means of interference fit, they are to be dismantled by
using special puller.If heating is to be adopted, the speed of heating should be swift and even, and
temperature of shaft should be checked by using temperature meter anytime. It should not exceed 120°C.
10.2.3 Assembly
All components should be cleaned, make sure the smoothness of oil channel, and fitting surfaces
should be applied with lubricating oil, and procedure is as same as above but reverse.

10.3 Disassembly and assembly of intermediate shaft assembly

See intermediate shaft assembly in figure 6 while manipulating.
10.3.1 Dismantling of shaft assembly
1) Dismantle all installation bolts and inserts on the bearing seat, then the whole intermediate shaft
assembly can be lifted out from drawworks top.
2) In order not to affect dismantling, assembling and internal part cleaning, remove dismantled
chain from the chamber of drawworks.
3) Dismantle internal gear shift mechanism and relevant components.
10.3.2 Disassembly, assembly
Implement part of or all of procedures below as required.
1) Dismantle pressing plates at shaft end then chain wheel can be taken off from journal, special
puller is needed for it's interference fit.
2) Knocking by using puller or wooden hammer (copper bar), then take off the bearing seat and
spacer sleeve, dismantle cap of bearing seat to facilitate cleaning or replacing bearing.
3) 2 idler chain wheels and internal and external gears of gear shift can be dismantled respectively
(Puller is needed or dismantling by even knocking).
4) Clean all components and replace all components as required.
5) Assembly procedures are same as above but reversed.

10.4 Removing, dismantling and assembling of rotary drive shaft

See Fig. 7 “the rotary drive shaft assy” for detailed processing

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 OPERATION MANUAL OF JC50D DRAWWORKS

10.4.1 Removing of the assy

1) Remove the mounting bolts and insert of bearing seat and the plugboard, lift out the overall
intermediate shaft assy directly from the top of the casing body.
2) In order not to affect the removing and assembling and the internal cleaning, the disconnected
chain shall be taken out from the casing cavity.
10.4.2 Dismantling and assembling
Carry out any part or all of the following procedures as required.
1) Dismantle the press plate at the shaft end, and then the chain sprocket can be removed from the
journal. Special puller shall be necessary due to the interference fit.
2) Knock with wooden hammer (or copper bar) or pull with puller to remove bearing seat and
bearing spacer, remove the bearing seat cover for easy cleaning or bearing replacement.
3) Clean all components and replace any component needed to be replaced.
4) Assembling: assembly shall be done as the reverse sequence to that of dismantling.

10.5 Removing, dismantling and assembling of rotary intermediate shaft

See Fig. 8 “rotary intermediate shaft assembly” for detailed processing.
10.5.1 Removing of the assembly
1) Dismantle all installation bolts and inserts on the bearing seat, then the whole intermediate shaft
assembly can be lifted out from drawworks top.
2) In order not to affect dismantling, assembling and internal part cleaning, remove dismantled
chain from the chamber of drawworks.
3) Dismantle internal gear shift mechanism and relevant components.
10.5.2 Dismantling and assembling
Implement part of or all of procedures below as required.
1) Dismantle pressing plates at shaft end then chain wheel can be taken off from journal, special
puller is needed for it's interference fit.
2) Knocking by using puller or wooden hammer (copper bar), then take off the bearing seat and
spacer sleeve, dismantle cap of bearing seat to facilitate cleaning or replacing bearing.
3) Clean all components and replace all components as required.
4) Assembly procedures are same as above but reversed.

10.6 removing, dismantling and assembling of rotary output shaft

See Fig.9 “the rotary output shaft assy” for the detailed processing.
10.6.1 Removing of the assy

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 OPERATION MANUAL OF JC50D DRAWWORKS

1) Removing the mounting bolts of the bearing seat and the plugboard, lift out the overall output
shaft assy directly from the top of the casing.
2) In order not to affect the removing and assembling and the internal cleaning, the disconnected
chain shall be taken out from the casing cavity.
10.6.2 Dismantling and assembling
Carry out any part or all of the following procedures as required
1) Dismantle the press plate at the shaft end, and then the chain sprocket can be removed from the
journal. Special puller shall be necessary due to the interference fit.
2) Knock with wooden hammer (or copper bar) or pull with puller to remove bearing seat and
bearing spacer, remove the bearing seat cover for easy cleaning or bearing replacement.
3) Clean all components and replace any component needed to be replaced.
4) Assembling: assembly shall be done as the reverse sequence to that of dismantling.

10.7 Assembly and commissioning of drawworks

1) After assembly of the drum shaft and passing of the inspection, it shall be lifted to the drawworks
frame integrally. Put down into the corresponding installation holes of the drawworks frame in good
alignment with the notch. Push the drum shaft assembly to the right and fix it with corresponding bolts
after putting the bearing seat position-finding-notch into the shaft hole of the box. The drawworks frame
inserts shall be installed and properly tightened in the notch. The frame inserts cannot be interchanged;
they must be installed in their original positions.
2) Transmission shaft assembly should be wholly hoisted and pushed in through the large hole end of
relevant shaft hole of drawworks framework, shaft assembly shall be fastened fast by relevant bolts after
position-finding-notch of bearing seat enters into the shaft hole of casing.
3) After assembly of the intermediate shaft and passing of the inspection, it shall be lifted to the
drawworks frame integrally. Put down into the corresponding installation holes of the drawworks frame
in good alignment with the rear notch. Push the shaft assembly to the right and fix it with corresponding
bolts after putting the bearing seat position-finding-notch into the shaft hole of the box. The drawworks
frame inserts shall be installed and properly tightened in the notch. The frame inserts cannot be
interchanged; they must be installed in their original positions.
4) After the rotary drive shaft assy being reassembled and being qualified through inspection, it
should be wholly hoisted and aligned with relative mounting hole in the casing, and when the shaft
centerline is aligned with the hole centerline, push the assy to rightwards until the positioning end of the
bearing seat falls into the shaft hole in the casing, then fasten the rotary drive shaft assy with the relative
bolts.

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 OPERATION MANUAL OF JC50D DRAWWORKS

5) After the rotary intermediate shaft assy being reassembled and being qualified through
inspection, it should be wholly hoisted and aligned with relative mounting hole in the casing, and when
the shaft centerline is aligned with the hole centerline, push the assy to rightwards until the positioning
end of the bearing seat falls into the shaft hole in the casing, then fasten the rotary intermediate shaft
assy with the relative bolts.
6) After the rotary output shaft assy being reassembled and being qualified through inspection, it
should be wholly hoisted and aligned with relative mounting hole in the casing, and when the shaft
centerline is aligned with the hole centerline, push the assy to rightwards until the positioning end of the
bearing seat falls into the shaft hole in the casing, then fasten the rotary output shaft assy with the
relative bolts.
7) Install gear shift mechanism, oil, gas, water pipelines.
8) Install chain, if chain needs to be replaced, it should be replaced wholly.
The side plan excursion of each pair of chain wheel mentioned above should not exceed 1 mm,
otherwise it should be adjusted, and each assembled shaft should rotate flexibly while being propelled
manually.
9) Install drawworks casing shield.
10) Install hydraulic disc brake.
11) Install Eaton disk brake, locate it according to limited block and then fix it.
12) Install drawworks shield.
After passing of inspection, drawworks assembly commissioning at zero load shall be done for at
least 2 hours to test gear shift and brake, after the commissioning is passed, the final assembly of rig can
be done.

11. Dismantling and transportation of drawworks main body

When drilling is completed, manipulating processes like lowering of mast and substructure etc
should be conducted as per relevant instructions in the manual of this drilling rig.
Only when it's confirmed that operation of drawworks is not needed anymore in later manipulating
process, the drawworks can be dismantled.

11.1 Dismantle drawworks from substructure

1）wind out all drilling lines on the drum (by using of wireline spooler)
2）Detach drawworks from power supply system, dismantle power circuit.
3）Dismantle air and oil pipelines (you can just dismantle one end according to the circumstance,
then put joints in protection to avoid damage and prevent foreign materials from entering).

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 OPERATION MANUAL OF JC50D DRAWWORKS

4）Remove connecting pin shafts between drawworks and substructure.

5) Lower down the drawworks with crane
6) Put all connecting fittings like bolts and nuts in storage for usage in future.

11.2 Transportation of drawworks

There's only one module in the transportation of JC50D drawworks, yet due to transportation
condition the electromagnetic eddy current brake may be dismantled and the main body of drawworks
can be transported as a module.
Transportation dimension of drawworks 6900×3285×2985mm(not including RT driving box)
Weight of main body of drawworks 38560kg （ including Eaton disk brake,
excluding the RT driving box body）
36325kg（excluding Eaton disk brake, the RT
driving box body）

12 Chains list for JC50D drawworks

No. Standard code Name & spec. Qty.

1 SY/T5595-1997 Chain (160-3×104) 1
2 SY/T5595-1997 Chain (120-6×68) 1
3 SY/T5595-1997 Chain (120-6×72) 1
4 SY/T5595-1997 Chain (160-3×78) 1
5 SY/T5595-1997 Chain (160-2×72) 1
6 SY/T5595-1997 Chain (160-2×64) 1
7 SY/T5595-1997 Chain (160-2×88) 1
13 Bearings list for JC50D drawworks
No Standard code Name Spec. Qty. Note
1 GB/T288-1994 bearing 23230C 2 Drive shaft
2 GB/T288-1994 bearing 23140 2 Intermediate shaft
3 GB/T283-1994 bearing NU1040 2 Intermediate shaft
4 GB/T288-1994 bearing 23040 2 Intermediate shaft
5 GB/T288-1994 bearing 22332CA/W33 2 Intermediate shaft
6 GB/T288-1994 bearing 22240C 2 Drum shaft
7 GB/T288-1994 bearing 22244CA 2 Drum shaft
8 GB/T283-1994 bearing N240 2 Drum shaft
9 GB/T288-1994 bearing 22226CA 4 Rotary drive shaft
Rotary intermediate
10 GB/T288-1994 bearing 22226CA 2
shaft
11 GB/T288-1994 bearing 23956CA/W33 2 Rotary output shaft
12 GB/T288-1994 bearing 23026CA 1 Rotary output shaft
13 GB/T283-1994 bearing NU1026 1 Rotary output shaft

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 OPERATION MANUAL OF JC50D DRAWWORKS

No Standard code Name Spec. Qty. Note

for water and gas
14 GB/T276-1994 bearing 6214 2
metering device
for water and gas
15 GB/T276-1994 bearing 6208 6
metering device

14 Recommended spare parts list of JC50D drawworks (one year)

N
Code Name Spec. Qty Note
o.
1 Clutch LT1070/200T 1 Drum shaft
2 Clutch LT1170/250T 1 Drum shaft
3 GB/T13871-1992 Oil seal FB260x300x20 2 Drum shaft
4 HG4-692-67 Oil seal PD240x280x18 2 Drum shaft
for water and gas
5 HG4-692-67 Oil seal PD50x70x12 1
metering device
for water and gas
6 HG4-692-67 Oil seal PD40x65x12 1
metering device
V type sealing for water and gas
7 HG4-337-66 D=70 2
rings metering device
for water and gas
8 GB/T13871-92 Oil seal B-80x100x10 2
metering device
9 GB/T13871-1992 Sealing rings 200x170x15 4 Drive shaft

Anti-explosive
10 YTXB-160 1
pressure gage

11 KCB83.3-2 Gear oil pump 1

12 QY34A.00 Toggle valve 1
13 JB/T7940.1 Oil cup M10×1 4
Fast line roller
14 2
stoper
15 Oil filter 2
One-way gas
16 QY94.00 2
guide tap
Quick exhaust
17 QY43 2
valve
Brake blocks for As per disc brake
18 1set
disc type brake device
Pneumatic RT driving output
19 LT500/250T 1
tube clutch sh a f t
RT driving output
20 GB/T13871-1992 Oil seal FB150x180x15 2
sh a f t
RT driving output
21 GB/T13871-1992 Oil seal FB170x200x15 2
sh a f t

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 OPERATION MANUAL OF JC50D DRAWWORKS

Translated by ： Date:

Proofread by： Date:

Finalized by： Date:

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