Service Manual

山东科瑞石油装备有限公司
ShanDongKerui Petroleum EquipmentCo.,Ltd
ZJ30/1800CZ Truck-mounted Drilling Rig

Service Manual
KR200.14.00SM
Edition：2014-A
Dongying•China
ZJ30/1800CZ Truck Mounted Drilling Rig Service Manual
Shandong Kerui Petroleum Equipment Co., Ltd.
Preface
Thank you for choosing truck-mounted drilling rigs of Shandong Kerui Petroleum
Equipment Co., Ltd.
The service manual of ZJ30/1800CZ truck-mounted drilling rig is written by the

engineers and technicians in our company, according to the module of function and based on
the product design and manufacture and service experience in oil field; it provides the
appropriate guidelines for product installation, use and operation.
This manual is as much as possible consistent with the actual product, however may be
slightly different from the actual product due to temporary change of technical agreements
and related technology improvement, the actual item is the standard.
To ensure your products run safely and steadily, please read carefully the instruction and
other information attached to the products, especially, the items about safety warning.
For that the drilling rig is consisted of many parts, only a few main parts are mentioned
in this service manual.For the suuporting parts not mentioned or only briefly introduced, their
structure, usage and maintenance please refer to the service manual of each part.
Special tips:
 The user of this service manual is professional technicians and operators who are
familiar with drilling equipment and drilling and production technology;
 Some of the equipment service manuals directly come from each manufacturer. If the
manufacturers update their manuals, unless otherwise specified, these manufacturers’
service manuals are prior to the documents this service manual provides;
 The information in this manual is based on the latest information when this manual is
published.Our company reserve the right to abolish or revise the service manual at any
time without notification, and do not bear any responsibility or obligation;
 Without our permission, it is forbidden to give this set of documents to the third party,
or we have rights to pursue legal responsibility for the consequence;
 Although this set of service manual has been revised carefully, there also may be
mistakes.Please correct us, if any.
—I—
InportantSafety Statement
Any use, management, operation, maintenance and repair personnel of the

product must know very well of the relative content of the manual and abide by the
regulation related to operation, management, maintenance and repair, especially
for the content such as safety warning and notes prompted by the instruction and
national law, regulation, industrial regulation and common-sense safety regulation
and matters needed attention in and to prevent the human injury and damage of the
equipment.
The instruction could not list all safety warning information in detail, so when
selecting a method to operate, firstly confirm the method neither can endanger the
human safety nor damage the equipment.
Correct maintenance is the key factor for the safe and reliable operation of the
product. The maintenance person should maintain the equipment according to the
method instruction introduced.
The correct repair of the product and replacement of the components original
factory manufactured are the key factors for safe and reliable operation of the
equipment. The user must maintain and replace componentsand parts according to
the authorized range by manufacturer.
—II—
Please read carefully when the instruction uses the following title and
mark!
Warning! Using for the condition which can cause human injury or
dead if not follow the operating steps or methods correctly;
Attention! Using for the condition which can cause the damage or
destruction of the equipment if not observe the operating
steps or methods closely;
Note! Using for attention or separate explaination condition.
—III—
Basic Safety Guideline

The following lists the basic safety precautions associated with this set of drilling rig.
These protective measures are not related with some special operations which is no longer
special explained in a later sections of this manual. In the course of the operation, the user
must be familiar with and understand these recommended safety precautions, other special
precautions are included in the warnings in the service manual.
 Qualifed operating personnel
Only authorized and qualified personnel can operate and maintain this set of rig and
the related equipment.
 Protective equipment
The operator and equipment maintenance personnel should wear the helmet,
protective clothing, protective shoes and other protective equipment ect; during the
drilling process, if there’s toxic gases escaping, operating and construction workers in the
job process also must wear gas-protection equipment.
 Safety habits
When installing, operating, disassembling and maintaining this set of equipment,

good and comprehensive safety habits must be maintained at any time. The duty of rig
owner (or operator) is to establish good safety habits, training and safety guidelines to
enforce.
 Equipment operation
To ensure your products are running safely, reliably and stably, befor the operator
use the equipment, please read the delivery attached documentation of this set of
euiqpmentcarefully and understand the operational requirements associated with
equipment and special remarks.
 Unauthorized personnel
When operating, maintaining or running the equipment, the unauthorized personnel
—IV—
should stay a safe distance away from the equipment.
 High voltage maintenance
Before disassembling and maintaining the high-pressureloop elements, ensure that

pressureof high-pressureloop system releases to zero. During the maintenance, send
special person to look after high-pressure loop power source, to make sure that the power
source during operation remains closed.
 Illegal operation and maintenance
No part is allowed to have illegal disassembly and maintanance, even illegal

operation.
 Electric control maintanance
Before maintaining and overhauling electric control system and electric components,
ensure the maintained and overhauled circuit and electrical appliance are in open-circuit
(power-off) state. During maintenance and overhaul, send special person to look after the
electric control system switch, to make sure it is always in open-circuit state; ensure there
are more than two overhaul and maintenance personnel of electric system.
 Lifting
When lifting or moving equipment, we should fully consider the ability of the
hoisting equipment and the weight of equipment, personnel should keep a safe distance
from the hoisted equipment; in any case, the people shall not be below the hoisted
equipment.
 Running parts
When operating running parts (running equipment), ,hands, clothes, tools and other
equipment should be away from the running equipment.
 Visibility
When visibility can not be guaranteed, unless there’s suitable light source, it is not
allowed to operate this set of equipment, including before sunrise or after sunset.
—V—
 Before starting
Before starting the equipment, check each operation and control components to
ensure that all elements are in the right position (on, off, neutral, etc.).
 Hot work requirement
During this equipment installation and disassembly process, hot work is allowed
(gas cutting, welding, etc.). But during the relevant procedure, hot work must stay away
from the dangerous zone and the related people authorize qualified personnel to perform
hot work.
 Compressed air
When using compressed air, it must be equipped with protective gear, not allowed to
put air end against oneself or other staff.
 Solvents or dyes
Follow the manufacturer's warnings and safety signs to use solvents or dyes in
ventilated or allowed area .Waste solvents or dyed contaminated rags, brushes, etc. must
be placed in particular disposal containers.
 Wind speed
When raising and lowering mast, the wind speed should be less than 10.8m/s
(20konts).
 Working area
When operating this set of equipment, keep the relevant working area clean, without
obstacles, tools and other objects affecting operations.
—VI—
Attention Please:
 The operator should wear helmet and labor protection articles before entering into the
well site.
 Before adjustment and maintenance of the drive system such as engine, hydraulic torque
converter, power tank-off case, angle transmission box and drawworks, etc., stop engine
firstly or make running equipment completely stop.
 No open flame or smoking is allowed when filling the engine with fuel oil or filling the
air circuit system with alcohol.
 The cooling water of the equipment various parts should be added with anti-freezing
solution in time or all changed with anti-freezing solution, when the ambient temperature
is lower than 4℃.
 Confirm that “+” and “-” pole of the battery are connected rightly and it’s not allowed to
be connected inversely, when changing the accumulator or starting the engine by
auxiliary battery. Otherwise it will cause the electric control system or the starting engine
burnt, even it will cause the heavy consequence such as the fire.
 Before starting engine, the hand brake must be in braking state and the shift valve (cab
and driller box) must be on neutral position. It’s forbidden to start engine in the state of
loosing brake or engaging a gear.
 After starting engine, it’s improper to immediately run with heavy load. It should run
with no-load or light load for a period time.Start heavy load operation after each part
temperature is normal and lubrication is good.
 Before driving, check whether the tire pressure is normal or not. When the pressure is
improper, inflate air or adjust the air pressure in time to prevent the equipment
—VII—
components from damaging.
 When the parallel power take-off case switches power, the input transmission shaft must
stop rotating completely.
 When the carrier is in position and start workover treatment, push the engagement &
disengagement operational handle of the drawworks-axle on the parallel power take-off
case, and the air control system changes to air supply on carrier state. During rig
operation, it’s forbidden to engage and disengage the power switching control handle on
and under carrier.
 After the carrier finishes drilling operation, shut down the engine at first, and then pull
the engagement & disengagement operational handle of drawworks-axle on the parallel
power take-off case, and the air control system changes to air supply under carrier state.
 During operation, the rotation speed of engine should not be less than 1200r/min in order
to provide enough lubrication oil for the hydraulic transmission box to keep circulating
cooling.
 It should adopt the double engines parallel when the hook load is more than 1150kN
(258530lbf). When operating parallel control device, shut down the engine firstly, and the
input transmission shaft must stop completely.
 The carrier is equiped with many kinds of electric elements. When the carrier needs to be
repaired by electric welding, the power source must be shut down to prevent the electric
elements from burning; when washing the carrier, the electric control case and all kinds
of electric wire (cable) plugs should not be splashed wet.
 Before the lifting cylinder of mast starts to work, it should be confirmed that the fixed
bolts at the mast front support and other locking devices have been disassembled;
meanwhile, the air in the hydraulic system and oil cylinder is discharged completely.
 When raising, lowering and telescoping the mast, there should be no any personnel on the
mast; there should be no any personnel to stay within the involved scope of mast front
and rear direction.
—VIII—
 When the mast telescopes (it is just applied to the telescopic mast with two sections), all
centralizers must be operated correctly.
 During mast stretching out, the hook should be under the mast.
 Before raising, lowering and telescoping the mast, clean the site, get rid of foreign
matters on the pistons and plunger rod of hydraulic oil cylinder, and straighten out all the
guy ropes.
 After the mast is erected to install, be sure to tighten all guy ropes in order to guarantee
that mast canwork safely; when adjusting the guy ropes, there should be no load on the
mast and the racking platform; during the working or mast is with load, the mast and the
racking platform are not allowed to loosen any guy ropes.
 When the mast is in the erection condition, it is forbidden strictly to move the leg oil
cylinder to prevent from the serious accidents such as the mast tilting.
 The workers on the mast must wear the safety rope, and fasten the safety rope at the mast
proper position; when climbing on or down the mast, workers must hang up well the rope
hook of falling protector to ensure the safety.
 Tripping operations shall be forbidden under reverse gears.
 After the engine is operated in the heavy load, it should keep idle running for 5 minutes
and then shut down.
 Check the safety of the mast if the hook load nearly equals to the max hook load.
 Pay attention to the oil level of the hydraulic oil tank and add the oil immediately after
the lack of oil is found to prevent the damage of the hydraulic elements such as the oil
pump etc.
 When the equipment is running, abide strictly by operation specifications, standardize the
operation, check and maintain at regular intervals; if there are any faults found,
troubleshoot in time to prevent the equipment from working with faults. Otherwise it will
cause the serious accidents.
—IX—
Product Information and Major Configuration Table

Product name: Truck-mounted drilling rig
Product specification: ZJ30/1800CZ
No. Name Specification Qty. Remark
I Carrier part
1 Chassis 14×8 self-moving chassis 1 set
2
2 Engine CAT C15
sets
Hydraulic transmission 2
3 M5620AR
box sets
Parallelpower tank-off
4 1 set Gear parallel box
case
5 Angle transmission box 1 set
Diameter of wire
6 Double-drum drawworks JC28/11 1 set
rope: φ32mm
Aircontrol and water

7 Auxiliary brake WPT324 auxiliary brake 1 set
circulation cooling
Rotary table transmission 5 forward and 5

8 1 set
box reverse, anti-reverse
2
9 Hydraulic winch YJ-3B、YJ-5B One set each
sets
10 Deadline anchor JZG24 1 set Weight indicator:
—X—
JZ250
11 Driller control box 1 set
2
12 Lifting oil cylinder YGQ3-280/2030
sets
Independent cooling
13 8m³ 1 set Dual pump
water tank
II Substructure part
6m, 6 gin poles spiral

1 Substructure DZ180/6 1 set
raising
2 Rotary table ZP275 1 set
3 Climbing chain box 1 set
4 Catwalk 800mm 1 set
8
5 Pipe rack 800mm
sets
6 5T air winch 1 set
III Mast part
38m, two sections

1 Mast JJ180/38 1 set
telescopic type
2 Crown block TC180 1 set
3 Monkey board 1 set
2
4 Telescopic oil cylinder YGS-110/16520
sets
—XI—
YGD-125/2015、 2
5 Tong oil cylinder One set each
YGD-100/2015 sets
6 0.5T air winch 1 set
IV Accessories part
1 Main drum wire rope 6×19S-IWRC-32-EIPS-RL 1 pc L=1000m
2 Traveling block & hook YG250 1 set
3 Single arm elevator link DH-250 1 set
4 Swivel XSL225 1 set
5 Rotary hose 4″ 1 pc L=17.5m
6 Escape device 1 set
7 Anti-drop unit TS-30 1 set
8 Climbing assist device ZPQ-00 1 set
Note：The table is a zoom table for the product information. Please refer to the
packing list to get some details. If there is slight mismatches against the
specification, be subject to the actual.
—XII—
Contents
CHAPTER ONE PRODUCT OVERVIEW ...................................................................................................1
1.1. Basic information of rig .....................................................................................................................1

1.2. General instruction of rig ...................................................................................................................1
1.3. The major structure of rig ..................................................................................................................3
CHAPTER TWO MAIN TECHNICAL PARAMETERS ............................................................................7
2.1. Basic parameters ................................................................................................................................7

2.2. Performance Parameters of the Main Components ...........................................................................8
2.3. Equipment tachometers of ZJ30/1800CZ truck-mouted rig ............................................................13
2.4. Transmission path of the drilling rig ................................................................................................14
CHAPTER THREE INSTRUCTIONS OF MAIN YSTEM COMPONENTS ...........................................7
3.1 Power Unit ...............................................................................................................................................7

3.2 Parallel power take-off case .....................................................................................................................9
3.3 Angle transmission box ..........................................................................................................................12
3.4 Drawworks System ................................................................................................................................13
3.5 Mast .......................................................................................................................................................26
3.6 Crown block ...........................................................................................................................................27
3.7 Traveling block & hook .........................................................................................................................29
3.8 Swivel ....................................................................................................................................................29
3.9 Standpipe................................................................................................................................................29
3.10 Rotary hose ..........................................................................................................................................30
3.11 Rotary table ..........................................................................................................................................30
3.12 Substructure .........................................................................................................................................31
3.13 Transmission system ............................................................................................................................32
3.14 Air control system ................................................................................................................................33
3.15 Hydraulic system..................................................................................................................................37
3.16 Hydraulic winch ...................................................................................................................................37
3.17 Electrical system ..................................................................................................................................38
CHAPTER FOUR USAGE INSTRUCTION AND OPERATION REGULATION FOR CARRIER ... 39
4.1 Movement for drilling rig.......................................................................................................................39

4.2 Installation requirements ........................................................................................................................44
4.3 Preparatory stage ....................................................................................................................................60
4.4 Commissioning stage .............................................................................................................................64
4.5 Operation stage ......................................................................................................................................71
4.6 Completion of the operation...................................................................................................................79
4.7 Parking and safekeeping of the rig .........................................................................................................81
CHAPTER FIVE PRODUCT PACKAGE AND TRANSPORTATION.................................................... 84
5.1 Product transportation method ...............................................................................................................84

5.2 Transportation of the carrier on the oilfield site .....................................................................................87
CHAPTER SIX ATTACHED DRAWING OF THE TRUCK-MOUNTED RIG ...................................... 88
—I—
Chapter One Product Overview
1.1. Basic information of rig
ZJ 30 / 1800 C Z
Self moving rig
Gear parallel rig
Max. hook load 1800kN

Nominal drilling depth up limit
30×100m （114mm drill pipe）
Rig code,
initials abbreviation of “rig” spelling
1.2. General instruction of rig
SY/T6584-2012 truck-mounted drilling rig ,SY/T6724—2008 the basic configuration
of petroleum drilling rig and workover rig, API and other relevant technical specifications
are followed in the design, manufacture and production of ZJ30/1800CZ truck-mounted
drilling rig.
ZJ30 truck-mounted drilling rig (hereinafter referred to as ZJ30 rig) is a
self-propelling type drilling rig driven by diesel engine, which is mainly used for
exploration and development of oil and gas well in the oilfield, meeting 3000m depth
working requirement. The workover rig is in accordance with the new process
requirements of workover, and can be operated normally within -25℃～+45℃ ambient
temperature. In addition, the rig also conforms to requirements of QHSE related
specification, and it has high adaptability in ex-proof, anti-seep, anticorrosion, anti-damp
and other aspects.
—1—
ZJ30 rig is mainly consisted by the self-propelled chassis, vehicle operating
mechanism, mast, substructure, drilling accessories and other parts. The rig possesses the
characteristics of fast moving and convenient installations in the well site. Meanwhile, it
can also fulfill the requirements of drilling rig, such as high load and long time continuous
operation, etc.
ZJ30 workover rig’s self-propelled chassis is the dedicated chassis for the 14×8
driving type, which adopts one-seater and pan-head driving cab, heavy-duty loading axle
and low section tire. The layout scheme of seven axles is 3 in the front and 4 in the rear.
Therefore, the load is distributed reasonably, strength is high and the cross-country
performance is strong. The 1st, 2nd, 5th and 6th axles are drive axles. The 3rd axles are driven
steering axles. The 4th and 7th axles are air suspension axles. The 1st and 6th axles have the
differential lock function between tires. The 2nd and 5th axles are tandem axles with the
differential lock function both between tires, and between axles.Differential type are
planetary gear, opening and locking of differentials are controlled by differential lock
switch control in the cab between wheel and axle. The first three axles adopt dependent
suspension with the structure of trigeminy leaf spring in longitudinal. The 4nd and 7th axles
are air suspended servo axles, The 5nd and 6th axles adopt (semi-rigid) rigid beam balance
suspension.
ZJ30 rig is equipped with double-section telescopic mast, and use the hydraulic
cylinder to raise and telescope in accordance with the API Spec-4F design requirements.
The height of operation is 38m, max hook load is 1800kN, it can satisfy the workover
process requirements that the servicing depth is 3000m （4-1/2" drill pipe)，the workover
depth is 8000m(2-7/8" drill pipe).
—2—
As one of important components of ZJ30 rig, substructure consists of the substructure
body, mast base, boat form base, walkway, ramp and BOP installation device, etc.
Substructure adopts the six gin poles spiral raising structure in accordance with the API
Spec-4F requirements, the height of working condition is 6m, the capacity of pipe setback
is 3200m (4-1/2″drill pipe),the rated load of rotary beam is 1800kN.
This manual focuses on the introduction of the carrier and working systems on the
truck, and mast, substructure, circulation system, auxiliary system and others are not
included in this manual.
1.3. The major structure of rig
 The self-propelled chassis
1. The dedicated self-propelled chassis of rig truck is adopted with the characteristics,
such as the reasonable load distribution, high strength, good cross-country
performance and stable & reliable working, etc.;
2. The high quality, heavy load and wide wheel tread axle, low end face tire, high
strength girder, steering of hydraulic power and double pipeline braking are adopted to
satisfy the usage of oilfield complex road condition;
3. Adopt standard flat single-seat cab.
 Mast
1. The design of mast is in accordance with API Spec-4F specifications;
2. The front open and double section telescopic mast can be raised and lowered
hydraulically, which is safe and convenient to operate;
—3—
3. The strength, stiffness and stability of mast can meet requirements of the drilling
operation after the load test;
4. Shot blastingtreatment is applied to increase surface hardness, paint adhesion and
corrosion resistance.
 Substructure
1. The design of substructure is in accordance with the relevant requirements of the API
Spec-4F specification;
2. The main body of substructure is consisted by rotary table base and pipe setback, and
adopts 6 gin poles and spiral raising structure which is convenient to hoist.
3. The BOP handling device is installed under the rotary table beam, and the installation,
disassembly and transportation of BOP is achieved by moving trolley guide rail on the
substructure.
4. The walkway on the either side of substructure body is foldable, which is convenient
to disassemble and provides enough working space.
 Power transmission system
1. CAT engine of reliable performance is equipped with ALLISON hydraulic
transmission case, which provides the strong horsepower, stable transmission.
2. The engine accelerator and gear shift adopt the pneumatic control by two site
remotely.
3. The special “T” gear parallel power tank-off case is adopted with simple structure
design, compact assemble, good dynamic performance and reliable transmission.
—4—
4. Rotary table transmission case are uniquely designed with clutch and brake which are
pneumatic controlled, and it possesses the performances of five forward & five reverse,
multi gears and anti- reverse brake.
 Drawworks system
1. Drawworks system adopts double-drum structure;
2. The main drum adopts the Lebus groove, which arranges the ropes orderly and also can
prolong the service life of wire lines;
3. It is air chamber acted push-disc clutch that has reliable performance;
4. The main drum and sand drum adopt band type brake, and auxiliary brake use air
control water-cooling disc brake. The torque of brake is large and the performance is
advantageous;
5. The brake system of main drum adopts the independent forced circulating water
cooling, and the brake system of sand drum adopts pressure spraying water cooling
type.
 Electric, air and hydraulic control system
1. Electric, air and hydraulic control systems are centrally controlled which is easy to
operate, and some executive components can adopt the remote air control;
2. The main electric, air and hydraulic components are imported components, which have
high quality and good performance;
3. The gas circuit pipeline adopts the copper pipe and the pressing type connector, and is
equipped with imported air compressor and dryer;
—5—
4. The operational lighting has the functions of ex-proof and anti-creep, and the circuit is
protected by steel pipe.
—6—
Chapter Two Main Technical Parameters
2.1. Basic parameters
1) Model：ZJ30/1800CZ
2) Max. dead load： 1800KN
3) Nominal drilling depth：1500m～2500m（5"drill pipe）
1600m～3000m（4-1/2" drill pipe）
4) Nominal workover depth
Nominal overhaul depth：5700m（3-1/2" drill pipe）
Nominal minor repair depth： 8000m（2-7/8" drill pipe）
5) Drive type of chassis： 14×8
6) Engine： CAT C15×2
Engine power 540HP×2
7) Model of transmission case： Allison M5620AR
Transmission gear：five positive and one reverse
8) The height of mast： 38m
Mast type：Mast type, front opening and double sections
9) Substructure working platform height：6m
Clearance height of rotary table beam：4.9m
Open diameter of rotary table： 698.5mm（27-1/2"）
10) Drawwokrs power： 750HP
11) Max fast line tension of main drum：280KN
12) Travelling ropes system： 5×6
13) Effective roper qty：10
—7—
14) Diameter of drilling line：φ32 mm
15) Hydraulic system working pressure：14MPa
16) Pneumatic system working pressure：0.75～0.95MPa
17) Electric control system
power source voltage of truck-mounted：DC-24V
power source voltage of lighting system：AC-220V/50Hz
power source voltage of power system：AC-380V/50Hz
2.2. Performance Parameters of the Main Components
Engine (2 sets)
Model： CATC15
Rated power：403kw（540hp）×2
Rated rotary speed：2100r/min
Transmission box (2 sets)
Model：Allison M5620AR
Max. input power：567KW（760HP）×2
Max. input rotary speed：2500r/min
Max. clear input torque：3254N·m（2400lbf·ft）
Transmission ratio：i 1 =4:1、i 2 =2.68:1、i 3 =2.01:1
i 4 =1.35:1、i 5 =1:1、i R =-5.15:1
Parallel power tank-off case
Structure type：gear parallel
Transmission type：Horizontal transmission
Transmission ratio to angle transmission case： 1:1
Transmission ratio to rotary table transmission case： 1:1.65
—8—
Transmission ratio to axle： 1:1
Drawworks
Model： JC28/11
Rated power： 750HP
Fast line tension of main drum： 280kN（61728lbs）
Wire line diameter： 32mm（1-1/4″）
Main drum brake drum diameter × wide： φ1170×310mm (46.1″×12.2″)
Main drum clutch model：Axial Push-disc typeATD-330H
Cooling type of brake drum：Circulating water cooling
Sand drum tension： 110kN(24250lbs)
Wire line diameter： 14.5mm（9/16″）
Sand drum brake drum diameter × wide： φ1070×210mm (42.1″×8.3″)
Sand drum clutch model：Axial Push-disc typeATD-124H
Auxiliary brake
Model：WPT-324
Braking power： 604kW(810HP)
Braking torque： 38400N·m（28343lbf·ft）
@air pressure 0.69MPa (100psi)
Max pressure：0.9MPa(130psi)
Max. slip rotary speed：640r/min
Max. disc free rotary speed： 1170r/min
Thermal power： 604kW（810HP）
Cooling water displacement： 307L/min（81 USgal/min）
Cooling water tank volume： 8m³（30320 US gal）
—9—
Mast
Model： JJ180/38
Max load： 1800kN（396826lbs）
Height： 38m（124.7ft）
Mast front tilted angle： 3°
Racking board height： 22m / 23m / 24m
(72.2ft/75.5ft/78.7ft)
Capacity： 3000m（9842ft）(4-1/2" drill pipe)
Wind resistance capability： 110km/h (full stands and no hook load)
Traveling block and hook
Model： YG250
Max load：2500kN（506160lbs）
Qty of sheaves： 5 pcs
Main sheave diameter： φ1120mm（44.09"）
Wire line diameter： φ32mm（1-1/4"）
Swivel
Model： XSL225
Max static load： 2250kN
Max working pressure： 35MPa（5000psi）
Bottom thread of the swivel joint： 6-5/8"REG-LH
Gooseneck joint and rotary hose connecting pipe thread 4"LP
Crown block
Model： TC180
Max. load： 1800kN（369826lbs）
—10—
Qty of sheaves： 6 pcs
Sheave diameter： φ915mm（36"）
Substructure
Structure type：6 gin poles spiral raise
Max. load of rotary table beam： 1800kN（369826lbs）
Setback capacity： 3200m（4-1/2″ drill pipe）
Working height： 6m（19.7ft）
Working space under rotary table： 4.9m (16.1ft)
Working area of upper flat： 7.4×5.4（㎡）
Rotary table
Model: ZP275
Max working torque: 27.5kN·m （20283 lbf·ft）
Max static load：4540kN
Opening diameter： φ698.5mm（27-1/2"）
Highest rotary speed： 300r/min
Transmission ratio： 3.67
3T Hydraulic winch
Model：YJ-3B
Rated pressure： 16MPa
Max lifting capacity： 30kN
Diameter of wire line： 14mm
Rope capacity：80m
5T Hydraulic winch
Model：YJ-5B
—11—
Rated pressure： 16MPa
Max lifting capacity： 50kN
Diameter of wire line： 15.5mm
Rope capacity： 100m
Hydraulic system
Rated pressure： 14MPa（2000psi）
Displacement：165L/min×2
Hydraulic oil：No.46 anti-wear hydraulic oil
Volume of oil tank： 1.46m³（1460L）
Gas circuit system
Rated pressure： 0.75～0.95MPa（110～140psi）
Displacement：800L/min×2
Electric circuit system
Truck-mounted power supply voltage： DC-24V
Power supply voltage of lighting system： AC-220V（50HZ）
Power supply voltage of dynamic system： AC-380V（50HZ）
Carrier
Drive type： 14×8
Maximum speed per hour(limited)： 45km/h
Maximum climbing gradient： ≥17%
Approach angle/departure angle： 33°/17°
Min. ground clearance(at bridge package)：340mm
Min. turning radius： 19.3m
Tire
—12—
Tire type： 445/65R22.5
12.00-20
Rim type： 12.25×14
8.5 standard rims
Note: For some part of selective purchasing accessory items not

listed in the table, their parameters can refer to their own service manuals or
2.3. Equipment tachometers of ZJ30/1800CZ truck-mouted
rig
（when the engine speed is2100r/min）
Rotary table
M5620A（R） Angle transmission Rotary table
Sand drum Main drum transmission
ALLISON box RPM
box
Gear
Gear Output Output

Output RPM Input RPM Input RPM Output RPM
Ratio RPM RPM
I 4.00 453 289 172 94 230 55
II 2.68 675 431 257 141 343 82
III 2.01 899 574 342 187 457 110
IV 1.35 1340 856 510 279 681 163
V 1 1811 1157 689 377 920 221
Rev. 5.15 352 225 134 73 179 43
—13—
2.4. Transmission path of the drilling rig
2.4.1 Complete making a trip of traveling system by single-unit or double-unit

parallel
engine 1 + transmission box 1 drive shaft drive shaft chain drive
� parallel box angle gear box sand
engine 2 + transmission box 2
chain fast line wire rope elevator link

drum main drum crown block traveling block &ℎ 𝑜𝑜𝑜𝑜𝑜𝑜 drill pipe
drive system &𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒
2.4.2 Complete rotating drilling function by single-unit or double-unit parallel

engine 1 + transmission box 1 drive shaft drive shaft drive shaft
� parallel box rotary table transmission box
engine 2 + transmission box 2
chain drive kelly bushing

climbing chain box rotary table kelly
2.4.3 Complete road travel operation condition by single-unit

engine 1 + transmission box 1 drive shaft drive shaft front drive axle
� parallel box �
engine 2 + transmission box 2 rear drive axle
Note: when the rig is moving ,it’s only allowed to use single
engine .Gauge in the cab will show the engine parameter
—14—
Service Manual of ZJ30/1800CZ Drilling Rig
Shandong Kerui Machinery Manufacture Co., Ltd
Chapter Three Instructions of Main ystem components
3.1 Power Unit

The power unit of ZJ30/1800CZ truck-mounted rig is consisted by two sets of CAT
C15 engine and two sets of Allison M5620AR hydraulic transmission cases, and the power
of power system is output by “T” gear parallel power take-off case.
Operation, maintenance and others of engine and transmission case in power system
can refer to operation and maintenance manual related to the equipment.
3.1.1 Engine
The engine is American CAT company C series diesel engine, which water-cooled
with six-in-line, electrical injection and four stroke. The complete machine is light and
compact and with wide power range and economic in fuel-burning, the response speed of
variable-speed governor to change in load is very fast.
The engine consists of engine body, cooling system, lubricating system, fuel supply
system, air intake & exhaust system and electronic control system, etc. In addition, it is
equipped with variable speed governor, and it can control the engine accelerator in the cab
and driller’s console. The control of accelerator adopts the air control electricity type.
It is equipped with engine tachometer, water-thermometer, oil pressure gauge, oil

filter, fuel filter and so on. The exhaust system is equipped with inflaming retarding
silencer. And the air intake system is equipped with turbocharger, air– to– air charge air
cooler, and air filter, etc.
The electronic control system consists of sensor, central control system (ECU),
executive mechanism and so on. The engine possesses the low oil pressure, high water
temperature and overspeed protective devices, and can diagnoses automatically.
Meanwhile, it can store the fault code, which is convenient to check and eliminate the
faults. The engine is supported by three points, and equipped with engine shield.
The relative parameters of the motor used onZJ30/1800CZ truck-mounted drilling rig：
—7—
Engine model ： CAT C15
Engine power： 403kW（540hp）
Rated speed： 2100rpm
Direction of rotation： Counterclockwise (watch from flywheel)
Temperature range：-25℃～+55℃
Note：For detail specification, please read the equipment list.
3.1.2 Transmission box
Allison M5620AR type transmission box is consisted of hydraulic torque converter

and planetary gear transmission case. When drilling (workover), the driller can shift by
using the gearshift valve in the driller control cabinet. As maindrive of the rig assorted with
engine, the following advantages have been attained:
 Reduce the shock load, eliminate the impact of torsion shaken from power
machine and dynamic load from working machine;
 Make the transmission of the machine more calm, the accelerating and
decelerating more smooth, give full play to the installed power, and so that the engine
often works at the economic speed;
 Including reduction gear for declivity, which can assist the main brake when the
drill is moving down declivity.
The torque converter is single-stage, single-phase and three elements structure, which
is consisted of pump impeller, turbine and guide roller. The engine drives vanes of the
pump impeller to pump the oil, and then the oil drive the turbine to rotate. The oil from the
turbine changes its flow direction via the effect of the guide roller and then enters into the
pump impeller so that it can flow circularly and the power transmission is achieved. The
transmission in planetary gear transmission case is constant mesh transmission between
gears, and is controlled by hydraulic multiple-piece friction clutch, and can engage and
—8—
disengage under load state to complete power gearshift.
Performance parameters of Allison M5620AR transmission box：
Model： Allison M5620AR
Max. net input power：567KW （760HP）
Max. net input speed： 2500r/min
Max. net input torque：3254N·m（2400lbf·ft）
transmission ratio： i1=4:1 、i2=2.68:1、i3=2.01:1
i4=1.35:1、i5=1:1、i(Rev.)=5.15:1
3.2 Parallelpower take-off case

3.2.1 Selective engagement for power
The parallel power take-off case adopts “T” structure and gear parallel. Respectively
output the power to each power output end after parallel of the two engines, and comoplete
the power input and output.
The parallel power take-off case adopts steel structure welding box and gear pair
driving mechanism. It has two power input ends and four power output ends.
The four output ends are used for front axle drive, rear axle drive, drawworks drive
and rotary table drive. The two input ends can adoptindividual or synchronous drive.
Among the four output ends, the output ends of front and rear axle drive can
simultaneously drive the chassis run, while the two output ends of driving drawworks and
rotary table can drive drawworks and rotary table either separately or simultaneously.
—9—
Fig.3-1 Parallel power take-off case
1. Left engine engagement handle2. Rotary table engagement handle

3. Power engagement handle of chassis and drawworks4. Right engine engagement handle
5. Right engine power input port 6. Power output port to car frame (drawworks power input end)
7. Left engine power input port 8. Power output port to rotary table transmission mechanism
9. Power output port to chassis (the lower input end)
Two (2) diesel engines can be used either separately or simultaneously:
 During the drilling operation, the engine power is delivered to the hoisting system
of the drawworks and the rotating system of rotary table through the upper two
output ends.
 When the carrier is moving, the power can be transferred to the lower two output
ends to drive two front steering axles and two rear driving tandem axles.
—10—
The power of four output ends can have the switchover at will, but it’s interlocked
between on and off the carrier. The power switchover and interlocked can be controlled by
a linkage rod. When pull handle outside, the power is delivered to the chassis, at this time,
cut off the transmission on carrier.
When pushing handle toward the side of parallel box, the power is cut off from the
lower output end, at this time, the power is engaged with the upper output end and middle
output end (Fig3-1). The drawworks is driven by the upper output end whose gear shifting,
engagement and disengagement can be controlled by air-controlled valve on the driller’s
console. Rotary table is driven by the middle output end. At this time, power is delivered to
rotary table power take-off case through the four drive shafts connected, and then
transferred to rotary table on the substructure by the climbing chain case. The clutch on the
upper end of rotary table transmission box, for releasing the reversal torsion of drilling
pipes, is controlled by the driller’s console.
Warning: when operating on carrier, please make sure that engagement device
on the lower end of parallelpower take-off case must be in disengagement status.
Note: when pushing the linkage rod, the two gears maybe can’t mesh because
intertoothspace of gears don’t match well. At this time you can move lower transmission
shaft lightly to make two gears match and then mesh.
3.2.2Parallel power take-off casedriving axles
The locking mechanism between front and rear axles is mounted between lower output
ends of the parallel power take-off case.
When any axle of the rear driving axles is in slipping status during shipping, the wheels
will idle reversely at the double speed and the complete unit will lose the driving force. At
—11—
this time, it is necessary to turn front and rear axles interlock switch on the control stand in
the cab (The differential of parallel power take-off case will be locked). The sliding wheels
in sliding status and the other wheels will rotate at the same time.
When any axle of either one side or two sides is in sliding status, you can turn the
differential locked through the lock switch between axles or wheels in the cab, to improve
the ability of working. After locked, please reset the switch to avoid damaging the axles.
Notes: The engagement of power input end handle, and switch between each
end of power output end shall be carried out before engine start or the gearbox is be
free position.Otherwise, it will arouse noise and the attrition of meshing parts.
3.3 Angle transmission box
The power of the angle transmission box is taken from the upper power output end of
the parallel power take-off case; the longitudinal power will be transferred into transversal
power through bevel gears to the chain case of drawworks system and drive double drum
drawworks.
The angle transmission case consists of case body, input shaft, gear pair, output shaft,
drive sprocket and installation frame, etc. It adopts the cast steel shell, and forged steel
spiral bevel gear. The input and output shaft are made by superior alloy steel, which not
only can change the transmission direction, but also can reduce the speed to transmit and
increase the output torque.
It is lubricated and cooled by the lubrication oil in the gear stirring case. The
schematic diagram of angle transmission case can be seen in the Fig.3-2.
—12—
1. Output chain wheel
2. Output shaft
3. Output Gear
4. Input Gear
5.Input Shaft
6.Input flange
Fig.3-2 Schematic Program of Angle Transmission Box
3.4 Drawworks System
Drawworks transfers the power to do the round trip work of traveling system and
auxiliary work of sand drums, located on the carrier floor with power unit. Drawworks
system mainly consists of main drum assembly, sand drum assembly, main drum braking
system, sand drum braking system, auxiliary braking system, crown-o-matic, brake rim
cooling water circulating system, drawworks frame and guard assembly, input &output
chain box shield,etc. The structure diagram of drawworks can be seen in the Fig.3-3.
Through the chain wheel, power output from the power units is delivered through
parallel power take-offcase and angle transmission case to sand drum shaft, and then
transferred to main drum. Auxiliary Brake WPT324 is fixed on the main shaft end driller
side. The whole drawworks system is equiped with many kinds of safety protection and
auxiliary operating equipments, to ensure the safe and reliable work.
Drawworks meets the requirements of Drilling and Production Lifting Device

Specification in API Spec 7K. Structure parameter of drawworks can be seen in Table.3-1.
—13—
Sand drum
Clutch
Main drum
Drum shield
Auxiliary
brake
Fig.3-3 Structure diagram of drawworks system
Table 3-1
Name JC28/11
Rated power 750HP（560KW）
Wire line diameter 1-1/4 "（32mm）
Max fast line tension 280kN
Drum size (diameter × length) Φ635×1056mm
Main drum Brake drum size ( diameter × width) φ1170×310mm
Brake type Belt brake
Brake wrap angle 340°
Brake cooling type Circulating water cooling
—14—
Auxiliary brake WPT224
Wire line diameter 9/16 "（14.5mm）
Max fast line tension 110kN
Drum size (diameter × length) Φ324×1070mm
Sand drum Brake drum size (diameter × width) Φ1070×210mm
Brake type Belt brake
Brake wrap angle（in the second layer） 340°
Wire line total capacity（9/16"） 3600m
Main drum clutch ATD-330H

Clutch
Sand drum clutch ATD-l24H
3.4.1 Main Drum
The main drum is used for spooling the wire lines in the traveling system, which is one
of important components of dual drum drawworks. The main drum assembly mainly
consists of drum body, drum shaft, push-disc clutch, sprocket, brake, crown-o-matic, shield,
and connecting disc, etc.
The drum shaft is forged by the superior alloy steel, the both sides are supported by
the self-aligning bearing, and the whole is installed on the drawworks frame. The brake
drum is alloy steel and dealt with the special heat treatment so that it has high strength,
good hardness, heatproof, wear-resisting and long service life. There is Lebus rope groove
on the drum body, and the wire ropes are arranged orderly and quickly. The power is input
through the double rows of chains, and the rotation of main drum is controlled through
ATD-330H axial direction push-disc clutch.
The brake system equipped on the main drum is used to brake the rotation of the main
drum, and consists of the main brake and the auxiliary brake. The main brake adopts the
—15—
band brake, the brake drum is installed on the both ends of the drum body, and the
circulating water is used for the forced cooling. The auxiliary brake is installed driller side,
and adopts the air control water cooling disc brake and the circulating water is used for the
forced cooling.
The brake system of the main drum adopts the independent circulating water cooling
type; the circulating cooling water is from the independent cooling water tank equipped on
the drawworks. And its brake rim is installed with water jacket and water circulating
pipeline, and achieves the circulation of cooling water through swivel at both ends of the
drum shaft to prevent the brake rim from high temperature which may lead to surface crack
of rim or become veneering with the brake band.Water cooling circulation system of brake
rim and water cooling circulation system of the auxiliary brake are set in the same system,
sharing with a cooling water tank; but their pipelines are independent. Centrifugal pump is
driven by the electric motor to send the circulating water with certain pressure to the
swivel of main drum shaft end; the circulating water is circulated in the water jackets of
two brake rims to flow out from the swivel of the main drum shaft end, and then returns to
the cooling water tank to cool. The ex-proof control switch of the electric motor is set aside
the water tank.
Note： Motor of the circulating water cooling system must be started first
before operation. It is prohibited to start the pump suddenly when the temperature of
the brake rim is excessively high during operation.
The rotation of the main drum is achieved through operating the main drum control
valve of the drum clutch. The control valve of the main drum is installed on the driller’s
console, referring to the fig 3-4. The main drum control valve controls not only the
engagement and disengagement of the clutch, but also the accelerator of the engine. Push
the handle of driller valve forward, when the handle turns 10°, the clutch begins to engage,
and the drum also begin to rotate; then the handle is continued to push forward, the
—16—
accelerator of the diesel engine is accelerated along with the increasing of handle rotary
angle. While the handle is pushed to the end, the accelerator of diesel engine is accelerated
to the maximum degree. When the control valve is loosened, the handle is reset
automatically, and the clutch of main drum disengages.
If the control handle is pushed backward from the neutral position, it can only control
the accelerator of engine, but fail to engage the clutch. Such an operation is applied to
control the engine accelerator when screwing on and off the drill pipe or other operations.
Picture 3-4 the driller’s control case
1. Case. 2.Shift valve. 3. Oil pressure gauge.4.Oil thermometer 5. Control valve of main drum.
6. Airpressure gauge. 7. Emergency braking valve of main drum.8. Engine parameter meter EDM.9. Control
valve of rotary table.10.Start switch of engine11. Air horn 12.Emergency stop switch of the engine.
13. “C” valve.14.Control valve of crown-o-matic15. Control valve of spinner. 16. Control valve of hydraulic
pump. 17. Control valve ofmud pump. 18.Control valve of mud pump accelerator. 19. Control valve of main
carrier accelerator. 20.Control valve of auxiliary brake.21.Engagement & disengagement of auxiliary
brake22. Control valve of pneumatic slip.
—17—
While making a trip, engage the gear and push upward the combination valves lever
of the main drum by 10° to engage the main drum which does not rotate while loading. At
the moment, the hydraulic torque converter, like a main clutch, departs from the working
condition: continue to push upward the lever and increase the rotating speed of the engine,
then the main drum starts to rotate and the hook goes up.
When the hook is required to stop moving, let loose the combination valves lever of the main
drum from the left hand, then the lever will return to the central position automatically. The main
drum clutch trips off and the engine goes back to idling rotation. The right hand clamps the
brake to make the hook come to a rest. The hook’s descending relies on its gravity and
managing the lever to control the hook’s falling speed.
3.4.2 Sand Drum
The main drum assembly mainly consists of drum shaft, drum, brake rim, axial push
disc clutch, input and output chain wheel. Drum shaft is machined from high quality alloy
steel; the brake rim is casted from alloy steel.
The sand drum should work though axial clutch. Its rotation is accomplished by the
chain drive of the right angle transmission boxes and the clutch. The sand drum’s clutch is
controlled be the control-air valve on the control console at the side of the sand drum. The
operation of the control-air valve is the same as that of the control valve of the main drum.
Please refer to the paragraph above.
3.4.3 Main Drum and Sand Drum Brake Mechanism
The brake mechanism of the drawworks is to stop the rotation of the drum.
The brake system of the main drum consists of two parts: the main brake and the
auxiliary brake. The main brake consists of brake drum, brake steel belt, brake block,
balance beam, crank shaft, location ring, regulating screw rod, pull rod, brake crank and
other brake mechanisms; it adopts the mechanical brake crank friction band type balance
brake, control the manual brake crank, via lever transfer mechanism, drive the crank to pull
the brake band, surround the brake drum to achieve the braking. The cooling method of the
—18—
brake drum adopts the forced cooling with the circulating water. And the auxiliary brake
adopts the Eaton pneumatic water-cooled disc brake.
The brake system has been adjusted before delivery. At this time, the performance of
braking system is the best and most reliable. When the brake band is used for a period time,
the brake block has been worn to certain degree, and it needs to be adjusted in time. The
adjustment method is to tighten the jackscrews on the location ring after tightening the
brake band, and then to loosen each jackscrew three circles to keep a 3～5mm clearance
between the brake band and the brake drum.
After the brake band is adjusted, the condition of brake band running end can refer to
the figure 3-5 under the tightening condition of the brake band. The distance from point C
to the line AB should be controlled about 30mm. If the distance exceeds 38mm, the brake
performance is not in a good condition; but if the distance is less than 25mm, the brake
system cannot brake normally, what is worse, it may cause the accident. When the brake
band is tightened, if the adjustment requirements and the correct position of the brake dead
end fail to conform to the status shown in the figure 3-5, it should be adjusted in time.
Warning: When the brake blocks have been worn to such a degree that the
fixed bolt heads can touch with the brake drum, all the brake band blocks should be
renewed immediately. Otherwise, if the slippage between the brake band block and the
brake drum happens, it may cause the equipment damages or the human injuries.
The abnormal abrasion of the brake drum rim and the brake block is usually caused
due to the bend or torsion of the brake band, instead of the normal usage. In order to
replace the brake block rapidly, it needs to pull the brake band out from the drawworks. At
this time, if the operation is conducted with too much force, the brake band will be
damaged, so that it should be careful to operate in order to avoid deformation of the brake
band and prevent the abrasion from being worse.
—19—
The uneven abrasion of the brake block will cause the brake performance in a bad
condition, and it also will cause the bounce back phenomenon of the brake crank during
braking. As a result, careful operation must be carried out when the brake block is replaced
in order to control the deformation of the brake band.
A— brake shaft end

B—brake end
C—brake crank arm end
Correct adjustment of brake band live end
在此进行调整
Correct adjustment of brake band dead end
Fig3-5 Correct location drawing of drum brake adjustment
Warning: The brake system of each shift must be well adjusted, or it will
cause serious accident.
—20—
Note: While checking the brake rim, if stripes of crack are found on the
surface of the brake rim fringe and its length has exceeded 100mm, the brake rim
should be changed immediately.
3.4.4 Auxiliary Brake
When lowering down the drill stem and casing pipe, the WPT324 type water cooled
disc brake equipped on the ZJ30 rig is used as the auxiliary brake. It is such a device that
drives the friction plate and the quenched copper alloy plate to engage and disengage via
the function of the compressed air and reset spring, in order to change the braking
performance. During the workover operation, it can coordinate with driller to operate the
band type brake in order to adjust the drilling pressure and workover speed. Its brake
torque is in direct proportion to the imposed air pressure, but what to be noted is that it
cannot be used with overload.
 Air pressure control of the auxiliary brake:
Rotate the auxiliary brake hand wheel on the driller’s console to adjust the air pressure
so as to make the brake torque is suitable to the auxiliary braking of the corresponding
tonnage load. When lowering, engage to control the handle of the air valve; when raising,
disengage the auxiliary braking.
 Cooling of the auxiliary brake
The torque of WPT324 type disc brake is formed by the friction force produced from
the compression of the compressed air on the friction disk. And under the brake in the
working condition, the large amount of heat is produced by the friction disk due to a long
period of friction, and must be taken away by the cooling water. In addition, the actual
condition of the cooling water should be observed frequently, in order to ensure that the
temperature of the ideal water outlet that fully cools the brake should be within 66℃. If the
outlet temperature exceeds 80℃, it will seriously affect the brake performance and the
service life, lead to the breakage of the friction plate and leakage of water cavity, the result
—21—
of which is the rapid decline of the brake torque and harsh noise when braking.
The working ambient temperature of the auxiliary brake should not be more than 43℃.
Due to the high ambient temperature in summer, the strong sunlight may cause the water
tank temperature is more than 50℃. Therefore, it is suggested that the high-capacity
auxiliary water tank be added if overshadowing of the water tank surface fails to meet the
cooling effect.
The detailed usage and maintenance documentation can refer to Operation Manual of
the Auxiliary Brake.
Note: the motor of circulating water cooling system must be started first while
using auxiliary brake to ensure the normal water circulation. Otherwise, it will damage
the internal spare parts of the auxiliary brake.
Warning: max. calcium carbonate equivalent hardness of cooling water

should not be more than 100ppm, and the Ph value should be controlled within
7.0-9.0. If the parameters of the cooling water exceed the standard mentioned above,
it is suggested to take the water treatment.
3.4.5 Water Circulating Cooling System
The cooling system of water circulation consists of the two sets of independent water
circulation devices, which share with one set of cooling water tank. One set of water
circulating devices is used for cooling the drum brake, and other is used for cooling the
auxiliary brake.
Water circulating system consists of 2 sets of pipeline centrifugal pump (one set is a
spare pump), a set of pressure regulating safety valve, a set of horizontal pneumatic
radiator, pipeline and cooling water tank, which can meet the cooling and external water
—22—
absorption function, as well as achieve the regulation and protection of the water circuit
pressure.
The cooling water tank can refer to the figure 3-6.
Fig 3-6： Cooling water tank assembly

1.Cooling water tank 2.Base 3.Safety valve 4.Centrifugal pump 5.water circulating pipeline
6.Radiator 7.Shade
The main parameters of cooling water tank；
Theoretical volume： 8m³
Radiator：JH-400
—23—
Power: 3KW×2
Max. flow: 25m³/h×2
Theoretical weight: 3300Kg
3.4.6 Rotary Table Transmission Case
The rotary table transmission box is mainly used to transmit the transmission shaft
power of the chassis crossbeam to the rotary table and to achieve the engagement &
disengagement of power transmission and release of the reaction torque energy. And it has
the following functions: pneumatic controls the engagement & disengagement, brake, five
forward and five reverse anti-reversion and so on.
The structure of rotary table transmission box can be referred to the figure 3-6 in
detail.
1. Input flange
2. Input shaft of
gearbox
3. gearbox
4. gear pair
5. output shaft of
gearbox
6. lower sprocket
7. clutch
8. upper sprocket
9. output shaft of
chain box
10. output flange
11. chain box
12. clutch
Fig.3-6 rotary table transmission box
—24—
The rotary table transmission case is mainly used to transmit power for rotary table,
and consists of input flange, output flange, gear case, chain transmission case, engagement
and disengagement unit of the forward and backward gear; ATD-218H thrust disk clutch
and reaction torque release unit, etc. The power is transmitted from the input flange to the
chain transmission case through the gear case, achieves the lifting and speed reduction via
chain transmission box and then is output from output flange. The gear case has the
function of reversing, and the power reversing is achieved by the engagement &
disengagement device. The power of output end is achieved from transmission shaft and
climbing chain case to the rotary table to achieve the driving of the rotary table.
The reaction torque release unit is installed on the shaft end of the output shaft, and its
main equipment is the ATD-218H axial thrust disk clutch, whose function is to release the
torque energy of drill pipe slowly to prevent drill pipe from rotating in reverse direction
rapidly and achieve the brake of rotary table after the clutch is disengaged.
Warning: Rotary table chaincase is not allowed to shift from reverse gear to forward
gear or shift from forward gear to reverse gear when the clutch is connected.
Or it will damage the parts of clutch or gear box.
3.4.7 Chassis
The chassis adopts the seven axle structure, 14×8 drive type, among which of I axle、
Ⅱ axle, V axle and VI axle are driving axle, Ⅲ axle is driven axle, IV and Ⅷ axles are air
suspension axle. I axle and VI axle in driving axle have Inter-wheel differential lock
function , Ⅱaxle and V axle are through axles with inter-wheel and inter-axle differential
lock between function.
The chassis mainly consists of the power system, the transmission system, the driving
system, the steering system, the braking system, cab, the electrical system and auxiliary
equipment, etc.
(The details can refer to Operation Manual for 14×8 Chassis)
—25—
Fig 3-7 chassis outside drawing
3.5 Mast
JJ180/38W mast is one of important components for 3000m truck-mounted

(ZJ30/1800CZ) rig. In the process of the workover and production, it is used for installing
and suspending crown block, traveling block, hook, elevator link, tongs and other lifting
equipment and tools; for installing and suspending standpipe, swivel, rotary hose and other
mud circulating equipment and tools; for lifting and lowering drill pipe, oil tube and other
tools; for dealing with down hole accidents and other drilling operations. When
transporting, the mast is laid on the front support of the carrier horizontally. Therefore, the
mast not only can meet load capacity required by various working condition in the process
of workover, but also must have enough rigidity and stability as well as has the small
weight and appearance size to the greatest extent, which is convenient to disassemble,
transportation, maintenance ,drilling and workover operation.
This derrick is front tilting type with the guy rope, telescopic, double sections mast. It
consists of crown block, mast upper part, mast lower part, bearing mechanism of upper and
lower part, Y type support, racking platform, escaping device, lifting cylinder, telescopic
—26—
cylinder and its centralizer, standpipe assembly, balance device, guy rope assembly,
stairways of upper and lower part, etc.
The lifting and lowering of mast is achieved by the dual acting & multi-stage lifting
cylinder connected on the carrier beam and the mast lower part. The extension and
retraction is achieved by two long telescopic cylinders of single acting, and there are
two-stage telescopic cylinder centralizer set in the middle in order to ensure safety and
stability during mast extension, retraction and working.
The mast and the carrier back support are connected via pins. In order to align the
traveling block with wellhead, adjust the screw rod between the Y type support and truck
frame to adjust the dip angle of mast, the dip angle of mast is 3° in the normal working
condition. There is angle indicator installed on the Y type support. Therefore, the angle
shown on the angle indicator is the dip angle of mast, when the mast is lifted in its position
and installed on the Y type mast.
Due to the condition restriction of the carrier, the cross section size of the mast should
not be too large, in order to prevent the traveling system from running upward and
downward inconveniently because of the narrow internal space of the mast, and to
accommodate mast telescopic requirements, the mast front steel frame is made into the part
or whole open structure, the mast should be tilted when operating to ensure that the
traveling system can run upward and downward conveniently.
The details can refer to Operation Manual for theJJ180/38W mast.
3.6 Crown block
TC180 crown block consists of the crown block base, sheaves, sheave shaft, bearing
and other parts, and it is multi-shaft structure. The traveling sheave system is 5×6, the
whole fixed sheave group and the crown block base are connected by bolts, and the
sheaves adopt the forge pieces, and are tested by the static balance. The rope groove arc of
the sheave is in accordance with requirements of API RP 9B; which applied to the Φ32
main wire line and the rope groove are dealt with surface hardening. The crown block shaft
—27—
is inspected by the heat treatment and flaw detection. There is lubricating grease nozzle set
on the ends of the sheave shaft to fill the grease to lubricate the bearing.
The fixed sheave group, whose rope system is 5×6, consists of seven sheaves and
adopts the multi-shaft structure. The fast line sheave and the dead line sheave adopt one
shaft separately, four fixed sheave groups have one shaft, and the sand sheave has one
shaft. There is rope guard on the sheave side plate in order to prevent the wire line from
jumping out from the groove. The crown block base is the integral structure, and there is
guide rail on the crown block platform.
Crown block is in accordance with specifications of API Spec 8C drilling and

production drilling and exploration, and its structure can refer to the figure 3-7.
The details can refer to the crown block part in the operation manual for JJ180/38
mast.
Fastline sheave Sand sheave Deadline sheave
Head block assembly Crown block base
Fig.3-7 outline drawing of crown block
—28—
3.7 Traveling block & hook
YG250 traveling block & hook system is an accessory to complete the lifting
operation in the process of drilling and workover, and consists of traveling block and hook.
The traveling block & hook is in accordance with the specification of API Spec 8C
drilling and production lifting equipment. And its usage method and maintenance can refer
to the operation manual for YG 250 traveling & hook system.
3.8 Swivel
XSL225 swivel is an accessory to complete the circulating operation in the process of

drilling and workover.
The swivel is in accordance with the specification of API Spec 8C drilling and
production lifting equipment. And its usage method and maintenance can refer to the
operation manual for XSL225 swivel.
3.9 Standpipe
Standpipe area consists of high pressure steel pipe, gooseneck and union connector,
etc, and is one of important accessories during mud circulating operation of the drilling and
workover rig.
Its structure composition can refer to the figure 3-8
1 2 3 4 5 6
Fig.3-8 standpipe assembly

1. Gooseneck 2. Straight pipe 3. Connecting union
4. Valve of the main passage 5. Pressure gauge 6. Valve of the bypass
—29—
Specification: ″ 4
Working pressure 35MPa
Applied ambient temperature -29℃～+121℃
Transmission medium water, crude oil, corrosive mud, etc
Thread type of pipe connector at both ends of rotary hose ″LP4external thread
3.10 Rotary hose
The rotary hose consists of high pressure hose, connector and union, etc. As the
connecting accessory between the mast standpipe and the swivel, rotary hose is one of
basic accessories during mud circulating operation of the drilling and workover rig.
Specification: ″ 4
Working pressure: 35MPa
Applied ambient temperature: -30℃～+120℃
Mini bending radius: ＜1200mm
Transmission media: water, crude oil, corrosive mud, etc
Thread type of pipe connector at both ends of rotary hose: ″LP4 external thread
3.11 Rotary table
Rotary table is an important component to complete the rotary operation in the

process of drilling.
There is lock claw installed on the rotary table. And its function is to lock rotary table
when rotary table is out of use. Therefore, before using rotary table, it must trip out the
lock claw at first. Otherwise, it will damage components and cause the unnecessary
damage.
The design and manufacture are in accordance with specification for API Spec 7K
drilling and production lifting equipment.
Please refer to Operation Manual for ZP275 Rotary Table.
—30—
The ZP275 rotary table can refer to the figure 3-7
bushing Master bushing
Chain
wheel
Fig.3-7ZP275 rotary table
3.12 Substructure
Substructure is used for supporting rotary table to operate, laying drill tools, providing
the drilling operational space, bearing the whole load of rotary table and laying the dead
weight of stands in the stand area.
DZ180/6 substructure is one of important components for ZJ30/1800CZ

truck-mounted rig, and consists of mud boat, mast base, substructure body, walkway, ramp,
catwalk, BOP installation unit and so on. The mud boat is used for supporting the carrier of
the truck-mounted drilling rig, the mast base is used for supporting the mast weight and the
hook load, the substructure body is used for bearing the rotary table load and storing stands
during drilling, the walk way on the drill floor is used for storing the wellhead tools and
—31—
providing the operational site for driller and wellhead operators, it provides the installation
space for the wellhead devices under the drill floor, the BOP installation unit is used for
installing BOP, pipe rack, catwalk and ramp are used for storing the single joints and
making the single joints upward and downward from substructure. In the process of
drilling, the load of workover rig is transmitted to the mast base and ground through
substructure components mentioned above.
(Please refer to Operation manual for DZ180/6 substructure.)
3.13 Transmission system
The power transmission of ZJ30/1800CZ truck-mounted rig is achieved through the

truck-mounted transmission system, and consists of transmission system on the truck and
transmission system under the truck.
The transmission system on the truck is mainly used for providing the power output
from the power take-off case to drawworks and rotary table. The power from the engine is
transmitted to the angle transmission case through upper power outlet on the power
take-off case and transmission shaft, and then transmitted to the sand drum through chains,
and the sand drum is controlled by the clutch to achieve fishing for sand and swabbing
operation. The power, which has been transmitted to the sand drum, is transmitted to the
main drum through chains, and the main drum is controlled by the clutch to achieve the
lifting operation. The power from the middle power outlet on the power take-off case is
transmitted to the rotary table transmission case through the transmission shaft; the power
is transmitted as the order: chains – transmission shaft – chains – rotary table to achieve the
rotation of rotary table. There is forward and reverse rotary control, pneumatic clutch
control and reaction torque release unit set on the rotary table transmission case
The transmission system on the truck is mainly used for the power transmission when
the carrier is driving. The lower power outlet of the transmission case is distributed to the
front and rear axles of the chassis through the transmission shaft to achieve driving of the
carrier and the clutch cylinder of the front axle can be controlled in the cab.
—32—
The power on the truck and the chassis power are controlled by the operational handle
set on the power take-off case to ensure using when operation on the truck and chassis
driving are not at the same time.
The transmission drawing can refer to drawing atlas along with the rig.
3.14 Air control system
The air control system for the ZJ30/1800CZ truck-mounted rig mainly consists of the
air control system on the truck and air control system under the truck. The air control
system on the truck is mainly used for controlling the engine accelerator, the hydraulic
pump clutch, the drawworks clutch, the rotary table clutch and so on; the air control system
under the truck is mainly used for controlling the truck driving and parking braking,
blockading of axles and wheels, locking for back up the truck, air suspension and so on. In
addition, it provides the air source for the truck-mounted pneumatic horn, pneumatic slip
and others.
This system mainly consists of air compressor, dryer, air storage tank, anti-cold
device, filter, all operational valves, pressure regulating valves, reducing valves pneumatic
brake on the driller’s console (the air control system drawings can refer to the drawing
atlas along with the rig). Pressure regulating valves and reducing valves have been adjusted
before delivery (max system pressure is regulated within 0.8～0.95MPa), and need not to
be regulated in the process of using. It is equipped with the anti-condensation device,

which is filled with quantitative ethyl alcohol and can be used when the temperature is
lower than 0℃.
The water drain valves under the filter and air storage tank need to be open at regular
intervals and drain away the accumulated condensate water.
Note: when filling the ethyl alcohol, it is forbidden to start the aircompressor.
—33—
3.14.1 Main drum control
The combination pressure regulating valve controls the engagement and

disengagement of main drum and the size of the engine accelerator. This valve has three
potencial four-way valve and two-way regulating valve function.The detailed operation
can refer to 3.4.1.
Warning: when the pressure is lower than 0.7MPa（100psi）, it’s forbidden

to operate the engagement of the main drum clutch.
3.14.2 Gear -shifting control of transmission case
Hydraulic transmission shift valve control gear box includes five forward gears, one
neutral, one reverse gear, it is forbidden to use the reverse gear during round trip to avoid
damaging the transmission case.
The gear shifting should be carried out without load. It is strictly forbidden to trip out
with overload at each gear, and the proper gear should be selected according to the weight
of gin poles in time.
When operating, the rotary speed of the engine should not be less than 1200r/min, to
ensure that there is enough lube in the transmission case. It adopts the hydraulic
mechanical transmission, and the output torque of torque converter is larger than the
engine torque in the zero working condition so that the workover rig possesses the
excellent starting characteristic. Because the engine and transmission case are connected
non-rigidly, it can lighten the impact on each other and improve the transmission
characteristic. Meanwhile, the engine does not have the reverse braking function, so it is
strictly forbidden to operate in the reverse gear in the process of running in, to avoid
damaging the torque converter and the engine.
—34—
Warning: if engaging the reverse gear of the transmission case in the process
of running, it will damage the engine and the transmission case.
3.14.3 Crown-o-matic and emergency brake control
The reset control valve of the crown block protector is the 3-way & 4-position
reversing valve. During the normal working of the workover rig, move the handle upward
to the anti-collision position; when the traveling block & hook system is lifted to the
setting height, and the twining layers of wire line are up to a certain height on the drum,
push the top rod of the toggle valve away, let the controlled air pass through shuttle valve,
open the normal closed pneumatic valve, and the main air reaches the brake cylinder
through valves to brake.
Meanwhile, the controlled air reaches and closes the normal open pneumatic valve to
cut off the air source of the main drum control valve. After faults are eliminated, it needs to
reset the push rod of the anti-collision toggle valve, put the handle of the anti-collision
reset valve downward to the reset position, the auxiliary brake and the cylinder piston reset,
the brake cylinder gets back to the shape, and the brake is removed. At this moment, it still
needs to push the handle of the control valve to the anti-collision position to ensure that it
can be used safely next time.
Warning: this system is the protective system, it should not be operated

frequently, and prevent the hook from lifting excessively.
Driller can also operate the emergency braking valves; under the dangerous condition,
push the handle of this valve downward to the braking position to achieve the braking of
the main drum. The working principle for operating the braking of emergency braking
valve is the same with the working principle for the braking of the anti-collision toggle
valve.
—35—
The emergency brake control valve is the handle reversing valve. In the normal
condition, the emergency brake control valve is in the normal closed status; in the
dangerous condition such as when the brake operating device is out of control, tighten the
handle of the emergency brake control valve downward, the compressed is input directly to
the brake pneumatic auxiliary piston cylinder and brake cylinder to brake the drum quickly,
and the working and principle of air control system is the same with working of crown
block anti-collision system. After the faults are eliminated, the handle is back to the reset
position, the brake cylinder releases the air to remove the brake, the handle of the
anti-collision reset control valve are pushed to the reset position, the pneumatic auxiliary
brake piston is retracted. At this time, the handle still needs to be pushed back to the
anti-collision position in order to make sure that it will be safe to use next time.
Warning: after the crown-o-block system is started each time, it should

operate the anti-collision reset control valve to reset the brake cylinder. After
resetting the cylinder, it must push the handle of the anti-collision reset control valve
and the push rod of the toggle valve to the anti-collision position. Otherwise, when
the traveling block lifting exceeds the alarm height, the crown-o-matic will not take
any effect so that it will cause accidents such as colliding the crown block.
3.14.4 Auxiliary brake control
The engagement & disengagement of the auxiliary brake is controlled by a 2-way and
tee valve. Control the valve handle to engage or disengage the auxiliary brake. The driller’s
hand wheel pressure regulating valve can control the braking force through the compressed
air to achieve the adjustment of brake torque.
3.14.5 Pneumatic slip control
The control valve of the pneumatic slip is a 3-way & 4-position valve; when it needs
to hold the down hole drill stem in making a trip operation, push the handle of the valve
forward so that the wellhead pneumatic slip can clamp the drill stem tightly. When it needs
—36—
to remove the pneumatic slip, it just needs to push the handle backward.
3.15 Hydraulic system
The hydraulic system mainly consists of main oil pump, lifting hydraulic cylinder,
telescopic hydraulic cylinder, lifting tong hydraulic cylinder, leg hydraulic cylinder,
hydraulic motor, hydraulic oil tank, filter, reducing valve, overflow valve and all kinds of
hydraulic operational valve (the hydraulic system drawing can refer to the maintenance
manual).
The pressure of the overflow valves, reducing valves and each pressure regulating
part has been adjusted before delivery, and it does not need to adjust any more when using.
The filter should be checked and cleaned at the regular intervals in order to ensure the
working reliability of the hydraulic system. The water limitation (weight ratio) mixed in
the hydraulic oil should be less than 0.05%. And the dirtiness degree should be less than
7.0～10.0mg/100ml. Under the normal condition, the replacement cycle of the hydraulic
oil is about a year and a half. If the limitation of the water mixed in the hydraulic oil and
the dirtiness degree are not in excess of the limited quantity, it can prolong the service
cycle of the hydraulic oil. But even through the time of replacement oil does not arrive, it
needs to replace the hydraulic oil in advance when the limitation of the water mixed in the
hydraulic oil and the dirtiness degree have exceeded the limited quantity
3.16 Hydraulic winch
The hydraulic winch, which is equipped on the ZJ30/1800CZ truck-mounted rig, has
two specifications to choose: 3T & 5T at present.
The hydraulic winch consists of the dual-stage planetary gear reduction gear, the
hydraulic clutch, brake valve and hydraulic motor, etc. It adopts the hydraulic drive type,
and mainly is used for lifting single oil tubes, drill pipes, and some auxiliary tools used in
the process of lifting and drilling.
The hydraulic winch is controlled by the hydraulic winch control valve on the driller’s
console. When the handle of the control valve is in the neutral position, the winch does not
—37—
rotates; the handle is pushed forward, the winch rotates in forward direction and lifts the
heavy object; then the handle is pushed backward, the winch rotates in reverse direction
and lowers the heavy object.
The hydraulic clutch on the hydraulic winch has the locking function when stopping
supplying the high pressure oil at the inlet and outlet of the hydraulic motor through the
brake valve, and. Therefore, the lifting heavy objects can stop at any height reliably.
The maintenance of the hydraulic winch can refer to Operation and Maintenance
Manual for Hydraulic Winch.
3.17 Electrical system
The electrical system mainly divides into the control of electric appliance including
driving control and operational lighting control:
 The driving system adopts 24V DC, and its power source comes from the accumulator
and silicon rectification generator driven by the engine, and mainly consists of the
starting of the engine, lamplight symbols of all parts monitoring instrument on the
chassis, lamplight when driving including outline marker lamps, headlight, sidelight,
front fog light, stop light, back-up warning, rear lamp, rear fog lamp and so on. All the
electrical wires are armored and fixed on the beam of the truck frame to avoid the
electrical wire damaging.
 Operational lighting system is supplied by the external alternating current power
source, and consists of engine, draw works, mast and substructure lighting. There is
ex-proof blink red height light on the top of the mast, the electrical wire of the lighting
system is protected by the steel pipes and adopts centralized control through dedicated
ex-proof control case.
The electrical system drawing can refer to the drawing atlas along with the rig.
—38—
Chapter four Usage instruction and operation regulation

for carrier
This chapter introduces the usage requirements and operation regulation of the
ZJ30/1800CZ truck-mounted drilling rig in brief.
In order to make sure that equipment can operate safely and operators are safe,
earnestly request users to operate the equipment according to the all operation regulations
of this chapter mentioned in this chapter. Before operating this set of equipment, operators
should be familiar with the structure, performance, and application scope of this drilling rig,
and master requirements of the relevant technical data. The rig works when all the parts
work normally. If abnormal running is found, stop it immediately and then inspect it.
Operate it again when the problem has been solved.
Due to the complex structures of this drilling rig, we may not give the whole
instructions. When problems we have not mentioned are found in this manual, please
contact with the technical service department of our company. Our company will explain
and deal with it actively.
We will introduce detailed operation regulations of the rig as follows according to the
four processes: movement of the rig, preparation before operation, operating process and
finish of operation.
4.1 Movement for drilling rig

4.1.1 Check items
 Check whether the cooling water in the engine cooling water tank is enough or not;
 Check whether the fuel amount of the engine is enough or not;
 Check whether the engine oil is within the calibrated oil level or not;
 Check whether the engine oil is qualified or not;
 Check whether the oil level of the hydraulic transmission box is within the calibrated
oil level or not;
 Check whether the hydraulic oil is qualified or not;
—39—
 Check whether the engagement and disengagement of the power take-off case is
flexible or not;
 Check whether the oil amount in the hydraulic oil tank is enough or not;
 Check whether the hydraulic oil is qualified or not;
 Check whether the water amount in the cooling water circulation tank is enough or
not;
 Check the clean degree of each filter;
 Check the oil quality and level in each gear case and chain case;
 Check whether each valve in the driller’s console is in the neutral position and the shift
valve is in neutral position;
 Check the air pressure of the tire;
Table 4-1 Charge pressure for tires
Tire Double tire 12.00-20 Single tire 445/65R22.5

Corresponding air
740(90psi) 830(100psi)
pressure / KPa（psi）
Note: when air inflation, the air pressure of tire should not be higher than this
pressure value.
Table 4-2Charge pressure of tire under various loads
Air pressure of air suspension axle /MPa 0.6 0.54 0.44 0.05
Load of air suspension axle /kg 13000 12000 10000 2000
 Check whether the air suspension pneumatic reversing valve is opened or not, and
whether the set pressure is right or not.
Note: The too high air pressure causes the overload of the air suspension axles,
and air chamber is damaged; the too low pressure causes the overload of the
rear driving axles.
—40—
4.1.2 Engine operation

 If the engine is started for the first time or not using for a long time, diesel is filled into
the high pressure chamber through hand oil pump until it is filled fully, to discharge air
in the pump chamber and fuel pipeline before starting the engine.
 Turn on the ignition lock, switch on the power source, pull the starting instant
connection handle (if there is air pressure, push the starting instant connection
pneumatic control valve), press the start button, and then the engine will be operated
with idle running. Let the engine idling run for 3-5 minutes after the starting the
engine until the water temperature and air pressure of the engine are normal.
Table 4-3
Water temperature of
Pointer in the green area or 70～93℃（184～245℉）
engine
Oil pressure of
Pointer in the green area or 0.14～0.42MPa（20～60psi）
engine
Fuel pressure of
Pointer in the green area or above 0.14MPa（20psi）
engine
Main oil pressure of
Pointer in the green area or 1.2～1.4MPa（170～200psi）
torque converter
Oil temperature of Pointer in the green area or 80～93℃（210～245℉），it can
torque converter reach 135℃（355℉）
Air pressure Pointer in the green area or 0.45～0.9MPa（64～129psi）
Note: When idle running, pay attention that whether the sound, fog exhaust,
heat and others of engine are normal or not. When all of them are normal, it can run
with load. When the temperature is lower in winter, the time of idle running should
be prolonged until the water temperature is raised and oil pressure gets normally.
When pressure of engine oil is normal, the engine can be accelerated to run and
engage a gear with load.
 Engine flameout control valve is placed on the instrument panel or driller’s cabinet at
one side of the engine. When it is necessary to extinguish the engine, set the
—41—
transmission case in the neutral gear, and then operate the flameout valve to extinguish
the engine.
Note: The engine cannot be stopped immediately after running in the high
speed, and it should keep the idle running for 5 minutes to stop after unloading.
Note: The detailed operation regulations of the engine and the transmission
case can refer to the operation manual along with the engine and the transmission case.
4.1.3 Operation in winter

When the temperature is lower than ℃
5 （13℉）, it means the operation of the rig
should be in winter operation condition. Before the winter, the season-shift maintenance
should be carried out as followings:
 Check whether the gasoline pre-heater works normally or not;
 Fill the ethyl alcohol in the ethyl alcohol anti-condensation device of the pneumatic
system (it is suggested to use when the temperature is below 0℃（2.6℉）);
 Check the working condition of the air heater;
 Change the engine anti-freezing solution used in winter;
 The water circulating system should adopt the anti-freezing solution.
4.1.4 Movement of the carrier
 When driving on the normal road, the carrier adopts the 14×4 to drive, and engages the
rear axle transmission handle of the power take-off case.
Warning: When driving on the highway, the front and rear handles of the
power take-off case are not allowed to engage at the same time. Only in the muddy
area or the desert where adhesion coefficient is small, it is allowed to engage the front
—42—
Note: When the whole set of rig is moved, it should not extinguish the engine
to slide.
 When driving on the muddy road, the front and rear axles are engaged at the same time
according to requirements, but it need to be noted that it should engage the rear axle at
first and then engage the front axle.
 When driving on the highway, air pressure of the truck tires should keep the normal
pressure.
 When driving in the desert area, the air pressure can maintain at 4.2kg/cm2（60 psi）
according to the requirement, so that the adhesion force between the tire and the
ground will become greater, and the low air pressure is only applied to drive in the low
speed.
 When driving in the snow, muddy or desert area, it can adopt the differential lock
method to pass if the wheel slips.
 When there is a height limitation, it needs to disassemble the mast to transport.
4.1.5 Emergency treatment of driving faults
Stop immediately after faults are found, check and judge the location, degree, reason,
hazard degree, repair method and difficulty level of the fault, and then decide that it should
drive continuously or deal with immediately or drive to the nearest place to repair or wait
for the rescue.
When the rig is dragged due to the power fault, it should run the engine as possible
under the allowable condition, in order to keep certain steering performance or brake
performance.
 When the rig is dragged due to the power fault, it should run the engine as possible
under the allowable condition, in order to keep certain steering performance or brake
performance.
 When the inner fault of the rear axle (intermediate axle) is found, it needs to disengage
the rear axle engagement & disengagement device of power take-off case, and then
—43—
engage the front axle to drive continuously.
 When the inner faults of the front and rear axles are found, it needs to disengage the
front and rear axles’ engagement & disengagement device of power take-off case
when the rig needs to drag.
 Due to the fault of the front and rear axle differential mechanism, it needs to pull out
the semi axis of the front and rear axles when the rig needs to drag.
4.2 Installation requirements

4.2.1 Tool requirements
 Equipment: 2 sets of 30T cranes
 Tools: flexible rule（≥30m）, 5m flexible rule, level bar, plumb line, tailor’s chalk line,
crow bar, wrench, sledge hammer, hammer, pipe tong, jack and hoisting rope and so
on.
4.2.2 Hoisting requirements
 When truck loading, disassembling and installing, the dedicated hoisting rope should
be used. When it is hoisted, hang the rope on the hoisting pad eye, and the length of
the hoisting rope should be suitable.
Note: if the length of the hoisting rope is too short, it will press the equipment
and parts, to damage the equipment and parts
 When the hoisting weight of the mast and substructure is more than 20T, it is
suggested to use 2 sets of crane with 30T to hoist, or use 50T crane to hoist.
4.2.3 Site requirements
 The area of the well site: it includes the ground anchor pit of the mast guy rope, and
the area of the site well is not less than70m×60m;
 The area of equipment installation: it regards the wellhead as the centre, the width
along the left and right side of the carrier is 7m, the front and rear distance of the
wellhead is 22m and 20m;
—44—
 Ground anchor: Dig four ground anchor pits of the guy rope, the depth of the ground
anchor pit is 1.8m, the upper length is 1.3m, the upper width is 0.8m, the low length is
1.6m, the low width is 0.8m, the bearing capacity of each ground anchor pit along the
direction of the guy rope should not be less than 98·kN (10t.f), or rebar precast block
is placed as the active ground anchor according to the showing in the diagram. The
active ground anchor does not need to dig a pit, which is the biggest advantage, so that
it can be moved along with the rig.
—45—
Ramp length Horizon
Installation surface Loading supporting

of drilling floor surface
The following requirements are put forward according to API RP4G specification recommends the guy rope, ground anchor of the guy rope and base of the ZJ30 drilling rig.
Ⅰ. Requirements for the guy rope: The min breaking strength of the guy rope load is 18T, the min breaking strength of the external guy rope is 12T, and the min breaking
strength of the crossover guy rope of the racking platform is 10T.
Ⅱ. The requirements for the guy rope ground anchor:
1. All ground anchors can bear the min tension load of 70kN when the angle between the wellhead and horizontal level is 45°. It can refer to the drawing (space
between ground anchors and the bearing capacity drawing) to design the ground anchor if it is limited by the well site condition.
2. The anchor should be checked according to the actual designed load.
3. The metallic part of anchor should be carried out with anti-corrosion treatment, and it should also set the pile as the mark.
Ⅲ. The requirements for the mast base
A——Four pieces of guy ropes are from the crown block to the ground, its wire line size is 3/4”, and its original tension is 4450N (the verticality is about 150mm).
B——Two pieces of guy ropes are from the racking platform to the ground, its wire line size is 3/4”, and its original tension is 2250N (the verticality is about within
300~450mm).
C——Two pieces of the internal loaded guy ropes are from the crown block to the truck, its wire line size is 3/4”, and its original tension is 6670N (the verticality is about
within 80mm).
D——Two pieces of guy ropes are located at the mast lower section, its wire line size is7/8”, and its original tension is4450N（the verticality is about within 80mm）.
Safe bearing capacity required for load supporting surface is 39t/m in minimum, it must be leveled and take drain treatment.
The installation surface of the drilling rig is far away the centre of the wellhead about 4m, and its max gradient of the downhill slant is 1:20, and the minimum needed safe
bearing capacity is 29t/㎡, the whole ground needs to drain away water.
Drawing 1 Location for guy lines and ground anchors
—57—
The bearing capacity of ground anchor (t)
Zone Dual section Single section Mast
A 15.6 7.0 7.0
B 11.5 5.0 5.0
C 9.0 5.0 5.0
D 7.4 5.0 5.0
Drawing 1 Location drawing for guy lines and ground anchors
—58—
4.2.4 Requirements for foundation

According to the actual well site condition, it should select the optimal installation
location of equipment, which can operate conveniently and stop smoothly for the carrier.
The installation area, where the carrier stops, requires slightly higher than the ground
around and the drainage ditch is dug to avoid hydrops of the well site after raining. When
the well site foundation location is confirmed, it should pay attention the wind direction of
well site area, to avoid mast bearing the side wind, and prevent the unnecessary loading in
order to avoid mast rollover.
 The foundation condition selects different base according to the different geological
condition of well site:
A：When the geology is rock, dry and solid clay, it can adopt the natural base to level
and tamp the foundation.
B: when the geology is wet clay, desert, intertidal zone and other soft ground, it can
adopt the artificial base. The soil property is relatively well-distributed and stable, and
the active foundation is optimal choice to adopt. If the soil property is relatively soft
and possesses the strong mobility, it can adopt the foundation grouted in site or pile
foundation.
C: The foundation should carry out the excavation operation to level and tamp; after
the carrier is in its position, it is forbidden to carry out the excavation operation around
the foundation.
 The foundation should meet the bearing capacity as following:
A: The carrier foundation. The carrier is equipped with the mud boat, and its basic
bearing capacity should not be less than 290kN/m³; the carrier is installed on the
ground base directly, and its bearing capacity should no less than 390kN/m³.
B: The mast foundation. Its basic bearing capacity should not less than 390kN/m³.
C: The substructure foundation, its basic bearing capacity should not less than
390kN/m³.
D: The foundation of the drill pipe racking area, and its basic bearing capacity should
not be less than 290kN/m³.
—59—
 Levelness of the foundation should meet the following requirements:

A: The mud boat foundation of the carrier: the horizontal error along the left and right
direction should be less than 2mm/m, along the front and rear direction of the wellhead,
the headstock is low, but the gradient should not be more than 1:20.
B: The mast foundation and the substructure foundation: the horizontal error along the
right and left direction should not be more than 1mm/m, and the horizontal error along
the front and right direction of the wellhead should not be less than 3mm/m.
4.3 Preparatory stage

4.3.1 Clean up the well site
 Clear up the well site, the area of the well site should not be less than 4200㎡
(45210ft2), its length is 70m(230ft), and the width is 60m(197ft). The other relative
requireme45nts can refer to 4.2.3 and 4.2.4.
 The ground bearing capacity of the area within 5m(16.4ft) around the wellhead should
not be less than 0.39MPa(55psi); the area, whose ground bearing capacity cannot
reach the requirement, needs to be strengthened by dinas and then be smoothed out.
For the clay and soft sandy soil ground, the foundation of laying the mast should be
paved by stone with thickness of 150～200mm and be leveled due to the soft soil
property.
4.3.2 Installation preparatory
 Make sure the central line of the wellhead, and draw the right and left direction of the
wellhead and the datum line of the front and rear direction with tailor’s chalk line.
 According to the actual condition of the well site, the parking location and direction of
the drilling rig should have been selected well.
 Substructure installation: According to the location of the wellhead, hoist the
substructure in its position, align the rotary table centre with the wellhead centre, the
location of the substructure should be higher a bit, and it is not allowed to have
hydrops after raining. And its installation should refer to Sevice manual for
DZ180/6substructure in detail.
—60—
 Carrier in its place: after the substructure is put and installed, the rig is driven to the
site to place well; the tail beam centre of the carrier aligns with the wellhead, the
distance from central line of the 2 rear hydraulic leg jacks to the wellhead centre is
3182mm, and located in the supporting base ring of mast base.
 Put the leg support: after the carrier in its place, place the corresponding supporting
base well according to the hydraulic leg and mechanical jack.
 According requirements of 4.2.3 the mast guy rope drawing, dig the four guy rope
anchor pits well, and each anchor pit’s bearing capacity along the guy rope direction
should not less than 98kN(21952lbf).
 Switchover the power and control: operate the engine with idling running (Allison
transmission case is in the neutral position), operate the control handle of the power
take-off case to the operation position, and switchover the engine power and air
control system to the draw works part on the truck.
 Working of hydraulic pump: operate the engine with idling running (Allison
transmission case is in the neutral position), operate the driller’s control case and put
the control handle of hydraulic pump clutch to the engagement position to make the
main pump start to work.
 Discharge the air in the hydraulic system: operate the engine with idling running
(Allison transmission case is in the neutral position), operate the handle of working
condition selection on the quintuplet valve to the adjustment position, and supply the
hydraulic oil to the operational case of the six-up valve. On the control penal of the
six-up valve, open the needle valve E, control the handle of the operational valve B,
operate the system with dry running for 5 minutes, run the hydraulic oil in the system
without load, and drain the air in the system away. After all is finished, operate the
handle of the operational B in the neutral position, and close the needle valve E.
 Test the pressure of the system: control the engine accelerator to let its rotary speed
run within 800～1000rpm. Control one set of leg cylinder to retract to the extremity,
and observe the pressure gauge of the hydraulic system, whose shown value is 14MPa.
 Level the carrier: control the engine accelerator to let its rotary speed run within 800～
—61—
1000rpm, operate the operational valve handles of the hydraulic jacks separately to
control the four hydraulic legs of the carrier and support them on each position, use the
gradienter to measure all sides of the chassis beam on the horizontal position (at this
moment, all tires do not bear load basically), lock the hydraulic leg jam nut tightly,
and release the pressure of hydraulic leg cylinder. If it needs to operate for a long
period, the surface of the oil cylinder screw rod should be painted with lubricating
grease, to avoid rusting.
 Adjust mechanical jack: adjust the mechanical jack and Y type support jack to the
supporting condition, lock the nut tightly. If it needs to operate for a long time, the
screw surface of the oil cylinder should be painted with lubricating grease to avoid
rusting.
 Connect adjusting screw: connect the adjusting screws between the mast base and the
carrier, between the mast base and the Y type support, and between the Y type support
and the substructure; and adjust to tighten.
 Install other accessories.
4.3.3 Check work after installation
 Align the tail beam centre of the truck frame with the wellhead centre.
 The distance between the leg cylinder centre of the mast tail beam and the wellhead
centre is 3182mm.
 The distance between the chassis tire and the ground is 10～15mm.
 The main beam of the truck frame is in the horizontal status.
 The compound transfer case is in the operation status.
 The operational control valve of the hydraulic and pneumatic system is in the proper
position.
4.3.4 Necessary work after the rig is in its place
 Place the rig on the working position, for left and right, the distance from the tires to
both sides of the ship type substructure should be equal, for front and rear, the distance
from tail beam leg cylinder center to well head center should be 3182mm.
 Move the handle of the compound transfer case to the operation position (at this time,
—62—
the dual-lock valve moves along with the control handle and supply air to the truck,
and the chassis stop air supplying).
 Put the shutting control valve of the torque converter in the operation position.
 When the air pressure reaches more than 0.7MPa(100psi), engage the hydraulic pump
to make the transmission case in the neutral position.
 Level the whole unit by controlling the hydraulic leg control valve, and make each tire
below the bearing load. Support the mast, mechanical leg of the Y type supporting
base, locking hydraulic leg, connect the transmission shaft between climbing chain
cases, to make the transmission shaft connecting with the climbing chain case in the
horizontal position.
 Adjust and lock tightly the adjusting screw connecting the front-end of the truck and
mud boat, the rear part of the truck and the mast base.
 Put down the pedal, install the pedal well at the clutch shield of drawworks, connect
the handrails and install the ladders.
 Raise the brake crank, and loosen the brake in low position.
4.3.5 Substructure hoisting
（The detailed documentation can refer to DZ180/6 Substructure Service Manual.）
4.3.6 Installation of the water circulating system
Place the circulating water tank at the driller’s side of the rig along the axes line of the
drawworks, connect the water circulating pipeline. Connect the water outlet pipeline of the
water pump to the water inlet connected with dual-purpose swivel and the auxiliary brake;
leave the other pump as spare. The backwater gap is corresponding with the location of the
pump. Before making a trip, turn on the power source at first to start the water pump.
Note:In the process of the operation, it is not allowed to start the water pump
suddenly when the temperature of brake hub is too high.
4.3.7 Installation of the carrier auxiliary accessories

 Connect the mast guy rope, escape device and steel wire rope.
—63—
 Install the movable platform on the upper part of the climbing chain case, and install
the handrail.
 Install unions on the mud standpipe, and connect the rotary hose well.
 Install lifting rope of the balance hydraulic cylinder.
4.4 Commissioning stage

4.4.1 Checking
 Check if the transmission shafts, locking pins, bolts on the truck has looseness,
damage or other problems.
 Check each lubricating part, and fill with the lubricating oil and grease according to
the requirement in time.
 Check the height of each oil level, the liquid level height of the water tank, the height
of the fuel level.
 Check each kind of the control handle is in the proper position.
 Check whether the pipelines, joints, valves and instruments of the hydraulic and
pneumatic system is complete and in good condition.
 Check that the lines and joints of the hydraulic and pneumatic system are connected
reliably without loosening and leakage.
 Check that the brake system of the double drum operates flexibly without loosening,
blocking and other faults.
 Check that all kinds of steel wire ropes are not flattened, worn, or wire fractured etc.
 Check that there is no foreign matter and attached parts are not loosened, etc.
4.4.2 Commissioning
4.4.2.1. Engine running
See details in CAT Diesel Engine Operation Manual, and CAT Diesel Engine
Operation and Maintenance Manual.
4.4.2.2. Hydraulic transmission case running
See details in Allison Hydraulic Transmission Case Operation Manual and Allison
Hydraulic Transmission Case Operation and Maintenance Manual.
—64—
4.4.2.3. Mast hoisting

A：Natural condition
 Visibility: the visibility should not be less than 40m in daytime.
 Wind power: the wind power should not be more than level 4, and the wind speed
should not be more than 10.8m/s.
 Temperature: the temperature should not be less than -4℃; when the temperature is
lower than -4℃, it shoul d be operated according to the recommended method of
API-4E low temperature workover rig.
B：Hoisting the low section of the mast
Note: before hoisting mast, make sure to loosen the locking bolts connecting mast
and front support, or the mast may not be hoisted.
 Check to confirm that the carrier frame is in leveling condition.

 Check and confirm to lock the support jack nut tightly and rotate the adjusting screw
tightly after the Y type support of the mast is at 3° dip angle.
 Check that the guy rope and the ground anchor conform to the requirements of the
load.
 Check the locking device of the upper and low sections should rotate flexibly without
blocking.
 The rotary speed of the engine should be controlled within 800～1000rpm.
 Engage the main pump of the hydraulic system, operate the hydraulic system with idle
running for 5 minutes, and drain air in the system away.
Note:Before hoisting headgear, first row to the best of the hydraulic

system and the air in the cylinder.
 Check the pressure in the hydraulic and pneumatic control system should reach the
working pressure.
 Operate the control valve of the raising hydraulic cylinder, lift this control valve
handle to increase pressure to 2MPa, open and control the exhaust switch valve of the
—65—
raising hydraulic cylinder. When the oil liquid of the hydraulic cylinder air outlet
reaches to the line, it proves that the air in the cylinder has been evacuated. Close the
air exhaust valve to make the operational handle in the neutral position.
 Try to raise the mast
a：Operate the control valve handle of the raising hydraulic cylinder slowly to make
the mast deviate from the front support about 100mm, and then the handle is back to
the neutral position, the mast is in static position, observe the raising hydraulic
cylinder and other parts of the hydraulic system should not leak and the pressure of
instruments should be normal. Press the valve handle down slowly, and lower down
the mast.
b：Operate the control valve handle of the raising hydraulic cylinder slowly again to
make the mast deviate from the front support about 200mm, and then the handle is
back to the neutral position, the mast is in the static position, observe the raising
hydraulic cylinder and other parts of the hydraulic system should not leak, there is no
gliding phenomenon for the mast, the pressure of instruments should be normal. Press
the valve handle down slowly, and lower down the mast.
c：The valve handle is lifted slowly to make the second stage plunger of the raising
hydraulic cylinder output 10mm, the handle is back to the neutral position, the mast
keep static for 3 minutes; observe that each part of oil cylinder in the hydraulic system
should not have the leakage phenomenon, there is no interfering and gliding
phenomenon for the mast, and the pressure shown on the pressure gauge should be less
than 14MPa. Press the valve handle down slowly, and lower down the mast.
 Lift the valve handle slowly, and raise the mast smoothly and steadily. Observe the
raising order of the raising hydraulic cylinder, and the right extended order should be
the one-stage plunger piston firstly, the two-stage plunger piston secondly, and the
three-stage plunger piston at last. During the transition period of each cylinder
extension, it should be operated slowly to avoid impacting.
 When the mast is raised to nearly vertical position, reduce the opening of the handle
correspondingly, and reduce the needle type check valve“D” opening of the piston
—66—
rod oil return circuit. When the mast gets over 90°, locate the mast on the Y type
support slowly through controlling the needle type check valve“D”, tighten up the
locking bolt between the mast and Y type support in time, adjust the screw jack of the
Y type support to let the screw locate on the basic support of the mast, tighten the
locknut well, fix the windproof guy rope of the low section well, and the guy rope
verticality should be 150mm±50mm.
Note: In the process of mast raising, it should always operate the brake, and
the rope of traveling hook system should be in the proper tenseness degree to avoid
troubles of mast raising.
C：Extension of the mast upper section

 Confirm that the doublication of the mast upper and lower sections should be painted
with lubricating grease.
 The hook falls at the proper position to avoid impeding the mast upper section
hoisting.
 Before operating to extend the mast upper section, air in the telescopic hydraulic
cylinder should be discharged. Shut down the needle valve, open the air discharge cap
on the top of the telescopic hydraulic cylinder, uplift the operational valve handle of
the telescopic cylinder slightly, keep the pressure of pressure gauge not more than
1MPa, fill the hydraulic oil in the oil cylinder and evacuate the air in the oil cylinder.
Repeat it several times to ensure that the air in the oil cylinder should be evacuate,
tighten the air discharge cap, and then place the valve handle back to the neutral
position.
 Try to extend for the mast upper section:
a：Uplift the control valve handle of the telescopic hydraulic cylinder to extend the
mast upper section slowly about 300mm～400mm, place the handle back to the
neutral position, and keep the mast static for 5 minutes.
—67—
b：Observe whether the telescopic cylinder, each pipeline and others in the hydraulic
system have the leakage phenomenon or not, observe whether pressure of the pressure
gauge is normal or not, observe whether there is intervening, dragging and other
phenomenon, observe whether the uplifting of the mast upper section has serious
climbing phenomenon or not.
c：When lowering the mast upper section, the action should be normal without
abnormal phenomenon.
 Operate the control valve of the telescopic hydraulic cylinder, uplift the telescopic
cylinder slowly to 200mm～300mm, observe there is no motion phenomenon and then
continue to uplift; if it has the motion phenomenon, it proves that the air may be
contained in the hydraulic cylinder, and then repeat the air discharge operation of
hydraulic cylinder mentioned above.
 In the process of uplifting, pay attention that the pressure shown on the pressure gauge
should be less than 14MPa.
Note: if the pressure value is more than 14MPa, the mast upper section
cannot stretched out immediately, inspect whether the mast wire should be twined or
whether there is blocking of components between the mast upper section and the
lower section or not.
 Observe whether the centralizer can work normally or not; when the centralizer cannot
be open in time, it should stop telescoping the mast, and lower down the mast. After
check and eliminate the faults, it can continue to uplift the mast upper section.
 At the time that the mast is stretched out, please pay attention to operate the draw
works, and keep the height from the traveling hook system to the substructure within
2～3m.
 When the mast upper section is nearly to its position, it should reduce the opening of
the handle, and decrease the uplifting speed of the mast upper section. Inspect the mast
—68—
upper section visually lifting to position higher than the bearing position until the
bearing block is popped out normally, place the handle of the operational valve in the
neutral position, and then open the needle valve, put the mast upper section down
slowly, locate the bearing block on the bearing beam completely, finally shut down the
needle valve.
 After the mast upper section is placed in its position, climb on the mast, inspect
visually that the latching device should be stretched out completely and placed in its
position correctly. Insert the safety pin, switch on the lighting and signal circuit.
 Adjust the dip adjusting screw, adjust the mast dip to achieve the usage requirements,
align the centre of the traveling hook system with the wellhead centre, and then lock
the adjusting screw among the mast base, the carrier, substructure and mast
 Install the high position driller console; connect the brake pull rod of high position, to
align with the high position brake.
 Operate the control handle of the six-up valve, and place the handle of working
condition selector valve in the neutral position. Open the needle type valve C, E on the
control panel, unload the raising hydraulic cylinder and the telescopic hydraulic
cylinder.
 Use the adjusting screw to tighten the guy rope with load outside the front support in
the front of the mast, fix 4 pieces of the mast upper section windproof guy rope on the
anchor pile, and the verticality of the guy rope is 150mm±50mm.
 After the mast is raised to the operational condition, the plunger and piston rod, which
are stretched out from the lifting cylinder, should be painted with the lightweight
grease or protected by the waterproof and fire-proof canvas to prevent them from
rusting.
4.4.2.4. Lower down the mast
 Loosen all guy ropes, lightings and signal circuit joints on the mast.
 Check to confirm that the centralizer is not damaged.
 Climb onto the mast and pull out the safety pins.
 Control the rotary speed of engine within 800～1000rpm.
—69—
 Engage the main oil pump of the hydraulic system, and operate the hydraulic system
with idle running for 5min to discharge the air in the hydraulic system.
 Before lowering down the mast, firstly shift the driller brake crank to the low position
from the high position, and then demount the brake pull rod.
 Try to stretch the mast upper section out and control the valve handle to keep the
pressure of the pressure gauge is 7.5Mpa, then the mast upper section will be raised
and stretch out slowly about 50～100㎜, keep the mast at this status for 5 min and
observe whether there is leakage on the telescopic hydraulic cylinders and pipelines of
hydraulic system and check whether there is interference and jamming between parts
and mechanisms.
 Lift up the control valve handle of the telescopic hydraulic cylinder from the neutral
position to make the mast upper section stretch out 50～200㎜, open the needle valve
after the load-carrying block retracting, and the mast upper section will be retracted
slowly; Shut off the needle valve after the mast upper section is completely retracted.
Note: In the process of the mast upper section retracted, the draw works
should be always operated to place the traveling hook system in the proper position;
after the mast upper section is retracted completely, the hook should be near to the
substructure and fix, if the mast is not be laid down.
 Unscrew the locking nuts of mast lower section.

 Open the venting plug of the raising oil cylinder and manipulate the reversing valve of
the lifting hydraulic cylinder to keep the pressure of pressure gauge no more than
0.5Mpa, then inject hydraulic oil into the oil cylinder and evacuate the air in the oil
cylinder. Do the operating steps repeatedly to make sure that the air in the oil cylinder
is exhausted completely, and shut off the switch valve and press down the valve
handle, and then the mast will be lowered down steadily.
 The normal retraction sequence of the lifting oil cylinder is three-stage plunger piston
—70—
firstly, two-stage plunger piston secondly and one-stage plunger piston last. If not, stop
retracting and remove the fault.
 Operate the main drum to locate the hook onto the hook bracket box.
 When lowering the mast down to the position about 200～500㎜ above the front
support, slow down the lowering speed to make the mast be lowered on the front
support slowly.
 After lowering down the mast steadily, operate the control valve to unload the lifting
oil cylinder and telescopic oil cylinder.
4.5 Operation stage

4.5.1 Power system
There is engine electric switch equipped in the cab and on the driller’s control case.
The left and the right engine have one set separately, which is set with starting, operation
and flameout position.
 Before starting the engine, put the key into the electric switch to switch to the
operation position clockwise, and then rotate it clockwise with 45° once more. After
starting the engine, the hand should be released immediately, and the key will be back
to the operation position automatically.
 The starting/ flameout switches have the continuous function without intervals. If the
engine is not started successfully, when restarting, the key cannot be rotated clockwise,
but it should be rotate counterclockwise with 45°, and return to its position to run so
that the engine can be started clockwise.
 When the engine is shut down, the key should be rotated counterclockwise 45°, after
flameout, it can be released, and then the key will be back to the operation position
automatically.
 Under the emergency condition, press the emergency flameout button of the engine
directly to shut down the engine.
4.5.2 Compound transfer case
Take reasonable match for power according to the actual load during operation.
—71—
 When the rig is working or rotary drilling with maximum hook load less than 1150kN
(257600 lbf), the single engine can meet the power demand. Choose the needed engine,
control the transmission box to put the handle on neutral position, and engage the
manual disengagement &engagement device of the parallel box to connect the engine.
 When the rig is working or rotary drilling with the maximum hook load more than
1150kN (257600 lbf), suggest the two sets of engine to work simultaneously. Choose
the needed engine, control the transmission box to put the handle on neutral position,
engage the handles on both ends of the parallel case on the responding engine
respectively, then the double engines can provide power for drilling operation
simultaneously.
4.5.3 Hoisting system
Hoisting system mainly consists of drawworks, crown block, traveling block hook
and steel wire rope.
4.5.3.1 Selection of gears
 Choose the single engine or double engines operation, gears of transmission box and
the hoisting speed of travel hook according to the hook load.
 When shifting gears, the engine should be on idling state, and the traveling hook is
non-loaded.
4.5.3.2 Operation of main drum
The main drum is mainly used for twining the steel wire rope of the winding traveling
block, to drive the movement of the traveling block hook.
The rotation of the main drum is achieved through operating the control valve of the
clutch on the driller case, and the detailed operation can refer to the 3.4.1 related
instructions.
4.5.3.3 Brake control of the main drum
When the hook stops moving, release the combination valves handles of the main
drum controlled by main drum with left hand, the handle will return to the neutral position
automatically, the main drum clutch disengages and the engine returns to idling running.
Tense the brake handle of the band brake with right hand to make the hook still.
—72—
The hook falls down depend on its own weight, and control the band brake handle to
control the dropping speed.
4.5.3.4 Operation of the auxiliary brake
The auxiliary brake is controlled by a two-position & three-way valve. Operate the
valve handle to make the auxiliary brake engaged to brake or disengaged to stop braking.
The air pressure in the auxiliary brake air chamber can be controlled by operating the
pressure regulation valve handle, which can realize the adjustment of the brake torque.
4.5.3.5 Sand drum and its brake control
Like the main drum, the sand drum is also controlled by a combined pressure
regulating valve that can control the clutch and the accelerator. The only difference is that
this pressure regulating valve is mounted on the drawworks frame on one side of driller. Its
brake operation is in the same position correspondingly. The brake control and adjustment
principle for the sand drum is as same as that of the main drum.
4.5.4 Rotary system
Rotary system mainly consists of the rotary table and swivel.
4.5.4.1 Power control
Before operating the rotary table, please firstly engage the rotary table power. There’s
selection handles of “rotary table working condition” on compound transfer case.
 When the operating handle is in “On” position, the power of engine will transmit to
the transmission system of the rotary table.
 When the operating handle is in “Off” position, the power of engine will be cut off
with the transmission system of the rotary table.
4.5.4.2 Control in forward and reverse
The gear case of the rotary table transmission box is equipped with “forward and
reverse” operational handle, which has two operational positions: forward and reverse.
 When the operational handle is in the “forward” position, the rotary table is rotated in
forward.
 When the operational handle is in the “reverse” position, the rotary table is rotated in
reverse.
—73—
Note: when operating the reversing handle, the input shaft of the gear case
should stop rotating completely; otherwise, it will damage the gear of the gear case.
4.5.4.3 Control of rotary table

The control of the rotary table is achieved through controlling the transmission case of
rotary table.
The operation of the rotary table transmission case is done through the rotary table
control valve andreaction torque release control valve on the driller’s console. Unscrew the
hand wheel of the reaction torque release control valve to the maximum degree when
working.
The rotary table control valve is a three-position & four-way valve.
 Push forward the control valve handle to engage the clutch of the rotary table
transmission case, which can drive the rotary table to rotate.
 Put the control valve handle in the neutral position, the clutch will be disengaged, and
then the rotary table is in free status.
 When the rotation and drilling operation is stopped, push the control valve handle of
the rotary table downward, the main air will supply air to the inertia brake through the
control valve of rotary table so that it can stop the rotary table and corresponding
transmission parts reversing due to the deformation energy release of the drill pipe to
avoid the damage of the transmission components. Place the control valve handle of
the rotary table back to the neutral position so that the deformation energy of the drill
pipe will be released slowly.
4.5.5 Hydraulic, pneumatic circuit and electric control system
4.5.5.1 Hydraulic system

According to the principle of centralized control for this rig, hydraulic winches, tong
—74—
cylinder control valve are all installed beside the driller’s control cabin where they are
easily to be controlled by the driller. For the raising hydraulic cylinder, telescopic
hydraulic cylinder and hydraulic supporting legs need not to move when working, its
control valve is installed in the operational case on the truck. These two operation positions
use interlock loop.
 There is a three-position & four-way valve used for controlling the engagement and
disengagement of the hydraulic pump on the driller control cabin. When pulling the
control handle upwards, the left oil pump will work; when pulling the control handle
downwards, the right oil pump will work; when pulling it back to the neutral position,
both the left ＆right oil pump will not work.
 The reversing valve of the hydraulic winch controls the rotary direction of the
hydraulic winch drum on thequintuplet-valve control panel. When pulling the control
valve handle upwards, the hydraulic winch drum rotates clockwise to hoist the heavy
objects; when pulling the control valve handle downwards, the hydraulic winch drum
rotates anti-clockwise to lower down the heavy objects; when loosening the handle, it
can reset automatically.
 The stretching out and retraction of the hydraulic cylinder piston rod is controlled by
the control valve of the tongs hydraulic cylinder on thequintuplet-valve control panel;
when pulling the control valve handle upwards, the piston rod retracts back and the
screwing-on operation is finished; when pulling the control valve handle downwards,
the piston rod stretches out and the screwing-off operation is finished; when loosening
the handle, the handle goes back to the neutral position automatically.
The pressure of the overflow valve and other pressure adjustment parts in the
hydraulic system has been adjusted in the factory, so it is usually unnecessary to be
readjusted during the operation. The filter should be checked and cleaned periodically to
ensure the working reliability of the hydraulic system. The change of the hydraulic oil
should be determined according to the pollution degree of the hydraulic oil. The hydraulic
oil should be changed when the water weight ratio is higher than 0.05% or the dirtiness
—75—
degree is higher than 7～10mg/100ml.

4.5.5.2 Air control system
Air sourcecompressed air for the air control system is provided by an air compressor
on one side of the engine. There is a pressure regulating valve at the side of the air
compressor and the pressure is adjusted to the limited pressure before delivery. If the
pressure is lower for the user, it can be adjusted. The method is to remove the end cap,
rotate the adjusting stud inside anticlockwise in order to increase the pressure; to do the
reverse operation in order to decrease the pressure. There is an auto load-discharge device
inside the compressor. Once the pressure in the pulsation dampener researches the rated
limit, it can be feedback into the compressor through the pressure regulating valve and the
compressed air will be circulated between the two cylinders to make the compressor work
without load.
Compressors of two engines are parallel structure, check valves are installed at
exhaust ports of each compressor to avoid compressed air flowing back.
The total capacity of the air storage tank is 340L （90US gal）, and the set pressure of
its safety valve is 1.0 Mpa（150Psi）. There is a water drain valve at the bottom of the air
reserve tank, the water should be drained once each day and drained two times in winter.
The main gas circuit is equipped with the compressed air processing triple part, the
installation sequence is the pressure regulating valve, air filter and oil fog device and there
is coagulation preventer behind the oil fog device. The working air pressure of the pressure
regulating valve has been adjusted to the specified value before delivery, so that the user
needs not to adjust it additionally.
The working pressure of the air filter is 1MPa and the Max. working temperature is 52℃
（137℉）. There is a drainage valve, which is controlled manually or automatically at the
bottom of the air filter. If the manual drainage is used, it needs to be drained periodically.
During the maintenance of the filter, close the air inlet firstly to decrease the pressure in
the container and pipeline to zero. The plastic container only can be washed by the warm
water and other components can be washed by warm water and the soap water. Blow
towards to the filter core in the opposition direction of the airflow; remove the foreign
—76—
materials on the surface and dry components and the internal hole of shell with dry and
clean compressed air.
Pressure reducing valve and filter combines a single unit, which not only can ensure
the stability of the working pressure in the air way system, but also can filter the dirt, pipe
scale, and rust and condensate water in the upstream compressed air. The filtration
precision of the system is 40μm.
The oil fog device adopts the automatic variable throttling structure type, spraying the
oil fog into the compressed air evenly. The regulator ensures the oil fog amount is in
proportion to the flow of the compressed air. It causes the pressure loss when the
compressed air passes the Venturi nozzle to force the oil into the oil viewer from the oil
cup; the oil enters into the input port with the compressed air, and then is fogged at the
same time. The oil dip amount can be adjusted through the adjusting screw. Generally, it is
enough that 1000L（264 US gal） gas contains 1-12 drops.
The anti-condensation device is used to keep the air way system work normally. The
air flow is through theethanol anti- condensation device and takes the volatilized ethanol
away in order to prevent the pipelines and pneumatic elements from being freezed.
Note: Before filling with the ethanol, it should be shut down the ball valve in
front of the anti-condensation device to cut off the air circuit of the
anti-condensation device. When making sure that there is no air
pressure in the anti-condensation device, it can open the sprue to fill
the ethanol.
4.5.6Spare steel wire ropes

There are 3 ways for judging the service life of the main steel wire line as following.
A．It should cut the part of the steel wire ropes if the broken wire happens.
B. The unit for measuring the service life of the wire rope is Ton-Mile.
 Measure and record the following “Ton-Mile”.
①Ton-Mile for tripping ②Ton
out ③Ton
-Mile for drilling -Mile for coring
—77—
④Ton-Mile for running casing

You can get all the values above in America Drilling Manual. The value varies
in accordance with the difference of well depth, weight and mud proportion.
 The steel wire rope should be cut off for 80ft once the sum of the values above reaches
600-900Ton-Mile, in order to prolong the service manual of the steel wire rope, the
cutting plan should be selected and adjusted within 600 to 900Ton-Mile until it finds
the most appropriate point.
C． The service life of the wire rope is measured with Ton-Mile.
 Ton-Mile for running casing
 weight of string of casing in the air weight of hook assembly  well depth
 × mud buoyancy factor +  × 1000
 1000 1000 
 Ton-Mile for the round trip

 weight of drill collar and drill pipe in the air weight of hook assembly  well depth
 × mud buoyancy factor +  × 1000
 1000 1000 
 Ton-Mile for drilling and coring

 When drilling：3×(the wire rope Ton-Mile of this round trip-the wire rope
Ton-Mile of last round trip)
When coring：2× (the wire rope Ton-Mile of this round trip - the wire rope
Ton-Mile of last round trip)
 According to the sum of the above value to adjust with 600-900 ton, the value of
ton-mile is within the range of 875-1313 ton-kilometer. When reducing 80 feet, it
should reduce 24-25m in metric system.
4.5.7 Mud circulating system and the auxiliary equipment
For details, please refer to the relevant service manual & operation instructions of
mud circulating system. User also can propose the specified requirements for mud
circulating system according to the drilling technology needs.
—78—
4.6 Completion of the operation

4.6.1 Drag the whole set of the workover rig
The workover rig can take advantage of the skid-mounted function to transport from
one well to another when it comes to cluster wells. The steps are as following:
 Unfasten all the guy ropes of mast, retract the upper section of the mast, and then
lower down the low section of the mast.
 Loosen the transmission shaft used for connecting the carrier and substructure and the
adjusting lead screw used for connecting the mast and substructure, and then drive the
carrier.
 Remove the connecting pieces used for connecting the substructure to ground or the
other systems, such as ladders, escape slide, ramp and mud pipelines, etc.
 Connect the wire rope at rear end of the bulldozer’s tow bar with substructure’s tow
bar, and then use the towing machine of the bulldozer to drag the carrier to move its
substructure to the new well position.
 After the substructure of the carrier is located at the new well position, connect the
relevant transmission shaft and adjusting lead screw, etc.
 Raise the mast, fix all the guy ropes, and connect well all the connecting pieces used
for connecting the substructure to ground or the other systems, such as ladders, escape
slide, ramp and mud pipelines, etc.
 Lengthen the mud discharge pipeline; connect well all the pipelines of the mud
circulating system and well control system.
4.6.2 The movement and transportation of the workover rig
4.6.2.1 Preparation for the movement and transportation

After the operation is finished, prepare to move and transport the workover rig.
 Demount the adapting pieces used for connecting the workover rig with the solid
control system, the well control system and other accessories, and demount the mud
return pipeline.
—79—
 Lift down the BOP, and demount the movable platform between substructure and
mast.
 Shift the brake position of the main drum from the high brake position to the low
brake position.
 Switch the hydraulic power, and adjust the working condition of the hydraulic system
to the “adjustment” working condition.
 Retract the mast upper section and lower down the mast.( For details , please refer to
the mast raising ＆lowering down operation instruction).
 After lowering down the mast, fix the mast upper section at both sides of the mast
front bracket with bolts to avoid vibration during transporting.
 Collect accessories such as the mast guy rope, escape device, anti-falling device, etc.
 Demount all adjusting pull rods of chassis, mast and mast base, and substructure.
 Demount the input transmission shaft of the rotary table.
Note: the bolts and nuts, which are used for the transmission shaft, are the
dedicated and high strength parts. After demounting, they should be
kept properly to avoid mixing with the other normal bolts and nuts.
 Unscrew the locknuts between mechanical jacks and hydraulic landing legs, and
retract the mechanical jacks and hydraulic landing legs successively, and then remove
the jacks and landing leg’s support.
 Cut off the power of the main hydraulic system. Regulate the control valve handle of
the hydraulic pump to the neutral position, then the hydraulic pump stops working;
Open the needle valve “C”and “E”on the six-up valve operating panel to unload the
main hydraulic system.
 Switch the power working condition of the chassis engine to the driving working
condition.
 Switch the air control system to the chassis driving part.
 Cut off the lighting connecting circuits between chassis and mast and between chassis
—80—
and substructure.
 Check if the status of the chassis hydraulic ＆ pneumatic and electric control systems
and the relevant transmission systems can meet the working condition requirement of
the chassis driving.
 Pack up the walkway and railings on the chassis , and then the carrier reaches at the
moving＆transporting status.
 Lower down the substructure and fold it.
For details, please refer to the service manual of DZ180/6 substructure.
4.6.2.2 The movement and transportation of the rig
When moving or transporting the workover rig, it should be considered that the road
condition. Because the height of the carrier is 4.8m（15.75ft）.If there is height limited,
detach the racking platform to transport. If it is necessary, detach the mast and transport
it separately.
Platform trailer is the best choice while travelling. The pump units, tanks of solid
control system, water tank and the duty room can be pulled onto the truck either by the
crane or by the dedicated trailer. If the proper means of transportation is adopted, 3000m
drilling rig can be completely moved & transported, mounted and carry out the drilling
operation at the same day within well space of 40 ~60 km (25-37mile)
4.7 Parking and safekeeping of the rig

If the workover rig is not be used for a long time, its relevant transmission parts
should be lubricated, the engine should be maintained periodically.
If the workover rig will be stored for more than half a year, please clean the workover
rig, and demount the mast on the carrier. And drain out the cooling water in the water
circulating system completely.
The power unit should be covered with canvas. When parking the carrier, its
hydraulic landing legs should be stretched out, and the ground clearance of tire should be
no less than 30mm to avoid tires damage caused by the long-term heavy load. Discharge
the pressure in the hydraulic system, paint lubricating grease onto the stretching out parts
—81—
of the hydraulic landing legs to avoid rusting.
Warning: After the engine of the carrier is shut down, if the parking time is
too long, it needs to let the hydraulic leg stretch out, otherwise the truck frame will be
deformed permanently.
—82—
Chapter Five Product Package and Transportation
5.1 Product transportation method
ZJ30 rig is mainly divided into the carrier and mating accessories. The highway,
railroad and waterway transportation are available according to user’s requirements. The
railroad transportation should be taken as the key style in the long-distance, the highway
for the short-distance transportation, and the railroad or waterway transportation for
international transportation. And the user can select the economic and suitable
transportation method according to the actual condition.
5.1.1Highway transportation
It is recommended to adopt the self-propelled type of the whole truck to reach at the
ultimate destination under the condition of the unblocked main road within about 1000
kilometers. Without the need of packing, the mast and the hook can pickaback
automatically; the other standard configuration accessories should be transported by two
sets of 15-ton trucks and one set of 30-ton semi-trailer. When the carrier is driven with
self-propelled type,the traveling speed is designed for 35～60 kilometer per hour, with the
clear height of 4.7 meter, the load of the single front axle is less than 10 tons, the load of
the single rear axle is less than 13 tons to meet all the requirements of the highway bridge
& culvert’s height and the ground bearing capabilities
The size of the transportation status for the carrier can refer to the figure 5-1, the
length of the whole truck is 21.9m, its width is 3.71m, the height is 4.8m, the minimum
turning radius is 19.3m, and the maximum climbing gradient is 17%.
—84—
Fig 5-1 State diagram of overall transportation for the ZJ 30/1800CZ
5.1.2 Railway transportation

The railway transportation is suitable for the long distance transportation. In general,
the whole set shall be divided into three parts: the carrier (self-propelled chassis and
operating mechanism on the truck), mast and accessories (hook, swivel, substructure,
rotary table, mud boat, etc.). It will use 5~6 carriages generally. The mast, the carrier and
the large accessories shall be transported in nude (to prevent the accessories from losing or
damaging, the carrier can adopt the packing plate to pack the main accessories) and be
painted the clearly lifting marking. The small accessories can be packed by the wooden
case.
The weight of the carrier is 42 tons when transporting and hoisting, the carrier can be
driven in from the load and unload platform or can be hoisted by the hoisting equipment.
The weight of the mast is 25t, and it can be hoisted by the hoisting equipment which is not
less than 30t
—85—
Carrier Sub & RT Mast Travelling Stairway and other Mud boat,
hook & swivel accessories catwalk, ramp
Flat car1 Flat car2 Flat car3 Flat car4 Flat car 5 Flat car6
Fig 5-2 Train transportation loading reference diagram for ZJ30/1800CZ
truck-mounted drilling ring
Carrier package：
 The carrier should be placed on the platform car consequently and evenly. The center
of gravity projects on the intersection point of the vertical and horizontal centre on the
truck.
 The brake apparatus should be in the braking status, the transmission should be at the
initial speed, the braking handle should be bounded and fixed together with the pull
rod by iron wire. The carrier should be fixed by the triangular wood and strengthened
by the iron wires.
5.1.3Waterway transportation
Waterway transportation is mainly used for the ocean transportation of product export.
It is shipped at the inland port or the coastal port, and then transported to the destination by
the international oceangoing freighter.
When shipping, the whole set shall be divided into three parts: the carrier
(self-propelled chassis and operating mechanism on the truck), mast and its accessories
—86—
(hook, swivel, substructure, rotary table, mud boat, etc). The mast, the carrier and the large
accessories shall be packed by the packing plate and painted with the clearly lifting
marking. The small accessories can be packed by the wooden case. The weight of the
carrier is 42 tons when transporting and hoisting, and the carrier can be driven in the port
or can be hoisted by the hoisting equipment. The weight of the mast is 25t, and it can be
hoisted by the hoisting equipment.
5.2 Transportation of the carrier on the oilfield site

The short-distance transportation on the oilfield site is the same as the highway
transportation basically. However, the following notices should still be considered as the
harsh terrain in the oilfield is more complex than highway：
 The driver of the carrier must read carefully the instructions about the self-propelled
chassis in order to make sure to drive correctly and safely.
 Avoid parking on the soft subgrade, especially at the side of subgrade to avoid sloping
and even overturning due to the large weight of the carrier. Please refer to Fig 5-3.
 Drive at a low speed when the road condition is not good.
 Check air pressure in the tires to make sure that it is in accordance with the inflation
standard.
Error！Correct！
Fig.7-3 Reference diagram of transporting in the oilfield site
—87—
Chapter Six Attached Drawing of the Truck-mounted

Rig
1. Stereoscopic plan of ZJ30/1800CZ truck-mounted drilling rig.
2. Carrier hoisting drawing of ZJ30/1800CZ truck-mounted drilling rig.
3. Mast installation diagram of ZJ30/1800CZ truck-mounted drilling rig.
4. Transmission system diagram of ZJ30/1800CZ truck-mounted drilling rig.
5. Air control principle diagram of ZJ30/1800CZ truck-mounted drilling rig.
6. Hydraulic principle diagram of ZJ30/1800CZ truck-mounted drilling rig.
7. Electric control principle diagram of ZJ30/1800CZ truck-mounted drilling
rig.
8. Electric appliance circuit diagram of ZJ30/1800CZ truck-mounted drilling
rig.
—88—
Technical parameters
1、Service depth: 1500～2500m(5"DP)；
1600～3000m(4-1/2"DP)；
2、Max static load: 1800KN；
3、Power system：
Engine： CAT C15×2
Transmission box： Allison M5620AR×2
4、Power of engine: 540HP（2100r/min）×2；
5、Main drum：
Max. fast line tension： 280kN；
Clutch model：： ATD-330H；
Diameter of wire line：∅ 32mm；
Auxiliary brake： WPT324；
Cooling type： Inner loop water cooling
6、Sand drum：
Max. fast line tension： 115kN；
Clutch model： ATD-124H ；
7、JJ180/38 mast：
Clear height： 38m；
Incline angle：： 3°
Monkey board height（to ground）： 22/23/24m；
Max. anti-wind ability： 110km/h（about 100 Class）
Travelling system: 5×6（∅ 32 wire line）
8、DZ180/6 substructure:
Working height： 6.0m
Rotary table： ZP275
9、Driving model： 14×8；
Minimum turning radius： 19.3m；
Approach / departure angle： 33°/17°
10、Travelling hook： YG250
11、Swivel： XSL225
12、Stand pipe： 4″
13、Rated working pressure of hydraulic system: 14MPa
14、Rated working pressure of air system 0.75～0.95MPa
15、Electrical control system：
Power source of carrier： 24V DC
Power/lighting source： 380V/220V 50Hz ～
Stereoscopic plan of ZJ30/1800CZ truck-mounted drilling rig
—89—
—64—
Hoisting beam Hoisting beam

吊装梁吊装梁
Hoisting instructions
 When hoisting, 2 sets of cranes, whose capacity are not less than 30T, are used to hoist.
 When hoisting, it must hoist front and rear hoisting beams, if it hoist another place, it is easy to damage the carrier and equipment on it.
 When hoisting, hoist the length of the wire rope properly to keep the carrier hoisting in the horizontal level.
Attached drawing 2 Carrier hoisting (without mast) drawing ofZJ30/1800CZ rig
—65—
Installation instruction
 When hoisting, 2 sets of cranes, whose capacity are not less than 30T, are used to hoist.
 When hoisting, two cranes can be used together to hoist, and make sure that the left and right of mast are hoisted in horizon.
 After aligning the pad eye pin shaft hole of the mast low section with the pad eye pin shaft hole of the rear bracket and Y type bracket, the pin roll can
be crossed.
 Before installation, the carrier should be adjusted to level.
Attached drawing 3 Mast installation drawing of ZJ30/1800CZ truck-mounted rig
—66—
Attached drawing 4 Transmission principle drawing for ZJ30/1800CZ truck-mounted rig
—65—
Attached drawing 5 air control principle drawing for the ZJ30/1800CZ truck-mounted rig
—66—
Attached drawing 6 hydraulic principle drawing for the ZJ30/1800CZ truck-mounted rig
—67—
Attached drawing 7 electric control principle drawing for the ZJ30/1800CZ truck-mounted rig
—68—
Attached drawing 8 Electrical appliance circuit for the ZJ30/1800CZ truck-mounted rig
—69—
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山东科瑞石油装备有限公司

ShanDongKerui Petroleum EquipmentCo.,Ltd

ZJ30/1800CZ Truck-mounted Drilling Rig

The service manual of ZJ30/1800CZ truck-mounted drilling rig is written by the

Any use, management, operation, maintenance and repair personnel of the

dead if not follow the operating steps or methods correctly;

destruction of the equipment if not observe the operating

steps or methods closely;

Note! Using for attention or separate explaination condition.

Basic Safety Guideline

 Qualifed operating personnel

When installing, operating, disassembling and maintaining this set of equipment,

When operating, maintaining or running the equipment, the unauthorized personnel

 High voltage maintenance

Before disassembling and maintaining the high-pressureloop elements, ensure that

 Illegal operation and maintenance

No part is allowed to have illegal disassembly and maintanance, even illegal

 Electric control maintanance

 Hot work requirement

 Tripping operations shall be forbidden under reverse gears.

Product Information and Major Configuration Table

Product specification: ZJ30/1800CZ

No. Name Specification Qty. Remark

1 Chassis 14×8 self-moving chassis 1 set

5 Angle transmission box 1 set

Aircontrol and water

Rotary table transmission 5 forward and 5

10 Deadline anchor JZG24 1 set Weight indicator:

11 Driller control box 1 set

6m, 6 gin poles spiral

2 Rotary table ZP275 1 set

3 Climbing chain box 1 set

4 Catwalk 800mm 1 set

6 5T air winch 1 set

III Mast part

38m, two sections

2 Crown block TC180 1 set

3 Monkey board 1 set

6 0.5T air winch 1 set

1 Main drum wire rope 6×19S-IWRC-32-EIPS-RL 1 pc L=1000m

2 Traveling block & hook YG250 1 set

3 Single arm elevator link DH-250 1 set

4 Swivel XSL225 1 set

5 Rotary hose 4″ 1 pc L=17.5m

6 Escape device 1 set

7 Anti-drop unit TS-30 1 set

8 Climbing assist device ZPQ-00 1 set

specification, be subject to the actual.

1.1. Basic information of rig .....................................................................................................................1

CHAPTER TWO MAIN TECHNICAL PARAMETERS ............................................................................7

2.1. Basic parameters ................................................................................................................................7

CHAPTER THREE INSTRUCTIONS OF MAIN YSTEM COMPONENTS ...........................................7

3.1 Power Unit ...............................................................................................................................................7

4.1 Movement for drilling rig.......................................................................................................................39

CHAPTER FIVE PRODUCT PACKAGE AND TRANSPORTATION.................................................... 84

5.1 Product transportation method ...............................................................................................................84

CHAPTER SIX ATTACHED DRAWING OF THE TRUCK-MOUNTED RIG ...................................... 88

Chapter One Product Overview

1.1. Basic information of rig

Gear parallel rig

Max. hook load 1800kN

1.2. General instruction of rig

SY/T6584-2012 truck-mounted drilling rig ,SY/T6724—2008 the basic configuration