Air Suspension Lines and Related Components for ZJ40 Truck

1

Z08130000003AA

Air suspension lines

Galvanized carbon steel pipe + NBR inner lining

1. Corrosion from drilling dust and moisture; 2. Vibration-induced pipe fatigue and cracking; 3. Wear from friction with other rig components.

1. Regularly clean the pipe surface to remove dust and debris; 2. Secure the pipe with supports to reduce vibration; 3. Avoid direct friction by adding protective sleeves at contact points.

2

Z08330300176AA

Hose assembly 10 L=1000

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Aging and hardening of outer layer due to extreme temperatures; 2. Internal wire breakage from excessive bending; 3. Leakage at joints due to vibration-induced loosening.

1. Avoid bending the hose at angles less than 90°; 2. Keep the hose away from high-temperature components (e.g., exhaust pipes); 3. Inspect joint tightness weekly and re-tighten if necessary.

3

Z08330100348AA

Hose assembly 6 L=800

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Wear from contact with rough road surfaces during transportation; 2. Pressure fatigue from frequent air inflation and deflation; 3. Corrosion from salt spray in coastal areas.

1. Secure the hose with pipe clamps to avoid contact with the ground; 2. Ensure system pressure stays within 0.6-0.8 MPa (per API Spec 7K); 3. Apply anti-corrosion spray in coastal environments.

4

Z08330100349AA

Hose assembly 6 L=900

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Aging caused by long-term exposure to sunlight and rain; 2. Damage from foreign objects (e.g., rocks) during rig movement; 3. Joint leakage due to improper installation.

1. Cover the hose with a protective sheath when not in use; 2. Inspect the hose for cuts or abrasions before each use; 3. Use a torque wrench to tighten joints to the specified torque (15-20 N·m).

5

Z08330100350AA

Hose assembly 6 L=500

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Fatigue cracking from frequent vibration during drilling operations; 2. Inner layer damage from impurities in compressed air; 3. Outer layer wear from friction with rig cables.

1. Install a filter in the air supply system to remove impurities; 2. Separate the hose from cables to avoid friction; 3. Replace the hose if cracks longer than 5mm are found.

6

Z08330100351AA

Hose assembly 6 L=1200

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Excessive stretching during rig transportation on uneven roads; 2. Aging due to high humidity in tropical drilling areas; 3. Leakage at joints from corrosion.

1. Ensure the hose length is sufficient to avoid stretching; 2. Store spare hoses in a dry, ventilated area; 3. Apply anti-rust grease to joint threads regularly.

7

Z08330100352AA

Hose assembly 6 L=1100

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Damage from chemical cleaning agents used on the rig; 2. Vibration-induced joint loosening; 3. Outer layer cracking from low temperatures (-40℃ or below).

1. Avoid contact with corrosive cleaning agents; 2. Check joint tightness after each rig movement; 3. Use low-temperature resistant hoses in cold regions (optional upgrade).

8

Z08330100353AA

Hose assembly 6 L=700

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Wear from contact with rig tires during transportation; 2. Pressure fatigue from frequent suspension adjustment; 3. Dust accumulation leading to corrosion.

1. Keep the hose away from tire contact areas; 2. Avoid frequent unnecessary suspension inflation/deflation; 3. Clean the hose surface weekly with a dry cloth.

9

Z08330100354AA

Hose assembly 6 L=400

NBR inner layer + stainless steel wire braid + PVC outer layer

1. Damage from impact during rig loading and unloading; 2. Aging of inner layer due to long-term high-pressure operation; 3. Joint leakage from thread wear.

1. Protect the hose with a buffer pad during loading/unloading; 2. Monitor system pressure to avoid over-pressurization; 3. Replace joints if thread wear is detected.

1

QBJ6051402

M14X1.5-NPT1/4 fitting

Stainless steel 304

1. Thread wear from repeated installation and removal; 2. Corrosion from drilling fluid and moisture; 3. Vibration-induced loosening leading to thread damage.

1. Use a torque wrench to tighten (20-25 N·m) to avoid over-tightening; 2. Apply thread sealant during installation to prevent corrosion; 3. Avoid frequent disassembly unless necessary.

2

QBJ5071802

M18X1.5-NPT1/4 fitting

Stainless steel 304

1. Salt spray corrosion in coastal drilling areas; 2. Thread damage from improper wrench use; 3. Internal clogging from air impurities leading to pressure buildup.

1. Apply anti-salt spray coating in coastal environments; 2. Use a wrench with a proper fit to avoid slipping; 3. Regularly clean the fitting interior to remove impurities.

3

QBJ5071402

M14X1.5-NPT1/4 fitting

Stainless steel 304

1. Fatigue damage from long-term vibration; 2. Corrosion from humid drilling environments; 3. Leakage-induced erosion of thread surfaces.

1. Secure the fitting with a support to reduce vibration; 2. Apply anti-rust grease every two weeks; 3. Inspect for leakage using soapy water weekly.

4

QBJ806020202

NPT1/4 tee

Stainless steel 304

1. Pressure fatigue from multi-directional air flow; 2. Thread wear at branch connections; 3. Corrosion from dust and moisture accumulation.

1. Ensure system pressure does not exceed the fitting’s rated pressure (1.0 MPa); 2. Tighten all branch connections evenly; 3. Clean the tee surface regularly to remove debris.

5

QBJ10010403

NPT1/2-NPT3/8 bushing

Brass + nickel plating

1. Nickel plating wear leading to brass corrosion; 2. Thread damage from over-tightening; 3. Loosening from vibration causing air leakage.

1. Avoid using abrasive cleaners that damage the nickel plating; 2. Tighten to the specified torque (25-30 N·m); 3. Use a lock washer to prevent vibration-induced loosening.

6

QBJ5230303

NPT3/8 fitting

Stainless steel 304

1. Damage from foreign objects during rig movement; 2. Thread wear from repeated maintenance; 3. Corrosion from drilling chemicals.

1. Install a protective cover over the fitting; 2. Replace the fitting if thread wear exceeds 0.1mm; 3. Avoid contact with drilling chemicals.

7

QBJ5071803

M18X1.5-NPT3/8 fitting

Stainless steel 304

1. High-temperature aging in desert drilling areas; 2. Vibration-induced joint loosening; 3. Internal corrosion from moist air.

1. Keep the fitting away from high-temperature components; 2. Check tightness monthly and re-tighten if necessary; 3. Install a dryer in the air supply system to reduce moisture.

8

QBJ5111402

M14X1.5-ZG1/4" fitting

Stainless steel 304

1. ZG thread wear from improper installation; 2. Corrosion from underground water in wet drilling areas; 3. Leakage leading to pressure loss and fitting damage.

1. Ensure proper alignment during installation to avoid thread misalignment; 2. Apply waterproof sealant in wet environments; 3. Monitor system pressure to detect leaks early.

1

P7100190AA

Support

Q235 carbon steel + hot-dip galvanizing

1. Corrosion from drilling dust and moisture; 2. Fatigue cracking from long-term vibration; 3. Bending deformation from excessive load.

1. Regularly inspect for rust and repaint if necessary; 2. Ensure the support is properly aligned to distribute load evenly; 3. Do not exceed the support’s rated load (50kg).

2

P7100180AA

Bending plate

Q235 carbon steel + galvanizing

1. Bending fatigue from repeated vibration; 2. Corrosion from salt spray in coastal areas; 3. Cracking at the bending point due to improper installation.

1. Ensure the bending angle matches the line layout to avoid stress; 2. Apply anti-corrosion spray in coastal environments; 3. Inspect the bending point monthly for cracks.

3

P7100048AA

Support, shuttle valve

Q235 carbon steel + galvanizing

1. Vibration-induced loosening of fixed bolts; 2. Corrosion from drilling fluid splashes; 3. Deformation from valve weight and vibration.

1. Tighten fixed bolts weekly (torque: 18-22 N·m); 2. Install a splash guard to prevent drilling fluid contact; 3. Check support alignment monthly.

4

P6210207AA

Support, solenoid valve

Q235 carbon steel + galvanizing

1. Fatigue damage from solenoid valve vibration; 2. Corrosion from humid air; 3. Bolt wear leading to support instability.

1. Add a rubber gasket between the support and valve to absorb vibration; 2. Store spare supports in a dry area; 3. Replace worn bolts immediately.

5

P6210208AA

Support, pressure regulating valve

Q235 carbon steel + galvanizing

1. Pressure-induced vibration damage; 2. Corrosion from dust and moisture accumulation; 3. Bending from improper valve installation.

1. Ensure the valve is installed vertically to reduce pressure-induced vibration; 2. Clean the support surface weekly to remove debris; 3. Tighten fixed bolts monthly.

6

Z08410200043AA

Support, ball valve

Q235 carbon steel + galvanizing

1. Damage from ball valve operation vibration; 2. Corrosion from drilling chemicals; 3. Bolt loosening leading to support displacement.

1. Secure the support firmly to the rig frame; 2. Avoid contact with drilling chemicals; 3. Check bolt tightness after each valve operation.

1

4316705050

Bolt 5X50

45# carbon steel + zinc plating

1. Thread wear from repeated installation; 2. Corrosion from moisture and dust; 3. Fatigue breakage from long-term vibration.

1. Use a torque wrench to tighten (8-10 N·m); 2. Apply anti-rust grease to threads; 3. Replace bolts if thread wear is detected.

2

4309300005

Nut M5

45# carbon steel + zinc plating

1. Thread wear from vibration-induced loosening; 2. Corrosion from humid environments; 3. Damage from improper wrench use.

1. Use a spring washer with the nut to prevent loosening; 2. Clean the nut surface regularly; 3. Use a wrench with a proper fit.

3

4313000005

Spring washer 5

65Mn spring steel + zinc plating

1. Fatigue loss of elasticity from vibration; 2. Corrosion leading to cracking; 3. Deformation from over-tightening.

1. Replace spring washers every 3 months; 2. Avoid over-tightening to prevent deformation; 3. Store spare washers in a dry area.

4

4300808050

Bolt M8X50

45# carbon steel + zinc plating

1. Fatigue breakage from supporting heavy components; 2. Corrosion from salt spray in coastal areas; 3. Thread damage from foreign objects.

1. Do not exceed the bolt’s rated load (200kg); 2. Apply anti-salt spray coating in coastal environments; 3. Clean threads before installation.

5

4313000008

Spring washer 8

65Mn spring steel + zinc plating

1. Elasticity loss from long-term vibration; 2. Corrosion from drilling fluid splashes; 3. Cracking from improper installation.

1. Install the washer with the curved side facing the nut; 2. Replace washers if they become flat; 3. Avoid contact with drilling fluid.

6

4309300008

Nut M8

45# carbon steel + zinc plating

1. Thread wear from repeated tightening; 2. Corrosion from dust and moisture; 3. Damage from impact during rig movement.

1. Tighten to the specified torque (18-22 N·m); 2. Clean the nut regularly with a wire brush; 3. Install a protective cover if exposed to impact.

7

4300306040

Bolt M6X40

45# carbon steel + zinc plating

1. Fatigue damage from solenoid valve vibration; 2. Corrosion from humid air; 3. Thread wear from improper installation.

1. Add a rubber gasket to absorb vibration; 2. Apply anti-rust oil to threads; 3. Ensure proper alignment during installation.

8

4313000006

Spring washer 6

65Mn spring steel + zinc plating

1. Deformation from over-tightening; 2. Corrosion leading to cracking; 3. Elasticity loss from long-term use.

1. Tighten bolts to the specified torque (12-15 N·m); 2. Replace washers if cracks are found; 3. Store spare washers in a sealed container.

9

4300305016

Bolt M5X40

45# carbon steel + zinc plating

1. Thread wear from repeated maintenance; 2. Corrosion from wet drilling environments; 3. Breakage from excessive torque.

1. Use a torque wrench to avoid over-tightening; 2. Apply waterproof sealant in wet areas; 3. Replace bolts every 6 months.

1

P1200162AA

Flat nut M28X1.5

45# carbon steel + hot-dip galvanizing

1. Thread wear from vibration-induced loosening; 2. Corrosion from drilling dust and moisture; 3. Damage from improper wrench use.

1. Use a torque wrench to tighten (45-50 N·m); 2. Apply anti-rust grease to threads; 3. Use a socket wrench to avoid slipping.

2

QBJ11040330

NPT3/8" pipe clamp

Stainless steel 304 + rubber gasket

1. Rubber gasket aging from extreme temperatures; 2. Stainless steel corrosion from salt spray; 3. Clamp loosening leading to hose wear.

1. Replace rubber gaskets every 6 months; 2. Apply anti-corrosion spray to the clamp body; 3. Tighten the clamp to secure the hose without damaging it.

3

P6400208AA

Clamping piece

Q235 carbon steel + zinc plating

1. Corrosion from moisture and dust; 2. Fatigue bending from vibration; 3. Wear from contact with hoses.

1. Clean the clamping piece weekly; 2. Ensure the piece is properly aligned to avoid stress; 3. Add a rubber pad between the piece and hose.

4

P6400209AA

Clamping piece

Q235 carbon steel + zinc plating

1. Corrosion from coastal salt spray; 2. Deformation from excessive clamping force; 3. Wear from long-term use.

1. Apply anti-salt spray coating in coastal areas; 2. Avoid over-clamping to prevent deformation; 3. Replace if wear exceeds 0.2mm.

5

4600300022

Ball valve NPT1/2"

Stainless steel 304 + PTFE seal

1. PTFE seal aging leading to leakage; 2. Ball corrosion from moist air; 3. Valve handle damage from impact.

1. Operate the valve handle gently to avoid seal damage; 2. Regularly lubricate the valve core; 3. Replace the PTFE seal if leakage occurs.

1

Are all these components fully compatible with the ZJ40 truck-mounted drilling rig’s air suspension system? Can they be directly replaced without modifications?

All components are specifically designed for the ZJ40 truck-mounted drilling rig’s air suspension system, with dimensions, thread standards (NPT, ZG), and load capacities strictly matching the rig’s original equipment. They are 100% compatible and can be directly replaced without any modifications, saving maintenance time and ensuring system stability.

2

What is the service life of the hose assemblies, and how often should they be replaced under normal operating conditions?

Under normal operating conditions (8 hours daily, moderate environment), the hose assemblies have a service life of 12-15 months. In harsh environments (high temperature, high humidity, coastal salt spray), we recommend shortening the replacement cycle to 8-10 months. Regular inspection (weekly) is required, and any hose with cracks, bulges, or leakage should be replaced immediately to avoid system failure.

3

How to quickly locate air leakage points in the air suspension system, and what are the common leakage causes?

To locate leakage points: First, maintain the system pressure at 0.6-0.8 MPa, then apply soapy water to all connections (fittings, hose joints, valves) — bubbles will form at the leakage point. Common causes include: 1. Thread corrosion or wear of fittings; 2. Aging or damage of hose joints; 3. Loosening of fasteners leading to component displacement; 4. Aging of seals (e.g., PTFE seals in ball valves).