Honghuda Drawworks Parts List (KG80 Series & Related Components)

1

Piston rod (KG80-1)

Alloy steel 40Cr; surface hard chrome plated (plating thickness ≥ 0.05mm)

1. Chrome plating peeling due to impact with foreign objects or improper assembly; 2. Rod bending deformation caused by uneven lateral loads; 3. Surface wear from friction with wiper seals under high-frequency movement.

1. Protect the rod surface from scratches and impacts during maintenance; use a protective sleeve when handling; 2. Inspect rod straightness monthly with a dial gauge (allowable deviation ≤ 0.05mm/m); straighten or replace if exceeded; 3. Clean the rod surface before retraction to prevent debris from damaging seals.

2

Wiper seal (KG80-2)

Fluororubber (Viton) or high-performance nitrile rubber (NBR); metal reinforcement ring

1. Wear of the wiper lip due to long-term friction with the piston rod; 2. Aging, hardening, and cracking caused by high temperature (above 120°C) and hydraulic oil erosion; 3. Damage from debris adhering to the piston rod surface.

1. Replace wiper seals every 12 months or immediately if oil leakage is detected; 2. Use a professional seal installer to avoid damaging the seal lip during installation; 3. Ensure the piston rod surface is smooth and free of burrs before assembly.

3

Front end cover (KG80-5)

Aluminum alloy ADC12 or cast iron HT200; precision-machined seal groove

1. Wear and deformation of the seal groove due to repeated seal replacement; 2. Crack formation around bolt holes caused by uneven tightening torque; 3. Corrosion in high-humidity oilfield environments.

1. Tighten end cover bolts in a crisscross pattern with a torque wrench (follow Honghuda's specified torque value); 2. Inspect the seal groove for wear and burrs when replacing seals; rework or replace the end cover if wear is excessive; 3. Apply anti-corrosion paint to the outer surface annually.

4

Wear ring 102.5x235 (KG80-8); Wear ring 10X2.5X448 (KG80-15)

Polyoxymethylene (POM) or bronze alloy; self-lubricating additive

1. Abrasive wear caused by contamination (dust, metal particles) in hydraulic oil; 2. Thermal deformation and softening under high-temperature operation; 3. Excessive wear due to misalignment between the piston and cylinder liner.

1. Replace wear rings when the radial clearance exceeds 0.1mm; 2. Ensure hydraulic oil cleanliness (NAS 8 class or higher); replace filters regularly; 3. Check piston-cylinder alignment during maintenance; adjust if necessary.

5

Spring (KG80-9)

Spring steel 50CrVA; surface phosphated or galvanized

1. Fatigue failure due to long-term cyclic compression and expansion; 2. Elasticity degradation caused by high-temperature baking (above 200°C); 3. Corrosion leading to reduced load-bearing capacity.

1. Inspect spring elasticity quarterly; replace if it fails to return to the original length after compression; 2. Avoid operating the brake system at excessive temperatures; ensure adequate cooling; 3. Store spare springs in a dry, sealed container to prevent corrosion.

6

Stop ring (KG80-10)

Stainless steel 304 or spring steel; surface passivated

1. Elasticity loss due to over-compression during installation; 2. Wear of the retaining surface caused by long-term contact with other components; 3. Corrosion in corrosive hydraulic oil environments.

1. Use pliers with protective sleeves during installation to avoid over-compression; 2. Inspect the stop ring for deformation and wear during each maintenance; replace if damaged; 3. Ensure compatibility with the hydraulic oil type to prevent corrosion.

7

Cylinder liner (KG80-11)

Alloy steel 27SiMn; inner surface honed (surface roughness Ra ≤ 0.4μm) and nitrided

1. Inner surface wear due to friction with the piston and contamination particles; 2. Nitride layer peeling caused by impact loads or improper assembly; 3. Cylinder wall scuffing due to insufficient lubrication.

1. Replace hydraulic oil and filters according to the maintenance schedule; 2. Inspect the inner surface for wear, scratches, and nitride layer peeling annually; honing or replace if necessary; 3. Apply a thin layer of hydraulic oil to the inner surface before piston assembly.

8

Locking nut (KG80-12); Adjusting nut (KG80-13)

Alloy steel 45#; surface zinc-nickel plated

1. Thread wear and stripping due to frequent adjustment and assembly; 2. Loosening caused by high vibration during drawworks operation; 3. Corrosion leading to thread seizing.

1. Apply anti-loosening thread lock compound (e.g., Loctite 243) after final adjustment; 2. Mark the nut position after tightening to monitor for loosening; 3. Clean threads with a wire brush before assembly; avoid using damaged nuts.

9

O ring 132x3.55 (KG80-14)

Fluororubber (Viton) or nitrile rubber (NBR); Shore hardness 70±5

1. Compression set and aging due to long-term compression and high-temperature exposure; 2. Cutting and damage caused by sharp edges in the seal groove; 3. Swelling and degradation in incompatible hydraulic oil.

1. Replace O rings every 12 months or when signs of hardening, cracking, or swelling are observed; 2. Ensure the seal groove is free of burrs and sharp edges; 3. Select O rings compatible with the hydraulic oil type and operating temperature.

10

Retainer CKW1400 (KG80-16); Retainer (KG80-18)

Carbon steel Q235 or stainless steel 304; surface plated or painted

1. Wear of the retaining surface due to long-term contact with seals or other components; 2. Deformation caused by uneven pressure during assembly; 3. Corrosion leading to reduced structural strength.

1. Inspect the retainer for deformation and wear during each maintenance; replace if necessary; 2. Ensure the retainer is correctly positioned and fully seated during assembly; 3. Apply anti-corrosion treatment to the surface annually for carbon steel types.

11

Key (KG80-17)

Carbon steel 45#; surface quenched (hardness HRC 40-45)

1. Shear failure due to excessive torque transmission; 2. Wear of the key and keyway caused by high vibration; 3. Deformation due to improper fitting during assembly.

1. Ensure the key fits tightly in the keyway (no excessive play); 2. Inspect the key and keyway for wear and deformation quarterly; replace if wear exceeds 0.05mm; 3. Apply a thin layer of anti-loosening compound to the key before assembly.

1

Bladder (LT500/250T)

High-strength rubber (EPDM or NBR); fabric reinforcement layer

1. Aging, hardening, and cracking caused by high temperature (above 150°C) and oil erosion; 2. Rupture due to excessive pressure or foreign object puncture; 3. Fatigue failure from frequent inflation and deflation cycles.

1. Monitor clutch operating pressure (do not exceed the maximum specified value); 2. Replace bladders every 18 months or if signs of aging, cracks, or bulges are found; 3. Clean the installation cavity to remove debris before installing a new bladder.

2

Friction pad (LT500/250T)

Base plate: Carbon steel Q235; Friction material: Ceramic composite (high-temperature resistant, low noise)

1. Friction material wear and ablation under high-temperature, high-torque engagement; 2. Delamination of friction material from the base plate due to thermal shock (rapid heating/cooling); 3. Wear unevenness caused by misalignment.

1. Replace friction pads when the friction material thickness is less than 2mm; 2. Avoid frequent emergency engagement to reduce thermal shock; 3. Check clutch alignment during maintenance; adjust to ensure even contact between friction pads and the pressure plate.

3

Balloon (LT500/250T clutch)

Elastomeric rubber (NBR); high-pressure resistant

1. Swelling and degradation due to contact with incompatible hydraulic oil; 2. Bursting caused by excessive pressure or aging; 3. Damage from friction with surrounding metal components.

1. Ensure the balloon is compatible with the type of hydraulic oil used; 2. Regularly inspect for signs of swelling, aging, or damage; replace immediately if any defects are found; 3. Install a protective sleeve if the balloon is in direct contact with sharp metal edges.

1

Breather valve (KG80-3)

Valve body: Aluminum alloy; Filter element: Polyurethane foam or stainless steel mesh; Seal: Nitrile rubber

1. Filter element clogging due to dust and debris ingress; 2. Seal failure leading to moisture and contamination entry; 3. Valve core jamming caused by oil contamination.

1. Clean or replace the filter element every 3 months; 2. Inspect the seal for wear and replace annually; 3. Install the breather valve vertically to prevent water accumulation; 4. Cover the valve during rig washing to avoid water ingress.

2

Filter disk (KG80-4)

Filter medium: Glass fiber or stainless steel mesh; Frame: Plastic or aluminum alloy

1. Clogging due to accumulation of metal particles, dust, and oil impurities; 2. Filter medium damage caused by high-pressure fluid impact; 3. Frame deformation due to improper installation.

1. Replace filter disks every 500 operating hours or when the differential pressure exceeds 0.3MPa; 2. Use only original filter disks to ensure filtration accuracy (5μm-10μm); 3. Tighten the filter housing evenly to avoid frame deformation.

3

Fine oil filter (GLYW-160X50); Primary oil filter (GLYW-160x30); SECONDRY FILTER，F/1000HP,HH27.5,CHINESE DRAWWORKS (CLYW-160*30); PRIMARY OIL FILTER (CLYW-160*50)

Housing: Carbon steel Q235 (surface painted); Filter element: Stainless steel mesh or paper; Seal: Nitrile rubber

1. Filter element clogging due to long-term oil filtration; 2. Housing corrosion caused by moisture and oil contamination; 3. Seal leakage due to aging and wear.

1. Replace primary filter elements every 1000 operating hours and fine filter elements every 2000 operating hours; 2. Drain water and impurities from the filter bottom regularly; 3. Inspect the housing for corrosion and seals for wear quarterly; repair or replace as needed.

4

Oil cup, M10x1 (KG80-22)

Glass or plastic; Thread: Carbon steel

1. Glass/plastic breakage due to mechanical impact; 2. Thread wear and leakage caused by repeated unscrewing; 3. Contamination of lubricating oil due to loose seals.

1. Handle with care to avoid impact; 2. Tighten the oil cup gently to avoid thread damage; 3. Check the seal for tightness regularly; replace the seal if leakage occurs; 4. Keep the oil cup clean and filled with the correct type of lubricating oil.

5

Grease fitting, 45℃ M10x1 (KG80-20)

Carbon steel or stainless steel 304; surface zinc plated

1. Clogging of the grease channel due to dust and debris; 2. Thread wear caused by repeated connection with the grease gun; 3. Corrosion leading to seizure.

1. Clean the fitting head before connecting the grease gun; 2. Install a dust cap on unused fittings to prevent contamination; 3. Apply anti-seize compound to the threads during installation; 4. Replace fittings if the grease channel is clogged or threads are damaged.

1

Rubber hose (25I-1150C; 32I-1200C; 32I-900C)

Inner tube: Nitrile rubber (NBR); Reinforcement layer: High-strength steel wire braid; Outer cover: Abrasion-resistant rubber

1. Aging, hardening, and cracking of the outer cover due to sunlight, high temperature, and oil erosion; 2. Steel wire reinforcement corrosion leading to reduced pressure-bearing capacity; 3. Hose rupture due to excessive bending or twisting.

1. Replace rubber hoses every 2 years or if signs of aging, cracks, or bulges are found; 2. Route hoses to avoid sharp bends (minimum bend radius ≥ 10 times the hose diameter) and contact with hot surfaces; 3. Use hose clamps of the correct size to avoid damaging the hose.

2

Press rubber hose (26711-10-10x1T10x600); Rubber hose (26711-06-05x1T05x700)

Inner tube: Fluororubber (for high-temperature oil); Reinforcement layer: Steel wire spiral; Outer cover: Heat-resistant rubber

1. Inner tube swelling and degradation in incompatible hydraulic oil; 2. Outer cover wear due to friction with surrounding components; 3. Joint leakage caused by improper crimping.

1. Ensure the hose is compatible with the hydraulic oil type and operating temperature; 2. Inspect the outer cover for wear monthly; use protective sleeves if necessary; 3. Use professional crimping tools for hose joint installation; check crimping quality before use.

1

Hydraulic pump for DW disk brake (A10VSO 10DR/52R- PPA14NOO)

Pump body: Cast iron; Rotor and plunger: Alloy steel; Valve plate: Copper alloy

1. Wear of plungers and cylinder bores due to contaminated hydraulic oil; 2. Valve plate wear and leakage caused by high-pressure fluid impact; 3. Bearing failure due to insufficient lubrication or dust ingress.

1. Maintain hydraulic oil cleanliness (NAS 7 class or higher); replace filters regularly; 2. Check pump oil pressure and flow rate monthly; abnormal values indicate internal wear; 3. Ensure the pump is primed before starting; avoid dry running; 4. Replace the pump's oil seal every 2000 operating hours.

2

Gear type oil pump (2.2 Kw) (KCB83.3)

Pump body: Cast iron HT200; Gears: Carbon steel 45# (quenched); Shaft: Alloy steel 40Cr

1. Gear tooth wear and pitting due to contamination particles in the oil; 2. Shaft bearing wear caused by high-speed rotation and insufficient lubrication; 3. Seal leakage due to aging and high temperature.

1. Replace oil and filters according to the maintenance schedule; 2. Monitor pump noise and temperature during operation; abnormal noise indicates gear or bearing wear; 3. Lubricate bearings with high-temperature grease every 1500 operating hours; 4. Inspect seals for leakage quarterly; replace if necessary.

3

Coupling for KCB 83.3 gear oil pump

Elastic element: Rubber or polyurethane; Metal flange: Carbon steel Q235 (surface painted)

1. Elastic element aging, hardening, and cracking due to high temperature and vibration; 2. Metal flange wear caused by misalignment; 3. Bolt loosening and falling off due to high vibration.

1. Replace elastic elements every 12 months; 2. Check coupling alignment with a dial gauge during installation (allowable deviation ≤ 0.1mm); 3. Tighten coupling bolts with a torque wrench; apply anti-loosening thread lock compound; 4. Inspect bolts for tightness monthly.

1

Screw, M12x30 (KG80-6); Screw, M12x25 (KG80-19)

8.8 grade alloy steel; surface black oxide treated or zinc plated

1. Thread wear due to repeated assembly and disassembly; 2. Head wear and rounding caused by improper tool use; 3. Fatigue failure under cyclic vibration.

1. Use socket wrenches matching the screw head size to avoid rounding; 2. Tighten to the specified torque (refer to Honghuda's maintenance manual); 3. Apply anti-loosening thread lock compound for high-vibration positions; 4. Replace screws that have been disassembled more than 3 times.

2

Spring washer 12 (KG80-7)

Spring steel 65Mn; surface phosphated

1. Loss of elastic tension due to over-compression; 2. Corrosion leading to brittle fracture; 3. Deformation caused by improper installation.

1. Do not reuse spring washers that have lost elasticity (fail to spring back); 2. Install with the open end facing the direction of rotation to enhance anti-loosening effect; 3. Store spare washers in a dry environment to prevent corrosion.

3

Cylindrical pin (KG80-24)

Carbon steel 45#; surface quenched and tempered

1. Shear failure due to excessive shear force; 2. Wear of the pin surface caused by sliding contact; 3. Corrosion leading to reduced strength.

1. Ensure the pin fits tightly in the pin hole; no excessive play; 2. Inspect the pin for wear and deformation quarterly; replace if necessary; 3. Lubricate the pin with anti-rust grease if it is in sliding contact; 4. Use retaining rings to prevent axial movement of the pin.

1

Rope retainer/kick back roller (DSQ-01.00); KICK BACK ROLLER (DSQ-01.00)

Roller body: Alloy steel 42CrMo (quenched); Shaft: Alloy steel 40Cr; Bearing: Deep groove ball bearing

1. Roller surface wear and grooving caused by long-term contact with the steel wire rope; 2. Bearing wear and jamming due to dust and lack of lubrication; 3. Shaft bending deformation due to impact from the rope.

1. Inspect the roller surface for wear and grooving weekly; replace if the groove depth exceeds 2mm; 2. Lubricate the bearing with lithium-based grease every 500 operating hours; 3. Check the shaft for straightness annually; straighten or replace if deformed; 4. Ensure the steel wire rope is properly aligned with the roller to avoid uneven wear.

2

Toggle valve (FP-L6A)

Valve body: Aluminum alloy; Spool: Alloy steel; Seal: Nitrile rubber

1. Spool wear and jamming caused by contaminated hydraulic oil; 2. Seal leakage due to aging and high pressure; 3. Handle damage caused by improper operation.

1. Maintain hydraulic oil cleanliness; replace filters regularly; 2. Inspect the valve for leakage and smooth operation monthly; disassemble and clean if jamming occurs; 3. Operate the handle gently to avoid damage; 4. Replace seals annually or if leakage is detected.

3

Crown bar (KG80-21)

Alloy steel 42CrMo; surface quenched and tempered (hardness HRC 35-40)

1. Wear of the contact surface due to long-term load transmission; 2. Fatigue cracking under cyclic load; 3. Corrosion in high-humidity environments.

1. Inspect the crown bar for wear and cracks quarterly; use magnetic particle inspection (MPI) annually for critical positions; 2. Lubricate the contact surface regularly to reduce friction; 3. Apply anti-corrosion paint to the surface annually; 4. Replace if cracks or excessive wear are found.

4

Oscillating bearing (KG80-23)

Inner/outer ring: Alloy steel; Rolling elements: Bearing steel; Cage: Nylon or steel

1. Wear of rolling elements and raceways due to insufficient lubrication; 2. Damage caused by dust and debris ingress; 3. Cage deformation due to excessive tilting angle.

1. Lubricate the bearing with high-performance grease every 800 operating hours; 2. Install effective dust seals to prevent contamination; 3. Ensure the operating tilting angle does not exceed the bearing's specified limit; 4. Inspect for smooth rotation and abnormal noise monthly; replace if worn or damaged.