Self-controlled Pulley Assembly & Matching Parts for ZJ40 Rig

1

Self-controlled pulley assembly

Z16020000002AA

Main body: High-strength alloy steel 40Cr, surface anti-corrosion electrophoresis coating; pulley groove: Wear-resistant manganese steel (Mn13); internal bearing: Chrome steel GCr15; load-bearing capacity ≥ 50kN, compliant with API Spec 7K and ISO 10819

1. Pulley groove wear from long-term rope friction; 2. Bearing jamming from dust intrusion and insufficient lubrication; 3. Body deformation from uneven rope tension or impact.

1. Regularly inspect pulley groove wear and replace if the wear depth exceeds 2mm; 2. Lubricate internal bearings monthly with lithium-based grease; 3. Ensure uniform rope tension and avoid impact on the assembly.

1

Guard assembly

Z03060300001AA

Low-carbon steel Q235B, surface powder coating, thickness 5mm, impact resistance ≥ 20J, compliant with GB/T 700-2006 and API Spec 7K

1. Deformation from impact by drilling tools or debris; 2. Coating wear and corrosion from drilling fluid and outdoor humidity; 3. Welding joint cracking from long-term vibration.

1. Install protective buffers around the guard to avoid impact; 2. Clean the surface regularly and reapply paint if the coating peels; 3. Inspect welding joints monthly for cracks.

2

Cover plate

P6700002AA

Carbon steel AISI 1045, surface zinc plating, precision machining to match the pulley assembly, thickness 4mm, compliant with ISO 10819

1. Damage from improper disassembly with tools; 2. Zinc layer damage and corrosion from dust and moisture; 3. Deformation from uneven pressure during installation.

1. Use professional tools for disassembly and assembly; 2. Clean and apply anti-rust oil regularly; 3. Ensure even pressure when installing and tightening fasteners.

1

Sheave

P1400038AA

Wear-resistant manganese steel (Mn13), surface quenching (hardness HRC 55-60), pulley groove roughness Ra≤1.6μm, compliant with API Spec 7K and ISO 10819

1. Groove wear from long-term rope friction; 2. Surface scratches from hard debris mixed with the rope; 3. Cracking from uneven load distribution.

1. Inspect the groove wear monthly and replace if the wear depth exceeds 2mm; 2. Clean the rope and sheave groove regularly to remove debris; 3. Ensure uniform load distribution during operation.

2

Shaft

P2100039AA

Alloy steel 40Cr, surface chrome plating (thickness 0.05-0.1mm), tensile strength ≥ 830MPa, hardness HRC 45-50, compliant with GB/T 3077-2015

1. Bending from uneven load or impact; 2. Surface wear and chrome layer peeling from friction with the shaft sleeve; 3. Corrosion of the base material from chrome layer damage.

1. Avoid uneven load and impact during operation; 2. Lubricate the shaft and shaft sleeve interface regularly; 3. Inspect the chrome layer monthly and replace if peeling is found.

3

Shaft sleeve

4101800005

Copper alloy (ZCuSn10Pb1), surface polished, self-lubricating performance, inner diameter matching the shaft size, compliant with GB/T 1176-2013

1. Wear from long-term friction with the shaft; 2. Scratches from impurities entering the interface; 3. Corrosion from moist air and drilling fluid residues.

1. Clean the shaft and shaft sleeve before assembly to remove impurities; 2. Lubricate the interface with lithium-based grease; 3. Replace if the inner diameter is excessively enlarged or scratches are found.

1

Pipe sleeve

P2100037AA

Seamless steel pipe (ST52-3), surface anti-corrosion electrophoresis coating, inner diameter 30mm, wall thickness 3mm, compliant with GB/T 8163-2018

1. Deformation from external impact; 2. Coating wear and corrosion from drilling fluid; 3. Internal wear from friction with inserted components.

1. Avoid impact and protect the pipe sleeve with a buffer; 2. Clean the surface promptly after contact with drilling fluid; 3. Ensure proper fit with inserted components to reduce friction.

2

Round pipe

P2100038AA

Seamless steel pipe (ST52-3), surface anti-corrosion painting, outer diameter 38mm, wall thickness 3.5mm, tensile strength ≥ 520MPa, compliant with GB/T 8163-2018

1. Bending from uneven load or impact; 2. Paint peeling and corrosion from outdoor exposure; 3. Welding joint cracking from long-term vibration.

1. Ensure uniform load distribution and avoid impact; 2. Reapply anti-corrosion paint annually; 3. Inspect welding joints monthly for cracks.

3

Bottom pipe

P2000179AA

Seamless steel pipe (ST52-3), surface zinc plating, outer diameter 45mm, wall thickness 4mm, compliant with GB/T 8163-2018 and ISO 10819

1. Corrosion of the zinc layer from drilling fluid and moisture; 2. Deformation from ground impact during rig movement; 3. Internal blockage from debris.

1. Clean and apply anti-rust oil regularly; 2. Protect the bottom pipe during rig movement to avoid ground impact; 3. Clean the internal cavity periodically to remove debris.

4

Plate

Z16020000001AA

Carbon steel AISI 1045, surface zinc plating, thickness 6mm, precision machining for structural connection, compliant with API Spec 7K

1. Deformation from uneven pressure during installation; 2. Zinc layer damage and corrosion from dust and moisture; 3. Hole wear from friction with fasteners.

1. Ensure even pressure during installation; 2. Clean and apply anti-rust oil regularly; 3. Replace fasteners if they cause excessive hole wear.

1

Cam

4300308040

Alloy steel 40Cr, surface quenching (hardness HRC 50-55), precision machining for cam profile, compliant with GB/T 3077-2015 and ISO 10819

1. Wear of the cam profile from long-term contact with other components; 2. Jamming from dust and debris intrusion; 3. Cracking from fatigue due to repeated movement.

1. Lubricate the cam surface monthly with lithium-based grease; 2. Clean the cam and its surrounding area regularly to remove debris; 3. Inspect the cam profile for wear and replace if needed.

2

Operation rod

P6400019AA

Alloy steel 45#, surface chrome plating, length 500mm, tensile strength ≥ 600MPa, compliant with GB/T 699-2015

1. Bending from improper manual operation (excessive force); 2. Chrome layer peeling and corrosion from impact and moisture; 3. Wear at the connection end from repeated movement.

1. Operate the rod gently and avoid excessive force; 2. Protect the rod from impact and clean it regularly; 3. Inspect the connection end for wear and lubricate it regularly.

1

Bolt M8X38

4300308015

Alloy steel 8.8 grade, surface zinc plating, thread pitch 1.25mm, length 38mm, compliant with ISO 898-1 and API Spec 7K

1. Fatigue fracture from long-term high-frequency vibration; 2. Thread wear from over-tightening; 3. Corrosion of the zinc layer leading to rust.

1. Tighten to standard torque (18-22 N·m) and re-tighten monthly; 2. Clean and apply anti-rust oil regularly; 3. Replace if thread wear or rust is found.

2

Bolt M8X15

P1400037AA

Alloy steel 8.8 grade, surface zinc plating, thread pitch 1.25mm, length 15mm, compliant with ISO 898-1

1. Thread wear from frequent disassembly; 2. Deformation from over-tightening with improper tools; 3. Corrosion in humid drilling site environments.

1. Use a matching wrench to avoid over-tightening; 2. Minimize frequent disassembly; 3. Store in a dry environment when not in use.

3

Nut M8

4309300008

Carbon steel 45#, surface zinc plating, thread compliant with ISO 262, hardness HRC 28-32; compatible with M8 bolts

1. Thread wear from over-tightening; 2. Corrosion of the zinc layer leading to thread jamming; 3. Damage from impact by external objects.

1. Tighten to standard torque with matching bolts; 2. Clean and apply anti-rust oil regularly; 3. Install protective covers to prevent impact.

4

Spring washer ８

4313000008

Spring steel 65Mn, surface galvanized, hardness HRC 42-48, compliant with GB/T 93-1987; used with M8 bolts for anti-loosening

1. Fatigue loss of elasticity from long-term compression; 2. Corrosion causing fracture; 3. Deformation from incorrect installation direction.

1. Replace together with bolts and nuts during maintenance; 2. Do not reuse deformed or rusted washers; 3. Ensure the curved surface faces the nut during installation.

5

Cylindrical pin

4314503020

Stainless steel 304, surface polished, diameter 8mm, length 30mm, compliant with GB/T 119.1-2000

1. Wear from long-term friction with the pin hole; 2. Bending from impact; 3. Corrosion from chemical contaminants in the drilling environment.

1. Clean the pin and pin hole before assembly; 2. Avoid impact on the pin; 3. Replace if bending or excessive wear is detected.

6

Cotter pin 3.5X20

P2600010AA

Carbon steel 45#, surface zinc plating, diameter 3.5mm, length 20mm, compliant with GB/T 91-2000

1. Fatigue fracture from long-term vibration; 2. Zinc layer damage and corrosion; 3. Damage from improper removal with pliers.

1. Use pliers gently during removal to avoid damage; 2. Clean and apply anti-rust oil regularly; 3. Replace if bending or corrosion is found.

7

Escaping line

Z04210100019AA

High-strength polyester fiber, diameter 12mm, tensile strength ≥ 100kN, wear-resistant, corrosion-resistant, compliant with API Spec 9A

1. Wear from long-term friction with pulley and other components; 2. Aging and brittle fracture from outdoor exposure to sunlight and moisture; 3. Damage from contact with sharp objects.

1. Inspect the line monthly for wear and replace if the diameter is reduced by more than 10%; 2. Avoid contact with sharp objects; 3. Store in a dry, shaded area when not in use.

1

Grease ｄ2=M6X1 taper thread

P2000180AA

Carbon steel 45#, surface zinc plating, taper thread (M6X1), standard grease fitting (DIN 3404), compliant with ISO 6431

1. Blockage from dust and debris, preventing lubricant injection; 2. Zinc layer damage and corrosion, leading to thread jamming; 3. Damage from improper grease gun use.

1. Clean the nipple before injecting grease to avoid blockage; 2. Apply anti-rust oil to the thread monthly; 3. Use a matching grease gun to avoid damaging the nipple.

What are the common causes of Z16020000002AA Self-controlled pulley assembly jamming, and how to handle it on-site?

Common causes include: 1. Insufficient lubrication (blocked grease nipple or lack of grease); 2. Worn shaft sleeve or sheave with impurity intrusion; 3. Cam jamming. On-site handling: Disassemble the assembly, clean all components, replace worn parts, unblock the grease nipple and inject grease; reassemble and test run to confirm normal operation.

How often should the Self-controlled pulley assembly and its matching parts be maintained and replaced?

Weekly inspection: Check for jamming, rope slipping, and component loosening. Monthly maintenance: Inject grease via the grease nipple, clean components, tighten fasteners, and inspect sheave groove wear. Replacement cycle: Grease nipple (1-2 years), shaft sleeve (2 years), sheave (2-3 years), escaping line (1-2 years), fasteners (2 years)—adjust based on on-site working conditions.

Can non-original parts be used to replace damaged components of the Self-controlled pulley assembly?

It is not recommended. Original parts (e.g., P1400038AA, 4101800005) are precision-manufactured to match the Z16020000002AA assembly, complying with API Spec 7K and ISO 10819 standards. Non-original parts may have improper size, insufficient wear resistance, or poor compatibility, leading to assembly jamming, rope slipping, and safety hazards. Always use original parts for replacement and procurement.