Z04010000009AA Mast Lower Section Parts Guide for ZJ40 Drilling Rig

1

Side column

Z04010100001AA

High-strength alloy steel (Q355B), welded per API 4F, shot-blasted for anti-corrosion

1. Fatigue from repeated load cycles; 2. Weld stress cracking during rig transport vibration; 3. Corrosion from ground moisture and drilling fluid.

1. Inspect welds quarterly per API 4F; 2. Secure tightly during transport to reduce vibration; 3. Touch up anti-corrosion coating on damaged areas.

2

Bottom cross beam L2824

P9941604AA

Alloy steel (Q355B), reinforced with structural ribs, API 4F load-bearing certified

1. Bending from uneven load distribution; 2. Wear at connection points with side columns; 3. Corrosion from prolonged ground contact.

1. Ensure level rig placement to avoid uneven loading; 2. Inspect connection bolts monthly; 3. Use corrosion-resistant pads between beam and ground.

3

Bottom beam L2520

P9941605AA

Alloy steel (Q355B), precision-cut for dimensional accuracy, anti-wear surface treatment

1. Stress concentration at rib connections; 2. Wear from friction with auxiliary components; 3. Impact damage during mast assembly.

1. Avoid overloading beyond OE-rated capacity; 2. Lubricate contact points with auxiliary parts; 3. Handle with care during assembly to prevent impacts.

4

Bottom beam L2824

P9941606AA

Alloy steel (Q355B), dual-reinforced for heavy load-bearing, API 4F compliant

1. Same as bottom beam L2520; 2. Additional stress from front/rear leg connections; 3. Corrosion from drilling fluid splatter.

1. Inspect leg connection points for tightness; 2. Clean off drilling fluid promptly; 3. Inspect for bending or warping quarterly.

5

Base plate 200X146

P6202249AA

Heavy-duty alloy steel plate, forged for rigidity, zinc-plated for corrosion resistance

1. Wear from ground friction during rig movement; 2. Corrosion from salt or moisture; 3. Deformation from uneven ground pressure.

1. Clear debris from ground before placing; 2. Inspect for deformation monthly; 3. Replace zinc coating if worn to prevent rust.

6

Rod type beam

Z04010200005AA

High-tensile alloy steel (4140), heat-treated for fatigue resistance, precision-machined

1. Tensile fatigue from repeated load cycles; 2. Wear at threaded connections; 3. Corrosion from environmental exposure.

1. Torque threaded connections to OE specs; 2. Apply anti-seize compound to threads; 3. Inspect for cracks using non-destructive testing annually.

7

Side column L1182

Z04012500004AA

Alloy steel (Q355B), length-optimized for ZJ40 mast, welded and reinforced

1. Fatigue from vertical load bearing; 2. Weld cracking from lateral vibration; 3. Corrosion from rain or humidity.

1. Inspect vertical alignment before operation; 2. Secure with proper bracing during transport; 3. Keep surface clean and dry to prevent rust.

8

Rear leg L19452

P9840557AA

Alloy steel (Q355B), telescopic design for adjustability, anti-corrosion coating

1. Wear at telescopic joints; 2. Bending from uneven ground; 3. Corrosion from ground moisture.

1. Lubricate telescopic joints every 100 operating hours; 2. Level legs before deploying mast; 3. Retract and clean after use in muddy conditions.

9

Front leg L19522

P9941615AA

Alloy steel (Q355B), same telescopic design as rear leg, load-tested per OE specs

1. Same as rear leg; 2. Additional impact damage during rig positioning; 3. Stress from front bolster connections.

1. Avoid sudden impacts when positioning front legs; 2. Inspect bolster connections regularly; 3. Follow same lubrication and cleaning protocols as rear legs.

10

Rectangular tube L1282

Z04010600046AA

Alloy steel (Q235B), seamless tube design, anti-corrosion coating

1. Bending from lateral stress; 2. Corrosion from moisture ingress (if seams are damaged); 3. Wear at connection points.

1. Inspect for seam damage quarterly; 2. Seal any cracks to prevent moisture ingress; 3. Avoid using as a pry point during maintenance.

11

Front bolster

P9840558AA

Alloy steel (Q355B), reinforced for front leg load distribution, API 4F compliant

1. Stress concentration at leg connections; 2. Wear from repeated front leg adjustments; 3. Corrosion from drilling fluid splatter.

1. Tighten leg connections before each use; 2. Clean off drilling fluid after operations; 3. Inspect for bending or warping monthly.

12

Rectangular tube

P6013174AA

Alloy steel (Q235B), seamless construction, zinc-plated for corrosion resistance

1. Same as rectangular tube L1282; 2. Wear from auxiliary component contact; 3. Impact damage during tool handling.

1. Keep area around tube clear of tools; 2. Inspect contact points for wear; 3. Replace if tube is bent or corroded through.

1

Bottom brace (multiple)

P9840541AA, P9840542AA, P9840543AA, P9840544AA, P9840545AA, P9840546AA, P9840547AA, P9840548AA, P9840549AA, P9840550AA, P9840551AA, P9840552AA, P9840553AA, P9840554AA, P9840555AA

Alloy steel (Q355B), welded or threaded design, anti-corrosion coating

1. Fatigue from vibration; 2. Loosening of threaded/welded connections; 3. Corrosion from environmental exposure.

1. Tighten threaded braces monthly; 2. Inspect welds on welded braces quarterly; 3. Apply lubricant to threaded connections to prevent seizing.

2

Side brace (multiple)

Z04011100010AA, P6202114AA, P6202115AA, P9840556AA, P9941616AA, P9941617AA

Alloy steel (Q355B), lightweight yet rigid, API 4F compliant for bracing strength

1. Lateral stress fatigue; 2. Wear at hinge or bolt connections; 3. Impact damage during mast deployment.

1. Ensure proper tension when installing; 2. Inspect hinge connections for wear; 3. Avoid forcing braces during mast raising/lowering.

3

Reinforced pipe

Z04010300001AA

Seamless alloy steel pipe (20#), heat-treated for strength, anti-corrosion coating

1. Corrosion from internal moisture (if not sealed); 2. Wear at connection points; 3. Stress cracking from load vibration.

1. Seal pipe ends when not in use to prevent moisture ingress; 2. Inspect connections for tightness; 3. Avoid overloading beyond rated capacity.

4

Reinforced plate 102X480

P6202117AA

Alloy steel plate (Q355B), precision-cut, welded to reinforce load-bearing areas

1. Weld fatigue from vibration; 2. Wear at contact points with other components; 3. Corrosion from environmental exposure.

1. Inspect welds quarterly; 2. Lubricate contact points to reduce wear; 3. Clean and touch up anti-corrosion coating as needed.

5

Reinforced plate

P6202127AA

Alloy steel plate (Q355B), thin yet durable, used for localized reinforcement

1. Wear from friction with adjacent components; 2. Corrosion from moisture; 3. Bending from uneven pressure.

1. Inspect for bending during monthly checks; 2. Keep surface clean and dry; 3. Replace if plate is cracked or severely worn.

6

Reinforced support

P9941622AA

Alloy steel (Q355B), forged support structure, anti-wear and anti-corrosion treatment

1. Stress fatigue from repeated load cycles; 2. Wear at contact points; 3. Corrosion from ground moisture.

1. Ensure proper alignment with supported components; 2. Inspect for wear monthly; 3. Use corrosion-resistant pads if in ground contact.

7

Beam, doorframe

P9941621AA

Alloy steel (Q355B), doorframe-specific reinforcement, welded for rigidity

1. Wear from doorframe movement; 2. Weld fatigue from vibration; 3. Corrosion from environmental exposure.

1. Inspect doorframe movement for excess friction; 2. Check welds quarterly; 3. Clean and lubricate doorframe hinges regularly.

8

Brace, doorframe

P9840561AA

Alloy steel (Q355B), lightweight bracing for doorframe stability

1. Loosening from vibration; 2. Wear at hinge connections; 3. Impact damage from doorframe use.

1. Tighten connections monthly; 2. Inspect hinge wear; 3. Avoid slamming the doorframe to prevent impact.

9

Side supporting box, at driller's side

Z04020601002AA

Alloy steel (Q355B), box-shaped structure for lateral support, anti-corrosion coating

1. Lateral stress fatigue; 2. Wear at connection points with side columns; 3. Corrosion from drilling fluid or moisture.

1. Inspect lateral alignment before operation; 2. Tighten connection bolts; 3. Clean off fluid promptly to prevent corrosion.

10

Side supporting box, at off driller's side

Z04022100004AA

Alloy steel (Q355B), same design as driller's side box, OE-matched for symmetry

1. Same as driller's side supporting box; 2. Uneven stress if mast is misaligned; 3. Wear from tool access.

1. Ensure mast symmetry during setup; 2. Keep tool access areas clear to prevent impact; 3. Follow same inspection protocols as driller's side box.

11

Pitch plate

P6202250AA

Alloy steel (Q355B), angled design for load distribution, anti-wear surface

1. Wear from load friction; 2. Corrosion from environmental exposure; 3. Bending from uneven pressure.

1. Inspect for wear monthly; 2. Apply anti-wear coating to contact surfaces; 3. Ensure proper load distribution to avoid bending.

1

Bolt M20×75

4300820075

High-tensile steel (10.9 grade), heat-treated, zinc-plated for corrosion resistance

1. Loosening from vibration; 2. Thread wear from repeated assembly/disassembly; 3. Corrosion-induced weakening.

1. Torque to OE specifications (typically 150-180 N·m); 2. Use lock washers to prevent loosening; 3. Replace corroded or stripped bolts.

2

Nut M20

4309300020

High-tensile steel (10 grade), zinc-plated, precision-threaded

1. Thread wear from bolt interaction; 2. Corrosion from moisture; 3. Stripping from over-torquing.

1. Torque to matching bolt specifications; 2. Replace if threads are stripped; 3. Store in dry areas to prevent rust.

3

Spring washer 20

4313100020

Carbon steel (65Mn), heat-treated for elasticity, zinc-plated

1. Fatigue from repeated compression cycles; 2. Corrosion from moisture; 3. Deformation from over-torquing.

1. Replace washers when re-torquing bolts; 2. Inspect for deformation before installation; 3. Use with compatible bolts/nuts.

4

Pin shaft

Z04011600001AA

Stainless steel (304), precision-ground, corrosion-resistant

1. Wear at bearing surfaces; 2. Corrosion from moisture (offshore/ humid environments); 3. Bending from lateral force.

1. Lubricate with anti-corrosion grease; 2. Inspect for wear monthly; 3. Replace if bent or severely worn.

5

Safety pin

P2001315AA

Carbon steel (Q235B), zinc-plated, spring-loaded for secure fit

1. Wear from repeated insertion/removal; 2. Corrosion from moisture; 3. Spring fatigue (if applicable).

1. Inspect spring function monthly; 2. Clean and dry after use; 3. Replace if pin is bent or spring fails.

6

Shackle S-DX10

P6000228AA

Alloy steel (4140), forged, heat-treated, galvanized for corrosion resistance

1. Fatigue from load cycles; 2. Wear at pin connection; 3. Corrosion from salt/moisture.

1. Never exceed rated load (10 tons); 2. Inspect for bending or cracking; 3. Lubricate pin regularly to prevent seizing.

7

Latch pin unit

Z04011600002AA

Alloy steel, integrated latch mechanism, anti-corrosion coating

1. Latch wear from repeated use; 2. Corrosion of moving parts; 3. Spring fatigue (if applicable).

1. Lubricate moving parts monthly; 2. Inspect latch engagement before operation; 3. Replace if latch fails to secure properly.

8

Hinge seat

P9840003AA

Alloy steel (Q355B), precision-machined for hinge pin fit, anti-wear surface

1. Wear from hinge pin rotation; 2. Corrosion from moisture; 3. Impact damage during assembly.

1. Lubricate with high-temperature grease; 2. Inspect for wear monthly; 3. Handle carefully during assembly to prevent impact.

9

Hinged seat

Z04011500001AA

Alloy steel (Q355B), same design as hinge seat, OE-matched for specific connections

1. Same as hinge seat; 2. Additional stress from load-bearing hinge applications; 3. Wear from heavy use.

1. Follow same lubrication and inspection protocols as hinge seat; 2. Avoid overloading hinge connections; 3. Replace if seat is worn or cracked.

1

Plug plate (multiple sizes)

P6101668AA, P6101545AA, P6101672AA, P6101673AA, P6101560AA

Alloy steel (Q235B), precision-cut, used to seal openings, anti-corrosion coating

1. Wear from installation/removal; 2. Corrosion from environmental exposure; 3. Damage from improper handling.

1. Install/remove gently to avoid bending; 2. Clean and dry before reinstallation; 3. Replace if cracked or severely worn.

2

Plug plate 148×108

P9840560AA

Alloy steel (Q235B), size-specific for targeted openings, zinc-plated

1. Same as general plug plates; 2. Loosening from vibration; 3. Corrosion from moisture ingress behind plate.

1. Secure tightly to prevent loosening; 2. Inspect for moisture behind plate quarterly; 3. Replace if plating is worn.

3

Plug plate 200×92 (multiple)

P9960374AA, P6202125AA

Alloy steel (Q235B), larger size for larger openings, reinforced edges

1. Bending from external pressure; 2. Wear at edge connections; 3. Corrosion from environmental exposure.

1. Avoid placing pressure on plate surfaces; 2. Inspect edge connections monthly; 3. Apply anti-corrosion coating to edges.

4

Plug plate 200×66

Z04011500009AA

Alloy steel (Q235B), size-optimized for specific openings, anti-wear treatment

1. Same as 200×92 plug plates; 2. Wear from tool contact (if in high-access areas); 3. Loosening from vibration.

1. Keep tool access areas clear; 2. Tighten connections regularly; 3. Inspect for wear during monthly checks.

5

Pad eye (multiple)

P9840559AA, Z04310000003AA

Alloy steel (Q355B), forged, welded to mast for lifting/securing, API 7K compliant

1. Weld fatigue from lifting loads; 2. Wear at lifting point; 3. Corrosion from environmental exposure.

1. Never exceed rated lifting capacity; 2. Inspect welds before each use; 3. Clean and lubricate lifting point.

6

Pad eye, wireline

Z04010400001AA

Alloy steel (Q355B), wireline-specific design, reinforced for wire tension

1. Wear from wireline friction; 2. Fatigue from repeated wire tension; 3. Corrosion from moisture.

1. Inspect wireline contact area for wear; 2. Lubricate wireline to reduce friction; 3. Replace if pad eye is cracked or worn.

7

Lifting ring

P9960375AA

Alloy steel (4140), forged, heat-treated for lifting strength, galvanized

1. Fatigue from lifting loads; 2. Wear at connection point; 3. Corrosion from salt/moisture.

1. Match lifting ring capacity to load; 2. Inspect for bending or cracking before use; 3. Store in dry areas to prevent rust.

8

Seat plate (multiple)

Z04011300001AA, P991004394AA

Alloy steel (Q355B), flat design for component mounting, anti-wear surface

1. Wear from component mounting/dismounting; 2. Corrosion from moisture; 3. Bending from uneven component weight.

1. Ensure components are mounted evenly; 2. Clean plate surface regularly; 3. Inspect for bending during monthly checks.

9

Seat plate, cylinder

P9941622AA, P6202125AA

Alloy steel (Q355B), cylinder-specific mounting, reinforced for hydraulic cylinder loads

1. Stress from cylinder pressure; 2. Wear at cylinder mounting points; 3. Corrosion from hydraulic fluid leaks.

1. Inspect for hydraulic fluid leaks; 2. Tighten cylinder mounting bolts; 3. Replace if plate is cracked or deformed.

10

Liner (multiple)

P9840561AA, P9840556AA

Stainless steel (304), precision-machined to reduce friction, corrosion-resistant

1. Wear from component movement; 2. Corrosion from moisture or fluid; 3. Damage from improper installation.

1. Lubricate liners during installation; 2. Inspect for wear monthly; 3. Replace if liner is scratched or worn.

11

End plate

4400200211

Alloy steel (Q235B), used to seal tube ends, welded or bolted design

1. Weld fatigue (if welded); 2. Corrosion from moisture ingress; 3. Impact damage during handling.

1. Inspect welds quarterly (if welded); 2. Ensure tight seal to prevent moisture; 3. Handle carefully to avoid impact.

12

Pot hook

P9960374AA

Alloy steel (Q355B), forged hook design, anti-corrosion coating

1. Wear from tool hanging; 2. Fatigue from repeated load; 3. Corrosion from environmental exposure.

1. Do not exceed rated load for hanging tools; 2. Inspect for bending or cracking monthly; 3. Clean and lubricate hook regularly.

13

Tubing support, spinner

Z04011600003AA

Alloy steel (Q355B), spinner-compatible design, anti-wear contact surface

1. Wear from spinner rotation; 2. Corrosion from drilling fluid; 3. Bending from tubing pressure.

1. Lubricate contact surface with drilling fluid-compatible grease; 2. Inspect for wear during spinner maintenance; 3. Replace if support is bent.

14

Tubing support, cathead cylinder

P2000036AA

Alloy steel (Q355B), cathead cylinder-specific, reinforced for cylinder movement

1. Wear from cylinder movement; 2. Corrosion from hydraulic fluid; 3. Stress from cylinder pressure.

1. Inspect during cathead cylinder maintenance; 2. Clean off hydraulic fluid leaks; 3. Replace if support is worn or cracked.

15

Stairs assembly

P9840555AA

Alloy steel (Q235B), welded stair structure, anti-slip steps, anti-corrosion coating

1. Wear from personnel access; 2. Weld fatigue from vibration; 3. Corrosion from environmental exposure.

1. Inspect steps for anti-slip wear; 2. Check welds quarterly; 3. Keep stairs clear of debris to prevent slips.

16

Limit seat

Z04011100010AA

Alloy steel (Q355B), limit switch mounting, reinforced for impact resistance

1. Impact damage from limit switch activation; 2. Wear at mounting points; 3. Corrosion from moisture.

1. Inspect limit switch alignment; 2. Check for impact damage monthly; 3. Clean and dry to prevent corrosion.

17

Raising limit seat

Z04010400001AA

Alloy steel (Q355B), mast raising limit, heavy-duty impact resistance

1. Heavy impact during mast raising; 2. Wear from repeated limit activation; 3. Corrosion from environmental exposure.

1. Inspect after each mast raising; 2. Check for deformation or cracks; 3. Replace if impact damage is severe.

18

Support (multiple)

P991000145AA, Z04010500004AA

Alloy steel (Q355B), general-purpose support, welded or bolted design

1. Fatigue from load-bearing; 2. Wear at connection points; 3. Corrosion from environmental exposure.

1. Avoid overloading beyond rated capacity; 2. Inspect connections monthly; 3. Apply anti-corrosion coating as needed.

19

Support, guyline

Z04010600045AA

Alloy steel (Q355B), guyline-specific support, reinforced for tension loads

1. Stress from guyline tension; 2. Wear at guyline connection; 3. Corrosion from environmental exposure.

1. Adjust guyline tension evenly; 2. Inspect connection for wear; 3. Replace if support is bent or cracked.

Are these parts only compatible with the Z04010000009AA mast lower section?

Yes, all parts are exclusively engineered for the Z04010000009AA mast lower section of the ZJ40 truck-mounted drilling rig. They match OE specifications to ensure perfect fit, complying with API 4F for structural safety.

What torque should be used for M20×75 bolts?

M20×75 bolts (4300820075) should be torqued to 150-180 N·m, matching OE specifications. Use spring washers (4313100020) and anti-seize compound to prevent loosening and corrosion, critical for load-bearing connections.

How often should bottom braces be inspected and tightened?

Inspect bottom braces monthly for loosening and wear, and tighten to OE specs. For rigs operating in high-vibration environments, shorten the interval to biweekly to prevent structural instability, per API 4F maintenance guidelines.