ZJ40 Truck-mounted Drilling Rig-SJ Petro-1

1

Mast assembly (Z04000000491AA)

Q690 high-strength alloy steel; 304 stainless steel fasteners; EPDM rubber sealing gaskets

1. Fatigue cracking of structural members due to repeated hoisting load cycles; 2. Corrosion of connecting parts from rain, humidity, and drilling fluid splashing during outdoor operation

1. Conduct non-destructive testing (NDT) for welds and stress points every 6 months; 2. Apply anti-corrosion coating to exposed components annually and cover with waterproof tarpaulin when the rig is idle

2

Mast lower section (Z04010000009AA)

Q550 alloy steel; cast steel (ZG270-500) connecting flanges; galvanized steel bolts

1. Wear and deformation of the lower section base due to uneven ground during rig setup; 2. Bolt loosening and thread wear caused by vibration during truck transportation

1. Level the ground and use backing plates before rig setup to distribute load evenly; 2. Use lock washers and torque wrenches to fasten bolts to OEM-specified torque, and recheck tightness after transportation

3

Latch pin unit (Z04010500004AA)

42CrMo alloy steel pin; PTFE wear-resistant coating; carbon steel (A3) housing

1. Wear of the pin surface due to frequent insertion/extraction and friction with the mast; 2. Jamming and corrosion caused by dust and moisture intrusion into the pin hole

1. Apply molybdenum disulfide lubricant to the pin monthly to reduce friction; 2. Install dust caps on the pin hole and clean the pin surface with diesel oil before each use

4

Mast upper section (Z04020000018AA)

Q690 high-strength alloy steel; aluminum alloy lightening panels; silicone rubber seals

1. Stress concentration and deformation at the joint due to high wind loads during outdoor drilling; 2. Seal failure leading to moisture intrusion and internal corrosion

1. Monitor wind speed in real-time and stop operation when wind speed exceeds the rig’s rated limit; 2. Inspect seals for cracks monthly and replace them with OEM-compatible parts if damaged

5

Cathead cylinder unit (Z04020000154AA)

27SiMn alloy steel cylinder barrel; chrome-plated piston rod; nitrile rubber piston seal

1. Scratches on the piston rod surface due to collision with drilling tools during operation; 2. Hydraulic oil contamination causing wear of the cylinder inner wall

1. Install a protective sleeve on the piston rod and avoid placing tools near the cylinder; 2. Replace hydraulic oil and filters according to the maintenance schedule, and test oil cleanliness regularly

6

Crown block assembly (Z04120000011AA)

45# carbon steel frame; 20CrMnTi alloy steel sheaves; deep groove ball bearings (GCr15)

1. Sheave groove wear due to long-term friction with the drilling wireline; 2. Bearing damage caused by insufficient lubrication and vibration during high-speed rotation

1. Check the sheave groove wear condition every 500 drilling hours and replace sheaves when wear exceeds 3mm; 2. Inject lithium-based grease into bearings every 100 operating hours and clean bearing seats regularly

7

Sand sheave assembly (Z04120200003AA)

20CrNiMo alloy steel sheave; polyurethane wear-resistant lining; stainless steel (304) shaft

1. Wear of the polyurethane lining due to abrasive sand and debris in desert or construction drilling areas; 2. Shaft corrosion caused by sand and moisture intrusion

1. Clean the sheave surface and replace the lining every 300 operating hours in sandy environments; 2. Apply anti-corrosion grease to the shaft and install sand-proof covers on both ends of the sheave

8

Crown sheaves (Z04120900005AA)

20CrMnTi alloy steel; carburizing and quenching surface treatment; copper alloy bushing

1. Surface pitting and wear due to high-pressure contact with the wireline under heavy load; 2. Bushing overheating and wear caused by poor heat dissipation during continuous operation

1. Ensure the wireline is properly tensioned and aligned to avoid uneven load on the sheave; 2. Check the bushing temperature during operation and stop to cool down if it exceeds 70°C, and add lubricant regularly

9

Fastline sheaves (Z04121000005AA)

20CrNiMo alloy steel; hard chrome plating on surface; GCr15 bearing steel

1. Accelerated wear due to higher rotational speed and load compared to other sheaves; 2. Corrosion and pitting caused by drilling fluid splashing and electrochemical reaction

1. Inspect the sheave surface for wear and pitting every 200 operating hours; 2. Install splash guards to prevent drilling fluid contact and apply anti-corrosion coating annually

10

Deadline sheaves (Z04121200001AA)

45# carbon steel; rubber damping ring; stainless steel (316) fasteners

1. Damping ring aging and cracking due to long-term vibration and temperature fluctuations; 2. Fastener loosening caused by rig vibration during operation

1. Replace the damping ring every 6 months and inspect for cracks monthly; 2. Use locking nuts and retighten fasteners every 150 operating hours

11

Crown block platform (Z04130000011AA)

Q235B carbon steel platform plate; angle steel reinforcement; anti-slip rubber mat

1. Anti-slip mat wear due to frequent personnel walking and equipment placement; 2. Platform corrosion from rain and humidity in outdoor operation

1. Replace the anti-slip mat when it shows signs of wear (anti-slip coefficient <0.6); 2. Paint the platform annually and drain accumulated water in a timely manner after rain

12

Mast base (Z04150000017AA)

ZG310-570 cast steel; Q690 alloy steel connecting plates; galvanized steel bolts

1. Base deformation due to uneven ground stress during rig setup; 2. Bolt corrosion and fracture caused by long-term contact with soil and moisture

1. Use level gauges to ensure the base is horizontal during setup and use backing plates for soft ground; 2. Replace bolts with hot-dip galvanized ones annually and apply anti-corrosion grease to threads

1

Racking board assembly (Z04160000156AA)

Q355B alloy steel frame; polyurethane anti-collision blocks; stainless steel (304) pins

1. Wear and deformation of anti-collision blocks due to frequent drilling rod insertion and removal; 2. Frame fatigue cracking caused by drilling rod impact during transportation

1. Replace anti-collision blocks when wear exceeds 50% of the original thickness; 2. Secure drilling rods on the racking board with binding straps during transportation to avoid impact

2

Racking board body (Z04160208025AA)

Q355B carbon steel; welded structure with flaw detection; anti-corrosion paint coating

1. Weld cracking due to repeated impact of drilling rods; 2. Corrosion of the board body from drilling fluid and rainwater

1. Conduct NDT on welds every 6 months and repair cracks immediately; 2. Clean the board body with diesel oil after each drilling operation and touch up anti-corrosion paint when damaged

3

Centralizer, telescoping cylinder (Z04170000038AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; Viton rubber seals

1. Piston rod wear due to collision with foreign objects during telescoping; 2. Seal failure caused by high-temperature environment near the drilling platform

1. Install a protective cover on the telescoping end of the cylinder; 2. Use high-temperature resistant seals and check the cylinder surface temperature regularly (avoid exceeding 120°C)

4

Mast support (Z04180000007AA)

Q690 high-strength alloy steel; cast steel (ZG270-500) support feet; rubber damping pads

1. Damping pad wear and deformation due to long-term mast load; 2. Support foot corrosion caused by contact with moisture and soil

1. Replace damping pads when compression deformation exceeds 20%; 2. Apply anti-corrosion grease to support feet before each use and clean them after operation

5

Guyline assembly (Z04210000054AA)

High-strength steel wire rope (6×19S+FC); aluminum alloy wire rope clips; galvanized steel anchors

1. Wire rope wear and broken strands due to friction with the ground or other components; 2. Corrosion of wire rope clips and anchors in humid environments

1. Use wire rope protectors at friction points and inspect for broken strands every 100 operating hours; 2. Apply anti-rust oil to wire rope and replace corroded clips/anchors in a timely manner

6

Regulator of load guyline (Z04220000001AA)

45# carbon steel adjusting screw; brass nut; stainless steel (304) shell

1. Thread wear due to frequent adjustment of guyline tension; 2. Nut jamming caused by dust and moisture intrusion

1. Apply thread lubricant during adjustment and avoid over-tightening; 2. Install dust caps on the regulator and clean threads with diesel oil every 3 months

7

Mast foundation assembly (Z04230000010AA)

Q355B carbon steel base; reinforced concrete prefabricated blocks; galvanized steel connecting rods

1. Base deformation due to uneven ground load; 2. Connecting rod corrosion caused by long-term outdoor exposure

1. Level the ground and compact it before installing the foundation; 2. Paint connecting rods annually and inspect for corrosion monthly

8

Front support assembly (with load guyline regulator) (Z04240000073AA)

Q690 alloy steel support frame; integrated load regulator; rubber damping pads

1. Damping pad aging due to long-term vibration and temperature changes; 2. Frame weld cracking caused by uneven load distribution

1. Replace damping pads every 6 months; 2. Check the load distribution regularly and adjust the regulator to ensure balanced stress on the frame

1

Standpipe assembly (Z15010000154AA)

API 5L X65 steel pipe; 2205 duplex stainless steel flanges; PTFE gasket

1. Pipe wall wear and corrosion due to high-pressure drilling fluid containing abrasive particles; 2. Gasket leakage and damage caused by improper flange fastening torque

1. Monitor drilling fluid pressure and particle content, and replace the standpipe when wall thickness decreases by 10%; 2. Use torque wrenches to fasten flanges to API-specified torque and replace gaskets after each disassembly

2

Power system (Z01000000058AA)

Cast iron (HT250) engine block; aluminum alloy cylinder head; copper alloy cooling system pipes

1. Engine block wear due to poor-quality fuel and lubricating oil; 2. Cooling system pipe corrosion caused by scale accumulation

1. Use fuel and lubricating oil that meet OEM specifications and replace filters regularly; 2. Clean the cooling system every 6 months and add scale inhibitor to the cooling water

3

Transfer case assembly (Z01030000022AA)

Alloy steel (40Cr) case; 20CrMnTi gear set; GCr15 bearing steel

1. Gear wear and tooth breakage due to improper power switching during operation; 2. Bearing damage caused by insufficient lubrication

1. Follow the correct power switching procedure and avoid switching under load; 2. Replace the transfer case oil according to the maintenance schedule and check oil level weekly

4

Connection of engine and transmission (Z01020000147AA)

42CrMo alloy steel coupling; rubber damping sleeve; stainless steel (304) bolts

1. Damping sleeve aging and cracking due to long-term vibration; 2. Bolt loosening caused by engine vibration and thermal expansion

1. Replace the damping sleeve every 1000 operating hours; 2. Use locking bolts and retighten them after the first 50 operating hours and then every 500 hours

5

Connection diagram of fuel lines (Z01090000002AA) [Auxiliary Part]

Oil-resistant rubber fuel hose; brass fittings; stainless steel (316) clips

1. Fuel hose aging and cracking due to high-temperature radiation from the engine; 2. Fitting corrosion caused by fuel leakage and moisture

1. Install heat shields between the fuel hose and the engine; 2. Inspect fuel lines for leakage weekly and replace aging hoses and corroded fittings immediately

6

Preheating and warming system (Z01130000004AA)

Stainless steel (304) heating pipe; aluminum alloy heat exchanger; silicone rubber seals

1. Heating pipe scaling and blockage due to impure cooling water; 2. Seal failure caused by temperature cycling

1. Use purified water or add antifreeze in cold areas and clean the heating pipe every 6 months; 2. Inspect seals for cracks monthly and replace them with high-temperature resistant ones

7

Air filling system (Z01200000024AA)

Aluminum alloy air compressor cylinder; cast iron piston; nitrile rubber O-rings

1. Piston wear due to dust and debris in the intake air; 2. O-ring failure caused by high-pressure and high-temperature air

1. Replace the air filter regularly and ensure the intake air is clean; 2. Check the air compressor temperature and pressure regularly, and replace O-rings every 800 operating hours

8

Wireline for 5t hydraulic winch (Z02200000002AA)

High-strength galvanized steel wire rope (6×37S+FC); fiber core for flexibility

1. Wire rope wear and broken strands due to friction with the winch drum and sheave; 2. Corrosion caused by outdoor rain and humidity

1. Ensure the wireline is evenly wound on the drum and use wire rope lubricant regularly; 2. Cover the winch with a waterproof tarpaulin when idle and inspect for broken strands weekly

1

Deck frame assembly (Z02010000011AA)

Q355B carbon steel frame; anti-slip steel plate; welded structure with flaw detection

1. Frame deformation due to uneven load during transportation of drilling equipment; 2. Anti-slip steel plate wear due to frequent equipment movement

1. Distribute load evenly on the deck and secure equipment with binding straps; 2. Check the anti-slip plate wear condition regularly and replace it when the anti-slip pattern is worn flat

2

Rear mechanical jack assembly (Z02080000002AA)

42CrMo alloy steel jack screw; cast steel (ZG310-570) base; copper alloy nut

1. Screw wear and jamming due to dust and soil intrusion; 2. Base deformation due to uneven ground during rig leveling

1. Clean the screw with diesel oil after each use and apply lubricating grease; 2. Use backing plates under the base on soft ground to avoid deformation

3

Rear suspension assembly (Z02040000008AA)

Alloy steel (40Cr) leaf spring; rubber shock absorber; steel frame

1. Leaf spring fatigue and breakage due to rough road conditions during transportation; 2. Shock absorber oil leakage caused by vibration and impact

1. Avoid driving on excessively rough roads and reduce speed on uneven roads; 2. Inspect shock absorbers for oil leakage monthly and replace them if damaged

4

Front mechanical jack assembly (Z02070000003AA)

42CrMo alloy steel jack screw; aluminum alloy handle; stainless steel (304) fasteners

1. Handle wear and deformation due to frequent use and improper operation; 2. Screw corrosion caused by rain and moisture

1. Operate the jack smoothly and avoid excessive force; 2. Cover the jack with a waterproof cover when not in use and apply anti-corrosion grease to the screw

5

Front suspension assembly (Z02040000016AA)

Coil spring (60Si2Mn alloy steel); rubber bushing; steel suspension arm

1. Coil spring fatigue and deformation due to long-term load; 2. Bushing aging and cracking caused by vibration and temperature changes

1. Check the coil spring for deformation every 500 km of transportation; 2. Replace bushings every 1000 km or when abnormal noise occurs during driving

6

Steering mechanism (Z02030000016AA)

45# carbon steel steering rod; aluminum alloy steering knuckle; rubber steering boot

1. Steering rod ball joint wear due to dust and moisture intrusion; 2. Steering boot damage leading to internal component corrosion

1. Inspect the steering boot for cracks monthly and replace it if damaged; 2. Apply lubricating grease to the ball joint every 500 km of transportation

7

Steering power assisting cylinder (Z02030900002AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; nitrile rubber seals

1. Piston rod wear due to collision with foreign objects; 2. Seal failure caused by contaminated hydraulic oil

1. Install a protective sleeve on the piston rod; 2. Replace hydraulic oil and filters according to the maintenance schedule and test oil cleanliness regularly

1

Substructure assembly (Z05000000143AA)

Q690 high-strength alloy steel; cast steel (ZG270-500) support legs; anti-corrosion paint coating

1. Support leg deformation due to uneven ground load; 2. Weld cracking caused by long-term vibration during operation

1. Level the ground and use backing plates before installing the substructure; 2. Conduct NDT on welds every 6 months and repair cracks immediately

2

Escaping sliding way (Z05010200005AA)

Q235B carbon steel slide rail; wear-resistant steel plate (NM400); stainless steel (304) guide groove

1. Slide rail wear due to frequent personnel evacuation drills and friction; 2. Guide groove corrosion caused by rain and humidity

1. Conduct evacuation drills smoothly to avoid excessive friction; 2. Clean the slide rail and guide groove regularly and apply anti-corrosion grease; install a rain cover when not in use