JC-70D Drawworks Instruction Manual

JC-70D Drawworks Instruction Manual

BA702302-00SM
June, 2007
CONTENT
1. GENERAL ......................................................................................................................................................... 1 1.1. FEATURES .................................................................................................................................................... 1 1.2. TECHNICAL PARAMETERS .............................................................................................................................. 2 1.3. HOOK LOAD AND SPEED LIST ....................................................................................................................... 3 1.4. DRIVE PRINCIPLE ......................................................................................................................................... 3 2. STRUCTURE ................................................................................................................................................... 4 2.1. GENERAL ARRANGEMENT .............................................................................................................................. 4 2.2 DRAWWORKS FRAME ................................................................................................................................... 5 2.3. DRUM SHAFT ASSY........................................................................................................................................ 6 2.4. BAILING DRUM ASSY. .................................................................................................................................... 7 2.5. MAKE UP/BREAK DOWN CATHEAD ................................................................................................................. 8 2.6. DRIVE SHAFT ASSEMBLY...............................................................................................................................11 2.7. INPUT SHAFT .............................................................................................................................................. 12 2.8. CROWN BLOCK PROTECTOR ......................................................................................................................... 13 2.9. PRIMARY BRAKE MECHANISM....................................................................................................................... 14 2.10 AUXILIARY BRAKE ...................................................................................................................................... 15 2.11 AIR TUBE CLUTCH ...................................................................................................................................... 16 2.12 AIR CONTROL SYSTEM ............................................................................................................................... 18 3. LUBRICATING SYSTEM ............................................................................................................................ 27 3.1. OIL LUBRICATION ...................................................................................................................................... 27 3.2 GREASE LUBRICATION ................................................................................................................................. 28 4. INSTALLATION ........................................................................................................................................... 28 4.1. INSTALLATION OF DRAWWORKS TRANSMISSION ........................................................................................... 28 4.2. PIPELINES INSTALLATION OF AIR CONTROL SYSTEM AND LUBRICATING SYSTEM ............................................. 29 4.3. GUARD ...................................................................................................................................................... 29 4.4. FILLING OIL ............................................................................................................................................... 29 5. OPERATION AND MAINTENANCE ........................................................................................................ 29 5.1. OPERATING CONTROL HANDLE .................................................................................................................... 30 5.2. FIRST TIME START OF DRAWWORKS ............................................................................................................ 31 5.3. SYSTEM PRESSURE SETTING FOR OIL, AIR AND WATER SYSTEM .................................................................. 34 5.4. OPERATION MANUAL .................................................................................................................................. 35 5.5. ROUTINE CHECK AND MAINTENANCE .......................................................................................................... 36 5.6. GENERAL TROUBLE AND TROUBLESHOOTING ............................................................................................... 37 5.7. PERIODICAL INSPECTION ............................................................................................................................ 38 6. MAINTENANCE AND ADJUSTMENT ..................................................................................................... 39 6.1. ALIGNMENT AND ADJUSTMENT OF TRANSMISSION SHAFT IN POWER UNIT ................................................... 39 6.2. MAINTENANCE AND ADJUSTMENT OF AIR TUBE CLUTCH .............................................................................. 40 6.3. MAINTENANCE AND ADJUSTMENT OF CATHEAD ............................................................................................ 41 6.4. POSITION-SETTING OF ELECTROMAGNETIC EDDY CURRENT BRAKE .............................................................. 42
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6.5. MAINTENANCE AND ADJUSTMENT OF CHAIN TRANSMISSION.......................................................................... 43 7. DISMANTLE DISASSEMBLE AND RE-ASSEMBLE DRAWWORKS SHAFT ASSEMBLY ...... 47 7.1. DISMANTLE, DISASSEMBLE, AND RE-ASSEMBLE THE DRUM SHAFT ASSEMBLY .................................................. 47 7.2. DISMANTLE, DISASSEMBLE, AND ASSEMBLE OF BAILING DRUM ...................................................................... 48 7.3. DISMANTLE, DISASSEMBLE, AND ASSEMBLE DRIVE SHAFT ............................................................................. 49 7.4 DISMANTLE, DISASSEMBLE AND ASSEMBLE INPUT SHAFT ................................................................................ 50 7.5. ASSEMBLY OF SHAFT ASSEMBLY ................................................................................................................... 50 8. DISMANTLE AND TRANSPORT DRAWWORKS ................................................................................. 51 9. JC-70D DRAWWORKS VULNERABLE PARTS AND SPARE PARTS LIST ................................... 52 10. JC-70D DRAWWORKS TRANSMISSION CHAIN LIST .............................................................. 55
11. JC-70D DRAWWORKS NAMEPLATE .................................................................................................. 56
1. General
JC-70D drawworks is one of transmission systems of ZJ70D drilling rig. It is used to complete the operation of tripping drill string in and out of the well, running casing with making up and breaking out tubular goods as well as controlling the drilling pressure, handling accidents, taking the core barrel and testing oil. Besides, it is used to complete the operation of raising and lowering the mast and the front and rear drill floors of the substructure. It consists mainly of two components---drawworks and power unit (including input shaft), see drawing 1. Design for JC-70D drawworks is according to the standard SY/T5532 Petroleum Drilling Drawworks .
Drawing 1 Transmission for drawworks 1-JC-70D Drawworks main body2-Power unit
1.1. Features
JC-70D drawworks has the following features: 1) High power Drawworks is powered by two YZ08 electric motors (made in China), thus have big power with 1470KW rated input power, joint together through input shaft of power unit.
2) Good speed adjusting performance and high power utilization factor To suit the loading change and save the hoisting time, JC-70D drawworks will form two shifts through two steps chains between input shaft and drive shaft, meanwhile drive shaft and drum shaft will form two shifts between high and low speed clutch, so that the total steps for drawworks will reach to four forward and four reverse. Meanwhile, it can greatly increase utilization percent for power of electric motor because the DC electric motor has the stepless speed regulation as well as saving the operation time and increase the availability. 3) Equipped with the hydraulic disc brake that has the large brake torque and the safe and reliable operation. The drawworks can adjust and control the drill pressure accurately, run the drill string evenly; besides, it can control the running speed during the tripping in. Water cooling electromagnetic eddy brake is used as an auxiliary brake that will greatly promote the operation reliability of drawworks. 4) Drawworks features the labor-saving operation and the up-to-date control mode. The drawworks uses mechanic-electric-hydraulic control system for easy and safe operation, control handle, brake and drilling parameter instruments are all concentrated in the drillers control cabin for easy operation. The drawworks could drive in simple, close construction, a large range for speed regulation, high efficient, long service time, reliable operation and beautiful appearance.
1.2. Technical Parameters

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Rated input power Max. pull of fast line Wireline diameter Gear shifts Grooved drum size (D x L) Brake disc size (OD x thickness) Wireline for bailing drum Bailing drum dimensions Bailing drum brake hub dimensions Overall dimensions Drawworks main body Power unit 11) Weight Drawworks main body Power unit 45785kg 12460kg
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1470kW 485kN 38mm 4F and 4R gears (stepless variable drive) 7701310mm 165076mm 14.5mm 4001320mm 1608220mm
JC70D 752032503216mm 640015801876mm
1.3. Hook Load and Speed List

Gear step Drum speed (r/min) 078 0120 0217 0336 Traveling System 6 x 7 Hook speed(m/s) 00.33 00.52 00.91 01.58 Hook load(kN) 04500 02800 01600 01000 Fast line pull (kN) 0487 0303 0173 0108 0159 0276 Speed of cathead (r/min)
1.4. Drive principle

For drive flow diagram of JC-70D drawworks, see drawing 2.
Drawing 2 Flow diagram of drawworks drive The drawworks is four-shaft type in structure, namely input shaft, drive shaft, bailing drum shaft and drum shaft. Two YZ08 motors are paralleled through input shaft power device, their power joins to form two steps through two-row chains between the input shaft and the drive shaft, meanwhile, two-row chains between the drive shaft and the drum shaft also produce two steps. Therefore, the drawworks
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produces 2 x 2 gears, after this, one roller chain between drive shaft and cathead shaft could produce two positions for cathead shaft. The mechanical shift shall be done between the input shaft and the drive shaft; the air-tube clutch shift shall be done between the drive shaft and the drum.
2. Structure
2.1. General arrangement
JC-70D drawworks is an internal variable drive, side plate type and fully closed drawworks with four shafts, the internal variable drive enables the drawworks to obtain four gears. There are two gear shift modes: mechanical shift and air-tube clutch shift. Before the mechanical shift is done, the drawworks shall be shut off and change the model of shift! The forced lubrication is used for drive chains, the drawworks is equipped with the cooling water circulating device for the brake disc and water cooling electromagnetic eddy brake. For the functions, JC-70D drawworks includes the following mechanisms, see drawing 3. 1) Drive mechanism: The function is to input, distribute and transmit the power. It consists of input shaft, drive shaft, bailing drum shaft, drum shaft and drive chains. 2Hoisting mechanism: The function is to raise and lower mast and drill floors, trip in and out drill string and drill tools, run casing, hoist heavy substance, make-up and break-down, etc, it is mainly includes drum shaft assembly and bailing drum shaft assy. 3) Control mechanism: The function is to control the operation and speed regulation for drawworks and rotary table. It consists of drillers control cabin, air-tube clutches, gear clutch, electric and air valves and pipelines. 4) Lubrication mechanism: The function is to lubricate all bearings and chains of drawworks with the lubricating oil and the lubricant grease. It consists of lubricate oil pump, over-flow valve, throttle valve, pressure gauge, oil cup, nozzle, oil way and pipelines, etc. 5) Brake mechanism: The function is to control the tripping-in speed and brake the drawworks. It consists of primary brake and auxiliary brake. Primary brake of JC-70D applies hydraulic tong disc brake, for the auxiliary brake, it uses water cooling electromagnetic eddy brake. 6) Support mechanism: The function is to fix and support all parts of drawworks. It consists of base, support and guards. According to the component category, the drawworks consists mainly of drawworks frame, drum shaft, bailing drum shaft, power unit, water cooling electromagnetic eddy brake, crown block protector, primary brake mechanism, electric-pneumatic control system, lubrication system, etc.
Drawing 3 JC-70D Drawworks 1. Bailing drum assy.2. Drive shaft assy.3. Gear shift mechanism4.Drawworks frame5. DWS70 electromagnetic eddy brake; 6.Hydraulic disc brake; 7.Drum shaft assy.; 8.Bailing drum brake
2.2 Drawworks frame

JC-70D drawworks is side plate type welded fabrication, can exactly locate and support drum shaft, bailing drum shaft and drive shaft. The input shaft is supported by the support of the power unit. All drive chains of the drawworks are closed. The primary side plate of the drawworks frame is made of 26mm thick steel plate while the secondary wallboard is 8mm thick steel plate. A hole on the side plate is accessible for installation and fixity of drum shaft, bailing drum shaft and drive shaft. The power unit input shaft may be installed and fixed from one side of the power unit support. The main beam of the drawworks base is welded with I-type beam, four corners of the base are fitted with hoisting piles one piece each to hoist the drawworks. An oil tank is mounted inside the power unit base to store the lubricating oil and to radiate the oil heat. All air, oil and water pipelines are arranged inside the base, the removable covers are fitted in some places where the inspection is needed, and walkway of basement is paved with slip-proof checkered
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steel plate.
2.3. Drum shaft assy.
Drawing 4 Drum shaft assy. Of drawworks 1.Water and pneumatic instrument unit2.Friction drum I3.Clutch4.Sprocket5.Left bearing seat 6.Hose assy7.Drum body assy.8.Shaft9.Bearing10.Right bearing seat11.sprocket body 12. Friction drum II13-Hub Drum shaft assembly is the key component of drawworks, which consists of drum body, hub, brake drum, bearing seats, shafts, sprocket body, LT1168x305T and LT 965x305T ventilated type air-tube clutches, etc. See Dwg. 4 for details. When working, the traveling system wireline onto the drum can be winded or withdrawn onto or from the drum by the clockwise or counter clockwise rotation of the drum shaft, thus the drill tools can be tripped in or out during the drilling operation. By means of left and right bearing seats, the drum shaft assembly is fixed on the primary side plate with 16 pieces of M36x120 bolts. After the power inputs the free quadruplex sprocket (Z=39 or Z=86), the free sprocket will be rotated (the free sprocket is connected to the friction drum with bolts, the friction drum is rotated accordingly). The duplex sprocket (Z=39) on the free sprocket drives the rotary table drive case through the chain. The connecting disc fixed on the drum shaft connects LT1168x305T and LT965X305T clutches together as a whole with bolts and conveys the torque by adding two corresponding end face keys individually. After one among clutches is filled with air and holds the friction drum, it drives the drum shaft to rotate through the connecting disc, thus hoisting drill tools. Both ends of the drum shaft assembly are fitted with the air-conducting joints and the water/air piping device. The air conducting joint is mounted on the water/air piping assembly by means of threads.
Install air guide joint and hydro pneumatic instrument unit on the two ends of drum shaft, install air guide joint on hydro pneumatic by screw, it shall provide air for clutch, hydro pneumatic joint shall provide inlet and outlet water to brake disc. The right end of the drum shaft is equipped with the water cooling electromagnetic eddy current brake that can control the tripping-in speed and lessens the main brake force by means of the reversed torque produced by the electromagnetic brake. The drum brake disc is equipped with a circulating cooling water jacket that is welded with the steel plate and ensures the brake effect and the service life under cooling-water circulating conditions. The cooling water flows into two brake discs through water/air piping assembly, water inlet and pipeline on the left end of the drum shaft to cool the brake discs continuously and then flows back the water tank through the water/air piping assembly and water outlet on the right end of the drum shaft. The drum is cast-welded with grooves to line up the wireline (38mm) in order when winding and avoid extrusion each other, effectively prolonging the service life of the wireline. There is a pit on the right side of the drum to place the fast line clip and facilitate the assembly and the disassembly. When the air way or the clutch is out of order, an emergency bolt on the clutch is used to connect the clutch with the friction drum as a rigid member to transmit the power and ensure the drum running.
2.4. Bailing drum assy.

The bailing drum shaft consists of sprocket, shaft, make up cathead, break down cathead, etc. See Dwg 5. The bailing drum shaft is driven by the duplex sprocket and fixed on the primary side plate with 12 pieces of M24x85 bolts by left and right bearing seat. The make up cathead is mounted at the left end of the shaft and the break out cathead at the right end of the shaft. It is used to make up and break out threads on the drill tools and hoist heavy goods. Drum body is casting welded and suitable for 14.5mm wireline, it can control rotate and stop by engage and declutch clutch with LT700 x 135.
Drawing 5 Bailing drum assy.

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1.Make up cathead2.Left bearing seat3.Sprocket4. Brake hub; 5. Drum body; 6.Shaft7. Clutch; 8.Right bearing seat9.Bearing 10. Break down cathead
2.5. Make up/Break down cathead

2.5.1 General
1) Make up cathead This is a friction cathead. It provides the air tube with air through a control valve on the drillers console, the air tube pushes the small drum inside the cathead against the friction lining fixed on the cathead shaft, thus enabling the small drum to rotate and wind the wireline and performing the make-up operation. It reduces the labor intensity and ensures the safe and reliable operation. 2) Break down cathead The body structure of break out cathead is similar to make up cathead, however, the small drum moves toward the right side, it results in the drum friction surface against the external tooth friction disc, the friction disc against the internal tooth disc and the internal tooth disc against the friction lining fixed on the cathead shaft. The geared ring of the internal tooth disc rotates against the external gear of the small drum. The actuating power is transmitted by the friction force and the gear, the force moment produced is double than make up cathead, so that to ensure the high torque is provided when breaking down. Make up/break down cathead is a common component; it can be used in any rig, for view, see drawing 6, for structure, see drawing 7A and 7B. 2.5.2. Structure and working principle Compressed air enter into blade from entrance, blade expansion through axial shaft after fill in gas, push cathead drum to move by a thrust bearing, meanwhile, friction plate of clutch press wind wireline barrel (dead cat head) of which rotated with cathead shaft, and then cathead drum shall rotate follow this movement system. Strength of make up/break out is decided by air pressure of air blade, during low air pressure, force tension of wire should be steady when make up, cathead drum can be combined fast when in high air pressure to produce a emergency force to suitable for break out or connection for drill pipes. Notice: when in low speed rotation of cathead shaft, it will produce Max. Tension, in case of this, it is forbidden to increase cathead shaft speed to strong tension. Stop rotation of cathead shaft, disengage drive clutch of primary drum and cathead shaft. Max. Compressed air for cathead is 0.9MPa, match big blade with big clutch to provide enough power for cathead. Make a small taper for cathead drum to ensure enough binding between clutch and friction surface when engage, without this small taper, pressure at the outside of plate diameter shall less than that of inside diameter, it is caused by deforming of outside support area under pressure as well as warping informed by temperature gradient. But non-uniformed pressure can be compensated by above taper. Note: do not machine this side to a flat surface.
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Compressed air of blade will be released after air supply is cut off by cathead control valve, cathead drum will separate with cathead shaft under the spring action, at this time, drum should not creeping or crawling.
Drawing 6 View for make up/break down cathead
Drawing 7A Make up cathead
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Drawing 7B Break down cathead
2.6. Drive shaft assembly

The drive shaft consists of left and right bearing seats, four quadraplex sprockets (Z=23, Z=29), one duplex sprocket (Z=21) and free sixtuplex sprockets (Z=53, Z=82) etc. See Dwg. 8. The drive shaft between the input shaft and the drum shaft transmits and distributes the power to the drum shaft. It is fixed on the primary wallboard with 16 pieces of M24x95 bolts by means of right and left bearing seats. The power from the input shaft is transmitted to two free sprockets through two sixtuplex chains so as to control the shift gear and to other sprockets through one of two sixtuplex sprockets. The duplex sprocket transmits the power to the bailing drum while two quadruplex sprockets transmit the power to the drum shaft. Therefore, the drive shaft can provide the drum shaft and bailing drum shaft with two speed ratios.
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Drawing 8 Drive shaft assy. 1.Sprocket Z=23 P=50.8 2.Bearing seat 3. Sprocket Z=21 P=50.8 4.Shaft 5.Free sprocket Z=53 P=38.1 6.Inner gear ring 7.Shift gear wheel 8.Sprocket Z=29 P=50.8 9.Bearing seat 10.Bearing 11.Free sprocket Z=82P=38.112.Bearing13. Bearing14. Bearing15. Bearing
2.7. Input shaft

The input shaft assembly consists of two sextuple sprocket Z=26, one duplex sprocket Z=40, two gear type clutch, inertia brake, etc. see drawing 9.
Drawing 9 Input shafts assy.

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1.Shaft2.Bearing seat3.Sprocket P=19.05Z=404.Sprocket P=38.1Z=265.Bearing seat 6.Friction hub7.Frame8.Air tube clutch9. Bearing Combine power of two YZ08 DC motors by shaft, input to drive shaft through one sprocket with Z=26. Output power to drive lubricating oil pump through duplex sprocket with Z=40 of the same shaft.
2.8. Crown block protector

When the traveling block is raised to the limited position, the crown block protector is used to urgently brake to prevent it from colliding with the crown block. There are two safety systems for the Z70D serial drilling rig protector, firstly, the wireline protecting device that is mounted on the mast to prevent the traveling block from exceeding the limited position, for the secondary, overrun limit valve (see drawing 10), the last one is traveling block digital display preventer. Use three units together to ensure safety during drilling operation. JC-70D drawworks is equipped with an air-control limit valve that is mounted above the drawworks drum and adjusted along the axial direction. The length of the limit valve lever is adjusted according to the wireline amount on the drum when the traveling block is raised to the ultra height (it is raised to 6~7 m from the crown beam bottom). When the traveling block is raised to the ultra height, the fast line collides with the valve lever, the drum clutch discharges air and the closed tong of the disc brake urgently brakes the drum. Notice: Before each shift begins, pull down the limit valve lever to check the limit valve for normal working. After the valve is used and before the drum is engaged, press the anti-collision release valve to release the disc brake tongs and pull the limit valve lever to the upright position.
Drawing 10 Structure for overrun limit valve 1. Body 2. Retainer 3. Spring 4. Seat 5. O-ring 6.Sleeve 7. Spring 8. O-ring 9.Guide sleeve
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10. Ring 11. Rod 12. Ball guide sleeve 13. Cap 14. Ball handle 15. Nut 16. Arm bar 17. O-ring
2.9. Primary brake mechanism

JC-70D primary brake mechanism is a hydraulic disc brake (see drawing 11).
Drawing 11 Hydraulic disc brake
2.9.1. General The hydraulic disc brake system is composed of hydraulic control and hydraulic brake caliper (brake caliper for short). The hydraulic control includes hydraulic pump station and control console. As the power source and power control mechanism, it provides necessary hydraulic pressure for the brake caliper. As power executive mechanism, the brake caliper provides the adjustable positive pressure for the disc brake to apply the brake. The brake caliper consists of service caliper and emergency caliper. Compared with the conventional brand brake, the hydraulic disc brake has features of larger capacity of braking torque, more stable braking, less inertia, better adjustability of braking force, smarter braking, easier operation, and convenient maintenance and repair, etc. The hydraulic system has simple and compact structure, reasonable layout, reliable performance and safe operation. 2.9.2. Main Technical Parameters 2.9.2.1. Hydraulic control system 1) Rated working pressure 7.5MPa
2) Medium: Hydraulic oil (low temperature abrasion-proof hydraulic oil L-HM20 in winter, and N46 in summer) 3) Rated flow of single pump in the system 4) Capacity of oil tank 18L/min 80L
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5) Power of motor 6) Capacity of accumulator 7) Power of electric heater 8) Flow of cooling water 9) Volume (LXWXH) 10) Weight 2.9.2.2. Normally open service caliper 1) Max. positive pressure of single side 2) Effective working area of piston 3) Overall dimension (ODL) 4) Weight 2.9.2.3. Normally close emergency caliper 1) Max. positive pressure of single side 2) Max. working clearance of braking block 3) Effective working area of piston 4) Overall dimension (ODL) 5) Weight 2.9.3. General
22.2kW 46.3L 1kW 2m3/h 11609601220(mm) 650kg
N=75kN A=12271.8mm2 165380(max)(mm) 210kg
N=75kN 1mm A=12644.9mm2 230420(max)mm 235kg
Normal brake: Provide adjustable braking torque for the disc brake to realize the tripping, WOB adjustment, tripping speed adjustment, etc by operating the control handle of the braking valve to control the positive pressure of service caliper to brake disc. Emergency brake: In emergency, press the red button and make service caliper and emergency caliper braking together, fulfill the emergency brake. Notice: It is prohibited to use this red button during the normal drilling activity. Overrun protection: When hook is hoisted to a certain height, it can not be braked because of mishandling or other reasons, at this time, overrun limit valve will change the direction automatically and finish emergency brake, avoid the collision of crown block. Parking brake: When rig does not work or driller wants to leave working console, pull the parking control handle and emergency caliper works to prevent the hook slip. See the details in specification of hydraulic disc brake
2.10 Auxiliary brake

The water cooled DWS70 electromagnetic eddy current brake is used as auxiliary brake.
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2.10.1. General Electromagnetic eddy current brake is new type auxiliary brake in offshore and onshore drilling rigs. It has many features, such as no wear brake, big torque, no wearing parts, long service life, easy to operation. So, it can relieve the wearing of main brake largely, increase the service life of brake disc, and lower the labor intensity. What is more, it is no need to use the main brake when tripping in and auxiliary brake can control the speed of tripping in via adjusting the brake torque by changing the exciter current. The speed can be reduced to 50r/min and it reaches the 75% of Max. torque, so it can meet the requirement of heavy duty while tripping in. 2.10.2. Technical parameters 1) Type 2) Max. braking torque 3) Drilling depth 4) Max. exciting power 5) Weight 2.10.3. General operation When the power and cooling action is normal, it can use electric-magnet eddy current brake. Usually, trip in the each drill stem freely and move the handle of control valve to the middle position when drill stem locates on the half way. Then, slowly move the handle while tripping in, handle shall reach the max. position when the elevator is 2 or 3 meters over the rotary table. Finally, slightly move the handle and make the elevator on the rotary table steady. If it needs the drill stem falling slowly at first, it shall put the handle to the suitable position (according to speed) before tripping in, then adjust the position according to requirement. 2.10.4. Matters need attention 1) Eddy current brake shall only be used in the interruption working activity while tripping in and out. It is prohibited to be used in other working activities electrified for a long time. 2) Do not use it without cooling water. DWS70 110000N.m 7000m 23kW 11000kg
2.11 Air tube clutch

Ventilated air tube clutch is used to control start and stop via combination and engaging/disengaging of transmission parts. See Fig.12 and Fig.13 for its work principle and structure.
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Fig.12
Working principle of clutch
Fig.13
Structure of clutch
2. Air tube 3.Elbow 4.Pressure ring 5.Connecting pipe 6.Washer 7.Firction block 10.Pin for friction block 11.-Locking wire Flange on the casing of clutch is connected with the hub of transmission shaft by bolts. Another matching parts installed friction hub is stretched in the clutch. Compressed air from air control system
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enters the pneumatic bag and pulls the friction block against friction hub, so the torque is transmitted by friction. When the air is discharged, disengage the clutch and a matching part is stopped, another part is still running (idle). How to use emergency bolts: During operation, clutch is in trouble or the pressure of compressed air is too low, it can not be repaired quickly. Assemble the emergency bolts according to the drawing. It connects the two transmission parts by emergency bolts and keeps running. See the marks A in Dwg.14 Notice: there are two clutches (high speed and low speed) in the main drum, when use emergency bolts, only one of them can be used.
Dwg.14
Use of emergency bolts
2.12 Air control System

2.12.1. Use of air control system Drawworks air-control system schematic is shown in Fig.15. The air handling device provides the air source for the drawworks. The clean compressed air with 0.8-0.9 MPa pressure enters the drawworks through the air tank under the drawworks base and then enters control element and action element of drawworks. 1Control of high and low speeds of drum The drum high/low speed is controlled by a 2-HA-2Z 3 position 4 ways reset operating valve. When the valve handle is set in the neutral position, high/low speed clutch of drum is declutched. When the valve
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handle is set in the high speed position, the air from valve opens the ND12 2 position 3 way normally closed valve controlling the high speed clutch of drum, thus, air enters ND12 2 position 3 way normally closed valve through ND12 2 position 3 way normally opened valve. One air way enters the high speed clutch of drum, and the other air way is distributed by tee bend and then enters the ND5 double pressure valve. At the same time, low speed clutch of drum is in air discharge. If the air entry of the high speed clutch and the air discharge of low speed clutch are not finished, one air way in low speed clutch is also distributed by tee and then enters the ND5 double pressure valve. Thus, ND5 double pressure valve is opened because two control units of ND5 double pressure valve get the air pressure signals at the same time, and compressed air from ND5 double pressure valve via ND5 shuttle valve will close the ND12 2 position 3 way normally opened valve. It can prevent the high speed and low speed clutch from being engaged at same time because two clutches are in air discharge conditions. When 2-HA-2Z 3 positions 4 ways reset operating valve is set in low speed position, the principle is the same as that of high speed position. The low speed clutch is engaged, while high speed clutch is discharged, which can also protect the unit. 2Control of the rotary table clutch and the inertial brake The clutch and inertial brake of rotary table are controlled by a 2-HA-2 handle switch valve. While the rotary table is driven independently, the power for rotary table is input by the driving motor directly. After the handle switch (2-HA-2) opens to the inertial brake, one way of control air enters rotary inertial clutch and the other way of air controls pressure switch via Tee joint. The pressure switch is opened to provide air signals for rotary motor control system to stop the motor rapidly. Only when the control valve of the inertial brake is in release position, the motor can be restarted. Caution: While the independent drive is used, the plug switch controlling the output end of clutch of rotary table and the ball valve of input clutch of rotary table shall both be closed, and the motor input device should be connected properly before using it. Besides, the lubricating oil pump of rotary drive box must be stated first for the power input. Only when the output pressure of oil pump is normal, can the rotary table be operated.
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Dwg.15 Principle drawing of air control system
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3) Air Control O-matic Valve of Crown Block Saver The compressed air enters the O-matic valve (FP-L6) which is mounted over the drum of drawworks via the release valve (normal opened CD7 push button valve). When the traveling block raises to the limited position, the wireline pushes down the valve handle lever to open the O-matic valve, one way of the control air enters the hydraulic disc brake and the other way of air shuts off ND12 two position three way normal open air control valve via ND5 shuttle valve so as to make high and low speed clutches discharge air to stop the raising of the traveling block. After the crown block saver completes the anti-collision operation, press the anti-collision release valve on the air control box to release the disc brake, so that the traveling block can be lowered. Assure that each system is normal. Before the crown block saver restarts to work, the O-matic valve handle shall be reset. Be sure that while using the crown block saver with the O-matic valve, the wireline on the drum shall be winded in order, or the anti-collision control will be in failure. 4) Traveling Block Digital-display Saver Digital-display Saver is a new digital instrument which can indicate the position of traveling block and avoid the collision between traveling block and crown block, traveling block and rotary table. It has function of warning in the specific height, applying the brake for drawworks, indicating the height at any position from 0 meter to 50 meter above drilling floor. It mainly consists of programmable controller, digital-display operating plate, encoder, etc. Drum shaft encoder changes the height of traveling block to rotation of drum and outputs impulse to PLC, and then transmits to the digital-display operating plate. Raising height is set in two levels: The first level is for warning and will output two way signals, one way to buzzer to provide warning sound and the other way to provide electrical signal for input plug of SCR driller console to make SCR system reduce the motor speed rapidly to zero so as to complete the soft stop. The second level is for emergency brake and it will output the electrical signal to electromagnet valve of disc brake to apply the emergency brake. Lowering height is set in two levels: The first level is for warning and will output one way to buzzer to provide warning sound to warn the driller to operate the braking valve. The second level is for emergency brake and it will output the electrical signal to electromagnet valve of disc brake to realize the emergency brake. 5) Crown Saver For crown saver, check whether crown anti-collision valve handle can be reset automatically after pull out the pin and anti-collision rope is well. 6) Shift control The shift control device consists of inertial brake valve of input shaft (2-HA-1R), shift switch (2-HA-1), 3 position air cylinder shift valve (2-HA-3), 3 position air cylinder, lever valve (QF518) and locked shift air cylinder, (ND 7) two position five way valve, etc. If gearshift is needed during drilling process, stop the drawworks first and then open neutral brake switch of input shaft and air from neutral brake switch enters neutral clutch of shaft and applies brake. (If the inertial switch (2HA1R) is turned on and motor still running, a way of air distributed from tee enters the pressure switch and pressure switch provides the electrical signal to motor control system of drawworks to stop the motor quickly. Notice:
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This operation shall not be used or rarely be used.). Turn on the shift switch (2-HA-1), a way of air is provided to control shift valve (2-HA-3) for gearshift, and another way of air to open ND 7 two position five way valve and unlocks the locked shift air cylinder for gearshift. When the operation is finished, close shift switch (2-HA-1) and observe the lock shift pressure gauge to see whether pressure indicated is equal to air source pressure. If two values are equal, it is proved to be successful. 7) Others The drillers console is equipped with (2-HA-2) bailing drum clutch control valve to control the running and the stopping of bailing drum, the air horn switch (CD7 normal closed push button valve) used for communication, and the pneumatic spinner control valve (2-HA-2) used to control make-up/break-down of the pneumatic spinner. 2.12.2. Maintenance of air control system The trouble of air control system can cause severely effect to the operation, so check and maintenance carefully drilling rigs air control elements is very important. Details maintenance as follow: 1) Check before use Check if the meter indicating of drillers control box is correct, around box is clean, if have air
leakage phenomenon. Whether every control valve parts is reliable If the gear shifting and lock shifting is dependable, rotary table and input shaft inertial brake is
normal. Crown blocks saver, before tripping in every time, need try to operate crown block saver and find
it is dependable. If the single direction guide swivel is fever or leak. If the fast release valve is smooth, if have block phenomenon. If every hose pipeline is leak. Adjust pressure of gas storage tanks safety valve under the substructure of drilling rig to 0.9MPa. Single direction guide swivel should be filled grease.
Check above items every eight hours except crown block saver. 2) Prevent the losing of compressed air The normal operation of the air control system must be assured by compressed air with certain volume and certain pressure; otherwise, it may misact or be lack of power. So if the air leakage is supposed to be reduced, the seal of all air control elements and pipeline connectors must be noticed. When the power unit is stopped running, no noise caused by air leakage is allowed. After the unit is stopped, all clutches should be connected, and the pressure fall of the pipeline should be within the permitted limit. When the pressure of the compressed air is not lower than 0.9MPa, the pressure fall should not be more than 0.1MPa within 30 minutes. While uninstalling the plastic fast pipe, press down the anti-loose washer with one hand, and pull the plastic pipe with the other hand. After the plastic pipe is installed
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and uninstalled for several times, 10~20mm should be cut off from the front end of the pipe, and then the pipe should be insert into the joint. Especially after the system is operated for a period, the plastic pipe may be loosened and dropping out because of high pressure of the system, 1020mm of the front end of the pipe should be cut off or the whole pipe is replaced and then connected to the connector. Otherwise, the pipeline may not be sealed reliably and the pipe may drop out again. 3) Pay attention to the cleanness of pipeline If there is any impurity in the air pipeline, the pneumatic element may be in failure. While the rig is moving, the pipeline connectors uninstalled must be well protected, and the openings of metal pipeline must be stuffed by cork plug. Before the installation of the pipeline, the compressed air should be used to clean the pipeline. After the impurity is cleaned out, the pipelines should be connected. 4) Treat in case of air control element failure When the air control element is in failure, do not uninstalled the valve pieces freely, because there are many reasons why the air control valve pieces are in failure, sometimes, it is not the defect of the valve pieces itself but such reasons as blockage in air pipeline or the value of air pressure (low pressure of air supply and leakage in pipeline), etc. Thus, it must be checked section by section. The method is as follows: open the air connectors one by one from control valve, control pipeline to the remote control valves to check the ventilating condition. If the control air pipeline is smooth, check the ventilating condition; if not, there are problems with the valves. If there is replacement valve, replace it first and then contact the relative technical department and if it is permitted by the department, open the valve to find out the problems. To sum up, if there is any problem with the air control system, find out the reasons patiently and deal with the problems correctly, and blind overhaul is not allowed. There are another two features of the air control valve. It is very well during the continuously working but suddenly in failure after it is stopped using for a few days. Such condition may happen to the two-position three-way air control valve easily. It is because the valve core may produce incrustation during the free time, which may increase the resistance for the action part of the valve and lead it into failure and air leakage. In such occurrences, block the air-out end of the normal close two-position three-way air control valve by hand. If the air leakage is stopped, it means that it is rusted. Move the spool repeatedly for several times, and it will work normally. If the air leakage is not stopped, the valve should be opened to find out the reasons. When the rig finishes drilling a well, or experiences a certain period (not more than three months), the complete air system must be maintained once. The wearing parts should be checked completely, replaced and cleaned timely, and prevent the valve pieces from working in abnormal conditions. 2.12.3. Trouble and Troubleshooting of Air System Normal trouble and troubleshooting lists are as follows: Item 1 Description (2-HA-2Z), 3 position 4 way reset air valve Trouble 1.air leakage 2.failure Reason Valve is broken Valve spring is broken Troubleshooting Replace Replace
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3.non-reverse
Valve is rusted, blocked by sewage
Wash Replace Wash Replace
(ND5) shuttle valve
1. air leakage 2. non-reverse
Valve is broken Valve is rusted, blocked by sewage
(ND5) pressure valve
double
1. air leakage 2. non-reverse
Valve is broken Valve is rusted, blocked by sewage
Replace Wash
(ND7) choke valve
Air leakage
The end face of piston is worn, and sewage is inserted
Replace or wash
(ND12), 2 direction, 3 way air control valve
1. air leakage
Valve
is
broken
or
Block use it
air for
leaking some
inserted by sewage 2. Non-reverse Wall of cylinder is rusted
hole by hand, or time, it will be ok. Replace
(2-HA-1), 2 direction 3 way air valve
1.air leakage
Valve
is
broken
or
inserted by sewage 2. Non-reverse Valve is rusted or Wash
inserted by sewage 7 (2-HA-2) 3 direction 4 way air valve See position 2-HA-2Z 8 (ND7), 2 direction 3 way air control valve 2. Non-reverse 1.air leakage Valve is broken, sewage is inserted. Cylinders wall is rusted Block use it air for leaking some Replace or wash three four See three position four way air valve 2-HA-2Z See three position four way air valve 2-HA-2Z
way air valve
hole by hand, or time, it will be ok. 9 Push (QF518) 10 XL-L15 single 1. air leakage Carbon brush is broken, seal ring is wore 2. high Lubricating not filled grease is Timely fill Replace rod valve Air leakage O-ring and valve is wore Replace
direction air coupling
temperature
lubricating grease
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11
Fast air relief valve (ND12)
completely
Sewage
Wash
blocked 2. air leakage 3 exhaust is not smooth O-ring Air tube is leaking Replace Check and repair
12
Fast air relief valve (ND10)
See relief
fast
air valve
See fast air relief valve (ND12)
See fast air relief valve (ND12)
(ND12) 13 Fast air relief valve (QKPJ-1/2) See relief (ND12) 14 2-HA-IR two position three way air valve 2.Non-reverse 1.air leakage The valve is broken, sewage is poured The valve is completely rusted, poured 15 ND7, 2 position 5 way air control valve 2.Non-reverse 1.air leakage The valve is broken, sewage is poured. Cylinders wall is rusted Block use it air for leaking some Replace or wash sewage is Wash Replace fast air valve See fast air relief valve (ND12) See fast air relief valve (ND12)
hole by hand, or time, it will be ok. 16 LT1168X305T clutch Open LT1168X305T air tube clutch, the drum is still rotating. 1. air circuit is not cut off 2. the air is not released automatically 3. The newly-replaced friction plate Check air circuit,
solve the problem Replace the fast air relief valve. Replace it by thin friction plate and assure clearance 2-3mm. the of
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Drum
Not flexible for the start of
1. There are troubles for the air circuit
Check
air
circuit,
troubleshooting
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drum
2. The friction block is worn badly, overloaded, or blocked.
Replace
friction
plate and check if the rotation place is deformed or with sewage
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Air pipeline pressure
air
circuit
s the
1. Air circuit leakage or cut off 2. The bladder of clutch is broken and leaking
Check
air
circuit,
pressure reached fall suddenly
cant
troubleshooting Check the bladder and replace it by new one
rated value or down
3. Pipeline is blocked
Check
air
circuit,
remove blocks 19 Air friction cathead Disengage pneumatic friction cathead, and the friction cathead goes on rotating 1. air circuit is not cut off 2. the air is not released automatically 3. The newly-replaced friction plate Check air circuit,
solve the problem Replace the fast air relief valve. Replace it by thin friction plate and assure clearance the
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Air friction cathead
Engage the pneumatic friction cathead, and the friction cathead does not rotate.
1. Air circuit leakage or cut off 2. The bladder is broken and leaking
Check
air
circuit,
troubleshooting Check the bladder and replace it by new one
3. Pipeline is blocked
Check
air
circuit,
remove blocks 21 Coupling The shaft end of coupling leaking water 22 LT965x305T clutch Disengage the LT965X305T air tube clutch, the drum shaft go 1. air circuit is not cut off 2. the air is not released automatically Check air circuit, The seal of coupling is damaged. Replace pieces. sealing
solve the problem Replace the fast air relief valve.
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on rotating.
3. the newly-replaced friction plate
Replace it by thin friction plate and assure the clearance or increase the thickness of adjusting washer.
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ND7
EX
1. air leakage
The valve is broken, sewage is poured.
Replace
electromagnetic valve 2.Non-reverse
The valve is completely rusted, sewage is poured The electromagnetic coil is damaged.
Wash or replace
Replace the electromagnetic coil 220VAC
3. Lubricating System
The chain in drawworks unit and rotary table assembly is lubricated forcedly. Except the bearing in transmission shaft is lubricated forcedly, the other bearings are all lubricated with grease.
3.1. Oil Lubrication

There are six roller chains in the drawworks, of which two 2 duplex chains; two 2 quadruplex chains and two 1-1/2 sextuplex chains, in addition, there are three bearings on the drive shaft. All chains and bearings mentioned above are lubricated with lubricating oil. The input shaft of the power unit is equipped with the sprocket driving the lubricating oil pump. The lubricating oil pump mounted on the power unit frame inhales lubricating oil from the oil tank under the power unit base and transmits the oil to all lubricating sites. To ensure the constant pressure in the oil pipeline system (the pressure may be freely adjusted), a pressure gauge and a throttle valve are mounted on the pipeline, the pressure is usually adjusted within 0.06~0.6MPa. The oil filter in the oil pipeline shall be frequently cleaned to ensure the smooth oil suction. CB-100 gear oil pump is equipped. During installation, ensure that the end plain error between the sprocket on the gear oil pump and the corresponding sprocket on the input shaft shall not be more than 0.50mm. Notice: The gear oil pump is the one-way pump. After it is fully rotated clockwise, it can only be rotated counterclockwise five minutes and then it continues its clockwise and counterclockwise rotation five minutes each. The drawworks shall not be operated before the gear oil pump and the oil tank of the lubricating system are connected to each other.
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The type of oil used: L-AN100 machine oil is used at temperature of 0--50 in summer and L-AN46 machine oil is used at temperature of 30--0 in winter. The oil shall be added to the range between two graduation marks of the oil dipstick.
3.2 Grease Lubrication

For JC-70D drawworks, all lubricating sites of main lubricating components are concentrated in the front-lower position of the clutch guard of the drum shaft at the left end of the drawworks, other lubricating sites shall be arranged in the locations where the lubrication is needed. The lithium-base grease (at 0--50, 3#; and at -30--0, 1#) shall be applied in all grease fittings. Before filling the lubricating grease, the oil cup at the oil filler with the copper tube between them shall be disassembled first, and the oil filler shall be connected to the joint and injected the grease by the grease station. The oil cup that is directly connected to the grease chamber may be injected with the grease by the grease gun or by the grease station. On the left side of the drawworks, there is a lubrication nameplate (see Dwg.16) on which positions of all lubricating sites are shown. The lubricating grease shall be injected according to requirements shown on the nameplate.
Dwg.16 Lubrication Nameplate
4. Installation
4.1. Installation of drawworks transmission
The drawworks body and the power unit are divided into two pieces for transportation. The blank boards are used to plug the connection positions between the two. Before installation, disassemble the
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blanks and store them properly for future use. Two pieces of chains are placed inside the drawworks. The same method is used during moving of the rig after a hole is finished. Align two support beams for installation of the drawworks on the substructure to make them on the same level vertically and horizontally. Then install the drawworks body to the substructure of ZJ70D rig and fix them according to the positioning blocks welded in factory. Finally, fix it with bolts M36120. Clean the contact surfaces between the drawworks and the power unit and install the gaskets. The male and female couplings are used to fix drawworks and power unit, and then fix them firmly by bolts (with M2045 on the top and M2070 at the bottom). All bolts have to be fastened and their tightening force should be uniform so as to assure the seal of contact surface. The power unit base and the substructure are fixed by bolts M36100. A thin wireline is placed in the power unit from the upper window to connect the chain of drawworks. Then the chain is led to the sprocket in the power unit, at the same time, the motor coupling or other suitable parts must be rotated by hand to make the chain match the sprocket smoothly. During this process, chain must be checked to see whether chain pin is riveted and whether chain plate is hindered. Tighten the chain with chain tightening device until the chain pin is filled in the hole of chain plate and lock the chain link by cotter pin. (The cotter pin must be checked to see whether it is in good condition and the tail part of the cotter pin shall be properly opened.) The parameters of transmission system (coplanar and sag of two sprockets) have been adjusted in factory and generally is not necessary to be adjusted by customer.
4.2. Pipelines installation of air control system and lubricating system

Pipeline of air control system and lubricating system has been removed from the end of pipeline and connectors have been wrapped. The inlet and outlet of pipeline is marked and please match the connector in accordance with the marks.
4.3. Guard
Owing to the possible deformation caused by colliding and extruding when it is lifted or transported, customer shall pay attention to keep the seal surface in good conditions. If required, it can be repaired.
4.4. Filling oil

Lubricating oil has been discharged before delivery, so it shall fill enough oil according to requirement of section 3 in the manual (lubricating system) after installation.
5. Operation and Maintenance

Safety First! Avoid the body injured; power source shall shut down while maintaining the rigs. Locking device shall be assembled in order to avoid mishandling and warning signs shall be obvious. Safety First!
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When mechanical and electrical device is running, the entire safety device shall be in good conditions. It includes crown protector, relief valve, overflow valve of air, hydraulic, oil system and warning & safe broken device of power machine, etc. The entire safety device shall be checked every shift and ensured them work normally.
5.1. Operating control handle

All the buttons and switches of drilling rigs are installed in the operating board of drillers cabin together with the main operating handle of drawworks which locates the front-left of the main operating console. All the operating parts as well as the function in different position are described by words. Switch for shift change
This switch has three positions: I shift, neutral shift and II shift. The neutral gear position is separated the driving shaft from input axis, the driving shaft is at the stopped situation. I shift and II shift connect with high speed, low speed clutch separately and produces four classes speed so as to meet the drilling requirements. Make reference in this manual term1.3, the principle of work see term 2.13. Attention: When the drawworks has load, gear shift is strictly prohibited! When shift gear must stop. Shift lock switch
The switch can control the lock/release of locking mechanism. When rig is working, switch handle shall be in the lock position. It can change shift when switch handle is in the open/release position. After shift is changed, switch handle shall be removed to lock position. (See section 2.13) Power unit inertial brake
Change work situation of power unit inertial brake 1. Brake: it means to apply the brake for input shaft (Usually, it is rarely used by worker) 2. Release: it means to be back to the normal working state. Bailing drum clutch
Control the work/stop of bailing drum. The speed of bailing drum is related to the transmission shaft speed and it includes two shifts, one is 0~159 r/min, the other is 159~276r/min. Rotary table inertial brake clutch
1. Inertial brake: Power is stopped and rotary table is braked quickly. 2. Clutch: Release inertial brake. Control catheads
1. Middle position: Two friction catheads are both stopped. 2. Left, right position: It controls the left or right cathead separately. This handle can not control the dead cathead. Anti-collision release
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When O-matic valve is working, it will stop the drawworks operation through the control system. Lower the hoisting system and withdraw the lever of O-matic valve, press the button to restore the system to normal operation. Air horn
Press the button and make the sound signal. High speed and low speed of drum
The handle shall always be in the middle position. When the drawworks speed has to be changed, move the handle to the necessary position (high speed or low speed), then release handle (the handle is back to the original position), drawworks speed is changed automatically. Hydraulic disc control
The relevant operating element is located in another control plate of control console. See the relevant operating manual of the hydraulic disc brake. Switch for auxiliary brake
Control work/stop of electromagnetic eddy current brake.
5.2. First time start of Drawworks

First time run (also called trial run) means the first operation of new drilling rig or equipment operating first time after it is repaired in repairing workshop, taken from warehouse and removed from the other place.
5.2.1. Check before trial run

Check again the assembled drawworks 1) The connecting bolts or the other fastening parts shall be enough tighten and complete. 2) The marker of two ends of oil, air, water, and pipeline shall be the same. If the marker is different, please change it immediately. (Especially the air pipeline, if it is connected incorrectly, its functions may be affected and it may cause accident.) 3) Check for the impurity in all the parts, especially in the cavity. Do not leave the tools in the drawworks. 4) Check the lubricating oil, if necessary, fill the oil. 5.2.2. Idle run check Check the following items without power input: 1) Open the air source valve to make the compressed air enter the system, check the pressure of every working points. 2) Check control valve and relevant mechanism (see section 2.13) a) Move the locking shift switch out and back while anther person is observing the action of stop blank from the check window of locking shift mechanism. Insert the stop blank to the required position and the distance between the stop blank and locking plate shall be 5~10mm when pull out the stop blank.
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b) Move shift switch and observe the active state of gearshift mechanism as the above process. Change handle to I- O II shift and ensure the gap of locking plate matches the stop blank after every shift. Locking shift must be checked after change shift and action shall be smooth. c) Move inertial brake of power unit to see if air clutch is working normally from the inflation and air release. d) As the above process, check the working state of bailing drum clutch. e) As the above process, check the working state of the rotary table inertial brake clutch. f) Move the handle of high speed and low speed drum clutch to any position (high speed or low speed), keep 3-5 seconds and release the handle, thus the clutch is charged. Move the handle to opposite position (keep 3-5 second and release the handle), the inflated clutch discharges quickly and after a while, another clutch is inflated. So there is a time delay between two actions. (See section 2.13.1 use of air control system). g) Check the working tong and safety tong by operating handle according to specification of disc brake. h) Operate the O-matic valve by handover the main drum of drawworks thus, make all the brake tongs of hydraulic disc brake against the brake disc tightly. i) Move the anti-collision O-matic valve to the original position and press anti-collision release button to make system restore to normal condition. j) Operate friction cathead switch (left/right) and judge its working state from the inflation and discharge. After finishing above check, if all the executive parts controlled by valve work well, it means air way, valve and executive parts is normal. If it has problem, please check the connection of air way. For example, if the pipeline of high speed clutch is connected properly, if the manifold is blocked, if valves are in failure, etc. It should be checked according to the trouble and air path principle diagram, then analyzed and solved. When everything is ready, move the gearshift switch to the free position and lock it, then operate machine according to the following procedure. 5.2.3. Idle run test Before operation, check the power system (diesel engine, generator, electrical system, etc) in accordance with its own specification and make sure everything is ready, then turn on the power for power supply for drawworks. 1) Start motor A, ensure its rotating direction from shaft coupling. Observer stands at the left of drawworks (the same side as driller) and look to the right (side of auxiliary brake), the rotation of motor shall be positive rotation (clockwise). Stop motor A and start motor B, judge its rotation and ensure it is clockwise. Notice: Only when the direction and rotating direction (clockwise) of two motors are the same, can the next step be carried on. Ensure the first start shall be positive rotation, otherwise, lubricating oil pump can not work and will cause severe accident. 2) Start motor A or motor B at speed of 970r/min and check the oil supply. The lubricating pressure gauge should be about 0.4 Mpa .If the pressure is ok and all lubricating points work well, carry on next
32
step. Notice: When drawworks is working, the lubricating oil reached lubricating point can not return the oil tank immediately. As a result, the oil level will go lower. If the oil level is lower than the bottom line of oil scale, suitable oil shall be filled in the oil tank. 3) Move the handle of high speed /low speed drum to low speed position (no matter where the handle locates, the handle shall be moved to the low position once again). 4) Stop drawworks and move the speed-changing handle to shift I. (Of course, the locking shift mechanism shall be released first and then locked again after speed-changing is completed.) 5) Check the following items after the drawworks running for 1020 minutes at lowest speed: a) No friction, touch and interference, etc while running. b) Pressure of lubricating oil shall be stable and lubricating system shall work well. c) Engage the drum high speed/low speed, rotary table clutch respectively to check the condition of operation and brake. 6) Change shift II, repeat the procedure above mentioned. 7) The requirement for adjustment: a) Operation of different parts shall be accurate and flexible. b) All the parts are well sealed and oil leakage is prohibited. c) Pressure of lubricating oil shall be stable and oil volume in lubricating point shall be suitable. d) Running smooth without abnormal vibration and noise. e) The elevated temperature in all bearing is normal. 8) If all tests above are normal, the rope clamp can be assembled of fast line and wind the fast wireline. (See the relevant specification) If there is any abnormal phenomenon during the idle run test, find out the reason in accordance with section 5.6 and solve the problem. Then it shall be checked again and then can be operated. 5.2.4. Work after the mast and substructure is raised When installing mechanical anti-collision device, crown saver should be first installed and then O-matic anti-collision device. 1) Install, operate and check crown saver device a) Install guide line accessories of crown saver before rig-up, put the wireline on, grease the guide line sheave to make the wireline no block through guide way shaft and guide way wheels. The start end of anti-collision wireline should be firmly fastened by three standard clips. The anti-collision line should be started to be installed 6m from traveling block top to crown block bottom. b) Install crown saver after rig-up, and fasten it at the proper height on the front leg of the mast. c) Move crown saver handle to off position manually, insert the pin to lock, pull the anti-collision line into the line connector bore of crown saver and fasten it with two standard clips. d) Adjust the valve rod extension length of drum O-matic valve to the minimum valve, test the
33
anti-collision performance of crown saver twice or three times, observe anti-collision effect and check whether system action meet the requirements (like if brake works, if system power shut down). 2) Install, operate and check O-matic valve anti-collision device Before install and adjust O-matic valve device, the crown saver handle should be at off position, insert the spare pin to lock it and make crown saver not work. Adjust the left/right position of O-matic valve on the top of drawworks and extension length of valve rod to make traveling system up to anti-collision height (6m from traveling block top to crown block bottom) and touch O-matic valve rod to start position, and then fasten fixed bolts of o-matic and lock nuts, test anti-collision performance twice or three times to observe the anti-collision effect and check whether system action meets requirements (like if brake works, if system power shut down). After finish the adjustment of drum o-matic anti-collision device, take out the spare pin of crown saver, move crown saver handle to off position, insert pin with anti-collision line to lock and make these two anti-collision devices waiting for working. 3) Adjust as anti-collision device instruction manual: a. Set up alarm to make the alarm works when the traveling block is 10~8m away form the bottom of the crown block platform. b. Set up brake to make the brake works and cut off the power when the traveling block is 8~7m away form the bottom of the crown block platform.
5.3. System Pressure Setting for Oil, Air and Water System
Before operation, the system pressure of compressed air, lubricating oil, cooling water, etc must be checked. If it is necessary, the system shall be adjusted to the normal scope. The normal data is as follows: Air pressure Data Chart Position Max. Main pipeline of control console Low speed clutch High speed clutch Rotary table clutch Bailing drum clutch Inertial brake of input shaft Break down cathead Make up cathead 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 Pressure MPa Normal 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 Min. 0.8 0.7 0.7 0.6 0.6 0.5 0.7 0.7
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Lubricating system Position Max. Lubricating point 0.6 Pressure MPa Normal 0.4 Min. 0.1
Water Pressure Position Max. Main drum brake 0.6 Pressure MPa Normal 0.3 Min. 0.1
5.4. Operation Manual

1. The power for JC-70D drawworks is provided by two sets of YZ08/YZ08A motor. Check the motor connection and guard before running. 2. There are four shifts in JC-70D drawworks which combined by mechanical shift and high speed /lower speed of drum. When tripping in or tripping out, it adopts the mechanical shift first, then high speed /lower speed of drum to get the required shift combination. Before change the shift by mechanical methods, stop the motor and ensure the input shaft stopping running. 3. When tripping out, if brake is required, disengage the low or high speed clutch first, and then brake the drawworks quickly. 4. When tripping in, especially, it is with high speed and heavy load, it is prohibited to control speed in slight brake conditions (friction block does not against the disc heavily, just contacts the disc surface) for a long time in order to avoid the early damage of brake block and brake disc. 5. When tripping in the drill stem over 700m, the electric magnet eddy current brake must be engaged. 6. Before tripping in every time, check the circuit water way and ensure that there is no blockage and no leakage. 7. It is prohibited to cool the brake disc by cool water when brake disc (hub) is in high temperature to prevent from emergency cooling which may cause crack. Before tripping in, start water pump and circulate the water and lasts for 1015 minutes after tripping in is finished, then stop the water pump. 8. It is prohibited that oil or impurity enters between brake disc and brake block to avoid slip or damage of the brake disc/hub. 9. Check the oil way and chain carefully every shift and ensure the chain and lubricating pipeline work in good condition. Pressure of lubricating oil shall be between 0.10.4MPa. If the pressure exceeds this range, find out the reason and solve the problem in time. 10. When drawworks is running, the guard must be fastened and the window must be fixed. It is prohibited to fill the oil or grease while running to prevent from accident. 11. When drum shaft is not stopped completely, it is prohibited to engage the electromagnetic eddy current brake to prevent form damaging the gear sleeve.
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5.5. Routine Check and Maintenance

5.5.1. Check items every shift 1. Whether bolts connecting the drawworks and substructure are complete and fastened. 2. Whether press plate bolts of fast rope clamp is complete and fastened. 3. Whether fixed bolts of brake mechanism is complete and fastened, whether bearings work well and link pin, gasket, cotter pin are complete, band brake tightness is suitable. 4. Whether oil level in oil tank is in the oil scale scope. 5. Whether pressure of gear oil pump is between 0.0.4Mpa. 6. Whether chains are in good lubricating conditions. 7. The elevated temperature of every shaft end. 8. Check oil leakage in shaft end, bearing cover and tank cover. 9. The lowest air pressure of air-tube clutch is 0.7Mpa. 10. Whether all the air valve, air pipeline and connector are leaking air. 11. Whether lubricating pipeline is leaking oil, injecting nozzle is blocked, direction of nozzle is correct. 12. Whether the transmission parts are normal. 13. The reliability test of anti-clash device: While the drawworks is stopped, move the O-matic valve manually, and the clutch should
discharge air at the moment and the disc brake applies brake immediately. Move the O-matic valve to its original position, and press the reset button. While there is no drilling tools, put through the power to drive the drawworks to operate at low
speed, when the traveling block is lifted to certain height and it alarms, then the traveling block is lifted continuously and the power will be cut off and the brake is applied. After the above two tests are all ok, it can be operated.
5.5.2. Other checking items 1. Changing period of machine oil: It is about 2000 hours or more if there is less impurity in the oil tank and oil is in good conditions. 2. During stop, check and adjust it, fasten the connecting elements. If necessary, check whether chain pin is loosened or side plate is scraped. 3. Check the clutch and wearing condition of friction block at any moment, adjust and replace them timely. 4. Usually, check the wearing of chain, chain bearing, gear, seal ring every half year .If necessary, and replace them timely. Check lubricating system, air way hose to see if they are aging or damaged, and check whether connection, fastening piece is loosed.
36
5. The item which is not included in the item above mentioned shall be noticed during patrol inspection and routine observation. Solve any problem in the equipment timely to assure the normal operation.
5.6. General Trouble and Troubleshooting

Trouble Reason A. Pressure of lubricating system is low B. Pipeline is blocked Temperature is above the rating C. Lubricating oil is deteriorated D. Revolving parts are hindered and stagnant E. Oil level is too low and oil is less, affecting radiating. A. Chain is too loose B. Bearing is damaged Noise is above the rating C. Connector or fastening piece is loosed D. System resonance vibration E. Abnormal sound caused by colliding because of impurity entering to machine or parts are pull-off Troubleshooting Adjust system pressure to 0.20.4MPa Find the pipeline related heating parts and drain the block Clean and replace oil Find the reason and solve it
Fill the lubricating oil to rated value Operation as the manual of section Adjustment of chains Replace bearing Find the reason and solve it Change operating speed to avoid it Find the reason and solve it, make sure it will never happen again. Oil steam pressure of cavity is too high---check respiratory valve, clean impurity
A. Leakage from bearing location Oil leakage
Damage of oil seal---replace it Lubricating oil is not heavy---chose suitable oil type according to season Hood deformationmake plain
B. Leakage from guard
Seal is not effective-find reason and solve it
A. Trouble of air control, electric, Others hydraulic system B. Trouble of brake system
See the relevant section of specification See the relevant section of specification
37
5.7. Periodical Inspection

When drawworks runs for a certain period, it will cause such phenomenon as wearing of running area, loose of connection, block in pipeline, and aging of seal element. If these problems can not be solved in time, it will bring bad influence for the machine. So besides the daily inspection and general maintenance as mentioned above, the machine should be checked and repaired regularly by special repairer. The complicated repair, such as changing bearing, shall be finished in repair factory or maintenance station. See the details of repair and adjustment to parts and assembly in section 6. See details of disassembly and assembly in section 7. 5.7.1. Regular inspection every quarter 1. Open the window and cover board of hood, check status of chain and chain, chain pin, roller, cotter pin shall be checked one by one. Judge the statue of parts according to inspection results and replace it if it is worn heavily. 2. Check the friction block and replace it when it is worn heavily. 3. Check pneumatic bag of air tube clutch and ensure whether it is aging, replace it when it is worn heavily. 4. Check the working gap of friction cathead and if necessary, adjust gasket or replace friction block. 5. Check the wear of brake hub and replace it when it is worn heavily. 6. Oil way Check the following parts and replace, repair or adjust according to real status. Oil tank Filter Oil pipeline Grease pipeline Chain lubricating nozzle Pressure gauge Sealing element
5.7.2. Regular inspection every year
1) Check all the bolts and nuts of connector and fasted them if they are loosened. Replace the cotter pin and fixed iron wire if necessary. 2) 3) 4) 5)
Check the wearing of bearing and replace it if necessary. Check all lubricating /grease pipeline and make sure there is no leakage or block. Check the clutch and replace the wearing piece. Check the wearing condition of sprocket tooth and chain.
38
6) Check the wearing condition of brake disc/hub, and check condition of all the connector or pipeline of cooling system. 7) 8) 9)
Check the wearing condition of brake block. Clean the oil tank thoroughly. Check the inner status of motor and alignment.
10) Check all the pipelines, valves, executive mechanism of pressure gauge in air control system. 11) Check all the oil seal.
After checking, replace and repair the parts needed to be repaired and replaced. Some complicated parts shall be maintained in repairing factory or maintenance station.
6. Maintenance and Adjustment

6.1. Alignment and Adjustment of Transmission Shaft in Power Unit
Two motors and transmission shaft are connected by the coupling, and their positioning precision is adjusted well in factory. Owing to maintenance or other reason, disassemble the connection. During installation, measure and adjust the relative position. Do not connect the coupling first during installation to leave them rotary. Install a dial indicator on the one of coupling, stretch feeler pin to another outside surface of coupling Rotate one coupling to measure the radial deviation and its maximum value is 0.08mm. The installation precision can be obtained by moving the motor or increasing or decreasing the gasket. Fasten all assembling bolts and measure it again. If it is ok, connect the coupling as a whole.
Dwg.17 Alignment of coupling of transmission shaft
39
6.2. Maintenance and Adjustment of Air Tube Clutch

The balance test and alignment adjustment for air tube clutch assembly have been done in the factory. After operating for a certain period, the wearing parts are worn step by step and ability to transfer torque is decreased. When the thickness of friction block is 2/3 times of original block, it shall be changed. As for friction hub, the wearing in diameter (compare with original diameter) surpasses 4~6mm, it must be replaced. If any of clutch couple is disassembled, it shall be aligned according to the following methods during reinstallation. (See Dwg. 18)
B Dwg.18 Alignment of Clutch
Test according to Dwg. 18A, install a dial indicator, and rotate one of the clutches to read the gauge while rotating by 90 every time. Pay attention to the radial deviation which shall be less than 0.05mm. Test according to Dwg. 18B, rotate one of the clutches, read the gauge while rotating by 90every time. Pay attention to the end face deviation which shall be less than 0.005Dmm. (D means the diameter measured by dial indicator in friction hub)
40
Test according to Dwg.18 C, install two dial indicators (use the tools in the Dwg. during installation) to measure the depth of parallelism. After rotating by a certain degree, record the margin of value in two gauges. 0.005L. L: distance of two gauges NoticeGrease and liquid are prohibited to enter the friction surface of clutch because they will decrease the friction factor and lower the transmitted torque. If they enter the friction surface, they shall be cleaned by solvent and then dried.
6.3. Maintenance and Adjustment of Cathead

Install the cathead according to Dwg. 7A and Dwg. 7B. Because the make-up cathead and break down cathead have similar structures, the following items are just described in accordance with the make-up cathead. 6.3.1. Dismantle the cathead (See Dwg. 7A) 1. Dismantle the air pipeline. 2. Dismantle the bolts (33) by the long stem sleeve spinner and dismantle all the assembly from the shaft with pulling tools, then all the elements shall be dismantled from shaft according to following procedure one by one. The dismantling shall be done according to the repair requirement, and just dismantle the parts that needed to be repaired or replaced such as bearing and seals. So it is not necessary to dismantle all elements as stated here. 3. Take off three screws (31), and then take off the guard for make-up wireline (30). 4. Dismantle the screw (44), and take off the guard (11). (It consists of two pieces one of which has window.) 5. Dismantle the spring (13). 6. Take off the bolts (33), and dismantle the dead cathead (1) from shaft. 7. Take off the bolts (36), and separate the bearing cover (18) and sleeve (19). 8. Dismantle the parts related to the drum (5) from the cathead shaft, one ring of end thrust bearing 45still remains in the shaft and another ring of end thrust bearing is dismantled together with the drum. The roller has nothing to do with them now. Then check the bearing, if it needs to be replaced, all rollers in the bearing shall be replaced. (Notice: When replace the bearing, inner race is tightened if it matches the shaft and outer ring is tightened if it matches the bearing seat.) 9. Dismantle bolts (42), take off spacer (24) and separate the piston (22) and other relevant parts from the drum. (Refer to the item mentioned above for dismantling of the end thrust bearing.) 10.Remove the retainer ring for the hole (6) by special pincers, then remove the sealing ring (7), caulking ring (8), inner race (9), bearing (40) (totally two units), end thrust bearing (41) respectively. Check the condition of each bearing and replace it if necessary. Check the length of all spring. 11. Check condition of friction block (4) and if necessary, take off the sunk screw (27) to replace it. 6.3.2. Reinstallation
41
Assemble all components and parts to the original position as the procedure contrary with above. Check the conditions of all parts again. The components installed shall be no block or hinder, etc. It is necessary to adjust the clearance between the clutch friction block and wireline drum. The process is as follows: 1. Adjust the thickness of filling piece (49) to make the clearance between the friction block and wireline drum be 0.8~1.6mm. Check the clearance every six months. 2. When wearing of friction block is 2/3 times of original thickness, it must be replaced. 6.3.3. Replace the air bladder The process is as follows: Coat the grease in the lip of bladder for installation. 1. Check and ensure no burr and arris at the position of pressing the lip. If necessary, polish the position with a clean oil stone. 2. Assemble the bladder (20) in the retainer (21), and then assemble the gasket ring (14). 3. Install the assembled bladder unit in the sleeve (19), and tighten it by screw 37. Pay attention to the match of air inlet. Notice: Do not install the bladder by force because it may damage the bladder. Caution: The air cannot be charged until the whole assembly is installed. Otherwise, it may injury the worker.
6.4. Position-setting of Electromagnetic Eddy Current Brake

It is a must to align electromagnetic eddy current brake after again installation. The process is as follows: 1. Take off screw (1) and separate shift fork (2) from outer gear sleeve (3), then pull the outer gear sleeve (3) to the right side (see Dwg.19). 2. Rotate the brake shaft, measure the misalignment between them. The accepted radial runout is 0.25mm (See Dwg.20). 3. Adjust the brake position (dismantle the original positioning device) and central height (adjust the filling shim thickness) to change the alignment. Fasten all the setting bolts after measuring and measure alignment again, if it is out-of-tolerance, repeat the procedure mentioned above. 4. Weld the positioning block. 5. Connect the shifting fork and sleeve again.
42
Dwg.19 Auxiliary Brake Clutch 1. Screw; 2. Shift fork; 3. Outer gear sleeve; 4. Gear sleeve (Brake side); 5. Gear Sleeve (Drawworks Side); 6. Positioning Block
Dwg.20 Electric-magnetic eddy current brake alignment
6.5. Maintenance and adjustment of chain transmission

The center distance of sprockets in the chain transmission system is fixed and no tension pulley. All the transmission parameter is fixed before ex factory and is fixed by positioning device which can guarantee the transmission precision after many time installations. If it is operated in accordance with the specification, chain will have a long service life which is determined by load, working status, operation, lubrication, etc. When the abnormal sound and vibration is checked, it means the heavy wear in chain and sprocket, so it needs to be checked. Open the cover or observe hole cover of transmission system, check the chain and sprocket. First, check the crack, abruption, deformation, corrosion of component and check the dead chain link and
43
whether chain pin is revolving in the chain plate hole. If something is wrong, find reason and solve it, then replace the whole set chain, even if the part of chain is in good conditions. If the chain is in good conditions, do as the following process: Measure the section of chain according to Dwg. 21 and table, and if the wear extension surpasses the 3% or regulates limitation, change the whole set chain. It is prohibited to connect the new chain and old chain section because it may damage the transmission device because of transmission rough running. In the no- adjusting drive mechanism, allowable wear extension is limited in the half pitch of chain. Measuring length
Dwg.21 Measure the wear extension of chain - gear number of big chain wheel Table I Measure the wear extension of chain Chain pitch Link No. mm 38.10 44.45 50.80 57.15 63.50 (in) 1.500 1.750 2.000 2.250 2.500 16 14 12 12 10 mm 609.6 622.3 609.6 685.8 635.0 Measuring length Nominal link length (in) 24.00 24.50 24.00 27.00 25.00 Link length (3% wear status ) mm 627.86 640.97 627.86 706.37 654.05 (in) 34.719 25.235 24.719 27.810 25.750
If the wear extension is within the permitted scope, it can be used continually. Because the chain length is added and sag is bigger, it shall get rid of two chain links and connect again. Sometimes, it can not be connected because it is short of two link chains or it is so tight (no sag or sag is so small), it shall add a bridge link. Usually, it shall be avoided to use bridge link because the load of bridge link is smaller than other links. If required, it shall use the bridge link whose pin is force fit. (See Dwg. 21)
44
6.5.1. Check chain tightness Brake one of sprocket shaft and tension another sprocket shaft rotating by hand. See Dwg. 22. Measure the sag and see the data in chart .
Dwg.21 Combined bridge chain link Chart II Recommended data for chains middle point motion AC Middle position of transmission device 250(10) 510(20) Tangent line length of two chains mm (in) 760(30) 1270(50) 1780(70) 2540(100) Horizontal ~45 mm 10~15 20~30 30~45 51~76 71~107 102~152 in 0.4~0.5 0.8~1.2 1.2~1.8 2.0~3.0 2.8~4.2 4.0~6.0 45~Vertical mm 5~8 10~15 15~23 25~38 36~53 51~76 in 0.2~0.3 0.4~0.6 0.5~0.9 10.~1.5 1.4~2.1 2.0~3.0
45
Dwg. 22 Motion of middle point 6.5.2. Check sprocket wear. Check the contacting status of transmission parts and surface roughness of tooth in sprocket by eye. Check the tooth thickness (Max. 5% thickness which is worn is permitted) and whether sprocket mate is sunk. The sprocket must be replaced if it is obvious to see the sprocket wear without checking template (see Dwg.23).
Dwg. 23 Wearing sprocket It is prohibited to connect the new chain with worn sprocket because it will cause wear to chain quickly. The new chain link pitch distance is much shorter than the worn sprockets. Before disengaging of the chain link and the sprocket, all loads on the chain link concentrate on last sprocket tooth. Then, when the chain link and the sprocket are separated from meshes, roller jumps out suddenly from sunken location of sprocket. When the load transmits from a wheel tooth to the next wheel tooth, causes a impact load on the chain link. 6.5.3. Sprocket maintenance While the maintenance, if any of sprocket shaft has been dismantled, such as replace the bearing, sprocket, gear, etc, it shall be checked depth of parallelism and coplanar again after installation. See the checking method in Dwg. 24: Use a long leveling ruler or tension the thin steel wire against the side face of sprocket and measure the depth of parallelism and coplanar. See permitted tolerance in drawing. If it is out-of tolerance, it
46
shall be adjusted and added/decreased suitable shims in the proper position of the shaft (or change the sleeve size) to make the shaft move cross direction and improve coplanar.
Dwg.24 Alignment of chains drive
7. Dismantle disassemble and re-assemble drawworks shaft assembly

When operate for a certain period, rig needs to be repaired in repair station and repairing factory because of inner parts wear and troubleshooting. This section mainly introduces how to dismantle shaft assembly from drawworks, disassemble the assembly for easy changing the parts and reassemble etc. Dismantle parts according to repaired requirement. Dismantle it to parts need to be replaced like bearing, seal elements, and then stop to repair. There is no need to disassemble it completely as this section describes.
7.1. Dismantle, disassemble, and re-assemble the drum shaft assembly

7.1.1. Dismantle the drum shaft assembly. See details in Dwg.4. Dismantle all the components relevant to drum shaft assembly: Air/Water pipeline Auxiliary brake system (move or dismantle the electrical-magnet eddy current brake) Relevant guard Transmission chain Relevant parts (brake tongs, etc) of disc brake system
Left-right bearing seat of drum shaft assembly is a flat circle. After taking off all the connecting bolts, rotate the left-right bearing seat and match the fan-shaped section to the gap of drawworks wall plate. Lift the assembly lowly from the gap. Put the dismantled drum shaft assembly on the floor made from wood and keep it steady. It is prohibited to put the dismantled drum shaft assembly on the cement floor or steel plate.
47
Check the damaged parts and dismantle the necessary parts. Keep and guard the other parts in good conditions. 7.1.2. Dismantle the air tube clutch Dismantle the pipeline and some relevant parts, such as water/air instrument device. Dismantle connecting bolts. Take off the outer rim and some relevant parts. Dismantle bolts connecting the friction hub and connecting sprocket. Dismantle the friction hub directly.
7.1.3. Dismantle the sprocket Sprocket is connected by two sets bearing and shaft. The fit of bearing and some relevant parts is transition fit. So it is easy to dismantle the bearing by screw drawing device (two jaws or three jaws) or strike the bearing by wood hammer and copper rod. 7.1.4. Dismantle left and right bearing seat Dismantle the bearing striking by wood hammer after take off the screw in the bearing seat. If it is required to change the oil seal or bearing, bearing need to be dismantled from shaft. The fit
of bearing and bearing journal is little magnitude of interference, so advice to dismantle it by screw drawing device. If the bearing has been damaged, dismantle it freely and replace it, but it shall be avoided to damage the bearing journal. If it is dismantled by heating method, it shall be operated by experienced gas welder and measure the temperature of assembled location by thermometric gauge. The max. Temperature is lower than 350 C and it is prohibited to dismantle the bearing by torch cutting. 7.1.5. Disassemble drum body The drum body and the axis joint are the light full coordination, the drum body is fixed in the factory after the well type stove internal heating, suggested the user does not disassemble, if the user really has the essential disassembling to have to use the press (horizontal-type hydraulic press machine) to press out the axis. 7.1.6. Re-assemble the drum shaft Clean all the parts before assembly, lubricate fitting surface and install them again.
7.2. Dismantle, disassemble, and assemble of bailing drum

See details in drawing 5: bailing drum assembly. 7.2.1. Dismantle bailing drum from drawworks body Dismantle air pipes and related components. Dismantle the guard; Disconnect chains;
48
Dismantle the wallboard from bailing drum as the instruction of 7.1.1.
7.2.2. Disassemble of bailing drum Screw off M42 bolt on the end of bearing using a long handle box spanner; hammer the right side
of cathead assembly or use a puller (see section 6.3.1 in this manual) to disassemble the cathead assembly and drum shaft (they are105, 1:10 taper fitting); and then cathead assembly can be disassembled. Dismantle left and right bearing seats to take down the bearing cover and seat as a whole; it can
be dismantled separately. Using a puller to take out left chain; Dismantle the main air-in pipes of the clutch. Take out the M20x40 connecting bolts of air-tube clutch land to dismantle the outside of clutch. If the brake hub (left or right) needs be disassembled, first take down the grease pipes and then
connecting screw to disconnect. Dismantle the drum and the bearing as follows:
1) Take down left and right bearing covers. 2) Use copper rod underlying wood hammer or hammer to move the bearing rightwards (or move the drum leftwards) 3) After disassembly, the interior ring of right bearing is left on the drum. If bearing needs be changed, further dismantle work would be done. 7.2.3 Re-assemble Clean the parts needs be changed before assembly, lubricate fitting surface and install them again.
7.3. Dismantle, disassemble, and assemble drive shaft

See details in drawing 8: drive shaft assembly. 7.3.1 Disassemble the drive shaft assembly Before dismantling transmission shaft, separate power unit and drawworks totally. Take chain
from drawworks cavity so as to dismantle and clean inside drawworks. Dismantle all the bolts of bearing seat; Dismantle shift mechanism and related components; There are two moving stopper in bearing seat of drawworks. First, dismantle them and expose
two breaches. Pay attention to moving stopper position and they shall be installed back to original position. Rotate bearing seat 90 and make flat surface of bearing match breach, then pull transmission
shaft integrity from drawworks frame.

49
7.3.2 Disassemble and re-assemble Do the following procedure according to requirement. Dismantle two press plates at the end of shaft end and take out sprocket from shaft. Special puller
has to be used because it is magnitude of interference. Use puller or wood hammer (copper rod) to knock and take out bearing seat, sleeve. Dismantle
bearing cover so as to clean or change bearing; Take out oil guiding ring near right bearing seat; Dismantle two free sprockets, internal and external gear of change shift separately by special
puller or knocking. Clean all the parts and replace parts if needed. Install them on the opposite procedure.
7.4 Dismantle, disassemble and assemble input shaft

See details in drawing 9: Input shaft assembly. 7.4.1. Disintegrate, assemble shaft assembly. Dismantle two sets motor, two sets chains first before dismantling shaft assembly. According to real situation to decide if separate case with drawworks, if only case need to be
required, it needs not to be separate the case. Dismantle press plate at two ends. Dismantle shaft coupling by puller. Dismantle sleeve. Dismantle supporting bolts of air tube clutch. Take out support and air tube clutch. Dismantle connecting bolt of friction hub. Disconnect friction hub and shaft hub; Dismantle connecting bolts of left, right bearing seat and move parts to left, take it out from big
hole direction. Dismantle bearing seat completing with bearing and replace bearing; Because it is magnitude of interference between sprocket and shaft, use special puller to take
them out. If taking them out by heating, it must be done by experienced gas welder. Heat them quickly and uniform, measure shaft temperature continually by measuring gauge and maximum temperature shall be lower than 350C. 7.4.2. Re-assemble Clean all the parts and coat lubricating oil in matching surface. Assemble them at opposite process of disassembly.
7.5. Assembly of shaft assembly

When it is troubled in any component of drawworks, it need to be repaired, such as change bearing,
50
please assemble the parts according to the item7.1~7.4, and then do as the following procedure. 1) Assemble drum shaft well and check it. Lift assembly as a whole to the drawworks frame. Bearing seat at two ends of drum shaft is oblate. Flat breach shall be matched to assembled hole in drawworks frame during lifting. When shaft center and hole center are matched together, rotate bearing seat to 90 and tighten them by bolts. 2) Assemble bailing drum shaft, transmission shaft well and check it. Lift assembly as a whole to the drawworks frame and bearing seat breach shall be matched to assembled hole in drawworks frame. When shaft center and hole center are matched together, rotate bearing seat to 90 and tighten them by bolts. 3)) The way to assemble drive shaft is similar with 1) and 2) above, while its notch in wall-plate is closed by flashboard and all flashboards and stoppers can not be interchangeable, so they must to be installed to original position. The side face deflection of matching sprocket is less 1 mm and if it is out-of- tolerance, adjust it by changing the thickness of shims. After finished, the entire shaft shall revolve smoothly rotated by hand.
8. Dismantle and transport drawworks

After finishing drilling work, please operate as the instructions of rig-down the mast and substructure in this manual. Note: Do not dismantle drawworks until you assure there is no following work which needs drawworks.
8.1. Dismantle the drawworks form the drilling floor

Unwind all the wireline in the drum by wireline spooler. Separate drawworks with the supplied system and dismantle the power circuit. Dismantle the air, oil, water pipeline. According to real situation, dismantle one end and keep the
connector in good conditions avoiding the damage and impurity. Open the window of power unit and take apart the chain from connector, put the chain in the
drawworks. Take off the bolts connecting the main body of drawworks and power unit, connecting window. Take off the bolts connecting the drilling floor and drawworks main body, power unit. Dismantle the power unit and main body of drawworks. Use cover plate matched by factory to seal two windows and prevent the impurity. Preserve all the dismantling bolts and nuts, other connecting elements.
8.2. Transportation
When it is delivered, the main unit and power unit are divided into two parts separately and transported in nude. Usually, transport electric-magnetic eddy current brake and drawworks main unit as a whole, or dismantle electric-magnetic eddy current brake and deliver it with power unit or other parts.
51
Transportation size of power unit: (LXHXW) Transportation size of drawworks main body: (LXHXW) Weight of power unit: Weight of drawworks main body :
640016001890mm 752036703216mm. 12460kg 45785kginclude electric-magnet eddy current brake 33285kgexclude electric-magnet eddy current brake
9. JC-70D drawworks vulnerable parts and spare parts list

No. 1 Code GB/T288-94 Description Bearing Specification No:22230/W33/C3 15027073 No:22338CA/W33/C3 190400132 No:23048/W33/C3 24036056 No:32148 24036056 No:32140 20031051 No:322348 17031052 No:22234C/W33/C3 17031086 No:22230C/W33/C3 15027073 No:22244CA/W33/C3 220400108 No:22240CA/W33/C3 20036098 No:32240 20036058 Drum shaft Bailing drum shaft Remarks Input shaft
GB/T288-94
Bearing
Transmission shaft
GB283-64
Bearing
Transmission shaft Transmission shaft Transmission shaft Bailing Drum shaft Bailing Drum shaft shaft, Drum shaft, Drum
GB283-64
Bearing
GB283-64
Bearing
GB283-64
Bearing
GB/T288-94
Bearing
GB/T288-94
Bearing
GB/T288-94
Bearing
10
GB/T288-94
Bearing
Drum shaft
11
GB283-64
Bearing
Drum shaft
52
No. 12 13 14 15 16 17 18 19 20 21 22 23
Code
Description LT1068/305T clutch LT965/305T clutch LT700/135 clutch
Specification
Remarks
T14-002.00 HG4-692-67 GB3452.1-82 HG4-692-67 JJ982-7767 L-63B Y-63B CB-100 YN60-1 MJU-250X180 F G1/8 GB/T288-94 2-HA-2 397.2234 2-HA-2Z CD7 G1/4 ND10 Y-60ZT 2-HA-3 2-HA-1
LT500/125 clutch Oil seal O-RING Oil seal Combined washer 36 Flow regulating valve Overflow valve Gear Pump Shockproof gauge(0-1.6Mpa) Oil suction filter Pressure switch Bearing3509 Three position four way air guide valve Air treatment dual parts Three position four way air guide valve (reset) Push button valve Quick release valve Pressure gauge (01.0MP) Three way switch for shift Two position Three way switch Imported Imported Imported Imported Imported Imported Imported Imported Imported pressure 17020016 12.52.65 PD25029018
24 25 26 27 28 29 30 31 32 33 34
53
No. 35
Code 2-HA-1R
Description Two position Three way switch Three position Three way electromagnetic valve Explosion proof
Specification
Remarks Imported
36
ND7 G1/4
Imported
37 38 39 40
220VAC K23JK-F40 K23JQ-F40 ND7
electromagnetic valve air control reversing valve air control reversing valve Two position Three way reversing valve Two position Three way reversing valve Shuttle valve O-matic valve Quick release valve Post rod valve Two position Three way air control valve 30 three way air cylinder
Imported
Imported
41 42 43 44 45 46
ND12 ND5 FP-L6 ND12 QF518 ND7
Imported Imported Imported Imported Imported Imported
47 48 49 50 QGA50X25-J ND7 ND5
air cylinder of rear flange Flow regulating valve Double press valve Imported Imported
54
10.
No. 1
JC-70D drawworks transmission chain list

Code GB1243.1-83 Description & Specification 12A-2 chain (Double row) 24S-6 chain (1-1/2" six row ) 24S-6 chain (1-1/2" six row ) 32S-4 chain (2" four row ) 32S-4 chain (2" four row ) Qty. 84 Weight 4.8
GB3638-83
136
174
GB3638-83
120
153.6
GB3638-83
114
226
GB3638-83
90
179.2
55
11. JC-70D drawworks nameplate
56

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