Rotary Well Drill Rig Operators Manual
on CD

This manual contains instructions for operating and servicing the Drilling System, Well, Rotary, Truck- Mounted, Air-Transportable, 600-Feet Capacity (drilling system). The drilling system includes two primary units: a drilling rig, and a support vehicle commonly referred to as a rig tender. The drilling rig requires a three-man crew. It is designed for use in all types of environmental conditions.

a. Major Components Features and Capabilities.
(1) Mast. (a) Mud and air discharge piping. (b) Hydraulic mast raising cylinders. (c) Mast lighting. (d) Chain pulldown assembly. (e) Chain feed sprocket assembly. (f) Crown block assembly.

(2) Mud Pump System. (a) Mud pump drive. (b) Air clutch. (c) Powerend. (d) Fluid end.

(3) Air Compressor System. (a) Air compressor. (b) Air/oil separator. (c) Oil cooler. (d) Air cleaner. (e) Air clutch.

(4) Sub-Drive Assembly. (a) Mud pump driveshaft. (b) Power take-off. (c) Drawworks driveshaft. (d) Hydraulic pumps.

(5) Drawworks. (a) Hoist drum. (b) Auxiliary drum. (c) Third drum. (d) Bevel gear box. (e) Band-type brakes. (f) Air clutch.

(6) Hydraulic System. (a) 3-micron oil filter. (b) 40-gal oil reservoir. (c) Control valves. (7) Water/Foam Injection System. (a) Hydraulic motor. (b) Water pump.

(8) Force-Feed Lubricator. (a) Electric motor driven pump. (b) Reservoir.

(9) Break-Out Assembly. (a) Break-out wrench. (b) Break-out tongs. (c) Hydraulic break-out cylinder.

(10) Rotary Table and Drive. (a) Transfer cylinders. (b) Hydrostatic transmission. (c) Hydraulic motor. (d) Rotary table.

(11) Pulldown Drive System. (a) Chain feed drive. (b) Hydraulic motor. (c) Pulldown transmission.
(12) Operator's Instrument Cluster. (a) Air control valves. (b) Air line conditioner. (c) Gages and meters.
(13) Frame Components. (a) Frame lighting. (b) Operator's and helper's platform. (c) Front and rear hydraulic leveling jacks.
(14) Truck. (a) Rear axle or front and rear axle drive. (b) Air brakes. (c) 6-cylinder diesel engine. (d) Turbocharger. (e) Five-speed transmission. (f) Two-speed transfer case. (g) Power steering.

b. Location and Description of Major Components.
(1) Mast (1, Figure 1-2). The mast is mounted to mast pivot brackets at the rear of the drilling rig. Hydraulic cylinders raise and lower the mast to upright or transport positions. The mast's height (32') permits the use of 20' drill pipe or'20' lengths of casing. The mast is equipped with a chain feed, hydraulic-motor powered pulldown system for applying drilling pressure on the bit. A lighting system allows use of the drilling system at night.

(2) Mud Pump (2, Figure 1-2). The mud pump provides circulation of drilling fluid during drilling operations. It is a duplex, double-acting, piston-type pump with removable, hardened-steel cylinder liners. The pump is driveshaft driven from the sub-drive, by way of an air-clutch operated mud pump drive unit.

(3) Air Compressor (3, Figure 1-2). The air compressor provides air for air rotary drilling; it can also be used to supply air for drilling large diameter holes using the foam method. The compressor is powered from the sub-drive through an air clutch.

(4) Sub-Drive (4, Figure 1-2). The sub-drive assembly is a power transfer unit that receives power from the truck's power take-off. One side of the subdrive delivers power to drive the drawworks and the air compressor; the other side delivers power to drive the mud pump and the four hydraulic pumps used to deliver hydrostatic power to other rig systems.

(5) Drawworks (5, Figure 1-2). The drawworks consists of three cable drums used for lifting drilling components at the drilling site. The hoist drum supports the swivel, kelly, drill pipe, drill collars, and bits-elements that make up the "drill string." The auxiliary drum is used to handle drill pipe when adding joints of drill pipe to the drill string.

(6) Water/Foam Injection Pump (6, Figure 1-2). This pump system injects water and foam into the drilling system discharge line during certain drilling operations. It includes a high-pressure piston pump powered by a variable-speed hydraulic motor. Foam concentrates are injected into the water discharge line by a pulse pump, at a controlled rate.

(7) Force Feed Lubrication System (7, Figure 1-2). This system provides lubrication into the air discharge line to lubricate down-the-hole drilling tools. It includes a force feed pumping mechanism; it has two feeds and one check valve.

(8) Break-out Tool Assembly (8, Figure 1-2). This device consists of a wrench and a hydraulic cylinder. It providesa mechanical leverage to separate the drill pipe connections when the drill string is being removed from the hole.

(9) Rotary Drive and Rotary Table (9, Figure 1-2). The rotary table is driven by a hydraulic motor, through a 4-speedtransmission and a drive shaft. These components work together to provide the rotating motion that is then transferred to the drill pipe, and therefore, to the drill bit.

(10) Pulldown and Chain Feed (10, Figure 1-2). This system, most of which is mounted on the mast, includes a hydraulic motor and a 2-speed transmission. Power from the motor/transmission is transferred to shaft sprockets, and then to the chain which spans the length of the mast. The chains connect to a yoke that is attached to the rotary swivel.
When power is applied to the chains, pressure is transferred to the yoke, swivel, drill pipe, and subsequently, to the drill bit.

(11) Instruments (11, Figure 1-2). The controls needed to perform most of the drilling operations are located at the left rear corner of the drilling rig. Gages and indicators provide sight readings of the various conditions of components of the drilling rig. Some indicators and controls are located at other remote points around the drilling rig.

(12) Hydraulic Jacks (12, Figure 1-2). Four hydraulic cylinders and jack baseplates are mounted to the drill frame at each of the rig's four corners. Each cylinder is controlled, independent of the others, by hydraulic actuators on the operator's control panel. The removable baseplates include security chains. Ample blocking is provided to ensure rig stability in sandy locations.

(13) Winch Assembly (13, Figure 1-2). A hydraulically driven, 20, 000 pound capacity winch is mounted on the front bumper of the drilling rig truck. It is operated from inside the truck cab by an air-shift control. Normally, the winch is used for non-drilling related operations, such as pulling the drilling rig, or other vehicles, from difficult-terrain situations.