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明 书 J S 津石®
津 石 R
Service Instructions
for
FDX140D Transfer Case
(No.: FDX140D 001SM)
Tianjin DFXK Petroleum Machinery Co., Ltd.
产Service
品 说 Instructions
明 书 J S 津石®
津 石 R
Foreword
These Service Instructions mainly introduce the model, technical parameters, main
structure, working principle, installation, debugging, common troubleshooting,
maintenance methods, and other knowledge of the transfer case, for use by equipment
management personnel, operation personnel and maintenance personnel during work.
These Service Instructions have been as consistent as possible with the actual product.
However, due to structural improvements or temporary changes in technical agreements,
these Service Instructions may differ slightly from the actual product. In such case,
please refer to the actual product. In case you encounter any situation not mentioned in
these Service Instructions, please notify our Technical Service Department, and we will
promptly provide technical answers or send service personnel to provide services.
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明 书 J S 津石®
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Safety Instructions
To avoid personal accidents and equipment damages, any personnel who use, manage, inspect,
maintain and repair this product must know very well the relevant contents of these Instructions,
observe the specification and procedures for use, management, operation, maintenance and repair of
this product, and pay special attention to the safety warnings, notices and other contents given herein,
as well as the safety rules and precautions as specified in the national laws and regulations, industry
regulations and of general common sense.
These Instructions may not be exhaustive. Therefore, when selecting any operation method, you must
first confirm that the method will neither jeopardize personal safety nor damage the equipment.
Correct maintenance is an important factor in the safe and reliable running of the product. The
maintenance personnel shall observe the methods specified in these Instructions for maintenance.
Correct maintenance and replacement with original parts is an important factor in the safe and reliable
running of the equipment. The user must repair and replace parts within the authorization scope of the
manufacturer.
Please pay close attention to the following headings and symbols when reading
these Service Instructions!
产Service
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明 书 J S 津石®
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Warning: It indicates a situation where casualties may occur if operating steps, methods, etc. are not properly
observed;
Notice: It indicates a situation where personal injuries or equipment damages may occur if operating steps,
methods, etc. are not properly observed;
Note: It is used to remind or explain the situation separately.
Table of Contents
1. Model and Main Technical Parameters.........................................................................1
1.1 Model..........................................................................................................................1
1.2 Main Technical Parameters...........................................................................................1
2. Main Structure and Operating Principle.........................................................................1
2.1 Structure.......................................................................................................................1
2.2 Operating Principle.....................................................................................................1
2.3 Position of Engagement Handles................................................................................3
2.4 Lubricating System.....................................................................................................3
3. Installation and Adjustment...........................................................................................3
3.1 Installation...................................................................................................................3
3.2 Adjustment...................................................................................................................3
4. Service and Maintenance..............................................................................................4
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明 书 J S 津石®
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4.1 Preparation and Inspection before Service of New Transfer Case...............................4
4.2 Engagement/Disengagement Operations......................................................................4
4.3 Inspection and Maintenance.......................................................................................4
4.4 Maintenance before Storage.......................................................................................5
4.5 Lubrication...................................................................................................................5
5. Common Troubles and Troubleshooting.........................................................................6
6. Figures and Lists............................................................................................................6
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明 书 J S 津石®
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1. Model and Main Technical Parameters
1.1 Model
FDX 140 D
FDX - Abbreviation of transfer case in Chinese Pinying
140 - Maximum output torque (KN.m)*10
D - Structure modification code
1.2 Main Performance Parameters
Maximum output torque 14KN.m
Maximum input speed 2500r/min
Output-to-drawworks transmission ratio i=1
Output-to-rotary table box transmission ratio i=1.53
Output-to-front/rear axle transmission ratio i=1
Dimension (L×W×H) 900×920×1386mm
Mass 905kg
2. Main Structure and Operating Principle
2.1 Structure
The transfer case is a power distribution device that exports the engine power to each
power output end. It is mainly used for 1,000m, 1,500m and 2,000m truck-mounted
drilling or workover rigs. Its body adopts a steel plate welded structure; the gear pair
transmission mechanism has one input end and four output ends. The engine power is
imported from input end 6 and exported from four power output ends. The output end 2
is used to drive the drawworks, the output end 7 is used to drive the rotary table, and the
output ends 8 and 9 are used to drive the rear and front axles. The transfer case is
manually engaged by operating the engagement mechanisms 1, 3 and 5, so as to achieve
power output at different positions. (Please see Figure 1: Structure of Transfer Case)
This transfer case has the characteristics such as compact structure, easy installation, and
reliable lubrication; the engagement devices are all manually operated, so that they have
the advantages such as flexibility, simplicity, safety, reliability, and long service life.
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2.2 Operating Principle
During drilling operations, if the handle 3 is turned to the "on-board drum
engagement" position and the handle 5 is turned to the "disengagement"
position (at this point, the front and rear axles under the vehicle are
disengaged), the drawworks will be engaged and the power will be transmitted
to the lifting system through the transmission shaft; in addition, if the handle 1
is turned to the "engagement" position, the rotary table will be engaged, and
the power will be transmitted from the transmission shaft to the rotation
system of rotary table.
Turntable Front Axle
Liquid tank
Engaged Disengaged Disengaged Engaged
Axle engaged
engaged
Carriage beam
Carriage beam
Travelling direction
分动
2
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Structure of Transfer Case (Figure 1)
1. Rotary table engagement handle 2. On-board drum output end 3. Upper/lower engagement
handle 4. Case body 5. Front axle engagement handle 6. Power input end 7. Rotary table output
end 8. Lower (rear axle) output end 9. Lower (front axle) output end
When the vehicle is moving, the power is switched to the lower output end
through the upper and lower engagement handle 3, so as to drive the rear axle.
If necessary during movement, the front axle of the vehicle may be driven by
operating the engagement handle 5.
Notice: The engagement of front axle is only used in special situations such as
slipping of rear tyres.
2.3 Position of Engagement Handles
The upper/lower engagement device 3 is controlled by a linkage lever. When the handle
is pushed towards the side of transfer case, power will be imported to the drawworks and
the transmission to lower part of vehicle will be cut off. When the handle is pushed away
from the side of transfer case, the transmission to drawworks will be cut off, and the
power will be transmitted to the rear axle under the vehicle; the accuracy of engagement
position can be controlled by adjusting nut (Top right figure in Figure 1).
Rotary table engagement handle 1: When the handle is turned close to the side of transfer
case, the rotary table will be disengaged; when the handle is turned away from the side of
transfer case, the rotary table will be disengaged (Top left figure in Figure 1).
Front axle engagement handle 5: When the handle is turned close to the side of transfer
case, the front axle will be engaged; when the handle is turned away from the side of
transfer case, the front axle will be disengaged (Top right figure in Figure 1)
Notice: The engagement position has been adjusted and locked before the
transfer case is delivered, and no adjustment is required during normal operation.
2.4 Lubricating System
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Three lubricating methods are adopted for the transfer case (See Figure 2).
Oil lubrication as indicated by 1
Splash lubrication as indicated by 2
Grease lubrication as indicated by 3
Schematic Diagram of Lubrication (Figure 2)
3. Installation and Adjustment
3.1 Installation
Assemble the transfer case and the transfer case bracket as a whole, and then tighten the
bolts; ensure that the output flange of the power system is parallel to the input flange
surface of the transfer case and the central height is consistent, position the transfer case
bracket on the frame beam, recheck whether the relative position between the output
flange surface of transfer case drawworks and the input flange of angle transmission box
is correct, weld the transfer case bracket on the frame, with continuous fillet welding and
a welding height of no less than 10mm.
3.2 Adjustment
The engagement movement distance of the fork in each engagement mechanism is
25mm, which has been adjusted in place according to the limit position before the
transfer case is delivered and secured with a locking nut. The bearing clearance of each
shaft system is 0.08-0.15mm, which may be controlled by adjusting the adjusting shims
between bearing cover and bearing box. The input and output flanges are matched with
the transmission shaft flange connections, which may vary due to changes in
transmission shaft flange.
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4. Service and Maintenance
4.1 Preparation and Inspection before Service of New Transfer Case
The newly-assembled transfer cases shall undergo a comprehensive inspection before
use, which mainly includes:
Rotate the input flange by hand, and inspect whether there is no abnormal
sound or jamming and it rotates smoothly.
Inspect all fasteners and ensure that they are securely connected without any
looseness.
Use a dipstick to inspect whether the oil level in the transfer case meets the
requirements.
After the above work is completed, an idle running test shall be conducted, and the
transfer case shall undergo a continuous running-in test for no less than 6 hours, so as to
inspect whether there is any abnormal noise and whether the temperature is too high. The
maximum temperature shall not be higher than the ambient temperature by 50℃, and the
local maximum temperature shall not exceed 80℃; the transfer case may be normally
used only after everything is normal.
4.2 Engagement/Disengagement Operations
4.2.1 Preparation for Engagement
If it is necessary to engage or disengage the engagement system during the operation, the
engagement or disengagement operation shall only be carried out after the engine is set at
the neutral position or turned off.
Notice: The engagement of power input control handle and the switching between
different power output ends must be carried out before the engine starts or when the
transmission is set at the neutral position; otherwise noise may occur and the engagement
components may get damaged.
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4.2.2 Please refer to Figure 1 for the position of engagement handles
Notice: When pushing the handle of engagement device, it may be difficult to
engage due to the mismatch between the teeth of the two gears. In such case, it is
necessary to slightly rotate the lower transmission shaft to align the gears, so as to
facilitate the engagement. When switching the power with other handles, if the
engagement cannot be achieved smoothly, the upper transmission shaft may be slightly
turned. The engagement position has been adjusted and locked before the transfer case is
delivered, and no adjustment is requirement during normal operation.
4.3 Inspection and Maintenance
4.3.1 Inspection items every 100 service hours
Inspect whether the oil level is normal
4.3.2 Inspection items every 300 service hours
Repeat the inspection item in 4.3.1
Inspect whether the external fasteners and connectors are loose
4.3.3 Inspection items every 1,000 service hours
A comprehensive inspection shall be carried out:
Repeat the inspection items in 4.3.1 and 4.3.2
Inspect for abnormal noises and looseness of all fasteners. During the
inspection, other parts and components shall be maintained, and any damaged
or severely-worn part or component shall be replaced in a timely manner.
4.4 Maintenance before Storage
Before storage, a comprehensive maintenance and anti-rust treatment shall be carried out.
After long-term storage, the transfer case shall be fully maintained before being put into
use. The maintenance method is to inspect the main components, clean them with light
oil, and then assemble them.
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4.5 Lubrication
The lubricating oil used for the transfer case is heavy-duty gear oil GL-5, with a viscosity
grade that varies with the season. 85W/90 (SAE) is used in summer and 75W/90 (SAE)
is used in winter, with a filling amount of 31L. When used in low-temperature
environments, the heating measures shall be taken.
Oil Replacement Cycle:
The oil shall be replaced for the first time after the first 300 service hours
Thereafter, the oil shall be replaced once every 1,000 service hours
After overhaul or repair, the oil shall be replaced
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5. Common Troubles and Troubleshooting
S/
N Trouble Symptom Causes Troubleshooting
1 Oil leakage The oil cup is damaged Replace the oil cup
The bearing is damaged Replace the bearing
The lubricating oil is insufficient Add the lubricating oil
2 Abnormal noise The gear clearance is too large
(neither of the above situations is
true) Replace the gear
The spline teeth on the shaft and
Carry out overlay welding to
the spline of the sliding gear
repair the shaft, or replace the
sleeve are worn
part with a new one
The clearance is too large
3 Gear tripping
The bearing is worn unevenly Replace the bearing with a
and severely. new one
The shifting fork is worn and
deformed. Carry out welding for repair
4 Difficulty in Rotate the input flange to
engagement/disen It is difficult to get engaged adjust the position
gagement The engagement sleeve cannot be Carry out adjustment
completely separated
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The lubricating oil is insufficient Supplement or replace the
or unsuitable lubricating oil
The engagement sleeve assembly
is worn Carry out replacement
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6. Figures and Lists
Table 1: List of Transfer Case
Quanti Quantit
S/N Name No. Name
ty y
1 Bolt 10 23 Case cover 1
2 Baffle 5 24 Air filter 1
3 Flange 5 25 Bolt 20
4 Bolt 48 26 Bolt 4
5 Bearing cover 4 27 Oil groove 1
6 Oil seal 5 28 Bearing cover 1
7 Sealing gasket 29 Bearing cover 1
8 Bearing 4 30 Sensor 1
9 Output shaft 4 31 Sensor cover 1
10 Bearing 4 32 Bolt 12
Shaft retaining
11 4 33 Bolt 4
ring
Shifting fork
12 4 34 Connecting shaft 1
sleeve
Shifting fork
13 3 35 Dipstick 1
support
14 Sealing ring 36 Intermediate shaft 1
15 Shaft sleeve Ⅲ 4 37 Key 6
16 Bearing 6 38 Input shaft Ⅱ 1
Hole retaining
17 6 39 Gear 1
ring
Shifting fork
18 Shaft sleeve Ⅰ 3 40 1
support
19 Gear 2 41 Plug 5
20 Input shaft Ⅰ 1 42 Oil cup 4
21 Case body 1 43 Spring 8
22 Sealing gasket 1 44 Steel ball 8
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放 大 View图 A 19 20 31
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