Technical Documents【No.

6 book】

Drop Box

Operation Manual
JJX140 DROP GEAR BOX

CONTENTS

ⅠMain Structure and Working Principle .............................................................................1

Ⅱ Model and Main Function Specification.........................................................................1
2.1 Model: ....................................................................................................................1
2.2 Main function specification.....................................................................................1
Ⅲ Installation and Adjustment............................................................................................2
3.1 Installation ..............................................................................................................2
3.2 Adjustment..............................................................................................................2
Ⅳ No-Load Test ................................................................................................................2
4.1 Test Run..................................................................................................................2
4.2 No-load test ............................................................................................................2
4.3 Loading test ............................................................................................................3
Ⅴ Inspection and Maintenance .......................................................................................3
5.1 The inspection for gear oil.......................................................................................3
5.2 The inspection of fastener .......................................................................................3
5.3 The test item of cover-off ........................................................................................3
5.5 Maintenance ...........................................................................................................3
5.6 Maintains before storage .........................................................................................4
Ⅵ lubrication ....................................................................................................................4
6.1 Period of replace oil ................................................................................................4
6.2 The oil sites like the following Fig: .........................................................................4
Lubrication points .............................................................................................................4
Ⅶ The Operation of Engaging/disengaging device .........................................................5
Ⅷ operation for front axles and rear axles ......................................................................5
Ⅸ Common Troubleshooting .........................................................................................5
Ⅹ Quick-Wear Parts list ..................................................................................................6
10.1 Bearing .................................................................................................................6
10.2 Oil seal..................................................................................................................6
Ⅺ. Attached drawings .......................................................................................................6

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JJX140 DROP GEAR BOX

ⅠMain Structure and Working Principle

JJX 140 drop box adopts multi-grade gear actuating system, its input axle is connected
with the change-speed box's input axle by the engagement equipment. On the contrasting
side of the input axle there is another input axle with the same axial line that is the delivery
outlet of the power. There is a set of engagement device between the drop box and its input
shaft which makes it possible that the drop box doesn’t run when the engine flames out. So
it reduces the starting and stopping frequency of the engine.
JJX140 drop box output axle's two sides has the delivery outlet which connects with
each drive axle by the universal transmission equipment, the front and back axle could
engage or disengage at the same time, and also could run by each.
Drop box dropped with five shafts. The first one and the third one arrange parallel at
the same flat, and the fifth one and the third one also do, the two flats make an angle. All of
this meets the need of the long drop distance, and also solve the antinomy about the big
offset angle between the engine derailleur output axle and vehicle centre.
The drop box has the advantage of large transmission torque and big drop distance. It is
important power transmission parts upon and down the workover.
Detailed information view attached Fig.1, Fig 2.

Ⅱ Model and Main Function Specification

2.1 Model:
JJX 140

Max. Output torque* 100N.m(885lbf.in)

The first letter of Chinese phonetic alphabet of
Drop box

2.2 Main function specification

Max. Output Torque: 14KN.M(123894lbf.in)
Gear Ratio: I=1:1
Max. Input rotating speed: 2100r/min
The excursion Qty. of the first fifth axle at the same flat: 750mm (29.5276in)
The vertical drop distance of the first and the fifth axle: 870mm (34.252in)
Overall dimensions (L ×W ×H): 1390 ×1047 ×1370(mm)
Weight: 1706kg (3761.09lbs)

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JJX140 DROP GEAR BOX

Ⅲ Installation and Adjustment

3.1 Installation
Weld the drop box on the proper place according the two output flanges’ center line of
the two engines, refer to the attach Fig.2

3.2 Adjustment
1.Gear adjustment
1) The misalignment of every gear teeth end
The way is: reduce or add the number of gasket at the two ends of the axles, insure the
big coincidence of the gears
2) The space of flank of tooth: the space should be controlled at 0.10-0.35mm
2. Adjustment of the bearing
The axle could run easily, and no axial gap, the way is to add or reduce the gaskets
under the bearing cap.

Ⅳ No-Load Test
4.1 Test Run
When the above work finished, take no-load test, run the machine for 5-10 seconds at
600r/min and 1800r/min, watch out the condition of the gear teeth, the condition of the
equipment running, the open conduit of the lubrication oil. If there is something wrong, stop
and check immediately. Operation is forbidden until all are OK.

4.2 No-load test

When test run goes well, checks the follow item at n=1700rpm, 4 hours
Item Project Contents Consequence
Put the decibel meter in the
half-height of the box , distance ≤85db(class A)
1 Running noise is about 1 m(no less than 0.5m
from the ground)
The equipment runs smoothly, Smooth and irregular sound
2 Stationary no irregular sound
The fastener is fasten, loose, Safety
3 Confidence the engage normally
The standard height The safe contact spot is
4 of the contact gear Gear teeth contact spot 70% working length,
face 50%working high
Bearing temperature must
80℃
Survey the temperature of below , oil
5 Temperature temperature below 70 ℃ ,
bearing and oil and the temperature isn't
over the surrounding's 40℃
Filtration with 200 mesh
Clear the parts in the box by wire screen, the weight of
6 Cleanliness of inner oil contamination welding
kerosene, let the waste oil out slag should no more than
1500mg

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JJX140 DROP GEAR BOX

4.3 Loading test

1.conventional test
Examination when the truck-mounted drilling Rig is driving (with of without derrick ),
the drop box’s bearing temperature is no more than 40℃ than the surrounding 's .The
bearing is no more than 80 ℃.The temperature of oil sump should no more than 70℃ , the
bearing should no damage of stuck loose, the gear teeth should no broken、crack.
4.3.2 Loading test should be done with 3000m truck-drilling rig, check item as 4.3.1
4.3.3 Max. Loading test
Drive the 4000m truck-mounted drilling rig on the bad muddy road, check bearing,
gear and oil temperature. repeat 10 times, same as 4.3.1
4.3.4 Factory test
Before delivery the examination and inspection should be taken, .If everything goes
well, the box could leave factory.

Ⅴ Inspection and Maintenance

5.1 The inspection for gear oil
After the vehicle has been stopped for several minutes, do oil inspection for gear.
Firstly, check oil seals, ensure they are no leakage. Then screw off the choke plug to check
the oil level. The level should no less than the choke's 10-15mm. Inject the oil into the gear
according to standard line.

5.2 The inspection of fastener

Check whether the outside and junction blocks are loose or not, replace and fasten if
necessary

5.3 The test item of cover-off

Open the cover-plate of the gearbox, check the wearing condition of the gears and
multiple spline keys, and the fasteners are loose or not.
Check the shift fork of the clutch deformation of not by the sample, the elastic
properties of the spring, adjust or repair if necessary.
5.4 Drop box's work condition could judge by driving examination, there should no
irregular sound, no trip out of the clutch or hard engagement. If there are, remove the cover
and check.

5.5 Maintenance
At the same time, the other parts should be maintenance、check and replace
The replace of the gear oil should be taken at the third-stage maintenance .The replaced
gear oil should let out when it still hot, and watch out the oil has the junk or not. If there is,

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JJX140 DROP GEAR BOX

remove the drop box's cover and check. When the washed oil let out, put back the plug, use
light diesel 1/3 total quantity. Or the Rerense with 5% engine oil injection. Then runs the
engine some minutes at low speed, (Engaging the front axle is forbidden.) and then stop the
engine. Let out the waste oil; inject the new gear oil at the standard. Also, the above
detergent additive could be spray into the box by the jet gun.

5.6 Maintains before storage

A complete maintains and anti-rust treatment should be taken before storage
The drop box should be complete maintained after long time storage, the way is: check
the main parts, cleared by the light oil, then assemble it.

Ⅵ lubrication
The lubrication oil is required No.8 hydrodynamic oil, the quantity is 20GAL

6.1 Period of replace oil

Replace oil at the first 300 working time
Then change oil at per.1000 working time
Replace the oil after a complete check or inspection

6.2 The oil sites like the following Fig:

Lubrication points and lubrication period for gear box see following table.

Lubrication
Oil site Methods lubricant period
points
A Forced No.8 hydrodynamic oil Oil circuit on Often lubricate when
lubrication the box body working
B Oil ring No.8 hydrodynamic oil Splash oil Often lubricate when
working
C Forced No.8 hydrodynamic oil Oil circuit on Often lubricate when
lubrication the box body working
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JJX140 DROP GEAR BOX

D Immersion No.8 hydrodynamic oil Reserve oil in Often lubricate when

box working
E Immersion No.8 hydrodynamic oil Reserve oil in Often lubricate when
box working
F Immersion No.8 hydrodynamic oil Reserve oil in Often lubricate when
box working
G Grease NO.3 lithium-base Grease nipple Every shift
nipple lubrication oil
H Grease NO.3 lithium-base Grease nipple Every shift
nipple lubrication oil
I Grease NO.3 lithium-base Grease nipple Every shift
nipple lubrication oil

Ⅶ The Operation of Engaging/disengaging device

Engaging/disengaging operation should be done when the engine at neutral or stop

Ⅷ operation for front axles and rear axles

It required: No front axle, engaging low speed shift is forbidden.. if low speed shift
doesn’t disengage, disengaging front axle is forbidden.

Ⅸ Common Troubleshooting
Item Cause Resolve
Repair by welding or replace with
1 Over wear of the gear
the new one
Repair by welding or replace with
2 Over wear of the multiple spline keys
the new one
3 The irregular wear of the bearing Replace with the new one
4 The shift fork shape-off repair
Engaging/disengaging device doesn’t work
5 Repair or replace steel ball.
well
Remedies the ball seat, replace
6 The disengagement didn't work well
the ball
The bearing wear or loose Replace the new one
Big space of flank of flank of
bearing and the key of the gear and Repair or replace gears
7 noise
axle
Oil leakage or lubrication oil isn’t
Add or replace the proper gear oil
enough. or wrong oil viscosity

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JJX140 DROP GEAR BOX

Ⅹ Quick-Wear Parts list

10.1 Bearing

Item Code Type Qty. Remarks

1 GB276-89 124 4 Purchase
2 GB283-87 42319 6 Purchase
3 GB276-87 119 4 Purchase
4 GB281-84 1507 2 Purchase
5 GB283-87 42322 2 Purchase
6 GB276-89 214 2 Purchase
7 GB276-89 1000926 1 Purchase

10.2 Oil seal

Item Code Type Qty. Remarks

1 WA 130 ×160 ×15 2 Imported
2 WA 105 ×130 ×12 2 Imported
3 GBT1235-76 O ring 24 ×2.4 2 Purchase

Ⅺ. Attached drawings

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JJX140 DROP GEAR BOX

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JJX140 DROP GEAR BOX

Fig.1 Drop box structure

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JJX140 DROP GEAR BOX

Fig.2 Drop box installation

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JJX140 DROP GEAR BOX

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