Instruction of FD100 transfer case

Company Introduction

RG PETRO-MACHINERY (GROUP) CO. LTD is a stock company, reorganized from

Nanyang petroleum machinery plant (former No.2 Petroleum Machinery Manufacturing
Plant of National Petroleum Industrial Ministry of China). As a former national technical
equipment production base, authorized by former national economic and commercial
committee of China, RG PETRO-MACHINERY (GROUP) CO. LTD has become a
company for national new product trial production of China, light-duty drilling rigs
production base of SINOPEC and a high-tech enterprise in Henan Province.
RG PETRO-MACHINERY (GROUP) CO. LTD, with its technical center, information
center and quality inspection center at provincial level, has possessed 16 production plants
for forging, metal machining, heat treatment, steel-structure manufacturing, general
assembly, painting and new product trial production, and 4 comprehensive testing sites for
drilling rigs as well as 2 Sino-American joint ventures
RG PETRO-MACHINERY (GROUP) CO. LTD has established a complete quality
assurance system and HSE system. It is one of the first companies that received the
certification of ISO9001 /2000 in the industry of China and now its products are licensed
with API spec 8A, 8C, 11E, 4F,7K and pass the “3C” compulsory certification of China.
RG PETRO-MACHINERY (GROUP) CO. LTD provides the following products:
² 1000m-4000m truck-mound drilling rig
² 1000m-7000m skid-mounted drilling rig
² 1000m-4000m trailer-mounted drilling rig
² 35t-225t onshore workover rig
² 60t-225t offshore drilling and workover rig
² 4000m-7500m well-logging equipment
² 50t-70t heavy-duty trailer
² top-drive drilling unit
² petroleum special vehicles

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 Instruction of FD100 transfer case

² wellhead tools
Firmly holding the principle of “Customer First”, RG PETRO-MACHINERY (GROUP)
CO. LTD has established a professional service organization in all the domestic major
oilfields to provide all-around after-sales services ranging from equipment installation,
debugging, maintenance, training and spare parts supply. The products of RG
PETRO-MACHINERY (GROUP) CO. LTD are in great demand in all the oilfields of China
and have been exported to about 30 countries and regions across the world such as, The
United States of America, Canada, Mexico, Turkmenistan, Kazakhstan, India, Iraq, Egypt,
Sudan, Nigeria and Venezuela.
RG GROUP warmly welcomes customers home and abroad for contact and
cooperation to create a shining success for all!
RG GROUP will be your cordial friend and desirable partner forever.

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Instruction of FD100 transfer case

Preface
Nanyang RG Petro-machinery (Group) Co. Ltd. thanks you for choosing transfer case
developed and produced by our company.

TheXJ350 workover rig are both self-propelled drilling rig, which is suitable for oil,
gas and well drilling operation. In order to make sure that the equipment operates well and
the operator is safe, so when you operate this equipment, please make sure that you are
accordance with the operating regulation and maintenance programs that is formulated by
this instruction. Before you operate this rig for first time, the operator should know all the
technical documents, operating instruction and regulation well, follow operating
procedure and notice matters, do some maintenance for equipment regularly, if any
abnormal appears, the equipment must be stopped and be checked for the reasons, after all
malfunctions are expelled, then the equipment could operate again, the correct operating
procedure could make its performance displaying sufficiently and extend its service life.
This instruction main introduces the main technical parameters, main structure,
working principle, function, operation of engagement and disengagement device, operation
of the front and rear axle engagement and disengagement device, maintenance of the
transfer case. It is used for equipment managers, operators, and maintenance personnel.
As the structure of FD100 transfer case is very complex, this manual can’t cover
everything. If the user meets the situation not mentioned in this manual, please inform the
technical service department of RG at once, and we will provide technical support or
dispatch personal for after-sale service.

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 Instruction of FD100 transfer case

Important safety statement

Any operation, management, maintenance and repair personnel of the product must
know very well of the relative content of the instruction and abide by the regulation related
to operation, management, maintenance and repair, especially for the content such as safety
warning and attention given by this instruction, as well as common-sense safety regulations
and matters needing attention prompted by national law, regulation, industrial regulation, so
as to avoid human injury and damage of the equipment.
The instruction could not list all safety warning information in details, so any method I
is selected for operation, it must be ensured that it will neither endanger the human safety
nor damage the equipment.
Correct maintenance is the key factor for safe and reliable operation of the product.
The maintenance personnel shall maintain the equipment according to the method
introduced in the instruction manual.
The correct repair of the product and replacement of the components manufactured by
origin factory are key factors for safe and reliable operation of the equipment. The user must
maintain and replace the component within the scope authorized by the manufacturer.
When the user has special requirement for the product, the configuration of the product
may differ from the instruction manual, and the actual configuration of the product shall
govern.

Please read carefully when the instruction manual uses the following title and mark!

Warning: Used for the situation where incorrect operation procedures and methods
may lead to human injuries.

Caution: Used for the situation where there may be human injuries and damage of
equipment if the operation procedure and method is not observed strictly.

Note: Used for the situation where there is need for attention or independent
explanation.

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Instruction of FD100 transfer case

Contents
Ⅰ. Main 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 ........................................................................................ 1
3.1 Installation ................................................................................................................. 1
3.2 Adjustment ................................................................................................................. 2
Ⅳ. No-Load Test ................................................................................................................ 2
4.1 Elimination 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
5.4 Inspection of transfer case's work condition ................................................................ 4
5.5 Maintenance ............................................................................................................... 4
5.6 Maintenance of Storage .............................................................................................. 4
Ⅵ. Lubrication .................................................................................................................. 4
6.1 Period of replace oil ................................................................................................... 4
6.2 The oil sites like the following Fig: ............................................................................ 5
Ⅶ. The Operation of Engaging/disengaging device ......................................................... 5
Ⅷ. Common Troubleshooting ........................................................................................... 6
Ⅸ.Quick-Wear Parts list ................................................................................................... 6
9.1 Bearing ......................................................................................................................... 6
9.2 Oil seal ....................................................................................................................... 6
Ⅹ.Attached drawings ........................................................................................................ 6

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Instruction of FD100 transfer case

Ⅰ. Main Structure and Working Principle

FD100 transfer case adopts multi-grade gear actuating system; its input axle is
connected with the change-speed box's output axle by transfer draft. On the contrasting side
of the input axle there is a output 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 drilling rig working possible.
There is another output axle on back axle of FD100 transfer case and rolling off
equipment is installed which makes drilling can rig running possible.
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.

Ⅱ. Model and Main Function Specification

2.1 Model:
FD 100

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: 3500r/min
Overall dimensions (L ×W ×H): 720×980×1330 (mm)
Weight: 854.8kg (1884.5lb)

Ⅲ. Installation and Adjustment

3.1 Installation
Weld the drop box on the proper place according the two output flanges’ center line of
change-speed and given dimensions of the attach Fig. Weld hole is continuous fillet whose
height is not less than 10m.

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 Instruction of FD100 transfer case

3.2 Adjustment
1. Gear adjustment
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 0.21-0.32mm
3. 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 Elimination Run

When the above work finished, affix on heavy load gear oil 75W/90(API GL-5) to oil
dipstick mark. 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
1 Running noise of the box , distance is about 1 m(no less ≤85db(class A)
than 0.5m from the ground)
The equipment runs smoothly, no
2 Stationary Smooth and irregular sound
irregular sound
The fastener is fasten, loose, the engage
3 Confidence Safety
normally
The standard The safe contact spot is 70%
4 height of the Gear teeth contact spot working length, 50%working
contact gear face high
Bearing temperature must
below 80℃ , oil temperature
Survey the temperature of bearing and
5 Temperature below 70℃, and the
oil
temperature isn't over the
surrounding's 40℃
Filtration with 200 mesh wire
Cleanliness of Clear the parts in the box by kerosene, screen, the weight of oil
6
inner let the waste oil out contamination welding slag
should no more than 1500mg

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Instruction of FD100 transfer case

4.3 Loading test

1. Conventional test
Examination when the truck-mounted drilling Rig is driving (with of without derrick ),
the transfer case’s bearing temperature is no more than 80℃ than the surrounding 's .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.
2. Loading test should be done with workover rig,
Check item as 4.3.1
3. Max. Loading Test
Drive workover rig on the bad muddy road, check bearing, gear and oil temperature.
Repeat 10 times, same as 4.3.1
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.

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 Instruction of FD100 transfer case

5.4 Inspection of transfer case's work condition

Transfer case'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,
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 Maintenance of Storage

Do a full maintenance before storage and rust prevention. The transfer case stored
long-term should be maintenanced one time when used again. The method is to check the
main parts and clean them by clean oil. Then install.

Ⅵ. Lubrication
The lubrication oil is required heavy load gear oil 75W/90(API GL-5), the quantity is
16L(4.224Gallons)

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

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Instruction of FD100 transfer case

6.2 The oil sites like the following Fig:

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

Oil
Methods lubricant Lubrication points period
site
Forced
A 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
NO.3
Grease
B lithium-base Reserve oil in box Often lubricate when working
nipple
lubrication oil
Forced
C 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
D 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
E 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
F 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
G 75W/90 Splash oil Often lubricate when working
lubrication
Forced
H 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
I 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
NO.3
Grease
J lithium-base Reserve oil in box Often lubricate when working
nipple
lubrication oil
Forced
K 75W/90 Oil circuit on the box body Often lubricate when working
lubrication

Ⅶ. The Operation of Engaging/disengaging device

Engaging/disengaging operation should be done when the engine at neutral or stop，two
engaging device can’t engage at the same time.

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 Instruction of FD100 transfer case

Ⅷ. Common Troubleshooting
Item Cause Resolve
Repair by welding or replace with the new
1 Over wear of the gear
one
Repair by welding or replace with the new
2 Over wear of the multiple spline keys
one
3 The irregular wear of the bearing Replace with the new one

4 The shift fork shape-off repair

5 Engaging/disengaging device doesn’t work well Repair or replace steel ball.

6 The disengagement didn't work well Remedies the ball seat, replace the ball

The bearing wear or loose Replace the new one

Big space of flank of flank of bearing
7 noise Repair or replace gears
and the key of the gear and axle
Oil leakage or lubrication oil isn’t
Add or replace the proper gear oil
enough or wrong oil viscosity

Ⅸ.Quick-Wear Parts list

9.1 Bearing

No Code Type Qty Remark

1 GB283-87 42222E 9 Purchase
2 GB281-84 1507 3 Purchase

9.2 Oil seal

Item Code Type Qty Remark
1 BAMX7 130×160×15 4 Imported
2 GB3452.1-82 O-ring 20×1.8 2 Purchase
3 GBT3452.1-86 O-ring 25×3.55 3 Purchase

Ⅹ.Attached drawings

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Instruction of FD100 transfer case

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 Instruction of FD100 transfer case

No. Name Code Qty No. Name Code Qty No. Name Code Qty
1 Plug screw FD140-33 6 40 Bolt M5X20 GB5781-86 6 79 Spring washer 24 GB93-87 6
2 Sealing cushion 1 41 Bearing cover FD100B-15 1 80 Pipe end joint QJKT-2J4-Z4 Z1/8" 5
3 Oil filter WU-25X180-J 1 42 Oil sealPD12X25X10 HG4-692-67 1 81 Nameplate FD100B-24 1
4 Reducer union FD100B-01 1 43 Shaft FD100B-16-00 1 82 Bolt FD140-48 4
5 Pipe end joint QJKT-2J4-Z15 Z3/4" 2 44 Sensor IE472 1 83 Oil drip pan FD100B-25-00 2
6 Bolt M8X19 GB5781-86 4 45 Cover JJX140-33-03-00 1 84 Air core bolt FD140-44 4
7 Spring washer 8 GB93-87 4 46 Spring washer 12 GB93-87 6 85 Fuel-injection pipe FD100B-26 2
8 Output shaft FD100B-02 3 47 Bolt M12X29 GB5781-86 6 86 Straight joint QJKT-2J2-8 M18X1.5 2
9 Input shaft II FD100B-03 1 48 Sealing plate 1 87 Copper pipe L=3.5 1
10 Gear Z=46 m=8 FD100B-04 2 49 Joint I FD100B-34 2 88 Oil dipstick FD140-38-00 1
11 Bolt M8X23 GB5781-86 6 50 Bearing1507 GB281-84 3 89 Sealing plate 1
12 Spring washer 8 GB93-87 6 51 Shift yoke FD100B-17 3 90 O sealing ring 25X3.55 GB3452.1-82 3
13 Center shaft FD100B-05 1 52 Shift yoke sleeve FD100B-18 3 91 Gear change lever FD100B-27 3
14 Bearing cover FD100B-06 1 53 Bearing cover FD100B-19 3 92 Nut M20X1.5 GB6171-86 3
15 stop plate FD100B-07 1 54 Oil seal130X160X15 BAMX7 4 93 Spring washer 10 GB93-87 6
hexagon socket head cap
16 Joint III FD100B-36 2 55 Flange FD140-06 4 94 GB70-85 6
screw M10X23
17 Sealing plate 1 56 Shaft sleeve FD140-09 4 95 Shaft sleeve I FD100B-28 1
18 Gear Z=47 m=8 FD100B-08 1 57 Bolt M8X22 GB5781-86 18 96 deep groove ball bearing 107 GB276-89 62X35X14 2
19 Bearing cover FD100B-09 1 58 Spring washer 8 GB93-87 18 97 Bearing cap FD100B-29 1
20 Bolt M10X27 GB5781-86 10 59 Sealing plate 3 98 Copper pipe L=1.2m 1
21 Spring washer 10 GB93-87 10 60 Shift yoke base FD100B-20-00 3 99 Gear pump CBW-F306-CFP 1
Spring stop collar for
22 Stop plate FD140-07 3 61 GB894.1-86 3 100 Shaft FD100B-30 1
shaft 105
23 Key 32X88 FD140-25 4 62 Sahft sleeve Ⅲ FD100B-21 3 101 Key FD100B-31 1
24 Input shaft I FD100B-10 1 63 Bolt M12X40 GB5781-86 18 102 Shaft sleeve II FD100B-32 1
25 Sealing plate 1 64 Spring washer 12 GB93-87 18 103 Spring washer 8 GB93-87 4
26 Case body FD100B-11-00 1 65 Sealing plate 3 104 Bolt M8X29 GB5781-86 4
27 Case cover FD100B-12 1 66 Pressure gage（0.4Mpa） 1 105 Sealing plate 1
28 Bolt M8X23 GB5781-86 20 67 Oil separater FD100B-22 1 106 Sealing plate 1
29 Spring washer 8 GB93-87 20 68 Pipe end joint QJKT-2J1-Z4 Z1/8" 7 107 Elastic damping ring 35 GB894.1-86 2
30 Sealing plate 1 69 Pipe end joint QJKT-2J1-Z15 Z3/4" 1 108 Pinion FD100B-33 1
31 Spring stop collar 200 GB893.1-86 6 70 Gas cap EF1-25 1
32 Bearing 42222E GB283-87 9 71 Bolt M4X15 GB5781-86 4
33 Shaft sleeve I FD100B-13 3 72 Gear change device FD100B-23-00 1
34 Iron ball φ12 6 73 Pump joint flange II FD140-42 1
35 Spring FD140-15 3 74 Pump joint flange I FD140-41 1
36 Key 32X73 FD100B-14 2 75 Joint II FD100B-35 1
37 Bolt M8X24 GB5781-86 4 76 Three way Pipe end joint QJKT-3J-Z15 Z3/4" 1
38 Spring washer 8 GB93-87 4 77 Nut M24 GB6170-86 6
39 Spring washer 5 GB93-87 4 78 Bolt M24X100 GB5781-86 6

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transfer case

roup) corporation. Ltd 9

 Instruction

RG petro-machinary (group) corporation. Ltd

文件名: FD100 分动箱（英）
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英文
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标题: 1、 主要结构及工作原理
主题:
作者: supervisor
关键词:
备注:
创建日期: 2006-10-8 14:40:00
修订号: 4
上次保存日期: 2010-1-11 16:11:00
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