XCMG XDN450 User manual

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Xuzhou Construction Machinery Group Co.,Ltd.!
XDN450 Pipe Jacking Operation Manual

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Introduction
Distinguished customers：
We are deeply grateful for your selection of the XDN450 pipe jacking machine from
Xuzhou Construction Machinery Group Co.; Ltd.
This instruction offers relative information and instruction manual of XDN450 pipe jacking
machine of Xuzhou Construction Machinery Group Co.; Ltd for users.
This instruction manual covers the following parts including safety requirements, product
information, operation instruction, and common troubleshooting, etc. of the machine.
In order to make you understand the operate and use of this machine better, please be sure to
read this instruction manual carefully in advance, especially the parts with regard to safety, and
operate the equipment in accordance with regulations, otherwise it may bring you some
unnecessary bothering due to some minor mistakes in operation.
This company takes no responsibility for any adverse consequences in the following
conditions：
1.unauthorized modification；
2.unstandardized operation；
3.Any operation out of the range of application.
This company will not provide “three guarantees”(for repair,replacement or compensation of
faulty products in the following conditions：
1.incorrect operation；
2.insufficient maintenance；
3.Using other types of fuel or lubricant.
Continuous upgrading of machine designs and diverse customers’ demands will result in
modification of our instruction book and of the proper maintenance methods. So any users,
especially the freshmen, should get the latest and complete instruction. Any questions about this
manual or for the latest equipment information, please contact Xuzhou Xugong Foundation
Construction Machinery Co. , Ltd. or its distributors, or access to WWW. XCMGJC.COM.
Put this manual and equipment always together in order to consult it at any time.!

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How to make full use of the instruction manual
Quickly look up the information you wanted!
This manual falls into 6 chapters:
1. Safety requirements；
2. Product information；
3. Operation instruction；
4. Lubrication and maintenance；
5. Common troubleshooting；
6. Transportation, storage and protection；
And each chapter is further divided into sections with page number in the bottom right
corner corresponding to the contents for your fast location.
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Contents
How to make full use of the instruction manual 2....................................................................................................
Chapter One Safety part 16.....................................................................................................................................
1.2 Safety signs 18............................................................................................................................................
1.4 Major dangers 22........................................................................................................................................
1.6 Equipment prepared by users 26................................................................................................................
1.7 Classification of Underground Haz 27.......................................................................................................
1.8 Classification of Construction Site and Prevention Measures 28...............................................................
1.9 Basic Knowledge to Avoid Electric Shock 29............................................................................................
1.10 Basic Knowledge for Safety Emergency 30.............................................................................................
Chapter Two Product Information 31......................................................................................................................
2.1 Product Overview 31..................................................................................................................................
2.2 Model Composition 1.................................................................................................................................
2.3 Application Scope 1....................................................................................................................................
2.4 Product Boundary Dimension 1.................................................................................................................
2.5 Main technical features of equipment 4.....................................................................................................
2.6 Product Nameplates 5.................................................................................................................................
2.7 Main technical features of equipment 5.....................................................................................................
2.8 Components and Structures 6.....................................................................................................................
2.9 Using and operation 11...............................................................................................................................
3.1 Device installation 15.................................................................................................................................
3.2 Equipment safety inspection 20..................................................................................................................
3.3 Start machine 20.......................................................................................................................................
The action of internal bypass valve and inside and outside bypass valve must be checked before
conveying slurry action. 22.............................................................................................................................
4.1 Recommendation Form of Lubricating Oil and Antifreeze Liquid 68.......................................................
4.2 The maintenance schedule of machine 69..................................................................................................
Chapter Five Common Malfunctions and Solutions 72...........................................................................................
5.1 Hydraulic System Common Malfunctions and Solutions 72.....................................................................
5.2 Hydraulic system failures and troubleshooting 72.....................................................................................
6.1 Transportation of drill 80............................................................................................................................
6.2 Equipment shipment 80.............................................................................................................................
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Chapter One Safety part
This manual in the first part lists safety requirements and any users must observe these
safety requirements when operating the machine so as to minimize possible dangers and injuries!
We adclamp any operator should carefully read this instruction manual in advance,
especially the parts with regard to safety, and operation of the machine, otherwise it may bring
you some unnecessary bothering due to some minor mistakes.
Do’s and Don’ts：
1.Users must operate XDN450 pipe jacking machine in accordance with instruction
manual.Any other usages are forbidden.
2.Workers must observe the safety requirements in assembling the machine.
3.The unauthorized or untrained are not allowed to operate it.
4.Construction personnel must wear appropriate safety clothing, such as rubber insulating
gloves and boots.
5.Please keep the control panel, pedal plate and handle clean, and regularly check the oil
channels and lubrication grease to avoid possible dangers.
6.Joystick and rubber pipe can’t be used as handle to avoid any mistakes in operation.
7.Please line out the construction area in advance and set some warning marks around it.
8.When two people conduct the operation and maintenance at the same time, one should
monitor the other’s security and operation.
9.Only when the whole set of machine is off power, user can conduct maintenance work
alone.
10.In maintenance, monitors can touch the emergency stop switch in any time.
11.There should be adequate lighting in the construction areas.
12.The operator and monitor should keep in good connection and be familiar with signal-
sending ways.
13.Please check the emergency stop switch before and after usage.
To prevent electric shock, please ensure that the console and the electric control cabinet are
grounded before operation, and be sure to use the attached grounding copper rod to avoid danger.
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Warning, caution and other cautionary signs and words would be used in
this manual：
Danger!
This safety sign means that failure to observe the standard operation stipulated in this
manual would lead to direct dangers, which will result in possible equipment damage, serious
injury or even death.
Warning!
This safety sign means that failure to observe the standard operation stipulated in this
manual would lead to potential dangers, which may result in possible equipment damage, serious
injury or even death.
Caution！
This safety sign means that failure to observe the standard operation stipulated in this
manual would lead to potential dangers, which may result in possible equipment damage, slight
or medium injury.
1.1 Safety of the machine
Related personnel, including operating personnel and maintenance personnel should
carefully read this instruction manual in advance, especially the parts with regard to safety, and
operate and maintain this equipment in accordance with regulations, otherwise it may bring you
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some unnecessary bothering due to some minor mistakes in operation and maintenance.
1.2 Safety signs
Safety Sign
Illustration
Keep a safe distance to the machine in
operation, or may result in personal injury or
death.
Keep a safe distance to the machine in
operation!
Please carefully read this instruction
manual especially the parts with regard to
safety before operation. With any problem,
please contact our sales department.
Risk of electrical shock！Keep a safe
distance!
Keep a safe distance to the articulated
area of the machine!
Danger! Rolling wheel gear，keep
hands and arms away.
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Safety Sign
Illustration
Avoid discharge liquid under pressure，
if necessary,please reference safe operation
rules in part 1.5.
Keep a safe distance to the high-
pressure jet nozzle in operation!
Keep a safe distance to the ground
anchor!
Keep a safe distance to the machine to
avoid being wounded by object throwing
out!
Risk of electrical shock！
Danger of fire-highly flammable mate -
rials!
Caution Danger!
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Safety Sign
Illustration
No smoking!
No burning!
Must wear safety helmet
Must wear protective gloves
Must wear protective footwear
Hydraulic oil sign
Lubrication oil filling port sign
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1.3 General safety requirements
1.3.1 During the pre-construction period, please set some warning marks such as fence or
colorful flags in the construction areas, and even arrange specially-assigned personnel if
necessary.
1.3.2 Please wear safety helmets, protective gloves and
footwear in accordance with the safety regulations,
otherwise may bring you some unnecessary bothering due
to some minor mistakes in operation.
1.3.3 Do not put engine oil, toolbox and other
materials on the equipment, otherwise may result in damage to
the machine.
1.3.4 Understand and master particular hands signals and
only receive hands signals from specially-assigned personnel.
Lubricating grease filling port sign
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Safety Sign
Illustration
Toolbox sign
Lifting point sign
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1.3.5 After start, please do not conduct any adjustment to the machine.
1.3.6 Stay away from the rotating and working machine.
1.3.7 As a pollutant, waste oil is not allowed to be
dumped into the sewer and river or splashed upon the floor.
It should be poured into certain containers or disposed
according to the relevant laws and regulations.
1.3.8 The burning hot oil and components may cause
personal injuries.
1.3.9 Before welding, the main power switch on the
machine must be turned off, otherwise, the stray current and voltage produced during the
welding process will damage the electrical elements.
1.4 Major dangers
1.4.1 When abnormal condition or personal injuries occurred, scram button should be
pressed to shut down the equipment.
1.4.2 When the equipment is working,the main oil cylinder pushes the head to move
forward, keep away from the motion to avoid personal injuries.
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1.4.3 During the transportation of the machine, Rotation- prevent pin must be assembled and
the truck-mounted crane is forbidden to use.
1.4.4 If the machine is assembled with cutter disc revolving device,keep away from the
machine to avoid being cut by the cutter.
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1.4.5 Check the hydraulichose Frequently and change it when partial swell, leakage or wear
out is observed.
1.4.6 Check the electric wire harness Frequently and change it when insulated skin peeling,
ageing or wear out is observed.
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1.5 Safe operation rules
1.5.1 Inspection before operation
Check if any bolt and pin is loose.
Check the liquid level of grease,lubricating oil,coolant liquid,engine oil,fuel and hydraulic
oil.
Check if any leakage occurred.
Check the capacities of battery power.
Make sure that the scram button, the pilot handle and so on in normal condition.
1.5.2 Warning
Turn on the horn to avoid people around away from the machine before start it.
1.5.3Cleaning up sundries
Before running the machine,clear the main hydraulic device,especially the sundries on the
guide rail,so as to keep the head running smoothly.
1.5.4 Leakage of hydraulic oil
Carefully observe the hydraulic oil of the hydraulic system
and find out the reason and repair it if leakage exists.
When checking or repair the leakage of pressure pipe before
the pressure is released, use a thin plate or paperboard to shield
any spraying liquid under high pressure that could cause severe
injuries through the skin.
1.5.5 Change or refuel hydraulic oil
Turn down the engine before changing or refueling
hydraulic oil. Slowly unscrew the Air cleaner on top of the
hydraulic tank to release the pressure within and avoid scald
caused by the spraying of the hot oil.
1.5.6 Maintenance
Maintenance is able to be conducted after the equipment is steadily supported. Do not
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support the equipment only with hydraulic cylinder since there are high risks of injuries or death
caused by the falling of the declamp once the hand lever is malfunctioned or hydraulic pipe
blows out or wears out.
1.5.7 Usage of mud pump
Pump is forbidden to start without mud supply.Any other attentions is list on the instruction
manual of mud pump.
1.5.8 Usage of engine
Safety operation of the engine is list on the instruction manual of engine.
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1.6 Equipment prepared by users
1.6.1 Extinguisher
Extinguisher should be able to put out the fire caused by oil and
electricity.
1.6.2 Working light
If the visibility is low, working lights set by the users should
provide enough lights for construction site.
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1.7 Classification of Underground Haz
Electricwire
Naturalgaspipeline
Optical fiber cable
Waterpipe
Discharge pipe
Transmission pipes for other chemical materials, liquid or gas.
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1.8 Classification of Construction Site and Prevention Measures
1.8.1 Classification of construction site
The construction site can be classified into electric, gas and other types according to the
underground hazards.
1.8.2 Specific prevention measures of various kinds of Construction sites
1.8.2.1.Prevention measures of electric sites
1) Expose the electric wires through hand digging.
2) Cut off the power during construction and let powerdepartment examine the circuit
before the power is restored.
1.8.2.2.Prevention measures of natural gas sites
Configure the methane alarm. When the methane concentration exceeds the standard,
immediately cut off all equipment power and report it to the gas company for maintenance.
When the risk factor is removed, the construction can be continued.
1.8.2.3.Prevention measures of other sites
For construction sites with other underground hazards, communication and consultation
need to be conducted with relevant public utility administrative departments or special
departments in charge of safety to seek proper solution that applies to different situations.
Construction area
Type
within 3m of power line
Electric
within 3m of natural gas pipeline
Natural gas
within 3m of other hazards
Others
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1.9 Basic Knowledge to Avoid Electric Shock
1.9.1 Current can be conveyed underground through various ways.
1.9.2 Current can be conveyed to the equipment through various cables on the drill pipes,
flexiblepipes and machines.
1.9.3 Current with low voltage can also cause fatality.
1.9.4 Electric shock can be presumed and the machine should be shut down and examined if
the following situations occur:
1) power failure
2) smoulder
3) explosion
4) noise of burst
5) electricarc
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1.10 Basic Knowledge for Safety Emergency
1.10.1 Electric shock
1）If working near the power line, consult with the
power company for operation details in advance and seek
the guidance of assistant staff. Keep away from power
lines and cables to avoid accidents.
2）If getting electric shock, stay on the pipe jacking
machine or grounding pad. No one is allowed to touch or
approach the drill. No one is allowed to enter the site
unless wearing insulated shoes. Contact power
departments immediately and do not resume jacking unless getting the approval.
1.10.2 Take the following measures when the gas pipeline is jacked to break.
1）Shut down the engine immediately and eliminate all kinds of combustionsource.
2）Leave the site as soon as possible.
3）Warn and evacuate people to leave the site.
4）Contact relevant utility piping departments.
5）No access to the site prior to the permission of the pipeline department.
1.10.3 Take the following measures when the optical fiber cable is drilled to break.
1）Shut down the pipe jacking machine immediately and contact relevant utility piping
departments.
2）Do not look at the cutting section of the cable to avoid visual impairment.
1.10.4 Take the following measures when the water pipe is drilled to break.
1）Shut down the pipe jacking machine immediately and contact relevant departments.
2）No one is allowed to enter the dangerous areas.
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Chapter Two Product Information
2.1 Product Overview
2.1.1 Product usage
XDN450 pipe jacking machine is a kind of construction machinery to set various
underground public utilities in the condition of not or slightly excavating the earth’s surface. This
kind of construction machinery is widely used to set pipes for water, coal gas, electric power,
natural gas and petroleum supply and communication passing though highways, railways,
buildings, rivers, downtown area, historic reservation, crop and vegetation protection zones
which are difficult to excavate.
2.1.2 Product operating principle
The main structural functions of the XDN450 pipe jacking machine are divided into
downhole installation operations, main jacking operations, downhole pipe jacking operations and
well operations.
Downhole installation operations: Install the main jacking device in the initiating well then
perform welding and fixing; Place the main jacking device on the guide rail Z of the main
jacking cylinder device through the lifting device, install the mud pipeline, connect the wire
harness, etc., and then calibrate the laser theodolite, rotation angle and tilt angle.
Main jacking operations: The motor-driven hydraulic pump provides power to the main
jacking cylinder, and pushes the main jacking device through the jacking iron and the jacking
ring, and then pushes the main jacking device into the formation; The main jacking cylinder is
retracted to the end when the jacking is completed.
Downhole pipe jacking operations:The pipe is placed on the guide rail of the main top
device with the lifting device; The mud pipe and the connection harness are installed; the motor
driven hydraulic pump provides power to the main jacking cylinder, and then the pipe is pushed
through the jacking iron and the jacking ring to complete. Repeat this operation until all pipes are
laid
Well operation: After the main jacking device reaches the receiving well, dismantle the
shell, mud pipe and wire harness, etc., and remove the head, mud pipe and wire harness through
the lifting device until the top pipe operation is completed.
2.1.3 Method summary
This equipment adopts the slurry pressure balance type jacking method, and the mud type
jacking method uses the mud pump to send the mud pump to the sealed mud room of main
jacking device. The pressurized mud water and the machine head keep the excavation surface
stable and rotate at the same time. The cutterhead of the pipe jacking machine is used to cut and
excavate the soil layer, and then the sludge is sent to the muddy water treatment equipment by
the mud mud pipe, and then the mud water is sent to the mud supply room. Slurry is generally
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