XCMG XDN450 User manual

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

!
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.!

!
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.
!
Ⅰ

!
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.............................................................................................................................
!II

!
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.
Product information !16

!
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
Product information !17

!
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.
!
!
!
!
!
!
Product information !18

!
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!
!
!
!
!
!
!
!
Product information !19

!
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
!
!
!
!
!
!
!
Product information !20

!
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
!
Safety Sign
Illustration
Toolbox sign
Lifting point sign
!
!
Product information !21