INSTRUCTION MANUAL

PIPE JACKING SYSTEM

Hydraulic Pump Unit NVF22-15/400-40V-R

Thrust Jack T-20/400-400

Inter Jack S-5-30

 CONTENTS
1. INTRODUCTION ……………………………………………………………………………………………1
2. PIPE JACKING SYSTEM……………………………………………………………………………………2
3. EQUIPMENT ･………………………………………………………………………………………………2
4. SPECIFICATION OF EQUIPMENT………………………………………………………………………2～4
5. CAUTION ITEMS……………………………………………………………………………………………5
(1)Cautions for handling electrical parts･……………………………………………………5～7
(2)Cautions for handling hydraulic parts･……………………………………………………7～10
(3)Cautions for using high pressure hose ･…………………………………………………10～11
(4)Cautions for setting thrust jacks ･………………………………………………………12～13
6. ELECTRIC WIRING DIAGRAM ………………………………………………………………………14～15
7. HYDRAURIC PIPING………………………………………………………………………………………16
8. PREPARATION FOR OPERATION …………………………………………………………………………16
(1)Preparing to set up the starting board and unit …………………………………… 16～17
(2)Inverter Trouble ……………………………………………………………………………………18
(3)Emergency stop method …………………………………………………………………………… 19
9.CHECK AT END OF OPERATIONS………………………………………………………………………… 20
10.SUPPLEMENT OF HYDRAULIC FLUID ………………………………………………………………21～22
11.MAINTENANCE & INSPECTION……………………………………………………………………………23
(1)Daily inspection ……………………………………………………………………………………23
(2)Periodic inspection ………………………………………………………………………… 24～27
12.TROUBLE SHOOTING …………………………………………………………………………………… 28
(1)Hydraulic related …………………………………………………………………………… 28～35
(2)Electric related ………………………………………………………………………………36～38
13.SUCTION FILTER OPERATING INSTRUCTION………………………………………………………39～40
14.RETURN FILTER OPERATING INSTRUCTION ………………………………………………………41～42
15.PIPE JACKING SYSTEM ASSEMBLY PROCESS CHART……………………………………………………43
(1)ID1800HP………………………………………………………………………………………………43
(2)ID2200HP………………………………………………………………………………………………44

APPENDIX OF DRAWING
(1)Pipe Jacking System …………………………………………………………………DWG No.C-14146
(2)Primary thrust jacks…………………………………………………………………DWG No.B-14531
(3)Inter jack………………………………………………………………………………DWG No.B-07999
(4)GUIDE FRAME Ass’y………………………………………………………………………DWG No.C-14272
(4)PRESS RING Ass’y………………………………………………………………………DWG No.B-17564
(4)Hydraulic pump unit …………………………………………………………………DWG No.C-14264
(5)Hydraulic pump unit(Starter for power pack)…………………………DWG No.B-17644～B-17651
(6)Hydraulic circuit ……………………………………………………………………DWG No.C-14265
(7)Hydraulic piping Ass’y………………………………………………………………DWG No.C-14319
 No.1

1.INTRODUCTION
(1) This Primary and Intermediate Thrusting Jack system by your company in accordance with
your basic specification, as shown in the attached Construction Drawing. Also, this
system has been shop-tested and inspected, thoroughly for quality and performance
before shipment. However, proper operation, maintenance and inspection of the unit are
always necessary for safe operation at its maximum performance in the best working
condition during its service life. This Operating Manual describes the construction
of various components, and the methods of operation, maintenance and inspection of Unit
to be required for its safe and proper operation. You are requested to read this Manual,
by all means, until you become familiar with the Unit before starting it.

REMARK! SAFETY FIRST

(2) Safety Precautions

Instruction of symbol

! WARNING
Denotes operating procedures and practices that may result in personal injury or loss
of life if not correctly followed.

! CAUTION
Denotes operating procedures and practices that、if not strictly observed、 may result
in damage to, or destruction of the equipment.

! NOTE
Notes call attention to information that is especially significant in under standing
and operating the equipment.

A-08420
 No.2

2.PIPE JACKING SYSTEM.... See DWG C-14146

3.EQUIPMENT
(1) Hydraulic pump unit NVF22-15/400-40V-R
(2) Primary thrust jack T20/400-400
Inter Jack S-5-30
(3) Intermediate thrust jack control valve NVS-3-2(I)
(3-1) Intermediate thrust jack control valve NVS-3-2
(4) Hydraulic piping C-14319
(5) Electrical wiring B-17644

4.SPECIFICATION OF THE EQUIPMENT

(1) Hydraulic pump unit
1) Specification

THRUST INTER

2) Outside view
130

2000 L
1655

A-08421
2250 1300
 No.3

T-20/400-400
2000 kN
4000 mm
40 MPa
14 MPa

380
1200 kg

2600

120 30 2150

280
E:Rc1/2 R:Rc3/8

550

35 10 505

R:2-Rc3/8 E:2-Rc3/8
A-08750
 No.4

OPTION
(3)Intermediate thrust jack control valve

175
150
130.6 120.6 4.5

155
185
15
(3-1)Intermediate thrust jack control valve
model No. NSV-3-2

175
150
4.5 102.6 126.6
185
155
15

(6) Hydraulic piping.... See DWG No,B-14319

(7) Electrical wiring.... See DWG No,C-17644

A-08187
 No.5

5. CAUTION ITEMS
(1) Caution for handling the electrical parts

! WARNING

WIRING
1) Connect the power supply to the main power supply terminals of the hydraulic pump
unit via a circuit breaker on a leakage current breaker.

FIRE HAZARD

2) Disconnect the main power supply when or connecting cables.

ELECTRICAL SHOCK HAZARD

3) Do not operate the hydraulic unit or the operation board without the ground wire
connected.

ELECTRICAL SHOCK HAZARD

4) Wiring is done by qualified professional person to avoid making in correct

connections.

ELECTRICAL SHOCK OR FIRE HAZARD

! WARNING

OPERATING
1）Do not touch the electrical parts of the hydraulic pump unit or the operation
board when power supply is connected. Make sure to disconnect power supply.

ELECTRICAL SHOCK HAZARD

A-08423
 No.6

2）Close the doors of the starter box the operation board when power supply is connected.

ELECTRICAL SHOCK HAZARD

3）Do not operate or handle the electrical equipment with wet hand.

ELECTRICAL SHOCK HAZARD

! CAUTION

1) Place the arranged wiring cables to suitable location for operating to avoid
obstruction of passage.

PERSONAL INJULY HZARD

2) Tighten all screw and terminal connections.

PERSONAL INJULY HZARD

! NOTE

1）Protect the hydraulic pump unit and the operation board with cover or proper sheets
to avoid rainwater in version.

EQUIPMENT MALFUNCTION HAZARD

2）Push the emergency stop buttons on the hydraulic pump unit or the operation board
to stop operation, if abnormal noise, vibration, fevers, smell of burn and incorrect
indication of gauges is found out. Check the defective condition, place or regulation
the defect parts.

EQUIPMENT MALFUNCTION HAZARD

A-08424
 No.7

3) The power supply voltage must be adjust to the rated voltage level to assure its
conformance.

OVER VOLTAGES - BURNOUT

UNDER VOLTAGES - ELECTROMAGNETIC SWITCH HUNTINGS
- MOTOR OUTPUT DROPS

(2)Caution for handling the hydraulic parts

! WARNING

1) Do not put into your hands or the hydraulic hose between topper of thrust jacks at
the end of stroke during operation.

PERSONAL INJULY HAZARD

WARNING during RETRACT operation.

A-08384
 No.8

2）Shut the doors of hydraulic equipment during operate hydraulic pump unit to avoid danger
of touch rotation parts or electrical shocks.

PERSONAL INJULY OR ELECTRICAL SHOCK HAZARD

! CAUTION

1) Piping must connect according to this instruction.

(See Hyd. Piping & elect. Wiring diagram page No,14～16)
(THRUST、INTER PIPING)

PERSONAL INJULY OR HYDRAULIC EQUIPMENT BROKEN HAZARD

2）Place the hydraulic hose arranged clearly to suitable location for operation to avoid
obstruction of passage.

PERSONAL INJULY HAZARD

! NOTE

1) Check for an appropriate oil level of the oil tank and against the oil soilage.
The hydraulic oil supply or exchange must be done according to this instruction.

HYDRAULIC EQUIPMENT DAMAGE HAZARD

A-08425
 No.9

2) Check against loosened or disengaged joints the high-pressure piping.

MECHANICAL MOTION HAZARD

3）Check to assure the zero indication by various pressure gauge pointers. If not, replace
the gauge.

MECHANICAL MOTION HAZARD

4）Check to assure the suction filter and the line filter to have been opened fully.

HYDRAULIC PUMP DAMAGE HAZARD

5）Always clean the thrust jacks rod surface in order to prevent damages. No dirt and
sands on rod surface are allowed.

JACKS DAMAGE HAZARD

6）Check to assure the removal of air breather packing. The packing has been mounted on
to prevent the intra-tank oil leakage during. Transportation, and will have to been
removed before initially running the equipment.

HYDRAULIC PUMP DAMAGE HAZARD

7）Check against the presence of impeding objects with in the thrust jacks and operation
board operating radii.

PERSONAL INJULY OR EQUIPMENT DAMAGE HAZARD

A-08426
 No.10

8）Even when a continuous run at a 40MPa hydraulic pressure level of the jacks is made
for long hours、no problem will arise relative to the equipment, but to extend the
equipment life and to avoid eqercising unduly high forces on the shield itself, hold
a propelling mode hydraulic pressure level at or below 30MPa as general guidelines
for normal facing excavation purposes.

EQUIPMENT SHORT LIFE HAZARD

9）Since an unloading circuit has been employed for the power pack、no problems will arise
from a continuous run、but running it only when required will be preferable when
considering：
① Run Noises
② Consumption Power Savings.
③ Life if Motor, Hydraulic Pump, Switching Valves, and Other Equipment.
④ Hydraulic Fluid Deterioration, and similar other aspects.

(3)Caution for using high-pressure hose

! CAUTION

The high pressure hose should be replace periodically in consequence of the equipment
operation frequency or total time, because of it is impossible to expect that burst,
pinhole or disconnection joints occur under the normally condition on the outside of hoses.
Maintenance and check as follow for the high-pressure hose.

A-08427
 No.11

Items Condition Probable cause Remedy

Loosened threads. Tighten thread.

Thread joints
Deterioration of packing. Replace packing.

Loosened bolts. Tighten bolts.

Flange joints
Deterioration of packings. Replace packing.
Oil leakage
Replace.
Assembled Deterioration of rubber. Check against piping
adapter Cause of heat or oil stick. procedure of assembled
joints part Excessive bending. adapter joint for
excessive bending.

Impact from the outside oil Eliminate causes.

Dents stick on outside. Cover the outside of hose.
Distortion
swellings Oil turns round from the Replace.
connection parts. (Depend on degree)

Eliminate causes.
Interference with the other
Cover the outside of hose.
Outside damage Wear, Cut parts.
Replace.
Impact from the outside.
(Depend on degree)

Outside rubber Effective of ozone, Replace. Cover the

cracks sunshine or paints. outside of hose.

Unsuitable hose length.

Abnormal Swelling,
Unsuitable piping Use adapter.
distortion Shrinkage
procedure. Replace.
during operation Torsion.
Fatigue.

Hardening Deterioration caused of

Replace.
Softening heat or oil stick.

Noise, offensive Caused of the related Check the whole circuit.

smell circuit. Maintenance

Outside Stick of dust or drop water,

Corrosion of Supply preservation oil
surface fallen water, and sea
metals except rubber part.
corrosion breeze.

Replace that have been

Manufacturing Symptoms of aging,
used more than 2years.
date deterioration.
(depend on degree)

A-08119
 No.12

(4) Caution for setting thrust jacks

! WARNING

① Use prepared hole, when life the thrust jacks.

PERSONAL INJURY HAZARD

② Life work should be operated by qualified operator.

PERSONAL INJURY HAZARD

1) Caution for setting the primary thrust jacks to the counter force wall.

! NOTE

① Set the primary thrust jacks that no clearance are permitted between jack end
and counter force wall. (See figure below)

JACK DAMAGE HAZARD

NO CLEARANCE NO CLEARANCE
1
MAX0.5°
THRUST JACKS 3
PRESS RING

COUNTER FORCE PLATE 2

② The counter force wall or plate must have enough strength.

JACK DAMAGE HAZARD

A-08442
 No.13

③ The slant counter force wall or plate must be less than 0.5°on all directions.

JACK DAMAGE HAZARD

2) Pressure ring related

! NOTE

① The slant between jack and the pressure ring must be less than 0.5°on all
directions.
(See figure below)

MAX 0.5°

NO CLEARANCE MAX0.5°

PRESS RING

THRUST JACKS

A-07770
 No.14

6. ELECTRIC WIRING DIAGRAM

(1) Wiring and cable connection procedure.

NOTE
Wiring or connection must have practiced
observing chapter5 paragraph (1) strictly

PERSONAL INJURY OR EQUIPMENT DAMAGE HAZARD

1) Connect the electrical equipment follows.

HADRAULIC PUMP UNIT

1.25

AC400V 50Hz
POWER SOURCE CABLE

OPERATION BOARD

OPTION INTER SOLENOID VALVE

A-08447
 No.15

3) Power supply cable specification

① When connecting power cables to a motor, observe the below listed combinations in
accordance with the motor output power level.

400V 3-Ppase motor Wiring Parameters

Minimum Power
Maximum Minimum 3P Maximum Minimum
Cable
Motor Output Aggregate Switching Fuse Ground
Conductor
kw( HP ) Wiring Length Capacity Capacity Thickness
Thickness
( m ) ( A ) ( A ) ( mm2 )
( mm2 )

0.4 200

0.75 5
100
1.5( 2 ) 2.0 3.5

1 50
10
2.2( 3 ) 40
30
3.7( 5 ) 70

5.5( 7.5 ) 15
3.5 40
6 5.5

7.5( 10 )
35 30
8

11( 15 ) 8
8
12 30 60 60

15( 20 ) 14

40
19
22( 30 ) 22 35 100 100 14
30
25

37( 50 ) 20
38 200 150
45 25 22

② Check the power supply voltage to assure its conformance with the rated voltage
level.
Over voltages may cause electrical equipment to burn out, and under voltages may
invite electromagnetic switch hunting and/or motor output drops.

A-0842
7. HYDRAULIC PIPING No.16
See dr awing No -14319 on the appendix.

! NOTE
Hydraulic piping must be practiced observing chapter5 strictly.

PERSONAL INJULY OR EQUIPMENT DAMAGE HAZARD

8. Preparation for Operation

Item5.Observe each paragraph in Handling Cautions] on page No5.
(1) Preparing to set up the starting board and unit
1) Thermal relay of the electro magnetic contactor within the starting board
Prevents the induction motor from burning out accidents due to overload operation.
2) Setting up the thermal relay

! CAUTION

The thermal relay is already set when this equipment is shipped. Do not exceed the
following current values. Set the relay as follows, if required.

EQUIPMENT DAMAGE HAZARD

Set the machine according to the full load current value of the induction motor.
Set value
1. Parts Arrangement in Starting Board
2. Induction Motor for General Use Thermal relay(high speed)
3. INV
4. Thermal Relay for INV Motor

INDUCTION MOTOR SYMBOL TYPE SETTING

OL1 TH-N60 42A

OL2 TH-N20TA 29A

INV

A-07790
3) Function of thermal relay No.17

TH-N60 TRIP TH-N20TA 29A

50 42A 34A

RESET TRIP
42 29

34 24 H A
H A RESET

OL1(42A) OL2(29A)

Manually trip procedure

Press the reset button.

! CAUTION
Manually trip operation must be practiced for checking the sequence of thermal relay
Under the condi tion that the main circuit equipment is not supplied power.

PERSONAL INJURY HAZARD

A- 08429
 No.18
(2) Inverter Trouble
In the case the inverter is not operated suitably, serious trouble will occur.

Operate th e inverter, following the inverter manual attached as the separate volume.

In the case the safety system in the inverter operates, the inverter stops the output
Instantly, the alarm is indicated on the LED, and the motor stops.

The contents a nd indication on the alarm are explained in the inverter manual attached
as the separate volume.

The stop of the inverter continues until the cause is cleared and INV RESET BUTTON is

Pushed. After the cause of the stop is cleared and INV RESET BUTTON is pushed, then

the operation switch is to be on.

INVERTER

LED

INV RESET BUTTON

A - 08705
 No.19

(3) Emergency Stop Method

1) Press the EMERGENCY STOP on the starting board.
Hydraulic actuation is stopped. The push-button is locked.
2) Emergency Stop Reset
Turn the push-button clockwise, and the lock status is reset.
3) To restart the machine, take steps sequentially from the pump start operation.

A-08448
 No.20

9.CHECKS AT END OF OPERATIONS

1) Engage a “ neutral” position of the various switching valves.

2) Throw the various power supply switches off.

3) Carefully clean various units of the equipment.

4) Conduct touring inspection against any and all troubles in the various
equipment units.

5) In rainy weather, or when rainfalls have to be expected, be sure to cover the

power pack and Operation Board with water proofing sheets.
The invasion there into of rain water will invite corrosions and failures.

A-08431
 No.21

10.SUPPLEMENT OF HYDRAULIC FLUID

(1) Lubrication
Since lubrication is the most important run requirement，always exercise the utmost
of cautions thereon．Check the lubrication status as required in accordance with
the run frequency, against oil level drops and oil soil ages.

(2) Hydraulic Fluid supplying Procedure

When replenishing hydraulic fluid through the oil tank inlet，exercise utmost caution
against the invasion of foreign matter．

Oil Tank Capacity: 2000L

Fill the oil tank up to the highest oil gauge level with all the jacks completely retracted．
Do not Fill it to such a level with jacks extended，since the tank oil will then overflow
when they are retracted.

A-08432
 No.22

(3) Recommendation
A Comparative Study on Various Hydraulic Oil Brands

Viscosity
Category
ISO Viscosity Grade Auxiliary Viscosity Grade
(Cst)
Companies ISO－VG 46 Grade VG 32 ,VG 68
Name

Nuto-H 32
Esso Standard Nuto-H 46
Nuto-H 68

Cosmo Super Epoch UF 32

Cosmo Cosmo Super Epoch UF 46
Cosmo Super Epoch UF 68

Shell Tellus S2M 32

Shell Oil Shell Tellus S2M 46
Shell Tellus S2M 68

Shown up above in each box of the above table is a general purpose lubricating oil,
and down below a wear-resistant lubricating oil.

A-08433
 No.23

11.MAINTENANCE & INSPECTION

(1) Daily inspection
1) Hydraulic equipment

Item Inspection Specification

Abnormal noise, vibration No noise, vibration is permitted.

Hydraulic
pump unit
Upper level on gauge is permitted
Hydraulic oil level
under jacks retract position.

Operation board Operation pressure Max. Operating pressure 50Mpa

Oil temp. Do not increase

Oil temperature
abnormally.

No leakage is permitted from piping,

Oil leakage
hydraulic equipments, hoses.

Filter element See chapter13 or 14.

Oil leakage No leakage is permitted.

Thrust jacks
Damage rod No harmful damage is permitted.

Piping Rubber hose joint parts See chapter5. Paragraph (3)

2) Electric equipment

No open wire, loosen terminal are

Starter Wiring
permitted.

Earth-Leakage circuit breaker Check for trip.

Operation
board
Push buttons lamps No damage is permitted.

Connecting cable No damage is permitted.

A-08434
 No.24

(2) Periodic inspection

The items listed below are mandated for the equipment to render its satisfactory
services，so that their strict observance is requested．

1) Hydraulic Related Items

Maintenance
Specifics
Check Point

When the oil temperature during a run has exceeded 60℃

(which is too hot for a hand to remain in contact with
the pump case for long)，stop the pump and lower the
Oil Temperature temperature.
A temperature in excess of 60℃ is deemed to indicate the
presence of a trouble(s) so that due checks will be called
for.
Power
Pack Check the oil gauge level from time to time，and exercise
Hydraulic Fluid care to avoid the oil level dropping below the gauge top
in a retracted model of all the jacks.

For the relief valve setting, refer to the attached

Pump Outflow hydraulic system block diagram.
Pressure Maintain a normal state of the pressure gauge at all
times.

After checking against oil leakage at joint and flange

areas of the hydraulic piping，provide such remedial
Oil Leakage
measures at leakage locations as replacing sealers,
retightening joint bolts，etc.

Exercise caution against the primary thrust jack spreader

Hydraulic
binding sand or grit in their retracting mode at the
Equipment
out-conveyance of earth or sand, and against the
Related Jacks
intermediate thrust jack（mounted on the underside of
equipment）spreader behaving similarly in the presence
of excessive spring water or in similar other situations．

High-Pressure Avoid damaging outer hose surfaces，and applying undue

Rubber Hoses twisting，bending，stretching，or other forces to hoses．

A-08435
 No.25

Electrical Related Items

Checking Interval
Category Item Check point
1d. 1w. 1m. 3m. 6m. 1y.

With non-fuse breaker NFB

thrown ”off” and all the other
switches pushed “on”, check to
assure no electric power applied
to any of the circuits, and then
take measurements with a 500V
400V AC
megger on the NFB secondary side 1
Circuits
and the electromagnetic switch
secondary side to assure the
readings to be as follows:

Typical: 1MΩmin
Minimum (Regulatory): 0.2Ωmin.
Insulating
Resistance
With non-fuse breaker NFB thrown
”off” and all the other switches
pushed “on”, check to assure no
electric power applied to any of
the circuits，and then take
measurements with a 500V megger
200V AC
on the NFB secondary side and the 1
Circuits
electromagnetic switch
secondary side to assure the
readings to be as follows:

Typical: 1MΩmin
Minimum (Regulatory): 0.2Ωmin.

Non-Fuse Breaker,
Ground Leakage Breaker,
Appearance
Electromagnetic Switch,
and Flaws/ 1
Pilot Lamp Pushbutton Switches,
Damages
Operation Plug Fuses, and
Board Terminal Board Transformers

Loosened
Terminal Same as the above 1
Connections

A-08167
 No.26

Checking Interval
Category Item Check point
1d. 1w. 1m. 3m. 6m. 1y.

Non-Fuse
Loosened Terminal Connections 1
Breaker
Worn Terminals 1
（NFB）

Ground
（Earth） Operational Test
Leakage With NFB on, push the ELB test 1
Breaker button to assure ELB to trip.
（ELB）

Operational Test 1

Thermal Relay Operational Test:

With the electro switch ”on”,
pull the thermal relay resetting
bar to assure the 1
electromagnetic switch to trip．
Electro- After the test is over, push the
Operation
magnetic resetting bar in.
Board
Switch

Worn contact Points:

Where a contact point has worn
1
down to a 50% thickness or the
new part, replace it.

Electromagnet Humming. 1

Operational Test
Timer (TR) 1
(Time Delay Checks)

Pilot Lamps
Open Lamps 1
(PL)

Pushbutton Operational Test

Switches (Push and Return Behaviors, 1
(PB) and Contact wear Rate)

A-08168
 No.27

Checking Interval
Category Item Check point
1d. 1w. 1m. 3m. 6m. 1y.

Fuse Checks
Plug Fuses (Blown Fuses, Terminal
1
(F) Tightening, and Screw
Tightening.)

Pushbutton Switches,
Operation Appearance
Indicator Timer, Relays，and 1
Board Defects
Terminal Boards.

Loosened
Same as the above. 1
Terminals

Relay (R) Operational Test 1

Appearance Cables to Control Panel and

Cable 1
Defects Operating Panel

A-08169
 No.28

12.TROUBLE SHOOTING
(1) Hydraulic Related

Trouble Symptom Potential Causes Remedial Measures

(1) A wrong rotary (1) An inadequate relief valve pressure

direction. setting immediately shut the drive
power off，and reverse the rotary
direction.

(2) An overly low tank (2) Replenish a prescribed hydraulic Fluid

oil level. up to the rated oil level.

(3) A clogged intake (3) Remove and thoroughly clean the

pipe or strainer. strainer，and check against a clogging
offender within the intake pipe．

The pump discharges (4) Air leakage in the (4) Check for a rated oil level of the tank，
no or little oil. intake piping as well as against loosened pipe
circuit. joints，
and retighten such joints．

(5) An overly low (5) Observe the lowest rotary speed

rotary speed. requirement given in operating
instructions

(6) A worn pump with (6) Repair worn areas or replace parts
power. thereof．

(7) A sheared coupling (7) Dismount and repair the coupling or

or shaft. pump.

A-08108
 No.29

Trouble Symptom Potential Causes Remedial Measures

(1) An inadequate (1) Slowly make an upward adjustment to

relief valve the rated pressure level while
pressure setting. watching the pressure gauge.

(2) Malfunctioning of (2) Dismantle and repair the offending

the relief valve relief valve, as well as replace other
faulty parts if any.
The pump
discharges (3) Miss operation of (3) Operate valves one after another
pressure level valve in the in conformance with operating
refuses to rise. hydraulic circuits. instruction, until an offender is
The pump uncovered．
discharges
pressure level (4) A leakage in the (4) Check and repair the individual
refuses to rise. hydraulic circuits. circuits，one by one.

(5) Equipment (5) Check and repair the equipment or

Malfunctioning. replace its parts.

(6) Damages in，or (6) Dismantle and repair the pump， and
malfunctioning of, replace other faulty parts if any.
the pump itself.

A-08109
 No.30

Trouble Symptom Potential Causes Remedial Measures

(1) A clogged intake (1) Remove and thoroughly clean the

pipe or strainer. strainer，and check against a clogging
offender in the intake pipe.

(2) Air invasion through (2) Check against and retighten loose
a piping joint or segments of the intake piping
equivalent on the circuit.
pump intake side.

(3) Residual air within (3) Remove the air through an air
the pump casing. breather at the drain plug or end
plate.

(4) The intra-tank (4) Check to localize the water invasion，

hydraulic Fluid has and replenish the hydraulic Fluid.
The pump noises are turned white in
excessive. color，and generates
air bubbles.

(5) A clogged suction (5) Dismantle and thoroughly rinse the

valve, or its suction valve，as well as replace
mechanical failure. failing parts.

(6) A clogged air (6) Remove and thoroughly rinse the

breather packing or replace failing parts.

(7) An excessive relief (7) Slowly adjust the relief valve

valve pressure pressure downward to a rated level.
setting.

(8) Air leakage at the (8) Check and retighten the packing area,
pump shaft packing. or replace the packing.

(1) A worn oil seal. (1) Replace the offending oil seal.
Oil leakage has
(2) A worn gasket or (2) Replace the offending gasket or
developed
O-ring. O-ring.
at the pump.
(3) A loosened joint. (3) Evenly retighten the joint．

A-08110
 No.31

Trouble Symptom Potential Causes Remedial Measures

(1) Decreased viscosity (1) Check the oil temperature rise

of the hydraulic behavior， and if it is found to be
Fluid. excessive，replace it with a higher
viscosity index oil．

(2) An overly long (2) After operations，restore a neutral

operating time of position of the switching valve．
The hydraulic Fluid
the relief valve.
has overheated.
(3) A faulty relief (3) Dismantle and repair the valve, or
valve. replace its failing parts．

(4) A low hydraulic (4) Either replenish the hydraulic Fluid

Fluid level，or its to its rated level, or replace the
deterioration. entire hydraulic Fluid.

(1) Decreased viscosity (1) Check the oil temperature rise

of the hydraulic behavior， and if it is found to be
Fluid. excessive，replace it with a higher
viscosity index oil．

(2) A damaged packing (2) Check against the damage, twisting,

The hydraulic Fluid or equivalent. ripping, etc. of packing at the time of
has leaked out. their mounting，and replace any
offenders uncovered.

(3) A damaged (3) Check and correct any unduly forced

high-pressure hose. mounting angle and bending arrangement
levied on the high-pressure hose.

(1) An excessive (1) Check the hydraulic Fluid operating

viscosity index of environment, and in particular,
the hydraulic Fluid. assure the lowest operating oil
temperature in winter to be well above
the coagulation point of the oil.
Unduly high heat
(2) Excessive internal (2) Check against and repair or replace
has been generated.
leakages. worn or loose packing， and an overly
worn valve piston or cylinder.

(3) An excessive (3) Check against a bypassed or otherwise

discharge pressure misbehaving hydraulic pressure
level. circuit．

A-08111
 No.32

Trouble Symptom Potential Causes Remedial Measures

(1) The speed drops down (1) Check against any degraded pump
along with a rising efficiency and excessive internal
oil temperature. leakage in the valve or cylinders，and
repair or replace any such failing
parts uncovered．Also check the speed
control bleed-off circuit.

(2) The speed increases (2) This symptom frequently develops in

along with a rising the meter in-, or output circuit of the
oil temperature. speed control block，and may require
the provision of an oil cooler or the
replacement with a higher viscosity
index oil.
The system
misbehaves. (3) Knocking motions. (3) Check against and correct any poorly
fitting sliding area，low oil level,
air invasion, overly tightened
packing，etc．

(4) Speed instability in (4) Due to the narrow throttle opening

a low speed mode. involved，check against and eliminate
or replace dust and other foreign
matter therein or a damaged orifice．

(5) The rated feed (5) Check against and correct or

speed fails to be eliminate an excessive piping path
attained. resistance or foreign matter
in a valve port.

A-08112
 No.33

Trouble Symptom Potential Causes Remedial Measures

(1) The speed drops down (1) Check against any degraded pump
along with a rising efficiency and excessive internal
oil temperature. leakage in the valve or cylinders，and
repair or replace any such failing
parts uncovered．Also check the speed
control bleed-off circuit.

(2) The speed increases (2) This symptom frequently develops in

along with a rising the meter in-, or output circuit of the
oil temperature. speed control block，and may require
the provision of an oil cooler or the
replacement with a higher viscosity
index oil.

(3) Knocking motions. (3) Check against and correct any poorly
fitting sliding area，low oil level,
air invasion, overly tightened
packing，etc．

(4) Speed instability in (4) Due to the narrow throttle opening

The system
a low speed mode. involved，check against and eliminate
misbehaves.
or replace dust and other foreign
matter therein or a damaged orifice．

(5) The rated feed (5) Check against and correct or

speed fails to be eliminate an excessive piping path
attained. resistance or foreign matter
in a valve port．

(6) The misbehavior of (6) Check against and correct or

a usual operating eliminate any poorly fitting valve or
valve. piston, internal leakage,
backpressure generation，unevenly
tightened joint, intra-valve foreign
matter，etc．

(7) The misbehavior of (7) Check against and corrector replace

an electromagnetic any short pull force inside a magnet,
valve. voltage drop, power, cycle variations,
intra-solenoid foreign matter,
overheating solenoid，etc.

A-08113
 No.34

Trouble Symptom Potential Causes Remedial Measures

(1) A low tank oil (1) Replenish the hydraulic fluid.

level.

(2) Air invasion into (2) Check and retighten the piping joints.
its suction line.
The behavior of a
jack is sluggish, (3) A clogged filter. (3) Check and clean the filter．
and its response
slow. (4) An overly viscous (4) Replace it with prescribed oil.
oil.

(5) Its relief valve (5) Clean and readjust the valve.
has been forced into
its open position.

(1) An overly low (1) Make a rated pressure setting over

setting of its again while watching the pressure
relief valve. gauge.

(2) Its relief valve has (2) Clean and readjust the valve．
been forced into its
open position.

(3) The hydraulic oil (3) Check the return line and the
is circulating back behavior of valves connected thereon.
to the tank through
another valve.

The jack thrust has (4) Internal leakage in (4) Dismount the component and run
dropped down. the valve or jack. pressurizing checks thereon.

(5) External leakage. (5) Check the piping, pump, motor, valve,
etc. And repair the leakage area
uncovered.

(6) A loosened pump (6) Check against bolts that may have
casing. caused oil leakage or air invasion,
and evenly retighten any such bolts
uncovered.

(7) An internal pump (7) Either repair the pump or replace it

trouble. if circumstances so dictate.

A-08114
 No.35

Trouble Symptom Potential Causes Remedial Measures

(1) Check the tank oil level.

(2) Check and retighten its piping

The jack behaves Air invasion in its
joints.
irregularly. circuit
(3) Check against air invasion at the
pump intake.

A-08115
 No.36

(2) Electrical Related

Trouble
Potential Causes Remedial Measures
Symptom

1, A ground leakage breaker

has tripped.
(1) Ground leakage. (1) Localize and repair the leakage area．

(2) Short-circuit. (2) Localize and repair the shorted area．

(3) Overload. (3) Limit further operations at or below

the rated current level．

(4) Single (missing) phase run. (4) Localize and repair the miswired
area.

2, A thermal relay or a motor

relay has tripped．
(1) Reversed phases. (1) Reverse the offending.

(2) Overload. (2) Limit further operations at or below

the rated current level.

The motor (3) Single (missing) phase run. (3) Localize and repair the miswired
refuses area．
to run．
3, A blow fuses.
(1) Ground leakage. (1) Localize and repair the grounding
area．

(2) Short-circuit. (2) Localize and repair the shorted area．

(3) Electromagnetic switch (3) Readjust its voltage or replace its

misbehavior. contact points.

4, Electromagnetic switch
misbehavior.
(1) Worn contact points. (1) Replace the contact points．

(2) An overly low voltage (2) Operate the switch at its rated
level. voltage.

(3) Ground leakage breaker, (3) Refer to the above remedial measures
thermal relay, for 1， 2, and 3.
motor relay, fuses.

A-08116
 No.37

Trouble
Potential Causes Remedial Measures
Symptom

5, The overheating of a
rubber-sheathed cable.
(1) An open rubber-sheathed (1) Repair or replace the cable.
cable.

(2) A poorly engaged (2) Check for the secure insertion of

connector. the connector.

(3) A worn or damaged (3) Replace the connector.

connector.

(4) Overload. (4) Limit further operations at or below

the rated current level．

(5) Overly fine (5) Replace the cable with one at the
rubber-sheathed cable prescribed wire gauge.
conductors.

6, The voltmeter fails to

The motor indicate the rated voltage
refuses level．
to run. (1) Under capacity of the (1) Rearrange for a rated capacity power
power supply. supply．

(2) An overly long or fine (2) Rearrange for a prescribed length or

gauge rubber-sheathed wire gauge.
cable.

(3) A misconnected (3) See the above measures for 5.

rubber-sheathed cable.

7, Motor burnout.
(1) Overload. (1) Limit further operations at or below
the rated current level.

(2) Single （missing） phase (2) Localize and repair the misconnected
run. area.

(3) Misconnections. (3) Reconnect the cable correctly.

(4) Insulation deterioration. (4) Make repairs.

Check against an excessive power, and all

The motor has
A drastic voltage drop. poor contacts power, and all poor
overheated.
contacts in the power circuit．

A-08117
 No.38

Trouble
Potential Causes Remedial Measures
Symptom

An open wire in one of the Check against loose terminals and poor
phases. contacts.
(1) Loose or disconnected (1) Retighten.
The motor
terminals.
hums but
refuses
(2) An open wire. (2) Run checks with a circuit tester.
to start up.
(3) Power interruption or a (3) Measure the power mains voltage.
drastic voltage drop.

(1) A shorted stator coil. (1) Rewind The coil.

(2) A shorted rotor coil. (2) Rewind The coil．

The no fuse
breaker trips. (3) A shorted or grounded (3) Measure its insulating resistance．
equipment circuit.

(4) Grounded equipment. (4) Measure its insulation resistance．

(1) An excessive voltage drop. (1) Run checks．

(2) Poor contract at the (2) Readjust．

auxiliary contact points.
The electro-
magnetic (3) Worn contact points. (3) Replace．
switch refuses
to open a (4) An open wire coil. (4) Replace．
circuit
(5) Loose terminals. (5) Check and retighten．

(6) Trouble in the operating (6) Check and repair．

power supply circuit.

(1) A fused contact point. (1) Touch up or replace.

The electro-
magnetic
(2) Deterioration of a (2) Replace.
switch refuses
returning spring.
to open its
circuit.
(3) Scarred contact surfaces. (3) Touch up or replace.

The electro-
magnetic
switch (1) Deterioration of a (1) Replace．
generates returning spring.
excessive
sparks.

A-08118
 15.(1) PIPE JACKING SYSTEM No.43
ASSEMBLY PROCESS CHART (ID1800HP)

1 3

4-THRUST JACK
UPPER FRAME
(W=75kg) (W=1200kg)

8-SPACER(2)
(W=35kg)

GUIDE FRAME (W=1500kg) UNDER FRAME (W=250kg)

PRESS RING
(W=2200kg)
2 4 HOSE BRANCH
(W=25kg)

4-SPACER(1)
(W=20kg)
 (2) PIPE JACKING SYSTEM No.44
ASSEMBLY PROCESS CHART (ID2200HP)

1 3
6-THRUST JACK
UPPER FRAME
(W=75kg) (W=1200kg)

8-SPACER(2)
(W=35kg)

GUIDE FRAME (W=1500kg) UNDER FRAME (W=250kg)

HOSE BRANCH PRESS RING

(W=25kg) (W=2200kg)
2 4

4-SPACER(1)
(W=20kg)
- - - - - -

E R

E R

MODEL NVF22-15/400-40V
VOLTAGE.CYCLE
50Hz 60Hz
THRUST INTER
INDUCTION MOTOR INV22KWx4P+15KWx4P INV22KWx4P
4p
DELIVELY
RATED PRESSURE 40MPa 50MPa 7 - RING(M) B-17570 - 1
OIL TANK CAPACITY 2000L 6 - RING(S) B-17569 - 1
WEIGHT 3800kg
5 - PIPING Assy C-14305 - 1
MODEL T-20/400-400
RATED POWER 4 - PRESS RING Assy B-17564 - 1
TOTAL RATED POWER 8000KN 3 - C-14264 - 1 NVF22-15/400-40V
STROKE 4000mm
2 - C-14272 - 1
WEIGHT
1 - THRUST JACK B-17551 - 4 T-20/400-400
 FINISH SYMBOL HEAT TREATMENT MATERIAL QTY WEIGHT SCALE DATE

- - - 1 08.4.18
HRC HS 12
NO INSTRUCT CORNER C0.5 , R0.5
NAME TYPE T-20/400-400
OVER 0 UP TO 6 0.1 OVER 0 UP TO 200 1.5 APP'D CHE'D DES'D DRW'N
OVER 6 UP TO 30 0.2 OVER 200 UP TO 400 2.5
0.3 3.5
THRUST JACK
OVER 30 UP TO 120 OVER 400 UP TO 800

OVER 120 UP TO 315 0.5 OVER 800 UP TO1600 4.5 K,N

OVER 315 UP TO1000 0.8 OVER 1600 UP TO3150 7.0
APPLICATION PART NO. DWG NO.
- -
14531 -
SYM. DATE REVISION NAME
- - - - -

2150
2600
1850

H150
5

380
380 H150
8 10 12

380
380

380
8 10 12

380

380
H400 100 380

380
2 1
3 7 10 12

100
H400
6 9 11

H300

H300
RG1300
RG1600
75 H300 1900 H300 1900 H300 1900 H300 25
2650
7000

FINISH SYMBOL HEAT TREATMENT MATERIAL QTY WEIGHT SCALE DATE

- 1 4500kg 1 14.12.12
HR C HS 30
NO INSTRUCT CORNER C0.5 , R0.5
NAME TYPE -
OVER 0 UP TO 6 0.1 OVER 0 UP TO 200 1.5 APP'D CHE'D DES'D DRW'N
OVER 6 UP TO 30 0.2 OVER 200 UP TO 400 2.5
OVER 30 UP TO 120 0.3 OVER 400 UP TO 800 3.5 GUIDE FRAME Assy
OVER 120 UP TO 315 0.5 OVER 800 UP TO1600 4.5 Y,F
OVER 315 UP TO1000 0.8 OVER 1600 UP TO3150 7.0
APPLICATION PIPE JACKING SYSTEM PART NO. DWG NO.
C-14146 -
14272 -
SYM. DATE REVISION NAME
- - - - -

150
2650
25 100 25

4 6 7

0
.D .29
P.C
380
380

1550
2710

ID2200 CL=1025
760

ID1800 CL=850
290
335

1294
RG1300
5 3 2 1
RG1600
FINISH SYMBOL HEAT TREATMENT MATERIAL QTY WEIGHT SCALE DATE

- - - 2050kg 1 14.12.16
HRC HS 20
NO INSTRUCT CORNER C0.5 , R0.5
NAME TYPE ID1800-ID2200
OVER 0 UP TO 6 0.1 OVER 0 UP TO 200 1.5 APP'D CHE'D DES'D DRW'N
OVER 6 UP TO 30 0.2 OVER 200 UP TO 400 2.5
OVER 30 UP TO 120 0.3 OVER 400 UP TO 800 3.5 PRESS RING Assy
OVER 120 UP TO 315 0.5 OVER 800 UP TO1600 4.5 Y,F
OVER 315 UP TO1000 0.8 OVER 1600 UP TO3150 7.0
APPLICATION PART NO. DWG NO.
PIPE JACKING SYSTEM
C-14146
-
17564 -
 FINISH SYMBOL HEAT TREATMENT MATERIAL QTY WEIGHT SCALE DATE

- 1 - 1 14.12.11
HRC HS 10
NO INSTRUCT CORNER C0.5 , R0.5
NAME TYPE NVF22-15/400-40V
OVER 0 UP TO 6 0.1 OVER 0 UP TO 200 1.5 APP'D CHE'D DES'D DRW'N
OVER 6 UP TO 30 0.2 OVER 200 UP TO 400 2.5
0.3 3.5
HYDRAULIC PUMP UNIT
OVER 30 UP TO 120 OVER 400 UP TO 800

OVER 120 UP TO 315 0.5 OVER 800 UP TO1600 4.5 Y,F

OVER 315 UP TO1000 0.8 OVER 1600 UP TO3150 7.0
APPLICATION PART NO. DWG NO.
- -
14264 -
 FINISH SYMBOL HEAT TREATMENT MATERIAL QTY WEIGHT SCALE DATE

- 1 - 1 14.12.5
HR C HS 1
NO INSTRUCT CORNER C0.5 , R0.5
NAME TYPE NVF22-15/400-40V-R
OVER 0 UP TO 6 0.1 OVER 0 UP TO 200 1.5 APP'D CHE'D DES'D DRW'N
OVER 6 UP TO 30 0.2 OVER 200 UP TO 400 2.5
OVER 30 UP TO 120 0.3 OVER 400 UP TO 800 3.5
OVER 120 UP TO 315 0.5 OVER 800 UP TO1600 4.5 Y,F HYDRAULIC PUMP UNIT
OVER 315 UP TO1000 0.8 OVER 1600 UP TO3150 7.0
APPLICATION PART NO. DWG NO.
- -
14265 -
- - - - - -