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

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

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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.
Product information 16
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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!
manual would lead to potential dangers, which may result in possible equipment damage, serious
injury or even death.
Caution！
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.
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Keep a safe distance to the machine in

operation!
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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!
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Keep a safe distance to the articulated

area of the machine!
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Danger! Rolling wheel gear，keep

hands and arms away.
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Avoid discharge liquid under pressure，

if necessary,please reference safe operation
rules in part 1.5.
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Keep a safe distance to the high-

pressure jet nozzle in operation!
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Keep a safe distance to the ground

anchor!
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Keep a safe distance to the machine to

avoid being wounded by object throwing
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Risk of electrical shock！
Danger of fire-highly flammable mate -

rials!
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Caution Danger!
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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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Lubricating grease filling port sign

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Toolbox sign
Lifting point sign
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.
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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.
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.
Construction area Type

within 3m of power line Electric
within 3m of natural gas pipeline Natural gas
within 3m of other hazards Others
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.
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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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made of bentonite as the parent material of the slurry, and is sent to the excavation surface at the
front end of the top of the pipe jacking machine by a slurry pump. The fluid mechanics and the
stability of the soil mechanics generated by the pressurized muddy water are formed on the
excavation surface. The cement-impermeable membrane, muddy water penetrates into the soil of
the excavation surface through the cutter head, and it will have the effect of suppressing the
hydraulic pressure of the site and the cohesive force of the earth pressure so as to achieve the
effect of stabilizing the cutting surface, and then using the cutter head of the pipe jacking
machine head, Cut the site of the excavation surface. In the construction of pebbles and hard
ground, the muddy water method can use a cutter head with a hob, and use a hob on the cutter
head to break the larger diameter pebbles or rocks for the first time. The conglomerate is broken
once. Through the opening of the cutter head into the secondary crushing chamber, the second
crushing is performed with the eccentric cone crusher in the head of the jacking machine.
Slurry water circulation is a compulsory circulation method. When the machine head starts
to operate, the mud in the pipe is always in a flowing state. The mud discharge valve is adjusted
through the amount of earth in the head by the operator. The muddy water is pumped to the
muddy water treatment equipment on the ground by mud pumping, and the debris is collected
and discarded. The muddy water is sent to the machine head for recycling.
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2.2 Model Composition

XDN 450
Max Pipe Size，Φ450mm
Slurry Balance Pipe Jacking Machine

2.3 Application Scope
Environment Requirements：
All the operations should be conducted under the conditions of temperature between -15℃
～ +45℃, working environment temperature less than 3bar.
2.4 Product Boundary Dimension

1.Handpiece
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Size：φ630mm×2827mm Quality：2500kg
2. Main jacking device（Unit：mm）
Size：1890×1330×905mm Quality：1930kg
3. Console（Unit：mm）
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4. Electric control cabinet（Unit：mm）
5. Main pump station（Unit：mm）
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2.5 Main technical features of equipment
Item XDN450 parameter
Nominal pipe diameter mm Φ500
Outer diameter × Length mm Φ630×2840
Motor power kW 22×1

Cutting
wheels Torque kN.m 9.76
Rotate speed r/min 16.6

Force per
cylinder kN 192
Head
Number of
EA 3
Steering cylinders
system
Steering
angle ° 3
Motor power kW 0.18
Slurry line diameter mm Φ75
Total power kW 22.18
Weight kg 2300
Thrust kN 800
M a i n
j a c k i n g Numbers EA 2
cylinder
Stroke mm 760×2
Starting well size mm Φ2090

Well size
Receiving well size mm Φ1540
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2.6 Product Nameplates
2.7 Main technical features of equipment

1. Occupy small space: Detachable lightweight, compact structure design, small footprint,
greatly reducing the influences of the road;
2. Visual remote control: During jacking operations, the operator can monitor the entire
construction process in real time in the operating room,Also can intuitively and accurately
grasp the cutting speed, travel path and working conditions by the electronic display, and truly
realize visualized remote control;
3. Strong rock breaking ability: Equipped with a conical butterfly hob, the broken rock
hardness is up to 300 MPa.
4. Conical eccentric crushing position: The specially designed large-diameter conical

eccentric crushing crusher will crush the large rock twice and improve the construction
efficiency.;
5. Stepless speed regulation: The jacking speed of the main top oil cylinder and the flow
rate of the mud to be pumped and discharged are adjusted by frequency conversion to meet the
actual requirements of different working conditions with strong adaptability.
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2.8 Components and Structures
XDN450 pipe jacking machine is a split jacking device. The whole machine is mainly
composed of articulated shield, main jacking device, main jacking pumping station, console,
electric control cabinet and other components,etc.
No. Name Note No. Name Note

1 Articulated shield 4 Main jacking device
Main jacking pumping

2 Electric control cabinet 5
station
3 Console
2.8.1 Articulated shield
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Modular design, easy to disassemble and transport; Use special deceleration device, strong
power, output the largest torque in the smallest volume; the mud in and out system is equipped
with bypass valve and bypass valve inside and outside the pipe, through each bypass valve The
control can not only meet the needs of the mud in the working well and in the machine, but also
can be used to meet the needs of the construction of the mud outside the pipe.
Rated power 22kW
Rated voltage AC220V(three phase 60Hz)
Rated output torque 9.76kN•m
Rated output speed 16.6r/min
Maximum correction angle 3°
Slurry pipe diameter Φ75mm
Work quality 2300kg
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2.8.2 Main jacking device
XDN450 adopts double cylinder jacking, sliding top iron, and stopper card slot design,
which can realize multiple stage jacking.
Jacking progress 670 mm×2
Overall width 1330mm
Overall length 1890 mm
Work quality 1930kg
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2.8.3 Main pump station
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The main pump station motor can achieve stepless speed regulation. Apply hydraulic
confluent technology to improve the working efficiency of the main top device.
String pump HAWE
MAX pressure 35MPa
Work quality 700kg
rated power 7.5kW
2.8.4 Console
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For the construction technology of the pipe jacking machine, advanced PLC control
technology is applied and a large 15-inch display screen is used for easy observation. Through
the lack of phase detection, pressure monitoring, current monitoring, bypass valve limit
monitoring parameters such as monitoring and alarm, effectively protect the safety of the
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machine and construction.
PLC OMRON
Rated voltage AC220V(three phase 60Hz)
Working frequency 60Hz
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2.8.5 Electric control cabinet
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Control circuit breakers related to power supply systems, frequency converters for main
pumping stations, frequency converters for supplying、discharging mud and solenoid valves.
Stable performance, reliable quality.
The whole input voltage AC220V(three phase 60Hz)
Head motor power 22kW
Internal pump station motor power 0.18kW
Main pump station motor power 7.5kW
Work quality 100kg
2.9 Using and operation

1）The main jacking device is fixed in the initial well and the nose is suspended to guide
rail of the main jacking device;

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2）After installing the mud pipe, hydraulic oil pipe and electrical harness, the pipe is
hoisted into the originating well and connected;
3）Correct the direction of operation , and advance the propulsion pipe in sequence At the
same time;
Before performing the corrective operation, the operation of the main jacking
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cylinder must be stopped; Correct operations frequently when the jacking pressure is
large.
4）Repeat steps 2 to 3, and the jacking pipe work is completed when the head reach to the
receiving well.
2.10 Other auxiliary tools

1）Mud mixing device
The mud mixing device is a device for manufacturing a pipe jacking mud,
which can fully stir the additives such as bentonite and water to prepare mud for
the pipe jacking.
2）Mud processing equipment
The mud processing equipment which facilitates the recycling

of the mud can filter out the particulate matter discharged from the
mud, and has the function of purifying the mud and filtering the
sand.
3）Laser emitter
The laser emitter is an important tool for the direction of

construction of the jacking pipe. It provides an accurate
reference for the jacking direction through the laser position
displayed on the laser target.
4）Grouting pump
The grouting pump is used for the lubrication of the outer

wall of the top pipe, effectively reducing the jacking resistance
and preventing the ground from collapsing.
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5）Feed mud pump
Sludge pump is mainly used for water supply and sludge

discharge. During the pipe jacking process, sludge is delivered to
the head of the machine.And the muck under the cutting is
pumped to the ground along with the mud.
The maximum power of the mud pump motor can’t exceed 11 kW, and the maximum
power of the mud pump motor can’t exceed 15 kW.
6）Support tube
It is connected to the tail of the machine head and placed into the cement pipe in order to
prevent rotation of the machine head. It can also be used as a laser
channel and mud conveying channel.
Due to the lack of self-weight of the XDN450 head, it is necessary to add support tube
devices. 
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Chapter Three Operational Instruction
3.1 Device installation
3.1.1 System structure
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3.1.1.1 Electric control cabinet
Equipped with three frequency converters, respectively control the mud pump, sludge
pump, main pump, and electromagnetic switch control cutter motor, hydraulic pump station. All
of the above are operated by the IO/DA/AD module and the operating panel PLC using
OMRON's dedicated communication compobus.
3.1.1.2 Console
Configured with OMRON PLC, Delta human machine interface, industrial computer, 7"
display
1) PLC: programmable controller. The entire system's control center collects all signals to
communicate with the module through the program, and then controls the appliances on the
system, and sends the collected information on the human-machine interface display system for
the operator to interpret.
2) Man-Machine Interface: Through RS232 communication with the PLC, the system data
is presented as icons or numbers. Changing the system parameters is also performed via the
man-machine interface. The historical record review is implemented by the man-machine
interface.
3) Industrial computer: The image signal of the camera in the target box is represented by
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coordinates by means of software calculations. The calculated coordinates are communicated
with the PLC via RS232, and the PLC obtains the coordinate values for transmission from the
man-machine interface.
4) 7" display (1): The display of the industrial computer presents the image in the target
box, the laser spot and coordinates.
5) 7" display (2): External camera can be monitored to monitor the scene.
3.1.1.3 Articulated shield

It is equipped with cutter motor, internal hydraulic pump station, internal solenoid valve
group, laser target box, correction cylinder, internal bypass valve, internal and external bypass
valve, pressure sensor, displacement sensor and proximity switch.
1) Cutter-plate motor: The power line will output three-phase 220V voltage from the
electric control cabinet, which can be reversed.
2) Internal hydraulic pump station: The power supply is controlled by a one-way 220V
output from the electric control cabinet, and the pressure source of the hydraulic system is
supplied to the machine.
3) In-machine solenoid valve group: Controls the movement of the hydraulic components
inside the machine. The DC24V electric control solenoid valve is supplied by the target control
box.
4) Laser target box: The built-in camera captures the laser spot position, the DI module
reads the proximity switch signal, the DO module controls the solenoid valve, and the AD
module reads the pressure displacement signal.
5) Correction cylinder: control the nose jacking direction.
6) Internal bypass valve: Control mud open or closed.
7) The bypass valve inside and outside the pipe: control the position of the mud to be sent
out. The inside of the pipe is to send mud water to the inside of the crusher, and the outside of
the pipe is to send the muddy water to the outside of the fuselage.
8) Pressure sensor: Detect hydraulic oil pressure and hydraulic pressure.
9) Displacement sensor: Detect the displacement of the correction cylinder and convert the
correction angle at the same time.
10) Proximity switch: Detects the opening and closing of the bypass valve and the bypass
valve inside and outside the tube.
3.1.1.4 Main pump station
Provides the main oil pressure source of the top cylinder, and provides the pit bypass valve
control oil pressure source. Built-in pressure sensor detects hydraulic pressure, built-in gear
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flow meter detects main jacking cylinder speed.
3.1.1.5 Main jacking device
Jack into the articulated shield and pipeline.
3.1.1.6 Mud pump
Sent the mud water to the articulated shield.
3.1.1.7 Sludge pump
Slurry treatment system for transporting broken sandy soil from muddy water to the ground.
3.1.2 Control cabinet online
1）The main power supply is accessed from the rear of the electric control cabinet. The
power supply must be three-phase 220V.
Do not connect the green ground wire to the generator.

2） Feed pump, sludge pump, and main pump station are connected
with the power supply.
The green ground wire is connected to the corresponding motor.
3）Electrical harness is installed correct as marked.
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4）Check if the voltage is 220V.
5）The main switch in the electric control cabinet.
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3.2 Equipment safety inspection
3.2.1 Check if that all threaded connections are tight and the pins are secure.
3.2.2 Check if the grease, lubricating oil, etc. are adequate.
3.2.3 Check if the hydraulic oil is sufficient and if the hydraulic oil circuit leaks.
3.2.4 Check if r the operation and instrument display are normal.
3.2.5 Check if the function and status of each device component are normal.
3.2.6 Check supply voltage: Three-phase AC220V, Frequency: 60Hz
Incorrect power supply voltage will cause damage to the

equipment and even cause electric shock or other hazards.
3.2.7 Check if the supporting facilities are complete and if they correspond the safety
requirements. The supporting facilities are as follows:
1) Laser emitters. Required battery device must have enough spare batteries.
2) Random spare parts box and tool box.
3) Pipes, seals, sealants and connecting devices.
4) Mud supporting facilities, such as mud pump, mud pump, mud pump, grouting pipe,
pipe card, water source, mixing station, Pengrun soil, polymerization agent and other
added materials.
5) Flag or self-painting.
6) Insulated boots and insulating gloves.
7) Notebook and pen.
8) Fire extinguisher.
9) Power supply and lighting equipment.
3.3 Start machine

1）After ensuring that the power supply is connected in normal condition, open the
control cabinet and turn the power switch QF0 (located in the upper left of the control cabinet)
to the ON position to turn on the power.
20
!
!
2）Turn the power switches QF1, QF2, and QF3 up to the ON position one by one.
!
3）Turn the power switch on the console clockwise to start the console.
21
!
In order to prevent electric shock, ensure that the operator's desk and cabinet are
grounded before operation, and be sure to use the grounded copper
rods attached to avoid danger.
3.4 Equipment operation check
3.4.1 head operation inspection
1) Check if the axis of the head is accurate.
2) Check if the corrective action is normal.
3) Check if the rotation of the knife plate is normal.
4) Check if the internal bypass valve and the bypass valve inside and outside the pipe are acting
normally.
5) Check if the calibration position of the laser is accurate.
The action of internal bypass valve and inside and outside bypass valve must be
checked before conveying slurry action.
3.4.2 main top device operation inspection
1) Check if the operation of the main top oil cylinder is normal.
22
!
2) Check if the sliding of the top iron is normal.
3) Check if the operation of the globe valve is normal.
3.4.3 mud unit operation inspection
1) Check if the mud line is leakage.
2) Check if the flow of the flowmeter is normal.
3) Check if the hose is distorted or flattened.
4) Check if the delivery of sludge pump is normal.
5) Check if the running of the grouting pump is normal.
6) Check if the mud treatment equipment is normal.
7) Check if the mud mixing device is normal.
3.5 Operation and setting instructions
1) network port: it can communicate with computer and man-machine network.

2) man-machine USB: connect to human-machine USB, insert USB portable disk, and send
the jacking record to the disc.
3) computer USB: connect computer USB, you can insert mouse to control computer.
4) head volume: clockwise volume increases and counterclockwise volume decreases.
23
!
5) computer monitor: monitor the laser coordinates of the target, install the camera to
monitor the scene, and there are buttons to switch on the monitor.
6) monitor display: the camera can be installed to monitor the scene, and the buttons on the
monitor can be switched.
7) buzzer: When the button is pressed, there will be a short sound to confirm whether the
key is normal.
8) human-machine interface: display the main operation interface and set various
parameters.
9) operation key: control and operate all functions of pipe jacking machine.
10) speed control knob: clockwise acceleration and counterclockwise deceleration, which
can be displayed by the man-machine interface.
11) power switch: the operation panel controls the power supply ON/OFF control.
12) tone volume: clockwise volume increases and counterclockwise volume decreases.
Operation panel:
A：
开启停⽌关闭
! ⽴坑旁通阀
1) vertical pit bypass valve
Start button: Click the start button to turn on the light and the pit bypass valve opens.
Close button: Click the close button to turn off the light and the pit bypass valve closes.
Stop: stop action immediately when click the stop button.
24
!
开启停⽌关闭
!
2）Inner tube external bypass valve

Start button: Click the start button to turn on the light and the slurry is transported to the
crusher.
Close button: Click the close button to turn off the light and the slurry is transported to the
bottom of the fuselage.
Stop: stop action immediately when click the stop button
开启停⽌关闭
!
3）Internal bypass valve

Start button: Click the start button to turn on the light and the internal bypass valve opens.
Close button: Click the close button to turn off the light and the internal bypass valve closes.
4）Cutter motor:
Left turn button: Click the left turn button to turn on the light and the
cutter head motor runs, looking counterclockwise in the rear of the fuselage.
Right turn button: Click the right turn to turn off the light and the cutter head motor runs,
looking clockwise in the rear of the fuselage.
After stop, the stop light flashes for 8 seconds.When the rotation angle is greater than
25
!
the rotation angle setting value, the cutterhead motor will automatically stop. At this time,
the cutter motor will only be able to run in one direction. When the rotation angle is
positive, it can only rotate right; When the rotation angle is negative, it can only rotate
left.
When running, when detecting that one phase current is 0, the cutter disk motor will
automatically stop (under-phase protection).
When the cutter motor exceeds the set current, the cutter motor will stop
automatically.
B
! !
In the upper left figure, the middle red button: The internal hydraulic pump station is
depressurized.
Upward adjustment: press down, press right (left) and left (right).
Downward adjustment: Press up, press left (lower left) and right (lower right).
Adjust to the right: press left (top right) and right (bottom right), go up or down to reach
the desired position.
Adjust to the left: press the right (left) and the left (low left), with the up or down to reach
the desired position.
Correction cylinder position: as the upper right diagram, the upper is the upper correction
cylinder; the lower left is the left deviation correction cylinder; the lower right is the right
deviation correction cylinder.
26
!
!
The yellow block on the display represents the elongation of each correction cylinder. When the
data is 0, it means that the error correction cylinder is completely retracted. The maximum
elongation varies from machine to machine. Please test your own records.
Upper reach: The upper correction cylinder extends and the red dot on the display moves
downwards.
Shrink: The upper correction cylinder retracts and the red dot on the display moves upwards.
Left extension: The left lower correction cylinder extends and the red dot on the display moves
to the upper right.
Left-handed: The left-hand correction cylinder is retracted and the red dot on the monitor
moves to the lower left.
Right extension: The right lower correction cylinder extends, and the red dot on the display
moves to the upper left.
Right contraction: The lower right correction cylinder is retracted and the red dot on the display
moves to the lower right.
!
The laser was in the middle and did not deviate from the plan line
27
!
!
The laser is on the upper side, Y is negative, the nose is lower than
the planned line and needs to be revised upwards
!
Under the laser, Y is positive, the head is higher than the planned line
and needs to be revised downwards
!
The laser is to the right, X is negative, the nose is off the plan line and
needs to be corrected to the right
28
!
!
The laser is to the left, X is positive, the nose is deviated from
the right of the plan line and needs to be repaired to the left
The correction position is basically in the same direction as the laser, that is, when the
laser is in the upper right, the correction point is also in the upper right.
After the correction, you must pay close attention to the laser movement trend and
correct it back at the right time. If you are going back to repair the laser when it is in the
middle, the laser will move in the opposite direction and produce a snake phenomenon.
Assume that the head is left (x=-20). You fix it to the right. After pushing 1M, the
head is left (x=-23), indicating that your correction is not enough. You need to fix it a little
more to the right; if you push 1 meter After that, it is still (x=-20), indicating that the nose
will not continue to shift to the left. Please continue to observe after halving the
correction. If the offset starts to decrease, the head will return to the design line. At this
time, you The correction can be repaired to 0 to avoid returning too fast to produce a
snake moving.
The above correction method is for reference only, and the specific implementation
method must consider the situation in the field!
29
!
C
备⽤警报复位机头电源
现场操作操作台操作
操作臺操作距离归零
!
Alarm reset: When a fault occurs, the button is released.
Head Power: The target in the head control box power control button, click to send power, and
then click to stop sending power.
On-site operation: Pressing, the control of the main fuel tank is changed to the on-site button
control, and the power of the machine head will be cut off.
Console operation: Press this button to control the main jacking cylinder.
Distance to zero: Press this button to zero the advance distance.
主顶压⼒中继泵压⼒1 中继泵压⼒2

顶进选择
前进停⽌后退
!
Main jacking cylinder pressure: The oil pressure is switched to the main jacking cylinder
of the main device.
Relay pump pressure 1: The oil pressure is switched to the first group of relay cylinders.
Relay pump pressure 2: The oil pressure is switched to the second group of relay cylinders.
(Relay function is reserved)
Forward: Press the foot pedal and press the forward button at the same time, the main top
cylinder advances.
Back: Press the pedal and press the back button at the same time, the main head cylinder
back.
Stop: Press Stop and the main head cylinder stops.
30
!
When the crusher current exceeds the set current of the main jacking cylinder, it
automatically stops;
When the muddy water flow rate is lower than the set value and the flow rate is too low to
stop the main jacking cylinder, it will automatically stop;
When the rotation angle exceeds the set value, the main jacking cylinder automatically
stops;
When checking the corrected pressure over pressure warning, if the correction pressure
exceeds the set value, the main jacking cylinder automatically stops.
D区
! 中继泵排泥泵送泥泵主顶泵

Please start the mud pump, sludge pump and oil pressure in the electric control cabinet
before operation;
Rotary speed knob: Increase the clockwise rotation speed, counterclockwise lower speed
rotation speed is displayed on the console display.
During the initial advancing, in order to avoid too fast forward speed, first turn the
number of revolutions to 0, and then increase the number of
revolutions as the main crown cylinder advances. 
31
!
Man-machine interface boot screen:
1 2 3 4 5 6
No. Name Function Description Note
Delta display parameter
1 System Setting See details 3.5.1
settings
New project clear records and
2 Open new project See details 3.5.2
initial settings
Setting pipe jacking machine
3 Menu See details 3.5.3
parameters
Old construction continues Enter the old construction
4 See details 3.5.4
construction construction operation screen
5 traditional Chinese Switch language type See details 3.5.5
6 Tips Operation function tips See details 3.5.6
32
!
3.5.1 System Setting
Please refer to Delta human machine operation manual for this part
3.5.2 New project clear records and initial settings
Enter the "new project clear records and initial settings" screen:
1 2
3
4
5
6
No. Name Function Description Note

1 Please enter the project name Fill in the project name See details 3.5.2.1
2 Please enter the project Fill in the project number See details 3.5.2.2
number
3 Solenoid valve detection Check if the solenoid valve is See details 3.5.2.3
normal
4 Zeroing Zero value of each parameter See details 3.5.2.4
5 Bull's eye correction Adjust the bull's eye position See details 3.5.2.5
6 Face plate rotation direction Adjust the rotation direction See details 3.5.2.6
correction of the cutterhead
7 Operation screen Pipe jacking operation mode See details 3.5.2.7
33
!
The operation record of the upper stage project will be

automatically transferred to the connected USB storage device. When “! ” is
entered, the operation record of the upper stage project will be automatically cleared.
3.5.2.1 Please enter the project name
Used to fill in the project name

.3.5.2.2 Please enter the project number
Used to fill in the project number.
3.5.2.3 Solenoid valve detection
Enter the "solenoid valve detection" screen:
Instructions:
"Solenoid valve rated current" is set to 0.5. Press ! , the system will automatically
detect the current of each solenoid valve. If the current is lower than the rated current, it will be
displayed! , indicating that the solenoid valve is faulty; if it is higher than the rated current,
34
!
it will be displayed! . That means the solenoid valve is normal.
3.5.2.4 Zeroing
Enter the "zeroing" screen：
No. Name Function Description

Before and after the tilt relative value zero
1 Tilt
and fine-tune
Zero rotation and fine adjustment of rotation
2 Rotation angle
angle
3 Correction value is zeroed Correction correction value is zeroed
4 Water pressure is zeroed Mud pressure is zeroed
Before setting zeroing and fine tuning, the correction cylinder must be fully retracted,
the head placed horizontally, and rotate to level.
35
!
3.5.2.5 Bull's eye correction
Enter the "bullet correction" screen:
Instructions:
Put appropriate light into the target box, small display on the left side of the console (as
shown in the figure below) can see the target circle and XY coordinates as the principle, the
small green coil of the display must match the target circle seen by the camera is the correct
design set. If there is no match, adjust the X coordinate value, Y coordinate value and radius so
that the green drawing line matches the actual target circle.
36
!
When you change the XY number, the green drawing will move, and changing the
radius will change the size of the circle.
37
!
3.5.2.6 Face plate rotation direction correction
Enter the "face plate rotation direction correction" screen:
Instructions:
If the rotation direction of the cutterhead is opposite to the console control button, press
! to switch.
38
!
3.5.2.7 Operation screen
Enter the "operation screen":
1 2 3 4 5 6 7
1 Location display area Laser target position display
2 manufacturer Equipment manufacturing company name
3 Correction display area Deviation correction, correction, pressure display
4 Information display area Display operation instructions
5 Number of tubes display area Top tube quantity display
6 Date and time display area Display current date, time
7 Menu area Set top pipe machine parameters
39
!
1 2 3 4
1 Current display area Cutter motor three-phase current display
Left working When the cutter wheel rotates to the left, it is displayed
2 in green
3 Current display area Cutter motor current display
Right operation When the cutter wheel rotates to the right, it is

4 displayed in green
Machine oil pressure display Internal pump station pressure display
5 area
6 Water pressure display area Mud line water pressure display
7 Rotation angle display area Left and right rotation angle display
Front tilt display area Correction cylinder front housing relative offset
8 display
9 Rear tilt display area Correction cylinder rear housing relative offset display
40
!
1234567 8 9 10 11 12 13
In-tube bypass display area When the bypass in the tube is on, it is displayed in
1
green
Inside bypass opening display When the bypass is turned on, it is displayed in green
2
area
3 Pit pit bypass open display area When the pit is bypassed, it is displayed in green
4 Sludge rotation display area Mud motor speed display
Outer bypass display area When the bypass is outside the tube, it is displayed in
5
green
Machine bypass bypass display When the bypass is turned on, it is displayed in green
6
area
7 Pit stop bypass display area When pits are closed, they are green
8 Send mud rotation display area Mud motor speed display
9 Push speed display area Main jacking cylinder speed display

41
!
10 Push distance display area Pipe jacking construction advance distance display
11 Muddy water flow display area Sludge pump flow display
12 Push pressure display area Main jacking cylinder push pressure display
13 Oil pressure display area Main top pump station motor speed display
42
!
3.5.3 Menu
Enter the main menu "menu" area：

1 2 3
4 5 6
1 Crusher over current Cutter motor maximum current limit
Stop the main jacking cylinder Main motor limit of the main pump station
2 current
Over current delay detection Delayed alarm time after maximum limit current is
3 seconds exceeded
4 Low flow limit Sludge flow rate minimum limit
5 Delay warning seconds Delay alarm time after the minimum limit traffic
If the flow is too low, stop the The mud flow is too low to stop the main jacking
6 main jacking cylinder cylinder
43
!
! Instructions：
When the motor speed of the cutterhead exceeds the set value of ! and the
time exceeds the set value of ! , the cutterhead motor stops automatically;
When the motor speed of the cutterhead exceeds the set value of ! , the
master cylinder will automatically stop, but the cutterhead motor will continue to operate.
When the current of the cutterhead motor drops to the set value, the main jacking
cylinder is operated to carry out the jacking operation; in order to
avoid that the instantaneous electric current is too large to stop the
operation too often, the overcurrent time is stopped after
exceeding the set value! .
! Instructions：
When the flow rate is lower than the set value of ! and the time exceeds the
set value of ! , the equipment prompts a warning;
! set to ! , when the flow rate is lower than the set value of
! and the time exceeds the set value of ! , the main head cylinder
automatically stops;
! set to ! , the main cylinder will not stop automatically when the
flow rate is lower than the set value of ! and the time exceeds the set value of
! .
Sometimes, the flow rate decreases immediately and then rises immediately. At this
time, the warning is meaningless. Therefore, when the flow rate is lower than the setting
value of ! and exceeds ! , the device only warns.
44
!
1 2 3 4
5 6 7
High pressure and low pressure Maximum propulsion pressure limit when operating
1 the console
Low pressure and high pressure Maximum propulsion pressure limit during on-site
2 operation
3 Back pressure Main top cylinder maximum retraction pressure limit
Low-pressure high-speed Maximum speed limit during on-site operation

4 rotation
5 Internal hydraulic pressure In-machine pump station maximum pressure limit
6 Correct pressure warning value Correction cylinder pressure warning value setting
Correct the pressure is too large Whether the pressure is too large
7 to warn
45
!
! Instructions：
When the operation console operates the main jacking cylinder forward, when the
operation screen displays ! and the set value exceeds ! , the main jack
cylinder automatically stops;
When the on-site operation of the main top cylinder is taken over to take over the
operation, if the value displayed on the operation screen exceeds the set value !
of ! , the low-pressure hydraulic pump stops working, leaving only the high-pressure
pump to discharge oil;
When the operation screen display ! exceeds value of ! , the main head
cylinder automatically stops;
When the on-site operation of the main top cylinder is taken over to take over, set the
appropriate parameter values of ! to make the pressure at the time of back fall
below ! .
When the console is operated, the propulsion pressure is high but
the speed is slow; in the field operation, the propulsion pressure is low but the speed is
fast.
When the on-site operation of the main jacking cylinder is reversed, if the speed is too
high, the pressure will exceed the low pressure and high speed setting, and the low
pressure pump will stop the pumping, and the speed will be slower.
! Instructions：
When the hydraulic pressure in the machine is greater than this set value, stop the hydraulic
action.
Correct pressure warning value: warn when correction pressure exceeds this setting.
Correct pressure warning: When it is set to ! , the main jacking cylinder will be
automatically stopped during the propulsion and warning, on the contrary when set to !
, only warning.。
46
!
1 2 3 4
5 6 7 8 9 10 11
1 Push record interval (minutes) Pushover time of the pushover machine
2 Rotation angle warning value Maximum rotation limit
Is the bypass valve not open Is the internal bypass valve not open warning
3
warning
Is the rotation angle too large Whether the rotation maximum angle setting exceeds
4
Warning the warning
5 Computer shutdown Turn off industrial computer
6 Advance records Pipe jacking operation record display
7 Adjustment adjustment Pipe jack parameter setting
8 Warranty record Pipe jack warranty record display
9 PLC module monitoring PCL port communication detection
47
!
10 startup screen Boot interface display
11 Operation screen Operation main interface display
Enter the "Promotion Records" area：
1
2
3
4

X coordinate Display the X-direction offset track of the jacking
1 machine
Y coordinate Display pipe jacking machine Y direction offset
2 trajectory
XY coordinates Display the X, Y direction offset trajectory of the pipe
3 jacking machine
Electric current Display cutter motor current change path
4
thrust Display the main thrust cylinder thrust force change
5 track
Advance speed Display the trajectory of the advance speed of the main
6 crown cylinder
7 Push the form Pipe pusher drive record details
8 Alert Form Record operation alarm details
48
!
49
!
Enter the "X coordinate" area：
Enter the "current" area：
50
!
51
!
Enter the "thrust" area：
Enter the "propulsion speed" area：
52
!
Enter the "Advance Form" area：
Enter the " Alert Table " area：
53
!
Enter the "adjustment calibration" area：
Solenoid valve detection, zero return, and bull's-eye correction are the same as the initial
settings. See 3.5.2.3~3.5.2.5 for details.
Other functions In addition to "PLC monitoring", you need a password to log in, if you press
the function button
Enter the following characters：
LEVEL：1
ACCOUNT:CHCEL
PASSWORD：CHCEL123
After entering, press OK to enter this function
The function that requires a password to log in is not

recommended for general operator operation. If the device is
54
!
damaged due to the operator's change of settings, the user is responsible for it.
Enter the "solenoid valve operation setting"area：
The pipe jack is set according to the above figure before leaving
the factory. When it is found that the button does not match the
action, it needs to be reset. Setting method: send electricity to the
head, press and hold the ! key, check the movement of the head, and the pull-down
option is the same as the actual action. Follow the same method to set up 10 actions one by one.
After setting is complete, use the actual buttons of the console to test whether the action is
correct.
Be careful not to set the repetitive movement to avoid damage to the equipment
during construction operations when setting the solenoid valve in the pipe jacking
machine.
Enter the "Electromagnetic Valve Action Settings" area:
55
!
!
Correction method:
1) In order to facilitate the correction, please remove the target box from the nose, connect the
operation line, and send power from power supply of the head.
2) Use the electronic leveler to correct the horizontal direction according to the following
figure;
3) Press ! after adjusting the target box to level;
4) Tilt the target box at a certain angle (approximately 5°) and press the fine or coarse
adjustment to make the data the same as the horizontal ruler (above figure, the tilt angle is
negative).。
56
!
Enter "rotation angle correction" area：
!
Correction method:
1) In order to facilitate the correction, please remove the target box from the nose, connect
the operation line, and send power to the head.
2) Use the electronic leveler to correct the horizontal direction according to the following
figure.
3) Press ! after adjust the target box to level；
4) Rotate clockwise about 5 degrees, then press the fine or coarse adjustment to make the
data on the display same as the electronic level (as shown above figure, rotation angle is
positive).
57
!
Correction method:
1) Parameter setting (ANHI) is required when the frequency transmitter in the control
cabinet is used in a new machine or a frequency transmitter is changed.
! !
2) Press the hydraulic pump start button of the electric control cabinet.
3) Open the electric control cabinet door, frequency sensor press 【ENT】 8 times until
display ；
4) Press to enter the setting, press to move the cursor, press to

58
!
change the value, change the data to 00400, and then press [ENT] for more than 2s to complete
the setting.；
To understand frequency transmitter operation instructions,

please refer to the TA-MF series SetPro microcomputer-based
frequency isolation transmitter instruction manual.
5) The operating table adjusts the speed about 1500r/min;
6) Install the top iron and the stopper on the main top device so that the two main top oil
cylinders can run synchronously;
7) Enter the "rotation angle correction" interface, operate the main top cylinder retract to
the end, make a mark, the main top cylinder advances for 1 minute to stop, measure the amount
of advancement of the main top cylinder (unit mm), this data is the advancing speed mm/ Min,
fill this data into step 1;
If the two main jacking cylinders cannot be synchronized, the two main jacking cylinders are
added together and divided by two.
8) The main jacking cylinder continues to advance, and when the
frequency transmitter data is stable, press [OK] in step 2;
9) The main jacking cylinder retreats to the end, according to step 3 of
the [return to zero];
10) The main jacking cylinder is advanced to the end, measure the actual extension of the
main top (mm), fill in the data column of step 4, and press [to obtain the forward
distance];
11) After the main jacking cylinder is back to the end, press [OK] in step 5.
59
!
Enter the corresponding address information in the [input IO address] position, you can view
the data of the PLC's IO address, as a reference for maintenance judgment.
Enter the "front tilt correction" area：
60
!
Correction method:：
1）The nose is corrected downwards, and the front and rear tilt angles A and B are
measured by an electronic level rule, expressed in terms of thousandths.
2) After inputting A minus B data, press OK to complete the setting (note the positive and
negative);
3) If level ruler does not have a 1000-degree function, only the angle, use the calculator tan
(angle) × 1000 is a thousandth.
Principle explanation: The inclinometer in the target box is to monitor the back tilt angle, and
61
!
the front tilt is calculated by using the corrective angle. This correction is calculated by
comparing the proportion of the upper and lower corners of the correction calculated by the
displacement sensor.
Enter the "rear gear warranty" area：
!
1) The operating hours of various devices can be seen at the top of the screen. You can
understand the relationship between how long each device is operating and the
consumption of parts, and it is used as the basis for replacing the consumables in
advance.
2) Reducer warranty, according to the input on the screen after the warranty item, press
[record];
3) The table below is the history warranty record.
For the maintenance of the reducer motor, please refer to the
manual of the reducer. 
62
!
Enter the "Hydraulic Unit Warranty" area：
!
1) According to the items in the above figure, after entering the items to be maintained, press
[Record];
2) The table below shows the historical warranty record.
63
!
Enter the "Repair Department Warranty" area：
1) According to the items in the above figure, after entering the items to be maintained,
press [Record];
2) The table below shows the historical warranty record. 
64
!
Enter the Run Hours Correction area：
!
You can modify the operating hours to ensure the correctness of the hour record when
replacing a new part.
65
!
Enter the "PLC module monitoring" area：
When the error box flashes red, it indicates that the module is faulty or the communication
line is disconnected. Check whether the module is normal. 
66
!
3.5.4 Continuation of Construction of old project
Continue to complete the old project and enter the construction operation screen.
3.5.5 Traditional Chinese
Switch language types, including Chinese Simplified and Traditional Chinese.
3.5.6 Tips
pipe jack operation Tips.
Chapter Four Lubrication and Maintenance

67
!
4.1 Recommendation Form of Lubricating Oil and Antifreeze Liquid
Recommendation form of the lubricating oil, diesel, hydraulic oil and antifreeze liquid
used by Xuzhou Construction Machinery Group Co., Ltd.
Recommendation form 1 for the actual refilled oil brand of drill in temperature
-15℃~+40℃：
Application Code and

Volume(L) Product name Manufacturer Attentions
component Grade
Internal
Antiwear Above 2/3 of oil
pump station HD68 About 1.2
hydraulic oil leveler window
fuel tank
Caltex
Main pump
station fuel HD68 About 300
tank
Ecommendation form 1 for the actual refilled oil brand of drill in temperature -30℃~+40℃
Application Code and
Volume(L) Product name Manufacturer Attentions
component Grade
Internal
pump station HDZ68 About 1.2
fuel tank
Caltex
Main pump
station fuel HDZ68 About 300
tank
68
!
4.2 The maintenance schedule of machine
69
!
Period of maintenance
Inspe Draina Clea Add Initial Regular
Items to be maintained ction ge n lubricat replace replacem
ing oil ment ent
(grease)
Hob After
using
Guard knife After
using
Wear-resistant After
weld using
Cutter reducer 50
Head
Internal 250 After
bypass valve using
Inside and
After
outside 250
using
bypass valve
Correction
500 250
ring O-ring
Cutter motor 50
Machine
pump station 50
motor
Main pump
50
station motor
Electrical
Proximity 50 After
system
switch using
Cable plug 50
Laser
After
emission 50
using
device
Correction
50
cylinder
Main top
Hydraulic 50
cylinder
system
Internal
bypass valve 50
cylinder
70
!
Inside and
outside
50
bypass valve
cylinder
Suction filter 500 1000

Return filter 500 1000
leakage Before
working
Mud system After After
Mud using using
system
leakage Before 100 1000
working
Fasteners 50
71
!
Chapter Five Common Malfunctions and Solutions
5.1 Hydraulic System Common Malfunctions and Solutions

No. Causes Measures
According to R phase: red, S phase:

Reversed white, T phase: blue, correctly
1 phase Power supply wiring is incorrect. connected, if the reverse phase still
abnormality occurs, R phase and T need to be
exchanged with each other.
Power supply cable is faulty. Check each power cable in turn.
Abnormal
leakage The plug is loose or damaged, leading to After drying the water, tighten or
water ingress. replace the plug.
2
The cable is damaged, leading to water After drying the water, replace the
ingress. cable.
Machine head water inlet. After drying the water, disassemble
the motor and dry it.
In-machine Solenoid valve coil disconnected. Reconnect or replace the solenoid
solenoid valve.
valve group
failure Poor contact between the solenoid valve Lock the cable.
3 and the target box connection.
Failure of the relay in the target box. replace.
Cutter The console shows that the current Adjust the limit value or adjust the
4 overload exceeds the maximum limit current of the operation to reduce the operating
deck motor. current of the cutterhead motor.
Live Water in the handle, rusted switch leads Clean contacts or replace handles.
operation to abnormal contact.
5 handle
abnormality The handle connection cable is damaged Repair or replace the cable.
or short-circuited.
Work or Broken fuse replace
instrument
lights are Rocker switch is damaged Repair or replace
6 off Light bulb damage replace
Line connector loose Repair line
5.2 Hydraulic system failures and troubleshooting

1）Phenomenon: No pressure or low pressure
No. Causes Measures

Hydraulic pump steering error Change direction
72
!
Damaged parts Replace parts
Parts wear, gap is too large, leakage is Repair or replace parts
serious
Hydraulic
1 pump The oil level is too low and the Supplement fluid
hydraulic pump is empty
Insufficient sealing of suction pipe, Tighten joints, check tubing, strengthen
resulting in suction seals
Pressure oil pipeline is not tightly Tighten joints, check tubing, strengthen
sealed, causing leakage seals
Spring deformation or break Replace spring
Spool stuck in open position, unable to Sliding slide valve makes it flexible
build pressure
Relief valve Pole valve or steel ball and valve seat Replacement of poppet or steel ball,
2
closely with grinding seat
Damping hole plugging Cleaning orifice
Remote port to tank Cut off the oil circuit of the tank
The hydraulic cylinder communicates with the high Repair the piston and replace the seal
3 and low pressure chambers
Some valve unloading in the system Identify unloading reasons and take
4 appropriate measures
5 Severe system leak Strengthen sealing to prevent leakage
6 Pressure gauge failure causes no pressure artifact Replace pressure gauge
7 Too low viscosity of oil, exacerbating system leakage Increase oil viscosity
Excessive temperature leads to reduces oil Find out the cause of the heat, take
8
viscosity appropriate measures, or dissipa
73
!
2）Phenomenon: Crawling
No. Causes Measures

Throttle valve or throttle valve flow instability Use Throttle valve or throttle valve flow
1 flow control valve with good flow stability instability Use flow control valve with
good flow stability
Hydraulic cylinder parts are poorly Replace parts that do not meet
machined and assembled with high accuracy requirements and reassemble
Hydraulic friction
2 cylinder
Improper installation of hydraulic re-install
cylinder, inconsistent with the axis of
the guide mechanism
Low oil level, poor suction Supplement fluid
Filter plug Cleaning the oil filter
Suction and drain pipes are too close to Keep the suction and discharge pipes
Mix in the each other away from the setting
air
3 The return pipe is not inserted below Insert the return pipe into the oil
the oil level
Poorly sealed, mixed with air Reinforced seal
Hydraulic fluid loss when the machine Add back pressure valve or check
stops moving valve to prevent fluid loss during
shutdown
Dirty stuck in the liquid motive to Cleaning fluid motive, replace oil or
U n c l e a n increase frictional resistance strengthen filter oil
4 fluid
Dirt jamming throttling, causing flow Clean hydraulic valve, replace oil or
changes filter oil
The viscosity of the oil is not proper. Change the hydraulic oil with the
5 specified viscosity.
Drag wedge or platen over tighten Re-regulate
E x t e r n a l Guide rails and other guide mechanism Scrape the guide rails as required to
6 accuracy is not high, poor contact ensure good contact
friction
Poor lubrication conditions Improve lubrication conditions
74
!
3）Phenomenon: Impact
No. Causes Measures
Set the buffer device Set the buffer device
Hydraulic Repair buffer device check valve Repair buffer device check valve
1 cylinder
Repair buffer plunger as required Repair buffer plunger as required
Prepare a buffer plunger or piston Prepare a buffer plunger or piston
Throttle opening too large Adjust the throttle valve

2
Directional valve or pilot valve brake Reduce brake cone angle or increase
cone angle is too large brake cone length
Directional Hydraulic valve control hydraulic flow Reduce the flow of control pressure oil
valve is too large
3
Improper adjustment of hydraulic valve Adjust throttle opening in damper
damper
Sliding valve movement is not fast Repair spool valve
Adjust pressure valve to reduce Adjust pressure valve to reduce

working pressure properly working pressure properly
Pressure Troubleshooting overflow valve Troubleshooting overflow valve

4
valve
Appropriately increase back pressure Appropriately increase back pressure
No back pressure valve installed Set back pressure valve or throttle

5 valve to generate back pressure for oil
return
Vertically-moving hydraulic cylinder lower chamber Set the balance valve to balance the
6 does not take balancing measures impact of gravity
System does not seal tightly, suck in air Replace seal
Fluid loss of fluid during shut-down A one-way valve or back pressure

Mix in the valve is installed in the return line to
7
air prevent the loss of oil from the module.
Hydraulic pump suction Strengthen the oil suction pipe seal,
make up the oil
Inertia caused by inertia of hydraulic actuator Set the brake valve
8
Oil viscosity is too low Replace oil
9
75
!
4）Phenomenon: Vibration and Noise
No. Causes Measures
cient fluid causes suction Make up the fluid
Hydraulic pump suction position is too Adjust the hydraulic pump suction
high
Suction pipe is not tightly sealed and Strengthen the suction pipe seal
air is sucked in
The viscosity of the oil is too large and Replace hydraulic oil
it is difficult to absorb oil
Working temperature is too low Increase operating temperature or tank

Hydraulic
heating
pump
1 Oil filter blocked oil suction Cleaning the oil filter
Hydraulic pump speed is too high Select the appropriate speed
Improper installation of the hydraulic Reinstall the hydraulic pump

pump, the pump shaft is different from
the prime mover
Loose coupling Tighten the coupling
H y d r a u l i c p u m p m a n u f a c t u r i n g Replace parts with poor accuracy and

accuracy is too low reassemble
Hydraulic wear parts wear Replace worn parts
Hydraulic pump is too pulsating Repair or replace the pump
Seat damage Repair valve seat
Damping hole plugging Cleaning orifice
Excessive gap between valve plug and Replace spool, reconfigure gap
valve body
Relief valve Spring fatigue or damage makes valve Replace spring

2 movement inflexible
Body pulls or dirt stuck on the spool Removal of burrs, cleaning of dirt,
sliding movement of spool
76
!
Co-quake with other components Adjust pressure to avoid common

shock, or change the natural vibration
frequency of the vibration system
Electromagnet suction is not strict Repair electromagnet

Directional
Spool stuck Clean or rest valve bodies and spools
3 valve
Bad electromagnet welding Resolder
Damaged or hard spring Replace spring
Pipeline Uneven internal diameter of hydraulic Replace tubing
4 hose
Loose or loose tube Refix the pipe
5 Shock caused by shock and noise See table: 3. Phenomenon: Impact
Hydraulic system vibration caused by external Take earthquake-isolation measures

6
vibration
Vibration caused by motor and hydraulic pump Take measures to reduce vibration
7
rotation
Hydraulic cylinder seal is too tight or machining Appropriate adjustment of seal

8 assembly error tightness, replacement or repair of
defective parts, reassembly
77
!
5）Phenomenon: Increased oil temperature
No. Causes Measures
Unreasonable operation, the hydraulic system is Reasonably operate the machine,

1 overflowing for a long time, and the system generates especially to prevent prolonged
heat pressure
High work pressure Reduce work pressure reasonably
2
Leakage causes serious loss of volume Reinforced seal
3
Hydraulic pipe joints age, causing pressure loss Replace pipe fittings
4
Excessive friction between moving parts Improve the precision of parts
5 processing and assembly, reduce the
friction of the movement
Excessive oil viscosity Use low viscosity hydraulic oil
6
Small oil tank, poor heat dissipation conditions Increase fuel tank capacity, improve
7 heat dissipation conditions, set cooler
Temperature rise caused by external heat source Isolated heat source
8
6）Phenomenon: leaked
No. Causes Measures
Damaged or reversed seals Replace the seal and correct the

1 installation direction
Loose fittings Tighten the fitting
2
One-way valve ball is not round, valve seat is Replace ball, with test seat
3 damaged
Mutual movement surface clearance is too large Replace some parts and reduce fit
4 clearance
Some parts wear Replace worn parts
5
Pressure adjustment is too high Reduce work pressure
6
Oil viscosity is too low Use higher viscosity fluid
7
Working temperature is too high Reduce operating temperature or take
8 cooling measures
78
!
1. The above content is just the basic experience and solution method summarized
in practice for some common problems. The causes or exclusion methods of failures are
not detailed in detail and need to be determined according to the actual situation.
2. Only professional trained personnel can carry out maintenance of hydraulic and
electrical systems.
3. For the common faults and elimination of the motor, see the motor instruction
manual.
79
!
Chapter Six Transportation, Storage and Protection
6.1 Transportation of drill
Please conduct the following operations during the transportation.
1. For safety precaution and easy operation, drilling operators or other personnel are
forbidden from riding the drill.
2.Check whether the fastening parts such as the limited pin shaft of the anchor or the truck
mounted crane are installed in the right ways.
3. In order to get the excellent max ramp angle and stability during the moving, you should
put the carriage horizontally and put carriage in the back of the drilling machine as the picture
below.
4.Please keep the engine in a low running state when the drill gets on the trailer or truck.
5. For safety precaution and easy operation, please conduct the following operations
totally :Keep the operator behind the drilling machine during both ascent and downhill.
6.2 Equipment shipment
Pipe jacks need trucks to transport at long distances. The equipment needs to be lifted
when loading the truck:
The hoisting holes are arranged on the components of the pipe jacking machine, and the
steel wire ropes can be hoisted into the hoisting holes and hoisted by cranes. The hoisting
modes are as follows:
1) Ensure that the components of the pipe jacking machine are in the horizontal state and
adjust the rope position to ensure horizontal lifting.
2) Add protective articles at the contact point between the wire rope and the pipe jacking
machine, especially add a rubber pad to the machine cover to prevent the parts such as the nose
shell and the main top device from being damaged by the wire rope.
3) Select a set of wire ropes, the ends are connected by a ring, and there are several
branches. Each branch has a hook, and hang the hooks in the hoisting holes of each part;
4) Hoisting with crane equipment such as truck cranes.
XDN450 Pipe jacking machine transport dimensions as shown below
80
!
Cutting head
81
!
Main jacking device
82
!
Console Electric control cabinet Main pump station
83
!
6.3 Daily storage and protection
When storing the pipe jacking machine, note the following:
1) Before the pipe jacking machine is stored, the entire machine is cleaned. In particular,
the mud pumping system needs to be cleaned to keep the whole machine clean and tidy.
2) It is recommended to place the parts flat on the ground, correcting the cylinder, the main
fuel tank are in a fully contracted state (the whole state and the same transport status, see the
transport dimensions of the drawings);
3) After closing the equipment, inspect the valve block lever, key switch, power switch,
circuit breaker switch, etc.
4) The place where the pipe jacking machine is placed shall be capable of sheltering from
wind and rain, suitable temperature, and away from flammable, explosive and other dangerous
articles.
5) The machine must be covered with a canvas to prevent dust, dust, etc. from damaging
important parts of the machine.
6) Start the pipe jack once every one month or so, and test all the actions of the whole
machine 2-3 times.
7) If the downtime exceeds 2 months, check the cleanliness of the hydraulic oil tank
regularly. If it is not required, the tank must be cleaned and the oil body replaced. And in
accordance with Chapter 4 lubrication maintenance rules, the entire machine maintenance.
Remarks:
Motor storage precautions are detailed in the motor instruction manual.
84
!
Appendix A Electrical schematic diagram
!
XDN450 Electrical schematic diagram（⼀）
85
!
!
XDN450 Electrical schematic diagram（⼆）
86
!
!
XDN450 Electrical schematic diagram（三）
87
!
!
XDN450 Electrical schematic diagram（四）
88
!
!
XDN450 Electrical schematic diagram（五）
89
!
!
XDN450 Electrical schematic diagram（六）
90
!
!
XDN450 Electrical schematic diagram（七）
91
!
!
XDN450 Electrical schematic diagram（⼋）
92
!
!
XDN450 Electrical schematic diagram（九）
93
!
!
XDN450 Electrical schematic diagram（⼗）
94
!
!
XDN450 Electrical schematic diagram（⼗⼀）
95
!
!
XDN450 Electrical schematic diagram（⼗⼆）
96
!
!
XDN450 Electrical schematic diagram（⼗三）
97
!
!
XDN450 Electrical schematic diagram（⼗四）
98
!
!
XDN450 Electrical schematic diagram（⼗五）
99
!
!
XDN450 Electrical schematic diagram（⼗六）
100
!
Appendix B Hydraulic schematic diagram
!
XDN450 Machine hydraulic schematic diagram
101
!
!
XDN600 Machine hydraulic schematic diagram  
102
!
!
XDN450 Main top hydraulic schematic diagram
103
!
徐州⼯程机械集团有限公司
XUZHOU CONSTRUCTION MACHINERY GROUP Co.,Ltd.
⽣产单位：徐州徐⼯基础⼯程机械有限公司
Xuzhou Xugong Foundation Construction Machinery Co.,Ltd.
地址：中国.江苏.徐州经济开发区驮蓝⼭路36号
Add：No.36 Tuolanshan Road, Economic Developing zone,Xuzhou JiangSu, China
全国统⼀客服热线：（Tel）：400-110-9999
销售部电话（Tel）：0516-87892612 87892620
服务处电话（Tel）：0516-87892690
传真（Fax）：0516-87738173
邮编（Postcode）：221004
⽹址：http://www.xcmgjc.com
2016年5⽉版
104
!
105

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1.1 Safety of the machine

1.2 Safety signs

Keep a safe distance to the machine in

Keep a safe distance to the machine in

Please carefully read this instruction

Risk of electrical shock！Keep a safe

Keep a safe distance to the articulated

Danger! Rolling wheel gear，keep

Safety Sign Illustration

Avoid discharge liquid under pressure，

Keep a safe distance to the high-

Keep a safe distance to the ground

Keep a safe distance to the machine to

Risk of electrical shock！

Danger of fire-highly flammable mate -

Safety Sign Illustration

Must wear safety helmet

Must wear protective gloves

Must wear protective footwear

Hydraulic oil sign

Lubrication oil filling port sign

Lubricating grease filling port sign

Safety Sign Illustration

Lifting point sign

1.3 General safety requirements

1.3.2 Please wear safety helmets, protective gloves and

1.3.3 Do not put engine oil, toolbox and other

1.3.4 Understand and master particular hands signals and

1.3.7 As a pollutant, waste oil is not allowed to be

1.3.9 Before welding, the main power switch on the

1.4 Major dangers

1.5.4 Leakage of hydraulic oil

1.5.5 Change or refuel hydraulic oil

1.5.7 Usage of mud pump

1.6.2 Working light

Construction area Type

1.8.2 Specific prevention measures of various kinds of Construction sites

1.9.3 Current with low voltage can also cause fatality.

1）If working near the power line, consult with the

2）If getting electric shock, stay on the pipe jacking

2）Leave the site as soon as possible.

3）Warn and evacuate people to leave the site.

4）Contact relevant utility piping departments.

2）No one is allowed to enter the dangerous areas.

2.1 Product Overview

2.1.3 Method summary

2.2 Model Composition

Max Pipe Size，Φ450mm

Slurry Balance Pipe Jacking Machine

2.4 Product Boundary Dimension

2. Main jacking device（Unit：mm）

5. Main pump station（Unit：mm）

Item XDN450 parameter

Nominal pipe diameter mm Φ500

Outer diameter × Length mm Φ630×2840

Xuzhou Construction Machinery Group Co.,Ltd. 