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Common Troubleshooting Of Trenchless Drilling Rigs

December 24, 2021

1. Hydraulic system part

Some common fault handling table of hydraulic system

Failure phenomenon	Cause of issue	Method of exclusion
Under pressure	1. The pressure gauge is damaged	Replace the pressure gauge
	2. The pump speed is too low	Check the diesel engine
	3. Internal leakage of actuator	Replace the seal of the actuator or replace the new actuator (cylinder or hydraulic motor)
	4. The oil pump is damaged	Repair or replace the oil pump
	5. Oil pipe leakage	Check and replace the oil pipe
	6. Improper pressure adjustment	Re-adjust the pressure
	7. Insufficient hydraulic oil	Fill hydraulic oil
	8. The system oil temperature is too high and the leakage is too large	Cooling hydraulic oil
The actuator speed is too slow (hydraulic cylinder or hydraulic motor)	1. Internal leakage of actuator	Replace the seal of the actuator or replace the new actuator (cylinder or hydraulic motor)
	2. Oil pump leakage	Repair or replace the oil pump
	3. The one-way valve in the oil circuit fails, causing oil leakage	Repair or replace the one-way valve
	4. The solenoid valve fails, and the valve is not fully opened	Clean or replace the solenoid valve
	5. Excessive load	Reduce the load
	6. Improper adjustment of overflow valve	Re-adjust the overflow
	7. The variable mechanism of the oil pump fails, and the flow cannot be increased	Check the oil pump and repair or replace
	8. Insufficient hydraulic oil	Fill hydraulic oil
	9. The system oil temperature is too high and the leakage is too large	Cooling hydraulic oil
	10. The filter element is blocked	Check and clean all filter elements
System oil temperature is too high	1. The pressure of the relief valve is too high	Properly adjust the pressure of the relief valve
	2. Too little hydraulic oil	Fill hydraulic oil
	3. Leakage in system executive components	Repair or replace internal leakage components
	4. The system heat sink is damaged	Repair the heat sink

2. Electrical part

Common fault handling table for electrical parts

Failure phenomenon	Cause of issue	Method of exclusion
The battery cannot be charged	1. The generator burns out	Replace or repair generator
	2. The electronic regulator is burned out	Replace the regulator
	3. The battery is damaged	Replace or repair the battery
	4. Poor wiring	Reconnect the wires
Electrical appliances have no related operating actions	1. The operation button or handle is damaged	Replace related buttons or knobs
	2. Poor wiring	Check and re-wire
	3. Relay ablation	Replace the relay
	4. The solenoid valve coil or relay coil is burnt out	Check and replace the relevant coil
	5. The solenoid valve is stuck	Clean the solenoid valve
	6. The battery is dead	Charge the battery
	7. The emergency button is pressed or the power switch is not closed	Pull out the emergency button or switch on the power switch after handling the relevant incident
	8. The voltage regulator tube or switching power supply is damaged	Replace related accessories
	9. The fuse is burned out	Replace the fuse

3. Reducer part

Some common fault handling table of reducer

Failure phenomenon	Cause of issue	Method of exclusion
Reducer overheating	1) Overload	1) Check the actual load, adjust to the specified value or replace with a larger power reducer
Reducer overheating	2) Insufficient or excessive lubricating oil	2) Use oil in accordance with the prescribed amount of oil
Abnormal and stable running noise	1) Rotation/grinding noise, bearing damage	1) Check the oil
Abnormal and stable running noise	2) Knocking noise, irregular meshing	2) Contact the user service organization
Abnormal and unstable running noise	Oil pollution or insufficient oil	Change the oil or refuel to the specified value
Oil spill	Seal damage	Contact the user service agency
The output shaft does not rotate when the motor is rotating	The reducer motor is damaged	Send for repair or replacement

4. Push and pull action

Troubleshooting table for common faults in the push-pull part of the power head

Failure phenomenon	Cause of issue	Method of exclusion
Weak push and pull	1. Motor internal leakage	Repair or replace the motor
	2. The overflow valve of the proportional multi-way valve is stuck	Repair or replace the overflow valve
	3. Push-pull speed is too slow	Refer to the solution for too slow rotation speed
No push-pull action	1. Motor is damaged	Repair or replace the motor
	2. The handle is damaged	Repair or replace the handle
	3. The oil pump is damaged	Replace the oil pump
	4. The oil pump is damaged	Replace the oil pump
Abnormal sound of gearbox	1. Gearbox is out of oil	After replacing the damaged parts, add oil
Abnormal sound of gearbox	2. Bearing damage	Replace damaged bearings
Oil leakage in the gearbox	1. The paper pad where the motor is installed is damaged or not installed properly	Replace the paper pad
Oil leakage in the gearbox	2. The oil seals or gaskets at both ends of the spindle output are worn or not installed	Replace the oil seal

5. Rotating action

Common troubleshooting table for rotating part of power head

Failure phenomenon	Cause of issue	Method of exclusion
Weak rotation	1. Internal leakage of electro-hydraulic valve	Repair or replace the electro-hydraulic valve
	2. The oil pump is damaged	Repair or replace the oil pump
	3. Internal leakage of hydraulic motor	Repair or replace the motor
	4. The system oil temperature is too high	Reduce oil temperature
	5. The system is short of oil	Add hydraulic oil
Rotation speed is too slow	1. Excessive load	Reduce the load
	2. Low system pressure	Increase system pressure
Rotation speed is too slow	3. The electro-hydraulic valve is stuck	Clean the electro-hydraulic valve
	4. Insufficient oil supply from the oil pump	Repair or replace the oil pump
	5. Motor internal leakage	Repair or replace the motor
No rotation	1. The closed pump is damaged or the closed pump coil is burned out	Repair or replace closed pumps or coils
	2. The handle is damaged	Repair or replace the handle
	3. Motor damage	Repair or replace the motor

6. Clamping action

Common troubleshooting table for clamping part

Failure phenomenon	Cause of issue	Method of exclusion
Weak clamping	1. The clamping multi-way valve is blocked	Cleaning the clamping multi-way valve
	2. The clip strip is severely worn	Replace the clip strip
	3. Internal leakage of clamping hydraulic lock	Replace or repair the hydraulic lock
	4. Internal leakage of the clamping oil cylinder	Repair the clamping cylinder and replace related seals

7. Crawler walking action

Walking part (caterpillar) common troubleshooting table

Failure phenomenon	Cause of issue	Method of exclusion
Walking weakness	1. Internal leakage of walking motor	Repair or replace the walking motor
	2. The pressure of the walking system is not adjusted enough	Re-adjust the pressure
	3. Leakage inside the oil pump	Repair or replace the oil pump
	4. The overflow valve is blocked or damaged	Clean or replace the overflow valve
	5. Slack track	Re-adjust the track tensioning mechanism
The track is off the chain	1. Insufficient tension	Re-adjust the tensioning mechanism
	2. The track shoe is broken	Replace the track shoe
	3. The chain track is cracked	Replace the chain track

8. Mud pump part

Common fault handling table of mud pump

Failure phenomenon	Cause of issue	Method of exclusion
Mud pump does not deliver water	1. Air enters the mud pump	Exhaust treatment
	2. No water source enters the mud pump	The water tank is filled with water, the water valve is opened, and the water inlet is unblocked;
	3. The mud pump does not rotate	Check whether the mud pump drive motor is working normally, whether the hydraulic pipeline is under pressure, and whether the solenoid valve is working;
	4. The mud pump pressure is too low (water pressure)	The mud pump cylinder sleeve wears out and needs to be replaced; the water source has many impurities, and the inlet and outlet valve seats of the pump head should be disassembled and cleaned;
	5. The mud pump check valve seat is worn or the steel ball is out of round	Replace related accessories
The mud pump can’t reach the displacement or can’t discharge the medium at all	1. The filter comes out of the water	Make the filter immerse into the liquid surface, the depth is not less than 0.3～0.5m
	2. The filter is blocked	Take out the filter for cleaning
	3. The suction pipe is blocked	Disassemble and clean the suction pipe
	4. The suction pipe is not tightly sealed to inhale air	Check the connections and hoses and try to eliminate them
	5. The inlet and outlet valves are stuck and do not work	Replace the parts due to the valve or valve seat being worn and stuck; due to the clogging of sediment, the bottom of the pump head and the cylinder liner can be opened for cleaning;
	6. Piston or cylinder liner wear	Open the cylinder head, tighten the copper screw sleeve pressing the piston or replace the piston or cylinder liner;
	7. The suction channel is not filled with water or air pockets are formed	Fill with water and exhaust air (a water filling funnel can be installed for filling and exhausting)
	8. The water absorption height exceeds the allowable height	Adjust the water absorption height to within 2.5m (for thick mud, drop to within 1m)
	9. The suction pipe is too long or the diameter is too small	Reduce the length to less than 5m; increase the pipe diameter to the specified size
	10. Insufficient oil supply or insufficient pressure of the oil pump, reducing the speed and torque of the motor;	Check and exclude
Difficulty in operation of mud pump	1. The filter comes out of the water	Loosen the adjusting screw sleeve to reduce the interference of the sealing ring
	2. The filter is blocked	Check the gap and adjust
	3. The suction pipe is blocked	Check and eliminate
	4. The suction pipe is not tightly sealed to inhale air	Check and tighten
There is a strange sound during operation	5. The inlet and outlet valves are stuck and do not work	Adjust the bearing gap or replace with a new bearing
	6. Piston or cylinder liner wear	Check and tighten
	7. The suction channel is not filled with water or air pockets are formed	Check and replace damaged parts
	8. The water absorption height exceeds the allowable height	Check and adjust the adjustment bolts on the shaft end cover
Excessive pressure pulsation	1. The through hole on the head of the pressure gauge is blocked	Cleaning the through hole on the head of the pressure gauge
	2. The piston of a cylinder is severely worn	Check and replace new parts
	3. The valve seat or valve seat hole of a cylinder is severely worn	Check and replace new parts or repair valve seat holes
	4. The valve seat of a certain cylinder is stuck by impurities and cannot work	Check and clear
	5. The clearance between the valve seat and the valve seat hole is too large	Eliminate the gap
	6. The discharge medium contains a lot of gas	Check the cause and eliminate
	7. The pressure gauge is damaged	Replace the new pressure gauge
Local fever or excessive temperature rise	1. There is too much lubricating oil in the crankcase, which greatly exceeds the specified liquid level	Check and drain the oil to the specified height
	2. The connecting rod bearing bush is assembled too tightly, and the clearance of the three tapered bearings is too small	Check and adjust to a reasonable gap
	3. The piston seal assembly is too tight	Adjust the tightness of the seal
Shift gears out of gear	1. After the gear is engaged, the top adjusting bolt is not tight, and the positioning steel ball on the shift lever is pressed	Check and tighten the top adjustment bolt until it stops
Shift gears out of gear	2. The set screws on the shift fork and the shift guide rod are not tightly pressed	Check and tighten the set screws, add iron wire to prevent loosening
The safety valve and the unloading valve are leaking, and the safety valve is malfunctioning	1. The pre-pressure of the compression spring in the safety valve is insufficient	Adjust the spring pressure;
	2. The end surface of the valve seat is not flat and the inner hole is not round	Inspect and repair;
	3. There is debris in the contact between the valve and the valve seat	Check and clean;
	4. Compression spring is crushed	Re-adjust the looseness to ensure the spring margin

Trenchless Drilling Rigs Troubleshooting

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Wuhan Yichao Technology Equipment Co., Ltd. is a professional supplier of horizontal directional drilling rigs. We are XCMG authorized distributor and has nearly 10 years of trenchless pipeline experience.