HYDRAULIC CRANE TROUBLESHOOTING GUIDE
A) SLEWING OPERA OPERATION : Rotary Rotary Movement of Structure Structure around Vertica Vertica A!i" of #rane Line $ia%ram : MONO ,LO#=
PRESS;RE RELIE< VALVE
PRESS;RE RE$;#ING VALVE
PILOT VALVE ,LO#=
S.;TTLE VALVES
,RA=E LI
.$RA;LI# MOTOR
.$RA;LI# P;MP:
SLEW LIMIT SWIT#.
SLEW
PRELIMINERY CHECKS TO BE PERFORMED AFTER STARTING: 1) Check Check Slewi! Slewi! P"#$ P%e&&"%e P%e&&"%e : Indicated on t&e Gau%e connected in t&e #a'in 'y "(itc&in% t&e I"oator no' to Se( Pre""ure Pre""ure ' S&oud 'e around around *+ ,ar (&en "y"tem ide ide -.ande in neutra neutra /o"ition)0 O/erationa /re""ure around 12+ ,ar0 If Pre""ure Pre""ure o'"erved i" LESS t&en ti%&ten t&e Reief Vave Gru' Scre( on t&e Mono'oc in coc(i"e direction direction to increa"e "y"tem /re""ure to t&e de"ired vaue0 Pea"e en"ure t&at t&e Loc Nut 3 #a/ of t&e Gru' Scre( i" ti%&tened once re4uired /re""ure "ettin% i" done0 •
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() Check Check Pil* Pil* Lie Lie P%e&& P%e&&"%e "%e: Indicated On Piot Line Pre""ure Gau%e Piot Line /re""ure to 'e around 5+67+ ,ar0 #&ec if Oi 8o( i" avaia'e in t&e Piot Piot ine" to Mono'oc9 Mono'oc9 S&utte Vave and ,rae ,rae Liftin% Vave0 • •
+) Check Check Li#i* Li#i* Swi*ch Swi*ch P&i*ii P&i*ii!' !' ,) Check -% -% ./ ""&".l i&e 0&e%e2 0&e%e2 -%# ./ - *he i2ii2".l c#$e*&'
,) LUFFING CIRCUIT: Liftin% and Lo(erin% of #rane ,oom0 #om/onent" Invoved: MONO ,LO#=
PRESS;RE RELIE< VALVE
PRESS;RE RE$;#ING VALVE
PILOT VALVE ,LO#=
S.;TTLE VALVES
,RA=E LI
.$RA;LI# MOTOR
L;<< LIMIT SWIT#.
L;<< PAWL
L;<< OVER RI$E
.$RA;LI# P;MP
#.E#=S TO ,E PER
1) Check L"3! P"#$ P%e&&"%e : S&oud 'e around *+ 'ar (&en "y"tem ide0 O/erationa /re""ure around >++ ,ar0 If e"" t&en ti%&ten t&e Reief Vave S/rin% on t&e Mono'oc to increa"e "y"tem /re""ure to t&e de"ired vaue0 • • •
() Check Pil* Lie P%e&&"%e: Piot Line /re""ure to 'e around 5+67+ ,ar0 #&ec if Oi /re""ure in Piot ine" to Mono'oc and ,rae reea"e vave0 • •
+) ,) 4) 6)
Check Li#i* Swi*ch P&i*ii!' Check i- B%.ke Li-*i! C/li2e% i& O$e%.*i.l' Check i- L"5 P.wl C/li2e% i& O$e%.*i.l' Check -% ./ ""&".l i&e % he.*i! 0&e%e2 -%# ./ - *he i2ii2".l c#$e*&'
#) MAIN7 AU8ILLARY HOISTING CIRCUIT: Liftin% and Lo(erin% of Load Line $ia%ram : MONO ,LO#=
PRESS;RE RELIE< VALVE
PRESS;RE RE$;#ING VALVE
PILOT VALVE ,LO#=
S.;TTLE VALVES
,RA=E LI
.$RA;LI# MOTOR
L;<< LIMIT SWIT#.
#.E#= ?6METER VALVE
Emer%ency Load Lo(erin% Vave
.$RA;LI# P;MP
#.E#=S TO ,E PER
1) Check Hi&*i! P"#$ P%e&&"%e : S&oud 'e around *+ 'ar (&en "y"tem ide0 O/erationa /re""ure around >++ ,ar0 If e"" t&en ti%&ten t&e Reief Vave S/rin% on t&e Mono'oc to increa"e "y"tem /re""ure to t&e de"ired vaue0 • • •
() Check Pil* Lie P%e&&"%e: Piot Line /re""ure to 'e around 5+67+ ,ar0 #&ec if Oi /re""ure in Piot ine" to Mono'oc and ,rae reea"e vave0 • •
+) Check Li#i* Swi*ch P&i*ii!' ,) Check -% ./ ""&".l i&e % he.*i! 0&e%e2 -%# ./ - *he i2ii2".l c#$e*&'
S% N
NATURE OF TROUBLE
PROBABLE CAUSES
IDENTIFICATION
TROUBLESHOOTING STEPS •
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a) Pum/ Not %eneratin% t&e $e"ired <o(0
Sy"tem Pre""ure Gau%e
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1
N Me#e* 9Slew7L"5 .2 Hi&*)
') No 8uid 8o( in .ydrauic Line" A 3 , from Mono'oc to .ydrauic motor0
No Piot for movement of Mono 'oc $irection contro "/oo0
Bammed Vave S/oo
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,rae not O/enin% c) No drive to Pinion from .ydrauic Motor and Gear ,o!
No /iot for o/enin% of ,rae Vave Motor not O/eratin%
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#&ec if Pum/ receivin% drive from En%ine0 Ti%&ten t&e Reief Vave on Mono'oc and c&ec t&e Sy"tem Pre""ure0 #&ec t&e ai%nment of t&e Pum/ #&ec t&e ma!imum /re""ure %enerated in t&e "y"tem 'y re"trictin% motion-Not ao(in% 'rae to 'e reea"ed)
#&ec t&e .ydrauic Pre""ure in Piot Line Indicated 'y Piot Line Pre""ure Gau%e0 If NO Indication on Gau%e @ Si%&ty oo"en a ttin% on t&e ine and c&ec if /re""ure o'"erved0
Arran%e for Over&auin% of Mono'oc0 #&ec if .ydrauic Pre""ure i" Indicated 'y Piot Line Pre""ure Gau%e0 If NO Indication on Pre""ure Gau%e @ Si%&ty oo"en a ttin% on t&e ine and c&ec if /re""ure o'"erved0 Remove &ydrauic motor from %ear 'o! a""em'y and c&ec if it i" o/eratin% "ati"factoriy (&en %iven /re""ure0 Reea"e 'rae 'y u"in%
e!terna &and6/um/ and c&ecin% if motion o'"erved0
d) Limit E!ceeded
Limit S(itc& Pre""ed and Indicated 'y Limit Indicator
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NO O$e%.*i 2"e * l.ck - $il* $%e&&"%e
Reduced Accumuator /re6 c&ar%e /re""ure
O'"erve t&e Piot Pre""ure readin%
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#avitation due to /re"ence of Air ,u''e" in .ydrauic Oi
+
Sl"!!i&h Re&$&e - D%ie
O'"erve t&e .ydrauic Oi in Leve Indicator
Bery Motion of #rane
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Over&eatin% of .ydrauic Motor •
Increa"e in "y"tem /re""ure
Move t&e #rane in O//o"ite $irection and reea"e t&e OverLimit0 #&ec if Limit S(itc& Vave i" fauty0 #&ec t&e /re6c&ar%e /re""ure on accumuator Rec&ar%e t&e Nitro%en /re""ure in Accumuator #&ec if Piot Pre""ure reducin% vave functionin% /ro/ery0 Re/aceCOver&au a" re4uired0 Remove tra//ed oi in circuit 'y o/enin% t&e &i%&e"t /oint in t&e /i/in% "y"tem0 O/erate t&e "y"tem for "ome time to reea"e tra//ed air in oi0 #&ec if "uDcient /re""ure 'uidu/ in ,rae ine 'y "i%&ty o/enin% t&e Line %oin% to ,rae on Gear'o!0 Remove &ydrauic motor from %ear 'o! a""em'y and c&ec if it i"
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4
6
S*ick Sli$ M*i Slew D%ie N L"3! Me#e*
B# C#i! 2w &lwl/
B# Dw Me#e* * -.&*
;
L.2 c#i! 2w 2"e * i*& w wei!h*
<
=i0%.*i& .2 >e%k/ M*i&
A'norma "e(in% motion
a)Lu Pa( #yinder not o/eratin% ') Lu ,rae ,and Not reea"in% c) Refer PtF1
Vi"ua In"/ection
Ina//ro/riate /re""ure "ettin% of #&ec ? Meter #&ec ? meter not &odin% oad Ina//ro/riate /re""ure "ettin% of #&ec ? Meter
O'"ervationa
O'"ervationa
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O'"ervationa
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#avitation
Air 'u''e" in 8uid
Lo( Tem/erature of Oi -u"uay o'"erved durin% r"t "tart")
In"uDcient Oi in t&e Tan
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Tem/erature Indicator
Oi Leve Indicator
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o/eratin% "ati"factoriy (&en %iven /re""ure0 Reea"e 'rae 'y u"in% e!terna &and6/um/ and c&ecin% if "u%%i"& motion rectied0 Remove t&e forei%n Materia #ean and Re6%rea"e Pinion and Se( Rin%0 #&ec if /re""ure 'uidu/ in Lu Pa(C ,rae #yinder O/enin% .ydrauic Line #yinder interna eaa%e to 'e rectied9 if re4uired0 Increa"e /re""ure "ettin% of #&ec ? Meter0 Over&au or re/ace c&ec 46meter0 Increa"e /re""ure "ettin% of #&ec ? Meter0
#&ec Pre""ure "ettin% of #&ec ? meter0 Over&au re/ace #&ec ? Meter if re4uired0 #&ec t&e Oi for "i%n" of tra//ed air0 O/erate for "ome time to reea"e air0
O/erate #rane for a fe( minute" to (arm u/ t&e oi0
#&ec t&e "ource of eaa%e and arre"t t&e "ame0
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1?
Pum/ Not %ettin% "uction
;nu"ua Noi"e from Pum/
#avitation
.i%& Noi"e
A0%#.l Ni&e -%# P"#$7 M*% % C*%l =.le
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Air In <uid
,u''e" in Oi Leve Indicator
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#ou/in% Mi"ai%ned E4ui/ment Worn Out or $ama%ed
11
A0%#.l He.*i! H/2%."lic Fl"i2
Pre""ure "ettin% too &i%&
Vi"ua O'"ervation No Pre""ure Indication on Gau%e C E!ce""ive &eatin%0 Sy"tem Pre""ure Gau%e
<uid $irty or Lo( Leve
<uid Leve Indicator
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Re t&e tan to de"ired eve of .ydrauic Oi0 #&ec if "uction "trainer co%%ed0 #ean or re/ace a" a//ro/riate0 #&ec for #o%%ed
Reduce Pre""ure to de"ired vaue Re/ace Oi and #&an%e
PROCEDURE FOR SETTING OF MAXIMUM SYSTEM PRESSURE
1) 2) ") ')
Check the Hydraulic Oil Level in the Level Indicator . Check the Pressure Gauge of Hydraulic Starter ccu!ulator. #urn on the $ngine and idle run for a fe% seconds to %ar! u&. O(serve any unusual sound or leakages. rrest the sa!e if found.
) #urn the Pressure Indicator *no( to Sle% Pressure+ O&erate the Sle% Lever and ,ote the Syste! Pressure on the Gauge. -esired eading /10002"00 &si 30140 5ar) #his is &ressure set on the elief 6alve &rovided on the 7ono(lock 4) If Pressure eading Sho%n in the Gauge is (elo% 1000 &si+ %e need to check if the Pu!& is (uilding u& the desired &ressure to rotate the !otor. 8ollo% the (elo% !entioned ste&s to check the !a9i!u! (uildu& &ressure fro! the Pu!&: a) e!ove the 7otor 5rake elease Line and (lank the line to avoid oil s&illage. () O&erate the Lever and note the Syste! Pressure eading. 3) #o S$# the Syste! Pressure %e need to d;ust the elief 6alve Gru( Scre% on the 7ono 5lock (y follo%ing the (elo% !entioned ste&s: a) Place the O&erator Lever in ,eutral Position. () e!ove the Ca& on Sle%ing 7ono 5lock Pressure Setting Gru( Scre%. c) Loosen the Lock ,ut Provided on the Gru( Scre%. d) #ighten the Gru( Scre% (y 2" ounds in Clock %ise direction to Increase Pressure or nticlock %ise -irection to educe Pressure. as re
No Slewing Operation: Possile Ca!ses: "# P!$p not gi%ing &esire& 'low :
Check the Syste! Pressure Gauge (y turning the indicator kno( on Isolator to S le% &osition. Sle% Pressure should (e in range of 1'0140 5ar to &rovide satisfactory !otion. (# )ow S*ste$ Press!re setting on Main Relie' +al%e: If &ressure indication on Gauge is lo%+ tighten the Gru( Scre% on the !ain relief valve
&rovided on the 7ono 5lock. Check if syste! (uildu& &ressure increases on tightening the elief 6alve.
,# No press!re in Pilot )ine: o Check &ressure in Pilot Line indicated on Pilot Pressure Gauge. o Pilot Pressure should (e in the range of '00 5ar to &rovide re
Shifting of -irection Control S&ool in the 7ono 5lock and to O&erate the 5rake Lifting 6alve for the Sle%ing Gear 5o9. -# Motor not Operating: a# .ra/e not operating: o ,o &ressure fro! Pilot Line to P / Port of 5rake Lifting 6alve. elease (rake using e9ternal hand&u!& and check if !otor o&erating. o # .ra/e )i'ting +al%e not getting Pilot line 'ro$ S0!ttle +al%e1 o Check if the Pilot Pressure Line at >&ort of 5rake Lifting 6alve is getting flo%
through Shuttle 6alve on o&eration of the ?oystick lever. ,o oil flo% indicates a faulty Shuttle 6alve. 2# Se3!en2e +al%e Setting too 4ig0 : o Check the setting on the Se
