Professional Documents
Culture Documents
PRESSURE RELIEF
VALVE
PRESSURE
REDUCING VALVE
PILOT VALVE
BLOCK
SHUTTLE VALVES
BRAKE LIFTING
VALVE
HYDRAULIC
MOTOR
HYDRAULIC PUMP:
PRESSURE RELIEF
VALVE
PRESSURE
REDUCING VALVE
PILOT VALVE
BLOCK
SHUTTLE VALVES
BRAKE LIFTING
VALVE
HYDRAULIC MOTOR
LUFF PAWL
CYLINDER
HYDRAULIC PUMP
CHECKS TO BE PERFORMED:
1) Check Luffing Pump Pressure :
Should be around 70 bar when system idle.
Operational pressure around 200 Bar.
If less then tighten the Relief Valve Spring on the Monoblock to
increase system pressure to the desired value.
2) Check Pilot Line Pressure:
Pilot Line pressure to be around 40-50 Bar.
Check if Oil pressure in Pilot lines to Monoblock and Brake release
valve.
3)
4)
5)
6)
PRESSURE RELIEF
VALVE
PRESSURE
REDUCING VALVE
PILOT VALVE
BLOCK
SHUTTLE VALVES
BRAKE LIFTING
VALVE
HYDRAULIC MOTOR
CHECK Q-METER
VALVE
Emergency Load
Lowering Valve
HYDRAULIC PUMP
CHECKS TO BE PERFORMED:
1) Check Hoisting Pump Pressure :
Should be around 70 bar when system idle.
Operational pressure around 200 Bar.
If less then tighten the Relief Valve Spring on the Monoblock to
increase system pressure to the desired value.
2) Check Pilot Line Pressure:
Pilot Line pressure to be around 40-50 Bar.
Check if Oil pressure in Pilot lines to Monoblock and Brake release
valve.
3) Check Limit Switch Positioning.
4) Check for any unusual noise or heating observed from any of the
individual components.
Sr No
NATURE OF
TROUBLE
PROBABLE
CAUSES
IDENTIFICATION
TROUBLESHOOTING STEPS
a) Pump Not
generating
the Desired
Flow.
No
Movement
(Slew/Luff
and Hoist)
b) No fluid flow
in Hydraulic
Lines A & B from
Monoblock to
Hydraulic motor.
System Pressure
Gauge
No Pilot for
movement of
Mono block
Direction control
spool.
Jammed Valve
Spool
Brake not
Opening
c) No drive to
Pinion from
Hydraulic
Motor and
Gear Box
No pilot for
opening of Brake
Valve
Motor not
Operating
Check if Hydraulic
Pressure is Indicated by
Pilot Line Pressure Gauge.
If NO Indication on
Pressure Gauge Slightly
loosen a fitting on the line
and check if pressure
observed.
Remove hydraulic motor
from gear box assembly
and check if it is operating
satisfactorily when given
pressure.
Release brake by using
d) Limit
Exceeded
NO
Operation
due to lack
of pilot
pressure
Limit Switch
Pressed and
Indicated by Limit
Indicator
Failure of buildup
of desired pilot
pressure
Reduced
Accumulator precharge pressure
Faulty Pressure
reducing Valve
Cavitation due to
presence of Air
Bubbles in
Hydraulic Oil
3
Sluggish
Response of
Drive
Observe the
Hydraulic Oil in
Level Indicator
Jerky Motion of
Crane
Faulty Brake
Overheating of
Hydraulic Motor
Increase in
system pressure
Stick Slip
Motion of
Slew Drive
No Luffing
Movement
Boom
Coming
down slowly
Boom Down
Movement
too fast
Load coming
down due to
its own
weight
Vibrations
and Jerky
Motions
operating satisfactorily
when given pressure.
Release brake by using
external hand-pump and
checking if sluggish
motion rectified.
Foreign Material
between Pinion
and Slew Ring
Abnormal slewing
motion
a)Luff Pawl
Cylinder not
operating
b) Luff Brake
Band Not
releasing
c) Refer Pt#1
Inappropriate
pressure setting
of Check Q Meter
Check Q meter
not holding load
Inappropriate
pressure setting
of Check Q Meter
Visual Inspection
Observational
Faulty Check Q
meter on Hoisting
Line
Observational
Cavitation
Air bubbles in
fluid
Temperature
Indicator
Low Temperature
of Oil (usually
observed during
first starts)
Insufficient Oil in
the Tank
Observational
Unusual Noise
from Pump
High Noise
Abnormal
Noise from
Pump/
Motor or
Control
Valve
Air In Fluid
Bubbles in Oil
Level Indicator
Overhaul or replace
Pressure setting
too high
Visual
Observation
No Pressure
Indication on
Gauge / Excessive
heating.
System Pressure
Gauge
Reduce Pressure to
desired value
Fluid Level
Indicator
Coupling
Misaligned
Equipment Worn
Out or Damaged
11
Abnormal
Heating of
Hydraulic
Fluid
1)
2)
3)
4)
5) Turn the Pressure Indicator Knob to Slew Pressure, Operate the Slew Lever and Note the
System Pressure on the Gauge.
Desired Reading 1000-2300 psi (70-160 Bar)
This is pressure set on the Relief Valve provided on the Monoblock
6) If Pressure Reading Shown in the Gauge is below 1000 psi, we need to check if the Pump
is building up the desired pressure to rotate the motor. Follow the below mentioned steps
to check the maximum buildup pressure from the Pump:
a) Remove the Motor Brake Release Line and blank the line to avoid oil spillage.
b) Operate the Lever and note the System Pressure Reading.
7) To SET the System Pressure we need to Adjust the Relief Valve Grub Screw on the
Mono Block by following the below mentioned steps:
a) Place the Operator Lever in Neutral Position.
b) Remove the Cap on Slewing Mono Block Pressure Setting -Grub Screw.
c) Loosen the Lock Nut Provided on the Grub Screw.
d) Tighten the Grub Screw by 2-3 Rounds in Clock wise direction to Increase
Pressure or Anticlock wise Direction to Reduce Pressure. (as required)
e) Operate the Lever and Check the Pressure on the Gauge and Set to as
required.
f) Re-tighten the Lock Nut and Install the Cap.
Note: Increase/Decrease of System Pressure is accompanied by corresponding Increase/Decrease
in speed of the connected drive motor.
No Slewing Operation:
Possible Causes:
1) Pump not giving desired flow :
Check the System Pressure Gauge by turning the indicator knob on Isolator to Slew
position. Slew Pressure should be in range of 140-160 Bar to provide satisfactory
motion.
2) Low System Pressure setting on Main Relief Valve:
If pressure indication on Gauge is low, tighten the Grub Screw on the main relief valve
provided on the Mono Block. Check if system buildup pressure increases on tightening
the Relief Valve.