HYDRAULIC CRANE TROUBLESHOOTING GUIDE

A) SLEWING OPERATION : Rotary Movement of Structure around Vertical Axis of

Crane
Line Diagram :
MONO BLOCK

PRESSURE RELIEF
VALVE

PRESSURE
REDUCING VALVE

PILOT VALVE
BLOCK

SHUTTLE VALVES

BRAKE LIFTING
VALVE

HYDRAULIC
MOTOR

HYDRAULIC PUMP:

SLEW LIMIT SWITCH

SLEW FREE VALVE

PRELIMINERY CHECKS TO BE PERFORMED AFTER STARTING:

1) Check Slewing Pump Pressure : Indicated on the Gauge connected in the
Cabin by switching the Isolator knob to Slew Pressure.
Should be around 70 Bar when system idle (Handle in neutral
position).
Operational pressure around 160 Bar.
If Pressure observed is LESS then tighten the Relief Valve Grub Screw
on the Monoblock in clockwise direction to increase system pressure
to the desired value. Please ensure that the Lock Nut & Cap of the
Grub Screw is tightened once required pressure setting is done.
2) Check Pilot Line Pressure: Indicated On Pilot Line Pressure Gauge
Pilot Line pressure to be around 40-50 Bar.
Check if Oil flow is available in the Pilot lines to Monoblock, Shuttle
Valve and Brake Lifting Valve.
3) Check Limit Switch Positioning.
4) Check for any unusual noise observed from any of the individual
components.

B) LUFFING CIRCUIT: Lifting and Lowering of Crane Boom.

Components Involved:
MONO BLOCK

PRESSURE RELIEF
VALVE

PRESSURE
REDUCING VALVE

PILOT VALVE
BLOCK

SHUTTLE VALVES

BRAKE LIFTING
VALVE

HYDRAULIC MOTOR

LUFF LIMIT SWITCH

LUFF PAWL
CYLINDER

LUFF OVER RIDE

VALVE

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)

Check Limit Switch Positioning.

Check if Brake Lifting Cylinder is Operational.
Check if Luff Pawl Cylinder is Operational.
Check for any unusual noise or heating observed from any of the
individual components.

C) MAIN/ AUXILLARY HOISTING CIRCUIT: Lifting and Lowering of Load

Line Diagram :
MONO BLOCK

PRESSURE RELIEF
VALVE

PRESSURE
REDUCING VALVE

PILOT VALVE
BLOCK

SHUTTLE VALVES

BRAKE LIFTING
VALVE

HYDRAULIC MOTOR

LUFF LIMIT SWITCH

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 Pump receiving

drive from Engine.
Tighten the Relief Valve
on Monoblock and check
the System Pressure.
Check the alignment of
the Pump
Check the maximum
pressure generated in the
system by restricting
motion(Not allowing brake
to be released)

Check the Hydraulic

Pressure in Pilot Line
Indicated by Pilot Line
Pressure Gauge.
If NO Indication on Gauge
Slightly loosen a fitting
on the line and check if
pressure observed.

Arrange for Overhauling

of Monoblock.

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

external hand-pump and

checking if motion
observed.

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

Observe the Pilot

Pressure reading

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

Move the Crane in

Opposite Direction and
release the OverLimit.
Check if Limit Switch
Valve is faulty.
Check the pre-charge
pressure on accumulator
Recharge the Nitrogen
pressure in Accumulator
Check if Pilot Pressure
reducing valve functioning
properly.
Replace/Overhaul as
required.
Remove trapped oil in
circuit by opening the
highest point in the piping
system.
Operate the system for
some time to release
trapped air in oil.
Check if sufficient
pressure buildup in Brake
line by slightly opening
the Line going to Brake on
Gearbox.
Remove hydraulic motor
from gear box assembly
and check if it is

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

Increase pressure setting

of Check Q Meter.

Faulty Check Q
meter on Hoisting
Line

Observational

Check Pressure setting of

Check Q meter.
Overhaul replace Check Q
Meter if required.

Cavitation

Air bubbles in
fluid

Check the Oil for signs of

trapped air. Operate for
some time to release air.

Temperature
Indicator

Operate Crane for a few

minutes to warm up the
oil.

Oil Level Indicator

Check the source of

leakage and arrest the
same.

Low Temperature
of Oil (usually
observed during
first starts)
Insufficient Oil in
the Tank

Observational

Remove the foreign

Material
Clean and Re-grease
Pinion and Slew Ring.
Check if pressure buildup
in Luff Pawl/ Brake
Cylinder Opening
Hydraulic Line
Cylinder internal leakage
to be rectified, if required.
Increase pressure setting
of Check Q Meter.
Overhaul or replace check
q-meter.

Pump Not getting

suction
Cavitation
10

Unusual Noise
from Pump
High Noise

Abnormal
Noise from
Pump/
Motor or
Control
Valve

Refill the tank to desired

level of Hydraulic Oil.

Check if suction strainer

clogged. Clean or replace
as appropriate.

Check for Clogged Filters/

Strainers/ Inlet Line
Set desired Engine RPM
(Too low can cause
cavitation)
Replace Oil if necessary

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

Bleed Air from System

Tighten all connections
and arrest all leakages
Check Pump Shaft Seal for
any leakages
Fill Oil to desired level to
avoid air ingress into the
system
Re-Align the same

Reduce Pressure to
desired value

Fluid Dirty or Low

Level

Fluid Level
Indicator

Replace Oil and Change

Filter

Coupling
Misaligned
Equipment Worn
Out or Damaged

11

Abnormal
Heating of
Hydraulic
Fluid

PROCEDURE FOR SETTING OF MAXIMUM SYSTEM PRESSURE

1)
2)
3)
4)

Check the Hydraulic Oil Level in the Level Indicator .

Check the Pressure Gauge of Hydraulic Starter Accumulator.
Turn on the Engine and idle run for a few seconds to warm up.
Observe any unusual sound or leakages. Arrest the same if found.

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.

3) No pressure in Pilot Line:

o Check pressure in Pilot Line indicated on Pilot Pressure Gauge.
o Pilot Pressure should be in the range of 40-50 Bar to provide required pressure for
Shifting of Direction Control Spool in the Mono Block and to Operate the Brake
Lifting Valve for the Slewing Gear Box.
4) Motor not Operating:
a) Brake not operating:
o No pressure from Pilot Line to P Port of Brake Lifting Valve.
o Release brake using external hand-pump and check if motor operating.
b) Brake Lifting Valve not getting Pilot line from Shuttle Valve.
o Check if the Pilot Pressure Line at X-port of Brake Lifting Valve is getting flow
through Shuttle Valve on operation of the Joystick lever. No oil flow indicates a
faulty Shuttle Valve.
c) Sequence Valve Setting too High :
o Check the setting on the Sequence Valves provided on Hydraulic Motors. Too high
a setting will not allow fluid to pass through return line. Adjust the setting screw
and try to operate.
d) Motor not able to take Load:
o Open and Check the oil flow from the Case Drain Line from Slewing Motor.
Excessive flow in the drain line means that Motor is unable to take the load.
Overhaul/ Replace the Hydraulic Motor.