Chapter 8 Troubleshooting

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8.1 Common Troubleshooting
If crane breaks down during working, a comprehensive inspection and analysis should be
carried out to find out the cause of fault and proper measures should be taken to remedy it.
And now common failures and their fixing measures are listed in the following table for
reference.

Part Fault Cause Troubleshooting

1. The bulb is damaged 1.Replace.
The working lamp is off. 2. The fuse burns out. 2. Replace after examine.
3. Bad earthed 3. Examine and repair.
4. The lead is broken off or 4. Examine and repair or
switch fails replace.
The vehicle length 1. The bulb is damaged. 1. Replace.
indicator is off. 2. The switch fails. 2. Examine and repair or
replace.
3. The lead breaks off. 3. Replace.
1. The bulb is damaged. 1. Replace.
The cab lamp is off. 2. The switch fails. 2. Replace.
3. The lead breaks off. 3. Examine and repair.
1. The bulb is damaged. 1. Replace.
The lighting lamp on the 2. The switch fails. 2. Replace.
dashboard is off. 3. The lead breaks off. 3. Repair.
The indicator lamp on the 1. The bulb is damaged. 1. Replace.
dashboard is off. 2. The lead breaks off. 2. Examine and repair.
Electric system

1. The fuse burns out. 1. Replace after examine.

The wiper doesn’t work. 2. The switch fails. 2. Replace.
3. The electrical motor is 3. Replace.
damaged.
1. The fuse burns out. 1. Replace after examine.
2. The switch fails. 2. Replace.
The horn doesn’t work. 3. The relay fails. 3. Replace.
4. The lead breaks off. 4. Examine and repair.
5. Examine and repair or
5. The horn fails. Replace.
1. The fuse burns out. 1. Replace after examine.
2. The switch fails. 2. Replace.
The buzzer doesn’t work. 3. The relay fails. 3. Replace.
4. The lead breaks off. 4. Examine and repair.
5. Examine and repair or
5. The buzzer fails. Replace.
1. The main fuse burns out 1. Examine and repair or
The operation can not be or loosens. replace.
executed in the operator’s
2. The switch fails or the 2. Examine and repair or
cab.
lead breaks off. replace.
3. Poor contact between the 3. Examine and repair or
brush and the sliding ring. Replace.

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1. The fuse burns out. 1. Replace after examine .
2. The winding box fails. 2. Examine and repair or
Replace.
3. The lead breaks off. 3. Examine and repair.
The hoisting limiter
4. Replace.
doesn’t work. 4. The limit switch fails. 5. Examine and repair or
5. The solenoid valve fails. replace.
6. The solenoid valve is 6. Examine and repair.
earthed badly.

Part Fault Cause Troubleshooting

The complete vehicle has 1. The fuse burns out. 1. Replace after examine.
no motions.
1. The fuse burns out. 1. Replace after examine.
2. Examine and repair or
The load moment limiter 2. The power switch of load replace.
Electrical system

moment limiter is damaged. 3. Replace.

works abnormally.
3. The relay fails. 4. Examine and repair or
4. The solenoid valve fails. replace.
5. Examine and repair.
5. The solenoid valve is 6. Contact with the service
earthed badly department of the company.
6. Other factors.
The overwinding / 1. The hoisting limiter / 1. Examine and repair.
overlowering indicator is lowering limiter switches
on and sounds alarm. fail.
2. Examine and repair.
2. Wire pulling box fails.
1. The oil is not enough. 1. Add the oil.
2. The oil-suction pipe fitting 2. Examine and repair.
inhales air.
3. The mounting bolt 3. Screw down.
Hydraulic pump

Abnormal noise.
loosens.
4. The hydraulic oil is 4. Replace the oil and filter.
polluted.
5. Examine and repair.
5. The transmission shaft
vibrates. 6. Replace.
6. The universal joint
abrades. 7. Replace.
7. The hydraulic pump fails.
Do no motion. 1. The overflow valve 1. Adjust.
pressure of outrigger oil
Outriggers

pipe of steering control

valve is too low.
2. The solenoid valve of
chassis fails. 2. Examine and repair.

It moves slowly. 1. The chassis solenoid 1. Examine and repair.

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valve leaks inside.
2. The overflow valve 2. Adjust.
pressure of outrigger oil
pipe of steering control
valve is too low.
The outrigger vertical 1. The bidirectional 1. Examine and repair.
cylinder telescopes in hydraulic lock fails.
spontaneously when 2. The cylinder leaks inside. 2. Examine and repair.
lifting a load.
The outrigger vertical 1. The bidirectional 1. Examine and repair.
cylinder sinks hydraulic lock fails.
spontaneously when 2. The cylinder leaks inside. 2. Examine and repair.
3. The cylinder leaks outside. 3. Examine and repair.
traveling.
The brake fails 1. The brake lining abrades. 1. Adjust or replace.
1. The set pressure of over 1. Adjust.
flow valve in slewing valve
Slewing Mechanism

It doesn’t slew. is too low.

2. The adjusting pressure 2. Adjust.
of slewing cushion valve is
too low.
3. The slewing valve fails 3. Replace.
4. The hydraulic motor is 4. Replace.
damaged.
5. The reducer of slewing 5. Examine and repair.
mechanism fails.

Part Fault Cause Troubleshooting

1. The adjusting pressure 1. Adjust.
The slewing motion is slow. of over flow valve in
slewing valve is too low.
2. The slewing valve fails. 2. Examine and repair.
Slewing Mechanism

3. The slewing cushion 3. Examine and repair.

valve fails.
4. The hydraulic motor 4. Examine and repair.
fails.
The slewing mechanism can 1. The switch fails. 1. Examine and repair or
not rotate freely. replace.
2. The lead breaks off. 2. Examine and repair.
3. The slewing cushion valve
3. Examine and repair.
fails.
4. The slewing brake is off. 4. Examine and repair.
The cylinder can not 1. The set pressure of 1. Adjust.
overflow valve of main valve
Mechanism

telescope out.
Derricking

is too low. 2. Examine and repair.

2. The main valve leaks
3. Examine and repair.
inside.
3. The cylinder leaks inside.
The cylinder can not 1. The derricking balance 1. Examine and repair or
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telescope in. valve fails.
2. The electrical system fails.
The cylinder telescopes in 1. The cylinder leaks inside.
spontaneously during 2. The derricking balance
operation. valve fails.
The boom can not telescope 1. The telescoping balance
in.. valve fails.
2. The electrical system fails.
3. The main valve leaks
inside.
1. The set pressure of over
The boom can not telescope flow valve is too low.
out. 2. The electrical system fails.
3. The solenoid valve can not
close because of seized.
4. The control valve fails.
1. The cylinder leaks inside.
The boom telescopes in 2. The telescoping balance
Telescoping mechanism
replace.
2. Examine and repair.
1. Examine and repair.
2. Examine and repair.
1. Examine and repair.
2. Examine and repair.
3. Examine and repair.
1. Adjust.
2. Examine and repair.
3. Examine and repair.
4. Examine and repair.
1. Examine and repair.
2. Examine and repair.

spontaneously during valve fails. 3. Examine and repair.

3. The cylinder, valve or
operation.
joint leaks outside.
The boom second section 1. Telescope out the boom 1. Examine and repair.
can not telescope out, but by telescoping changeover
the boom third, fourth and solenoid valve. If the
fifth sections can telescope solenoid valve is not
out. electrified, the boom second
section will telescope out. If
the solenoid valve is
electrified, the boom third,
fourth and fifth sections will
telescope out.
The third, fourth and fifth 1. When the boom third, 1. Pay attention to press
section can not telescope in fourth and fifth sections the button when
completely. nearly telescope in fully, operating.
does not press synchronous
telescope button on left
handle.

Part Fault Cause Troubleshooting

The hook can not be 1. The set pressure of 1.Adjust.
overflow valve of main
mechanism

lifted.
Hoisting

valve is too low. 2.Replace.

2. The hydraulic motor
fails.
3. The main valve fails.
4. The electrical system
3.Examine and repair.
4.Examine and repair.
5. Examine and repair.

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fails.
5. The winch brake is not
engaged.
1. The set pressure of over 1. Adjust.
flow valve of main valve is
too low.
2. The hydraulic motor 2. Examine and repair.
fails.
The hook can not be
3. The main valve fails. 3. Examine and repair.
lowered. 4. The electrical system 4. Examine and repair.
fails.
5. The balance valve fails. 5. Examine and repair.
6. The winch brake is not 6. Examine and repair.
engaged.
1. The brake is not engaged 1. Adjust.
(The pressure of pilot oil
source is too low). 2. Replace.
2. The brake lining wears
seriously.
The brake fails. 3. The brake oil circuit 3. Exhaust.
inhales air.
4. The hydraulic motor 4. Replace.
fails. (The capacity
efficiency is too low).

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