Hydraulic Training Cause

ShangHai ZhenHua Heavy Industry Co., LTD

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 Safety instruction for all hydraulic system

 Any misuse or insufficient handling or

maintenance maybe endangers life.
 Secure driving, installation and maintenance will
avoid most accident.
 Device should be maintained by professional.
 Please study manual before maintain any
hydraulic system.

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 Content

1. Main device introduce.

2. Wheel brake hydraulic system
3. Boom & Hoist emergency brake hydraulic system
4. Multi-function hydraulic system

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1. Main device introduce

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Piston Pump (PVH)
Piston pump
A piston pump is installed in system to
provide power to hydraulic system.

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Check valve

 Check valve will limit the

direction of oil flow.
 From position 1 to position 2
is permitted
 From position 2 to position 1
is forbidden

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Relief valve

 A Relief valve is installed in this system

to provide a safety pressure.

 Parameter:
 Supplied by VICKERS
 Pressure setting value is adjustable

 Function
 If relief valve is set at 150 bar. When
system pressure rise to 150 bar,
Relief valve will connect system
main line to tank. And System
pressure will be lower than 150 bar.

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Solenoid valve

 This type valve is a direction

valve. When this valve’s
solenoid is energized or de-
energized, power oil’s direction
will be changed.

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Pressure relay

 Pressure relay will provide two

pressure switch to detect system
pressure

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Cylinder

1.Head
2.Rod
3.Piston
4.Cylinder
5.Rear

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Counter balance valve

 Counter balance valve

could hold snag cylinder
when power is off.

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Proportional valve

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Proportional valve

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Proportional valve

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Integrated control electronics for proportional valve

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Characteristic curves

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2. Wheel brake hydraulic system

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Logic drawing for Wheel brake hydraulic system

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 Description of wheel brake hydraulic system

 There are two hydraulic station ,one station is designed

to control 4 wheel brakes.
 The wheel brake is released by hydraulic force and set
by it’s spring.
 Brakes can be released by hand pump in emergency
situation.

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 Wheel brake hydraulic system Working Order

Automatic hold system pressure

Pressure relay H will control Pump Motor M, when the Control power is on.

When P< low value, Pump After 5 seconds Motor

Pressure relay H  motor M   M will
opens and sends will start. stop.
out a low pressure
signal.

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 Wheel brake hydraulic system Working Order

Release brake
Push "Release" button release gantry drive is allowed hold on the
pressure automatically system will brake if gantry stops for 5 minutes.
Push "release" button or gantry T1-T4 and T5-T8 set out
drive joystick leaves “zero” position, signals and green indicator
M and S will be energized,  lights, it means the crane has
accumulator and pump supply oil to been released ， gantry drive
wheel brakes, release starts. is allowed.

When pressure S is de-energized, 8 limit

contractor of the
Pressure relay H opens
 and sends out a
pressure signal, after 5s
then M is de-energized.
gantry stops switches send out signals
 and red indicator lights, it
for 5 minutes means the wheel brakes
have been clamped.

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 Wheel brake hydraulic system Working Order

 Brake set

Pressure "clamp" button clamp

Push "clamp" button or control T1~T8 sent out signals, red

power off, S is de –energized  indicator lights and it means
and wheel brakes clamp system clamp.

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 Trouble shooting of the wheel brake hydraulic system

Fault class Reason How to solve

Exterior oil leakage Check
Throttle valve B7 open Close it
Throttle valve B14 close Open it
Motor start too
frequently The setting pressure of the switch is proper Adjust it
The pressure of the Accumulator is not Check it
proper or Accumulator is destroyed
Solenoid valve have large internal leakage Exchange it

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 Trouble shooting of the wheel brake hydraulic system

Fault class Reason How to solve

Exterior oil leakage Check
Throttle valve B7 open Close it
The higher setting pressure of the switch is Adjust it
Motor run too too high
long The setting pressure of the relief valve is not Adjust it
proper
Solenoid valve have large internal leakage Exchange it
The pump is worn Change it

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 Trouble shooting of the wheel brake hydraulic system

Fault class Reason How to solve

Exterior oil leakage Check
Throttle valve B7 open Close it
Over
temperature The setting pressure of the relief valve is Adjust it
fault not proper
Solenoid valve have large internal leakage Exchange it
The immersion heater can't stop work Check programme
Exterior oil leakage Check
Oil level too The oil level is too level in fact Fill the oil
low fault
The float switch have wrong Check programme

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 Trouble shooting of the wheel brake hydraulic system

Fault class Reason How to solve

Exterior oil leakage Check
Throttle valve B7 open Close it
The setting pressure of the relief valve is Adjust it
The time not proper
releasing the The coil and plug of the solenoid valve can’t Change it
brake too long work
The setting pressure of the pump is not Adjust or change
proper or pump is worn it
The limit switch of the brake can’t work Change it

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3. Boom & Hoist Emergency Brake Hydraulic System

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 Description of Boom & Hoist Emergency Brake
Hydraulic System

 There are one station to control two Boom and two Hoist
emergency brakes.
 The emergency brake is released by hydraulic force and
set by it’s spring.
 Brakes can be released by hand pump in emergency
situation.
 08A throttle valve should open before we change any
hydraulic valve from this station
 Solenoid valve B9.1,B9.2 control hoist brake
 Solenoid valve B9.3,B9.4 control boom brake

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 Boom & Hoist Emergency Brake Hydraulic System
Working Order

Automatic hold system pressure

Pressure relay H will control Pump Motor M, when the Control power is on.

When P< value, Pump After 5 seconds Motor

Pressure relay H  motor M   M will
opens and sends will start. stop.
out a pressure
signal.

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Boom & Hoist Emergency Brake Hydraulic System
Working Order
Hoist Operate:
The Pump motor M and
When Hoist joystick  solenoid S1, S2 will be 
leaves "0" position. energized and the Main Hoist
Disc Brakes begin to release.

Limit switch T1,T2 sends out When the Hoist joystick

signal. It means Disc Brakes  returns to "0" position 
has been released, allows
main hoist.

The solenoid S1 will be de-  The system returns to the

energized at same time, after 5 automatical-pressure-
seconds, the solenoid S2 will be maintenance state
de-energized. Disc Brakes brake.

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Boom & Hoist Emergency Brake Hydraulic System
Working Order
Boom Operate:
The Pump motor M and
When Boom Hoist joystick  solenoid S3, S4 will be 
leaves "0" position. energized and the Boom Disc
Brakes begin to release.

Limit switch T3 sends out When the Boom Hoist

signal. It means Disc Brakes  joystick returns to "0" 
has been released, allows position
Boom to move.

The solenoid S3 will be de-  The system returns to the

energized at same time, after 5 automatical-pressure-
seconds, the solenoid S4 will be maintenance state
de-energized. Disc Brakes brake.

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 Trouble shooting of the Boom&hoist emergency brake
hydraulic system
Fault class Reason How to solve
Exterior oil leakage Check

Motor start too Throttle valve B7.1 open Close it

frequently The setting pressure of the switch is proper Adjust it
Solenoid valve have large internal leakage Exchange it

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 Trouble shooting of the Boom&hoist emergency brake
hydraulic system
Fault class Reason How to solve
Exterior oil leakage Check
Throttle valve B7.1 open Close it
The higher setting pressure of the switch is Adjust it
Motor run too too high
long The setting pressure of the relief valve is not Adjust it
proper
Solenoid valve have large internal leakage Exchange it
The pump is worn Change it

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 Trouble shooting of the Boom&hoist emergency brake
hydraulic system
Fault class Reason How to solve
Exterior oil leakage Check
Throttle valve B7.1 open Close it
Over
temperature The setting pressure of the relief valve is Adjust it
fault not proper
Solenoid valve have large internal leakage Exchange it
The immersion heater can't stop work Check programme
The oil level is too level in fact Fill the oil
Oil level too The float switch have wrong Check programme
low fault
Exterior oil leakage Check

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 Trouble shooting of the Boom&hoist emergency brake
hydraulic system
Fault class Reason How to solve
Exterior oil leakage Check
Throttle valve B7.1 open Close it
The setting pressure of the relief valve is Adjust it
The time not proper
releasing the The coil and plug of the solenoid valve Change it
brake too long can’t work
The setting pressure of the pump is not Adjust or change it
proper or pump is worn
The limit switch of the brake can’t work Change it

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4. Multi-function Hydraulic System

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 Description for Multi-function Hydraulic System

 One hydraulic station is installed on backreach.

 There are two pump assembly in station, one is
for rope tension system, one is for
snag/trim/list/skew system.
 Trim/list/skew function
 Anti-snag function
 Catenary Trolley rope tension function

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 Working order for Trolley & Catenary Rope Tension
Hydraulic System

When “Control on”, tensioning motor M2 energized automatically.

When “Control off”, M2 de-energized. If pump isolate valve limit
switch R2 open, M2 can not energized.
System’s working order when boom is horizontal ：
System’s working order when boom is moving
Rope tension pressure protection (low pressure fault, high pressure
fault)
Trolley motion prohibited.

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Snag protection block

 1 relief valve
 2 Main cartridge valve
 3 Pilot cartridge valve
 4.5 throttle valve

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 Snag function

 Snag occur.
 Pressure send out a open signal, main hoist stop.
 Relief valve 1 will open.
 Pilot cartridge valve will open after relief valve open.
 Main cartridge valve will open because pilot cartridge
valve open.
 Snag cylinder will retract with high speed.

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Snag system

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Snag block trouble shooting

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Snag block trouble shooting

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 Snag block trouble shooting

 If snag cylinder retract by itself when power off, we

should check it as below.
1. Close No.1 throttle valve (see picture above), if cylinder
retracting stop, please check counter-balance valve in
station.
2. Power on in cab, and open No.2 throttle valve
immediately, after cylinder retract 400mm, close the
valve, cylinder will extend by system. Do this job several
times. If problem is not fix, we should do it as below.
3. Control off, and open No.2 throttle valve to retract
cylinder to bottom position.
4. Unscrew four No.6 socket hex screws.

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Snag block trouble shooting

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Snag block trouble shooting

5. Take down small cover

block (see picture above)
6. Check No.8 Cartridge valve,
and clean it with diesel.
7. Check main cartridge
valve(No.11)
8. Clean main cartridge valve
9. Install all device.
10. Control on

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 Description for Trim/List/Skew system

 Solenoid valve (item7) could change system pressure.

 Proportional valve control cylinder speed and direction
 Counter-balance valve will hold cylinder when control off
 Pressure sensing valve will create a stable ΔP
 Every snag cylinder is equipped a liner encoder, and PLC could
detect every snag cylinder’s position.

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 Trouble shooting of Multi-function hydraulic
system
Fault class Reason How to solve

Exterior or internal oil leakage Check

Pump displacement is not enough adjust it

Signal to proportional is not enough increase it

Time for
trim/list/skew
The setting pressure of relief valve is not Adjust it
too long
proper
Throttle valve B26 is not opened fully Open it

Solenoid valve B13 is not energized check

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 Trouble shooting of Multi-function hydraulic
system
Fault class Reason How to solve

Exterior or internal oil leakage Check

Snag cylinder
act frequently The throttle valve B23 is not closed Close it
when do not fully
give any order The cylinder position sensor is not ok Check or exchange it

The power is not ok or wrong Check the power to

Cylinder sensor
sensor signal
wrong the electrical wiring is wrong or lax Check or tighten the
wiring

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 Trouble shooting of Multi-function hydraulic
system
Fault class Reason How to solve

The setting pressure of the tension Readjust it

pump is too low
Tension rope The setting pressure of the pressure Readjust it
too loosen fault switch is not proper
The pressure switch is not ok Change it

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 Maintenance for all hydraulic system

 Oil change: SHELL TELLUS S2 M68

1. First change 3 months after initial operation

2. After that once a year or after 2000 operating hours
3. Void oil should be drain completely
4. Tank should be clean before new oil is filled to tank.
 Change filter element every year or according it’s
indicator

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 Maintenance for all hydraulic system

 Check system monthly as below

1. Check oil level

2. Check if there is any water in tank
3. Check if there is any leakage at any hose and tube
connection
4. Check if operating pressure of hydraulic station is perfect
5. Check function of the brake and cylinder
6. Check oil cleanness

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