TROUBLE SHOOTING GUIDE - 140T Jamalpur Cranes140t.weebly.com/uploads/8/4/8/7/8487435/tr_sh_old.pdfJamalpur Loco Works 1 Old Design Crane PREFACE Crane organization/Jamalpur Workshop

ISO 9001-2000

For official use only

Certified Organisation

TROUBLE SHOOTING GUIDE For

140T GOTTWALD/JAMALPUR CRANE (Old Design)

JUN - 2007

CRANE ORGANISATION EASTERN RAILWAY, LOCOMOTIVE WORKS

JAMALPUR – 811214

140 T Gottwald/Jamalpur Crane A Handbook on Troubleshooting

------------------------------------------------------------------------------------------------------ Jamalpur Loco Works 1 Old Design Crane

PREFACE

Crane organization/Jamalpur Workshop manufactures and overhauls following two designs of 140T DHBD Crane, under Transfer of Technology from M/s Gottwald/Germany.

(i) Old design (also called 1986 design or with ‘A’ frame) (ii) New design (also called 1997 design or without ‘A’ frame)

This TROUBLE SHOOTING GUIDE is related to only HYDRAULICS (Chapter- 1.1 to 1.36), PNEUMATICS (Chapter- 1.37 to 1.42) and ELECTRICALS (Chapter- 1.43 to 1.55) for Old Design Crane. This guide gives pictorial explanation of steps to be taken to troubleshoot different types of problems in simple languages.

Utmost care has been taken to ensure the correctness of informations. However the errors and omissions may be pointed out , to enable us to issue necessary amendments.

Suggestions are most welcome to help us update and upgrade this guide on continual basis.

This troubleshooting guide is the result of collective work from the Crane Organisation. We are especially grateful to Sri Rajendra Prasad, SSE/Crane Shop, Sri A. Guria, SSE/Crane Shop, Sri J. K. Sharma, SE/Crane Shop, Sri. I. D. K. Mandal, JE-I/ Drawing Centre (Crane), and Sri. Vijay Kumar, JE-I/ Drawing Centre (Crane).

(U.Halder)

Dy. CME (Crane) Jamalpur Loco Works



INDEXING P1/2 Hydraulics

Sl Description Chapter 1. PILOT PRESSURE LOW/NIL 1.1 2. MAIN HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.2 3. AUX. HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.3 4. DERRICKING IN & OUT BOTH NOT IN FUNCTION 1.4 5. MAIN HOIST UP NOT IN FUNCTION 1.5 6. AUX. HOIST UP NOT IN FUNCTION 1.6 7. DERRICK IN NOT IN FUNCTION 1.7 8. MAIN HOIST LOWERING NOT IN FUNCTION 1.8 9. AUX. HOIST LOWERING NOT IN FUNCTION 1.9 10. DERRICK OUT NOT IN FUNCTION 1.10 11. CWT FALLING AUTOMATICALLY 1.11 12. GALLOWS UP & DN NOT IN FUNCTION 1.12 13. GALLOWS UP NOT IN FUNCTION 1.13 14. GALLOWS DN NOT IN FUNCTION 1.14 15. CWT CYLINDER LEAKAGE 1.15 16. ALL MOTIONS BY AUX ENGINE ARE SLOW 1.16 17. HYDRAULIC OIL COOLER FAN IS NOT WORKING 1.17 18. ENGINE COOLING HYD. FAN MOTOR IS NOT WORKING 1.18 19. COOLER FAN’S SPEED IS VERY SLOW 1.19 20. RAPID MOTION IS NOT WORKING 1.20 21. RECOVERY WINCH IN/OUT NOT FUNCTIONING 1.21 22. SLEWING OPERATION WITH JERK 1.22 23. SLEWING LEFT AND RIGHT BOTH NOT WORKING 1.23 24. SLEWING LEFT IS NOT WORKING 1.24 25. SLEWING RIGHT IS NOT WORKING 1.25 26. TRAVEL OPERATION IS NOT WORKING IN BOTH DIRECTION 1.26 27. AXLE BLOCKING IS NOT WORKING 1.27 28. PROPPING IS NOT WORKING 1.28 29. OUT RIGGING IS NOT WORKING 1.29 30. OPERATIONS ARE NOT WORKING WITH AUX. ENGINE 1.30 31. ENGINE IS NOT STARTING (CRANKING DOES NOT EXIST) 1.31 32. ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE PRESENT) 1.32 33. ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST) 1.33 34. ENGINE STOPS AFTER STARTING 1.34 35. ENGINE IS NOT SHUTTING DOWN 1.35 36. LUBRICATING OIL PRESSURE LOW 1.36



INDEXING P2/2

Pneumatics

Sl Description Chapter 37. AIR PRESSURE NOT BUILD UP 1.37 38. AXLE BLOCKING ON BUT TRAVEL PINION NOT ENGAGED AND BRAKE NOT APPLIED 1.38 39. AXLE BLOCKING OFF BUT TRAVEL PINION ENGAGED AND BRAKE APPLIED 1.39 40. BRAKE RELEASE / APPLICATION NOT FUNCTIONING

IN SELF TRAVEL OPERATION 1.40 41. MALFUNCTIONING OF SERVICE BRAKE (APPLICATION / RELEASE IN SERVICE BRAKE MODE) (AIR MODE) 1.41 42. MALFUNCTIONING OF SERVICE BRAKE

IN VACUMME MODE 1.42

Electricals

43. ENGINE NOT STARTING 1.43 44. GAUGE NOT SHOW PROPER READING 1.44 45. RPM METER NOT WORKING 1.45 46. BATTERY NOT TAKING CHARGE 1.46 47. UP WARD MOTION NOT WORK OF MAIN HOIST / AUX. HOIST 1.47 48. DN WARD MOTION NOT WORK OF MAIN HOIST / AUX. HOIST 1.48 49. DERRICKING IN IS NOT WORKING 1.49 50. DERRICKING OUT IS NOT WORKING 1.50 51. SLEW LEFT & RIGHT NOT WORKING 1.51 52. GALLOWS NOT WORKING IN UPWARD MOTION 1.52 53. AUX ENGINE IS RUNNING BUT NO WORK IS GOING ON 1.53 54. INDICATON OF COUNTERWEIGHT NOT SHOWING PROPER 1.54 55. BOOM ANGLE, SLEW ANGLE AND LOAD NOT SHOWING PROPER 1.55



PILOT PRESSURE LOW/NIL 1.1 P 1/2

Hydraulic Charging Circuit S/S



PILOT PRESSURE LOW/NIL 1.1 P 2/2

If found, arrest leakage.

Check Non-Return Valve No. 26 in pilot circuit with Q5 & Q9 pump flow for mal-functioning.

Clean and refit the Non-Return Valve. If damages noticed in the internal parts, replace valve.

Check Flow Regulator No.46.

Check for Leakage in 0-40 barsgauge line.

Arrest leakage, if any. Set flow at 15 L/Min after starting the engine. In the event of internal damages noticed, replace by new one.

Check Gauge No. 45 for mal-functioning.

Replace gauge.

Check Q5 pump for flow at Max.50 L/Min different RPM of the main engine.

In the event of inadequate flow, replace the Q5 pump with a new one.

Check Q5 Pump drive coupling.

If found defective, replace coupling.

Check Pressure Regulator ValveNo. 47.

Arrest leakage, if any. Set Pr in the pressure valve cartridge at 30 bar. In the event of internal damages noticed, replace by new one.



MAIN HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.2 P 1/2

Main Hoist Circuit Operation UP

Main Hoist Circuit Operation DN



MAIN HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.2 P 2/2

Check Solenoid 15Y11 & 15Y12.

Rectify the electric line and relay, limit & other current continuity in wiring to get the solenoids energized.

Check the relays, Limit cut-off & wire energizing the Solenoids.

Check Mo 32/4F (M1) spool HIH & HIS whether shifting either sideby Pilot Circuit at Pr.30 bar.

Due to air locking spool may not shift. Avoid or release air locking of Input pressure port area to get easy shifting of spool.

Check Lamina brakes if jammed.

Withdraw lamina brake from assembly and overhaul. (Report the incident to JMP WS).

Replace the Hydraulic Motor.

Check gearbox for internaldamages and motion is not transmitted from motor to gear box.

Overhaul the gearbox and refit or replace with a new gear box. (Report to JMP WS) if required.

Check Main Hoist Motor No. 6 for damages or internal leakage inMotor’s Port Plate having Ports A & B.

Check for Pilot Pressure.

Clean and refit Solenoid.

Check functioning of SLI System by mechanically pushing Solenoid 15Y11 & 15Y12.

Refer chapter 1.47 & 1.48

Refer chapter 1.1



AUX. HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.3 P 1/2

Aux.Hoist Circuit Operation UP

Aux. Hoist Circuit Operation DN



AUX. HOIST UP & LOWERING BOTH NOT IN FUNCTION 1.3 P 2/2

Check functioning of Solenoid 15Y111 & 15Y121.


Due to air locking spool may not shift. Avoid or release air locking of Input pressure pot area to get easy shifting of spool.

Clean and Refit the Solenoid.


Check for Pilot Pressure. Refer chapter 1.1

Check functioning of SLI System by mechanically pushing Solenoid 15Y111 & 15Y121.

Check the relays, Limit cut-off & wire energizing the Solenoids.

Check Mo 32/4F (M1) Spool HIIH & HIIS whether shifting either side by Pilot Circuit at Pr.30 bar.

Check Lamina brakes if jammed.

Withdraw lamina brake from assembly and overhaul. (Report the incident to JMP WS).

Check Aux. Hoist Motor No.6 for damages or internal leakage inMotor’s Port Plate having Ports A & B.






DERRICKING IN & OUT BOTH NOT IN FUNCTION 1.4 P 1/2

Derrick Circuit Operation IN

Derrick Circuit Operation OUT



DERRICKING IN & OUT BOTH NOT IN FUNCTION 1.4 P 2/2

Check functioning of Solenoid 15Y113 & 15Y123.


Due to air locking spool may not shift. Avoid or release air locking of Input pressure pot area to get easy shifting of spool.

Clean and Refit the Solenoid.


Check for Pilot Pressure. Refer chapter 1.1

Check functioning of SLI Systemby mechanically pushing Solenoid 15Y113 & 15Y123.

Check the relays, Limit cut-off and wires energizing theSolenoids.

Check Mo 32/4F (M2) Spool WH & WH whether shifting either side by Pilot Circuit at Pr.30 bar.

Check Lamina brakes if jammed. Withdraw lamina brake from assembly and overhaul. (Report the incident to JMP WS).

Check Derrick Motor for damages or internal leakage inMotor’s Port Plate having Ports A & B.






MAIN HOIST UP NOT IN FUNCTION 1.5 P 1/2

Main Hoist Circuit Operation UP



MAIN HOIST UP NOT IN FUNCTION 1.5 P 2/2

Check Pressure of Mo 32/4FValve No.10 spool at 15-30 bar by fitting a gauge on the Minimesh Coupler provided.

Check if Solenoid 15Y11 isenergized.

Check if Brake Valve No.13(NG-30) whether it is struck in shifted condition.

Refer chapter 1.1

Check Pressure at Pilot ValveNo.35, it should be 30 bar.

Clean & refit Pilot Valve, if problem persist change the pilot valve.

Check Pressure at outgoing Solenoid Port to Spool, it should be 25-30 bar.

Check Pressure at Shuttle Valve WV 10L at 25-30 bar.

Check Pressure at Supply Linesto i) Motor at 80-280 bar & ii) Brake Valve at 15-30 bar.

Clean & refit Solenoid Valve, if problem persist change the solenoid valve.

Clean & refit Shuttle Valve, if problem persist change shuttle valve.

Remove the air locking to get spool shifting smoothly.

Clean & refit Motor & Brake Valve, if problem persists change them.

Energise Solenoid Valve by pushing pin & check for UP motion of motor.

In case of brake valve sticking: i) Isolate the valve from circuit. ii) Clean thoroughly, & check.

(It should shift at moderate pressure of <50 bars).

Check for Pilot Pressure.



AUX. HOIST UP NOT IN FUNCTION 1.6 P 1/2

Aux. Hoist Circuit Operation UP



AUX. HOIST UP NOT IN FUNCTION 1.6 P 1/2

90

Check Pressure of Mo 32/4FValve No.10 spool at 15-30 bar with the help of a gauge on Minimesh Coupler provided.

Check for Solenoid 15Y111 if energized.

Check if Brake Valve No. 13 (NG-30) whether it is struck in shifted condition.

Check Pilot Pressure

Check Pressure at Pilot ValveNo.35 at 30 bar.

Clean & Refitted Pilot Valve, if problem persists change valve.

Check Pressure at outgoing Solenoid Port to Spool at 25-30 bar.


Check Pressure at Supplying Line to i) Motor at 80-280 bar & ii) Brake Valve at 15-30 bar

Clean & Refitted Solenoid Valve, if problem persists change valve.

Clean & Refitted Shuttle Valve, if problem persists change valve.

Rectify the air locking to get spool shifting smoothly.

Clean & Refitted Motor & Brake Valve, if problem persists change it.

Energized Solenoid Valve by pushing pin & check for UP motion of motor.

In case of brake valve sticking: i) Isolate the valve from circuit. ii) Clean thoroughly, & check. (It should shift at moderate

pressure of <50 bars).

Refer chapter.1.1



DERRICK IN NOT IN FUNCTION 1.7 P 1/2

Derrick Circuit Operation IN



DERRICK IN NOT IN FUNCTION 1.7 P 2/2

90

Check Pressure of Mo 32/4FValve No.10 spool at 15-30 bar with the help of a gauge on Minimesh Coupler provided.

Check for Solenoid 15Y113 if energized .

Check if Brake Valve No.13 (NG-30) whether it is struck in shifted condition.

Check Pilot Pressure.

Check Pressure at Pilot Valve No.35 at 30 bar.

Clean & Refitted Pilot Valve, if problem persists change valve.

Check Pressure at outgoing Solenoid Port to Spool at 25-30 bar.


Check Pressure at supplying line to i) Motor at 80-280 bar & ii) Brake Valve at 15-30 bar

Clean & Refitted Solenoid Valve, if problem persists change valve.

Clean & Refitted Shuttle Valve, if problem persists change valve.

Rectify the air locking to get spool shifting smoothly.

Clean & Refitted Motor & Brake Valve, if problem persists change it.

Energized Solenoid Valve by pushing pin & check for UP motion of motor.

In case of brake valve sticking: i) Isolate the valve from circuit. ii) Clean thoroughly, & check.

(It should shift at moderate pressure of <50 bars).

Refer chapter.1.1



MAIN HOIST LOWERING NOT IN FUNCTION 1.8 P 1/2

Main Hoist Circuit Operation DN



MAIN HOIST LOWERING NOT IN FUNCTION 1.8 P 2/2

Leakage found to be arrested immediately afterby shuting down the engine.

Check for leakage in the main hoist lowering circuit i.e. a) Brake valve line. b) Solenoid 15Y12 line c) Lamina brake line d)Hoses connected to hydraulic

motor from Mo 32/4F (M1)

If pressure is inadequate, connected hoses & pipes with fitting to be cleaned thoroughly.

Check the pressure at the inlet of Lamina brake and Brake valve no 13 (NG-30) mounted on motor for 120 bar pressure.

Check Solenoid Valve 15Y12It must be energized to get the spool shifting of DC Valve Mo 32/4F (M1).

a)If de-energized, electrical line to be checked & rectified to energize it.

b)By pushing the pin of solenoid, check the lowering motion.

Check pressure supply for spool shifting of M1 (HIS) for 30 bar pressure.

If less, concerned pipe and fittings as well as Shuttle Valve (WV-10L) to be checked and rectify and get the spool shift for correct flow pressure.

Check Brake Valve No.13 for smooth movement.

Clean and refit the brake valve.

Check Pilot Pressure. Refer chapter.1.1



AUX. HOIST LOWERING NOT IN FUNCTION 1.9 P 1/2

Aux.Hoist Circuit Operation DN



AUX. HOIST LOWERING NOT IN FUNCTION 1.9 P 2/2

Leakage found to be arrested immediately after shuting down the engine.

Check for leakage in the aux.hoist lowering circuit i.e. a) Brake valve line. b) Solenoid 15Y121 line c) Lamina brake line d) Hoses connected to hydraulic

motor from Mo 32/4F (M1).


Check the pressure at the inlet of lamina brake and brake valve no.13 (NG-30) mounted on motor for 120 bar pressure.

Check Solenoid Valve 15Y121.It must be energized to get the spool shifting of DC Valve Mo 32/4F (M1).

a) If de-energized, electrical line to be checked & rectified to energize it.




Check Pilot Pressure. Refer chapter.1.1

Check Brake Valve No.13 for smooth movement.

Clean and refit the brake valve.



DERRICK OUT NOT IN FUNCTION 1.10 P1/2

Derrick Circuit Operation OUT



DERRICK OUT NOT IN FUNCTION 1.10 P2/2

Check for leakage in particulars area of main hoist lowering circuit i.e. a) Brake valve line. b) Solenoid 15Y123 line. c) Lamina brake line. d)Hoses connected to Hydraulic

Motor from Mo 32/4F (M2).


Check Solenoid Valve 15Y123.It must be energized to get the spool shifting of DC Valve Mo 32/4F (M1).

a)If de-energized, electrical line to be checked & rectified to energize it.




Refer chapter.1.1 Check Pilot Pressure.

Clean and refit the brake valve. Check Brake Valve No.13 for smooth movement.

Check the pressure at the inlet of lamina brake and brake valve no 13 (NG-30) mounted on motor for 120 bar pressure.

Leakage found to be arrested immediately after shuting down the engine.



CWT FALLING AUTOMATICALLY 1.11 P 1/2 Charging of Gallows Circuit

Gallows Down



CWT FALLING AUTOMATICALLY 1.11 P 2/2

If any pressure exists in neutral condition of valve, replace valve.

Check pilot pressure at GG in Valve No. 10 for 30 bar pressure.

Clean and refit if problem persists replace valve.

Check Valve No. 11 for 30 bar pressure.

Check Valve No. 14. Clean all internal part of valve, refit if problem persists replace valve.

Check internal leakage of Cylinder No.19.

If internal leakage found replace seal or cylinder.

Check contamination level of hydraulic oil.

If contamination level more than requirements, replace oil.



GALLOWS UP & DN NOT IN FUNCTION 1.12 P1/2

Charging of Gallows Circuit

Gallows UP Gallows DOWN



GALLOWS UP & DN NOT IN FUNCTION 1.12 P2/2

Refer chapter 1.1Check Pilot Pressure.

Clean & refitted Valve, if problem persists change valve.

Check Preselector No.38 for 30 bar pressure.

Check Pilot Valve No.37 for 30 bar pressure.


Check pressure at GG point of M2 (N0.10).

Clean & refitted Hose /Tubes connections.

Check pressure at GGH/GGS point of SM 12 1F (No.11) for 30 bar pressure.


Check Solenoid Valve No.28 for 240 bar pressure.

Check electrical power, Clean & refitted Valve, if problem persists change valve.

Check Brake Valve No.14 for 240 bar pressure.

Check Orifice 3 mm for 240 bar pressure.


Check internal leakage, if any internal leakage - observed replace seal or cylinder.

Clean & refitted Orfice.

Clean & refitted Brake Valve, if problem persists change valve.



GALLOWS UP NOT IN FUNCTION 1.13 P 1/2

Gallows UP



GALLOWS UP NOT IN FUNCTION 1.13 P 2/2

Refer chapter 1.1 Check Pilot Pressure.





Check pressure at GG point of M2 (N0.10) for 30 bar pressure.


Check pressure at GGH point of SM 12 1F (N0.11) for 30 bar pressure.





Check Pressure relief valve in SM – 12 1F (No.11) for 30 bar pressure.


Check internal leakage, if any internal leakage observed replace seal kit or cylinder.

Clean & refitted Pressure Regulator of SM 12 1F if problem persists change valve.




GALLOWS DN NOT IN FUNCTION 1.14 P 1/2

Gallows DN



GALLOWS DN NOT IN FUNCTION 1.14 P 2/2

See Page No.1.1 Check Pilot Pressure.





Check pressure at GG point of M2 (N0.10) for 30 bar pressure.


Check pressure at GGS point of SM 12 1F (N0.11) for 30 bar





Check Orifice 3 mm for 240 bar pressure.


Check internal leakage, if any internal leakage observed replace seal kit or cylinder.

Clean & refitted Orifice.




CWT CYLINDER LEAKAGE 1.15 P 1/2

Gallows UP Gallows DOWN



CWT CYLINDER LEAKAGE 1.15 P 2/2

Replace the union. Check Body union.

Check hose & hose end fitting.

Check seals of cylinder.

Replace cylinder.

Replace hose.

Replace seal.



ALL MOTIONS FROM ENGINE ARE SLOW 1.16 P 1/2

Hydraulic Charging Circuit S/S



ALL MOTIONS FROM ENGINE ARE SLOW 1.16 P 2/2

See Chapter 1.1 Check Pilot Pressure by Q9 pump at 30 bar.

Check NRV 25.

Clean & refit if problem persists replace valve.

Check NRV 26.



Check Control Block No.12

Check Q8 Pump.

Check flow of pump at 20cc/rev & pressure at 240 bar, if not replace pump.



HYDRAULIC OIL COOLER FAN IS NOT WORKING 1.17 P 1/2

Radiator and Oil Cooling Circuit



HYDRAULIC OIL COOLER FAN IS NOT WORKING 1.17 P 2/2

Check belt tension, if any damage found replace belt.

Check pump drive Belt for tension.

Check Pressure regulator No.21 for 60 bar pressure.

Check fan drive key or pump shaft for any damage wear.

Clean, refit, adjust recommended pressure, if problem persists replace valve.

Clean, refit, if any problem found replace key.


Check Motor Check Valve No.27 for protection of flow direction.

Check Motor No.9 for out put drive.

Check pumps Q6 (flow-50 Ltrs/min) & Q7 (flow-32 Ltrs/min) at 140 bar pressure.

Clean and refit if problem persists replace motor.

Check pump drive coupling, bearing & pump. If problem persists replace pump.



ENGINE COOLING HYD. FAN MOTOR IS NOT WORKING 1.18 P 1/2




ENGINE COOLING HYD. FAN MOTOR IS NOT WORKING 1.18 P 2/2

Check belt tension, if any damage found replace belt.

Check pump drive Belt for tension.

Check Pressure regulator No.21 for 60 bar pressure.

Check fan drive key or pump shaft for any damage wear.

Clean, refit, adjust recommended pressure, if problem persists replace valve.

Clean, refit, if any problem found replace key.


Check Motor Check Valve No.27 for protection of flow direction.

Check Motor No.9 for out put drive.

Check pumps Q6 (flow-50 Ltrs/min) & Q7 (flow-32 Ltrs/min) at 140 bar pressure.

Clean and refit if problem persists replace motor.

Check pump drive coupling, bearing & pump. If problem persists replace pump.



COOLER FAN’S SPEED IS VERY SLOW 1.19 P 1/2




COOLER FAN’S SPEED IS VERY SLOW 1.19 P 2/2

Pressure & Flow to be adjusted to get 60 bar pressure at Hydraulic Motor, if found less.

Pressure at outlet of Pressure Relief DBDS (No.21) may be in sufficient < 60 bar.

Faulty Check Valve No.27.

Hydraulic Motor’s fan may notbe balanced and infringing some where.

Check valve to be cleaned & refitted.

Balance if required by tightening the screw of mounting of fan blades with Hyd. Motor.



RAPID MOTION IS NOT WORKING 1.20 P 1/2

Rapid Motion



RAPID MOTION IS NOT WORKING 1.20 P 2/2

Clean and refit if problem persist replace valve.

Check valve 41 at 30 bar pressure.

Check pilot pressure at 30 bar pressure.

Check, Check Valve No.25 for any flow blockage.

Pilot pressure to be checked at the following points. i) at SG of M1 &M2 DC Valve

(30bar) ii) at pumps X1 port (30 bar).


Check SG spool of M1 & M2 block at 30 bar pressure.




RECOVERY WINCH IN/OUT NOT FUNCTIONING 1.21 P 1/2 Recovery Winch IN Recovery Winch OUT



RECOVERY WINCH IN/OUT NOT FUNCTIONING 1.21 P 2/2

Leakage to be arrested of any pilot pressure to be adjusted. Pressure to be checked at M032/4F M2 pilot port responsible for shifting the spool. Power pressure to be checked at Hydraulic motor port.

Low pilot pressure due to leakage in line.

Solenoid valve 15Y114 and 15Y 124 mal functioning.

Lamina brake not releasing.

Solenoid electric line to be checked and make it in energized mode. Check the operation by passing the solenoid manually.

Pressure to be checked responsible for lamina brake releasing.

Shuttle valve to be cleaned if required.

Shuttle valve having internal leakage.

Mo 32/4F(M2) spool may not shifting due to less pilot pressure or spool jamming due to forge material in between spool & housing of Air locking due to leakage of pilot line.

Pilot control valve may be faulty.

Make the spool for easy shifting by cleaning air locking to be rectified by the tightening of pipe points.

If Pilot control valve is defective, replace the valve by new one.

Lamina Brake may get jam.

Hyd. Motor No.7 may be defective.

Check the Lamina Brake if jam, refitted with assly.

Hyd. Motor to be replace by new one if found defective and unrepairable.



SLEWING OPERATION WITH JERK 1.22 P 1/2

Slewing LEFT Circuit

Slewing RIGHT Circuit



SLEWING OPERATION WITH JERK 1.22 P 2/2

Check the pressure at following points.

Lamina brake does not releasing fully.

Slewing Motor No.6 does not getting required pressure.

Solenoid valve 15Y112 and 15Y 122 mal functioning.

Pressure coming to laminar brake.

Inlet pressure to solenoid valve.Inlet pressure to motor port for concerned/slected slew operation.Pressure at Y1 or Y2 port of Q3 pump.

Electrical connection to be checked/rectified if need, coming to the solenoid valve.

Improper shifting of D.C valve fited with Q3 pump.

Improper flow of Q3 pump due to inadequate swash plate angle.

May be due to foreign material in between mashing Gear of slew & Gear of slewing ring.

Meshing Gears to be checked cautionly.

Slewing filter to be checked for closing. If so, new filter clear to be provided.



SLEWING LEFT AND RIGHT BOTH NOT WORKING 1.23 P 1/2





SLEWING LEFT AND RIGHT BOTH NOT WORKING 1.23 P 2/2

Refer chapter 1.1 Check Pilot pressure.

Check Pilot Valve No.36 at 30 bar pressure.

Check Solenoid Valve 15Y112 & 15Y122 for electrical continuity.

Clean & re-fitted Pilot Valve, if problem persists change valve.

Mechanically push up of Solenoid Valve, if problem persists change valve.

Clean & re-fitted Valve No. 20 and shuttle valve (DB) & adjust flow of Valve No.20.

Check 30 bar pressure at Lamina brake .

Check 30 bar pressure at Y1 & Y2 port of Q3 +Q4 Pump.

Check Q3+Q4 Pump Pressure Gauge No.43 (30-200 bar).

Clean & re-fitted Check Valve No. 48 & 49.

Cross check with Aux. Engine, if any fault replace pump.

Check Lamina Brake & Hyd. Motor No.6).

Clean & re-fitted Hyd. Motor & Lamina Brake if problem persists change it.

Check SLI. Refer chapter 1.51



SLEWING LEFT IS NOT WORKING 1.24 P 1/2




SLEWING LEFT IS NOT WORKING 1.24 P 2/2

Refer chapter 1.51

Check Electrical portion of Solenoid Valve 15Y 112.


Check Solenoid Valve 15Y 112 at 30 bar pressure.

Clean & re-fitted Pilot Valve.

Mechanically push up pin of Solenoid Valve, if problem persists change valve.


Check pressure at Lamina brake.

Check at 30 bar pressure at Y1 & Y2 port of Q3 +Q4 Pump.

Check failure of Pump internal control.



Check Lamina Brake & Hyd. Motor (Item -6).

Just alter hose of Y1 & Y2 or vise versa if problem persists change pump.

Check SLI Refer chapter 1.51



SLEWING RIGHT IS NOT WORKING 1.25 P 1/2




SLEWING RIGHT IS NOT WORKING 1.25 P 2/2

Refer chapter 1.51

Check Electrical portion of Solenoid Valve 15Y 122.


Check Solenoid Valve 15Y 122 for electrical continuity at 30 bar pressure.

Clean & re-fitted Pilot Valve.

Mechanically push up pin of Solenoid Valve, if problem persists change valve.


Check 30 bar pressure at Lamina brake.

Check pressure at Y1 & Y2 port of Q3 +Q4 Pump (30-200 bar).

Check failure of Pump internal control.



Check Lamina Brake & Hyd. Motor No-6.

Just alter hose of Y1 & Y2 or vise versa if problem persists change pump.

Check SLI Refer chapter 1.51



TRAVEL OPERATION IS NOT WORKING IN BOTH DIRECTION 1.26 P1/2

Travel Opeartion



TRAVEL OPERATION IS NOT WORKING IN BOTH DIRECTION 1.26 P2/2

Clean & refitted, if problem persists change valve.

Check Preselector Valve No.38.

Check 4/2 DC Valve No.39 at 30 bar pressure.

Check 3/2 DC Valve No.8 (DOW) at min. 6-30 bar pressure.This valve fitted in S/S.



If Pilot Pressure 30 bar is not available of Spool FW point again check above point.

Check Pilot Pressure at FW point of M1 & M2 at 30 bar pressure.

Check 30 bar pressure at X1 point of Q1& Q2 Pump.

Check Pressure Regulator ofMotor Protection Block at 280 bar pressure.

If Pilot Pressure 30 bar is not available of X1 point of Q1& Q2 pump again check above point.


Check Travel Motor No. 8.


Check Pilot Pressure Refer chapter 1.1



AXLE BLOCKING IS NOT WORKING 1.27 P 1/2

Axle Blocking Application

Axle Blocking Release



AXLE BLOCKING IS NOT WORKING 1.27 P 2/2


Check Preselector Valve No.38 at 30 bar pressure.

Check Relief Valve No.10 of SM 12 5F at 250 bar pressure.

Check Pressure 30 bar at UW point of M1 block.


If no pressure available, Then check above two points.

Measure Jet size, if problem persists change Jet valve.

Check Jet Valve 1mm for any blockage.

Check Valve No.13 at 250 bar pressure.




Check Pilot operated Check Valve No.12 at 250 bar pressure.


Check Pilot Pressure. Refer chapter 1.1

Check Axle Blocking Cylinder No.6.

Check Cylinder internal leakage, if problem persists change Cylinder.

Check Axle Blocking Pressure Gauge (0-600bar).

Clean & refitted, if problem persists change gauge.



PROPPING IS NOT WORKING 1.28 P 1/2

Propping IN

Propping OUT



PROPPING IS NOT WORKING 1.28 P 2/2



Check Valve No.9 & 10 at 250 bar pressure.

Check Pressure 30 bar at UW point of M1 Block.


If no pressure available, then check above two points.



Check Propping Cylinder.





OUT RIGGING IS NOT WORKING 1.29 P 1/2

Rigging IN

Rigging OUT



OUT RIGGING IS NOT WORKING 1.29 P 2/2



Check Valve No.9 & 10 at 250 bar pressure.

Check Pressure 30 bar at UW point of M1 Block.


If no pressure available,then check above two points.

Check Out Rigging Cylinder No.5.





OPERATIONS ARE NOT WORKING WITH AUX. ENGINE 1.30 P 1/1

Refer chapter 1.1

Check Pilot Pressure at 30 bar pressure.

Check NST Valve No.40 at 30 bar pressure.

Check Pressure 30 bar at N1/N2 point of SM 12 2F Valve.


If pressure is not found re-check Point No.2.


Check Check Valve No.26 at 30 bar pressure.

Check Pressure at 250 bar of Relief Valve of SM 12 2 F.

Check Aux. Engine Coupling.


If cupling failed, replace it.

Check Pump Q8 (at Pressure -250 Bar & Flow-36 ltrs/min) and Q9 (at Pressure - 30 bar & Flow-14 ltrs/min).

If this pump failed to develop 250 bar & 30 bar, then replace pump.

Check Electrical Change Over System.

Refer chapter 1.43



ENGINE IS NOT STARTING (CRANKING DOES NOT EXIST) 1.31 P 1/1

Close fuel solenoid manually. Check fuel solenoid for opening of fuel valve.

Check lubricant oil safety system componenets for proper pressure (3 kg/cm2-idle & 4.5 kg/cm2).

Check fuel system components for any blockage of fuel.

Clean & refit lub oil safety switch, if problem persists, replace switch.

See fuel level, replace fuel filter with ‘O’ ring, clean & refit water separator & check valve, clean & retighten fuel connection.

Check air intake system components for restriction of air.

Check cooling system safety components.

Clean & refit air filter, & turbo super charger.

Clean & refit water temperature Safety switch, if any problem found replace switch.

Check water pump belt tension.

Adjust belt tension if required.

Check electrical circuit for starter motor.

Refer chapter 1.43



Check Fuel system hoses and tubes.

Check fuel filter element for restriction.

Clean & refit if any damage, replace it.

Remove filter element & gasket.

Check air in the fuel system.

Check air intake system for any restriction.

Loose bleeding screw & allow oil 5-10 sec and after cranking retight screws.

Clean air filter element by pressure air. (Not more than 5 kg/cm2)

Tighten all joints in air line, if any damage found in connection, replace hose.

Check Engine cranking speed. It should be above 150 RPM.

If engine cranking speed below 150 RPM-check battery level.

If still problem, contact a Cummins authorized repair facility.

ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE PRESENT) 1.32 P 1/1



Use manual over ride of solenoid valve.

Check fuel solenoid valve.

Check fuel connections for any jamming or loosing or damage.

Check incoming of fuel to injectors.

Clean all fuel filter, fittings tubes hoses and connections from fuel tank to fuel pumps, if any damage replace it.

Loosen fuel supply line between fuel pump and cylinder head, while cranking the engine only 15-20 sec, if no fuel exists, check pump.

Check fuel filter for any restriction.

Check air locking of pump.

Taken out element from filter housing, Clean bowl & replace new element & gasket.

Lossen air bleeding screw, crank engine for 5-10 sec than retighten all the screws.

Check fuel in Tank. If shortage add fuel.upto top marking level.

If still problem, contact a Cummins authorized repair facility.

ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST) 1.33 P 1/1



ENGINE STARTS BUT WILL NOT KEEP RUNNING 1.34 P 1/1

Check fuel suction line hose & tubes for restriction.

Check fuel filter element for clugging.

Clean all hoses & tubes & refit, if problem persists replace it.

Replace fuel filter.

Check fuel & tank for contamination & sediment.

If problem persists, contact a Cummins authorized repair facility.

Clean fuel tank, replace fuel and refill fuel through filter.

Check air in the fuel system. Tighten fuel connections, tighten filter, check fuel tank stand pipe, if any problem replace it.



ENGINE IS NOT SHUTTING DOWN 1.35 P 1/1

Open solenoid, clean disc & outerside of solenoid, refit it, and if problem persists replace solenoid.

Check fuel pump shut off electrical solenoid & disc for any disc stricking or lack of energisation of solenoius.valve disc stuck.

Check fuel returning line for any restriction

Check fuel tank breather for any restriction.

Open all return hoses & tubes, clean it

Open breather assly & clean it.


Check fuel pump override screwsfor opening manually.

Tighten override screws manually and than open fully, if problem persists replace valve.



LUBRICATING OIL PRESSURE LOW 1.36 P 1/1

If any problem persists, replace gauge.

Check lub oil pressure gauge for malfunctioning.

Check lub oil for any dilutionwith fuel. (Cummins recommended specification-15W-40 CF4)

If fuel mixed with lub oil first replace oil & refilled fresh recommended oil.

Check lub oil temperature.


Maintain the temperature at i) 750c to 880c-best performance ii) 1200c-max.with certain period

with full load.

Check lub oil level. If shortage, add engine oil & check dipstick collaboration.



AIR PRESSURE NOT BUILD UP 1.37 P 1/4

Pn. Charging Circuit S/S



AIR PRESSURE NOT BUILD UP 1.37 P 2/4 Check air pressure in two stages. First confirm superstructure air then under carriage air.

Block rotor port 1 by D/plug on rotor bottom port.

Check cooling loop.

Clean and check any damage, if problem persist replace coil.

Check Valve No. 16 (at pressure 6.5 kg/cm2).

Check superstructure air pressure (6.5 kg/cm2).


Check unloader (at pressure 7 kg/cm2 max).

Clean & refit if problem persist replace valve.

Check Oiler No. 5 for any leakage.


Check Valve No. 12 (at pressure 5 bar).


Check blow out Cock – No. 4 for any leakage.


Check Horn Valve No. 10.


Check Pedal Valve No. 6.




AIR PRESSURE NOT BUILD UP 1.37 P 3/4

Pn.Charging Circuit U/C



AIR PRESSURE NOT BUILD UP 1.37 P 4/4 After confirm superstructure air then check following steps for whole charging system.

Check pressure gauge if any problem found replace gauge.

Check Pedal Valve No. 6. Check pressure gauge (0-10 bar).

Check under carriage air pressure. (at 5 kg/cm2).

Check DC Valve No. 32, 34, &35.

Check internal leakage of brake cylinder.

Check Relay Valve No. 1, 3 & 5.

Check, Check Valve No. 13 & 14 (at pressure 5 kg/cm2).


Check Drain Cock No. 12 of all reservoirs.





Open rotor port 1 and line up original system.



Axle blocking Release Circuit

AXLE BLOCKING ON BUT TRAVEL PINION NOT ENGAGED & BRAKE NOT APPLIED 1.38 P 1/2



Clean and refit if problem persists replace indicator.

Check Valve No. 35. Clean and refit if problem persists replace valve.

Check indicator.


Check Valve No. 32.


Check Relay Valve No.5.

Clean, replace damage seal, refit if problem persists replace valve.

Check DUV Cylinders No 25 & 27.

Clean and refit both cylinders if problem persist refit cylinder.

Check control port of Safety Valve No. 33 & 32.


Check Valve No. 34.

Check Safety Valve No. 23, 32, and 33

Check any leakage in pilot pot Clean and refit, if problem persists replace valve.

AXLE BLOCKING ON BUT TRAVEL PINION NOT ENGAGED & BRAKE NOT APPLIED 1.38 P 2/2



Axle Blocking Application Circuit

AXLE BLOCKING OFF BUT TRAVEL PINION ENGAGED & BRAKE APPLIED 1.39 P 1/2




Check Valve No. 35


Check indicator.


Check Valve No .32.


Check Relay Valve No. 5.

Clean, replace damage seal, refit if problem persists replace valve.

Check DUV Cylinders No 27.

Clean and refit both cylinders if problem persists refit cylinder.

Check control port of Safety Valve No.33 & 32.


Check Valve No.34

Check Safety Valve No. 23, 32, and 33

Check any leakage in pilot pot Clean and refit if problem persists replace valve.

AXLE BLOCKING OFF BUT TRAVEL PINION ENGAGED & BRAKE APPLIED 1.39 P 2/2



Service Brake Circuit

BRAKE RELEASE / APPLICATION NOT FUNCTIONING IN SELF TRAVEL OPERATION 1.40 P 1/2




Check Valve No.32 (UW).

Check DOW Valve No. 9 (SS).

Check Valve No. 8, 7 & 6.

Check DUW- 1&2 functions. (Valve No. 34 & 35).

Recharge axle blocking and observe the phenomenon in DUW – 2 function i.e, brake on and gear engaged. If problem persists check 34 & 35 valve.

Check Shuttle Valve No:.21 (UW).

Check Relay Valve No.5 (UW).





BRAKE RELEASE / APPLICATION NOT FUNCTIONING IN SELF TRAVEL OPERATION 1.40 P 2/2

Check Axle blocking. Axle blocking must on in this brake mode.



Train Brake Circuit

MALFUNCTIONING OF SERVICE BRAKE (APPLICATION / RELEASE IN SERVICE BRAKE MODE) (AIR MODE) 1.41 P 1/2



Check all pins & lever if any problem found rectify it.

Check Shut off Valve No. 11 in L & C Port.

Check mode selection lever & connection rod.

Check Dirt Collector No. 22 for blockage.

Check DV Valve No. 1


Check Shuttle Valve No. 21.

Check Emergency Brake Valve No.23 & 32.

Clean & refit Dirt collection.

Clean & refit.

Clean & refit.

Check axle blocking.

Confirm axle blocking must be off condition.


MALFUNCTIONING OF SERVICE BRAKE (APPLICATION / RELEASE IN SERVICE BRAKE MODE) (AIR MODE) 1.41 P 2/2



MALFUNCTIONING OF SERVICE BRAKE IN VACUUM MODE 1.42 P 1/2

Train Brake Circuit



MALFUNCTIONING OF SERVICE BRAKE IN VACUUM MODE 1.42 P 2/2

Check all pins & lever if any problem found rectify it.

Check Shut off Cock No.9 for any leakage.

Check mode selection lever & connection rod for any slackness.

Check shut off valve in VL port & C port of valve no: 3 for any leakage.

Check Valve No. 3 for blockage.

Check axle mounted compressor Relief Valve No. 31for 7.5 bar pressure.

Check Shuttle Valve No. 21 for blocking.

Check axle mounted compressor no: 28 for 7.5 bar pressure & 12.3 Cft/min.)

Clean & refit, arrest leakage if any.



Check axle blocking

Confirm axle blocking in off condition.

Check air chamber No: 7 for any leakage.

Clean & refit, if problem persists replace valve.

Check & compress confirms OK or not.


Clean & refit Check Non-return Valve No. 13 for blockage.

Check shut-off cock for leakage.

Select proper direction according to requirement. Observe any leakage Clean & refit, if problem persists replace shut-off valve.




ENGINE NOT STARTING 1.43 P /1/2



ENGINE NOT STARTING 1.43 P /2/2

If found loose, tighten it and clean it.

Check Magnetic switch 7K52 for self starter solenoid line.

Check line of 7K52 between 30 & 87 and connect it properly.

Check. Start push switch 7S52 forself starter.

Check Battery terminal connection.

Clean the contact NO. 13 & 14.

Check specific gravity of the batteries.

If low, charged it upto 1250.

Check fuel solenoid 7Y01 for fuel supply.

Check line and connect it properly

Check time Relay 7K030 for lub oil pressure.

Is it working properly & if not, check Lub Oil Pr. Switch connection.

Check stop push switch 7S51for fuel solenoid.

Clean the contact NC 21 & 22.

Check Air locking in fuel line for fuel supply.

Take help of engine expert and release the air locking.



GUAGE NOT SHOW PROPER READING (WATER TEMP, OIL TEMP AND OIL PRESSURE) 1.44 P 1/2



If not available, connect properly.

Check Sensor connection in gaugefor for continuity upto gauges.

Connect it properly.

Check gauge connection i.e. 24VDC.

Check Sensors for water temp, oil temp & oil pressure gauges function.

Connect it properly.

GUAGE NOT SHOW PROPER READING (WATER TEMP, OIL TEMP AND OIL PRESSURE) 1.44 P 2/2

Check Sensor for malfunction. Replace the sensor.



RPM METER NOT WORKING 1.45 P 1/2



RPM METER NOT WORKING 1.45 P 2/2

If not available, connect it.

Check connection of MPU for looseness or disconnection.

If not available, connect it properly and adjust it.

Check. MPU for malfunction.

Check 24VDC in Digital RPM Meter.

.Replace the MPU.

Check connection of Techo-generator in analogue RPM Meter.

If not available connect it properly.



BATTERY NOT TAKING CHARGE 1.46 P 1/1

If loose, connect properly.

Check the voltage near battery terminal (24VDC).

If not available, check and connect it properly.

Check the Sp. Gravity of Battery (1250)

Check the voltage of Alternator.

Fill up proper electrolyte.

Check the Ammeter for current. Connect it properly.



UP WARD MOTION NOT WORK OF MAIN HOIST/AUX HOIST 1.47 P 1/2



UP WARD MOTION NOT WORK OF MAIN HOIST/AUX HOIST 1.47 P 2/2

Check fuse 7F02.6, if burnt replace it.

Relay is OK, work not going on.

Check over load relay 19K040/19K041. These are relays of SLI, if SLI not working, press the Key of SLI bye pass if necessary and arrange for checking of SLI.

Relay 19K040 & 19K041 is OK.

Check 24V DC supply 7x21.25 (Terminal).

Check limit switch 15S11 & 15S 111 connections, if it is in off position, adjust it.

Fuse is OK, work not going on.

Check relay 7K02 connection at 30 & 87 and at 85 & 86.

Supply is there but Solenoid is not working.

Replace the solenoid with new one.

Check Solenoid. Check 24VDC supply at Solenoid 15Y 11 & 15Y 111.



DN WARD MOTION NOT WORK OF MAIN HOIST/AUX. HOIST 1.48P 1/2



DN WARD MOTION NOT WORK OF MAIN HOIST/AUX. HOIST 1.48P 2/2

Check fuse No. 7F02.6 if burnt, replace it.

Check Solenoid 15Y12 & 15Y121. Check 24VDC supply at solenoid

Supply is there but solenoid is not working.

Check 24 V DC Supply 7 x 21.25 (Terminal).


Fuse is OK but hoist not working.

Check limit switch 15S12 & 15S 121, if limit is in off position, adjust it.



DERRICKING IN IS NOT WORKING 1.49P 1/2



DERRICKING IN IS NOT WORKING 1.49P 2/2

Check Fuse 7F02.6, if burnt replace it.

Relay is OK, but work not going on.

Check limit switch15 S 112 & 15 S 113, if limit is in off position, adjust it.

Limit is OK, but work not going on.

Check 24 V DC supply at 15x21-1 (Terminal).

Check Relay 19K18 and its connection between 30 & 87.


Check relay 7K02, its connection between 30 & 87.

Supply is available but solenoid not working.

Replace it with a new one.


Check 24VDC supply at solenoid 15Y113.



DERRICKING OUT IS NOT WORKING 1.50 P 1/2



DERRICKING OUT IS NOT WORKING 1.50 P 2/2

Check Fuse 7F02.6, if burnt replace it.

19K042 relay is OK, but work not going on.

Checks limit switch 15S 122 & 15S 123, if limit is in off position, adjust it upto on position.

Limit is OK, still work not going on.

Check 24 V DC supply at 15 x 21-1 (Terminal).

Check 24V DC supply at solenoid valve no. 15Y123.


Check relay 7K02, its connection between 30 & 87.

Supply is available but solenoid not working.

Replace it with a new one.


Check relay 19K042, and its connection between 30 & 87. It is relay of SLI, If SLI not working press the key of SLI by pass if necessary and arrange for checking of SLI.



SLEW LEFT & RIGHT NOT WORKING 1.51 P1/2



SLEW LEFT & RIGHT NOT WORKING 1.51 P2/2

Check Fuse 7F02.6, if burnt replace it or repair it.

Check 24 V DC supply at 15x21-1(Terminal).


Check relay 7K02 and its connection between 30 & 87.


Check relay 19K21for left and 19K11 for right slew. If not working, arrange for checking of SLI and limit of load chart.


Check 24V DC supply at solenoid 15Y112 for left slew and 15Y122 for right slew.

Supply is OK but work is not going on.




GALLOWS NOT WORKING IN UPWARD MOTION 1.52 P ½



GALLOWS NOT WORKING IN UPWARD MOTION 1.52 P 2/2

Check Fuse 7F02.6, if burnt replace it or repair it.

Check 24 V DC supply at 15 x 21 -1(Terminal).


Check relay 7K02 and its connection between 30 & 87.

Limit is OK but solenoid is not working.

Check Limit switch 15S 125 (roller type) if it is off, Adjust it. Upto ON position.

Supply is available.

Check supply 24V DC at solenoid 15Y125.


Replace the solenoid valve.



AUX ENGINE IS RUNNING BUT NO WORK IS GOING ON 1.53 P 1/2



AUX ENGINE IS RUNNING BUT NO WORK IS GOING ON 1.53 P 2/2

If it is in off position, do ON. Check position of Battery switch.

Check position of Ignition switch. If it is in off position, do ON.

Check 24V DC supply at 15x21.1 (Terminal).

If supply is not available, checks fuse 7F02.6 and repair or replace it

If not available, check relay 15K01 and its connection between 30 & 87.

Check 24V DC supply at 7x21.25 (Terminal).



INDICATON OF COUNTERWEIGHT NOT SHOWING PROPER 1.54 P 1/2



INDICATON OF COUNTERWEIGHT NOT SHOWING PROPER 1.54 P 2/2

Check it at 19 X 21.15 (Terminal).

Check again 24V DC for full CWT Check it at 19 X 21.10 (Terminal).

Check relays for full CWT.

Check 24V DC. For CWT

Check relays 19K13 and 19K14 and connection between 30&87a of 19K13, 30 & 87 of 19K14.

Check pressure switch 19B52. Check it is working or not, adjust it at 110 bar for Half counter weight.

Check 24V DC. Check it at 19 X 21.11 (Terminal).

Check relays full CWT.

Connection between 30 & 87 of 19K16 and between 30 & 87a of 19K15 and 19 K17.

Check Pressure switch 19B53 for full CWT.

Check it is working or not, adjust it at 140 bar for full counterweight.

All relays are working but counterweight not showing.

Arrange to check X1 card of SLI system.



BOOM ANGLE, SLEW ANGLE&LOAD NOT SHOWING PROPER 1.55 P 1/2



BOOM ANGLE, SLEW ANGLE&LOAD NOT SHOWING PROPER 1.55 P 2/2

Check cable of load cell boom angle sensor & slew angle sensor.

Check cables are damaged or not, if damaged, replace it.

Check screen of cable. Should be earthed properly.

Check junction box of sensor.

All connections of sensor should be tightened.

Check cards X1, X3 and X5. Check out put and input voltage of cards if not replace the cards.

Check central unit of SLI. Check all glass fuses, if burnet replaces it.

TROUBLE SHOOTING GUIDE - 140T Jamalpur Cranes140t.weebly.com/uploads/8/4/8/7/8487435/tr_sh_old.pdfJamalpur Loco Works 1 Old Design Crane PREFACE Crane organization/Jamalpur Workshop

Documents