CERTIFICATE

This is to certify that, Path.P.Patel(086290319534) &

Dhaval.S.Prajapati(086290319544)
Work as per prescribed syllabus. [M4 Mechanical] Submission date: -

has successfully

completed his term work in_Hydraulic crane_Project in_Hydraulic crane_Project

H.O.D

GUIDED BY: D.T.Patel

Mechanical Engineering Dept.

PRINCIPAL

PROJECT REPORT ~

Government Polytechnic,Valsad

HYDRAULIC CRANE

 MAINTAINING & TROUBLESHOOTING HYDRAULIC CRANE

DEFINATION:Hydraulic cranes are heavy equipment used primarily for lifting. One of the most powerful means of lifting objects is with the strength of a hydraulic crane. Its also known as hydra crane One of the most powerful means of lifting objects is with the strength of a hydraulic crane. By harnessing the strength that liquid under.pressure gives, and the ease with which it can be used, it is possible to transfer a relatively small amount of effort from one place to another, and hydraulic cranes are amongst the most efficient lifting systems available in the modern workplace.

ABOUT:Quite simply, a hydraulic system works with a system of pumps and pistons that are filled with a liquid, usually a light oil or water.By moving the liquid under pressure from the pumps, pistons can be extended or reduced, and when these pistons are connected to a system of levers,the pistons can be used to lift surprisingly heavy weights.

DESIGN:Hydraulic cranes are very simple by design but can perform Herculean tasks that would otherwise seem impossible. In a matter of minutes,these machines are able to raise multiton bridge beams on highways, heavy equipment in factories and even lift beachfront houses onto pilings.Hydraulic truck cranes are also used to lift killer whales.

WORKING:Quite simply, a hydraulic system works with a system of pumps and pistons that are filled with a liquid, usually a light oil or water.By moving the liquid under pressure from the pumps, pistons can be extended or reduced, and when these pistons are connected to a system of levers, the pistons can be used to lift surprisingly heavy weights. Because the hydraulic cranes use a fixed system of pipes, constant pressure can be maintained once a part of the system has been moved into place,and this makes them extremely stable in use, and able to support relatively large weights.With the high

pressure hydraulic cranes, you are able to use a fairly light weight system that consumes a relatively small amount of power to move objects around, and these can actually be hand powered under certain circumstances to achieve the same results.

PROBLEM SUMMARY:-

AVOID PRODUCTION GAP VIA MAINTAINING & TROUBLESHOOTING HYDRAULIC CRANE & KEEP EFFECTIVE OPERATING MECHANISM OF IT.

DETAILED DESCRIPTION OF PROBLEM:Testing:Operational Tests

All new, altered, modified or extensively repaired cranes shall be tested for operational compliance. The following functions must be tested: Load lifting and lowering mechanisms Boom lifting and lowering mechanisms Boom extension and retraction mechanism Swinging mechanism Safety devices Operating controls comply with appropriate function labels Operational crane tests results shall be made available to designated person(s).

Rated Load Test

Prior to initial use, all cranes in which load sustaining parts have been altered, replaced or repaired should be load tested by, or under the direction of a qualified person. The replacement of the rope is specifically excluded from this requirement. However a functional test of the crane under a normal operating load should be made prior to putting the crane back in service. Test load shall not exceed 110% of the manufacturers load rating. Written reports shall be furnished by an appointed or authorized person, showing test procedures and confirming the adequacy of repairs or alterations.

IN HYDRAULIC SYSTEM.

1) CYLINDERS
a) Check rods for damage such as scarring, nicks, dents and rust on out-of-service units. b) Check for leaks at weld joints and rod seals. Check for drift indicating leakage around piston rings or defective holding valves. c) Check cylinder case for dents.

2) HYDRAULIC PUMP
a) Check for leaks at shaft seal. b) Check for drop in operating speed. c) Check hydraulic oil for excessive heating. d) Check bolts and fasteners for tightness. Note any unusual vibration or noise.

3) PTO AND PUMP

Inspect for proper transmissio gear to PTO engagement. b) When supplied, inspect driveline U-joints for securing cap tightness and adequate lubrication.

Parts of Hydraulic crane :

Although everything on the truck begins and ends with the hydraulic system, there's more to a hydraulic truck crane than the hydraulics.

(1)

Boom

Themost recognizablepart of anycrane is theboom.This isthesteelarm of the crane thatholds the load. Rising up fromjust behindtheoperator'scab,theboom is theessentialpieceof a crane

(2)

Jib

some booms are equippedwith a 'jib' ,which is thelattice structure attachedto the end of the boom.On the 70-ton hydraulictruck crane, the jib is 67feet (20.4 m) long, givingthe crane a total length of 194 feet (59.1 m). As theload is lifted, the sectionstelescope out to thedesired height.

(3)

Rotex gear

Underneath the operator'scab is a Rotexgear on aturntable bearing thatturns at 2 revolutions perminute (rpm). It is drivenby a bidirectional, hydraulicmotor mounted on the caband housed in a metal coverto prevent injuries. Therotation is controlled by afoot-operated, hydraulicpedal in the cab.

(4)

hook

Hydraulic hook systems allow for simplified cable routing along thebelly of the aircraft, and snagging or damage tothe cable will not lead to accidentally dropping the cargo.

IF CRANES NOT IN REGULAR USE

1 A crane that has been idle for a period of one month or more, but less than six months, must be inspected by a qualified person conforming with the requirements of the initial, regular and frequent inspections. 2 A crane that has been idle for a period of more than six months must be inspected by a qualified person conforming with the requirements of the initial, regular, frequent, and periodic inspections.

Safety Steps.
1) The first tool needed is the entire set of the crane circuit drawings and preferably from that machine serial number. These drawing are the road map to the machine and both electrical and hydraulic will be needed to be a more effective troubleshooter. Using them properly is a valuable tool, make sure you have them all and they are in a organized manner. The use of a volt-ohm meter today is absolutely necessary for troubleshooting electrical and electronic circuits. Test lights DO NOT WORK for crane circuits of today. Knowing the voltage is at 15 volts is a clue to the problem in a 24 volt circuit. It is also helpful to have a meter that can read amperage of the 10 AMP un-fused variety. Hydraulic pressure gauges are needed to determine if the proper pressure is being reached and the motion is correct. Gauges can tell many things in a system when you can properly interpret the hydraulic circuit drawings. Having gauges and using them can help in determining if your problem is hydraulic, electric, or mechanical and this is always a needed determination.

2)

3)

About Troubleshooting.
This information covers basic procedures and information needed to aid you in trouble shooting and understanding issues with your crane.

#1 If nothing works, first check for battery voltage and/or hydraulic power below the crane. Second check the pendant control connection and that it has voltage and is sending signals to the valves or relays.

#2 What functions do not work on the crane? What functions are working? Check every function when something is not working. This will determine whether or not a safety circuit is tripped.

#3 Manual override features are located on all hydraulic valves. The button is located on the end of the valves and may be pushed or pulled to operate the valve. On electric cranes the pump must be working before operating the valve manually. Locate the function that is not working and check it manually. If it works manually the problem is electrical, not hydraulic.

#4 All DC powered Cranes must have good voltage with adequate battery reserve to function. A Bad or Weak Battery will not allow the crane to operate as it is intended. Loose or bad connections are the same as having a bad battery.

#5 Always use a Volt Meter (Multi-Meter) when checking the crane. A Test Light may not give you the information needed. A test light may continue to burn even though the voltage is too low. The cranes voltage when running must be above 11.5 VDC.

#6 The crane must be running when voltage is measured. There may be adequate voltage before operating the crane but it will decrease as it is running. Voltage readings below 11.5 VDC are not adequate. At lower Voltages Amperage draw will increase and motors and solenoids will heat up rapidly under these conditions.

#7 The cause of most failures of Hydraulic Systems is trash or impurities in the oil. This is especially true of new cranes. Liftmoore provides an adapter fitting with all hydraulic cranes. This allows the pressure & return hoses to be plumbed together and the system run to circulate the oil. Typically 5-10 minutes run time will allow the return line filter to clean any impurities from the Reservoir, Hoses & Fittings. Doing this recirculation will insure a good working crane with no issues.

#8 When was the oil last changed? Oil will deteriorate over time as impurities or condensation enter the system. Keep the reservoir as full as possible to reduce the amount of condensation that will enter the system.

#9 All Liftmoore cranes are provided with a means of disconnecting the crane from the battery power source. Failure to use the crane disconnect will result in corrosion, bad connection's and a shorter life of all components. Both DC Powered Crane's and Hydraulic Crane's must be turned off when not in use.

MicroGuard 414

Trouble Shooting Manual AAA

Hydraulic Cranes

FAULT DIAGNOSIS PROCEDURES 000 001 AIN0 AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 NO FAULTS PISTON PRESSURE TRANSDUCER ROD PRESSURE TRANSDUCER EXTENSION SENSOR BOOM ANGLE SENSOR SSTRUCTURE ANGLE SENSOR SWING POTENTIOMETER A SWING POTENTIOMETER B

Faults in the system are detected automatically. Each time the system is switched on it goes through a start up self test which lasts about 2-3 seconds. During normal operation a self-test can be initiated by pressing the TEST button on the display. Fault conditions in external sensors are detected without

002 004 008 016 032 064

the need for a system self-test. If faults are detected in the system during a self-test they are indicated on the display in the following way:
GROUP B INPUTS AND OUTPUTS CODE

The word FAULT will appear in the information area of the left display. The RED LAMP will illuminate and the AUDIBLE ALARM will sound.

BB 00 01 02 04

FAULT 1 2 4 NO FAULTS DIGITAL INPUT AND OUTPUT ANALOG INPUT AND OUTPUT DISPLAY UNIT

When faults occur in the system they can be diagnosed by use of the display. Details of the fault locations are obtained by pressing
GROUP C MEMORY

and holding the test button. Holding the test button will
CODE

cause the system to go through a self test during which faults will be detected. On completion of the self-test, if the test button continues to be pressed, the fault screen will appear. The fault screen will remain visible for as long as the test button is pressed. Information will be displayed on the screen in four groups.

CC 00 01 02 04 08

1 2 4 8

NO FAULTS EXECUTIVE ROM DUTY ROM SCRATCHPAD RAM PERSONALITY ROM

Group A Group B Group C Group D

Sensor faults I/O faults

GROUP D GENERAL

Memory faults
CODE

General faults
DD 00 01 02 04 08 NO FAULTS NO DUTY FOUND CURRENT DUTY BAD CONFIGURATION UNCALIBRATED 2 HZ OSCILLATOR

1 2 4 8

EXPECTED OUTCOME
Adjustments & Repairs
Correct any hazardous conditions identified by the inspection requirements of this manual prior to resuming crane operation. Adjustments and repairs shall be done only by designated personnel. 1 Adjustments to maintain correct component function, such as: a) Functional operating mechanisms b) Operational aids (anti-two-block and overload protection devices) and limiting devices c) Electronic, hydraulic and mechanical control systems 2 Repairs or replacements as needed for operation, such as: a) Functional operating mechanisms that are cracked, broken, corroded, bent or excessively worn. b) Parts of the crane structure that are cracked, bent, broken, or excessively corroded. c) Damaged or worn hooks. IMT recommends hook replacement rather than repair. 3 Replacement parts shall have at least the original design factor. 4 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.

The most recognizable part of any crane is the Boom. This is the steel arm of the crane that holds the load. Rising up from just behind operator's cab, the boom is the essentialpiece of a crane.

ADVANTAGES:These cranes are ideal for lifting, weighing and moving heavy pieces of equipments. Hydraulic cranes are simple systems but with higher compatibility for any industrial process.They are easy to maintain because of their simple configuration. Because the hydraulic cranes use a fixed system of pipes, constant pressure can be maintained once a part of the system has been moved into place, and this makes them extremely stable in use, and able to support relatively large weights.

CAPACITY:A 40-ton crane can lift 40 tons (80,000 lb or 36,287 kg).

Project Summary

What is the goal of the project?

In Hydraulic crane,which is one of the most powerful means of lifting objects is with the strength.. Our goal is.. AVOID PRODUCTION GAP VIA MAINTAINING & TROUBLESHOOTING HYDRAULIC CRANE & KEEP EFFECTIVE OPERATING MECHANISM OF IT.

Why is this goal important?

A crane that has been idle for a period of one month or more, but less than six months, must be inspected by a qualified person conforming with the requirements of the initial, regular and frequent inspections. This information covers basic procedures and information needed to aid you in trouble shooting and understanding issues with crane. This is important that the crane shoud not breakdown, it creates production gap !!! Thats why troubleshooting is very important in crane maintenance !!!!

What methods will be used to achieve this goal?

Faults in the system are detected automatically method. Each time the system is switched on it goes through a start up self test which lasts about 2-3 seconds. During normal operation a self-test can be initiated by pressing the TEST button on the display. 1 Adjustments to maintain correct component function, such as: a) Functional operating mechanisms b) Operational aids (anti-two-block and overload protection devices) and limiting devices c) Electronic, hydraulic and mechanical control systems 2 Repairs or replacements as needed for operation, such as: a) Functional operating mechanisms that are cracked, broken, corroded, bent or excessively worn. b) Parts of the crane structure that are cracked, bent, broken, or excessively corroded. c) Damaged or worn hooks. IMT recommends hook replacement rather than repair. 3 Replacement parts shall have at least the original design factor. 4 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.

Name
Parth . P. Patel Dhaval.S.Prajapati

enrolment no.
(M4 Batch)

086290319534 086290319544

Guided

by.

D.t. D.t. Patel

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