Preventive Maintenance Of Port Mobile Machinery

In the daily operations of the port, large-scale machinery and mobile machinery have always cooperated with each other to complete the daily operation of the terminal. Mechanical equipment is an important infrastructure in the port’s business activities, so its operation is directly related to the normal operation of the terminal. According to the current use of mobile machinery in some ports and yards, the damage of mechanical equipment, in addition to reaching the service life of mechanical components and parts itself, is commonly caused by the following three reasons: one is improper operation; the other is Improper maintenance; thirdly, management is not in place. For this reason, machinery and equipment managers need to master a set of scientific, professional, and complete equipment management methods, not only on the technical level to manage equipment, but also consider the economic costs of the life cycle of machinery and equipment.

I. Common mobile machinery maintenance problems

At present, there are still some ports or container yards that do not have a high degree of awareness and attention to the maintenance of mobile machinery. It often occurs that the mobile machinery is overloaded in order to catch up with production. As long as the machinery and equipment can work, the regular maintenance of the machinery is ignored. Checking work, often delaying the maintenance of mobile machinery, or arranging new employees who just entered the industry to simply change the engine oil even if the maintenance work is completed. There is no complete mobile machinery maintenance system, and the equipment maintenance personnel should deal with the maintenance work of the locomotive. In case of trouble, the locomotive maintenance information registration is incomplete. I also often ignore minor problems in mobile machinery, replace maintenance with repairs, delay the maintenance plan for minor problems, and arrange maintenance work until the machine has a major problem and shut down, and delay the inspection of safety components and forced replacement work, which will be serious. Reduce the service life and safety and reliability of mobile machinery, and bring risks to enterprise production.

2. How to implement scientific, professional and complete preventive maintenance inspection work

Daily routine inspection

That is, the mobile machine driver needs to check the locomotive before the formal operation every day. The inspection content is mainly as follows: the driver needs to walk around the locomotive, check whether there are obvious signs of damage on the outside of the locomotive, check whether the tire pressure, tire fixing bolts and tire wear are abnormal, check various oil levels and engine coolant levels, and check whether there is oil leakage If there is water leakage, check whether the twist lock of the spreader is normal and whether the sensor is dirty. Then start the locomotive in accordance with the standard operating procedures. After starting, check whether the engine and gearbox have abnormal noises, check whether the warning indicator lights on the dashboard, check whether the lights and horns are normal, drive the locomotive carefully in the parking lot, and test back and forth at least three times Brake, check the steering function and the front and rear shift functions, and test whether the hydraulic operating functions are normal. Finally, the driver records the above inspections in the daily inspection records of the locomotive so that the managers can inquire about the status of the locomotive.

Regular preventive maintenance inspections

That is to say, the maintenance interval is divided according to the operating hours of the engine. At present, the primary and secondary maintenance of mobile machinery in some ports and container yards cannot meet the requirements of mobile machinery. In order to further extend the service life of the mobile machinery, Europe and the United States Developed countries have implemented four levels of A guarantee, B guarantee, C guarantee, and D guarantee for the regular maintenance of flow machines. The maintenance inspection items to be completed for each grade are specified in a more targeted and detailed manner. It is recommended to perform the following regular maintenance sequence according to the engine running hours and every 250 hours: A guarantee, B guarantee, A guarantee, C guarantee, A guarantee, B guarantee, A guarantee, D guarantee, that is, a regular maintenance cycle is completed every 2000 hours. According to the “Preventive Maintenance Work Checklist (Front Loader)” provided by Kalmar Asia-Pacific Training Center, there are 90 items of D-level maintenance inspections, which include the replacement of oil products and filter elements, as well as many inspection items. The following is an example of the regular maintenance and inspection items of the flow machine:
(1) Engine oil and filter element: Engine oil can take away the worn debris and carbon deposits in the system, and at the same time take away the heat generated by the engine and related moving parts to lubricate the moving parts. However, due to heat, carbon deposits and other factors, the performance of the engine oil will deteriorate, the decontamination ability will gradually weaken, and the viscosity grade of the engine oil will decrease. The blocked filter element prevents the oil from entering the system and reduces the lubrication and cooling effect of the oil. Therefore, the engine oil and filter element should be replaced regularly to effectively protect the engine and avoid unnecessary damage. It is recommended to use a clean container to receive the old engine oil at the bottom of the engine, so that you can check whether the old engine oil in the oil container has metal particles or debris, and further determine whether there is damage inside the engine.
(2) Engine belt inspection: Press the belt by hand, and the distance that can be pressed should not exceed 10mm. If the belt is too loose, tighten it. At the same time, check whether the belt is cracked or broken. Replace the worn belt. If the belt is too loose, it will not only damage the pulley, but also affect the cooling of the engine, the normal operation of the air conditioner and the generator. If the damaged belt can be found and replaced during maintenance and inspection, other damages or shutdown failures caused by broken engine belts can be avoided when the locomotive is in use.
(3) Check the drive shaft fixing bolts: the drive shaft fixing bolts will loosen under the action of load and vibration, and the loose drive shaft fixing bolts are easy to be cut, causing the drive shaft to detach and shake, which may damage other parts. It is recommended to tighten the drive shaft fixing bolts according to the standard torque of the locomotive.
(4) Check whether the steering wheel bearing and the fixing nut are loose: disassemble the rear axle steering wheel hub bearing cover, check whether there are metal shavings on the bearing lubricating grease, and if the bearing is damaged, replace it. For example, for the Kalmar stacker, the inner nut of the steering wheel hub bearing needs to be tightened with a torque of 500 NM, and then the hub is rotated about 10 times, and the nut is re-tightened with a torque of 500 NM, and finally the lock plate and outer nut are installed. Apply grease to the sleeve cover and install it, and continue to add grease to the grease nipple until the old grease on the inner side of the hub is squeezed out. There are other more detailed maintenance and inspection items, you can refer to the maintenance manual of each mobile machine and other materials.

Special maintenance check

Special maintenance inspections include special preventive inspections, long-term out-of-service maintenance, and so on.
Stackers and reach stackers are mainly designed to stack containers, not to transport containers. However, in actual operations, stackers or reach stackers are often seen to carry containers for long-distance transportation, which increases the main mobile machinery Fatigue damage of structural parts, so it is recommended to check the locomotive structure. There are also some long-lived machines that require special preventive inspections, such as engine inspections, gearbox inspections, electrical system inspections, hydraulic system inspections, drive and steering bridges, and locomotive structure inspections. In the summer high temperature season, in order to prevent the occurrence of locomotive fire accidents, it is recommended to perform a special inspection of the hydraulic system and electrical system for the flow machine, focusing on the inspection of aging and cracked oil pipes, oil leakage parts, aging cables, and poorly-fixed oil pipes and cables. . Each special inspection must strictly follow the inspection items of the corresponding “preventive checklist” to perform specific inspections.
In addition, if the flow machine is shut down for a long time due to other non-mechanical reasons, the locomotive needs to be shut down for maintenance. Because when the locomotive is not used for a long time, the oil inside the locomotive may deteriorate, the oil film on the surface of the moving parts may fail, and the exposed piston rod of the hydraulic cylinder may rust due to the salt environment of the port. Therefore, it is recommended to start a long-term inactive flow engine every half month and warm up the car, move the piston rod of each hydraulic cylinder from the minimum stroke to the maximum stroke, and then idle for at least one minute before turning off the engine.

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