The spreader of the container reach stacker is the core component of the equipment, responsible for grabbing, lifting and precise positioning of the container. Its reliability directly affects the operating efficiency and safety.
El spreader del reach stacker de contenedores es el componente central del equipo, responsable de agarrar, levantar y posicionar con precisión el contenedor. Su confiabilidad afecta directamente la eficiencia operativa y la seguridad.
The following is a systematic solution for the maintenance of the spreader:
1. Daily inspection and maintenance/ Inspección y mantenimiento diarios
Structural parts inspection/Inspección de piezas estructurales
Visual inspection: Check whether there are cracks, deformation or corrosion on the main frame of the spreader, telescopic arm, twist lock mechanism, etc., focusing on the welds and high stress areas.
Fastener inspection: Confirm that bolts, pins and other fasteners are not loose or missing, especially the fixing bolts of twist lock pins and guide plates.
Hydraulic system inspection/Inspección del sistema hidráulico
Leak detection: Check whether the hydraulic oil pipes, joints and cylinders are leaking, and pay special attention to the sealing of the telescopic cylinder and the locking cylinder.
Oil pressure test: monitor whether the hydraulic system pressure is stable (refer to the equipment manual for standard values, usually 12-18MPa).
Electrical and control systems/Sistemas eléctricos y de control
Sensor function test: Check whether the spreader position sensor and twist lock status sensor are sensitive and whether the signal transmission is normal.
Cable protection: Check whether the cables are damaged or aged to avoid short circuits or signal interference caused by wear and tear.
Locking device maintenance/Mantenimiento del dispositivo de bloqueo
Twist lock action test: Test the opening and closing action of the twist lock in manual/automatic mode to ensure flexibility and no jamming.
Cleaning and lubrication: remove the sand and residue from the container corner fittings in the twist lock, and apply grease (molybdenum disulfide grease is recommended).
2. Regular maintenance items/Elementos de mantenimiento regular
Hydraulic system in-depth maintenance/Mantenimiento en profundidad del sistema hidráulico
Oil change and filter replacement: replace the hydraulic oil (anti-wear hydraulic oil ISO VG46) every 2000 hours or annually, and replace the oil suction filter and oil return filter at the same time.
Cylinder maintenance: disassemble and check the inner wall of the cylinder for scratches, piston rod wear, and replace seals (such as O-rings, Step seals).
Spreader calibration and adjustment/Calibración y ajuste del esparcidor
Symmetry calibration: Use a laser rangefinder to check the synchronization of telescopic movement on both sides of the spreader. The error should be ≤3mm.
Twist lock clearance adjustment: Ensure that the clearance between the twist lock and the container corner fitting is ≤2mm to avoid shaking during loading and unloading due to excessive clearance.
Bearing and slideway maintenance/Mantenimiento de cojinetes y guías de deslizamiento
Lubrication of telescopic arm slideway: remove old grease and impurities, apply high-temperature grease (such as lithium-based grease NLGI 2), and maintain it every 500 hours.
Slewing bearing inspection: Check the clearance and tooth surface wear of the slewing bearing, and add grease (extreme pressure lithium-based grease) every 3,000 hours.
Anticorrosion treatment/Tratamiento anticorrosión
Coating repair: Grind and repaint the peeling parts, focusing on protecting the welds and the inner cavity of the telescopic arm (using epoxy primer + polyurethane topcoat).
Unblock the drainage holes: Clear the water channels inside the spreader to prevent rainwater accumulation and rust.
3. Common faults and emergency treatment/Averías comunes y tratamiento de urgencias
1) The twist lock cannot be locked/El cierre giratorio no se puede bloquear.
Possible causes: sensor failure, insufficient hydraulic pressure, twist lock deformation
Solution: Clean sensor contacts, check hydraulic pump, correct/replace twist locks
2) The extension and retraction of the spreader are not synchronized/La extensión y retracción del spreader no están sincronizadas
Possible causes: Hydraulic valve stuck, proportional valve signal abnormality
Solution: Clean the valve core and calibrate the solenoid valve current signal
3) The spreader is offset or tilted/ El esparcidor está desplazado o inclinado
Possible reasons: wear of guide plate, poor lubrication of telescopic arm slideway
Solution: Replace the guide plate bushing, clean the slideway and add grease
4) False alarm of electrical system/ Falsa alarma del sistema eléctrico
Possible reasons: poor line contact, controller program failure
Solution: Check the wiring terminals, restart the system or upgrade the control software
4. Safety operation specifications/Especificaciones de operación de seguridad
Pre-operation inspection: Before each loading and unloading, the lifting device must be tested with no load to confirm that the twist lock is in place.
Load limit: Overloading is strictly prohibited (e.g. the maximum load of a 40ft sling is usually 45 tons) to avoid structural damage caused by impact loads.
Environmental adaptation:
Low temperature environment (below -20°C): Use low-temperature hydraulic oil (ISO VG32) and preheat the hydraulic system for 10 minutes.
Dusty environment: Increase the frequency of filter replacement and clean the sensor surface daily.
5. Maintenance cycle recommendations/Recomendaciones del ciclo de mantenimiento
1) Hydraulic oil replacement: 2000 hours/year, ISO cleanliness standard NAS 1638 level 8 or below
2) Complete disassembly of the twist lock mechanism: 5000 hours/2 years Check the wear of the twist lock pin (allowed ≤1mm)
3) Electrical system insulation test: 1000 hours/half year, cable insulation resistance ≥5MΩ (500V megohmmeter)
6. Advanced maintenance suggestions/Sugerencias de mantenimiento avanzado
Condition monitoring technology: Install vibration sensors and oil particle counters to achieve real-time monitoring of the health status of the spreader.
Fatigue life assessment: Perform non-destructive testing (magnetic particle/ultrasonic testing) on the main structure of the spreader every 5 years to assess the remaining life.
Summarize:
Through standardized maintenance, the failure rate of spreaders can be reduced by more than 40% and the service life can be extended to 10-15 years.
A través de un mantenimiento estandarizado, la tasa de fallas de los esparcidores se puede reducir en más del 40% y la vida útil se puede extender a 10-15 años.
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Post time: May-26-2025