In recent years, container transportation has made great progress in railway transportation, and the reach stacker for loading and unloading containers has been used more and more widely. The reach stacker has a complex structure and is an efficient production equipment integrating mechanical, electrical and hydraulic functions. The maintenance of the hydraulic system of the container reach stacker is the key to ensure the efficient operation of the equipment, extend its service life and avoid failures.
En los últimos años, el transporte de contenedores ha logrado grandes avances en el transporte ferroviario y los apiladores retráctiles para cargar y descargar contenedores se han utilizado cada vez más. El reach stacker tiene una estructura compleja y es un equipo de producción altamente eficiente que integra maquinaria, electricidad e hidráulica. El mantenimiento del sistema hidráulico del reach stacker de contenedores es clave para garantizar el funcionamiento eficiente del equipo, alargar su vida útil y evitar fallos.
The following are the steps and precautions for maintenance of the hydraulic system:
1. Daily inspection and maintenance/Inspección y mantenimiento diarios
Hydraulic oil inspection/Inspección del aceite hidráulico
Oil level check: Check the oil level in the tank before starting each day to ensure that it is within the range marked on the level gauge (usually 2/3 of the height of the tank). If it is insufficient, add the same type of hydraulic oil in time.
Oil quality inspection: Observe the color of the oil (normally transparent or light yellow). If it is turbid, black or emulsified (white foam), it needs to be replaced immediately.
Leakage check: Check whether there is leakage or dripping in the oil pipes, joints, oil cylinders, valve blocks and other parts, and tighten or replace the seals in time.
Filter status/Estado del filtro
Check the blockage indicators of the oil suction filter, oil return filter and high-pressure filter (if any). If an alarm sounds or the replacement cycle is reached (usually every 500 hours), the filter element needs to be cleaned or replaced.
System operation monitoring/Monitoreo del funcionamiento del sistema
After starting the equipment, observe whether the hydraulic system has any abnormal noise (such as pump whistling, valve knocking), whether the movement is slow or jittery, and record any abnormal phenomena.
2. Regular maintenance (by working hours or monthly plan)
Mantenimiento regular (por horas de trabajo o plan mensual)
Hydraulic oil replacement/Reemplazo de aceite hidráulico
Cycle: Replace after the first 500 hours of use, and then every 2000 hours or once a year (depending on the working conditions).
Oil change steps:
Stop the machine to relieve pressure and drain the old oil.
Clean the inside of the fuel tank and remove iron filings and impurities.
Replace all filter elements (suction, return and high pressure filter elements).
Add new oil to the specified level, run the circulating oil at low speed after starting, and check the oil level again.
Key component maintenance/Mantenimiento de componentes clave
Hydraulic pump: Check whether the fixing bolts are loose, monitor the running noise, and if there is abnormal vibration, disassemble the pump to check the internal wear (such as the distribution plate and plunger).
Oil cylinder: Check whether there are scratches or rust on the surface of the piston rod, and apply grease after cleaning; check whether the sealing ring is aging and leaking.
Control valve group: clean the valve body surface, check whether the solenoid valve coil is loose, and manually test the flexibility of the valve core.
Pipes and connectors/Tubos y conectores
Check whether the high-pressure hose has bulges or cracks, and whether the hard pipe has rust or deformation. Aging pipelines need to be replaced in advance.
Use a torque wrench to tighten the fittings, avoiding over-tightening that may damage the threads.
3. Seasonal maintenance/Mantenimiento estacional
Winter (low temperature environment):/Invierno (ambiente de baja temperatura):
Replace low-freezing hydraulic oil (such as L-HV32) to avoid high oil viscosity causing the pump to suck empty.
Preheat the oil temperature to above 15°C before starting (you can install a heater or run at low speed and no load).
Summer (high temperature environment):/Verano (ambiente de alta temperatura):
Check whether the radiator (air cooling/water cooling) is blocked and clean the heat sink.
Monitor the oil temperature and make sure it does not exceed 60℃. If it is too high, stop the machine and check the cooling system.
4. Fault warning and handling/Advertencia y manejo de fallas
Common troubleshooting/Solución de problemas comunes
Insufficient pressure: Check the relief valve setting, pump wear, filter element blockage or internal leakage (such as valve core sticking, cylinder seal failure).
Slow movement: may be due to high oil viscosity, reduced pump efficiency or system leakage.
Abnormal noise or vibration: Check for air intake in the oil suction line, damage to the pump bearing, or hydraulic shock (install an accumulator to buffer).
Emergency measures/Medidas de emergencia
In case of sudden oil leakage, stop the machine immediately to release the pressure and turn off the hydraulic power source.
Spare key components (such as filters and seals) should be kept in stock at all times to shorten maintenance time.
5. Safety and operating regulations/Normas de seguridad y funcionamiento
Maintaining safety/Mantener la seguridad
The pressure must be released before maintenance (operate the multi-way valve to the middle position to release the accumulator pressure).
It is prohibited to operate the solenoid valve or disassemble the high-pressure pipeline while it is energized.
Operation training/Entrenamiento operativo
Avoid long-term full-load operation and prohibit running equipment with “illness”.
The operator needs to be familiar with the hydraulic system schematics and be able to identify basic fault codes.
6. Record keeping and professional maintenance
Mantenimiento de registros y mantenimiento profesional
Maintenance records: Record each maintenance time, replaced parts and oil model in detail, and establish equipment health records.
Professional maintenance: The manufacturer or a professional team will conduct a comprehensive inspection every year, using diagnostic instruments to analyze the system pressure and flow curves.
Registros de mantenimiento: registre cada hora de mantenimiento, piezas reemplazadas y modelo de aceite en detalle y establezca registros del estado del equipo.
Mantenimiento profesional: El fabricante o un equipo profesional realizará una inspección exhaustiva cada año, utilizando instrumentos de diagnóstico para analizar las curvas de presión y flujo del sistema.
Through systematic maintenance, the failure rate of the hydraulic system can be significantly reduced, and the operating efficiency and safety of the reach stacker can be improved. Regular training of maintenance personnel and strict implementation of standardized processes are key.
A través de un mantenimiento sistemático, se puede reducir significativamente la tasa de fallas del sistema hidráulico y se puede mejorar la eficiencia operativa y la seguridad del apilador retráctil. La capacitación periódica del personal de mantenimiento y la implementación estricta de procedimientos estandarizados son clave.
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Post time: May-18-2025