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Preventive Maintenance

How to improve spreader reliability
by

BROMMA SERVICES

on 2 March 2015

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Transcript of Preventive Maintenance

Preventive Maintenance Strategy

As a terminal Operator how can we improve the current situation
Not all is bad, there must be something we can do!
What if we do nothing?
If we continue to work on corrective problems only our productivity will be affected. The spreader may be the cheapest part of the crane, but without it the crane cannot operate.
Idea 1
Lets tackle one key area at a time!
Idea 2
There's a couple more things that we can do.
Key Systems that need Maintenance
The spreader is a tool that needs to be properly maintained in order to be effective.
Structural/Mechanical Inspections & Adjustments
Some keys areas need to be inspected regularly
Always Use Quality Spare Parts
How do we increase our reliability
Having a spreader that performs well is the manager's dream. however in order to achived this we need to have several things in order, these are:
Conclusion
Preventive Maintenance
Spreader maintenance must rely on running hours.
Pre Operation and post operation inspections are recommended
Adjustments and inspections must be done based on manufacturer's recommendations
Strategy
Begin with a handful of spreaders, do a complete survey to determine what components need replacement and/or adjustment
compile parts required and procure them
Summarize your recommendation
Based on your findings you can have these spreader(s) run as a model unit.
Customer is responsible for following all maintenance intervals.
Inspection, Surveys, Spreader Training, Training are key Services Bromma provides to customers
Structural Inspections / Mechanical
Twistlock Adjustments
Chain Adjustments
Spreader Structure (Gable Ends, Tower, Telescopic Beams, mainframe)
Bolt Torques, brake openings
Electrical inspections
Electrical Cabinets need to be opened and connections to be tightened, water ingress must be prevented
Sensors (inductive/infrarred/sonars) must be kept clean and connections must be kept free from moisture
Periodical current measurings are required to determine how the motor(s) are working with respect to the hydraulic pumps, does it need to be adjusted?
Can Open Devices, peripherals need to be kept clean and moisture proof
Use Quality Spare parts
Hydraulic Maintenance
Inspections of hydraulic components is required
Hydraulic fittings must be tightenend
Hydraulic oil and filters must be replaced periodically
Hydraulic Hoses have a service life, they should be replaced after approximately 5 yrs.
Use quality spare parts
Twistlocks
To be inspected every 300 hrs / Grease at least every 300 hrs.
Twistlock Separation Between TWL and Guieblock should be between 1-2 mm
Spreader Structure
Telescopic Beams need to be inspected for cracks and deformation, should be greased weekly.
If there is a tower it should be greased and lifiting pin structure inspected
Pre Operation/Post Operation recommended
Aligning arms need to be kept tight and if deformed must be repaired.
Chains/Brakes/Bolts
Telescopic and tower Chains must be kept at a tension of +/-25-35mm
Chain assemblies and shock absorbers have a service life and need to be replaced
On MHC Spreaders, Telescopic Motors need to be checked once/yr and the tower motor brake needs to be checked every 3 months

lack of adjustments and inspections
Spreader Cracks and lack of brake adjustments
Preventive measures
Keep a good work spreader, follow maintenance procedures for adjustments
Troubleshooting skills
Make sure you are proficient enough with troubleshooting both electrically and mechanically (with relay/scs2/scs3)
Periodical Training to further your knowledge
Bromma Offers Training Courses on site during startups and also Courses in our Factory in IPOH
Good Maintenance Practices
Spreader Maintenance must be periodical based on running hours and not on availability of the equipment.
Preventive maintenance must include mechanical, electrical, hydraulic, structural options.
Spreader manual includes maintenance schedules
Having a good stock of spare parts is paramount
Common problems encountered
Stock of parts is usually limited.
Personnel can only get access to the spreader between shifts.
Instead of preventive maintenance we usually rely on corrective practices

Read the Manuals and inspect the spreader throughly
Follow maintenance schedule
Based on Jim Harvey's speech structures
Bent Twistlocks & Burnt electrical components
Bad Operations and simply bad maintenance practices
Make sure electrical components are protected from moisture
Read the Manual
manuals wont bite! you can open them
If we follow proper maintenance practices the reliability (MMBF) of the spreader will increase
don't let technology beat you
keep a god stock of parts
Full transcript