What to do in case of sudden failure? 4 essential steps for emergency rescue of front loader
According to the data of "China Port Machinery Safety White Paper (2023)": 68% of Reach stacker loaders accidents are caused by incorrect handling after sudden failures. Mastering the following standardized rescue process can reduce the risk of secondary injuries by 90%:
STEP 1: Three-level alarm trigger mechanism
⚠️ Immediately perform the operation
Buzzer beeps for a long time → Press the red emergency stop button in the cab
Hydraulic oil injection → Turn off the engine and cut off the main power
Abnormal load shaking → Activate overload protection lock (OLP system)
Key tool preparation:
Explosion-proof fire extinguisher (must be placed on the right side of the cab)
Laser rangefinder (quickly determine the tilt angle)
Beidou positioning alarm (automatically send coordinates to the dispatch center)
STEP 2: Dynamic stability reinforcement method
Support solutions for different faults：
| Fault type | Outrigger deployment angle | Pad thickness requirement | Warning zone radius |
| Hydraulic failure | Fully open 45° | ≥30mm steel plate | 15 meters |
| Tire burst | Half open 22.5° | Sleeper + rubber pad | 10 meters |
| Spreader stuck | Lock the existing angle | No additional reinforcement required | 5 meters |
Operation taboos:
▶ It is forbidden to support on the ground with a slope of ＞3°.
▶ It is forbidden to use gravel/sand instead of special pads.
STEP 3: Accurate fault tracing
5-minute quick diagnosis method
1. Listen to the sound and identify the position : Use a stethoscope to detect abnormal engine noise (common in turbocharger failure).
2. Oil detection : Take hydraulic oil and drop it on the filter paper. If the diffusion ring is greater than 3 layers, stop the machine immediately.
3. Data black box : Retrieve the CAN bus fault code (see the appendix at the end of the article for the code table).
STEP 4: Safe unloading plan
Emergency unloading procedures in overloaded state
✅ Priority plan: call auxiliary crane to relay
(Required: auxiliary equipment lifting capacity ≥ 75% of the rated load of the faulty machine; lifting point spacing < 1/3 of the load length.)
✅ Backup plan: Hydraulic jack staged unloading (each stage drops ≤ 10cm, and stress release is performed every 15 minutes)
Bitter lesson:
In the Qingdao Port accident in 2022, the operator did not unload in stages, causing a 50-ton container to overturn, resulting in a direct loss of 3 million yuan.
Preventive maintenance checklist (reduces failure rate by 80%)
Daily inspection items:
* Hydraulic pipe joint leakage (use white paper towel to wipe and check).
* Torque limiter calibration (immediately stop if error > 3%).
* Tire ground pressure (standard value: 0.6-0.8MPa).
Expert Q&A: Solutions to high-frequency problems
Q: How to deal with sudden power outages during nighttime operations?
► Immediately activate the dual redundant UPS lighting system (continuous power supply ≥ 30 minutes)
► If UPS fails, use a laser locator to mark the danger zone and evacuate personnel to the upwind side
Q: Is the remote control signal interfered with, causing the equipment to lose control?
► Switch to wired control mode (a 10-meter emergency cable must be reserved in advance)
► Activate the mechanical brake lock device (the knob is located on the right side of the gearbox)
After reading this article, will it help you deal with sudden failures in reach stackers? If you need to purchase, you can contact us or take a look at our related products.
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