[Port] Equipment and Preventive Maintenance

The basic, medium, and difficult functions for each piece of equipment, with a strong focus on safety and practical man skills (manual operations, coordination, and human-machine interaction).

1. Ship-to-Shore (STS) Gantry Crane

Level	Functions	Safety Focus	Man Skills Example
Basic	- Startup/shutdown checks - Single-container lift/lower (pre-set path) - Emergency stop usage	- Verify spreader lock engagement - Monitor wind speed limits (<10 m/s)	- Hand signals for basic moves - Radio communication with ground crew
Medium	- Twin-lift (2x 20ft containers) - Adjusting for vessel movement (tidal comp) - Blind-spot lifts (with signaler)	- Dynamic load balancing - Anti-collision system awareness	- Coordinating with multiple spotters - Quick reaction to load swing
Difficult	- Operating in high winds (>15 m/s) - Precision landing on unstable chassis - Troubleshooting spreader mid-lift	- Emergency sway control - Manual override of automated systems	- Judging load swing physics - Calibrating trolley/hoist simultaneously

2. Rubber Tyre Gantry (RTG) Crane

Level	Functions	Safety Focus	Man Skills Example
Basic	- Stacking 1-high in marked lanes - Manual steering in open areas	- Check tyre pressure/trajectory - Confirm twist-lock engagement	- Simple joystick control - Spotting container alignment
Medium	- Auto-grading (weight/height sorting) - Operating in narrow lanes (<5m clearance)	- Correcting tyre slippage (wet surfaces) - Avoiding "container kissing"	- Manual GPS override - Adjusting trolley speed for stability
Difficult	- Blind stacking (5+ high) - Recovering misaligned containers	- Load sway damping - Structural stress awareness	- "Feeling" container contact via controls - Rapid container re-centering

3. Reach Stacker

Level	Functions	Safety Focus	Man Skills Example
Basic	- Picking up/lowering containers on flat ground - Traveling with boom lowered	- Load center of gravity checks - Horn usage in congested areas	- Basic spreader control (20ft/40ft switch)
Medium	- Double-stack handling - Loading uneven chassis trucks	- Stabilizing tilted containers - Working near pedestrians	- Judging boom extension limits - "Feathering" hydraulic controls
Difficult	- High-reach (3+ stacks) - Operating on slopes (>5% incline)	- Preventing tip-over - Emergency load drop procedures	- Simultaneous boom/steering adjustments

4. Empty Container Handler

Level	Functions	Safety Focus	Man Skills Example
Basic	- Moving empties in designated zones - Stacking 2-high	- Twist-lock visual checks - Avoiding "dropped corners"	- Smooth hydraulic control
Medium	- Handling damaged containers - Rail car loading/unloading	- Load shift prevention - Working near overhead obstacles	- Precision placement (1-inch tolerance)
Difficult	- Multi-container shuffling (yard reorg) - Mixed 20ft/40ft operations	- Avoiding domino-effect collapses	- Mental mapping of container weights/positions

5. Tractor Head

Level	Functions	Safety Focus	Man Skills Example
Basic	- Coupling/uncoupling chassis - Straight-line reversing	- Fifth wheel lock verification - Air brake tests	- Basic trailer alignment
Medium	- Blind-side reversing (with spotter) - Sharp turns with 40ft chassis	- Jackknife prevention - Mirror adjustment techniques	- Judging pivot points
Difficult	- Tight dock backing (<30cm clearance) - Emergency braking with load	- Trailer swing control - ABS system reliance	- "Instinctive" steering corrections

6. Chassis

Level	Functions	Safety Focus	Man Skills Example
Basic	- Pre-trip checks (twist locks, brakes) - Connecting to tractor	- Visual inspection for cracks - Landing gear stability	- Manual twist-lock engagement
Medium	- Adjusting for overweight containers - Manual alignment corrections	- Load distribution awareness	- Using pry bars for minor adjustments
Difficult	- Stabilizing a "kicked" container	- Emergency securing (chains/straps)	- Assessing load shift risks

7. Forklift

Level	Functions	Safety Focus	Man Skills Example
Basic	- Pallet handling (even surfaces) - Stacking 2-high	- Load capacity awareness - Fork spacing checks	- Smooth acceleration/braking
Medium	- Irregular loads (drums, pipes) - Dock/ramp operation	- Center of gravity adjustments - Overhead clearance checks	- "Float" control (hydraulics)
Difficult	- High-reach stacking (4m+) - Recovering tipping loads	- Lateral stability management - No-sudden-movements rule	- Counterbalance "seat feel" adjustments

Safety & Man Skills Summary

• Basic: Rule-following, simple coordination, pre-use checks.

• Medium: Risk assessment, precision control, teamwork.

• Difficult: Crisis management, advanced physics intuition, system overrides.

Need a training priority checklist or incident response protocols for these

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Training Priority Checklist & Incident Response Matrix in a clear, easy-to-read format:

Equipment Safety & Training Matrix

Equipment	Training Priority (Basic → Advanced)	Critical Incident Response Protocols
1. STS Gantry Crane	Basic: Pre-op checks, E-stop drills, hand signals Medium: Twin-lift balancing, blind-spot coordination Advanced: Sway control in storms, twist-lock failure recovery	Load Swing: Engage anti-sway, reduce speed, lower load Twist-Lock Failure: Secure secondary locks, ground load immediately
2. RTG Crane	Basic: Tyre/steering checks, auto-stack basics Medium: Narrow-lane ops, wet-surface recovery Advanced: Blind stacking (5+ high), GPS failure override	Tyre Blowout: Gradual stop, deploy outriggers Misaligned Stack: Micro-adjust or lower entire stack
3. Reach Stacker	Basic: Load COG, boom limits Medium: Double-stacking, slope ops Advanced: Tilt recovery, emergency load drop	Near Tip-Over: Lower load, steer into slope Hydraulic Leak: Shut engine, secure load manually
4. Empty Handler	Basic: Empty moves, 2-high stacking Medium: Damaged container handling Advanced: Multi-container shuffling	Dropped Corner: Isolate area, inspect spreader Rail Car Jam: Stop, chock wheels, realign
5. Tractor Head	Basic: Coupling/uncoupling, straight reversing Medium: Blind-side reversing, sharp turns Advanced: Tight dock backing (<30cm)	Jackknife: Straighten trailer, avoid over-correction Brake Failure: Downshift, use parking brake gradually
6. Chassis	Basic: Pre-trip (twist locks, brakes) Medium: Overweight adjustments Advanced: "Kicked" container stabilization	Twist-Lock Jam: Use pry bar, never force hydraulics Load Shift: Stop, secure with chains/straps
7. Forklift	Basic: Pallet handling, 2-high stacks Medium: Irregular loads, ramp ops Advanced: High-reach (4m+), tip recovery	Tipping Load: Tilt forks forward, abandon if unstable Battery Fire: Class D extinguisher, evacuate if toxic fumes

Symbols for Quick Reference

⚠️ Immediate Danger: Stop all operations.🛑 Emergency Protocol: Isolate area, alert team.🔧 Mechanical Fix: Requires technician intervention.📞 Contact Supervisor: Mandatory reporting.

How to Use This Matrix

1. Training: Progress left-to-right (Basic → Advanced).

2. Incidents: Follow right-column protocols verbatim.

3. Maintenance: Combine with PM checklist (previous matrix).

Preventive Maintenance (PM)

Preventive Maintenance (PM) Matrix for the listed equipment, covering daily, weekly, monthly, quarterly, and annual tasks. This ensures safety, reliability, and compliance with operational standards.

Preventive Maintenance Matrix

Equipment	Daily Checks	Weekly Checks	Monthly Checks	Quarterly Checks	Annual Checks
1. Ship-to-Shore (STS) Gantry Crane	- Hydraulic leaks - Wire rope wear - Brake function - Emergency stops	- Spreader twist locks - Hoist motor condition - Rail alignment	- Gearbox oil levels - Electrical panel inspection - Anti-collision sensors	- Structural weld inspection - Load cell calibration - Slewing bearing lubrication	- Full NDT (Non-Destructive Testing) of critical welds - Complete electrical system audit
2. Rubber Tyre Gantry (RTG) Crane	- Tyre pressure - Hydraulic hoses - Spreaders & twist locks - Engine oil level	- Steering system - Generator function - Safety alarms	- Drive motor brushes - Boom hydraulic cylinders - GPS/auto-stack alignment	- Wheel alignment - Gearbox oil change - Structural bolts torque check	- Full engine overhaul (if diesel) - Crane load test
3. Reach Stacker	- Engine oil & coolant - Hydraulic leaks - Fork/spreader condition	- Brake system - Steering linkage - Load chain inspection	- Boom pivot points lubrication - Transmission fluid check	- Hydraulic filter replacement - Tire wear & alignment	- Structural crack inspection - Full hydraulic system flush
4. Empty Container Handler	- Hydraulic leaks - Fork/spreader function - Tyre condition	- Brake performance - Lift cylinder inspection	- Engine air filter - Electrical connections	- Chassis lubrication - Hydraulic oil analysis	- Load test with overload simulation
5. Tractor Head	- Engine oil & coolant - Brake air pressure - Fifth wheel coupling	- Suspension system - Exhaust leaks - Lights & signals	- Transmission fluid - Turbocharger inspection	- Differential oil change - Fuel injector cleaning	- Full engine diagnostics - Frame crack inspection
6. Chassis	- Twist lock function - Brake lights - Tyre pressure & damage	- Axle alignment - Suspension wear	- Grease kingpin & landing gear - Structural cracks	- Brake chamber inspection - Wheel bearing repack	- Full structural integrity check
7. Forklift	- Hydraulic fluid level - Forks (cracks/bends) - Battery charge (if electric)	- Brake function - Steering play - Mast chain lubrication	- Engine spark plugs (if LPG) - Tire wear	- Hydraulic hose inspection - Valve adjustments	- Load-bearing component NDT - Full electrical test

Preventive Maintenance Principles:

1. Safety-First – Always check brakes, emergency stops, and structural integrity.

2. Lubrication – Pivot points, bearings, and gears must be greased regularly.

3. Fluid Management – Oil, coolant, and hydraulic fluids must be clean and at proper levels.

4. Wear & Tear – Inspect high-stress components (wire ropes, forks, tyres, brakes).

5. Calibration – Sensors, load cells, and GPS systems need periodic adjustment.

   
   

Note checklist format or predictive maintenance (IoT/telematics) integration for these

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The equipment, focusing on safety and man skills (manual operations, coordination, and human-machine interaction):

1. Ship-to-Shore (STS) Gantry Crane

• Basic:

  • Safe start-up/shutdown procedures.

  • Basic load lifting/lowering (pre-set paths).

  • Recognizing container spreader alignment.

  • Emergency stop usage.

• Medium:

  • Coordinating with signalers for blind-spot lifts.

  • Handling wind speed limits (dynamic stability).

  • Twin-lift operations (2x 20ft containers).

  • Adjusting for vessel movement (tidal compensation).

• Difficult:

  • Operating in high winds (>15 m/s) safely.

  • Precision landing on unstable chassis.

  • Troubleshooting spreader twist-lock failures mid-lift.

  • Managing simultaneous trolley/hoist/gantry movements.

2. Rubber Tyre Gantry (RTG) Crane

• Basic:

  • Stacking containers 1-high in marked lanes.

  • Manual steering in open areas.

  • Basic anti-collision system awareness.

• Medium:

  • "Auto-grading" (stacking containers by weight/height).

  • Operating in narrow lane widths (<5m clearance).

  • Recovering from rubber tyre slippage on wet surfaces.

• Difficult:

  • Blind stacking (containers 5+ high with no direct line of sight).

  • Correcting container sway during high-speed trolley moves.

  • Manual intervention during GPS/auto-stack system failures.

3. Reach Stacker

• Basic:

  • Picking up/lowering containers on flat ground.

  • Safe travel with loaded boom (low position).

  • Basic spreader controls (20ft/40ft switching).

• Medium:

  • Handling double-stacked containers.

  • Loading/unloading trucks with uneven chassis.

  • Working in congested yards with pedestrians.

• Difficult:

  • "High reach" operations (3+ container stacks).

  • Recovering tilted containers without destabilizing.

  • Operating on slopes (>5% incline) with load.

4. Empty Container Handler

• Basic:

  • Moving empty containers in designated zones.

  • Stacking 2-high with twist-lock checks.

• Medium:

  • Handling damaged/defective empties (e.g., bent corners).

  • Loading/unloading from rail cars.

• Difficult:

  • Simultaneous multi-container shuffling (yard reorganization).

  • Working with mixed 20ft/40ft empties in tight spaces.

5. Tractor Head

• Basic:

  • Coupling/uncoupling chassis (5th wheel checks).

  • Safe reversing in straight lines.

• Medium:

  • Blind-side reversing with spotter guidance.

  • Navigating sharp turns with 40ft chassis.

• Difficult:

  • Backing into tight loading bays (<30cm clearance).

  • Emergency braking with loaded chassis.

6. Chassis

• Basic:

  • Pre-trip checks (twist locks, brakes, lights).

  • Connecting/disconnecting from tractor heads.

• Medium:

  • Adjusting for overweight/overlength containers.

  • Manual correction of container misalignment.

• Difficult:

  • Stabilizing a "kicked" container (post-transport shift).

7. Forklift

• Basic:

  • Handling pallets on even surfaces.

  • Stacking loads 2-high in warehouses.

• Medium:

  • Handling irregular loads (e.g., drums, pipes).

  • Working on ramps/docks with load.

• Difficult:

  • "High-reach" stacking (4+ meters) in windy conditions.

  • Recovering tipping loads without dropping.

Safety Focus for All Equipment:

• Basic: PPE usage, horn/light signals, load charts.

• Medium: Risk assessment for blind spots, weather.

• Difficult: Emergency response (e.g., load drops, equipment failure).