How to maintain the four major vehicles of a coke oven?

It can’t be explained in just one sentence; take a look at the book \"Coke Oven Equipment Maintenance Technology\" compiled by Wuye, which provides detailed information on the four types of cranes

Check here to see if there’s what you’re looking for. http://bbs.hcbbs.com/thread-174724-1-1.html

Four requirements for the maintenance of mechanical equipment: 1. Equipment maintenance: Caring for equipment through general methods such as wiping, cleaning, lubrication, and adjustment in order to maintain and preserve its performance and technical condition is known as equipment maintenance. There are four main requirements for equipment maintenance: (1) Cleaning – Keep the inside and outside of the equipment clean; ensure that there is no oil residue on any sliding surfaces, screws, racks, gearboxes, or oil holes. There should be no leaks of oil or air in any part of the equipment, and debris, trash, and dirt around the equipment must be removed ； (2) Neatness: Tools, accessories, and workpieces (products) should be placed neatly, and pipes and wires should be organized in an orderly manner ； (3) Good lubrication: Oil is added or changed on time; there is no interruption in oil supply, no dry friction, normal oil pressure, a clear oil level indicator, unobstructed oil passages, oil of satisfactory quality, and clean oil guns, oil cups, and oil seals ； (4) Safety: Comply with safety operating procedures, avoid overloading the equipment, ensure that the equipment’s safety protection devices are complete and reliable, and promptly eliminate any unsafe factors. The maintenance tasks for equipment generally include routine maintenance, periodic maintenance, regular inspections, and accuracy checks. The maintenance of the equipment’s lubrication and cooling systems is also an important part of its upkeep. The daily maintenance of equipment is the fundamental task in equipment upkeep, and it must be carried out in a systematic and standardized manner. For the regular maintenance of equipment, work quotas and material consumption quotas should be established, and assessments should be carried out based on these quotas. Regular equipment maintenance should be included as part of the assessment criteria under the workshop’s responsibility system. Regular equipment inspection is a planned preventive inspection. In addition to human senses, certain inspection tools and instruments are also used for this purpose, and the inspection is carried out in accordance with a regular inspection checklist. Regular equipment inspection is also known as periodic inspection. Precision checks should also be carried out on mechanical equipment to determine the actual level of precision of the equipment. Equipment maintenance should be carried out in accordance with the maintenance procedures. Equipment maintenance procedures outline the requirements and guidelines for the daily maintenance of equipment. Adhering to these procedures helps extend the equipment’s service life and ensures a safe and comfortable working environment. Its main contents should include: (1) the operational requirements for the equipment to be neat, clean, sturdy, properly lubricated, resistant to corrosion, and safe; the operational methods; the tools and materials to be used; the standards to be met; and the precautions to take ； (2) Locations, methods, and standards for routine inspection and maintenance as well as periodic inspections ； (3) The contents and methods for checking and evaluating the extent to which operators maintain the equipment. II. The three-level maintenance system for equipment: The three-level maintenance system was developed in China in the mid-1960s, based on the experience of implementing the planned preventive maintenance system from the former Soviet Union, and through continuous improvement and development. It reflects a shift in the focus of equipment maintenance management in China from repair to maintenance, as well as progress in this field and a clearer emphasis on preventive maintenance strategies. The three-level maintenance system includes: daily maintenance of the equipment, level 1 maintenance, and level 2 maintenance. The three-level maintenance system is a mandatory maintenance regime that focuses on equipment care and repair, with the operator playing a key role in it. The three-level maintenance system is an effective approach to equipment maintenance that relies on the workforce, fully leverages their enthusiasm, implements collective management and repair, and combines specialized efforts with those of the staff, thereby ensuring proper maintenance of the equipment. (1) Daily maintenance of equipment: The daily maintenance of equipment typically includes daily tasks and weekly tasks, also known as routine daily maintenance and routine weekly maintenance. 1. Daily maintenance is carried out by the equipment operators during their shifts, with careful attention to the four tasks before starting work, the five things to be mindful of during work, and the four tasks after finishing work. (1) Four tasks before starting work: digest pattern data and check the shift handover records. Wipe the equipment and lubricate it as specified. Check whether the handle position and manual operation parts are correct and flexible, and whether the safety devices are reliable. During low-speed operation, check whether the transmission is functioning properly, as well as whether lubrication and cooling are working smoothly. (2) Five points of attention in the class: pay attention to the operating sounds, the temperature and pressure of the equipment, the liquid level, the electrical, hydraulic, and pneumatic systems, the instrument signals, and whether the safety devices are functioning properly. (3) Four things after class: Turn off the switches and set all levers to the zero position. Remove iron filings and dirt, clean the oil from the guide surfaces and sliding surfaces of the equipment, and apply oil. Clean the work area and organize attachments and tools. Fill out the shift handover record and the console log, and complete the shift handover procedures. 2. Weekly maintenance: Weekly maintenance is carried out by the equipment operators at the end of each week. The maintenance time required is 2 hours for regular equipment, and 4 hours for precision, large-scale, and special equipment. (1) Appearance: Wipe clean the equipment guides, all transmission parts, and exposed areas, and clean the work area. Achieve a clean interior and exterior without any dead corners or rust, with a tidy surrounding environment. (2) Transmission operation: Check the technical condition of all components, tighten any loose parts, and adjust the clearance gaps. Check the interlocks and safety devices. Achieve normal transmission sound, as well as safety and reliability. (3) Hydraulic lubrication: Clean the oil lines, dust seals, and oil filters; add oil to or replace the oil in the tank. Inspect the hydraulic system to ensure the oil is clean, the oil passages are unobstructed, and there are no leaks or abrasions. (4) Electrical system: Wipe the surfaces of the motors and flexible hoses, and check the insulation and grounding to ensure they are intact, clean, and reliable. (II) Level 1 maintenance: Level 1 maintenance is carried out primarily by operators, with the assistance of maintenance workers. It involves systematically disassembling and inspecting certain parts of the equipment as planned, cleaning the specified areas, clearing oil passages and pipes, replacing or cleaning oil lines, felts, and filters, adjusting the clearance between various components of the equipment, and tightening all parts of it. The time required for level 1 maintenance is 4–8 hours. After this maintenance is completed, records should be kept, indicating any defects that have not been resolved, and the workshop mechanic shall organize an inspection. The scope of protection should cover all equipment in use by the enterprise, with strict enforcement applied to key equipment. The main purpose of the first maintenance is to reduce equipment wear and tear, eliminate potential hazards, extend the equipment’s service life, and ensure that the equipment is in good condition to meet the production demands until the next maintenance period. (III) Secondary maintenance: Secondary maintenance is carried out primarily by maintenance workers, with the assistance of operators. Secondary maintenance is included in the equipment’s maintenance schedule; it involves partial disassembly and inspection of the equipment, replacement or repair of worn parts, cleaning, oil change, and inspection and repair of the electrical components, so that the technical condition of the equipment meets all the requirements specified for an equipment in good condition. The time required for level 2 maintenance is about 7 days. After the secondary maintenance is completed, the maintenance workers should fill out a detailed inspection report, which is then checked by the workshop mechanic and the operator; the inspection form is submitted to the Equipment Power Department for archiving. The main purpose of secondary maintenance is to bring the equipment up to standard condition, improve and maintain its reliability, and extend the interval between major overhauls. To implement the \"three-level maintenance system,\" it is necessary for operators to meet the requirements of \"three goods,\" \"four skills,\" and \"four requirements\" regarding the equipment, and to abide by the \"five disciplines.\" The three-level maintenance system emphasizes the role of maintenance in equipment management and scheduled repairs, makes the requirements for operators to achieve \"three excellences\" and \"four skills\" more specific, and enhances the knowledge and skills of operators in maintaining equipment. The three-level maintenance system overcomes the relevant provisions of the original Soviet planned preventive maintenance system, improves some of the shortcomings of that system, and is more practical. In the implementation of the three-level maintenance system, some practices from military weapon management were also adopted, with an emphasis on collective management and repair. The three-level maintenance system has achieved good results and yielded valuable experience in Chinese enterprises. Through its implementation, the integrity rate of enterprise equipment has been effectively improved, the incidence of equipment failures has been reduced, the cycle time for major equipment repairs has been extended, and the costs associated with such repairs have been lowered, resulting in favorable technical and economic outcomes. III. Requirements for the use and maintenance of high-precision, large-scale, and rare equipment (I) Four fixed aspects of operation (1) Designate specific personnel for use. Under the system of assigning specific personnel to specific machines, operators of precision, large-scale, and specialized equipment should be selected from those within that category who possess a strong sense of responsibility, high technical skills, and extensive practical experience, with relative stability maintained for as long as possible ； (2) Designate maintenance personnel. Companies that have a large number of precision, large-scale, and specialized equipment can, depending on their own conditions, form specialized maintenance teams for such equipment, tasked with carrying out inspections, precision adjustments, maintenance, and repairs on them ； (3) Establish operating procedures. For high-precision, large-scale, and low-volume equipment, operation procedures should be developed for each individual model, displayed clearly, and strictly followed ； (4) Standard spare parts. Based on the role of various precision, large-scale, and rare equipment in enterprise production as well as the sources of spare parts, reserve quotas are determined to ensure priority handling. (II) Requirements for the use and maintenance of precision equipment (1) The equipment must be installed strictly in accordance with the instructions ； (2) For equipment with special environmental requirements (constant temperature, constant humidity, shock protection, dust prevention), enterprises should take appropriate measures to ensure the precision and performance of such equipment. (3) During routine maintenance, it is not allowed to disassemble any components of the equipment; in case of any abnormalities, the equipment must be stopped immediately, and it is not permissible to operate it despite being faulty ； (4) Strictly follow the cutting specifications specified in the equipment manual; fine machining of parts is only permitted for their intended use. The machining allowance should be as small as possible. When machining castings, the blank surface should be pre-sandblasted or painted ； (5) A guard should be installed during non-working hours; when it is idle for long periods, it should be wiped regularly, lubricated, and run idle ； (6) Attachments and special tools shall be stored in dedicated cabinets to maintain cleanliness and prevent wear; they are not to be lent out. IV. Requirements for the Use and Maintenance of Power Equipment Power equipment is critical for enterprises; during operation, it is exposed to hazards such as high temperatures, high pressures, flammability, and toxicity. It represents key components for ensuring safe production. To guarantee a safe, continuous, and stable supply of the kinetic energy required for production, special requirements must be met regarding the use and maintenance of power equipment: (1) Operators must receive prior training and pass relevant examinations ； (2) Complete technical documentation, safety operation procedures, and operation records must be available ； (3) Operators must conduct regular inspections throughout their shift and are not allowed to leave their posts without permission ； (4) In the event of any abnormal conditions during operation, the duty personnel shall take emergency action in accordance with the operating procedures and report to their superiors promptly ； (5) Ensure that all indicating instruments and safety devices are sensitive and accurate, and calibrate them regularly. The backup equipment is complete and reliable ； (6) Power equipment must not operate when faulty; any malfunction must be resolved promptly ； (7) Conduct regular preventive tests and seasonal inspections ； (8) Regularly provide safety training to the personnel on duty, and strictly enforce the safety protection system. V. Regional maintenance of equipment: Regional maintenance of equipment is also known as the maintenance work package system. Maintenance workers are responsible for repairing equipment within a specific production area. Together with production operators, they carry out daily maintenance, routine inspections, periodic maintenance, planned repairs, and fault troubleshooting. They are also accountable for meeting various performance metrics related to the condition of the equipment and the rate of downtime due to faults in that area. The regional maintenance responsibility system is an effective approach to enhancing equipment maintenance to serve production, motivating maintenance workers, and encouraging production workers to take an active interest in equipment upkeep and repair. The main organizational form for professional equipment maintenance is regional maintenance teams. The Regional Maintenance Team is fully responsible for the maintenance and emergency repair of equipment in the production area. Its tasks include: (1) Handling the maintenance and repair of equipment within its assigned area, ensuring that targets such as the equipment integrity rate and downtime due to failures are met ； (2) Strictly implement the system of regular equipment inspections and routine area checks, and guide and supervise operators to carry out daily and periodic maintenance work ； (3) Under the guidance of the workshop mechanic, participate in comprehensive equipment inspections, accuracy checks, adjustments, and leak repairs, as well as carry out fault analysis and condition monitoring. The advantage of this equipment maintenance organization structure, namely the regional maintenance team, is its high level of mobility when carrying out emergency repairs, which allows for minimal downtime for equipment repair. Moreover, the on-duty fitters can carry out various preventive tasks and participate in scheduled repairs without being called upon for it. The zoning of equipment maintenance areas should take into account factors such as the distribution of production equipment, the condition of the equipment, technical complexity, production requirements, and the skill level of repair craftsmen. Based on the factors mentioned above, workshop equipment can be divided into several areas, or area maintenance teams can be formed according to the type of equipment. The equipment on the assembly line should have maintenance areas designated according to the line. The regional maintenance team is responsible for formulating plans for regular inspections and accuracy checks, and determining the time allocated for routine equipment inspections per shift. To ensure that these tasks do not disrupt production, scheduled inspections of the equipment should be carried out on days when the factory is closed, while routine inspections during each shift should take place during the lunch break of the production workers. VI. Measures to Improve Equipment Maintenance Levels To enhance the level of equipment maintenance, it is necessary to ensure that maintenance activities are carried out in a standardized, systematic, and institutionalized manner. Standardization means bringing maintenance procedures into unity; it is necessary to determine, based on the specific conditions of each company and in accordance with objective principles, which parts need to be cleaned, which components need to be adjusted, and which devices need to be inspected. Process standardization involves formulating various maintenance procedures based on different equipment, and carrying out maintenance in accordance with those procedures. Institutionalization means establishing different maintenance cycles and durations based on the various equipment and working conditions, and enforcing them strictly. For regular maintenance work, time quotas and material consumption quotas should be established, and performance should be evaluated based on these quotas. Equipment maintenance work should be evaluated in conjunction with the enterprise’s production and economic responsibility system. At the same time, enterprises should also mobilize staff to carry out equipment maintenance work that combines individual efforts with team collaboration, conducting self-inspections and mutual inspections, as well as thorough inspections of the equipment

Replying to floor 3: This book was published by Shanghai Jiao Tong University Press