Rear Axle Repair & Engine Inspection of Kalmar Reach Stacker RS-05 for Operational Continuity
Client
South Asia Gateway Terminals (SAGT) / Port of Colombo
Service Provider
Mermaid Solutions Pvt Ltd
Location
Colombo, Sri Lanka
Project Timeline
- January 2021 – Rear Axle & Steering System Repair
- August 2021 – Volvo Penta Engine Inspection & Overhaul Plan
Project Overview
The Kalmar DRF450 reach stacker (Equipment ID RS-05) operated by SAGT at the Port of Colombo is a critical asset for container handling. In early 2021, this machine suffered a major mechanical breakdown in its rear axle and steering system due to wear and tear from heavy-duty service. At SAGT’s request, Mermaid Solutions Pvt Ltd mobilized to perform urgent corrective maintenance, replacing and repairing the damaged components to quickly restore the reach stacker to operability and minimize terminal downtime.
Later in 2021, the reach stacker began exhibiting severe engine performance issues after extended operations. SAGT again engaged Mermaid Solutions to conduct a thorough inspection of the machine’s Volvo Penta TWD1240 VE diesel engine (Serial No: 2012007946). The inspection identified multiple problem symptoms and underlying causes, prompting a comprehensive overhaul plan to ensure the engine’s reliability and performance. All work was carried out on-site at the port with minimal disruption to ongoing operations.
January 2021 – Rear Axle & Steering System Repair
After a rear axle failure halted the reach stacker in January 2021, Mermaid Solutions undertook an on-site corrective maintenance operation to restore the machine’s running
gear and steering. The damage included a broken rear wheel hub and severe issues in the hydraulic steering mechanism (steering piston and link lever). The team of engineers and technicians disassembled the affected assemblies, replaced or rebuilt the faulty parts, and tested the system under load to confirm successful repairs.
Scope of Work:
- Removal of the damaged rear wheel hub and inspection of axle housing and bearings.
- Replacement of the broken wheel hub assembly with a new OEM-spec component, including new bearings and seals.
- Hydraulic steering system overhaul: repair and resealing of the leaking steering piston (cylinder) and replacement of the bent steering link lever.
- Lubrication of all rebuilt components and alignment of the rear axle and wheels to manufacturer specifications.
- Functional testing of steering and drive performance under operational conditions to ensure the reach stacker could safely return to service.
August 2021 – Volvo Penta Engine Inspection & Completed Repairs
By August 2021, reach stacker RS-05 showed signs of engine distress, prompting a detailed inspection of its Volvo Penta TWD1240 VE engine by Mermaid Solutions. Engineers documented several key findings indicating internal faults, and all identified issues were subsequently resolved through a full engine overhaul performed by Mermaid Solutions Pvt Ltd.
- Heavy white smoke billowing from the exhaust, especially under load.
- Abnormal engine noise (knocking and rattling) during operation.
- Excessive carbon deposits in the engine’s lubricating oil, indicating combustion blow-by.
- Noticeable oil leakage on the turbocharger compressor side (oil slippage past seals).
- Significantly reduced engine power output and performance under normal operating conditions.
Scope of Completed Repairs:
- Complete turbocharger overhaul to replace the worn labyrinth seals and restore proper boost pressure (eliminating oil leakage and white smoke issues).
- Servicing or replacing the diesel fuel injectors and recalibrating injection timing to ensure optimal fuel atomization and combustion.
- Cylinder head refurbishment (decarbonizing and rebuilding the head) and replacement of piston rings to improve cylinder compression and reduce oil blow-by.
- Thorough cleaning and pressure testing of the charge air cooler (intercooler) and engine cooling system to remove fouling and ensure efficient heat exchange.
- Opening of the engine sump to inspect and clean the sump pan and check bearing conditions for any wear or damage (bottom-end inspection).
- Adjustment of valve tappet clearances and verification of engine timing, ECU settings, and fuel pressure to factory specifications.
- Oil analysis to detect any contaminants or metal particles, guiding further maintenance actions.
Key Achievements & Outcome
- Successfully executed critical mechanical repairs on the reach stacker under urgent conditions, minimizing equipment downtime for the client’s operations.
- Restored full functionality of the Kalmar reach stacker’s rear axle and steering system, allowing a return to safe service in the container yard.
- Identified the root causes of the engine’s performance problems through expert diagnosis, avoiding unplanned engine failure and downtime.
- Provided a comprehensive engine overhaul plan to address all detected issues, enabling the client to budget and schedule necessary engine repairs confidently.
- Ensured the reach stacker’s continued reliability and extended operational life through professional maintenance, earning full satisfaction from the client.
Completion Status
Following the August 2021 engine inspection, Mermaid Solutions Pvt Ltd carried out all recommended repairs based on the documented findings. The Volvo Penta TWD1240 VE engine was fully overhauled and restored to operational condition.
Contact Details
Mermaid Solutions Pvt Ltd
No. 73, MJC Fernando Mawatha, Idama, Moratuwa, Sri Lanka
Email: info@mermaidsolutions.com
Tel: +94 11 264 5189