MZG / GRAB ACCESSORIES

MOTOR GRAB

&

GRAB ACCESSORIES

SUSPENSION

UPPER TRAVERSE

LOWER TRAVERSEWITH OIL

TANK

SCOOPS

KICK PLATES

CYLINDER

STEERINGARM

GENERAL ARRANGEMENT GRAB

ELECTRICALCONNECTION

BRACKETSFOR TENSION

RELEASE

SCOOP PIVOT POINT

CAP NUT

PISTON ROD

HYDRAULICUNIT

(INSIDE)

LOWER STEERINGARM PIN

UPPER STEERINGARM PIN

ELECTRICMOTOR

CONTROLBLOCK

HYDRAULIC PUMP

TANK LINE

B LINE(OPENING)

A LINE(CLOSING)

HYDRAULIC ARRANGEMENT

HYDRAULIC UNIT

RV3 / CHECK VALVE WITH PRESSURE RELEASE (SUCTION VALVE)

P2 LINE(OPENING)

LS LINE(LOAD SENSING CONTROL / POWER DEMAND & VOLUME SUPPLY )

P1 LINE(CLOSING)

RV4 / CHECK VALVE WITH PRESSURE RELEASE (SUCTION VALVE)

LEAK OILPUMP HOUSING

LEAK OILPUMP BEARING

E - MOTOR(TYPE: 200-L)CONTROL BLOCK

(TYPE: NG30 E)

HYDRAULIK PUMP(TYPE: V30D-095-BKN-LLS)

PRESSURE RELEASE VALVEDV1

PRESSURE RELEASE VALVEDV2

B-Line(opening)

A-Lineclosing

T-LINE(TANK)

CONTROL BLOCK

Lift ControlSV2

Lift ControlSV1

HYDRAULIC PUMP

LS REGULATOR(FOR POWER DEMAND & VOLUME SUPPLY )

RV4 / CHECK VALVE WITH PRESSURE RELEASE (SUCTION VALVE)

L REGULATOR(FOR POWER DEMAND)

MAX VOLUME CONTROL(FULL STROKE)

MIN VOLUME CONTROL(ZERO STROKE)

STROCKE IS CONTROLLED BY THE LS REGULATOR

CAP NUT

PISTON ROD

GUIDE BUSH

TUBE

BUSH

LIFTING CYLINDER

MessuringPiont

Grease Nippel

A-Lineclosing

Piston

B-Lineopening

Cap Nut locking

LIFTING CYLINDER

KANTSEAL

ROD GUIDE RING

SCRAPERRIMSEAL

(light)

ROD GUIDE RINGSTEPSEAL

(dark)

GUIDE BUSH

PISTON GUIDE RING

PISTON GUIDE RING O-RING

GLYD RING

PISTON

FILTERAssembled in the Reversing line

Filtration rate 10 μ(minimum particle size 0,01mm)

OIL DIPSTICK and SEALINGOil level check in closed grab position. Oil level betweenMinimum and MaximumHYDRAULIC – OIL - TANK

OIL ISO-viscosity VG 46 HLP 46 corrosp. DIN51524/2

OIL TABLE ATACHED!

Brand of used oil: FUCHS RENOLIN B15 VG 46Fuchs Ident No: A2480190

FILTER & DIPSTICK

HYDRAULIC DIAGRAM

Operation mode: Reversing operation (S3)Variable delivery pump (Power regulator plus Load-Sensing regulator)Control block NG 30-E-LS

GENERAL

Operation mode S3, also called reversing operation, means that the electric motor and thus also the pump are operated in clockwise rotary sense as well as anticlockwise rotary sense, thus influencing the opening and closing motion of the grab.This grab is equipped with a power-regulated axial piston pump with additional load-sensing regulator (LS).The power regulator of the pump is adjusted to the maximum drive motor power output, i.e. depending on the drive power, the output of the pump is continuously adjusted to the power output of the drive motor as the operating pressure continues to increase after having exceeded a certain level. Thus, the hydraulic power, the product of pump output and pressure, remains constant.The load-sensing regulator, for short LS regulator, only serves as „min./max.-regulator“. Via the LS regulator the pump recognizes that:1. A consumer has been connected and the pump must switch to max. output,2. A system pressure preset at the pressure relief valve (DV1 or DV2) has been reached and the pump has to change down towards "zero-lift regulation", so that only as much hydraulic fluid is displaced as is necessary for compensating the gap leakage in pump and system.

Legend:A = line (grab closing)B = line (grab opening)D1, D2 = nozzleDV1, DV2 = pressure relief valveF = filterKS = piston sideKSS = piston rod sideLS = Load-Sensing line (LS-line)M = electric motorMA = pressure gauge connection, cylinder pressure (closing)MB = pressure gauge connection, cylinder pressure (opening)MLS = pressure gauge connection for LS-signal pressureMP1 = pressure gauge connection, closing pressureMP2 = pressure gauge connection, opening pressureP = hydraulic pumpP1, P2 = pressure line pump / control blockR1, R2 = nonreturn valveRV3, RV4 = nonreturn valve (check valve) with pressure relief valveSt1, St2 = control lineSV1, SV2 = stop valve with lift stopT = tank connectionWV = shuttle valve

General: Pressure line

Signal line

None return valve

None return valve / pressure controlled

None return valve / pressure controlled

with lift stop

Lift Stop (Adjustable)

Pressure release valve

Pressure release valve / adjustable

Ø1Nozzle

connection

As soon as the drive motor M is started, the hydraulic pump P sucks hydraulic oil via nonreturn valve RV4 out of the tank and pumps it into pressure line P1.

The oil flows via nonreturn valve R1 and line A into the piston rod sides KSS of the lifting cylinders. At the same time, the pilot controlled stop valve SV2 is opened via control line St2. The oil returning from the piston sides KS can now return to the tank via SV2, tank line T and filter F.

The maximum pressure in pipe A is controlled by the pressure relief valve DV1. As soon as the maximum pressure (preset at DV1) is reached, the output of pump P is reduced (see paragraph "Power regulation").When the drive motor is switched off, the nonreturn valves R1, R2 and the pilot controlled stop valves SV1, SV2 avoid automatic opening or closing of the grab.

Closing procedure:

CLOSING

SV2OPEN

R1OPEN

R2CLOSED

SV1CLOSED

LS Signal(Pump at

Maximum Lift)

RV3CLOSED

Grab Closed

SV2OPEN

R1OPEN

R2CLOSED

SV1Closed

LS Signal(Pump at zero lift)

DV1Open

(230bar)

GRAB CLOSED

R1CLOSED

CONDITION

SV2CLOSED

SV1CLOSED

CONDITION

PRESSURE STAYS IN THECYLINDER!

&MOTOR STOPPED

R2CLOSED

Opening procedure:

As soon as the drive motor M is started, the hydraulic pump P sucks hydraulic oil via nonreturn valve RV3 out of the tank and pumps it into pressure line P2.

The oil flows via the nonreturn valve R2 and pipe B into the piston sides KS of the lifting cylinders. On extension of the cylinders, the oil flowing off the piston rod sides KSS via pipe A then flows via the stop valve SV1 opened by the control line St1 to pipe B and additionally fills piston side KS (quick-motion mode). During the opening procedure no oil returns to the tank.

The maximum pressure in pipe B is controlled by the pressure relief valve DV2. As soon as the maximum pressure (preset at DV2) is reached, the output of the pump P is reduced (see under „General“).

SV2CLOSED

SV1OPENED

QUICK RUNACTION

OPENING

R1CLOSED

R2OPEN

LS Signal(Pump at

Maximum Lift)

RV4CLOSED

DV2Open

(120bar)

LS Signal(Pump at zero lift)

SV2CLOSED

CONDITION SV1OPENED

CONDITION

Grab OPEN

R1CLOSED

R2OPEN

GRAB OPEN &MOTOR STOPPED

SV1CLOSED

CONDITION

R1CLOSED

CONDITION

PRESSURESTAYS IN THECYLINDER!

R2CLOSED

SV2CLOSED

Rattling of the shells:In order to avoid a rattling of the shells during the closing procedure, the pilot-controlled nonreturn valve SV should be slightly throttled (setting by means of adjusting screws,).

A T T E N T I O N ! SV must not be closed too much to avoid extreme heating of the oil.

A T T E N T I O N ! During load-lifting it must be observed that the grab is closed until the lifted load is suspended safely in the scoops when lifting the grab.Pressure to be set at DV1 and DV2.(see data sheet for pressure values)

DV1 = closingDV2 = opening

Security valves RV3; RV4:The complete hydraulic system is protected by the security valves (RV3; RV4). The security valves must always be set approx. 30 - 50 bar higher than the system pressure valves (DV1, DV2). Normally they are set at 280 bar ex works and should never be adjusted.

Pressure gauge connections:The system pressures can be checked at the provided measuring points (pressure values see data sheet).

Closing: on cylinder, on ring line, MP1, MAOpening: on cylinder, on ring line, MP2, MB

Pump pressure: MPLS-pressure: MLS

GENERAL ARRANGEMENT GRAB ACCESSORIES

CABLE DRUM

GUIDE SHEAVES

DEFLECTION SHEAVE

CABLE FOR GRAB

POWER SUPPLY

ELECTRICAL INSTALLATION

(INSIDE)

ROPE STABILISATION

DRUM

CONTROL PANEL

Timing relayK01, K02, K03,

K04, K05Motor-protection circuit-breaker Q2, Q3

(DRUM)

Motor-protection circuit-breaker Q1

(Grab)

TRANSFORMER

FUSE

Motor-protection circuit-breaker:Q1 = for the Motor of the GrabQ2 = for the motor of the cable drumQ3 = for the motor of the rope drum

Timing relay

K01 = 1.5 sec. – protection against direct reversing

K02 = 1.5 sec. – protection against direct reversing

K03 = 23 sec. – time of motor operation during closing

K04 = 11 sec. – time of operation of the motor during opening

K05 = 15 sec. – theoretical closing time

Application:The Cable drum have to tight the cable independent of the position of the Grab during cargo operation.

Performance:The pulling force of the Cable drum measured directly at the cable is 900N ( 90 kg ) if the cable is completely drummed on the body and 1200N ( 120 kg ) if the cable is completely drummed off the bodyMax Motor output on 440 V 60 Hz: 2,8 KWMax current consumption of the Motor: 6,3 A

CABLE DRUM

Operating and maintenance instructions for cable reeling drumtype KFM 8/600/11 Bo

The cable drum consists of the following components:a) - electric motorb) - turbo couplingc) - spur geard) - drum bodye) - brake

b

a

c

e

d

OperationDuring grab operation, the driving motor 27 is always running with rated speed, while the turbo coupling 17 is entirely absorbing the slip which is necessary for cable drums. Turbo coupling and electric motor are designed for 100 percent continuous running.

ATTENTION! Do not synchronize with hoisting and lowering the grab.

The driving shaft of the turbo coupling is constantly running at the motor's rated speed. The driven shaft of the turbo coupling transmits the torque to the drum body via spur gear and this in the same rotation sense as the cable is winding up. When the cable is unwinding, the driven shaft of the turbo coupling is running in the rotation sense opposite to the driving motor and the driving shaft of the turbo coupling.

ROPE DRUM

Operating and maintenance instructions for rope reeling drum type KSM 2 BoThe rope drum consists of the following components:

a) - electric motorb) - turbo couplingc) - spur geard) - drum bodye) - brake

b

a

c

e

d

OperationDuring grab operation, the driving motor 07 is always running with rated speed, while the turbo coupling 05 is entirely absorbing the slip which is necessary for rope drums. Turbo coupling and electric motor are designed for 100 percent continuous running.

ATTENTION! Do not synchronize with hoisting and lowering the grab.

The driving shaft of the turbo coupling is constantly running at the motor's rated speed. The driven shaft of the turbo coupling transmits the torque to the drum body via spur gear and this in the same rotation sense as the cable is winding up. When the cable is unwinding, the driven shaft of the turbo coupling is running in the rotation sense opposite to the driving motor and the driving shaft of the turbo coupling.

a) Connecting the rope to be wound upIntroduce the untwisted rope through the interior of the drum body and fasten it by strain-relief clamp. Before winding up the rope, adding 2 safety windings.

ATTENTION! Do not wind up rope when brake is not released.

b) Operation of brakeThe solenoid-operated spring pressure brake prevents the rope from winding off when motor is turned off. The brake is to be synchronized with the motor. When starting the motor, the springloaded disk is lifted from the brake disk and the brake is released. When cutting off the circuit, the springloaded disk is pressed towards the brake disk and the brake is put on.

ATTENTION! The braking is to be adjusted in a way that no rope can wind off by itself, if the equipment is out of operation. On the other hand, the adjustment shall allow the drum body to be turned manually, if the motor is turned off.

TURBO COUPLING

Turbo coupling 274

filler screwfuse screw

SHAFT SEALS

SHEAVES

Deflection Sheave(Rope)

Guide Sheave(Cable)

Deflection Sheave(Cable)

SWITCH

1. Combination switchThis switch is used for the semi-automatic grab control system, but can also be used for manual control. There is a green indicator lamp on the cover and a selector switch with the following three positions (manual, zero and semi-automatic). The switch lever automatically returns to the neutral position. Control is possible only when switch lever is pushed down. When the green indicator lamp lights up crane hoist motor can be started.The steel sheet case has IP 55 protection.

1

2

2. Foot-operated switchThis switch can be installed parallel to the combination switch for semi-automatic control.Protection: IP 54

3. Reversing switchFor separate reeling up and reeling off the electric cable by the motor cable drum and/or the stabilizing rope by the motor stabilizing drum. The plastic housing has IP 54 protection. The switch has a neutral position.Cable lead-in above and below, 2 x Pg16.

CABLE SOCKET

PUTTING INTO OPERATION

GRAB

GREASING

LOWER STEERING ARMS

UPPER STEERING ARMS

SCOOP PIVOT POINTS

CYLINDER BEARINGS

SUSPENSION

CHECKING

PIN LOCKING PIN LOCKING

PIN LOCKING

HOSES

PIN LOCKING

OILLEVAL

FILTER

ELECTRICALCONNECTION

CONNECTINGCABLE STEEL

WIRE

TESTING

FUNCTION

CYCLE TIMES

OPENING PRESSURE

CLOSINGPRESSURE

Dependent on cargos densityreduce number of kickplates

Filling volume [m³]

Piled density [t/m³]

adm. GRAB lifting capacity

/ SWL [t]

V1 = 12,5 1,2 15,0

V2 = 10,0 1,5 15,0

V3 = 8,5 1,75 14,87

V4 = 7,0 2,1 14,7

V5 = 5,3 2,8 14,84

MZGL 12500Deadweight:9.065 kgRequired crane lifting capacity: 24.000 kg

MZGL 14000Deadweight: 9320 kgRequired vrane lifting capacity: 27.920 kg

Filling volume [m³]

Piled density [t/m³]

adm. GRAB lifting capacity /

SWL [t]

V1 = 14,0 1,3 18,2

V2 = 12,0 1,55 18,6

V3 = 10,0 1,85 18,5

V4 = 8,5 2,15 18,3

V5 = 6,5 2,8 18,2

ADJUSTING

Filling volume [m³]

Piled density [t/m³]

adm. lifting capacity / SWL

[t]

V1 = 13,0 1,15 14,95

V2 = 11,0 1,35 14,85

V3 = 9,0 1,65 14,85

V4 = 7,0 2,1 14,85

V5 = 5,5 2,95 14,75

Product: MZGL 13000Deadweight: 8.995 kgRequired crane lifting capacity: 23.945 kg

Cargo; piled density (γ)and angle of repose (α)

grainγ = 0,6 – 0,8 α =30°

coalγ = 0,8 – 1,0 α =40°

aggregatesγ = 1,3 – 1,6 α =30°

bauxiteγ = 1,1 – 1,6 α =30°

fertilizerγ = 1,0 – 1,4 α =30°

iron oreγ = 1,8 – 2,6 α =35°

PUTTING INTO OPERATION

CHECKINGSWITCHES MUST BE

0FF (0 Position)SWITCHES MUST BE

0FF (0 Position)SWITCHES MUST BE

0FF (0 Position)

Motor-protection circuit-breaker

Q1, Q2, Q3

FUSE(Green = O.K.)

Setting of Timing relayK01, K02, K03, K04, K05

TESTINGSWITCH ONSWITCH ONSWITCH ON

RELEASE CABLE & ROPE CAREFULY! RELEASE CABLE & ROPE CAREFULY!

PREPARATION

CHECK!

CONNECTINGCABLE STEEL

WIRE

OPERATION SWITCHES MUST BE ALWAYS ON

PULLING DIRECTION!

SWITCHES MUST BE ALWAYS ON

PULLING DIRECTION!

SWITCHES ON MANUAL =

ONLY MANUAL OPERATION

(WITHOUT FOOD PEDAL)

SWITCHES ON SEMI AUTOMATIK =

SWITCH & FOOD PEDAL OPERATIONGRAB OPERATES

ATOMATICALY

STEPS DURING OPERATION

GRAB

1. To close the grab perfectly,lift up the grab slightly during closing

2. For a maximum filling ratethe grab should be set down

horizontally

3. Heavy impacts should be avoided,In order to prevent dameges

DAILY GREASING

LOWER STEERING ARMS

UPPER STEERING ARMS

SCOOP PIVOT POINTS

CYLINDER BEARINGS

SUSPENSION

The bushes are made of LYTEX which is made of composite material. This Material has a good hard shaped surface, high loadbearing capacity and is ideal to be used in salt water. A disadvantage is that dust is working abrasive. Grease in order to clean the bush.This will extend the lifetime and reduces wear.

DAILY CHECKING

PIN LOCKING PIN LOCKING

PIN LOCKING

HOSES

PIN LOCKING

OILLEVAL

ELECTRICALCONNECTION

STEPS TO PUT OUT OF OPERATION

GRAB

carry out a trial run without bulk material !

check working condition of the Hydraulik System and

fill out the test sheet for double check. carry out necessary repairs

and order Spare Parts.

Clean the Grab completely with aHIGH PRESSURE CLEANER

TESTING

FUNCTION

CYCLE TIMES

OPENING PRESSURE

CLOSINGPRESSURE

CHECKING

PIN LOCKING PIN LOCKING

PIN LOCKING

HOSES

PIN LOCKING

OILLEVAL

FILTER

ELECTRICALCONNECTION

GREASING

LOWER STEERING ARMS

UPPER STEERING ARMS

SCOOP PIVOT POINTS

CYLINDER BEARINGS

SUSPENSION

STORING

TURNBUCKELS

IN CLOSED POSITION ONLY

(Piston Rods inside)

grab has to be placedin closed and vertical position

the plastik hood ist to be replaced

grease must be applied to allLubrication points

Grab has to be cleanedfrom cargo and cargo dust

cover the plug in connectorby means of plastic cap

the grab condition has to be checked / carry out a test run

if necessary order spare parts for next port

SUMMARY

STEPS TO PUT OUT OF OPERATION

SECURE THE CABLE AND WIRE

CHECK!

CHECKINGSWITCHES MUST BE

0FF (0 Position)SWITCHES MUST BE

0FF (0 Position)SWITCHES MUST BE

0FF (0 Position)

Motor-protection circuit-breaker

Q1, Q2, Q3 OFF

FUSE(Green = O.K.)

Setting of Timing relayK01, K02, K03, K04, K05

MAINTENANCE SCHEDULE&

REPORT

DAILY( DURING OPERATION )

AFTER THE FIRST 50 WORKING HOURS

EVERY MONTH AFTER 1000 WORKING HOURS

lubricate all bearingscheck hoses, fittings and cylinder for tightness

check and changethe filter elements ( Use only Original Filter elements supplied by SMAG)

lubricate all bearings

check grab working conditionscheck degree of oil cleanness carried out by the laboratory of the oil supplier change the oil check and change the filter elements

EVERY YEAR AFTER 4 YEARS

check grab working conditionscheck degree of oil cleanness carried out by the laboratory of the oil supplier change the oil check and change the filter elements

CLASS SURVEY!!change all hoses, fittings open and clean the hydraulic system clean the tank check grab working conditionscheck degree of oil cleanness carried out by the laboratory of the oil supplier change the oil check and change the filter elements

GRAB

NO. ITEM INTERVAL

DURATION OF GRABS USE

WORKING HOURS

TOTAL WORKING HOURS

1 LUBRICATION OF ALL BEARINGS DAILY

2 INSPECTION OF HOSES, FITTINGS DURING CARGO

3 INSPECTION OF SUSPENSION OPERATION

4 INSPECTION OF CABLE AND PLUG

5 INSPECTION OF PISTON ROD AND SEALING

6 REPAIRS DURING OPERATION

7 CLEANING GRAB AND ITS INNER HOOD AREA AFTER COMPLETION

8 LUBRICATION OF ALL BEARINGS OF EACH CARGO

9 INSPECTION OF HOSES, FITTINGS OPERATION

10 INSPECTION OF SUSPENSION

11 INSPECTION OF CABLE AND PLUG

12 INSPECTION OF PISTON ROD AND SEALING

13 CHECK OF OIL LEVEL

14 INSPECTION OF FILTER ELEMENTS

15CHECK GRABS WORKING CONDITION

OPENING / CLOSING PRESSURE

16CHECK GRAB ACCESSORIES

CABLE, ROPE, DRUMS AND SHEAVES

17 REPAIR REQUIRED & PART

18REPAIR SUCCESSFUL DONE

Y / N

19 ISSUE & SIGN GRABS MONITORING REPORT

23 FILTER CHANGE / DATE EVERY YEAR

24 OIL CHANGE / DATE

25TANK AND SYSTEM CLEANING

HOSES CHANGE AFTER 4 YEARS

RESPONSIBLE FOR INSPECTION

GRAB

Solenoid-operated spring pressure brakeThe brake should be checked for its proper function in regular intervals. When the brake lining should be changed please make certain, that they are absolutely grease and oil free. There should be no grooves in the brake area.

Three-phase current motorOnly after about 5000 working hours the motor bearings will have to be refilled with suitable high temperature grease (drop point at between 170° and 190° celsiusapproximately). Before closing the terminal box cover shall be slightly spread with grease. Please observe the instruction plate inside the cover.

Turbo couplingThe hydraulic oil of the turbo coupling is to be lubricated after 5000 working hours. In the factory the turbo coupling has been filled with hydraulic oil.Shell Tellus C 22 ISO-VG-22 22 cSt / 40 °C; 4,3 cSt / 100 °C. Only fill in hydraulic oil with the same viscosity.Please observe the enclosed technical description of the turbo coupling.

ACCESSORIES

Spur gearThe oil of the spur gear is be renewed, according to the working hours, every 12 - 18 months. It is recommended to drain the oil by taking off the lower locking screwimmediately after having stopped the drum. If possible, refill the gear with same type of oil.

Sort of oil: synthetic oil brand - Mobil Glygoyle 30When changing the oil, beware of dust particles which might penetrate into the gear.

ACCESSORIES

OIL & GREASE RECOMMENDATION

Table: Oil recommendation - Hydraulic fluids

For normal operation, a hydraulic fluid of ISO-viscosity VG 46 shall be used. For summer or winter operation, a hydraulic fluid of ISO-viscosity VG 68 or FB 32 is to be used according to the ambient temperature.

Degree of oil cleanness:

According to the ISO- code 4406, to the maximum contamination level of the oil. (Laser - particulate-emission measurement ISO- code 11171, ISO MTD)

The particulate-emission limit for the grabs oil is:

ISO 17 – 16 – 13

Specific Water Content:

Max 300 PPM or 0.3 %

Winter Summer

ISO viscosity VG 32 VG 46 VG 68

Standard HVLP 32acc. to DIN 51524/3 HV

HLP 46acc. to DIN51524/2

HLP 68acc. to DIN51524/2

Range of oil temperature -20°C to +80°C -5°C to +80°C 0°C to +80°C

Ambient temperature < -5°C to -20°C -5°C to +30°C > +30°C

ARAL Vitam HF 32 Vitam GF 46 Vitam GF 68

BP ENERGOL SHF 32 ENERGOL HLP 46 ENERGOL HLP 68

CASTROL HYSPIN AWH 32 HYSPIN AWS 46 HYSPIN AWS 68

ESSO UNIVIS J 32 NUTO H 46 NUTO H 68

MOBIL DTE 13 DTE 25 DTE 26

SHELL Tellus Oel T 32 Tellus Oel 46 Tellus Oel 68

TEXACO Rando Oil HD AZ-32 Rando Oil HD B-46 Rando Oil HD C-68

Table: OIL recommendation

GRAB

Adhesive grease

DIN 51513 BC

Lithium saponified grease lubricantDIN 51825/2 KTA-L2k

AGIP FIN 332/F Longlime Grease 2

ARAL Sinit FZL 3 Aralub HL 2

AVIA Avilub BB 21 Avilub special grease WL

BP Energol WRL Energrease LS 2

Calypsol Eculit ST Calypsol H 442

Castrol Grippa 60 S Spheerol AP 2 LZV-EPSpheerol E PL 2

DEA Trixolit 2X Glissando 20

DEFROL Defrol BC Defrol Fett KTA-L2k

ESSO Surett Fluid 4K Beacon 2

FINA Cabline 1060 Marson LU

Fuchs Duotac F 310 L Renolit MP

Mobil Oil Mobiltac D Mobilux 2

Shell Cardium Fluid C Alvania R 2Alvania G 2

Table: Grease recommendation

GRAB

GRAB ACCESSORIES

Filling by manufacturer

Cable drum 4.5 l oil Mobil Glygoyle 30Rope drum 1.8 l oil Aral Degol GS 220Turbo coupling 2.0 l oil Shell Morlina 22 anciently Tellus C22

Gear unit

Brand synthetic oil ISO VG 220 for ambient temperatures of - 30°C to + 130°C.

Aral Degol GS 220BP Energol SG XP 220Esso Circulation oil 220Mobil Glygoyle 30Shell Tivela oil WBTexaco Rando oil HD CZ 68 X

Other brands with the same quality level can be also used.

Turbo coupling

The quality of the oil is of particular importance. Therefore, for oil change we advise to employ theabove mentioned oil exclusively.

GUIDE FOR TROUBLE SHOOTING

Important:Please check the grab condition intensive and carry out small repairs previously.

The Basic requirement of this instruction is that the problem was known by the SMAG ServiceDepartment in the past. So please help us to update these instructions continuously. Please contact and inform the SMAG Peiner Grab service department if you getting knowledge abouproblems which are not mentioned in this instruction.

Thank you very much in advance for your kind cooperation.

01. Guide to Examination

This instruction will show how to find the reason for a problemAnd how to solve this problem.

For further instructions fill it out and send it to SMAG PEINER GRABS SERVICE DEPARTMENT

Problem:Oil leakage at guide nutof lifting cylinder. Damaged or worn our

Sealings

Problem: Oil leakage at guide nut of lifting cylinder

Cause Action

Sealing rings worn out due to normal wear during operation.

•Disassemble piston rod and guide nut. Check piston rod and cylinder tube for damages and scratches. Change piston and guide sealing rings.

1/B. Disassemble guide nut and change sealing of guide nut.

Info under: PART 02 MZG_CHANGING SEALINGS OF HYDRAULIK CYLINDERS -MZG_HOW TO DISASSEMBLE THE PISTON ROD

Sealing rings damaged by damaged piston rod •Disassemble piston rod and guide nut. Change piston rod and sealing from piston and guide nut. Check cylinder tube for scratches.

1/B Disassemble piston rod and guide nut.2/B Slip out damaged areas of piston rod and change sealing rings of guide nut.

Info under: PART 02MZG_CHANGING SEALINGS OF HYDRAULIK CYLINDERS -MZG_HOW TO DISASSEMBLE THE PISTON ROD

Problem:Grab opens and close itself after Grab closed or open and motor stopped

a) Internal leakage in liftingcylinder

(Piston Seal)

b) Internal leakage in the controlblock (SV1 / R1)

Problem: Grab opens or close itself Cause Action

Sealing rings of lifting cylinder are worn out due to normal wear during operation.

Sealing rings damaged by dirt in the hydraulic system.

1. Disassemble lifting cylinder2. Change sealing rings from piston and guide nut3. Check cylinder tube for damages and scratches 4. Change the oil and filter5. Clean the tank and hydraulic hoses

Info under: PART 02MZG_CHANGING SEALINGS OF HYDRAULIK

CYLINDERS -MZG_HOW TO DISASSEMBLE THE PISTON ROD

None return valves SV and / or RV are worn out due to normal wear during operation

None return valves SV and / or RV are worn out due to dirt in the hydraulic system

1. Disassemble control block2. Clean valves and drillingsOR 1. Disassemble control block2. Change valves SV and / or RV3. Clean all drillings and other valves4. Change the oil and filter5. Clean the tank and hydraulic hoses

PART 02MZG_CHANGING SEALINGS OF HYDRAULIK

CYLINDERS -MZG_HOW TO DISASSEMBLE THE PISTON RODMZG_S3_CONTROL BLOCK_NG30E

Problem:Grab is not working with enough force

a) DV1 / DV2 are not working correcty

b) Huge internal leakage in liftingcylinder

c) None return valves damaged orworn out

d) Hose or hose-connectionsinside the take are loosen or

broken

e) Check valves RV 3 or and RV 4 damaged or worn out

f) Pump is damaged or worn out

g) Pump regulators are damaged or worn out

Problem: Grab is not working with enough force. Cause Action

Huge Internal leakage in lifting cylinder due to damaged sealing rings as mentioned previously.

Check for internal leakage as mentioned under 140

Info under : PART 01MZG_HOW TO CHECK INTERNAL LEAKAGE

Check valves RV 3 or / and RV 4 damaged and / or worn out due to dirt in the hydraulic system or due to oldness of the grab.

Disassemble pump and check valve seats.Change check valves.

Info under: PART 03MZG_S3_CONTROL BLOCK_NG30E

Hydraulic pump is damaged and / or worn out due to oldness of the grab or due to dirt in the hydraulic system or it was damaged due to overheating the hydraulic system.

Check pump working parameters. Try to adjust the pressure to max and also to minimum to ensure that the DV valves are working correctly.Change pump if necessary.

Info under: PART 01 /03MZG_Test SheetMZG_HYDRAULIC PUMP

Problem: Grab is not working with enough force. Cause Action

Dv1 and / or DV2 are not working correctly due to dirt in the valve housing or DV valves are worn out due to oldness of Grab.

Check if valves are working correctly. Try to adjust the pressure.Change valves if necessary.

Info under: PART 03MZG_S3_CONTROL BLOCK_NG30E

Hose or hose connections inside the tank are loosen or broken due to vibrations during normal operation or oldness of hoses and / or over pressure. Or Hydraulic system was overheated

Disassemble hydraulic unit. Check hoses and connections. If necessary change hoses and connections.

Info under: PART 03 MZG_HYDRAULIC PUMP_2 -MZG_HYDRAULIC PUMP_3

Pump regulators damaged and / or worn out due to dirt in the hydraulic system or they are worn out due to normal wear or hydraulic system was overheated

Check pump working parameter especially the rated current if the pump is moving. Change pump if necessary.

Info under: PART 01MZG_Test Sheet

None return valves SV blocked due to dirt in the valve housing

Disassemble valvesCheck valve seats Clean valves if necessary change valves.

Info under: PART 03MZG_S3_CONTROL BLOCK_NG30E

1.

Problem:Grab is not closing completely with cargo

c) Scoop bushes are worn out

d) Steering arm bushes are worn out

b) Working pressure is too low

a) Operator is not lifting the grab up

e) Grain size of the cargo is too big

f) Scoop lips are worn out

Problem: Grab is not closing completely with cargo.

Cause Action

Bushes worn out due to normal wear and tear during operation

Check if scoops and / or steering arms are moving in their connection. (gab between pin and bush)Disassemble Grab Change bushes

Info under: PART 02MZG_HOW TO DISASSEMBLE THE SCOOPS

Scoop lips worn out due to normal wear and tear during operation.

Close the grab without cargoCheck the gab between the lipsRenew scoop lips by hard surfacingOr by cutting worn out part and welding new parts at the lips.OrAssemble side and bottom sealing lips.

Info under: PART 02MZG_HOW TO DISASSEMBLE THE SCOOPS MZG_ REPAIR OF LIPS

Pilled density of cargo is too big Review operation conditions of the grab

Info under: PART 01 MZG_PRESENTATION

Working pressure is too low Check grabs working pressureAdjust the pressure

HOW TO ADJUST THE PRESSURE

GENERAL:

The Peiner Grab Type MOTOR DUAL SCOOP GRAB ( MZG ) is equipped with 7 measuring points.Which are as follows:

MP1

MAMLS MB

Cylinder

MP2

CLOSING PRESSURE:

LOAD SENSING (LS) PRESSURE

MA - SYSTEM pressure –OPENING (QUICK RUN MOTION) & CLOSING

Pressure in the hydraulic lines.Due to physical rules, the pressure measured here is approx. 30 to 40 bar higher than the pressure actually produced by the pump.Pressure can be checked if the Motor is stopped.

•MP1 – PUMP working Pressure•Pressure produced by the pump, limited by the pressure •release valve DV1 for"closing".•The pressure finally has to be checked and adjusted by •measuring at this point.•The pressure can only be checked if the pump is running.

MLS – Pressure for the PUMP regulatorPressure in the load-sensing signal line to the load-sensing regulator of the pump. The pressure measured here is approx. 20 to 30 bar higher than the pressure actually produced by the pump.•The pressure can only be checked if the pump is running

OPENING PRESSURE

LOAD SENSING (LS) PRESSURE

OPENING PRESSUREwith QUICK RUN MOTION

•MP2 – PUMP working Pressure•Pressure produced by the pump, limited by the pressure •release valve DV2 for“opening".•The pressure finally has to be checked and adjusted by •measuring at this point.•The pressure can only be checked if the pump is running.

MB - SYSTEM pressure – OPENINGPressure in the hydraulic lines.Due to physical rules, the pressure measured here is approx. 30 to 40 bar higher than the pressure actually produced by the pump.Pressure can be checked if the Motor is stopped.

MLS – Pressure for the PUMP regulatorPressure in the load-sensing signal line to the load-sensing regulator of the pump. The pressure measured here is approx. 20 to 30 bar higher than the pressure actually produced by the pump.•The pressure can only be checked if the pump is running

PRESSURE PROFILE - MZG

020406080

100120140160180200220240260280

1 6 11 16 21 26 31 36 41TIME

PRES

SUR

E (b

ar)

Pressure MP1Pressure MLSPressure MP2Pressure MA

CLOSING MOTOR STOP

OPENING MOTOR STOP

CLOSING

0

50

100

150

200

250

300

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97 101

105

109

113

117

121

Pressure MP1

Pressure MLS

Pressure MP2

Pressure MA

NOTE! The Working Pressure has to be checked and adjusted at operatingtemperature of the Hydraulic system with has to be approx between 30 and 60 °C.Due to technical reasons the measured pressure as well as the rated current of the grab motor at a “cold” system is higher then the declared and factory-adjusted pressure.

Carry out a test run with the Grab to heat up the system to the operation temperature before you make any new pressure settings.

All working pressure settings are done by measuring the pressure at the measuring point:

MP1 for closing pressureMP2 for opening pressure

The adjusted working pressure is declared at the type label which is assembled at the upper traverse.And in the MACHINERY DATA CARD which you can find in the DOKUMENTATION of our Grab.

CLOSING PressureChecked and adjusted viamessuring point MP1

OPENING PressureChecked and adjusted viamessuring point MP2

DV1

DV2

Pressure adjustment is done at the control block:

Closing pressure: Pressure release valve DV1Opening pressure: Pressure release valve DV2

OPENING PRESSURE

CLOSING PRESSURE

FRONT

LEFT SIDE

MO

TOR

SID

E

•The adjustment itself is to be done as follows:

1. Connect a pressure gauge to measuring point MP1 resp. MP2.

2. Check the existing pressure (operation into closing resp. opening direction).

3. Lower pressure = Loosen the counter nut at DV1 resp. DV2 and turn the adjustment screw to the left (anti-clockwise).

4. Then check the pressure and secure the adjustment screw.

5. Raise pressure = Loosen the counter nut at DV1 resp. DV2 and turn the adjustment screw to the right (clockwise).

6. Then check the pressure and secure the adjustment screw.

NOTE! NEW Control Blocks are not Factory adjusted.Before you put them into operation you have to loosen the counter nut at DV1 resp. DV2 and turn the adjustment screw to the left (anti-clockwise) 4 times around.

HOW TO CHECK INTERNAL LEAKAGE

Repair operations planning and scheduling:

Following tools, equipment and staff have to be available:

1 Crane for grab operation1 Crane operator1 Crane operating instructor2 skilled workers

1 set of SMAG Peiner Grab toolsNo.:23009997

Problem:Grab opens and close itself after Grab closed or open and motor stopped

a) Internal leakage in liftingcylinder

(Piston Seal)

b) Internal leakage in the controlblock (SV1 / R1)

GRAB CLOSED &

R1CLOSED

CONDITION

SV1CLOSED

CONDITION

PRESSURE STAYS IN THECYLINDER!

Repair description:

Note: This test can only be carried out in closed grab position due to theQUICK RUN ACTION of the grab both lines A and B are under pressure if grab is open.

Repair sequence:

1. hang the grab in the crane

2. connect the cable

3. close the grab slightly

4. connect the manometer at measuring point MA

5. disconnect the Hydraulic hoses which are assembled at the cylinder bottom

6. collect oil which is temporally coming out of the connection

5.

7. by using the grabs hydraulic close the grab.

8. check if oil is leaking outof the bolted joint of the cylinder

9. if not check if pressure rise down at the manometer ⇒ internal leakage must be inside the control block.

10. if oil is coming out of the cylinder ⇒ sealing rings or tube must be damaged or worn out.

8.

If oil is coming out of the cylinder ⇒sealing rings or tube must be damaged or worn out.⇒Have a look at instruction no.: PART 02HOW TO DISASSEMBLE THE PISTON ROD PART 03CHANGING SEALINGS OF HYDRAULIK CYLINDERS

If the cylinder is o.k and pressure rise down at the manometer ⇒ internal leakage must be inside the control block.

Have a look at instruction no.: PART 03CONTROL BLOCK_NG30