New 01 Mzg s3 Ng30 Service

MZG / GRAB ACCESSORIES

GRAB ACCESSORIES

MOTOR GRAB

&

GENERAL ARRANGEMENT GRAB SUSPENSION CYLINDER UPPER TRAVERSE STEERING ARM

LOWER TRAVERSE WITH OIL TANK SCOOPS

KICK PLATES

UPPER STEERING ARM PIN

CAP NUT

ELECTRICAL CONNECTION PISTON ROD

BRACKETS FOR TENSION RELEASE

HYDRAULIC UNIT (INSIDE)

SCOOP PIVOT POINT

LOWER STEERING ARM PIN

HYDRAULIC ARRANGEMENT ELECTRIC MOTOR

B LINE (OPENING)

A LINE (CLOSING) TANK LINE

CONTROL BLOCK

HYDRAULIC PUMP

HYDRAULIC UNIT E - MOTOR (TYPE: 200-L) LEAK OIL

CONTROL BLOCK (TYPE: NG30 E)

PUMP BEARING

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

LEAK OIL PUMP HOUSING

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

RV3 / CHECK VALVE WITH PRESSURE RELEASE

RV4 / CHECK VALVE WITH PRESSURE RELEASE

(SUCTION VALVE)

(SUCTION VALVE)

P2 LINE (OPENING)

P1 LINE (CLOSING)

CONTROL BLOCK

Lift Control SV1

T-LINE (TANK)

B-Line (opening) Lift Control SV2 PRESSURE RELEASE VALVE DV2 PRESSURE RELEASE VALVE DV1

A-Line closing

HYDRAULIC PUMP

LS REGULATOR (FOR POWER DEMAND & VOLUME SUPPLY ) L REGULATOR (FOR POWER DEMAND)

MAX VOLUME CONTROL (FULL STROKE)

STROCKE IS CONTROLLED BY THE LS REGULATOR

MIN VOLUME CONTROL (ZERO STROKE)

RV4 / CHECK VALVE WITH PRESSURE RELEASE (SUCTION VALVE)

LIFTING CYLINDER

CAP NUT PISTON ROD GUIDE BUSH TUBE BUSH

LIFTING CYLINDER

Cap Nut locking

A-Line closing

Messuring Piont Piston

B-Line opening

Grease Nippel

GUIDE BUSH

KANTSEAL

ROD GUIDE RING

SCRAPER

ROD GUIDE RING

RIMSEAL (light)

STEPSEAL (dark)

PISTON

PISTON GUIDE RING

PISTON GUIDE RING

O-RING

GLYD RING

FILTER & DIPSTICK FILTER Assembled in the Reversing line Filtration rate 10 μ (minimum particle size 0,01mm) OIL DIPSTICK and SEALING Oil level check in closed grab position. Oil level between Minimum and Maximum HYDRAULIC – OIL - TANK OIL ISO-viscosity VG 46 HLP 46 corrosp. DIN51524/2 OIL TABLE ATACHED! Brand of used oil: FUCHS RENOLIN B15 VG 46 Fuchs Ident No: A2480190

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 B D1, D2 DV1, DV2 F KS KSS LS M MA MB (opening) MLS MP1 MP2 P P1, P2 R1, R2 RV3, RV4 St1, St2 SV1, SV2 T WV

= line (grab closing) = line (grab opening) = nozzle = pressure relief valve = filter = piston side = piston rod side = Load-Sensing line (LS-line) = electric motor = pressure gauge connection, cylinder pressure (closing) = pressure gauge connection, cylinder pressure = pressure gauge connection for LS-signal pressure = pressure gauge connection, closing pressure = pressure gauge connection, opening pressure = hydraulic pump = pressure line pump / control block = nonreturn valve = nonreturn valve (check valve) with pressure relief valve = control line = stop valve with lift stop = tank connection = shuttle valve

General:

Pressure line Signal line None return valve

None return valve / pressure controlled

Lift Stop (Adjustable) None return valve / pressure controlled with lift stop

Pressure release valve

Pressure release valve / adjustable

Ø1

Nozzle

connection

Closing procedure: 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

SV2 OPEN

R2

SV1 CLOSED

R1 OPEN

CLOSED

LS Signal (Pump at Maximum Lift)

RV3 CLOSED

Grab Closed

SV2 OPEN

R2

SV1 Closed

R1 OPEN

CLOSED

DV1 Open (230bar)

LS Signal (Pump at zero lift)

GRAB CLOSED

& MOTOR STOPPED

SV2

CLOSED

PRESSURE STAYS IN THE CYLINDER! SV1 CLOSED CONDITION

R1

CLOSED CONDITION

R2 CLOSED

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“).

OPENING

QUICK RUN ACTION SV1

SV2 CLOSED

OPENED

R1 CLOSED R2 OPEN

LS Signal (Pump at Maximum Lift)

RV4 CLOSED

Grab OPEN

SV2 CLOSED CONDITION

SV1 OPENED CONDITION

R2 OPEN

R1 CLOSED

DV2 Open (120bar)

LS Signal (Pump at zero lift)

GRAB OPEN &

PRESSURE

MOTOR STOPPED

STAYS IN THE CYLINDER! SV1 CLOSED CONDITION

SV2 CLOSED

R1

CLOSED CONDITION

R2 CLOSED

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,). ATTENTION ! heating of the oil.

SV must not be closed too much to avoid extreme

ATTENTION ! 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 DV2

= =

closing 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, MA Opening: on cylinder, on ring line, MP2, MB Pump pressure: MP LS-pressure:

MLS

GENERAL ARRANGEMENT GRAB ACCESSORIES

CABLE FOR GRAB POWER SUPPLY

ELECTRICAL INSTALLATION (INSIDE)

DEFLECTION SHEAVE

GUIDE SHEAVES

CABLE DRUM

ROPE STABILISATION DRUM

CONTROL PANEL FUSE

TRANSFORMER Motor-protection circuit-breaker Q1 (Grab)

Motor-protection circuitbreaker Q2, Q3 (DRUM)

Timing relay K01, K02, K03, K04, K05

Motor-protection circuit-breaker: Q1 = for the Motor of the Grab Q2 = for the motor of the cable drum Q3 = 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

CABLE DRUM

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 body Max Motor output on 440 V 60 Hz: 2,8 KW Max current consumption of the Motor: 6,3 A

Operating and maintenance instructions for cable reeling drum type KFM 8/600/11 Bo The cable drum consists of the following components: a) - electric motor b) - turbo coupling c) - spur gear d) - drum body e) - brake

a d e

c

b

Operation During 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 Bo The rope drum consists of the following components: a) - electric motor b) - turbo coupling c) - spur gear d) - drum body e) - brake

a e

d b

c

Operation During 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 up Introduce 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 brake The 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 SHAFT SEALS

fuse screw

filler screw

SHEAVES

Deflection Sheave (Rope)

Guide Sheave (Cable)

Deflection Sheave (Cable)

SWITCH

1. Combination switch This 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.

2

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

3. Reversing switch For 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

GRAB

PUTTING INTO OPERATION

GREASING

UPPER STEERING ARMS

LOWER STEERING ARMS

SUSPENSION

CYLINDER BEARINGS

SCOOP PIVOT POINTS

CHECKING PIN LOCKING

HOSES

PIN LOCKING

FILTER OIL LEVAL

PIN LOCKING

PIN LOCKING

ELECTRICAL CONNECTION

CONNECTING

CABLE

STEEL WIRE

TESTING

FUNCTION

CYCLE TIMES

OPENING PRESSURE

CLOSING PRESSURE

ADJUSTING

Dependent on cargos density reduce number of kickplates MZGL 12500 Deadweight:9.065 kg Required crane lifting capacity:

Product: Deadweight:

MZGL 13000 8.995 kg

Required crane lifting capacity:

23.945 kg

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

24.000 kg

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 14000 Deadweight: 9320 kg Required 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

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

grain γ = 0,6 – 0,8 α =30°

bauxite γ = 1,1 – 1,6 α =30°

coal γ = 0,8 – 1,0 α =40°

fertilizer γ = 1,0 – 1,4 α =30°

aggregates γ = 1,3 – 1,6 α =30°

iron ore γ = 1,8 – 2,6 α =35°

PUTTING INTO OPERATION

CHECKING

SWITCHES MUST BE 0FF (0 Position)

Motor-protection circuit-breaker Q1, Q2, Q3

SWITCHES MUST BE 0FF (0 Position)

FUSE (Green = O.K.)

Setting of Timing relay K01, K02, K03, K04, K05

TESTING

SWITCH ON

SWITCH ON

RELEASE CABLE & ROPE CAREFULY!

PREPARATION

CHECK!

CONNECTING

CABLE

STEEL WIRE

OPERATION

SWITCHES MUST BE ALWAYS ON PULLING DIRECTION!

SWITCHES ON MANUAL = ONLY MANUAL OPERATION (WITHOUT FOOD PEDAL)

SWITCHES ON SEMI AUTOMATIK = SWITCH & FOOD PEDAL OPERATION GRAB OPERATES ATOMATICALY

GRAB

STEPS DURING OPERATION

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

2. For a maximum filling rate the grab should be set down horizontally

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

DAILY GREASING

UPPER STEERING ARMS

SUSPENSION

The bushes are made of LYTEX which is made of composite material. This Material has a good hard shaped surface, high load bearing 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.

CYLINDER BEARINGS

LOWER STEERING ARMS

SCOOP PIVOT POINTS

DAILY CHECKING PIN LOCKING

HOSES

PIN LOCKING

OIL LEVAL

PIN LOCKING

PIN LOCKING

ELECTRICAL CONNECTION

GRAB

STEPS TO PUT OUT OF OPERATION

Clean the Grab completely with a HIGH PRESSURE CLEANER

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.

TESTING

FUNCTION

CYCLE TIMES

OPENING PRESSURE

CLOSING PRESSURE

CHECKING PIN LOCKING

HOSES

PIN LOCKING

FILTER OIL LEVAL

PIN LOCKING

PIN LOCKING

ELECTRICAL CONNECTION

GREASING

UPPER STEERING ARMS

LOWER STEERING ARMS

SUSPENSION

CYLINDER BEARINGS

SCOOP PIVOT POINTS

STORING

IN CLOSED POSITION ONLY (Piston Rods inside)

TURNBUCKELS

SUMMARY the grab condition has to be checked / carry out a test run if necessary order spare parts for next port grab has to be placed in closed and vertical position Grab has to be cleaned from cargo and cargo dust grease must be applied to all Lubrication points

cover the plug in connector by means of plastic cap

the plastik hood ist to be replaced

STEPS TO PUT OUT OF OPERATION

CHECK!

SECURE THE CABLE AND WIRE

CHECKING

SWITCHES MUST BE 0FF (0 Position)

Motor-protection circuit-breaker Q1, Q2, Q3 OFF

SWITCHES MUST BE 0FF (0 Position)

FUSE (Green = O.K.)

Setting of Timing relay K01, K02, K03, K04, K05

MAINTENANCE SCHEDULE & REPORT

GRAB DAILY ( DURING OPERATION )

AFTER THE FIRST 50 WORKING HOURS

EVERY MONTH

AFTER 1000 WORKING HOURS

lubricate all bearings check hoses, fittings and cylinder for tightness

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

lubricate all bearings

check grab working conditions check 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 conditions check 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 conditions check 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

15

CHECK GRABS WORKING CONDITION OPENING / CLOSING PRESSURE

16

CHECK GRAB ACCESSORIES CABLE, ROPE, DRUMS AND SHEAVES

17

REPAIR REQUIRED & PART

18

REPAIR SUCCESSFUL DONE Y/N

19

ISSUE & SIGN GRABS MONITORING REPORT

23

FILTER CHANGE / DATE

24

OIL CHANGE / DATE

25

TANK AND SYSTEM CLEANING HOSES CHANGE

RESPONSIBLE FOR INSPECTION

EVERY YEAR

AFTER 4 YEARS

ACCESSORIES

Solenoid-operated spring pressure brake The 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 motor Only 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° celsius approximately). Before closing the terminal box cover shall be slightly spread with grease. Please observe the instruction plate inside the cover. Turbo coupling The 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 gear The 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 screw immediately after having stopped the drum. If possible, refill the gear with same type of oil. Sort of oil: synthetic oil brand - Mobil Glygoyle 30 When changing the oil, beware of dust particles which might penetrate into the gear.

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 %

GRAB Table: OIL recommendation Winter ISO viscosity

Summer

VG 32

VG 46

VG 68

HVLP 32 acc. to DIN 51524/3 HV

HLP 46 acc. to DIN51524/2

HLP 68 acc. 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

Vitam HF 32

Vitam GF 46

Vitam GF 68

ENERGOL SHF 32

ENERGOL HLP 46

ENERGOL HLP 68

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

Rando Oil HD AZ-32

Rando Oil HD B-46

Rando Oil HD C-68

Standard

ARAL BP

CASTROL

TEXACO

GRAB Table: Grease recommendation Adhesive grease

Lithium saponified grease lubricant DIN 51825/2 KTA-L2k

AGIP

DIN 51513 BC 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-EP Spheerol 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 2 Alvania G 2

GRAB ACCESSORIES Filling by manufacturer Cable drum Rope drum Turbo coupling

4.5 l 1.8 l 2.0 l

oil Mobil Glygoyle 30 oil Aral Degol GS 220 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 BP Esso Mobil Shell Texaco

Degol GS 220 Energol SG XP 220 Circulation oil 220 Glygoyle 30 Tivela oil WB 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 the above mentioned oil exclusively.

GUIDE FOR TROUBLE SHOOTING

01. Guide to Examination The Basic requirement of this instruction is that the problem was known by the SMAG Service Department 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 abou problems which are not mentioned in this instruction. Thank you very much in advance for your kind cooperation.

This instruction will show how to find the reason for a problem And how to solve this problem. Important: Please check the grab condition intensive and carry out small repairs previously. For further instructions fill it out and send it to SMAG PEINER GRABS SERVICE DEPARTMENT

Problem: Oil leakage at guide nut of lifting cylinder.

Damaged or worn our Sealings

Problem: Oil leakage at guide nut of lifting cylinder Sealing rings worn out due to normal wear during operation.

Cause Action

•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 02 MZG_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 lifting cylinder (Piston Seal)

b) Internal leakage in the control block (SV1 / R1)

Problem: Grab opens or close itself

Cause Action

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

1. 2. 3. 4. 5.

Sealing rings damaged by dirt in the hydraulic system.

Info under: PART 02 MZG_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

1. 2. OR 1. 2. 3. 4. 5.

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

Disassemble lifting cylinder Change sealing rings from piston and guide nut Check cylinder tube for damages and scratches Change the oil and filter Clean the tank and hydraulic hoses

Disassemble control block Clean valves and drillings Disassemble control block Change valves SV and / or RV Clean all drillings and other valves Change the oil and filter Clean the tank and hydraulic hoses

PART 02 MZG_CHANGING SEALINGS OF HYDRAULIK CYLINDERS MZG_HOW TO DISASSEMBLE THE PISTON ROD MZG_S3_CONTROL BLOCK_NG30E

Problem: Grab is not working with enough force b) Huge internal leakage in lifting cylinder c) None return valves damaged or worn out a) DV1 / DV2 are not working correcty

d) Hose or hose-connections inside 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.

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

Cause Action Check for internal leakage as mentioned under 140 Info under : PART 01 MZG_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 03 MZG_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 /03 MZG_Test Sheet MZG_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 03 MZG_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 01 MZG_Test Sheet

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

Disassemble valves Check valve seats Clean valves if necessary change valves. Info under: PART 03 MZG_S3_CONTROL BLOCK_NG30E

Problem: Grab is not closing completely with cargo a) Operator is not lifting the grab up

b) Working pressure is too low

1. d) Steering arm bushes are worn out

c) Scoop bushes are worn out

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 02 MZG_HOW TO DISASSEMBLE THE SCOOPS

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

Close the grab without cargo Check the gab between the lips Renew scoop lips by hard surfacing Or by cutting worn out part and welding new parts at the lips. Or Assemble side and bottom sealing lips. Info under: PART 02 MZG_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 pressure Adjust 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:

MP2

Cylinder

MP1

MLS

MA

MB

CLOSING PRESSURE: LOAD SENSING (LS) PRESSURE

•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.

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.

MLS – Pressure for the PUMP regulator Pressure in the load-sensing signal line to the loadsensing 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 OPENING PRESSURE with QUICK RUN MOTION LOAD SENSING (LS) PRESSURE

•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 – OPENING 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.

MLS – Pressure for the PUMP regulator Pressure in the load-sensing signal line to the loadsensing 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

280 260 240 220 200 180 160 140 120 100 80 60 40 20 0

Pressure Pressure Pressure Pressure

1

6

11

16

21

26

MP1 MLS MP2 MA

31

36

41

TIME

CLOSING

MOTOR STOP

OPENING

MOTOR STOP

CLOSING

300 250

Pressure MP1

200

Pressure MLS

150

Pressure MP2

100

Pressure MA

50 121

117

113

109

105

101

97

93

89

85

81

77

73

69

65

61

57

53

49

45

41

37

33

29

25

21

17

13

9

5

0 1

PRESSURE (bar)

PRESSURE PROFILE - MZG

NOTE! The Working Pressure has to be checked and adjusted at operating temperature 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 pressure MP2 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 Pressure Checked and adjusted via messuring point MP1

OPENING Pressure Checked and adjusted via messuring point MP2

SI LEFT DE

Pressure adjustment is done at the control block: Closing pressure: Opening pressure:

Pressure release valve DV1 Pressure release valve DV2

DV2

MOTOR SIDE

DV1 FRONT

URE CLOSING PRESS RE OPENING PRESSU

•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 operation 1 Crane operator 1 Crane operating instructor 2 skilled workers 1 set of SMAG Peiner Grab tools No.:23009997

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

Internal leakage in lifting cylinder (Piston Seal)

b) Internal leakage in the control block (SV1 / R1)

GRAB CLOSED & PRESSURE STAYS IN THE CYLINDER!

SV1 CLOSED CONDITION

R1

CLOSED CONDITION

Repair description: Note: This test can only be carried out in closed grab position due to the QUICK 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.

8.

7. by using the grabs hydraulic close the grab. 8. check if oil is leaking out of 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.

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 02 HOW TO DISASSEMBLE THE PISTON ROD PART 03 CHANGING 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 03 CONTROL BLOCK_NG30