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MZG / GRAB ACCESSORIES

MOTOR GRAB

MZG / GRAB ACCESSORIES MOTOR GRAB & GRAB ACCESSORIES

&

MZG / GRAB ACCESSORIES MOTOR GRAB & GRAB ACCESSORIES

GRAB ACCESSORIES

MZG / GRAB ACCESSORIES MOTOR GRAB & GRAB ACCESSORIES

GENERAL ARRANGEMENT GRAB

GENERAL ARRANGEMENT GRAB SUSPENSION CYLINDER UPPER TRAVERSE STEERING ARM LOWER TRAVERSE WITH OIL TANK SCOOPS
SUSPENSION CYLINDER UPPER TRAVERSE STEERING ARM LOWER TRAVERSE WITH OIL TANK SCOOPS KICK PLATES
SUSPENSION
CYLINDER
UPPER
TRAVERSE
STEERING
ARM
LOWER
TRAVERSE
WITH OIL
TANK
SCOOPS
KICK PLATES
CAP NUT PISTON ROD HYDRAULIC UNIT (INSIDE) LOWER STEERING ARM PIN
CAP NUT
PISTON ROD
HYDRAULIC
UNIT
(INSIDE)
LOWER
STEERING
ARM PIN
UPPER STEERING ARM PIN ELECTRICAL CONNECTION BRACKETS FOR TENSION RELEASE
UPPER
STEERING
ARM PIN
ELECTRICAL
CONNECTION
BRACKETS
FOR TENSION
RELEASE

SCOOP PIVOT POINT

HYDRAULIC ARRANGEMENT

HYDRAULIC ARRANGEMENT A LINE (CLOSING) B LINE (OPENING) TANK LINE ELECTRIC MOTOR CONTROL BLOCK HYDRAULIC PUMP

A LINE (CLOSING)

B LINE (OPENING) TANK LINE
B LINE
(OPENING)
TANK
LINE
ELECTRIC MOTOR
ELECTRIC
MOTOR

CONTROL

BLOCK

HYDRAULIC

PUMP

LEAK OIL PUMP BEARING LEAK OIL PUMP HOUSING
LEAK OIL
PUMP
BEARING
LEAK OIL
PUMP
HOUSING

HYDRAULIC UNIT

E - MOTOR (TYPE: 200-L)
E - MOTOR
(TYPE: 200-L)
CONTROL BLOCK (TYPE: NG30 E)
CONTROL BLOCK
(TYPE: NG30 E)
HYDRAULIK PUMP (TYPE: V30D-095-BKN-LLS)
HYDRAULIK PUMP
(TYPE: V30D-095-BKN-LLS)
(TYPE: NG30 E) HYDRAULIK PUMP (TYPE: V30D-095-BKN-LLS) LS LINE (LOAD SENSING CONTROL / POWER DEMAND &

LS LINE

(LOAD SENSING CONTROL / POWER DEMAND & VOLUME SUPPLY )

RV3 / CHECK VALVE WITH PRESSURE RELEASE

(SUCTION VALVE)

P2 LINE (OPENING) P1 LINE (CLOSING)
P2 LINE
(OPENING)
P1 LINE
(CLOSING)

RV4 / CHECK VALVE WITH PRESSURE RELEASE

(SUCTION VALVE)

RELEASE (SUCTION VALVE) P2 LINE (OPENING) P1 LINE (CLOSING) RV4 / CHECK VALVE WITH PRESSURE RELEASE

CONTROL BLOCK

Lift Control SV1 T-LINE (TANK)
Lift Control
SV1
T-LINE
(TANK)
CONTROL BLOCK Lift Control SV1 T-LINE (TANK) A-Line closing B-Line (opening) Lift Control SV2 PRESSURE RELEASE

A-Line

closing

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

HYDRAULIC PUMP

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

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
MAX VOLUME
CONTROL
(FULL STROKE)
STROCKE IS CONTROLLED
BY THE LS REGULATOR
MIN VOLUME
CONTROL
(ZERO STROKE)
BY THE LS REGULATOR MIN VOLUME CONTROL (ZERO STROKE) RV4 / CHECK VALVE WITH PRESSURE RELEASE
BY THE LS REGULATOR MIN VOLUME CONTROL (ZERO STROKE) RV4 / CHECK VALVE WITH PRESSURE RELEASE

RV4 / CHECK VALVE WITH PRESSURE RELEASE

(SUCTION VALVE)

BY THE LS REGULATOR MIN VOLUME CONTROL (ZERO STROKE) RV4 / CHECK VALVE WITH PRESSURE RELEASE

LIFTING CYLINDER

LIFTING CYLINDER CAP NUT PISTON ROD GUIDE BUSH TUBE BUSH
CAP NUT PISTON ROD GUIDE BUSH TUBE BUSH
CAP NUT
PISTON ROD
GUIDE BUSH
TUBE
BUSH

LIFTING CYLINDER

LIFTING CYLINDER Cap Nut locking A-Line closing Messuring Piont Piston Grease Nippel B-Line opening
LIFTING CYLINDER Cap Nut locking A-Line closing Messuring Piont Piston Grease Nippel B-Line opening
Cap Nut locking
Cap Nut locking
A-Line closing
A-Line
closing

Messuring

Piont

Piston

Grease Nippel

B-Line

opening

GUIDE BUSH

GUIDE BUSH RIMSEAL (light) KANTSEAL SCRAPER STEPSEAL ROD GUIDE RING (dark) ROD GUIDE RING
RIMSEAL (light)
RIMSEAL
(light)
KANTSEAL SCRAPER
KANTSEAL
SCRAPER
STEPSEAL ROD GUIDE RING (dark)
STEPSEAL
ROD GUIDE RING
(dark)

ROD GUIDE RING

PISTON

PISTON PISTON GUIDE RING O-RING PISTON GUIDE RING GLYD RING
PISTON GUIDE RING O-RING PISTON GUIDE RING GLYD RING
PISTON GUIDE RING
O-RING
PISTON GUIDE RING
GLYD RING

FILTER & DIPSTICK

FILTER & DIPSTICK FILTER Assembled in the Reversing line Filtration rate 10 μ (minimum particle size
FILTER & DIPSTICK FILTER Assembled in the Reversing line Filtration rate 10 μ (minimum particle size

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

HYDRAULIC DIAGRAM

Operation mode:

Variable delivery pump (Power regulator plus Load-Sensing regulator)

Control block NG 30-E-LS

Reversing operation (S3)

GENERAL

Control block NG 30-E-LS Reversing operation (S3) GENERAL Operation mode S3, also called revers ing operation,
Control block NG 30-E-LS Reversing operation (S3) GENERAL Operation mode S3, also called revers ing operation,

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.

so that only as much hydraulic fluid is displaced as is necessary for compensating the gap
Legend: A = line (grab closing) B D1, D2 DV1, DV2 F = filter KS

Legend:

A = line (grab closing)

B

D1, D2

DV1, DV2

F = filter

KS = piston side

KSS = piston rod side

LS = Load-Sensing line (LS-line)

M = electric motor

MA

MB = pressure gauge connection, cylinder pressure

(opening)

MLS = pressure gauge connection for LS-signal pressure

MP1 = pressure gauge connection, closing pressure

MP2 = pressure gauge connection, opening pressure

P

P1, P2

R1, R2

RV3, RV4

St1, St2

SV1, SV2

T = tank connection

WV = shuttle valve

= line (grab opening) = nozzle = pressure relief valve

= line (grab opening) = nozzle = pressure relief valve = pressure gauge connection, cylinder pressure

= pressure gauge connection, cylinder pressure (closing)

= hydraulic pump = pressure line pump / control block = nonreturn valve = nonreturn valve (check valve) with pressure relief valve = control line = stop valve with lift stop

General: Pressure line Signal line None return valve None return valve / pressure controlled Lift

General:

General: Pressure line Signal line None return valve None return valve / pressure controlled Lift Stop

Pressure line

Signal line

None return valve

General: Pressure line Signal line None return valve None return valve / pressure controlled Lift Stop

None return valve / pressure controlled

Lift Stop (Adjustable)

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

None return valve / pressure controlled with lift stop

Ø1 Pressure release valve Pressure release valve / adjustable Nozzle connection

Ø1

Ø1 Pressure release valve Pressure release valve / adjustable Nozzle connection
Ø1 Pressure release valve Pressure release valve / adjustable Nozzle connection

Pressure release valve

Pressure release valve / adjustable

Nozzle

connection

Closing procedure:

Closing procedure: As soon as the drive motor M is started, the hydraulic pum p P

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

CLOSING SV1 SV2 CLOSED OPEN R1 OPEN R2 CLOSED LS Signal (Pump at Maximum Lift) RV3
SV1 SV2 CLOSED OPEN R1 OPEN R2 CLOSED LS Signal (Pump at Maximum Lift) RV3
SV1
SV2
CLOSED
OPEN
R1
OPEN
R2
CLOSED
LS Signal
(Pump at
Maximum Lift)
RV3
CLOSED

Grab Closed

Grab Closed SV1 SV2 Closed OPEN R1 OPEN R2 CLOSED DV1 Open (230bar) LS Signal (Pump
SV1 SV2 Closed OPEN R1 OPEN R2 CLOSED DV1 Open (230bar) LS Signal (Pump at
SV1
SV2
Closed
OPEN
R1
OPEN
R2
CLOSED
DV1
Open
(230bar)
LS Signal
(Pump at zero lift)
GRAB CLOSED & MOTOR STOPPED PRESSURE STAYS IN THE CYLINDER! SV2 SV1 CLOSED CLOSED CONDITION

GRAB CLOSED

&

MOTOR STOPPED

PRESSURE STAYS IN THE CYLINDER! SV2 SV1 CLOSED CLOSED CONDITION R1 CLOSED CONDITION R2 CLOSED
PRESSURE
STAYS IN THE
CYLINDER!
SV2
SV1
CLOSED
CLOSED
CONDITION
R1
CLOSED
CONDITION
R2
CLOSED

Opening procedure:

Opening procedure: As soon as the drive motor M is started, the hydraulic pump P sucks

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

OPENING QUICK RUN ACTION SV1 SV2 OPENED CLOSED R1 CLOSED R2 OPEN LS Signal (Pump at
SV1 SV2 OPENED CLOSED R1 CLOSED R2 OPEN LS Signal (Pump at Maximum Lift) RV4
SV1
SV2
OPENED
CLOSED
R1
CLOSED
R2
OPEN
LS Signal
(Pump at
Maximum Lift)
RV4
CLOSED

Grab OPEN

Grab OPEN SV2 CLOSED CONDITION SV1 OPENED CONDITION R2 OPEN R1 CLOSED DV2 Open (120bar) LS
SV2 CLOSED CONDITION SV1 OPENED CONDITION R2 OPEN R1 CLOSED DV2 Open (120bar) LS Signal
SV2
CLOSED
CONDITION
SV1
OPENED
CONDITION
R2
OPEN
R1
CLOSED
DV2
Open
(120bar)
LS Signal
(Pump at zero lift)

GRAB OPEN

&

MOTOR

GRAB OPEN & MOTOR PRESSURE STAYS IN THE CYLINDER! SV2 CLOSED R1 R2 CLOSED CLOSED CONDITION
PRESSURE STAYS IN THE CYLINDER! SV2 CLOSED R1 R2 CLOSED
PRESSURE
STAYS IN THE
CYLINDER!
SV2
CLOSED
R1
R2
CLOSED

CLOSED

CONDITION

STOPPED

SV1

CLOSED

CONDITION

Rattling of the shells: In order to avoid a rattling of the sh ells during

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 heating of the oil.

!

SV must not be closed too much to avoid extreme

A T T E N T I O N

the grab. Pressure to be set at DV1 and DV2. (see data sheet for pressure values)

!

During load-lifting it must be observed that the grab is closed until the lifted load is suspended safely in the scoops when lifting

DV1

=

closing

DV2

=

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

GENERAL ARRANGEMENT GRAB ACCESSORIES CABLE FOR GRAB POWER SUPPLY ROPE ELECTRICAL STABILISATION INSTALLATION DRUM
GENERAL ARRANGEMENT GRAB ACCESSORIES CABLE FOR GRAB POWER SUPPLY ROPE ELECTRICAL STABILISATION INSTALLATION DRUM
CABLE FOR GRAB POWER SUPPLY ROPE ELECTRICAL STABILISATION INSTALLATION DRUM (INSIDE) GUIDE CABLE SHEAVES DRUM
CABLE
FOR GRAB
POWER SUPPLY
ROPE
ELECTRICAL
STABILISATION
INSTALLATION
DRUM
(INSIDE)
GUIDE
CABLE
SHEAVES
DRUM

DEFLECTION

SHEAVE

CONTROL PANEL

CONTROL PANEL FUSE TRANSFORMER Motor-protection circuit-breaker Q1 (Grab) Motor-protection circuit- breaker Q2, Q3
FUSE TRANSFORMER Motor-protection circuit-breaker Q1 (Grab) Motor-protection circuit- breaker Q2, Q3 Timing relay
FUSE
TRANSFORMER
Motor-protection
circuit-breaker Q1
(Grab)
Motor-protection circuit-
breaker Q2, Q3
Timing relay
K01, K02, K03,
K04, K05
(DRUM)
Motor-protection circuit-breaker: Q1 = for the Motor of the Grab Q2 = for the motor
Motor-protection circuit-breaker: Q1 = for the Motor of the Grab Q2 = for the motor

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.

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

during closing K04 = 11 sec. – time of operat ion of the motor during opening

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

drummed off the body Max Motor output on 440 V 60 Hz: 2,8 KW Max current
drummed off the body Max Motor output on 440 V 60 Hz: 2,8 KW Max current

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

instru ctions for cable reeling drum type KFM 8/600/11 Bo The cable drum consists of the

The cable drum consists of the following components:

a) - electric motor

b) - turbo coupling

c) - spur gear

d) - drum body

e) - brake

the following components: a) - electric motor b) - turbo coupling c) - spur gear d)
the following components: a) - electric motor b) - turbo coupling c) - spur gear d)
a d e c b
a
d
e
c
b
Operation During grab operation, the driving motor 27 is always running with rated speed, while

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.

coupling is running in the rotation sense opposite to the driving motor and the driving shaft
coupling is running in the rotation sense opposite to the driving motor and the driving shaft
ROPE DRUM

ROPE DRUM

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

the following components: a) - electric motor b) - turbo coupling c) - spur gear d)
e) - brake a e d b c
e) - brake
a
e
d
b
c
Operation During grab operation, the driving motor 07 is always running with rated speed, while

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

TURBO COUPLING

Turbo coupling 274

Turbo coupling 274 SHAFT SEALS filler screw fuse screw
SHAFT SEALS filler screw fuse screw
SHAFT SEALS
filler screw
fuse screw

SHEAVES

SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)

Deflection Sheave (Rope)

SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)
SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)

Guide Sheave

(Cable)

SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)
SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)
SHEAVES Deflection Sheave (Rope) Guide Sheave (Cable) Deflection Sheave (Cable)

Deflection Sheave (Cable)

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. Foot-operated switch

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

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

The plastic housing has IP 54 protection. The switch has a neutral position. Cable lead-in above
The plastic housing has IP 54 protection. The switch has a neutral position. Cable lead-in above

CABLE SOCKET

CABLE SOCKET
CABLE SOCKET

GRAB

GRAB PUTTING INTO OPERATION

PUTTING INTO OPERATION

GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GRAB PUTTING INTO OPERATION
GREASING SUSPENSION UPPER STEERING ARMS CYLINDER BEARINGS LOWER STEERING ARMS SCOOP PIVOT POINTS

GREASING

SUSPENSION
SUSPENSION
UPPER STEERING ARMS CYLINDER BEARINGS LOWER STEERING ARMS SCOOP PIVOT POINTS
UPPER
STEERING ARMS
CYLINDER
BEARINGS
LOWER
STEERING ARMS
SCOOP PIVOT
POINTS

CHECKING

CHECKING PIN LOCKING HOSES OIL LEVAL PIN LOCKING FILTER PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION
PIN LOCKING
PIN LOCKING
HOSES
HOSES
OIL LEVAL
OIL
LEVAL
CHECKING PIN LOCKING HOSES OIL LEVAL PIN LOCKING FILTER PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION

PIN LOCKING

FILTER PIN LOCKING PIN LOCKING
FILTER
PIN LOCKING
PIN LOCKING

ELECTRICAL

CONNECTION

CONNECTING

STEEL CABLE WIRE
STEEL
CABLE
WIRE

TESTING

TESTING FUNCTION CYCLE TIMES CLOSING OPENING PRESSURE PRESSURE
FUNCTION CYCLE TIMES CLOSING OPENING PRESSURE PRESSURE
FUNCTION
CYCLE
TIMES
CLOSING
OPENING
PRESSURE
PRESSURE

ADJUSTING

Dependent on cargos density reduce number of kickplates

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

MZGL 12500 Deadweight:9.065 kg Required crane lifting capacity:

24.000 kg

Filling volume

Piled density

adm. GRAB lifting capacity / SWL [t]

[m³]

[t/m³]

V 1 = 12,5

1,2

15,0

V 2 = 10,0

1,5

15,0

V 3 = 8,5

1,75

14,87

V 4 = 7,0

2,1

14,7

V 5 = 5,3

2,8

14,84

Product:

MZGL 13000

Deadweight:

8.995 kg

Required crane lifting capacity:

23.945 kg

MZGL 14000

Deadweight:

9320 kg

Required vrane lifting capacity:

Deadweight: 9320 kg Required vrane lifting capacity: 27.920 kg Filling volume Piled density adm. lifting

27.920 kg

Filling volume

Piled density

adm. lifting

Filling volume

[m³]

Piled density

[t/m³]

adm. GRAB lifting capacity / SWL [t]

[m³]

[t/m³]

capacity / SWL

[t]

         

V 1 = 13,0

1,15

14,95

V 1 = 14,0

1,3

18,2

     

V 2 = 11,0

1,35

14,85

V 2 = 12,0

1,55

18,6

     

V 3 = 9,0

1,65

14,85

V 3 = 10,0

1,85

18,5

     

V 4 = 7,0

2,1

14,85

V 4 =

8,5

2,15

18,3

     

V 5 = 5,5

2,95

14,75

V5 = 6,5

2,8

18,2

V 4 = 8,5 2,15 18,3       V 5 = 5,5 2,95 14,75 V
Cargo; piled density (γ) and angle of repose (α) grain γ = 0,6 – 0,8
Cargo; piled density (γ)
and angle of repose (α)
grain
γ = 0,6 – 0,8 α =30°
coal
γ = 0,8 – 1,0 α =40°
bauxite γ = 1,1 – 1,6 α =30°
bauxite
γ = 1,1 – 1,6 α =30°
fertilizer γ = 1,0 – 1,4 α =30°
fertilizer
γ = 1,0 – 1,4 α =30°
= 1,1 – 1,6 α =30° fertilizer γ = 1,0 – 1,4 α =30° aggregates γ
= 1,1 – 1,6 α =30° fertilizer γ = 1,0 – 1,4 α =30° aggregates γ
aggregates γ = 1,3 – 1,6 α =30°
aggregates
γ = 1,3 – 1,6 α =30°
=30° fertilizer γ = 1,0 – 1,4 α =30° aggregates γ = 1,3 – 1,6 α

iron ore γ = 1,8 – 2,6 α =35°

PUTTING INTO OPERATION

PUTTING INTO OPERATION

PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION
PUTTING INTO OPERATION

CHECKING

SWITCHES MUST BE SWITCHES MUST BE 0FF (0 Position) 0FF (0 Position)
SWITCHES MUST BE
SWITCHES MUST BE
0FF (0 Position)
0FF (0 Position)
SWITCHES MUST BE 0FF (0 Position)
SWITCHES MUST BE
0FF (0 Position)
Motor-protection circuit-breaker Q1, Q2, Q3
Motor-protection
circuit-breaker
Q1, Q2, Q3
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
(0 Position) Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01,
FUSE (Green = O.K.)
FUSE
(Green = O.K.)

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

Motor-protection circuit-breaker Q1, Q2, Q3 FUSE (Green = O.K.) Setting of Timing relay K01, K02, K03,

TESTING

T E S T I N G SWITCH ON SWITCHSWITCH ONON RELEASE CABLE & RELEASE CABLE
SWITCH ON SWITCHSWITCH ONON
SWITCH ON
SWITCHSWITCH ONON
RELEASE CABLE & RELEASE CABLE & ROPE CAREFULY! ROPE CAREFULY!
RELEASE CABLE &
RELEASE CABLE &
ROPE CAREFULY!
ROPE CAREFULY!

PREPARATION

CHECK!
CHECK!
PREPARATION CHECK!
PREPARATION CHECK!

CONNECTING

STEEL CABLE WIRE
STEEL
CABLE
WIRE

OPERATION

SWITCHES MUST BE

SWITCHES MUST BE

ALWAYS ON

ALWAYS ON

O N SWITCHES MUST BE SWITCHES MUST BE ALWAYS ON ALWAYS ON PULLING DIRECTION! PULLING DIRECTION!

PULLING DIRECTION!

PULLING DIRECTION!

BE ALWAYS ON ALWAYS ON PULLING DIRECTION! PULLING DIRECTION! SWITCHES ON MANUAL = ONLY MANUAL OPERATION
BE ALWAYS ON ALWAYS ON PULLING DIRECTION! PULLING DIRECTION! SWITCHES ON MANUAL = ONLY MANUAL OPERATION
SWITCHES ON MANUAL = ONLY MANUAL OPERATION (WITHOUT FOOD PEDAL) SWITCHES ON SEMI AUTOMATIK =
SWITCHES ON
MANUAL =
ONLY MANUAL
OPERATION
(WITHOUT FOOD
PEDAL)
SWITCHES ON SEMI
AUTOMATIK =
SWITCH & FOOD
PEDAL OPERATION
GRAB OPERATES
ATOMATICALY

GRAB

GRAB STEPS DURING OPERATION

STEPS DURING OPERATION

GRAB STEPS DURING OPERATION
1. To close the grab perfectly, lift up the grab slightly during closing 2. For
1. To close the grab perfectly, lift up the grab slightly during closing
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
2. For a maximum filling rate
the grab should be set down
horizontally
3. Heavy impacts should be avoided, In order to prevent dameges
3. Heavy impacts should be avoided,
In order to prevent dameges

DAILY

GREASING

DAILY GREASING SUSPENSION UPPER STEERING ARMS The bushes are made of LYTEX which is made of
SUSPENSION
SUSPENSION
DAILY GREASING SUSPENSION UPPER STEERING ARMS The bushes are made of LYTEX which is made of
UPPER STEERING ARMS
UPPER
STEERING ARMS

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 SCOOP PIVOT POINTS
CYLINDER
BEARINGS
SCOOP PIVOT
POINTS
LOWER STEERING ARMS
LOWER
STEERING ARMS

DAILY

CHECKING

PIN LOCKING
PIN LOCKING
DAILY CHECKING PIN LOCKING HOSES PIN LOCKING OIL LEVAL PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION
HOSES
HOSES

PIN LOCKING

OIL LEVAL PIN LOCKING PIN LOCKING
OIL
LEVAL
PIN LOCKING
PIN LOCKING
DAILY CHECKING PIN LOCKING HOSES PIN LOCKING OIL LEVAL PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION

ELECTRICAL

CONNECTION

GRAB

GRAB STEPS TO PUT OUT OF OPERATION

STEPS TO PUT OUT OF OPERATION

GRAB STEPS TO PUT OUT OF OPERATION
Clean the Grab completely with a HIGH PRESSURE CLEANER carry out a trial run without
Clean the Grab completely with a HIGH PRESSURE CLEANER
Clean the Grab completely with a
HIGH PRESSURE CLEANER
carry out a trial run without bulk material ! check working condition of the Hydraulik
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

TESTING FUNCTION CYCLE TIMES CLOSING OPENING PRESSURE PRESSURE
FUNCTION CYCLE TIMES CLOSING OPENING PRESSURE PRESSURE
FUNCTION
CYCLE
TIMES
CLOSING
OPENING
PRESSURE
PRESSURE

CHECKING

CHECKING PIN LOCKING HOSES PIN LOCKING OIL LEVAL FILTER PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION
PIN LOCKING
PIN LOCKING
HOSES
HOSES
CHECKING PIN LOCKING HOSES PIN LOCKING OIL LEVAL FILTER PIN LOCKING PIN LOCKING ELECTRICAL CONNECTION

PIN LOCKING

OIL LEVAL
OIL
LEVAL
FILTER PIN LOCKING PIN LOCKING
FILTER
PIN LOCKING
PIN LOCKING

ELECTRICAL

CONNECTION

GREASING SUSPENSION UPPER STEERING ARMS CYLINDER BEARINGS LOWER STEERING ARMS SCOOP PIVOT POINTS

GREASING

SUSPENSION
SUSPENSION
UPPER STEERING ARMS CYLINDER BEARINGS LOWER STEERING ARMS SCOOP PIVOT POINTS
UPPER
STEERING ARMS
CYLINDER
BEARINGS
LOWER
STEERING ARMS
SCOOP PIVOT
POINTS

STORING

STORING IN CLOSED POSITION ONLY (Piston Rods inside) TURNBUCKELS
IN CLOSED POSITION ONLY (Piston Rods inside) TURNBUCKELS
IN CLOSED
POSITION ONLY
(Piston Rods inside)
TURNBUCKELS
STORING IN CLOSED POSITION ONLY (Piston Rods inside) TURNBUCKELS

SUMMARY

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

grab has to be placed in closed and vertical position

grease must be applied to all Lubrication points

cover the plug in connector by means of plastic cap

points cover the plug in connector by means of plastic cap if necessary order spare parts

if necessary order spare parts for next port

Grab has to be cleaned from cargo and cargo dust

the plastik hood ist to be replaced

STEPS TO PUT OUT OF OPERATION

STEPS TO PUT OUT OF OPERATION

STEPS TO PUT OUT OF OPERATION
CHECK! SECURE THE CABLE AND WIRE
CHECK!
SECURE
THE CABLE
AND WIRE

CHECKING

SWITCHES MUST BE SWITCHES MUST BE 0FF (0 Position) 0FF (0 Position)
SWITCHES MUST BE
SWITCHES MUST BE
0FF (0 Position)
0FF (0 Position)
SWITCHES MUST BE 0FF (0 Position)
SWITCHES MUST BE
0FF (0 Position)
Motor-protection circuit-breaker Q1, Q2, Q3 OFF
Motor-protection
circuit-breaker
Q1, Q2, Q3 OFF
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
Position) Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01,
FUSE (Green = O.K.)
FUSE
(Green = O.K.)

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

Motor-protection circuit-breaker Q1, Q2, Q3 OFF FUSE (Green = O.K.) Setting of Timing relay K01, K02,
MAINTENANCE SCHEDULE & REPORT

MAINTENANCE SCHEDULE

&

REPORT

GRAB

GRAB DAILY ( DURING OPERATION ) AFTER THE FIRST 50 WORKING HOURS EVERY MONTH AFTER 1000
DAILY ( DURING OPERATION ) AFTER THE FIRST 50 WORKING HOURS EVERY MONTH AFTER 1000
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

oil cleanness carr ied out by the laboratory of the oil supplier change the oil check
GRAB NO. ITEM INTERVAL DURATION OF GRABS USE WORKING HOURS TOTAL WORKING HOURS 1 LUBRICATION
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
CHECK GRABS WORKING CONDITION
15
OPENING / CLOSING PRESSURE
CHECK GRAB ACCESSORIES
16
CABLE, ROPE, DRUMS AND SHEAVES
17
REPAIR REQUIRED & PART
REPAIR SUCCESSFUL DONE
18
Y / N
19
ISSUE & SIGN GRABS MONITORING REPORT
23
FILTER CHANGE / DATE
EVERY YEAR
24
OIL CHANGE / DATE
TANK AND SYSTEM CLEANING
25
HOSES CHANGE
AFTER 4 YEARS
RESPONSIBLE FOR INSPECTION

ACCESSORIES

ACCESSORIES Solenoid-operated spring pressure brake The brake should be checked for its proper function in regular

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

ACCESSORIES Spur gear The oil of the spur gear is be renewed, according to the working

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:

When changing the oil, beware of dust particles which might penetrate into the gear.

synthetic oil brand - Mobil Glygoyle 30

OIL & GREASE RECOMMENDATION

OIL & GREASE RECOMMENDATION

Table: Oil recommendation - Hydraulic fluids For normal operation, a hydraulic fluid of ISO-viscosity VG

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

GRAB Table: OIL recommendation   Winter   Summer ISO viscosity VG 32 VG 46 VG 68
 

Winter

 

Summer

ISO viscosity

VG 32

VG 46

VG 68

Standard

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

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

Oel T 32 Tellus Oel 46 Tellus Oel 68 TEXACO Rando Oil HD AZ-32 Rando Oil

GRAB

Table: Grease recommendation

GRAB Table: Grease recommendation   Adhesive grease Lithium saponified grease lubricant DIN 51825/2 KTA-L2k
 

Adhesive grease

Lithium saponified grease lubricant DIN 51825/2 KTA-L2k

DIN 51513 BC

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-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

GRAB ACCESSORIES Filling by manufacturer Cable drum 4.5 l oil Mobil Glygoyle 30 Rope drum 1.8

Cable drum

4.5 l

oil Mobil Glygoyle 30

Rope drum

1.8 l

oil Aral Degol GS 220

Turbo 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 220

BP

Energol SG XP 220

Esso

Circulation oil 220

Mobil

Glygoyle 30

Shell

Tivela oil WB

Texaco

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

GUIDE FOR TROUBLE SHOOTING

01. Guide to Examination The Basic requirement of this instruction is that the problem was

01. Guide to Examination

The Basic requirement of this instruction is that the problem was known by the SMAG Servic 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:

Problem: Oil leakage at guide nut of lifting cylinder. Damaged or worn our Sealings

Oil leakage at guide nut of lifting cylinder.

Damaged or worn our Sealings
Damaged or worn our
Sealings
Problem: Oil leakage at guide nut of lifting cylinder. Damaged or worn our Sealings
Problem: Oil leakage at guide nut of lifting cylinder Cause Action Sealing rings worn out

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 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

close itself after Grab closed or open and motor stopped a) Internal leakage in lifting cylinder
close itself after Grab closed or open and motor stopped a) Internal leakage in lifting cylinder
a) Internal leakage in lifting cylinder (Piston Seal)
a) Internal leakage in lifting
cylinder
(Piston Seal)
b) Internal leakage in the control block (SV1 / R1)
b) Internal leakage in the control
block (SV1 / R1)
Problem: Grab opens or close itself Cause Action Sealing rings of lifting cylinder are worn

Problem: Grab opens or close itself

Cause Action

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

1. Disassemble lifting cylinder

2. Change sealing rings from piston and guide nut

 

3. Check cylinder tube for damages and scratches

4. Change the oil and filter

5. Clean the tank and hydraulic hoses

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.

Disassemble control block

2.

Clean valves and drillings

 

OR

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

1.

Disassemble control block

2.

Change valves SV and / or RV

 

3.

Clean all drillings and other valves

4.

Change the oil and filter

5.

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

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

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 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

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
a) Operator is not lifting the grab
up
b) Working pressure is too low
b) Working pressure is too low
d) Steering arm bushes are worn out
d) Steering arm bushes are worn
out
pressure is too low d) Steering arm bushes are worn out 1. c) Scoop bushes are

1.

c) Scoop bushes are worn out
c) Scoop bushes are worn out
e) Grain size of the cargo is too big
e) Grain size of the cargo is too big
f) Scoop lips are worn out
f) Scoop lips are worn out
Problem: Grab is not cl osing completely with cargo. Cause Action Bushes worn out due

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

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:

MOTOR DUAL SCOOP GRAB ( MZG ) is equipped with 7 measuring points. Which are as
MP2 Cylinder MP1 MA MB MLS
MP2
Cylinder
MP1
MA
MB
MLS
CLOSING PRESSURE: LOAD SENSING (LS) PRESSURE • MP1 – PUMP working Pressure •Pressure produced by
CLOSING PRESSURE: LOAD SENSING (LS) PRESSURE
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 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

bar higher than the pressure actually produced by the pump. •The pressure can only be checked
OPENING PRESSURE OPENING PRESSURE with QUICK RUN MOTION LOAD SENSING (LS) PRESSURE • MP2 –
OPENING PRESSURE OPENING PRESSURE with QUICK RUN MOTION LOAD SENSING (LS) PRESSURE
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 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 280 Pressure MP1 260 Pressure MLS 240 Pressure MP2 220 200
PRESSURE PROFILE - MZG 280 Pressure MP1 260 Pressure MLS 240 Pressure MP2 220 200
PRESSURE PROFILE - MZG
280
Pressure MP1
260
Pressure MLS
240
Pressure MP2
220
200
Pressure MA
180
160
140
120
100
80
60
40
20
0
1
6
11
16
21
26
31
36
41
TIME
CLOSING
MOTOR
OPENING
MOTOR
CLOSING
STOP
STOP
300
250
Pressure MP1
200
Pressure MLS
150
Pressure MP2
100
Pressure MA
50
0
PRESSURE (bar)
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

NOTE!

NOTE! The Working Pressure has to be checked and adjusted at operating temperature of the Hydr

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

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.

CARD whic h you can find in the DOKUMENTATION of our Grab. CLOSING Pressure Checked and

CLOSING Pressure Checked and adjusted via messuring point MP1

OPENING Pressure Checked and adjusted via messuring point MP2

LEFT SIDE Pressure adjustment is done at the control block: Closing pressure: DV2 Opening pressure:
LEFT SIDE
Pressure adjustment is done at the control block:
Closing pressure:
DV2
Opening pressure:
Pressure release valve DV1
Pressure release valve DV2
DV1
FRONT
CLOSING PRESSURE
OPENING PRESSURE
MOTOR SIDE
Pressure release valve DV1 Pressure release valve DV2 DV1 FRONT CLOSING PRESSURE OPENING PRESSURE MOTOR SIDE

•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

3. Lower pressure =

Loosen the counter nut at DV1 resp. DV2 and turn the

adjustment screw to the left (anti-clockwise).

direction).

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).

DV2 and turn the adjustment screw to the right (clockwise). 6. Then check the pre ssure

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

HOW TO CHECK INTERNAL LEAKAGE

Repair operations planning and scheduling: Following tools, equipment and staff have to be available: 1

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

close itself after Grab closed or open and motor stopped a) Internal leakage in lifting cylinder
close itself after Grab closed or open and motor stopped a) Internal leakage in lifting cylinder
a) Internal leakage in lifting cylinder (Piston Seal)
a) Internal leakage in lifting
cylinder
(Piston Seal)
b) Internal leakage in the control block (SV1 / R1)
b) Internal leakage in the control
block (SV1 / R1)

GRAB CLOSED &

PRESSURE STAYS IN THE CYLINDER!

GRAB CLOSED & PRESSURE STAYS IN THE CYLINDER! SV1 CLOSED CONDITION R1 CLOSED CONDITION
SV1 CLOSED CONDITION R1 CLOSED CONDITION
SV1
CLOSED
CONDITION
R1
CLOSED
CONDITION
Repair description: Note: This test can only be carried out in closed grab position due

Repair description:

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

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

5. disconnect the Hydraulic hoses

which are assembled at the cylinder bottom

6. collect oil which is temporally coming

out of the connection

5.
5.
8. 7. by using the grabs hydraulic close the grab. 8. check if oil is
8.
8.

7. by using the grabs hydraulic

close the grab.

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

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