Page no.

Additional Service Guide

for
Peiner Motor Dual Scoop Grabs
Type MZG S3 NG30 / V30D

Part 03
 Page no. 2

Safety
About this Document
Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid for rope examination and should not be regarded as a substitute
for the competent person. The competent person should also be familiar, as appropriate, with the latest version of related International, European and
National standards. The contents of this documents are based on the needs of SMAG and the conditions under which it operates. It shall not therefore be
assumed that the contents stated therein necessarily meet the particular circumstances and requirements of other organisations. The principles set out in
this document are for information only and therefore SMAG is not liable to any third party for any loss or damage resulting from reliance on the contents. It is
the responsibility of such external organisations to check that the document is the latest version and is appropriate for their purposes.

The Original operating manual is part of the machine and describes the safe and correct use in all operational phases.
We reserve the right to make changes to our products in the interest of further development. Adhere to the operating instructions when using this machine.
Always keep the service manual close to the machine. Retain this service manual for further use.
Hand over the service manual to any further proprietor or user of the machine.

Audience
The audience of this manual is the technical personnel.
The machine must only be used, maintained and/or repaired by technically skilled personnel that is used to carry out such work.

Intended use
The machine has been designed for industrial applications.
It must only be used to lift free-dumped bulk material
Intended use includes adherence to the operating instructions of this machine and to the inspection and maintenance instructions.
The manufacturer does not accept any responsibility for any resulting damage caused by improper use. The operating company alone carries the risk here.
An improper use is, for example:
Breaking loose of bulk material
Horizontal movement of non-freely bulk material
Adding of bulk once it has already been raised
Causing the load to oscillate
Any loading that exceeds the permitted capacity (see SWL indicated on the slewing unit)
Lifting or dragging loads / bulk diagonally from the location
Riding on the load or on the machine
Operation of the machine at a higher working pressure than allowed..
Use of the machine in explosive atmosphere
 Page no. 3

Organizational Measures
Always keep the service manual at the place of operation of the machine!
In addition to the operating manual, observe generally valid legal and other binding regulations for accident prevention and for environmental
protection! Such obligations can also concern, for example, the handling of dangerous materials or the provision/wearing of personal protective
equipment or traffic safety regulations.
The machine has been built in accordance with the state of the art and is reliable if used as specified. However, dangers might emanate from this
machine if it is operated improperly by uninstructed or disregardful personal or used for any other purpose than it is intended for. (see 1.3 Intended
use, page no. 1-1). The manufacturer will not be liable for any other use in excess of the intended use nor for any damages resulting therefrom. The
user alone will bear such risk.
The machine must only be operated in perfect technical condition.
During operation of the machine keep sufficient safe distance to the load and to the machine! Don´t stay under the machine!
The personnel who is assigned to work on the machine must have read the operating instructions, in particular the chapter „Safety“ before starting to
work. This applies particularly to personnel who only works on the machine occasionally, e. g. for setup or maintenance.
Adhere to all warnings and safety instructions applied to the machine and make sure they are always completely legible!
For safety-relevant malfunctions or changes to the operational state, stop the machine immediately and report the fault to the responsible
office/person!
Augment the operating manual with instructions, including supervisory and reporting obligations, to cater for special operational situations, for
example, with regard to the work organization, work procedures and the delegated personnel.
Only sling any slinging gear (slinging ropes or chains) to the devices provided fort his purpose.
Check that the carrying capacity of the lifting tackle is adequate for the task before starting hoisting!
Do not make any changes, additions or modifications to the machine that could impair the safety without approval of the vendor! This is also the case
for the installation and the calibration of safety equipment and valves. The machine must not be subjected to welding work without prior consent and
specifications of the manufacturer.
Spare parts must conform to the technical specifications stipulated by the manufacturer. This always the case when genuine spare parts are used.
Genuine spare parts are specially designed for the particular machine. Parts and special equipment not supplied by the manufacturer have not been
approved. The installation and/or the use of such products can impair the safety. The manufacturer does not accept any liability for damage caused
by the use of non-genuine parts or any special equipment.
 Page no. 4

Personnel Selection and Qualification

Any person who is responsible for assembly/disassembly, putting into operation, operation, maintenance and repair of the machine must have read,
understood and adhere to the complete service manual, in particular the chapter „Safety“.
Only authorised, trained and instructed personnel is allowed to run, to maintain and to repair the machine. Such personnel must have been given special
instruction in the possible dangers. The personnel must be allowed to reject any safety-endangering instructions from third-parties.
The responsibilities of the personnel for the installation/dismantling, commissioning, operation, maintenance, servicing and repair must be clearly defined and
observed!
Make sure that only personnel assigned to run the machine will do so!
Only specialist electricians or instructed personnel under direction and supervision of a specialist electrician are allowed to work on the electric systems of the
machine and they must do this in compliance with the electrotechnical regulations.
Work on the hydraulic equipment may be performed only by personnel with special hydraulics knowledge and experience!
The personnel being trained, instructed or participating in a general training may work on the machine only under the continuous supervision of an
experienced person!

Measures to be Performed by the Operating Company

The owner must take appropriate maintenance and inspection measures to make sure the machine is always run in a perfect technical condition.
The owner must evidently manage and define the responsibilities for assembly / installation, operation, maintenance and repair.
The owner shall be obliged to make sure that any work on the machine is carried out by well-trained and instructed personnel only who
- is aware of the basic instructions about working safety and prevention of accidents and has been instructed to run the machine;
- has read and understood the safety instructions and warnings in this service manual.
The owner shall be obliged to verify regularly if the personnel works safety-consciously.
The owner shall be obliged to make sure that the service manual is always easily accessible.
 Page no. 5

Measures to be Performed by the Operator

The regulations applicable to the place of operation must be adhered to. The operation of the machine is in any case subject to the local safety regulations and
instructions for the prevention of accidents.
Before putting the machine into operation make sure that nobody might be endangered by operation of the machine! Machine components might automatically
restart when the machine is restarted!
The crane operator must at all times be able to see the working area and the load! Ensure adequate lighting in conditions of poor sight and darkness.
Do nor stand or work under suspended loads!
Avoid any safety-compromising working!
Examine the machine at least once per shift to make sure it is exempt from damages or defects! Notify the responsible post/person of any occurred abnormality
(including abnormal operating behaviour)! Immediately shut down and secure the machine if necessary! Remedy any failure immediately!

Measures for the Maintenance, Servicing and Repair

Observe the adjustment, maintenance and inspection tasks and schedules, including details concerning the replacement of parts and equipment prescribed in
the operating manual! These tasks may only be performed by specialized personnel.
Inform the operations personnel before commencing maintenance and servicing work! Designate a supervisory person.
The shutdown instructions according to the operating instructions must be adhered to during any work referring to assembly/disassembly, putting into operation,
operation, maintenance and repair.
Carry out repair work on the hydraulic and electric system in a clean and dust-free environment.
If necessary, secure the work area!
Before carrying out any maintenance or repair work completely shut down the machine and protect it against any unauthorized restart:
- Unplug electric plug-in connector.
Remove protective equipment only after the machine has been shut down!
Carefully fasten and secure spare parts and modules being replaced to the lifting gear so that they do not endanger anyone. Use only suitable and technically
perfect lifting gear and load carrying equipment with adequate carrying capacity!
Do not stand or work under suspended loads!
If necessary, use security-conform ladders and work platforms for installation and servicing work! Do not use machine parts as steps! Wear fall-prevention gear
for work performed at height.
Because contact with hot parts and the discharge of oil during maintenance and servicing work cannot be excluded, always wear protective glasses and
protective gloves.
Clean electric components in voltage-free state only. Unplug electric plug-in connector for this purpose. This regulation also applies to non-touch cleaning (air-
blasting).
 Page no. 6

Do not bypass pressure-operated switches, pressure-operated valves, safety valves and other sensors.
The pressure-operated switches, pressure-operated valves, safety valves and other sensors may only be adjusted with the written approval of the
manufacturer.
Safety valves may only be replaced with the same valves.
Replace immediately any damaged hydraulic hoses, pipes, cables and valves.
Replace hydraulic hoses at indicated or reasonable intervals, even if no safety-relevant defects can be detected.
Observe the prescribed tightening torques and check regularly.
For maintenance and repair work, always tighten loosened screwed joints as specified in the guidelines.
Before cleaning the machine with water or by means of a vapour stream (high-pressure cleaner) or with other detergents cover or obturate all openings in
which no water/vapour/detergent may penetrate for safety or functional reasons. Electromotors, switch cabinets, stop switches, ball bearings, gears and
chains are especially vulnerable.
Regularly check all electrical cables and hydraulic oil lines for damage and abrasion. Also inspect hydraulic oil lines for leaks.
Before resuming operation after completing maintenance or repair work, check whether all safety equipment has been reattached to the machine and is
operational! Check all functions of the machine and the working pressure!

Safety Notes for the Electrical System

In accordance with the electro-technical regulations, work on electrical systems may only be performed by an electrician or by instructed persons
under the guidance and supervision of an electrician.
Only use original fuses with specified amperage (see spare parts list)! Shutdown the machine immediately should any malfunctions occur in the
electrical power supply!
When prescribed, machine and system components for which inspection, maintenance or repair work is to be performed, must be disconnected from
the power supply. First check that the disconnected parts are in fact free of power, then ground and short-circuit, and insulate any neighboring parts
still under power!
Check the electric equipment of the machine regularly. Any defect, such as loose connections or damaged cables, must be eliminated immediately.
If work needs to be performed on live parts, a second person must be present who must always has visual or wireless contact and, in the case of an
emergency, can active the emergency-off switch or disconnect the master switch from the power supply. Secure the work area with a red-white safety
chain and a warning notice. Use only insulated tools!
After the associated electrical installation or repair, test the installed protective measures (e.g., earthing resistance).
 Page no. 7

Safety Notes for the Hydraulic System

Work on the hydraulic system may be performed only by persons with special knowledge and experience in hydraulics. The personnel must be able to read and
completely understand the hydraulic diagram, in particular the correlations of the integrated safety systems.
Wear your personal protective equipment, e. g. gloves, protective clothes, protective goggles or helmet with visor when working on the hydraulic system.
Avoid any oil leakages when working on the hydraulic units. Leaking oil must be collected in appropriate receptacles and disposed of in compliance with the
corresponding regulations.
The hydraulic system is under high pressure! Do not detach or tighten any screw fittings of the hydraulic lines (hydraulic couplings) as long as the system is
under pressure! Immediately eliminate any leakages.
Prevent the components (such as the double hook) from moving accidentally!
Utmost cleanliness must be observed for all work performed on the hydraulics! The external vicinity must be cleaned before removing the connections. Close all
openings with protective caps so that no dirt can enter.
Regularly inspect all lines, hoses and connections for leaks and externally visible damage! Repair any damage without delay! Tighten untight screw fittings in
pressure-free state only. Escaping oil can cause injuries, fire and environmental contamination.
Before starting the repair work on system sections and pressure lines of the hydraulics system to be opened, remove pressure in accordance with the
construction and function description! When present: remove pressure from system sections using the manometer connections (MA1, etc., in the hydraulics
diagram).
Route and install the hydraulic lines correctly! Do not interchange the connections! The fittings, length and quality of the hose lines must be appropriate for the
requirements.
Unapproved modifications and changes to the hydraulic system are prohibited.

Handling of Oil, Grease and Other Chemical Substances

Observe the appropriate product safety and environmental regulations for the handling of oil, grease and other chemical substances!
Take care with the handling of hot fuels and agents (such as hydraulic oil), there is danger of burning and scalding!
 Page no. 8

SMAG CONTACT

Salzgitter Maschinenbau AG
Windmühlenbergstraße 20 - 22
38259 Salzgitter
GERMANY
Phone : +49 – 5341 / 302 – 0
Telefax : # 49 - 53 41 / 3 02 - 4 24

Web: www.smag.de
 Page no. 9

Service

Mr. Kevin Wenke
- 493

kevin.wenke@smag.de
Service Administration
Mrs. Schwarz
- 673
elke.schwarz@smag.de
Service Technician
Mr. Müller
- 672
marcus.müller@smag.de
Mr. Olbrich
- 491
olaf.olbrich@smag.de

Spare Parts

Mr. Jens Hochheim
- 6 76

jens.hochheim@smag.de
Sales Spare Parts
Mrs. Malik
- 6 75
manuela.malik@smag.de
Mr. Mewes
- 741
frank.mewes@smag.de
Mr. Schnaak
- 6 74
daniel.schnaak@smag.de
 Page no. 10

CONTROL BLOCK
DISASSEMBLY
 Page no. 11

T
MLS

MP2
A
B
MP1

MA
MB
 Page no. 12

stop valve with lift stop [SV1]

 Page no. 13

stop valve with lift stop [SV1]

spring
pilot control
plug
plug with liftstop

nonreturn valve housing

nonreturn valve piston

spring
 Page no. 14

stop valve with lift stop [SV1]

1 2 5

thin spanner 41mm ; 20/22mm

allen key 30 mm
special tool 3 6

4 7
 Page no. 15

stop valve with lift stop [SV2]

spring
plug with liftstop
pilot control
plug

spring

nonreturn valve piston

nonreturn valve housing

 Page no. 16

stop valve with lift stop [SV1]

 Page no. 17

nonreturn valve [R1]

 Page no. 18

nonreturn valve [R1]

plug

nonreturn valve piston

spring
nonreturn valve housing
 Page no. 19

nonreturn valve [R1]

1 3

24mm

special tool

2
 Page no. 20

nonreturn valve [R2]

 Page no. 21

nonreturn valve [R2]

spring nonreturn valve housing

nonreturn valve piston

plug
 Page no. 22

shuttle valve

backside
 Page no. 23

shuttle valve

screw; M6

allen key
8mm
 Page no. 24

pilot valve [DV1]

„CLOSING“
(pressure release valve)

DV1
 Page no. 25

pilot valve [DV1] „CLOSING“

(pressure release valve)

valve housing with adjusting screw

sealing ring Valve cover valve piston spring

13mm, 24mm
 Page no. 26

pilot valve [DV2] „OPENING“

(pressure release valve)

DV1
 Page no. 27

pilot valve [DV2] „OPENING“

(pressure release valve)

valve housing with adjusting screw

sealing ring Valve cover valve piston spring

13mm, 24mm
 Page no. 28

nozzle [D1]
 Page no. 29

nozzle [D1]

nozzle

plug

6mm, 5mm

2
 Page no. 30

nozzle [D2]
 Page no. 31

nozzle [D2]

nozzle

plug

6mm, 5mm

2
 Page no. 32

HYDRAULIC PUMP
DISSASSEMBLY
Page no. 33
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 Page no. 48

CHANGING SEALINGS OF
HYDRAULIK CYLINDER
 Page no. 49

Installation of Piston Seals

The following points should be observed
before installation of the seals:
- Ensure the cylinder tube has a lead-in chamfer; if
not, use an installation sleeve
- Deburr and chamfer or round sharp edges, cover the
tips of screw threads

- Remove machining residues such as chips, dirt and

other foreign particles and carefully clean all parts
- The seals can be installed more easily if they are greased or oiled.
Attention must be paid to the compatibility of the seal materials with
these lubricants. Use only grease without solid additives (e.g.
molybdenum di sulphide or zinc sulphide).

- Use no sharp-edged installation tools

 Page no. 50

Installation in Split Grooves

Installation in split grooves is simple. The sequence of
installation corresponds to the configuration of the seal.

Individual seal elementsmust not be allowed to twist. During final installation (installation
of the piston in the cylinder), elastomer or spring-preloaded seals must be sized.

The corresponding cylinder barrel can be used for this

purpose, provided it has a long lead-in chamfer. Alternatively, a sizing sleeve should be
used.
 Page no. 51

Installation in Closed Grooves

- Without installation aids Observing the instructions in the
chapter ”Generalinstallation instructions”, installation of Compact
Seal and Wynseal seal elements in closed grooves is relatively
simple.
- The seals can be installedmore easily if they are greased or oiled. Attention must be
paid to the compatibility of for TurconR and ZurconR seals, the use of installation aids is
recommended. If installation has to be performed without installation aids, however, the
following points should be observed:
TurconR seals can be installed more easily by heating in oil, water or using a hot air fan
to approx. 80°C to 100°C (expanding and then shrinking back to the originalform).
Use no sharp edged tools to expand the seal rings.
 Page no. 52

Sizing of the installed seal

Sizing of the seal ring is achieved with a separate sizing sleeve, or with the cylinder
tube provided this has lead-in chamfers.
 Page no. 53

Installation in Closed Grooves

- With installation aids
Use of a three-piece installation tool is recommended for the series
production installation of TurconR and ZurconR seal elements. The tool
consists of:
- Installation sleeve
- Expanding sleeve
- Sizing sleeve
All these parts should be made of a polymer material (e.g. PA6) with the
good sliding characteristics and low abrasiveness to avoid damage to
seals.
 Page no. 54

heating in oil

80°C -100°C

expanding sleeve
1 2

installation sleeve 3 4

sizing sleeve 5
 Page no. 55

Installation of Rod Seals

The following points should be observed
before installation of the seals:
- Ensure the cylinder tube has a lead in chamfer; if not,
use an installation sleeve
- Deburr and chamfer or round sharp edges, cover the
tips of screw threads
- Remove machining residues such as chips, dirt and
other foreign particles and carefully clean all parts

- The seals can be installed more easily if the rod is greased

or oiled. Attention must be paid to the compatibility of
the seal materials with these lubricants. Use only grease
without solid additives (e.g. molybdenum disulphide or
zinc sulphide).
- Use no sharp-edged installation tools
 Page no. 56

Installation in Split Grooves

Installation in split grooves is problem free. The sequence
of installation corresponds to the configuration of the seal,
whereby the individual seal elements must not be allowed
to twist. During final installation (insertion of the piston rod
into the seal), elastomer or spring-energized sealsmust be
sized. The piston rod itself can be used for this purpose,
provided that it has a long lead-in chamfer, or use a sizing
sleeve.
 Page no. 57

Installation in Closed Grooves

By following the instructions in each seal type description (sizes

for closed or split grooves) or using the light series for TurconR
seals, it will result in a problem free installation of our rod seal
elements at small diameters.
For ZurconR and polyurethane (not TurconR) seals, the use of
installation tools is to be recommended. If installation has to be
performed without installation tools, however, the following points
should be observed:
- Place the O-Ring into the groove
- Compress the TurconR or ZurconR seals into a kidney shape.
The seal must have no sharp bends!
- Place the seal ring in compressed form into the groove and push
against the O-Ring in the direction of the arrow .
 Page no. 58

- After placing into the groove, form the seal into a ring again in
the groove by hand.
-Finally size the seal ring using a mandrel which should have a
chamfer of 10° to 15° over a length of approx 30 mm.

The sizing mandrel should be made from a polymer material (e.g. polyamide) with good sliding
characteristics and high surface quality in order to avoid damage to the seals.
The piston rod itself can also be used for calibration, provided it has a sufficiently long lead-in
chamfer.

30mm
15° - 20°

rounded, polished
 Page no. 59

GUIDE BUSH

light
Piston rod

dark NO
TE
:P
O
OF SITIO
SE N
AL OF
IN
G SEA
RI LIN
NG G

ip
LIP

g l
a lin
Se
Pressure
Page no. 60
 Page no. 61

Service Stations
 Page no. 62

Australien / Neuseeland Australia /New Zealand

CJA Marine Technology

Marine Diesel Engineering
phone: 0061-3-9532 1386
fax: 0061-3-9532 1413

Unit 3 136 Cochranes Road

Moorabbin 3189
near Melbourne
Australia

e-mail: cja@attglobal.net
PIC.:Mr. Bernhard Walther

Brazil

RIMAC Representatoes
Rua Sao Benedito, 509 –
Alto Da Boa Vista
Sao Paulo SP Brasil
CEP: 04735-000
phone/fax: 0055-11- 55460500

Mr. Marcelo Vieira

E-mail: mv@rimac.com.br
mobile phone: 0055-11 83894840
 Page no. 63

CANADA

NAGESCO North American Gantry &

Equipment Servicing Co. Ltd.
phone: 001-604-985-6173
fax: 001-604-980-4476

961 West 1st Street

North Vancouver, BC
Canada V7P 1A4

e-mail: nagesco@direct.ca
Steve Wittig
e-mail: steve@nagesco.com
China

Shanghai Peiner SMAG Machinery Co., Ltd

No. 6098-6099, Huqingping Road
phone: 0086 - 21 - 59240052
0086 - 21 – 59240054
0086 - 21 - 5924 1945
fax: 0086 - 21 – 59240057

Zhujiajiao Qingpu District

Shanghai 201713
P.R. China
e-mail: qfsketpn@public.sta.net.cn

Service Supervisor
Mr. Zhang Meng phone: +86 (21) 59232514
e-mail: zhangmeng@shpeiner.com
 Page no. 64
Dubai

GOLTENS
phone: 00971/43241642
fax: 00971/43241019
Al Jadaf Ship Docking Yard
PO Box 2811
Dubai

e-mail: kml@goltensdxb.co.ae

Arndt Strandene
e-mail arndt.hs@goltens.com

India

Chidambaram Shipcare Private Limited

38, Second line beach
Chennai 600001
India

Mail: headoffice@shipcare.in
phone: 0091-44-25220304
fax: 0091-44-25220080
Website: www.shipcare.in

PIC:
K.SUBRAMANIAN ( Subbu )
G.M (OPERATIONS)
+91 98408 16824
Mail: subbu@shipcare.in
 Page no. 65

Italy

G.D.M. di Cavalli Luigi & C.s.n.c

phone and fax: 0039-0341-286462

Via Previati 58
23900 Lecco
ITALIEN

Mr. Cavalli
E-mail: gdmlecco@libero.it
mobile: 0039-3486975646

Japan

Nakatani Transportation Co. Ltd.

Dept. of Technoservice
phone: 0081-66-5738121
fax: 0081-66-5738125

2-1-24 Kaigan-Dori
Minato-Ku
Osaka 552
JAPAN

Mr. Tanabe / Mr. Fukuya

e-mail: peiner@nakatani-osaka.co.jp
 Page no. 66

Singarpore

ALATAS Singapore Pte Ltd

CRANE SERVICES WORLD WIDE
phone 0065 68612336 (24 hrs)
fax: 0065 68616261

6A Benoi Road
Singapore 629881

Internet: www.singapore.alatas.com

Andreas Horntrich
email: horntrich@alatas.com

South Africa

Cps prospects
63 Grunter Gulley,
Bayhead Park,
Durban, 4001
Tel. +27 31 466 4396
Cell. +27 83 306 0472

Martin Tynan
Email: martin.tynan@cpsprojects.co.za
 Page no. 67

USA

HYDRAULIC PROFESSIONALS INC.

phone: 001-813-248 1968
fax: 001-813-247 5723

1302 N. 34th Street

Tampa, FL 33605
USA

Mr. Charles Robinson

 Page no. 68

TOPLIFT GDM SHP

INA

NAGESCO

NAKATANI

ALATAS
HYPRO

CJA

RIMAC CPS GOLTENS CHIDAMBARAM