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GENERAL ARRANGEMENT GRAB
SUSPENSION
CYLINDER
UPPER
TRAVERSE
STEERING
ARM
LOWER
TRAVERSE
WITH OIL
TANK
SCOOPS
KICK PLATES
UPPER
STEERING CAP NUT
ARM PIN
ELECTRICAL
CONNECTION
PISTON ROD
BRACKETS
FOR TENSION HYDRAULIC
RELEASE UNIT
(INSIDE)
SCOOP PIVOT
POINT
LOWER
STEERING
ARM PIN
HYDRAULIC ARRANGEMENT
B LINE
ELECTRIC (OPENING)
MOTOR
A LINE
(CLOSING)
TANK
LINE
CONTROL HYDRAULIC
BLOCK PUMP
HYDRAULIC UNIT
E - MOTOR
(TYPE: 200-L)
CONTROL BLOCK LEAK OIL
PUMP
(TYPE: NG30 E) 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 RV4 / CHECK
PRESSURE VALVE WITH
RELEASE PRESSURE
(SUCTION VALVE)
RELEASE
(SUCTION VALVE)
P2 LINE P1 LINE
(OPENING) (CLOSING)
CONTROL BLOCK
Lift Control
SV1
T-LINE
A-Line
(TANK) closing
B-Line
(opening)
Lift Control
SV2
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 RV4 / CHECK VALVE WITH
(ZERO STROKE) PRESSURE RELEASE
(SUCTION VALVE)
LIFTING CYLINDER
CAP NUT
PISTON ROD
GUIDE BUSH
TUBE
BUSH
LIFTING CYLINDER
Messuring
Piont
Piston
KANTSEAL RIMSEAL
SCRAPER (light)
STEPSEAL
ROD GUIDE RING ROD GUIDE RING (dark)
PISTON
FILTER
Assembled in the Reversing line
Filtration rate 10 μ
(minimum particle size 0,01mm)
OIL ISO-viscosity VG 46
HLP 46 corrosp. DIN51524/2
Operation mode S3, also called reversing operation, means that the electric motor and thus also the pump are
operated in clockwise rotary sense as well as anticlockwise rotary sense, thus influencing the opening and closing
motion of the grab.
This grab is equipped with a power-regulated axial piston pump with additional load-sensing regulator (LS).
The power regulator of the pump is adjusted to the maximum drive motor power output, i.e. depending on the drive
power, the output of the pump is continuously adjusted to the power output of the drive motor as the operating
pressure continues to increase after having exceeded a certain level. Thus, the hydraulic power, the product of pump
output and pressure, remains constant.
The load-sensing regulator, for short LS regulator, only serves as „min./max.-regulator“. Via the LS regulator the
pump recognizes that:
1. A consumer has been connected and the pump must switch to max. output,
2. A system pressure preset at the pressure relief valve (DV1 or DV2) has been reached and the pump
has to change down towards "zero-lift regulation", so that only as much hydraulic fluid is displaced as is necessary
for compensating the gap leakage in pump and system.
Legend:
A = line (grab closing)
B = line (grab opening)
D1, D2 = nozzle
DV1, DV2 = pressure relief valve
F = filter
KS = piston side
KSS = piston rod side
LS = Load-Sensing line (LS-line)
M = electric motor
MA = pressure gauge connection, cylinder pressure (closing)
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 = hydraulic pump
P1, P2 = pressure line pump / control block
R1, R2 = nonreturn valve
RV3, RV4 = nonreturn valve (check valve) with pressure relief valve
St1, St2 = control line
SV1, SV2 = stop valve with lift stop
T = tank connection
WV = shuttle valve
General: Pressure line
Signal line
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
SV1
SV2 CLOSED
OPEN
R1
OPEN
R2
CLOSED
LS Signal
(Pump at
Maximum Lift)
RV3
CLOSED
Grab Closed
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
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 OPENED
CLOSED
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 STAYS IN THE
STOPPED 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,).
DV1 = closing
DV2 = opening
Pump pressure: MP
LS-pressure: MLS
GENERAL ARRANGEMENT GRAB ACCESSORIES
CABLE
FOR GRAB
POWER SUPPLY
ROPE
ELECTRICAL STABILISATION
INSTALLATION DRUM
(INSIDE)
FUSE
TRANSFORMER
Motor-protection
circuit-breaker Q1
(Grab)
Timing relay
K01, K02, K03,
Motor-protection circuit- K04, K05
breaker Q2, Q3
(DRUM)
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
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
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.
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
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.
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.
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
filler screw
fuse screw
SHEAVES
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. 2
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
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
UPPER
STEERING ARMS
CYLINDER
BEARINGS
PIN LOCKING
HOSES
PIN LOCKING
FILTER
OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
CONNECTING STEEL
CABLE
WIRE
TESTING
FUNCTION
CYCLE
TIMES
CLOSING
OPENING PRESSURE
PRESSURE
ADJUSTING Dependent on cargos density
reduce number of kickplates
MZGL 12500
Deadweight:9.065 kg
Required crane lifting capacity: 24.000 kg
CHECK!
CONNECTING STEEL
CABLE
WIRE
OPERATION SWITCHES MUST BE
ALWAYS ON
PULLING DIRECTION!
STEPS DURING
OPERATION
1. To close the grab perfectly,
lift up the grab slightly during closing
CYLINDER
BEARINGS
PIN LOCKING
HOSES
PIN LOCKING
OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
GRAB
FUNCTION
CYCLE
TIMES
CLOSING
OPENING PRESSURE
PRESSURE
CHECKING
PIN LOCKING
HOSES
PIN LOCKING
FILTER
OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
GREASING
SUSPENSION
UPPER
STEERING ARMS
CYLINDER
BEARINGS
IN CLOSED
POSITION ONLY
(Piston Rods inside)
TURNBUCKELS
SUMMARY
if necessary order
spare parts for next port
SECURE
THE CABLE
AND WIRE
CHECKING
SWITCHES MUST BE SWITCHES MUST BE
0FF (0 Position) 0FF (0 Position)
WORKING HOURS
10 INSPECTION OF SUSPENSION
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.
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.
According to the ISO- code 4406, to the maximum contamination level of the oil.
(Laser - particulate-emission measurement ISO- code 11171, ISO MTD)
ISO 17 – 16 – 13
ISO viscosity VG 32 VG 46 VG 68
TEXACO Rando Oil HD AZ-32 Rando Oil HD B-46 Rando Oil HD C-68
GRAB
Filling by manufacturer
Gear unit
Brand synthetic oil ISO VG 220 for ambient temperatures of - 30°C to + 130°C.
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.
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.
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.
None return valves SV and / or RV are worn out due to 1. Disassemble control block
normal wear during operation 2. Clean valves and drillings
OR
None return valves SV and / or RV are worn out due to 1. Disassemble control block
dirt in the hydraulic system 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
b) Huge internal leakage in lifting
cylinder
d) Hose or hose-connections
inside the take are loosen or
broken
Huge Internal leakage in lifting cylinder due to damaged Check for internal leakage as mentioned under 140
sealing rings as mentioned previously.
Info under : PART 01
MZG_HOW TO CHECK INTERNAL LEAKAGE
Check valves RV 3 or / and RV 4 damaged and / or worn Disassemble pump and check valve seats.
out due to dirt in the hydraulic system or due to oldness of Change check valves.
the grab.
Hydraulic pump is damaged and / or worn out due to Check pump working parameters. Try to adjust the
oldness of the grab or due to dirt in the hydraulic system pressure to max and also to minimum to ensure that the
or it was damaged due to overheating the hydraulic DV valves are working correctly.
system. Change pump if necessary.
Dv1 and / or DV2 are not working correctly due to dirt in Check if valves are working correctly. Try to adjust the
the valve housing or DV valves are worn out due to pressure.
oldness of Grab. Change valves if necessary.
Hose or hose connections inside the tank are loosen or Disassemble hydraulic unit.
broken due to vibrations during normal operation or Check hoses and connections.
oldness of hoses and / or over pressure. If necessary change hoses and connections.
Or Hydraulic system was overheated
Info under: PART 03 MZG_HYDRAULIC PUMP_2 -
MZG_HYDRAULIC PUMP_3
Pump regulators damaged and / or worn out due to dirt in Check pump working parameter especially the rated
the hydraulic system or they are worn out due to normal current if the pump is moving. Change pump if necessary.
wear or hydraulic system was overheated
Info under: PART 01
MZG_Test Sheet
None return valves SV blocked due to dirt in the valve Disassemble valves
housing Check valve seats
Clean valves if necessary change valves.
1.
d) Steering arm bushes are worn
out
Bushes worn out due to normal wear and tear during Check if scoops and / or steering arms are moving in
operation their connection. (gab between pin and bush)
Disassemble Grab
Change bushes
Scoop lips worn out due to normal wear and tear Close the grab without cargo
during operation. 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.
Pilled density of cargo is too big Review operation conditions of the grab
MP2
Cylinder
MP1
MLS MA MB
CLOSING PRESSURE:
MA - SYSTEM pressure –
OPENING (QUICK RUN MOTION)
& CLOSING
Pressure in the hydraulic lines.
Due to physical rules, the pressure measured here is
approx. 30 to 40 bar higher than the pressure actually
produced by the pump.
Pressure can be checked if the Motor is stopped.
160
140
120
100
80
60
40
20
0
1 6 11 16 21 26 31 36 41
TIME
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!
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.
CLOSING Pressure
Checked and adjusted via
messuring point MP1
OPENING Pressure
Checked and adjusted via
messuring point MP2
LEFT
DE SI
Pressure adjustment is done at the control block:
DV1
MOTOR SIDE
FRONT
URE
CLOSING PRESS
RE
OPENING PRESSU
•The adjustment itself is to be done as follows:
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).
5. Raise pressure = Loosen the counter nut at DV1 resp. DV2 and turn the
adjustment screw to the right (clockwise).
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:
PRESSURE
SV1
STAYS IN THE CLOSED
CONDITION
CYLINDER!
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
5.
8.