Peiner Remote Controlled Singlerope Grabs - Egf - Service - 20!03!25

1
PEINER REMOTE CONTROLLED

SINGLE ROPE GRABS Type EGF
Subjecting: Full Service Manual for Peiner Remote Controlled Single Rope Grabs Type EGF
Content Page
Implementation and Grab function 8-22
Grab Control unit 23-39
Locking Cylinder 40-46
Putting into operation 47-53
Steps during operation 54-58
Steps to put the grab out of operation 59-64
Deaeration of the locking cylinder 65-72
Test sheet and Maintenance Table 73-76
Guide for trouble shooting 77-83
How to check the valve unit 84-89
How to check the locking cylinder 90-102
Rope maintenance and check 103-120
Inspection of shackles, chains and suspension 121-125
How to disassemble the guide nut 126-132
How to disassemble the Piston rod 133-135
How to change the seals of the locking cylinder 136-149
How to disassemble the cylinder 150-165
How to re.- & disassemble the Grab 166-185
How to straighten the side lips 186-192
How to straighten lateral offset 193-197
Scoop Body straightening 198-202
Welding guide 203-214
How to assemble side and bottom sealing lips 215-224
How to repair / change the lips 225-233
Date: 25.03.2020
Written by Kevin Wenke
2
Safety
About this Document
Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid for 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 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
Date: 25.03.2020
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.
Date: 25.03.2020
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.
Date: 25.03.2020
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).
Date: 25.03.2020
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).
Date: 25.03.2020
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!
Date: 25.03.2020
8
Implementation & Funktion
Date: 25.03.2020
Construktive description / main units 9
SUSPENSION
GRAB HEAD
PRESS ROD
MOBILE Traverse
LOCKING
ZYLINDER
Lower Traverse
HYDRAULIK ELEKTRIC SCOOP
Date: 25.03.2020
Functional description 10
phase 1
The opened grab hangs on the

lifting appliance.
The piston rods of the locking
cylinders are extended. The 4/2-
way valve is in switching position
„closed“.
Date: 25.03.2020
phase 1
Date: 25.03.2020
phase 2
The opened grab is set down on the

bulk material with the lifting rope
being released until the piston rods
are completely retracted in the
locking cylinders by the weight of
the mobile traverse. On retraction of
the piston rods, the hydraulic oil
flows out of the piston section of the
locking cylinders via the nonreturn
valves integrated in the piston into
the rod section of the locking
cylinders. The differential oil quantity
is conducted into the oil tank
through hose line L1.
The 4/2-way valve is still closed.
Date: 25.03.2020
phase 2
Date: 25.03.2020
phase 3
To close the grab the lifting rope is

to be pulled.
The closing rope force being
transmitted from roller block of the
mobile traverse to the traverse and
thus to the scoops by means of the
hydraulically locked locking
cylinders, the grab begins to close.
Towards out of the bulk material
and moved upwards by the same
lifting motion.
Date: 25.03.2020
phase 3
Date: 25.03.2020
phase 4
To open the grab the transmitter push
button is to be actuated.
The 4/2-way valve open and the locked
oil of the piston rod section folw through
the opened valve into the oil tank. The
piston rods of the locking cylinders are
extended, thus the grab beginning to
open.
The transmitter signal is a temporary
signal.
On dropping out of the transmitter signal
the 4/2-way valve is automatically closed.
As long as the center pin penetrates the
piston, the locking cylinders can be
hydraulically locked, i. e. on dropping out
of the transmitter signal the grab remains
in ist present position.
To open the grab completely, the
transmitter push button must be
actuated once again until the center
pin being drawn out of the piston and
the piston rod section no longer being
sealed towards the piston section.
The grab opens automativcally then
and no additional signal is required!
The hydraulic oil flowing out of the piston
rod section through a throttlíng port
provided in the piston rod, into the piston
section. The differential is sucked out of
the oil tank.
Date: 25.03.2020
phase 4
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phase 4
the transmitters signal is a
temporary signal
STOP
permanent actuation creates only one single transmitting

impulse of about 2 to 5 seconds
!
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phase 4
the transmitters signal is a
temporary signal
Date: 25.03.2020
emergency operating
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emergency operating
PULL
Date: 25.03.2020
phase 4
The 4/2-way valve open by pulling the
line and the locked oil of the piston rod
section folw through the opened valve
into the oil tank. The piston rods of the
locking cylinders are extended, thus the
grab beginning to open.
The transmitter signal is a temporary
signal.
On dropping out of the transmitter signal
the 4/2-way valve is automatically closed.
As long as the center pin penetrates the
piston, the locking cylinders can be
hydraulically locked, i. e. on dropping out
of the transmitter signal the grab remains
in ist present position.
To open the grab completely, the
transmitter push button must be actuated
once again.
The center pin being drawn out of the
piston and the piston rod section no
longer being sealed towards the piston
section. The hydraulic oil flowing out of
the piston rod section through a
throttlíng port provided in the piston rod,
into the piston section. The differential is
sucked out of the oil tank.
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23
Grab Control Unit
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24
Hydraulic Control Unit
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25
Grab Accumulator & Receiver
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26
NOTE:
The accumulators are dimensioned in such a way that the grab can be operated with 30 cycles
per hour for 24 hours approx. Accumulators to be stored preferably in a cool (below 21°C), dry
area that is subject to little temperature change. Do not place near heating equipment, nor to
direct sunlight for long periods. Elevated temperatures can result in reduced battery service life.
The accumulator for the grab is mounted in a fibre glass-reinforced polyester housing. A plug-in
connector ensures quick change of accumulators during handling operation and connection to
the charging set.
It is recommended to change the accumulator for the transmitter and for the grab after 24
hours.
An accumulator for the transmitter and an accumulator for the grab can be connected
simultaneously to the charging set for charging purposes. The max. charging currents are
permanently adjusted in the charging set. The set is short-circuit proof. After abt. 14 hours
charging time the charging set switches to conservation charging automatically where as the
charging current amounts to a fraction of the rated charging current only. The conservation
charging may be carried on for an unlimited period of time.
Accumulators which have been idle for a long time should be charged before being used again
so that their complete capacity can be exploited.
The charging set is suitable for a mains of 100 V to 240 V, 50 Hz to 60 Hz. The change-over for
the respective tension is effected automatically in the charging set. A manual adjustment is not
necessary.
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27
OLD Version Remote control set for 1 Grab
Tragegurt für Akkumulator
belt for accumulator
Antenne 7,0 Ah
Netzstecker
antenna main plug
Sender für Akkumulator
transmitter for accumulator
0,25Ah
Akkumulator für Sender Ladegerät
accumulator for charger
transmitter
12V, 0,25Ah
Antennenleitung Akkumulator für

antenna cable Greifer /
Antenne accumulator for grab
antenna 12V, 7,0Ah
Magnetventil mit
Freilaufdiode
Empfänger solenoid valve with
receiver protection diode
Verbindungsleitung
connection cable
Quantity per Grab Item No
1 6712202 Sender / transmitter
1 Empfänger / receiver
2 23079755 Akkumulator für Sender
accumulator for Transmitter (small)
2 23079754 Akkumulator für Greifer
accumulator for grab (big)
1 24863 Ladegerät / charger
2 22976 Antenne / Antenna
1 Tragegurt / Belt
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28
OLD Version Remote control set for 1 Grab
Technical data for the accumulators
For transmitter:
Type: Nickel-Metalhydrid
Operating voltage: 12 V
Rated capacity: 300 mAh
Rated charging current: 30 mA approx.
Charging time: 14 hours approx.
Conservation charging current: 5 mA approx.
Weight: 0.45 kg
Dimensions: 43 x 115 x 67 mm
Temperature range: -30°C up to +70°C
For grab:
Type: Nickel-Cadmium
Operating voltage: 12 V
Rated capacity: 7 Ah
Rated charging current: 700 mA approx.
Charging time: 14 hours approx.
Conservation charging current: 30 mA approx.
Weight: 3.6 kg
Temperature range: -30°C up to +70°C
NOTE:
The accumulators are dimensioned in such a way that the grab can be operated with 30 cycles per hour for 24 hours approx.
Accumulators to be stored preferably in a cool (below 21°C), dry area that is subject to little temperature change. Do not place
near heating equipment, nor to direct sunlight for long periods. Elevated temperatures can result in reduced battery service life.
Charging unit:
Declination of accumulator: Nickel-Metalhydrid and Nickel-Cadmium
Power supply: 100 to 240 V – 50 to 60 Hz
Weight: 5 kg
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29
NEW Version Remote Control Unit
Date: 25.03.2020
NEW Version Remote Control Unit 30
Operating Instructions Radio Control 56410 / 613A-1B
Intended use
This radio remote control unit has been developed exclusively for remote control of the opening process of a grab.
Do not modify nor convert the complete product.
All safety instructions of this operating manual and the prescriptions for the prevention of accidents must be adhered to.
Components
This system is made up by the following components:
Components (scope of supply)

Transmitter G 56410ZA
Receiver G 613A-1B
Without picture: transmitting antenna, accumulator (transmitter), receiving antenna,
accumulator (receiver), antenna cable, connecting cable for the receiver
Date: 25.03.2020
Fuctions: Transmitter G 56410ZA
Battery compartment Push button ‘‘Close“ Turns channel 1 on/off
(accumulators)
Transmission Time Limit
Cover of battery Printed Numbers Transmitter Identification
compartment
Antenna terminal (N Battery display Displays the operational mode and
connecter) charge of battery/accumulators
(see Table 2 on page 2).
Date: 25.03.2020
Meaning of the battery LED

Green LED lit Transmitter is ready for use, batteries/accumulators are charged
Green LED flashes Transmission in progress
Yellow LED lit Batteries nearly empty, alternative batteries/accumulators should be
kept ready
Note: Depending one what you use (batteries or accumulators) the
duration in which data can still be sent varies!
Yellow LED flashes Transmission in progress
Red LED lit The batteries/accumulators do not have enough power left for
transmitting. They have to be replaced immediately by new
batteries/charged accumulators.
Turning on/off
It is not necessary to turn on/off the transmitter separately as it is operated permanently
as soon as the batteries provide enough power. As soon as the corresponding push
button is used, the transmitter starts sending. When the button is no longer being pushed,
the transmission stops.
Operation
It is possible to telecommand the system which is connected to the receiver using the
push buttons of the transmitter. There is a 1:1 relationship between the button of the
transmitter and the relay of the receiver. As long as the button is pushed, the
corresponding relay is pulled in: the dedicated function is triggered. If the button is not
pushed any longer, the corresponding relay opens. If both buttons are pushed at the
same time, no relay confirmation (= no function) can be proceeded in the receiver.
System Identification
Transmitter and receiver have a one-time identification, clearly visibly affixed to each
component. Only devices with a corresponding identification work together.
Date: 25.03.2020
Transmission Time Limit
Terminates the maximum transmission
time, regardless of how long the button will
be pressed (default = 20s)
- Position 0 = 20 s
transmission time (default)
- Position 1 to 9 = 1 to 9 s
transmission time
Date: 25.03.2020
Receiver G 613A-1B
Functions: Receiver G 613A-1B
Antenna terminal (N connecter)
6 pin Harting connecter (for allocation details see Table 2 on page 2)
Receiver Identification
Table 5 Functions: receiver G 613A-1B

The switching functions are realized over the relay as NOC (normally open contacts). They are active as long as the corresponding function
is active on the transmitter (button pushed). If the transmitter does not transmit any data, all outputs are inactive. If no data is received the
relays are switched to initial state.
Maintenance
Proceed sight checks on a regular base. Pay attention to damages of the casings and clean the devices regularly with a wet cloth. Do not
use any detergent as they can cause damages to casings and seals.
Troubleshooting
If any problems concerning the radio control unit occur, please check first if you can fix them by yourself. When contacting our service,
please make sure that you can provide detailed information about the problem.
Date: 25.03.2020
Technical Data
Technical Data Transmitter G 56410ZA

Dimensions 199 x 80 x 42,5 mm (without antenna)
Weight about 600 g without antenna and batteries
Protection class IP 66
Transmitter channels 1
Frequencies Frequency range from 434.115 to 434.715 MHz
Channel spacing 150 kHz
SAR value Below 1 W/kg
Antenna Type Kathrein Multiflex K713226
Antenna terminator N connecter
Frequency stability 1 x 10-6
Class of emission F1B
Sets of data duration of 16 ms/set of data
Transmission power 10 mW ERP
Current 17 to 25 mA when transmitting; 3 to 5 mA in standby mode
consumption
Voltage supply 4 x AA batteries (mignon)
- NiMH accumulators (recommended type: eneloop by Sanyo)
- or batteries
Note: Depending one what you use (batteries or accumulators) the
operation time as well as the thresholds of the battery display may
vary (see Table 4 on page 4)
Controls 1 push buttons
Indicators 3-ary LED display for operational mode and charge condition (see
Table 4 on page 4)
Temperature range
Operation -10 to +60°C
Storage -20 to +70°C
Relative humidity
Operation <85 %
Storage <98 % without bedewing
Date: 25.03.2020
Receiver HG 613A-1A
Table 7 Technical data: receiver HG 613A-1A
Technical Data Receiver HG 613A-1A

Dimensions 220 x 120 x 100 mm
Weight 1,7 kg
Protection class IP 65 (if the plug-in connector is connected)
Frequencies Frequency range from 434.115 to 434.715 MHz (preferred frequency
434,475 MHz)
Channel spacing 150 kHz
Antenna Type Kathrein Multiflex K713226
Antenna terminator N connecter
Sensitivity approx. -100 dBm for reliable evaluation
Output channel 1 1 NOC (normally opened contact) (switched over relay)
Power consumption - receiving in progress: 6 W
- Standby mode: 1,6 W
Power supply 12 V ±10 %
Connecters 6 pin Harting connecter consisting of:
(not seawater proof) 1. Attachment housing standard 6 pin
2. Contact insert HanX without protection of wire; 6 pin
Temperature range
Operation -10 to +60°C
Storage -20 to +60°C
Relative humidity
Operation <85 %
Storage <98 % without bedewing
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NEW Grab 37
Accumulator
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NEW Grab 38
Accumulator
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39
Order Numbers for NEW Version Remote Control Unit & Accumulator
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40
Locking Cylinder
•Description and function of the construction
units
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41
HYDRAULIC CYLINDER
EGF
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GUIDE 42
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43
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PISTON (TUBESIDE) 44
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PISTON (GUIDE ROD SIDE) 45
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46
HIGH PRESSURE
line to the valve
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47
Putting in Operation
Prepare Read Work
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1. GREASING 48
SHACKELS, CHAINS,
LINK, SUSPENSION
4 X UPPER ROPES
PRESS RODS With Adhesive grease
only
4 X SCOOP
PIVOT POINT
4 X ROPE
4 X LOWER SHEAVES
PRESS RODS
Regular lubrication can ensure a significantly

longer permissible service life compared to
unlubricated parts.
1 X COMPENSATION
LEVER
Date: 25.03.2020
2. CHECKING 49
Ropes
Maximum permissible Deterioration: Suspension, Chains &
Max 15 % of the original rope diameter Shackles
Maximum permissible Wire Factures: Maximum permissible
Wire factures evenly distributed around the Deterioration:
core Max 5 % of the original
< 30 diameter
Wire factures priority at one core
< 10
Press Rods Sheaves

Maximum permissible Maximum permissible
Deterioration: Deterioration:
None / fully straight Max 3 % of the original
diameter
Free rotating & clean
grove
Pivot Points and
Bushes
Maximum permissible
Deterioration:
3mm
Oil
Scoop s & lips
Locking Cylinder leval
Maximum permissible
Maximum permissible
Deterioration: Maximum
Deterioration:
None / fully straight
None / fully dry and
Max gab 2mm
sealed Minimum
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3. PREPARING 50
(Electric)
Accumulators have to be charged

12 hour prior each use
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4. PREPARING 51
(Hydraulic)
replacing the filter cap
The black filter cap has to be fitted on the tank for operation
The white cap has to be used while the grab is transported lying on
side.
Correct!
Wrong!
Date: 25.03.2020
5. TESTING 52
SYSTEM FOR AIR
(Carry out the deaeration of the
hydraulic cylinder in case the gab
exceed 20mm
MAX 20 mm
FUCTION
CYCLE TIMES
Date: 25.03.2020
6. ADJUSTING 53
Dependent on cargos density

reduce number of kickplates
Specified to your
Documentation
Example! Example!
EGF 24,0 – 1,2 - 12500 EGF 24,0-1,1-13000
Deadweight: 9000 kg Deadweight: 9300 kg
Required crane lifting capacity: 24.000 kg Required crane lifting capacity: 24.150 kg
Filling volume Piled density adm. GRAB Filling volume Piled density adm. lifting
[m³] [t/m³] lifting capacity / [m³] [t/m³] capacity / SWL
SWL [t] [t]
V1 = 12,5 1,2 15,0 V1 = 13,0 1,10 14,300
V2 = 10,0 1,5 15,0 V2 = 11,0 1,35 14,850
V3 = 8,5 1,7 14,5 V3 = 9,0 1,60 14,400
V4 = 7,0 2,1 14,7 V4 = 7,5 1,95 14,625
V5 = 5,3 2,8 14,8 V5 = 6,0 2,45 14,700
Date: 25.03.2020
54
STEPS DURING
OPERATION
Date: 25.03.2020
55
1. For a maximum filling rate the grab should be set down

Horizontally. The max. work angle is aprox. 25°
2. Heavy impacts should be avoided,

In order to prevent dameges
3. Carry out the deaeration of the hydraulic cylinder in case

the grab start with not closing perfectly
4. You should not overload the Grab
5. The Grab has to be daily maintained
Date: 25.03.2020
1. DAILY Specified to your 56
GREASING Documentation
Lithium-saponified grease
DIN 51825/2 KTA-L2k
4 X UPPER
ROPES
PRESS RODS
With Adhesive grease
only
4 X SCOOP
PIVOT POINT
4 X ROPE
4 X LOWER SHEAVES
PRESS RODS
The bushes are made of LYTEX which is made of composite 1 X COMPENSATION

material. This Material has a good hard shaped surface, high
load bearing capacity and is ideal to be used in salt water. A LEVER
disadvantage is that dust is working abrasive.
Grease in order to clean the bush.This will extend the lifetime
and reduces wear.
Date: 25.03.2020
2. DAILY VISUAL 57
CHECK
Ropes Suspension, Chains &
Greased / free of bendings and cracks / Shackles
without looping from strands or Core Correct assembly with all
protrusion or broken cores lockings
Press Rods Sheaves

Maximum permissible Free rotating & clean
Deterioration: grove
None / fully straight
Oil
Locking Cylinder
Maximum permissible
leval
Deterioration: Maximum
sealed
Minimum
Date: 25.03.2020
2. DAILY CHECK 58
SYTEM FOR AIR
SYSTEM FOR AIR

(Carry out the deaeration of the hydraulic cylinder in case the gab
exceed 20mm
MAX 20 mm
Note: During Grab operation Air inside of the cylinder arise. This is normal.
Both grab locking cylinder need to be ventilated / de-aeriated regularly.
Date: 25.03.2020
GRAB 59
STEPS TO PUT OUT OF

OPERATION
Date: 25.03.2020
1. General 60
Clean the Grab completely with a

HIGH PRESSURE CLEANER
carry out a trial run without

bulk material !
check working condition of the
Hydraulik System and
fill out the test sheet for double check.
carry out necessary repairs
and order Spare Parts.
Date: 25.03.2020
2. GREASING Specified to your 61
Documentation
Lithium-saponified grease
DIN 51825/2 KTA-L2k
4 X UPPER ROPES
PRESS RODS With Adhesive grease
only
4 X SCOOP
PIVOT POINT
4 X ROPE
4 X LOWER SHEAVES
PRESS RODS
1 X COMPENSATION
LEVER
Date: 25.03.2020
3. CHECKING 62
Ropes
Maximum permissible Deterioration: Suspension, Chains &
Max 15 % of the original rope diameter Shackles
Maximum permissible Wire Factures: Maximum permissible
Wire factures evenly distributed around the Deterioration:
core Max 5 % of the original
< 30 diameter
< 10
Press Rods Sheaves

Maximum permissible Maximum permissible
Deterioration: Deterioration:
None / fully straight Max 3 % of the original
diameter
Free rotating & clean
grove
Pivot Points and
Bushes
Maximum permissible
Deterioration:
3mm
Oil
Scooplips
Maximum permissible leval
Locking Cylinder
Deterioration:
Maximum permissible Maximum
Max 50% from original Scoopplates
Deterioration:
plate thickness / fully Maximum permissible
straight Deterioration:max 50% Minimum
sealed
Max gab 2mm from original plate
Date: 25.03.2020 thickness
4. TESTING 63
SYSTEM FOR AIR
(Carry out the deaeration of the
hydraulic cylinder in case the gab
exceed 20mm
MAX 20 mm
FUCTION
CYCLE TIMES
SYSTEM FOR
AIR
Date: 25.03.2020
4. STORING 64
IN CLOSED OR
OPEN POSITION
(Piston Rods inside)
TURNBUCKELS
Note: The Electrical

system has to be
stored in a dry and
cool room.
Date: 25.03.2020
65
Deaeration of the
Locking Cylinder
Date: 25.03.2020
66
1. Connect the Crane and put down the grab with opened shells
on a horizontal even ground.
Date: 25.03.2020
67
2. Lower the MOBILE TRAVERSE completely
2.
Date: 25.03.2020
68
3. Operate the Crane carefully in the „LIFT“ mode and lift the lower
traverse in the grab by a few centimeters with this lifting movement
until the hydraulic oil pressure in the locking cylinders is sufficient.
3.
See next page.
Date: 25.03.2020
69
Max: 100 mm
Date: 25.03.2020
70
4. Carefully unscrew the vent screw on the locking cylinder-right

until an oil-air mixture visibly escapes from the cylinder. (Attention:
the vent screw must never be completely unscrewed)
1 2
VENTILATION SCREW FILLING SCREW
(small) (big)
LOCKING
CYLINDER
5. Retighten the vent screw if no more air escapes

Date: 25.03.2020
71
6. Carefully unscrew the vent screw on the locking cylinder-left

until an oil-air mixture visibly escapes from the cylinder. (Attention:
the vent screw must never be completely unscrewed)
VENTILATION SCREW
1 2 FILLING SCREW
(small) (big)
LOCKING
CYLINDER
7. Retighten the vent screw if no more air escapes
Date: 25.03.2020
72
2.
9. Lift The Mobile traverse up and repeat step 3 to 8 if gab

between mobile traverse and bracket is higher than 20mm.
10. Carry out a TEST Run without cargo

Date: 25.03.2020
73
Test Sheet
&
Maintenance Table
Date: 25.03.2020
74
Oil & Grease
Recommendation
Adhesive grease Lithium-saponified Hydraulic oil

oil / grease lubrication
DIN 51513 BC DIN 51825/2 KTA-L2k DIN 51524/2

Type: HLP 10 up to HLP 46
AGIP FIN 332/F Longlime Grease 2 Agip OSO

BP Energrease MP-MG2 Energrease LS 2 Energol HLP
ESSO Surett Fluid 4K Beacon 2 Nuto H
Mobil Oil Mobiltac D Mobilux 2 Mobil DTE
Shell Cardium Fluid C Alvania R 2 Tellus Oel
Alvania G 2
Date: 25.03.2020
Maintenance Table 75
ITEM INTERVAL
LUBRICATION OF ALL BEARINGS DAILY
INSPECTION OF HOSES, FITTINGS DURING CARGO
INSPECTION OF SUSPENSION OPERATION
INSPECTION OF ROPES
INSPECTION OF PISTON ROD AND SEALING
GRAB CLEANING AFTER COMPLETION

LUBRICATION OF ALL BEARINGS & ROPES OF EACH CARGO
INSPECTION OF HOSES, FITTINGS OPERATION
INSPECTION OF SUSPENSION
INSPECTION OF ROPES
INSPECTION OF PISTON RODS AND SEALING
CHECK OF OIL LEVEL
CHECKING GRAB COMPONENTS & ASSEMBLIES
CHECK GRABS WORKING CONDITION
ISSUE & SIGN GRABS MONITORING REPORT
LUBRICATION OF ALL BEARINGS & ROPES EVERY MONTH

GRAB TESTING / GRAB TRIAL RUN
INSPECTION OF HOSES, FITTINGS If grab is Not in Use
INSPECTION OF OIL QUALITY / WATER CONTENT
INSPECTION OF PISTON ROD AND SEALING
OIL CHANGE / OR OIL INSPECTION BY LOBORATORY EVERY YEAR

TANK AND SYSTEM CLEANING
HOSES CHANGE & GRAB SURVEY AFTER 4 YEARS
Date: 15.06.2016
76
Test Sheet
TEST SHEET EGF

CONFIRMATIO
WORK PART N REMARK
VISUAL CHECK SUSPENSION

SHACKLES
ROPES
PRESS RODS
CYLINDER
SHEAVES
SCOOPS
OIL LEVAL
HYDRAULIC HOSES
OTHERS
GRAB FUNCTION PRESSURE TEST 250bar

GRAB HOLD THE PRESSURE YES / NO CYLINDER 1:
WORKING TIMES OPENING CLOSING CYLINDER 2:
WITH REMOTE CONTROL 4/2 WAY VALVE:
WITHOUT REMOTE CONTROL REMARK
TOLERANCE OF PINS & BUSHES max 3mm
PRESS RODS
SCOOP PIVIOT POINTS
SHEAVES
Date: 15.06.2016
77
Guide for Trouble Shooting
Failures and reasons
Date: 25.03.2020
grab does not open 78
Battery receiver is discharged

or defective
Battery transmitter is discharged
or defective
Cable/plug-in connector between

Battery and transmitter or
Solenoid valve is defekt
Antenna is defective or not erected
Antenna cable is defective
The bolt connection of scoop pivot

Or press rods is slugging
Date: 15.06.2016
grab does not close 79
Emergency switch system is

not in „closed“ position
Solenoid valve seat is jamming
Leaking cylinder sealings
Demages of the internal tube

Surfaces of the cylinders
Date: 15.06.2016
grab closes, but opens 80
automatically
Grab is overloaded of overfilled
Defective pressure relieve valve
Defective 4/2 way valve
Leaking cylinder sealings
Leakage in the non return valve

of the cylinders
Leakage in the piping
Date: 15.06.2016
the piston rod does not remain in the 81
locking position and grab closes not
perfectly
air in the cylinder
filter cap has not been srewed on tank
sealing rings of ventilation srew is defective
Oil leval is too low
Pressure release valve is not working correctly
Grab is overloaded of overfilled

Date: 15.06.2016
Frequently Air inside of the Locking- 82
cylinders
The interval of air ventilation is short
Oil level is too low
filter cap is defective
sealing rings of ventilation srew is defective
Seals of the guide bush / piston rod defective or worn
Date: 15.06.2016
Mobile traverse does not move down 83
Grab is working angle is too high (max25°)
Piston rods are bend
Guide bush of piston rod worn
Retainer bush for Piston rod in mobile traverse is worn
Pins and bushes of pressure rods & Grab head are worn
Date: 15.06.2016
84
How to check the Valve
Date: 15.06.2016
85
Repair operations planning and scheduling:

Following tools and equipment and tools have to be available:
1 crane for grab operation
1 Crane operator
1 Crane operating instructor
2 skilled workers
1 open spanner 30 mm
Industrial cleaner, cleaning papers, oil-binding agent, 1 litter box, 2 buckets
Date: 15.06.2016
86
1. Connect the Crane and place the Grab in OPEN Position on

the ground and lower the MOBILE TRAVERSE completely.
Date: 15.06.2016
87
2. Open the box and disassemble the accumulator
and receiver
3. Disassemble the holding frame
Date: 15.06.2016
4. Open the Filter Cap and release the pressure out 88
of the Tank
5. Disconnect the hydraulic hose, which is

assembled to the tank cover
Date: 15.06.2016
8. Lift the hook slowly until the scoops start closing in order 89
to generate pressure inside of the system.
9. Check if no oil leak out of the open hose connection!
Valve defective
Valve o.k.
If Oil is leaking out of the hose connection Valve unit has to be changed
If no Oil is leaking out check the lifting cylinders for internal leakage.
Date: 15.06.2016
90
How to check the Cylinders
Date: 15.06.2016
91
Principally there are 2 methods to carry out the leak test on the hydraulic
cylinders:
Method A: Test by means of hydraulic pump
Method B:Test without any special tools such as hydraulic pump

(Attention! For method B a lifting appliance (crane) is necessary
to lift up/close the grab.)
Date: 15.06.2016
92
Necessary preparations for the leak

test
according to method A and method
B:
Place the grab on a clean and
even surface, the shells being
opened. The piston rods of the
hydraulic cylinders must be
completely retracted so that the
„mobile traverse“and the „lower
traverse“ touch each other in the
contact surfaces a (see fig. 1)
Fig.1
Date: 15.06.2016
93
Necessary preparations for the leak test

according to method A and method B:
Remove (unscrew) the

ventilation filter b
(on the tank cap) and
replace it by the transport
cover c
C b
Date: 15.06.2016
94

Remove the cover plate

d at the bottom side of
the „lower traverse“ by
untightening the screws
e
e
Date: 15.06.2016
95

Completely loosen the hose

connections f (see fig. 4). f
Attention! Before loosening the
hose connections, have ready
the screw plugs to plug up the
open hose ends. It is possible
to make the screw plugs by
oneself according to the fig. 5
Fig.4
Fig.5
Date: 15.06.2016
96

Use appropriate basins to collect the hydraulic oil dropping out of the
opened cylinder connections and hydraulic hoses.
Probably resulting oil puddles must be covered with an appropriate
fixing agent.
Wait until no more oil drops out of the opened cylinder connections; if
necessary, a clean cloth must be used to dab hydraulic oil from the opened
cylinder connections.
Date: 15.06.2016
97

ATTENTION!
If no screw plugs are available to plug
up the opened hose ends, it is also
possible to drain the hydraulic oil off the f
tank before loosening the hose
connections f (see fig. 1). For this
purpose the ventilation filter b (see
fig. 3) must be completely unscrewed
and the screw plug g (see fig. 2)
must be removed from the tank bottom.
Use an appropriate clean basin to
Fig.1
collect the hydraulic oil that drains off.
g
Fig. Fig.
2 C b 3
Date: 15.06.2016
98
Leak test method A
The following tools are necessary:
- hydraulic pump/ hydraulic unit, hand or motor

driven
- adapter union piece for the hose connection between the

hydraulic
pump and the hydraulic cylinder
Date: 15.06.2016
99
Leak test method A
Leak test procedure:
Remove the screw plug

h
h >M14x1,5< (see fig.)
of the hydraulic cylinder
and place the adapter
union piece for
connection of the
hydraulic pump.
Date: 15.06.2016
100
Leak test method A

Connect the hydraulic pump and the hydraulic cylinder by means of a
hose.
Produce a test pressure of about 100 to 150 bar in the cylinders
by means of the hydraulic pump.
Observe the opened hose f

connections f (see fig.)
on the cylinders. If the
quantity of oil leaking out of
the opened hose
connections increases,
there must be an internal
leak in the hydraulic
cylinders. In this case the
f
concerned hydraulic
cylinders must be replaced.
Date: 15.06.2016
101
Leak test method B

To carry out the test an appropriate lifting appliance (crane) is
necessary to lift up/close the grab.
Leak test
procedure:
Attach the crane hooks to the grab
suspension.
Operate the lifting gear of the crane in „lift load“ mode until the closing
ropes of the grab are taut and the „lower traverse“ of the grab is lifted by
about 10 cm.
Observe the opened hose connections as described under 4) - method
A.
Date: 15.06.2016
102
Leak test method B

Due to the weight of the empty grab that is not filled with bulk material,
the hydraulic pressure in the hydraulic cylinders is comparatively low
(about 50 bar) so that slight leakages might not be visible clearly enough.
To increase the hydraulic pressure in the hydraulic cylinders, it is
possible to close the grab and to fill it to the half of its capacity with bulk
material (e. g. humid gravel). The tightness is then to be tested as
described above, but in this case the closed grab must be lifted by a few
centimeters until it hangs freely on the lifting appliance (crane).
Special note:
The hose connections f (see fig. ) of the hydraulic
f
cylinders are not loosened before the grab is closed and
filled with bulk material.
The grab does not hang on the lifting appliance, i. e. the
closing ropes are relieved and there is no pressure in
the hydraulic cylinders.
Date: 15.06.2016
103
Rope Maintenance and Check

Instruction
Date: 15.06.2016
104
Important!
The basic requirement for repair is that other parts of the grab
especially the pins and bushes; rope guides and rope
protections are in optimal condition. Damaged parts are able to
affect the repair result negative.
Please check the grab condition intensive and carry out small
repairs previously.
Construction
The SMAG Peiner Grabs are constructed in order to resist high force
applications during cargo handling. The ropes are selected in
reference to all different grab applications.
In all of our grabs we have assembled left and right twisted steel wire
ropes, ordinary Lay (sZ & zS) . The reason for left and right twisted
rope is that due to the rope torque all rope gets a problem of torsional
instability. This torque is overridden if you use left and right twisted
ropes.
Date: 15.06.2016
Wire Rope Lays 105
Wire ropes have two types of lay. Lay means the direction in which the wires and strands are twisted around
the rope. Right or left are used to refer to the lay of the strands
• Regular lay, as opposed to lang lay, denotes the direction of wire twist in the strands. In regular lay
rope the wires in each strand lie in the “opposite” direction from the strands. “sZ” or “zS”.
• In Lang lay rope the wires in each strand lie in the “same” direction as the strands. “zZ” or “sS”.
Right regular lay is generally understood to be intended, unless other lay is specified. Exceptions occur in
the case of certain types of well-drilling equipment. In some rope applications, direction of lay is important
to proper performance of the job. In operating a clam-shell crane without a tag line to prevent rotation of the
bucket--holding and closing lines are frequently opposite in direction of lay.
Date: 15.06.2016
106
Guide to Examination
The continued safe operation of lifting equipment, lifting accessories and other
systems employing wire rope depends to a large extent on the operation of well-
programmed periodic rope examinations and the assessment by the competent
person of the fitness of the rope for further service.
Examination and discard of ropes by the competent person should be in accordance

with the instructions given in the original equipment manufactures handbook. In
addition, account should be taken of any local or application specific Regulations.
The competent person should also be familiar, as appropriate, with the latest version
of related International, European and National standards such as ISO 4309 “ Crane-
Wire ropes – code of practice for examination and discard”, BS 6570 “ The selection,
care and maintenance of steel wire ropes”, etc.
Particular attention must be paid to those sections of rope which experience

has shown to be liable to deterioration. Excessive wear, broken wires,
distortions and corrosion are the more common visible sings of deterioration.
Note: This publication has been prepared as an aid for rope examination and should
not be regarded as a substitute for the competent person.
Date: 15.06.2016
107
Wear is a normal feature of rope service and the use of the

correct rope construction ensures that it remain a secondary
aspect of deterioration. Lubrication may help to reduce wear.
Broken wires are a normal feature of rope service towards the

end of rope’s life, resulting from bending fatigue and wear. The
local break up of wires may indicate some mechanical fault in the
equipment. Correct lubrication in service will increase fatigue
performance.
Distortions are usually as a result of mechanical damage, and if

severe, can considerably affect rope strength.
Visible rusting indicates a lack of suitable lubrication, resulting in

corrosion. Pitting of external wire surfaces becomes evident in
some circumstances. Broken wires ultimately result.
Date: 15.06.2016
108
In Service:
Inspect the rope and the related equipment at the beginning of every working period and particularly
following any incident which could have damaged the rope or installation.
Maximum permissible Deterioration:
Max 15 % of the original rope diameter
Maximum permissible Wire Factures:
Wire factures evenly distributed around the core

< 30
< 10
Lubrication:
Ropes are like any other machine and to achieve maximum operating life in service lubrication must
be applied.The type of service lubricant and frequency of application varies with the rope operation
condition and it’s functional application. Lubricating intervals: every month or before every voyage
Date: 15.06.2016
109
Rope Assembly:
If you are going to change the ropes please check before:
1. If the new rope have the same length
2. If the rope have the same diameter
3. If the ropes have the same required breaking load
4. If all manufacturer certificates are o.k. and similar to the ropes.
5. If the new ropes have no damages or located faults
Never use wire rope which is
worn-out, damaged or abused
1. Connect the Crane to the suspension
2. Disassemble the pin
Date: 15.06.2016
110
3. Lower the Crane and move the rope joint to the ground
4. Cut off the Rope at the end of the rope joint by use
of a parting grinder with a suitable disc.
Cutting line
Date: 15.06.2016
111
5. By use of a Sledgehammer drive the remaining rope ends out of the

rope joint.
6. By use of the Crane move the old ropes out of the grab
7. Disassemble the shackles of the suspension
8. Assemble the new ropes with the shackles to the suspension
Date: 15.06.2016
112
10. Insert the new ropes into the Grab.
11. Clean and check the rope joint
12. Move the rope into the rope joint
13. Make a loop and move the dead end

back through the rope joint.
14. Check if the dead end of the rope is in a length of 7 X diameter

out of the joint.
15. Secure the dead end against moving by use of a suitable clamp
Date: 15.06.2016
113
16. Place the rope key into the rope joint
17. Hold the rope joint fast and pull by hand the working end.
18. Secure the rope joint in the near of the grab on the ground and pull
the working end by use of the crane deep into the joint.
19. Check the spacing between rope and pin hole it have to be 40mm
If it less then 40mm pull the rope again.
40mm
Date: 15.06.2016
114
20. Move the rope joint back to the rope compensation frame
21. Assemble the pin.
22. Carry out a trial run
Summary
Correct!
Date: 15.06.2016
115
Wrong!
Date: 15.06.2016
116
Problem
Mechanical damage caused by the rope contacting

The structure of the crane on which is operating or
an external structure – usually of a localised nature.
Cause / Action
Generally results from operational conditions.
Check sheave guards and support / guide sheaves
to ensure that rope has not “jumped out” of the
intended reeving system. Review operating
conditions
Problem Opening of strands.
Cause / Action
Caused by rope rotation.

Check installation method – turn inducted during
installation.Rope may have experienced a shock load
Date: 15.06.2016
117
Problem
Wires looping from strands.
Cause / Action
Insufficient service dressing
Check for areas of rope crushing or distortion
Problem
Core protrusion or broken core in single layer six
or eight strand rope.
Cause / Action
Caused by repetitive shock loading –
review operation condition
Date: 15.06.2016
118
Problem
Short rope life inducted by excessive wear and
abrasion
Cause / Action
Check that all sheaves are free and rotate
Problem
External Corrosion.
Cause / Action
Consider selection of galvanised rope.

Review level and type of service dressing.
Date: 15.06.2016
119
Problem
Internal corrosion
Cause / Action
Consider selection of galvanised rope

Review frequency amount and type of service
dressing.Consider selection of plastic
impregnated (PI) wire rope.
Problem
Broken rope – ropes are likely to break when
subjected to substantial overload or misuse
particularly when a rope has already been subjected
to mechanical damage. Corrosion of the rope both
internally and/or externally can also result in a
significant loss in metallic area. The rope strength is
reduced to a level where it is unable to sustain the
normal working load.
Cause / Action
Review operating conditions
Date: 15.06.2016
120
Warning!
Wire rope will fail if worn-out, shock loaded, overloaded,

misused, damaged, improperly maintained or abused.
Always inspect wire rope for wear, damage or abuse before

use
Never use wire rope which is worn-out, damaged or abused
Never overload or shock load a wire rope
Inform yourself: Read and understand the guidance on product
safety given in this publication; also read and understand the
machinery handbook.
Refer to applicable directives, regulations, standards and
codes concerninginspection, examination and rope removal
criteria
Date: 15.06.2016
121
Inspection of shackles, chains

and individual chain links
Date: 15.06.2016
122
Inspection of shackles, chains and individual chain links
The presence of wear, deformations and defects of the shackles, chains, individual
chain links and suspension must be inspected by a competent person* before and
the Grab is intendent to be used or at intervals of not more than 4 weeks of
continuous use of the grab.
Shorter intervals are required under unfavourable conditions of use such as

increased wear or intensified corrosion. In addition to visual inspections, a
magnetic testing for absence of cracks must be performed at intervals of maximum
three years.
* A competent person is someone who has sufficient knowledge of load-carrying

equipment due to their specialist training and experience. They must be familiar
with the corresponding state work safety rules, accident prevention rules, and
general recognised rules of engineering to an extent that they can evaluate the
work safety conditions.
Date: 15.06.2016
123
The shackles, chains and individual chain links or suspension links must be
inspected by a specialist* at intervals of not more than 12 months.
The inspections have to be documented in accordance with the regulations of the

country where the chain is used.
Prior to the inspection, the chain links must be thoroughly cleaned to ensure that
they are free from oil, dirt and rust. The cleaning method may not corrode the
base material and may not cover cracks or surface defects.
* Specialists are persons who, by virtue of their professional training and

experience, have sufficient knowledge in the field of lifting equipment for loading
of bulk materials and who are acquainted with relevant national work safety
regulations, accident prevention regulations, rules for safety and health at work,
guidelines and generally recognised technical standards (e.g. ISO sheets) as well
as the present operating instructions to the extent that they are able to judge the
safe working condition of lifting equipment, shackles and chains.
Date: 15.06.2016
124
The chains, shackles or suspension links must be replaced:

a) If it is deformed or broken and if it has deposits that cannot be removed.
b) If it were straightened, welded, bent, burned or otherwise changed.
c) If it has dents, cracks, grooves, cuts, corrosion pits or deformations. Minor dents
can be repaired by a specialist , provided that the remaining material
thickness in that place is more than 90% of the original diameter and no abrupt
change in cross section is noticeable.
d) If, as a result of plastic deformation, the outside length of a chain link has increased
by more than 3% of the outside nominal dimension.
e) If wear or excessive corrosion is present anywhere on a chain link. The wear of up
to 90 % of the original diameter (dn) is permissible, calculated as the average value
of two measurements of the diameters d1 und d2 performed at 90° to each other
(see Fig. 4.2.4).
f) If, as a result of wear, the inside length has increased by at least L=8% (
L = L1 – Lo ) for suspension links
by at least L=5% for a chain link
by at least L=2% for a chain with 11 pitches (links)
g) In the event of discolouration caused by heat or damage due to chemical
influences
Date: 15.06.2016
125
NOTE:
Regular lubrication of the chain, suspension links and shackles can ensure a
significantly longer permissible service life compared to unlubricated parts. It is
recommended to lubricate all chain links and shackles before the initial start-
up.
During lubrication, make sure that you lubricate the contact surfaces to prevent
premature wear. Suitable lubricants are those used for lubrication of wire ropes
or toothing
Date: 15.06.2016
126
How to disassemble the

Guide Nut & Piston Rod
Date: 15.06.2016
127
1 Crane operator
2 skilled workers
1 chain block 5 or 10 to.
1 striking face spanner 115mm (included in SMAG tool set)
1 striking face spanner for EGF CYLINDER (included in SMAG tool set)
1 sledgehammer 8 kg
1 slinging strap 1 to
1 rope 10m
Tool set for EGF Grabs (SMAG no 23024711)
Date: 15.06.2016
128
20
T = 20
Date: 15.06.2016
129
Date: 15.06.2016
130

the ground and lower the MOBILE TRAVERSE completely.
Date: 15.06.2016
131
2. Unscrew the Cap nut with the use of the

striking face spanner 115 mm
until you have a space of 10 mm between
the cap nut and the mobile traverse.
2
3
3. Move the Piston rod out of its seat in the mobile traverse
by dashing on the cap nut with the sledgehammer.
Then unscrew the cap nut completely.
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132
4. Lift up the mobile traverse until its in the top position

at the grab head.
4
5
5. Unscrew the VENT. / FILLING SCREWS and

the GUIDE BUSH by using the striking face
spanner for EGF Cylinder if you would like to change only
the sealing rings of the GUIDE BUSH and have a look at
instruction HOW TO CHANGE THE SEALS for further information's.
Do not disassemble the grab further.

Date: 15.06.2016
133
6. Disassemble the pins from the steering arms /

connection to the scoops.
6
7. Put the GRAB HEAD with all assembled items aside.
Date: 15.06.2016
134
8. Pull the PISTON ROD by using the crane out of the TUBE
8
5
9. Check the PISTON ROD for damages and if necessary

change it.Change the SEALING RINGS and assemble the
grab in inverted assembly sequence again. For further
information's please have a look at HOW TO CHANGE THE SEALS.
Date: 15.06.2016
135
10. Check the TUBE and the GUIDE ROD for damages.
And if necessary change the PISTON ROD
11. Refill the CYLINDER with oil.
• Refill hydraulic oil through the opened tank cover and the appertaining coarse filter until the maximum
tank filling level is reached (see paragraph 4.1 „Oil level check“in the manual)
• Refill 2 to 3 l of hydraulic oil into each of the locking cylinder-left and locking cylinder-right through the
opened filling holes 2 (see fig. 2)
• Operate the lifting device in the „LIFT“ mode and lift the mobile traverse by 120 mm max, then
continuously lower it. Repeat this procedure several times (pumping movement)
• Permanently check the oil level in the tank during the „pumping movement“ and refill hydraulic oil in the
same measure as the locking cylinder filling increases.
• If the locking cylinders are nearly completely filled, retighten the filling holes 2 (see fig. 2) with locking
screws.
• Deaerate the hydraulic system (see section 4.3)
1 2
12. Carry out a test run without cargo and deaerate the
HYDRAULIC SYSTEM.
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136
How to change the Seals

(Instruction no. 8)
Date: 15.06.2016
Installation of Piston Seals 137
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
Date: 15.06.2016
138
PISTON ROD
SCRAPER
GUIDE
GUIDE SEAL SECONDARY

SEAL
ROD GUIDE BAND
PRIMARY
CYLINDER SEAL
TUBE
GUIDE ROD
NONE RETURN
GUIDE ROD VALVES
SEAL
WITH
SEALING PISTON GUIDE
SUPPORT BAND
PISTON SEAL
Date: 15.06.2016
139
HIGH PRESSURE
line to the valve
Date: 15.06.2016
Sealing Set 0023141270 GUIDE
O-Ring
140
O-Ring
For ventilation srew 0000024640 + 0008014459
= Usit Ring Support ring
0074638017 0000024641
For Filling screw
=
O-Ring
0074721111
Scraper
0073534744
Guide ring Dark / Grey Light / yellow

Stepseal Guide ring
000021868 Stepseal
0000021884 000021868
NOTE! 0000021883
Correct assembly direction
pressure
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141
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.
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142
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.
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143
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.
Date: 15.06.2016
144

- 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.
Date: 15.06.2016
145
heating in oil
110°C -130°C
1 expanding sleeve 2
installation sleeve 3 4
sizing sleeve 5
Date: 15.06.2016
Installation of Rod Seals 146
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
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147
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.
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148
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 .
Date: 15.06.2016
149
- 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
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150
How to Disassemble the

Cylinder
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151
1 Crane operator
2 skilled workers
1 striking face spanner 115mm
1 sledgehammer 8 kg
1 rope 10m
1 eye screw M6
1 impact nut setter with accessories
1 set impact-nut setter sockets
1 set open end spanner, size 24, 27, 30, 36, 41, 46
1 set allen keys
1 barrel hydraulic oil
Date: 15.06.2016
152

the ground
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153
2. Lift up the MOBILE TRAVERSE until its in the top position at

the grab head.
3. Unscrew the VENT. / FILLING SCREWS
4. Drain the oil out of the grab
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154
5.
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155
6. Unscrew the Cap nut with the use of the

striking face spanner 115 mm
until you have a space of 10 mm between
the cap nut and the mobile traverse.
6.
7.
7. Move the Piston rod out of its seat in the

mobile traverse by dashing on the cap nut with
the sledgehammer. Then unscrew the cap nut
completely.
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156
8. Disassemble the traverse closing cover
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157
9. Disconnect the HYDRAULIK LINES from the

LIFTING CYLINDER
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158
10. Lift up the MOBILE TRAVERSE until its in the

Top position at the grab head.
11. 10
12
11. Assemble the chain block at the grab
12. Secure the LIFTING CYLINDER

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159
13. Unscrew the 4 FASTENING SRCEWS
Date: 15.06.2016
160
Remove the 4
fastening screws
Remove the hoses
Heat the lower and

upper upper foundation
and press the cylinder
down
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161
14
14. Lower the LIFTING CYLINDER on the ground
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162
15. Hoist the GRAB
15 15
16
16. Move the LIFTING CYLINDER away
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163
Prepair the new LIFTING CYLINDER
Unscrew the VENT. /

FILLING SCREWS
Check and grease the

contact surfaces.
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164
17. Move the new LIFTING CYLINDER under

the GRAB ( same position as the old one )
18. 18.
17
18. Lower the GRAB
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165
19. Assemble the GRAB in reverse order

20. Refill the CYLINDER with oil.
• Refill hydraulic oil through the opened tank cover and the appertaining coarse filter until the maximum
tank filling level is reached (see paragraph 4.1 „Oil level check“in the manual)
• Refill 2 to 3 l of hydraulic oil into each of the locking cylinder-left and locking cylinder-right through the
opened filling holes 2 (see fig. 2)
• Operate the lifting device in the „LIFT“ mode and lift the mobile traverse by 120 mm max, then
continuously lower it. Repeat this procedure several times (pumping movement)
• Permanently check the oil level in the tank during the „pumping movement“ and refill hydraulic oil in the
same measure as the locking cylinder filling increases.
• If the locking cylinders are nearly completely filled, retighten the filling holes 2 (see fig. 2) with locking
screws.
• Deaerate the hydraulic system (see section 4.3)
1 2
12. Carry out a test run without cargo and deaerate the
HYDRAULIC SYSTEM.
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166
How to Re & Disassemble the

Grab
Date: 15.06.2016
167

1 Crane operator
4 skilled workers
1 sledgehammer 8 kg
4 clumps of wood or 2 stabilising jacks
4 wooden panels
1 rope 10m
1 impact nut setter with accessories
1 se impact-nut setter sockets
1 open end spanner, size 24,
1 set allen keys
1 hexagon socket spanner, size 17
Industrial cleaner, cleaning papers, oil-binding agent, 1 litter box, 2 buckets
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168
1. Check all parts for shipping damages
BASIC UNIT
MARKING
GEARBOX WITH
COGWHEELS
SCOOP LEFT
SCOOP RIGHT
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169
2. Place the first scoop with the side lip vertical

onto 2 wooden pieces on the ground
wooden pieces
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170
3. Secure the scoop against fall over by use of

2 clumps of wood or 1 stabilising jacks
4. Place the 2 other wooden pieces at the corner

of the scoop lips
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171
5. Place the second scoop with the markings and

with utmost precision against the first scoop
6. Check with a ruler if the side lips are straight to
each other
7. Secure the scoop against fall over by use of 2

clumps of wood or 1 stabilising jacks
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172
8. Move the scoops by use of the chain blocks
close to each other until the side lie butt to
each other
CHAIN BLOCK
Date: 15.06.2016
Assembly of gearbox with cogwheel 173
9. Hook the gearbox on and move it in front

of the sleeve
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174
10. Check if the location bore of the cogwheels are

aligned to the sleeve.
By use of the chain block you are able to move the

scoops into the correct position to assemble the
gearbox with cogwheels
Date: 15.06.2016
175
11. Move the gearbox with cogwheels on the

sleeve completely.
Date: 15.06.2016
176
12. Turn the cogwheels until you are able to

fix the cogwheels with the hexagon socket screws.
Date: 15.06.2016
177
13. Bolt the cogwheels to the scoops by
use of the hexagon socket screws.
tightening torque
615 Nm.
The openings of the

split pins have to be
mounted 180° axially
offset
14. Assemble the big split pins
15. Assemble the small split pins
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178
. Connect the crane to the basic unit and lift it up
1 2
16. Mark the pin holders, pins, and drillings with

numbers
17. Disassemble the transportation device
18. Clean all drillings, pins and disks
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179
19. Move the basic unit with marking to marking

over the scoops
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180
20. Assemble the scoop pivot point pins and the

disks which have to be placed between the basic
unit and the gears behind the gears.
BASIC UNIT
SCOOP PIVOT PIN

DISK
GEAR
Date: 15.06.2016
181
21. Start at the left scoop than the other scoop.

By use of the chain block you are able to move the
scoops into the correct position
Ensure during assembly that you are able to

assemble the pin holders after the pins moved in.
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182
22. Assemble the pin holder
23. Open the steel box and change the

transportation plug to the filter cap.
Date: 15.06.2016
183
24. Pull the emergency line and lift up the grab

head slightly until you can move the press rods
between the shackle joints of the scoop
18. Lower the Grab head until all PRESS RODS

are between their connection.
Date: 15.06.2016
184
25. Assemble the press rod pins
20. Assemble the pin locking
Date: 15.06.2016
185
26. Now you can put the grab into operation as

mentioned in the manual or in the SMAG service
handbook for EGF Grabs.
Date: 15.06.2016
186
Straightening Instruction for

distorted Scoops side lips
Date: 15.06.2016
187
Important!
The basic requirement for this repair is that other parts of the grab especially the
pins and bushes; steering arms and hydraulic system are in optimal condition.
Damaged parts are able to affect the repair result negative.
Please check the grab condition intensive and carry out small repairs previously.
1 crane lifting capacity 12to with accessories for grab operation
1 Crane operator
2 skilled workers
1 hydraulic cylinder
Date: 25.03.2020
188
1 hand or mechanical operated pump
1 gas burner / heater
1 bottle acetylene
1 bottle oxygen
1 wooden beam or steel bar
3 pressing screws
Date: 15.06.2016
189
Repair description:
With the help of heating points, distortion of the side lips which have a lateral offset
in the middle of the side lip, lips can be repaired.
This heating points have to be placed outside of the bending radius for the
distorted lip.
Date: 15.06.2016
190
Repair sequence:
1. hang the grab in the crane
2. connect the cable
3. close the grab slightly until a gab of 2 mm remain between the grabs edge
4. heat the distorted lip as mentioned in the attached drawings.
Date: 15.06.2016
191
5. let the lip cool down
Attention!
Don’t use water, oil or other liquids to speed up the cooling process.
Date: 15.06.2016
192
If the distortion is to big to repair it only by heating you can also over push the distortion
with the help of an hydraulic jack or press screws.
Date: 15.06.2016
193
Scoop Body Straightening

Instruction for Lateral offset of
Scoops side lips.
Date: 25.03.2020
194
Important!
The basic requirement for this repair is that other parts of the grab especially the pins and bushes; steering arms and
hydraulic system are in optimal condition. Damaged parts are able to affect the repair result negative.
Please check the grab condition intensive and carry out small repairs previously.
Following tools and equipment have to be available:
1 crane lifting capacity 12to with accessories for grab operation
1 thick-walled steel tube with following dimensions:

Length : approx 500mm longer as the Scoop width
Overall diameter : approx 200mm
Wall thickness : approx 15mm
Both ends of the tube must be slashed V-shaped
1 Crane operator
2 skilled workers
2 clumps of wood
Date: 15.06.2016
195
Repair description:
To repair lateral offset of scoop lips you have to over push the lateral offset in opposite of the offset with the help of
the tube and the grabs own hydraulic.
The tube has to be placed diagonal between the scoop corners of the left and right scoop. Via closing the grab the scoops
will be over pushed.
Date: 15.06.2016
196
Repair sequence:
1. hang the grab in the crane
2. connect the cable
3. put the tube on the clumps of wood
4. open the grab
5. move the grab over the tube
6.close the grab slightly that the scoop

clamp the tube
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197
7. Go away from the grab and hold a safety distance

of min. 10 m around the grab.
8. close the grab a little bit more with the tube inside
9.. open the grab slightly
10. take out the tube
11. close the grab
12. check only at the end of the side lips if

the offset at the scoop is gone.
If not carry out the sequence again and close the grab at step
No. 8 a little bit more.
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198
Scoop Body Straightening Instruction for Grabs
Date: 15.06.2016
199
Repair operations planning and

scheduling:
Following tools and equipment and tools

have to be available:
1 Crane operator
2 skilled workers
1 gas burner / heater
Date: 15.06.2016
200
Repair description:
To repair this offset of scoop lips you have

to over push the offset means of a chain
block and by heating the pipes as
described below.
Note: First straighten the visible bended

areas and sections before you start to
repair the grab as mentioned in this
manual.
Date: 15.06.2016
201
Repair description:
1. Close the grabs and put a piece of Iron

or wood between the sides without gab (1)
2. Weld two pairs of pad eyes on the side

lip on the side with the gap (2)
3. Now by means of a chain block you can

pull the lips on this side close to each
other
4. Then heat the pipes inside of the scoops

at the points 3 and 4.
5. Carry out a test run
6. check if the offset at the scoop is gone

If not carry out the sequence again and
close the grab at step no. 3 a little bit more
to over push the grab.
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202
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203
Welding Instruction
Date: 15.06.2016
204
4.3.1 Welding work
All settings without guarantee obligation !

Read this instruction complete and if something is not clear or ununderstandable
please contact the SMAG Peiner Grab service department directly to remedy these
problems to your satisfaction.
To carry out the below mentioned technical description is a difficult work.
This work has to be carried out by certified steel workers. It needs a lot of practical
experience and technical understanding.
We advice you to carry out this work in attendance of an SMAG technician to avoid
mistakes, damages and operating errors during the repair.
It might be necessary for repair purposes to execute surfacing to protect parts against
wear or to seam-weld when worn out parts are replaced and weld cracks are repaired.
Weld damages are often caused by improper operation and repair.

Only certified welders with valid weld certificate are authorized to weld supporting
grab parts! Before carrying out difficult repair welding, please consult a local
graduated welding engineer or Workshop.
Or the SMAG - Service department fax no. 0049-5341-3 02 6 06 or 4 24!
Date: 25.03.2020
205
To produce reliable welded joints, the following should be particularly observed:
• Type of base material

• Weld seam preparation (groove preparation)
• Selection of working temperature (preheating temperature)
• Selection and handling of filler metal
• Seam structure
• Directives for protection against fatigue fractures
PEINER Grabs are mostly made of S355J2G3 (St 52-3) as per DIN 17100. For this
material we recommend a preheating up to the following temperatures:
Preheating always is necessary if:
- a hardness increase in the heat affected zone ("WEZ") is probable,

- the basic material has a high thermal conductivity,
- a hydrogen damage is probable
For material combinations, the higher preheating temperature is applicable,

but Hardox metal sheet max. 150 °C.
Date: 15.06.2016
206
preheating temperatures
material thickness of work piece (t) temperature
mm approx. °C
S235JRG2 > 30 120

(RSt 37-2)
S355J2G3 20 - 30 120
(St 52-3) 31 - 40 170
t > 40 220
Hardox 400 t < 20 100
Dillidur 400V t > 20 150
Hardox 500 t < 20 100

Dillidur 500V t > 20 150
GS-42MnV7 t < 20 230

CFV 30 (1.55.26 + C) t > 20 250
For the welding work, the material has to be free of paint, rust, forging scales, etc. The
welding work may only be carried out by tested welders (e. g. tests as per DIN 8560).
The welding work is done with direct current (DC) with the electrode being connected to
the positive pole.
Date: 15.06.2016
207
The table helps to select the additional material for the normally used material
combinations. Different basic material / additional material combinations have to be
determined for every single case with SMAG's responsible welding supervisor.
material combination additional materials DIN 1732 preheating follow –up
W1 – W2 E-HAND - MIG treatment
S235JRG2
(RSt 37-2)
S355J2G3 S355J2G3 EN 499-E382B42 EN 440G3Si1
St 52-3 (St 52-3)
Hardox 400 DIN 32526 see table,
Hardox 500 group M21 page-no. 13-1
GS-
42MnV7
CFV 30
(1.55.26 +
C)
Hardox 400
Dillidur
Hardox 400 400V
Dillidur Hardox 500
400V Dillidur
Hardox 500 500V
Dillidur
500V
Date: 15.06.2016
208
• Selection and handling of filler metal:
Filler metals must be selected in function of the required strength and toughness of the welded joint.A filler metal with
lower strength results in higher toughness of the weld in comparison with a filler metal with high strength, and thus the
risk of crack formation is reduced. Tack and root welds and Hardox joints must principally be executed with a low-
strength filler metal (i. e. high toughness)!
Filler metals should be selected so as to guarantee that the weld-metal hydrogen content is as low as possible, i. e.
coated electrodes must be well dried.
We recommend to use the filler metals indicated in the following table according to the base material combinations:
Material combination Filler metals
W1-W2
Manual electric welding MAG welding
St 52-3 N DIN 1913 E5143B(R)10 DIN 8559 SG 2
corr. to EN 499 E422 B 32 corr. to EN G 3 Si 1

440
St 52-3 N StE 355 to corr. to ISO 2560 E 514 B2 corr. to AWS ER 705-6
A5.18
StE 690 corr. to AWS A5.1 E 7016
ST 52 – 3 N GS-
42MnV7 EN 1600 E29 9R 12 Din 8556 SGX15CRNiMn
CFV 30 EN 287 18.8
(1.55.26 +
C)
corresponding to example: correspondin example:
g to:
HARDOX HARDOX - Thyssen Phoenix - Thyssen Union K 52
400/500 400/500 Spezial D
- ESAB ok53.16 - ESAB OKAutrod

12.51
- OERLIKON Spezial - CARBOFIL1
OERLIKON
- BÖHLER Spezial - BÖHLER EMK6
FOXEV 50-A
St 52-3 N GS-2MnV7 - UTP UTP 65 D -OERLIKON Interfill 188
CFV 30
1.55.26 + c
Date: 15.06.2016
209
Repair of the lips.
The lips are made of HARDOX. Small repair works on worn out sides of the lips can be
carried out by graining the complete scoop lips in assembled position of the lips.
Bigger repair works and repair of scoop gabs more then 4 mm can be carried out by
hard surfacing and graining the lips. This work can be carried out in assembled or
disassembled position.
HARD SURFACING
This chapter includes instructions to improve the wear resistance of structures by hard
surfacing.
1 SUMMARY
Hard surfacing is used to protect or to repair structure parts that are subject to wear.
There is a big variety of different wear types that may appear individually or in
combinations. To chose the appropriate filler alloy for hard surfacing, it is important to
know exactly the wear type or types.
Date: 15.06.2016
210
2 WEAR TYPES
ABRASION: Grinding/emerying wear, mostly caused by minerals.
ADHESION: Static friction between two sliding metal surfaces. Slight surface
roughnesses (microcontacts) weld with each other and rift.
EROSION: Material is removed by solid particles in the air or liquid stream.
SURFACE FATIGUE: Rolling wear caused by rolling contact between metal surfaces,
e. g. wheels running on rails, roller bearings. The aging surface layer causes surface
cracks and surface flaking.
SCUFFING: Oxidation and peeling of oxides between sliding and oscillating contact
surfaces, e. g. between chain links.
CAVITATION: If the pressure in liquids is locally very low, the liquid boils in this area so
that vapor bubbles are formed. If the vapor bubbles burst afterwards, this produces
shock waves that hit the surrounding material with a mechanic shock effect, e. g. within
pumps and turbines.
Date: 15.06.2016
211
3 HARD SURFACING ON HARDOX
HARDOX steels have excellent wear properties. Normally, no additional surfacing is

recommended as the wear resistance of such materials is reduced in the hard-faced
zone.
In case of locally heavy wear, however, it might be justified for financial reasons to
hard-face such surfaces instead of replacing the complete HARDOX part.
For this purpose it is necessary to chose a filler metal that guarantees total hardness
without ulterior heat treatment. As HARDOX steels have already been hardened during
their production, a heat treatment of the weld metal would reduce the steel hardness
very much.
The hard-facing metal is likely to tear. A tough buttering layer between the hard-facing
weld and plate prevents such cracks from continuing into the HARDOX plate. It is
recommended to use a basic low-hardness or austenitic filler metal. The surfacing
technique is described in fig. 3a.
If the weld metal of a HARDOX weld must also show high wear resistance properties,
surface hardening is only recommended for the top layer. Root layers and intermediate
layers must be welded with a basic low-hardness filler metal as usually. Fig. 3b shows
a correctly welded HARDOX joint with good wear properties.
Surface hardening often leads to microcracking of the weld metal. Under high stress,
these cracks might propagate down to the base material and finallly damage the
structure. For this reason it is recommended to avoid hard surfacing in areas that are
subject to high tensile load.
Date: 15.06.2016
212
Weld seam preparation:
A close fitting seam preparation is important to minimize tensions

and thus the risk of cracking.
Befor starting to weld the weld area must be free of any

contaminations such as:Cutting slag, scale, rust, paint coating,
oil and humidity
The workpiece temperature should not be below +10 °C in the

weld area. Cracked tack welds must be worked up!
Seam structure:
Use multiple-layer technique, I.e apply comparatively

many string bead layers without weaving
The last bead in the top layer must lie upon a previously welded
bead
Extremly embossed beads must be ground out
The order of welding should be from the middle to the outside
Date: 15.06.2016
213
Directives for protection against fatigue fractures:
Arc strikes out of the seam are not admissible. Unintentionally

produced arc strikes must be grounded out
Install and weld parts in such a way that they can can shrink without
hindrance
Avoid seam accumulations and crossings
Reduce rigidity leaps by means of long rounded interfaces
Prefer butt welds
Reduce the nitch effect, e.g by grinding of the seam interfaces

We recommend to use the following filler metals for wear
resistant surface welds:
a) electrode: DIN 8555 E6-UM-60(hardness: HRC 57-62)

e.g. Thyssen 600 violett
b) MAG wire: DIN 8555 MSG 6-GZ-60 material no. 1.4718

e.g. Thyssen Union A600IG
Date: 15.06.2016
214
WEAR
5.
4
3.
2.
1.
Date: 15.06.2016
215
How to weld Sealing Lips
Date: 15.06.2016
216
Following tools, equipment and staff have to be

available:
1 Crane for grab operation
1 Crane operator

2 skilled workers
1 gas / flame heater set
1 welding machine with

welding accessories
Date: 25.03.2020
217
If you want to mount sealing lips onto the grab shell, you have to take into
consideration some important facts:
During the welding process, the severe heat produces distortions in the
material. The following can be assumed: the longer the part to be welded,
the greater the distortion.
This is why it must be made sure just from the beginning that the material
distortion is avoided as much as possible when welding.
We therefore propose the following proceeding to weld on sealing lips:
1. Close the Grab
Date: 15.06.2016
218
2. Reopen the grab by 3 mm
3 mm
3. Lay the sealing lip into the shell and make sure that it abuts evenly in
all points
Date: 15.06.2016
219
4. Tack the sealing lip according to the enclosed pattern, making sure that
it has not already been distorted during tacking.
Tack the points 1 to 28 in the right order first.
Date: 15.06.2016
220
5. If the sealing lip has been distorted during tacking,

it must be slightly straightened immediately.
6. Open the grab completely.
7. Preheat the sealing lip.
8. Weld on the sealing lip
When welding on the sealing lip, the following must be observed:
1. Only a single layer must be welded first.

2. First of all, both ends of the sealing lip must be welded onto the shell.
3. Then the horizontal seams must be welded beginning from the centre.
4. If the first layer is completed all over the lip, the weld seam can be
built up until reaching the desired
thickness.
5. If all horizontal seams are accomplished, the welds of bevels and in the
lugs can be completed without
problems.
Date: 15.06.2016
221
Weld the surfaces 1 to 11 - but only with a single layer!
Date: 15.06.2016
222
Start building up the welds until the desired thickness is reached.
Date: 15.06.2016
223
If you have accomplished this, you can weld the bevels and the lugs
without problems.
Date: 15.06.2016
224
The Side sealing lips have to be fitted

Similarly on the same scoop
Date: 15.06.2016
225
How to Repair the Lips
Date: 15.06.2016
226
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227
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228
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229
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230
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231
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232
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233
Date: 15.06.2016

Peiner Remote Controlled Singlerope Grabs - Egf - Service - 20!03!25

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1

PEINER REMOTE CONTROLLED

Personnel Selection and Qualification

Measures to be Performed by the Operating Company

Measures to be Performed by the Operator

Measures for the Maintenance, Servicing and Repair

Safety Notes for the Electrical System

Safety Notes for the Hydraulic System

Handling of Oil, Grease and Other Chemical Substances

Implementation & Funktion

HYDRAULIK ELEKTRIC SCOOP

The opened grab hangs on the

The opened grab is set down on the

To close the grab the lifting rope is

permanent actuation creates only one single transmitting

Grab Control Unit

Hydraulic Control Unit

Grab Accumulator & Receiver

Antennenleitung Akkumulator für

Components (scope of supply)

Meaning of the battery LED

Table 5 Functions: receiver G 613A-1B

Technical Data Transmitter G 56410ZA

Technical Data Receiver HG 613A-1A

line to the valve

Prepare Read Work

Regular lubrication can ensure a significantly

Press Rods Sheaves

Accumulators have to be charged

Dependent on cargos density

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

2. Heavy impacts should be avoided,

3. Carry out the deaeration of the hydraulic cylinder in case

4. You should not overload the Grab

5. The Grab has to be daily maintained

The bushes are made of LYTEX which is made of composite 1 X COMPENSATION

Press Rods Sheaves

SYSTEM FOR AIR

STEPS TO PUT OUT OF

Clean the Grab completely with a

carry out a trial run without

Press Rods Sheaves

Note: The Electrical

2. Lower the MOBILE TRAVERSE completely

See next page.

4. Carefully unscrew the vent screw on the locking cylinder-right

5. Retighten the vent screw if no more air escapes

6. Carefully unscrew the vent screw on the locking cylinder-left

7. Retighten the vent screw if no more air escapes

8. Lower the MOBILE TRAVERSE completely

9. Lift The Mobile traverse up and repeat step 3 to 8 if gab

10. Carry out a TEST Run without cargo

Adhesive grease Lithium-saponified Hydraulic oil

DIN 51513 BC DIN 51825/2 KTA-L2k DIN 51524/2

AGIP FIN 332/F Longlime Grease 2 Agip OSO

GRAB CLEANING AFTER COMPLETION

LUBRICATION OF ALL BEARINGS & ROPES EVERY MONTH