MZG_S3_NG30

INDEX
PART 02
2–8 HOW TO CHANGE THE CONTROL BLOCK
9 – 13 HOW TO DISASSEMBLE THE HYDRAULIC UNIT
14 – 21 HOW TO CHANGE THE PISTON ROD
22 – 29 HOW TO CHANGE THE CYLINDER
30 – 36 HOW TO DISASSEMBLE THE SCOOPS
37 – 49 HOW TO ASSEMBLE THE SCOOPS
50 – 61 TIPS & TRICKS
62 – 70 HOW TO STRAIGHTEN THE LIPS
71 – 74 HOW TO STRAIGHTEN LATERAL OFFSET
75 – 83 HOW TO REPAIR THE LIPS
84 – 95 WELDING

02 - 1
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HOW TO CHANGE THE

CONTROL BLOCK

02 - 2
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1. Connect a manometer hose at the mesuring piont

of the lifting cylinder and release the oil pressure

2. Disconnect the hydraulic hoses from the control block

02 - 3
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3. Unscrew the fastening screws at the bottom of the control

block

4. Lift ub the controlblock by means of an Eye-screw and crane

02 - 4
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5. Disassemble the hydraulic fittings

6. Clean the container bottom

02 - 5
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7. Lift up the new control block and check the sealing rings at
the bottom plate

8. Move the control block close the the container plate and
assemble the fastening screws

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9. Move the control block down and tighten the fastening

screws

Assemble the hydraulic fittings and hoses

02 - 7
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10. Unscrew the adjusting screws of DV1 and DV2

11. Open the oil dipstick and carry out a testrung

without bulk material

12. Adjust the working pressure and check the oil leaval

02 - 8
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HOW TO DISASSEMBLE
THE HYDRAULIC UNIT

02 - 9
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1. Release the Pressure

2. Unscrew the hydraulic hoses

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3. Unsrew the fastening screws

02 - 11
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4. Connect the Crane to the lower hood

and lift up the hydraulic unit

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5. Check and secure the sealing ring

02 - 13
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HOW TO CHANGE
THE PISTON ROD
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 striking face spanner for the cap nut
1 sledgehammer 8 kg
1 manometer with connecting hose for Pressure check
2 slinging strap 1 to
1 rope 10m
1 impact nut setter with accessories
1 set impact-nut setter sockets
1 set allen keys
1 barrel hydraulic oil to refilling the grab
Industrial cleaner, cleaning papers, oil-binding agent,
1 litter box,
2 buckets

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Repair description

UPPER
TRAVERSE CAP
NUT

PISTON
ROD

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1. Connect the Grab to the crane and place the grab in complete
open position on the ground.

2. Unscrew the cap nut with the use of the striking face
spanner 135mm

02 - 16
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3. Secure the grab in open position with use of the Steel bars

4.Secure the cylinder with the rope against falling to the side

02 - 17
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5. Move the piston rode with use of the grabs of hydraulic down
CLOSING!!

NOTE! Hammer on the CAP NUT in order to presse the ROD out of ist seat.

6. Move the Cylinder to the side and connect the piston rod
to the Crane

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7. Unscrew the guide bush of the cylinder with use of the

impact nut setter

02 - 19
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8. Move the piston rod out of the cylinder tube

9. Unscrew the piston locking

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10. Unscrew the piston

11. Disassemble the guide bush

Assembly in reverse order

Note: We would like to advice you to change all sealing

rings of the cylinder during this works
Check the cylinder tube for any damages or scratches before
you start to assemble theses parts back to the grab.
Carry out a test run with the grab refill the oil and check if the
grab is working correctly.

02 - 21
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HOW TO CHANGE
THE LIFTING
CYLINDER

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 striking face spanner for the cap nut
1 sledgehammer 8 kg
1 manometer with connecting hose for Pressure check
2 slinging strap 1 to
1 rope 10m
1 impact nut setter with accessories
1 set impact-nut setter sockets
1 set allen keys
1 barrel hydraulic oil to refilling the grab
Industrial cleaner, cleaning papers, oil-binding agent,
1 litter box,
2 buckets

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Repair description

NUT
LOCKING AXIS

CAP NUT B-LINE

A-LINE

PISTON
ROD

02 - 23
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1. Connect the Grab to the crane close the grab slightly,

place the grab in complete closed position on the
ground and secure the grab against falling over

1.01 1.02

1.04
1.03

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2. Disassemble the locking screw for the cap nut then

unscrew the cap nut a little bit

10 – 20 mm

2.01 2.02

3. Press the piston rod by use of the grabs own hydraulic

(closing) out of it`s seat.
Then unscrew the cap nut completely.

3.02
3.01

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4. Release the pressure of the hydraulic system and unscrew

the hoses and fittings

4.01 4.02

!Attention!
Oil which may spill
out have to be
absorbed and
disposed
correctly.

4.03

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5. Disassemble the locking screws of the axis.

5.01 5.02

6. Connect the cylinder to the crane

6.01

6.02

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7. Drive out the axis of the cylinder

7.01
7.02

8. Move the cylinder out of the grab

8.02
8.01

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Assembly in reverse order

Note: We would like to advice you to change the Oil if

Cylinder has to be replaced.

Carry out a test run with the grab refill the oil and check if the
grab is working correctly.

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HOW TO
DISASSEMBLE THE
SCOOPS

Repair operations planning and scheduling:

Following tools, equipment and staff have to be available:

1 Crane for grab operation

1 Crane operator
1 Crane operating instructor
2 skilled workers / fitter
4 clumps of wood
Or
2 stabilising jacks
1 sledgehammer
1 steel bar Ø 60mm X 1000mm
1 impact nut setter with accessories
1 set impact-nut setter sockets

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1. Connect the Grab to the crane close the grab slightly,

place the grab in complete closed position on the
ground and secure the grab against falling over

1.01 1.02

1.04
1.03

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2. Disassemble the pin locking

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3. Disassemble the steering arm pins

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4. Disassemble the scoop pivot point pins

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13. Mark the Scoops and Basic Unit and move it away

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11. Clean and grease the scoop pivot point drill

12. Clean and grease the lower steering arm drill

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HOW TO ASSEMBLE
THE SCOOPS

Repair operations planning and scheduling:

Following tools, equipment and staff have to be available:

1 Crane for grab operation

1 Crane operator
1 Crane operating instructor
2 skilled workers / fitter
4 clumps of wood
Or
2 stabilising jacks
1 sledgehammer
1 steel bar Ø 60mm X 1000mm
1 impact nut setter with accessories
1 set impact-nut setter sockets

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1. Connect the 1st scoop to the crane

2. Place the 1st scoop on the lumbers

02 - 38
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3. Move the scoop until the side lip stays at a right

angle (90°) with the ground

4. Secure the scoop against toppling

02 - 39
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5. Place the 2nd scoop with marking to marking

towards the 1st

6. Move the 2nd scoop until the sides are aligned to

each other

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7. Secure the scoop against toppling

8. Close the scoops by use of the jack until the lips

are touching each other

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9. Connect the basic unit to the crane

10. Plug the cable to the basic unit

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11. Clean and grease the scoop pivot point drill

12. Clean and grease the lower steering arm drill

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13. Move the basic unit with marking to marking

over the scoops

14. Align the scoop pivot points

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15. Place the wear disks between the basic unit and
Scoops (1 disk each side)

16. Assemble the scoop pivot point pins

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17. Move the steering arms between the lashing

18. Align the steering arm drill by use of the

grabs hydraulic

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19. Place the wear disks between the Steering arm

and the lashing (1 disk each side)

20. Assemble the steering arm pins

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21. Assemble the pin locking

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22. Grease the Grab according to the manual

23. Carry out a test run and follow up the putting into
operation according the instructions mentioned in the
Manual or provided by the SMAG Peiner Grab
Service Department

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TIPS & TRICKS

02 - 50
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PIN 3

PIN 2

PIN 4

PIN 1

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TOOL LIST
Item. Quanti Description Remarks
no. ty
pressure force 50 to.
1 1 PRESS CYLINDER
WITH up to 120 to.
THROUGH HOLE through hole Ø45
(example: LUKAS
Hydraulik GmbH )

M36
2 1 THEADED ROD
( 17225 / 17227 ( 42
CrMo 4))

3 2 STEEL PIPE

4 1 DISK WITH HOLE

M36
5 2 NUT

Ø 90 – 120 X 1450
6 1 STEEL PIPE or
STEEL BAR (without drawing )

Ø 90 – 120 X 880
7 1 STEEL PIPE or
STEEL BAR (without drawing )

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Item. Quanti Description Remarks

no. ty
pressure force 50 to.
8 1 PRESS CYLINDER
up to 120 to.
(example: LUKAS
Hydraulik GmbH )

9 4 BRACKED

10 2 SUPPORT

60 X 60 X (60)
11 1 PAD
(without drawing )

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5 600 - 800
M36
2

Ø M36
250
20
50 to – 120 to
Ø (80)
Ø 45

10-20
Ø 160

140
Ø 45

150 - 350
3

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200 50
20

200
450

200
200
20

T = 20
50

10
8

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PIN 1
NUT
DISK WITH STEEL
HOLE PIPE

THEADED
ROD PIN

PRESS CYLINDER
WITH
THROUGH HOLE TRAVERSE

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PIN 1

WELD SEAM

11
8 9

02 - 57
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PIN 2 LIFTING CYLINDER

5
4 3

2 BUSH
AXLE

1
TRAVERSE

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PIN 2

10
8
WELD SEAM

02 - 59
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PIN 3

UPPER TRAVERSE

1
7
PIN

STEERING ARM

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PIN 4

1
6

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HOW TO STRAIGHTEN
THE LIPS

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Repair operations planning and scheduling:

Following tools and equipment and tools have to be

available:

1 crane lifting capacity 12to with accessories for grab

operation

1 Crane operator

1 Crane operating instructor

2 skilled workers

1 hydraulic cylinder

1 hand or mechanical operated pump

02 - 63
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1 gas burner / heater

1 bottle acetylene

1 bottle oxygen

1 wooden beam or steel bar

3 pressing screws

02 - 64
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Repair description:

With the help of heating points, distortion of the 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.

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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.
5. let the lip cool down
Attention!
Don’t use water, oil or other
liquids to speed up the
cooling process.

6. test the grab

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02 - 67
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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.

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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.

Repair operations planning and scheduling:

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

1 Crane operating instructor

2 skilled workers

2 clumps of wood

02 - 70
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HOW TO
STRAIGHTEN
LATERAL OFFSET

02 - 71
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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.

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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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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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HOW TO REPAIR THE

LIPS

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WELDING

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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!

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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.

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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 + t > 20 250
C)

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.

02 - 87
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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 additional materials DIN 1732 preheating follow –up

combination E-HAND - MIG treatment
W1 – W2

S235JR
G2
S355J2 (RSt EN 499-E382B42 EN 440G3Si1
G3 37-2)
St 52-3 S355J2 DIN 32526 see table,
G3 group M21 page-no. 13-1
(St 52-
3)
Hardox
400
Hardox
500
GS-
42MnV
7
Hardox CFV
400 30
Dillidur (1.55.2
400V 6 + C)
Hardox
500 Hardox
Dillidur 400
500V Dillidur
400V
Hardox
500
Dillidur
500V

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• 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 DIN 1913 E5143B(R)10 DIN SG 2

N 8559

corr. to EN 499 E422 B 32 corr. to G 3 Si 1

EN 440

St 52-3 N StE 355 corr. to ISO 2560 E 514 B2 corr. to ER 705-6

to AWS
A5.18
StE 690 corr. to AWS E 7016
A5.1

ST 52 – 3 N GS-
42MnV EN 1600 E29 9R 12 Din 8556 SGX15CRNiMn
7 EN 287 18.8
CFV 30
(1.55.2
6 + C)

corresponding to example: correspo example:

nding to:
HARDOX HARD - Thyssen Phoenix - Union K 52
400/500 OX Spezial D Thyssen
400/50
0
- ESAB ok53.16 - ESAB OKAutrod
12.51

- OERLIKON Spezial - CARBOFIL1

OERLIK
ON
- BÖHLER Spezial - EMK6
FOXEV 50-A BÖHLE
R
St 52-3 N GS- - UTP UTP 65 D - Interfill 188
2MnV7 OERLIK
CFV 30 ON
1.55.26
+c

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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.

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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.

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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.

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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

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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

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WEAR
5.

3.

2.

1.

02 - 95