• Author / Uploaded
• Abishek Dhar

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1

PEINER REMOTE CONTROLLED SINGLE ROPE GRABS Type EGF Subjecting: Full Service Manual for Peiner Remote Controlled Single Rope Grabs Type EGF Content Implementation and Grab function Grab Control unit Locking Cylinder Putting into operation Steps during operation Steps to put the grab out of operation Deaeration of the locking cylinder Test sheet and Maintenance Table Guide for trouble shooting How to check the valve unit How to check the locking cylinder Rope maintenance and check Inspection of shackles, chains and suspension How to disassemble the guide nut How to disassemble the Piston rod How to change the seals of the locking cylinder How to disassemble the cylinder How to re.- & disassemble the Grab How to straighten the side lips How to straighten lateral offset Scoop Body straightening Welding guide How to assemble side and bottom sealing lips How to repair / change the lips Date: 28.12.2017 Written by Kevin Wenke

Page 8-22 23-39 40-46 47-53 54-58 59-64 65-72 73-76 77-83 84-89 90-102 103-120 121-125 126-132 133-135 136-149 150-165 166-185 186-192 193-197 198-202 203-214 215-224 225-233

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: 28.12.2017 Written by Kevin Wenke

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: 28.12.2017 Written by Kevin Wenke

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: 28.12.2017 Written by Kevin Wenke

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 (airblasting).

Date: 28.12.2017 Written by Kevin Wenke

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: 28.12.2017 Written by Kevin Wenke

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: 28.12.2017 Written by Kevin Wenke

8

Implementation & Funktion

Date: 28.12.2017 Written by Kevin Wenke

Construktive description / main units

9

SUSPENSION GRAB HEAD

PRESS ROD

LOCKING ZYLINDER

HYDRAULIK ELEKTRIC

Date: 28.12.2017 Written by Kevin Wenke

MOBILE

Traverse

Lower

Traverse

SCOOP

Functional description

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

Date: 28.12.2017 Written by Kevin Wenke

10

Functional description

phase 1

Date: 28.12.2017 Written by Kevin Wenke

11

Functional description

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: 28.12.2017 Written by Kevin Wenke

12

Functional description

phase 2

Date: 28.12.2017 Written by Kevin Wenke

13

Functional description

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: 28.12.2017 Written by Kevin Wenke

14

Functional description

phase 3

Date: 28.12.2017 Written by Kevin Wenke

15

Functional description

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: 28.12.2017 Written by Kevin Wenke

16

Functional description

phase 4

Date: 28.12.2017 Written by Kevin Wenke

17

Functional description

18

phase 4 the transmitters signal is a temporary signal

STOP

permanent actuation creates only one single transmitting impulse of about 2 to 5 seconds

Date: 28.12.2017 Written by Kevin Wenke

!

Functional description

19

phase 4 the transmitters signal is a temporary signal

Date: 28.12.2017 Written by Kevin Wenke

Functional description

emergency operating

Date: 28.12.2017 Written by Kevin Wenke

20

Functional description

21

emergency operating

PULL

Date: 28.12.2017 Written by Kevin Wenke

Functional description

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.

Date: 28.12.2017 Written by Kevin Wenke

22

23

Grab Control Unit

Date: 28.12.2017 Written by Kevin Wenke

24 Hydraulic Control Unit

Date: 28.12.2017 Written by Kevin Wenke

25 Grab Accumulator & Receiver

Date: 28.12.2017 Written by Kevin Wenke

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. Date: 28.12.2017 Written by Kevin Wenke

OLD Version Remote control set for 1 Grab

27

Tragegurt belt

für Akkumulator for accumulator 7,0 Ah Netzstecker main plug für Akkumulator for accumulator 0,25Ah Ladegerät charger

Antenne antenna Sender transmitter Akkumulator für Sender accumulator for transmitter 12V, 0,25Ah

Akkumulator für Greifer / accumulator for grab 12V, 7,0Ah Magnetventil mit Freilaufdiode solenoid valve with protection diode

Antennenleitung antenna cable Antenne antenna Empfänger receiver Verbindungsleitung connection cable

Quantity per Grab 1

Item No 6712202

Empfänger / receiver

1 2

Sender / transmitter

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 Date: 28.12.2017 Written by Kevin Wenke

Tragegurt / Belt

OLD Version Remote control set for 1 Grab

28

Technical data for the accumulators For transmitter: Type: Operating voltage: Rated capacity: Rated charging current: Charging time: Conservation charging current: Weight: Dimensions: Temperature range:

Nickel-Metalhydrid 12 V 300 mAh 30 mA approx. 14 hours approx. 5 mA approx. 0.45 kg 43 x 115 x 67 mm -30°C up to +70°C

For grab: Type: Operating voltage: Rated capacity: Rated charging current: Charging time: Conservation charging current: Weight: Dimensions: Temperature range:

Nickel-Cadmium 12 V 7 Ah 700 mA approx. 14 hours approx. 30 mA approx. 3.6 kg 120 x 220 x 90 mm -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 Dimensions: 160 x 260 x 100 mm Date: 28.12.2017 Written by Kevin Wenke

NEW Version Remote Control Unit

Date: 28.12.2017 Written by Kevin Wenke

29

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: 28.12.2017 Written by Kevin Wenke

31

NEW Version Remote Control Unit Transmitter G 56410ZA Fuctions: Transmitter G 56410ZA Battery compartment (accumulators) Transmission Time Limit Cover of battery compartment Antenna terminal connecter)

Date: 28.12.2017 Written by Kevin Wenke

(N

Push button ‘‘Close“

Turns channel 1 on/off

Printed Numbers

Transmitter Identification

Battery display

Displays the operational mode and charge of battery/accumulators (see Table 2 on page 2).

NEW Version Remote Control Unit

32

Meaning of the battery LED Transmitter is ready for use, batteries/accumulators are charged Green LED lit Green LED flashes Transmission in progress Batteries nearly empty, alternative batteries/accumulators should be Yellow LED lit kept ready

Yellow LED flashes Red LED lit

Note: Depending one what you use (batteries or accumulators) the duration in which data can still be sent varies! Transmission in progress 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: 28.12.2017 Written by Kevin Wenke

NEW Version Remote Control Unit 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: 28.12.2017 Written by Kevin Wenke

33

NEW Version Remote Control Unit

34

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: 28.12.2017 Written by Kevin Wenke

NEW Version Remote Control Unit Technical Data Transmitter G 56410ZA 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

Controls Indicators Temperature range Operation Storage Relative humidity Operation Storage

Date: 28.12.2017 Written by Kevin Wenke

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) 1 push buttons 3-ary LED display for operational mode and charge condition (see Table 4 on page 4) -10 to +60°C -20 to +70°C 20

100 150

Hardox 500 Dillidur 500V

t < 20 t > 20

100 150

GS-42MnV7 CFV 30 (1.55.26 + C)

t < 20 t > 20

230 250

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 Written by Kevin Wenke

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 W1 – W2

S355J2G3 St 52-3

Hardox 400 Dillidur 400V Hardox 500 Dillidur 500V

Date: 15.06.2016 Written by Kevin Wenke

S235JRG2 (RSt 37-2) S355J2G3 (St 52-3) Hardox 400 Hardox 500 GS42MnV7 CFV 30 (1.55.26 + C) Hardox 400 Dillidur 400V Hardox 500 Dillidur 500V

additional materials DIN 1732 E-HAND MIG

EN 499-E382B42

preheating

follow –up treatment

DIN 32526 group M21

see table, page-no. 13-1

EN 440G3Si1

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 lowstrength 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: Filler metals

Material combination W1-W2

Manual electric welding St 52-3 N

St 52-3 N

ST 52 – 3 N

HARDOX 400/500

St 52-3 N

Date: 15.06.2016 Written by Kevin Wenke

MAG welding

DIN 1913

E5143B(R)10

DIN 8559

SG 2

corr. to EN 499

E422 B 32

G 3 Si 1

StE 355 to

corr. to ISO 2560

E 514 B2

corr. to EN 440 corr. to AWS A5.18

StE 690

corr. to AWS A5.1

E 7016

EN 1600

E29 9R 12

Din 8556 EN 287

SGX15CRNiMn 18.8

corresponding to

example:

example:

- Thyssen

Phoenix Spezial D

correspondin g to: - Thyssen

- ESAB

ok53.16

- ESAB

- OERLIKON

Spezial

OERLIKON

OKAutrod 12.51 CARBOFIL1

- BÖHLER

Spezial FOXEV 50-A

- BÖHLER

EMK6

- UTP

UTP 65 D

-OERLIKON

Interfill 188

GS42MnV7 CFV 30 (1.55.26 + C) HARDOX 400/500

GS-2MnV7 CFV 30 1.55.26 + c

ER 705-6

Union K 52

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 Written by Kevin Wenke

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 Written by Kevin Wenke

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 Written by Kevin Wenke

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 Written by Kevin Wenke

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

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WEAR 5. 4 3. 2. 1.

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How to weld Sealing Lips

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Following tools, equipment and staff have to be available: 1 Crane for grab operation 1 Crane operator 1 Crane operating instructor 2 skilled workers 1 gas / flame heater set 1 welding machine with welding accessories

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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

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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 Written by Kevin Wenke

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.

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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 Written by Kevin Wenke

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Weld the surfaces 1 to 11 - but only with a single layer!

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Start building up the welds until the desired thickness is reached.

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If you have accomplished this, you can weld the bevels and the lugs without problems.

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The Side sealing lips have to be fitted Similarly on the same scoop

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How to Repair the Lips

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