How to disassemble the

Guide Nut & Piston Rod

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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 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)

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 20

T = 20

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 1. Connect the Crane and place the Grab in OPEN Position on
the ground and lower the MOBILE TRAVERSE completely.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.
Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 6. Disassemble the pins from the steering arms /
connection to the scoops.

6
7. Put the GRAB HEAD with all assembled items aside.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 How to change the Seals
(Instruction no. 8)

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
Installation of Piston Seals

The following points should be observed

before installation of the seals:
- Ensure the cylinder tube has a lead-in chamfer; if
not, use an installation sleeve

- Deburr and chamfer or round sharp edges, cover the

tips of screw threads
- Remove machining residues such as chips, dirt and
other foreign particles and carefully clean all parts
- The seals can be installed more easily if they are greased
or oiled. Attention must be paid to the compatibility of
the seal materials with these lubricants. Use only grease
without solid additives (e.g. molybdenum di sulphide or
zinc sulphide).
- Use no sharp-edged installation tools

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 HIGH PRESSURE

line to the valve

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
GUIDE
Assembly
direction
Tube Top
side side

Dark / Grey Light / yellow

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 Page no.127

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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 Installation in Closed Grooves
- With installation aids
Use of a three-piece installation tool is recommended for the series
production installation of TurconR and ZurconR seal elements. The tool
consists of:
- Installation sleeve
- Expanding sleeve
- Sizing sleeve
All these parts should be made of a polymer material (e.g. PA6) with the
good sliding characteristics and low abrasiveness to avoid damage to
seals.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 heating in oil

110°C -130°C
1 expanding sleeve 2

installation sleeve 3 4

sizing sleeve 5

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
Installation of Rod Seals

The following points should be observed

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

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

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

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 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.

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 Installation in Closed Grooves

By following the instructions in each seal type description (sizes

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

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.
 - 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

Note: Copyright Salzgitter Maschinenbau AG 2010. This publication has been prepared as an aid 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 120306
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 KWE
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.