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DOCUMENTATION

Grab type:
EGF 24,0-1,25-12000

Com. - no.:
171.00.280

Serial - no.:
2103 / 2104 / 2105 / 2106

Salzgitter Maschinenbau AG Phone: E-mail: Board of management: Domicile of company: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 (0)53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Chairman), Registration court:
38259 Salzgitter / Germany Fax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 (0)53 41 / 302 424 www.smag.de Chairman of the Supervisory Board: Registration number:
www.peiner.de Ulrich Decker HRB 201 389
19.07.2001

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PEINER Greifer
OPERATING INSTRUCTIONS
ROPE GRABS
Class-no. Page-no.
A 25.0333 E 1-1

Contents Page-no. Class-no.

1.0 Machine card

2.0 Constructive description 3/1-3 A 25.0263/1-3 E

3.0 Functional description 4/1-6 A 25.0332/1-6 E

3.1 Prerequisites for the transportation of grab 4-7 A 25.0299 E

4.0 Maintenance of the hydraulic system 5/1-4 A 25.0274/1-4 E

4.1 Oil level check 5/1-4 A 25.0274/1-4 E

4.2 Oil filling 5/1-4 A 25.0274/1-4 E

4.3 Deaeration of the hydraulic system 5/1-4 A 25.0274/1-4 E

4.4 Oil change 5/1-4 A 25.0274/1-4 E


4.4.1 Remove waste oil (drain)
4.4.2 Refill hydraulic oil

5.0 Emergency operation 6-1 A 25.0334 E

6.0 Lubricating points 7/1-2 A 25.0271/1-2 E

7.0 Failures and causes 8-1 A 25.0265 E

8.0 Technical data of the radio remote control 9/1-5 A 25.0272/1-5 E

9.0 Technical data of the accumulators 10/1-4 A 25.0273/1-4 E

Salzgitter Maschinenbau AG Telefon: E-mail: Vorstand: Sitz der Gesellschaft: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 (0)53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Vorsitzender), Registergericht:
38259 Salzgitter / Germany Telefax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 (0)53 41 / 302 424 www.smag.de Vorsitzender des Aufsichtsrates: Registernummer:
www.peiner.de Ulrich Decker HRB 201 389
MEGFE.DOT
Salzgitter Maschinenbau GmbH Operating Instruction Order-no. : 171.00280
Single Rope Grab / Remote Control Date : 21.08.2003
1. Machinery Data Card (techn. data) Sheet-no. : 1

Operating Instruction: A 25.0333 Spare part list: T 2301.0613

Product* Item-no. Serial-no.* Year of built* Client


EGF 24,0 - 1,25 - 12000 2301.0613 2103-2106 2003 Marmaras Navigation Ltd.
Piraeus / Griechenland

General Data:

Capacity* 12,0/10,0/8,0/6,0 m³ Cylinder-mat.-no. 24421 / 1380 lift


Payload 15000 kg 4/2 way-valve -type NG6 12V DC 4D01-
3103
Dead weight* 9200 kg 4/2 way-valve -mat.-no. 22524
Required SWL* 24200 kg Control voltage 12 V
Bulk material different Oil capacity 100 l
Piled density 1,25-2,5 t/m³ Type of oil HLP10
Granulation up to 30 mm theor. opening time 15+3 s

Dimensions:
A 8600 mm D 3795 mm
B Max. 9000 mm E 3910 mm
C 3280 mm F mm

Grab stop by means of: Suspension link size A45 DIN 5688

Ropes / Sheaves

Closing rope Casar-Stratoplast 1960N/mm² Rope sheave-Ø 560 mm


Closing rope-Ø 28 mm Rope Joint 22-29
Closing rope length 9100 mm Rope grommet size 28 DIN 3090
Closing rope withdrawn to close 3450 mm Rope bell mouth 2300.1106

Scoops / Lips:

Design TS 22.02(pos.C) / TS 21.03;TS 21.06 Material 1.0570 / Hardox 400


A-A

Desgn of bearings:

Scoops : slide bearings made of manganese steel,relubricatable

Press rods : slide bearings made of manganese steel,relubricatable

Rope sheaves : bronze slide bearings,relubricatable

Remark : LRS-acceptance
scoops:equipped with kick plates; bottom lips screwed; lateral lips with
welded sealing strip of steel

*Data of designation plate

Responsible for control

J:\2003\Maschinenkarten\17100280e.doc
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2.0 Constructive description PEINER Single-Rope Grab, type EGF

The PEINER Single-Rope Grab, type EGF, consists of following main units
(see page-no. 3-3).

Item 1: suspension
Item 2: grab head
Item 3: pressure rod
Item 4: mobile traverse
Item 5: rope compensation frame
Item 6: traverse
Item 7: locking cylinder
Item 8: scoop
Item 9: elektric system
Item 10: hydraulic system
Item 11: radio remote control

The suspension connects the two closing ropes and the lifting rope.
The crane hook is simply attached to provided oval suspension eye.

ATTENTION ! For reasons of operational safety, the hook must be provided


with a securing device.

Housed in the grab head is the upper roller block of the lifting block with three-fold
reeving. Screwed rope bell mouths made of hardened steel serve as closing rope guide.

The pressure rods connect the scoops and the grab head, thus forming the counterpoint
for grab closing rope guide.

The mobile traverse houses in lower roller block of the lifting block system. The closing
rope forces are transmitted the the piston rods of locking cylinders being thightly
screwed to the mobile traverse.

The extremities of the closing ropes are linked to the rope compensation frame which is
connected in pendulum fashion with the mobile traverse. If the grab has a tilt, the ropes
being centrally transmitted to the mobile traverse.

The traverse is the pivot connection of the scoops and hoses the hydraulic and electric
system.

The locking cylinders connect the mobile traverse and the traverse, the closing rope
forces thus beeing transmitted via the traverse to the scoops of the single-rope grab. To
open the grab, the locking cylinders are hydraulically unlocked, i. e. the piston rods are
extended due to the weights of traverse, scoops and bulk material until the grab is
openend.
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The scoops serve to pick up the bulk material. When handling heavy bulk materials, the
grab and the lifting appliance can be protected against overload by opening the spill
plates provided in the scoops.

Housed in a steel plate case, the electric system is protected against atmospheric
influences.
A nickel-cadmium battery provides for the energy supply of the consumers (transmitter
and solenoid valve) for a grab operating time up to 24 hours, depending on the
switching rate.

The hydraulic system is housed in the traverse.


Hydraulic hoses serve to connect the locking cylinders with the oil tank and the control
block. In case of a remote control or electric failure the hydraulic system (solenoid valve)
can be controlled manually via an emergency switch system to open the grab.

The radio remote control mainly consists of a transmitter and a receiver.


Being housed in a steel plate housing together with the elctric system, the receiver is
protected against any influences. The transmitter can either be carried by the operator
by means of a neck strap or remains stationary in the crane cabin. Depending on the
switching rate, the max. operating time is about 24 hours. If the transmitter is stationary,
it can be additionally equipped with a suitable power pack (extra equipment).

The batteries of transmitter and receiver can be simultaneously recharged by means of


the charger included in the scope of supply. The recharging time amounts to about 12 to
14 hours. The required mains voltage can be either 110 V or 220 V. The charger
automatically settles to applied voltage.
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3.0 Functional description PEINER Single-Rope Grab EGF

The PEINER Single-Rope Grab functions in four different operational phases.

Phase 1 (see page-no. 4-3):

The opened grab hangs on the lifting appliance.


The piston rods of the locking cylinders are extended. The 4/2-way valve is in switching
position „closed“.

Phase 2 (see page-no. 4-4):

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.

When the piston comes down in the cylinder, the center pin at the button of the locking
cylinder completely penetrates the piston rod, thus sealing the piston rod section
towards the piston section. Being hydraulically locked, the locking cylinders thightly
connect the mobile traverse (lower roller block) and the traverse (scoops).

The 4/2-way valve is still closed.

Phase 3 (see page-no. 4-5):

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.

Phase 4 (see page-no. 4-6):

To open the grab the transmitter push button is to be actuated.


The transmitter signal releases a switching pulse to the solenoid valve of the control
block. The 4/2-way valve is out of the piston rod section of the lifting cylinders and the
center pin through a throttling port provided in the piston rod, via hose line L2 and the
opened valve into the oil tank. The piston rods of the locking cylinders are extended,
thus the grab beginning to open.
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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 rod of the locking cylinders, the locking
cylinders can be hydraulically locked, i. e. on dropping out of the transmitter signal the
grab remains in ist present opening position and the bulk material can flow out in definite
dosis.

To open the grab completely, the transmitter push button must be actuated once again.
Thus, the 4/2-way valve releases the locking cylinders again until the piston rods are
extended, thus the center pin being drawn out of the piston rods and the piston rod
section no longer being sealed towards the piston section of the locking cylinders. On
dropping out of the transmitter signal, the 4/2-way valve is automatically closed again,
the hydraulic oil flowing out of the piston rod section of the locking cylinders through a
throttlíng port provided in the piston rod, into the piston section of the locking cylinders.
The differential is sucked out of the oil tank via hose line L1 into the piston section of the
locking cylinders. The piston rods are continously extended until the grab is completely
opened and thus the operational phase 1 is reached again.
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Class-no. Page-no.
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3.1 Prerequisites for the transportation of grab

If the grab is transported while lying down, the tank must be closed tightly. This is
done by replacing the filter cap by the plug with o-ring.

Condition for grab operation


(tank ventilated)

Condition for transport of the grab


(tank closed)
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ROPE GRABS
Class no. Page no.
A 25.0274-1 E 5-1

4.0 Maintenance of the hydraulic system

4.1 Oil level check

• Put down the grab with opened shells on a horizontal even ground.
• The mobile traverse must be in lower position (piston rods of the locking cylinders
are completely retracted)
• Remove the tank cover
• The oil level is correct if it is about 50mm to 60mm below the top edge of the filter
housing (see fig. 1)

Attention! The following hydraulic oil quantity must be refilled for a difference of
1 cm of the fill level in the oil tank:

grab type EGF 20,0: 0,63 l


grab type EGF 24,0: 0,90 l

Only mineral oil-based hydraulic oil as indicated in the table of recommended oil (see
section 6.0) is admissible for refilling. If other oil grades are used, this might lead to
malfunctioning and to deteriorations or destructions of components. Alternative oil
grades may only be used with prior consent of the PEINER service department.

Fig. 1
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ROPE GRABS
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4.2 Oil filling

• Check the oil level observing the provisions of section 4.1 „Oil level check “
• The admissible soiling degree of the hydraulic oil must be according to NAS 1638
class 7-9 (to be reached with a filter mesh of β 10 > 75 according to ISO 4572; if
necessary, the admissible soiling degree must be guaranteed by filtering the oil
before refilling it)
• Only refill hydraulic oil through the opened tank cover and the appertaining coarse
filter
• Check the oil level observing the provisions of section 4.1 „Oil level check “

4.3 Deaeration of the hydraulic system

• Put down the grab with opened shells on a horizontal even ground.
• The mobile traverse must be in lower position (the piston rods of the locking
cylinders are completely retracted)
• Suspend the grab suspension device from the crane hook (as far as not already
done)
• Operate the lifting device carefully in the „LIFT“ mode and lift the lower traverse in
the grab by a few centimeters with this lifting movement until the hydraulic oil
pressure in the locking cylinders is sufficient.
• Carefully unscrew the vent screw 1 (see fig. 2) on the locking cylinder-right until an
oil-air mixture visibly escapes from the cylinder. (Attention: the vent screw must
never be completely unscrewed)
• Retighten the vent screw if no more air escapes
• Carefully unscrew the vent screw on the locking cylinder-left and proceed as
described for deaeration of locking cylinder-right.
• Check oil level observing paragraph 4.1 „Oil level check“, if necessary refill
hydraulic oil observing the provisions of paragraph 4.2 „Oil filling“

1 2

Fig. 2
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ROPE GRABS
Class no. Page no.
A 25.0274-3 E 5-3

Attention! The hydraulic system must be deaerated before being put into operation
for the first time always. This is particularly necessary after a transport
and after long downtimes. It is recommended, however, to deaerate the
system each time before putting it into operation.
According to the refilled oil grade, to the service and ambient
temperature, the functioning of the grab can be improved (tightly closing
grab lips) by deaerating the system two or three times every 60 minutes
after putting the grab into operation.

4.4 Oil change

4.4.1 Remove waste oil (drain)

• Put down the grab with opened shells on a horizontal even ground.
• The mobile traverse must be in upper position (the piston rods of the locking
cylinders are completely extended)
• Put an appropriate pan under the grab / oil tank to collect the waste oil. The
capacity of this pan should be as follows

for grab type EGF 20,0 60 l


for grab type EGF 24,0 100 l

• Completely unscrew the oil drain plug at the bottom of the tank and drain the waste
oil (Recommendation: The oil tank should be cleaned with appropriate agents and
observing the according safety regulations after emptying it.)
• To empty the locking cylinder completely, the locking screws 2 (see fig. 2) of the
locking cylinders must be completely unscrewed
• Rescrew the oil drain plug and tighten it, if necessary replace the sealing before
rescrewing the oil drain plug.

4.4.2 Refill hydraulic oil

Attention! Only use mineral oil-based hydraulic oil as indicated in the table of
recommended oils (see table in section 6.0). If other oil grades are used,
this might lead to malfunctions and destroy or deteriorate components.
Alternative oil grades may only be used after the PEINER service
department´s consent.

• The admissible soiling degree of the hydraulic oil to be refilled is in conformity with
NAS 1638 class 7-9 (to be reached with a filter mesh of β 10 > 75 according to ISO
4572; if necessary, the admissible soiling degree must be guaranteed by filtering
the oil before refilling it)
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• 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“)
• 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)

Attention! The functional and operational safety extremely depends on the hydraulic
oil quality. This is why the hydraulic oil must be checked and replaced at
regular intervals. We recommend to have the suitability of the hydraulic
oil checked every 1000 service hours or after every 12 months.

Generally all well-known oil and lubricant suppliers offer oil analysis.

If you have any questions regarding the oil analysis or its execution, feel
free to contact the SMAG service department´s staff.
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5.0 Emergency operation

The grab can also be opened manually in case of electric or radio remote control
failures or of repair and maintenance purposes.

In case of emergency, a steel cable provided at the rear of the steel plate case is to be
pulled. The actual emergency switch is housed in the steel plate case.
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6.0 Lubricating points (see page no. 7-2)

Lubricating instructions

Lubricate the ∆ -marked lubricating points as follows:

- prior to every operation


- during operation at least all 24 hours
- after taking out of operation
- after taking out of operation at least one time every week

lubricating intervals depend on bulk cargo

Ropes resp. links to be lubricated at the same intervals.

Recommended lubricant: lithium-saponified oil / grease


DIN 51825 - KTAL2k
for wire rope - adhesive grease lubrication
DIN 51513-BC

Adhesive grease Lithium-saponified Hydraulic oil


oil / grease lubrication

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


Type: HLP 10

AGIP FIN 332/F Longlime Grease 2 Agip OSO 10

BP Energrease MP-MG2 Energrease LS 2 Energol HLP 10

ESSO Surett Fluid 4K Beacon 2 Nuto H 10

Mobil Oil Mobiltac D Mobilux 2 Mobil DTE 21

Shell Cardium Fluid C Alvania R 2 Tellus Oel 10


Alvania G 2
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7.0 Failures and causes

Failure Cause

Grab does not open - Battery receiver is discharged or


defective
- Battery transmitter is discharged or
defective
- The cable of the plug-in connector
between battery and transmitter or
solenoid valve is defective
- Antenna is defective or not erected
- Antenna cable is defective
- The scoop pivot point or thrust rods
bolt connection is tight

Grab does not close - The directional valve is defective


(valve piston is jamming / is stuck in
opened position)
- Emergency control is tight or is
jamming, i. e. the valve piston is kept
in opened position

Grab closes, but opens automatically - Leaking cylinder sealings


- Leaking nonreturn valves in the
cylinder
- Leaking valve seat
- Leakage in the piping

Locking cylinder slips, i. e. the piston rod - Air in the cylinder or in the piping
does not remain in the locked position system
20.10.1999

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8.0 Technical data of the radio remote control

Transmitter:

Operating voltage: 12 V
Transmitter frequency: 434,475 MHz
HF-output: 500 mW
Length of rod antenna: ca. 170 mm
Protection system: IP 55
Weight with accumulator: ca. 2 kg

Receiver:

Operating voltage: 12 V
Length of rod antenna: ca. 170 mm
Protection system: IP 65

The radio remote is designed for correct, wireless transmission of the command „open
grab“. It consists of a portable transmitter and a receiver mounted on the grab.

By a codified data on a carrier frequency being checked in the receiver by means of a


microprocessor is a transmission security achieved that only mathematically an error
can come up every million of years.

The transmitter is mounted in a rectangular tube, the rod antenna and the push button
for the transmitting impulse are mounted on the upper front side of the tube. The Ni-Cd-
accumulator for the power supply of the transmitter box from below.

The receiver is mounted in a fibre glass-reinforced polyester housing.


The antenna screw connection with the rod antenna is provided at one front side, the
other front side is provided with a plug-in connector for power supply and with the outlet
for control of the solenoid valve.

The transmitter will operate after actuation of the push button only.
Permanent actuation creates one single transmitting impulse of about 2 to 5 seconds.
By means of a potentiometer, the time can be adjusted continuosly at the lower side of
the male insert. The transmitting impulse can be interrupted by releasing the push
button. If several transmitting impulses are necessary for opening the grab, at least 0,5
secs should be waited until the push button is pushed again.

In case several remote controls with the same carrier frequency give in close proximity
to each other a transmitting impulse, the receivers may influence each other and do not
give an output signal due to safety reasons. Consequently an operation of several grabs
can be done successively only.

Attention! The application of this system requires previous authorization of the


corresponding country in question and observance of ist regulations. The
responsibility for it has be borne by the owner.
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Prinzipschaltplan
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9.0 Technical data for the accumulators

For transmitter:

Type: Nickel-Cadmium
Operating voltage: 12 V
Rated capacity: 0,30 Ah
Rated charging current: 30 mA approx.
Charging time: 14 hours approx.

For grab:

Type: Nickel-Cadmium
Operating voltage: 12 V
Rated capacity: 7 Ah
Rated charging current: 0,87 A approx.
Charging time: 14 hours approx.

The accumulator for the transmitter is mounted in a aluminium cast housing.


A plug-in connector ensures quick change of the accumulators during handling
operation and connection to the charging set.

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.

The acculmulators are deminsioned in such a way that the grab can be operated with 30
cycles per hour for 24 hours approx. It is recommended to change the accumulator for
the transmitter and for the grab after 24 hours latest.

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 120 V and 200 V to 240 V, 50 Hz
and 60 Hz. The change-over for the respective tension is effected automatically in the
charging set. A manual adjustment is not necessary.
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