Terex Crawler Crane Superlift CC3800 650 Ton Maintenance Manual – PDF DOWNLOAD

Terex Crawler Crane Superlift CC3800 650 Ton Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Terex Crawler Crane Superlift CC3800 650 Ton Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 572
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Terex Crawler Crane Superlift CC3800 650 Ton Maintenance Manual – PDF DOWNLOAD

Foreword 1
1 Safety Instructions 3
1 1 General 3
1 2 Personnel Selection and Qualifications 5
1 3 Particular Hazards 5
1 3 1 Risks from Crushing / Shearing 5
1 3 2 Risks of Snagging and Dragging 5
1 3 3 Dangers Due to Slipping, Tripping, Falling 5
1 3 4 Risks of Thermal Effects 7
1 3 5 Gas, Dust, Smoke 7
1 3 6 Risk of Residual Energy in the Hydraulic System 7
1 4 Before Commencing Lubrication and Maintenance Work 9
1 5 Carrying out Lubrication and Maintenance Work 13
1 6 Repair Work 17
2 Oils, Lubricants and Capacities 3
3 −
4 Lubrication and Maintenance Schedule 3
4 1 Initial Lubrication and Maintenance 3
4 2 Regularly Repeated Lubrication and Maintenance Work 3
4 3 Tips on Maintaining the Crane 5
4 4 Measures for Maintaining the Crane 5
4 4 1 Inspections of the condition 5
4 4 2 Preventative Maintenance 7
4 5 Maintenance List 9
5 Drive 3
5 1 Engine 3
5 2 Pump Distributor Gear − Checking the Oil Level 5
5 3 Pump Distributor Gear − Changing Oil 7
5 4 Checking the Pump Distributor Gear for Leaks 7
5 5 Pump Distributor Gear − Checking the External Screw
Connections 9
6 Roller−bearing Slewing Ring 3
6 1 Lubricating the Roller−bearing Slewing Ring 3
6 2 Lubricating the Ring Gear 5
6 3 Checking the Bolts on the Slewing Ring for Tightness 7
6 4 Checking the Lip Seals on the Slewing Ring 9
6 5 Quick Release Coupling 11
Index
036−2000−108_en 2
7 Slew Gear 3
7 1 Carrying out Visual and Noise Checks 5
7 2 Lubricating the Slew Gear Pinion 5
7 3 Slew Gearbox − Cleaning the Housing 7
7 4 Slew Gearbox − Checking the Oil Level 7
7 5 Slew Gearbox − Changing the Oil 9
7 6 Cleaning the Bleeder Valves 11
7 7 Slew Gearbox − Checking the Brakes 13
7 8 Slew Gearbox − Checking the Bolted Connections 15
8 Hoists and Reeving Winch 3
8 1 Hoists 1 and 2 − Checking the Transmission Oil Level,
Topping up Oil 5
8 2 Hoist 3 − Checking the Transmission Oil Level,
Topping up Oil 7
8 3 Hoists 1, 2 and 3 − Changing the Transmission Oil 9
8 4 Reeving Winch − Checking the Oil Level 13
8 5 Reeving Winch − Changing the Oil 15
8 6 Hoists and Reeving Winch − Lubricating the Rope Drum
Bearings 19
8 7 Checking the Rope End Fixture 19
8 8 General Overhaul of the Hoist Winches 19
8 9 Hoists and Reeving Winch − Checking the Brakes 21
8 10 Checking the Lower Limit Switches of the Hoists for Function 25
8 11 Checking the Hoist Limit Switches of the Hoists for Function 25
8 12 Hoists and Reeving Winch − Checking the Screw
Connections 27
9 Luffing Gears 3
9 1 Luffing Gear 1 − Checking the Oil Level, Topping up Oil 5
9 2 Luffing Gear 1 − Changing the Oil 7
9 3 Luffing Gear 2 − Checking the Oil Level, Topping up Oil 11
9 4 Luffing Gear 2 − Changing the Oil 13
9 5 Luffing Gear 1 and 2 − Lubricating Rope Drum Bearings 17
9 6 Luffing Gears 1 and 2 − Checking the Luffing Gear Brakes 17
9 7 Checking Exterior Screw Connections and Tightening if
Required 23
10 Derricking Gear 3
10 1 Derricking Gear − Checking the Oil Level, Topping up Oil 5
10 2 Derricking Gear − Changing the Oil 7
10 3 Derricking Gear − Checking the Brakes 11
10 4 Derricking Gear − Checking the Bolted Connections 17
Index
036−2000−108_en 3
11 Equipment 3
11 1 Service the Hydraulic Cylinders and Equipment 3
11 2 Boom − Lubricate the Bearing Points 5
11 3 Hook Blocks 7
11 3 1 Hook Blocks − Lubricate Bearing Points 7
11 4 Ropes 11
11 4 1 Lubricate Ropes 13
11 4 2 Clean Ropes 15
11 4 3 General Notes on Handling and Assembly 15
11 5 Sheaves 35
11 5 1 Check the Roller Bearings on the Sheaves 35
11 5 2 Check the Sheaves 37
11 5 3 Lubricating / Checking the Sheave Bearings 37
11 6 Adjustment Winch 41
11 6 1 Adjustment Winch − Checking the Oil Level 41
11 6 2 Adjustment Winch − Changing Oil 43
11 6 3 Adjustment Winch − Checking Bolted Connections 45
11 7 Carriage 47
11 7 1 Lubricating the Wheels 47
11 7 2 Tyres − Checking the Air Pressure 47
11 7 3 Removing a Wheel 47
12 Hydraulic System 3
12 1 Hydraulic Oil Reservoir − Checking the Oil Level 3
12 2 Hydraulic Oil Reservoir − Replacing the Return Line Filter 5
12 3 Hydraulic Oil Reservoir − Replacing the Aeration Filter 5
12 4 Leak Oil Circuit − Return Oil Filter − Cleaning the Filter
Element 7
12 5 Hydraulic Pump − Changing the Add−on Filter 9
12 6 Replacing the Hydraulic Oil 11
12 7 Bleeding the Hydraulic System 13
12 8 Checking the Hydraulic System for Leaks 13
12 9 Hydraulic System − Checking the Pressure Hoses 15
12 10 Hydraulic System − Changing the Pressure Hoses 15
12 11 Hydraulic System − Handling the Hose Couplings 17
12 12 Hydraulic System − Checking the Accumulator Initial Gas
Pressure 19
12 13 Lower Luffing Mast Support Cylinders 21
12 13 1 Lower Luffing Mast Support Cylinders − Checking the Oil
Level 21
12 13 2 Lower Luffing Mast Support Cylinders − Bleeding the
Cylinders 23
12 13 3 Checking the Lower Luffing Mast Support Cylinders for
Leaks 27
12 13 4 Lower Luffing Mast Support Cylinders − Checking the Bolted
Connections 27
12 14 Fly Jib Support Cylinders 29
12 14 1 Fly Jib Support Cylinders − Checking for Leaks 29
12 14 2 Fly Jib Support Cylinders − Checking the Oil Pressure 29
12 14 3 Fly Jib Support Cylinders − Checking the Gas Pressure 29
12 14 4 Correcting the Oil and/or Gas Pressure and Filling the
Support Cylinder 31
Index
036−2000−108_en 4
13 Heating and Air Conditioning 3
13 1 Engine−Independent Heating 3
13 1 1 Check the System is Functioning Correctly 3
13 1 2 Fault Diagnosis 5
13 1 3 Check the Water Level 9
13 1 4 Replace the Heat Exchanger 9
13 1 5 Replace Fuel Filter 11
13 2 Air Conditioning 13
13 2 1 Switch on the Air Conditioning 13
13 2 2 Air Conditioning − Visual Inspection by the Crane Operator 15
13 2 3 Have the Air Conditioning Checked 19
13 2 4 Air Conditioning − Having the Collector Dryer Replaced 21
13 2 5 Air Conditioning − Error Diagnosis of the Condenser 21
13 2 6 Air Conditioning − Error Diagnosis of the Heating /
Air Conditioning Unit 23
13 3 Liquid Petrol Gas Heating “Trumatic E2400” 31
13 3 1 Check the System is Functioning Correctly 33
13 3 2 Replace the Heat Exchanger 33
13 3 3 Having the System Checked 33
13 3 4 Perform a Visual Check 35
13 3 5 Replacing the Fuse of the Electronic Control Unit 37
13 3 6 Replacing the Gas Cylinder 39
14 Electrical System 3
14 1 Check the Lighting System 3
14 2 Check the Limit Switches 3
14 2 1 Lower Limit Switch − Checking the Functionality 3
14 2 2 Hoist Limit Switch − Checking the Functionality 3
14 3 Checking the Slip Ring Contacts on the Winches and the Rotary
Joint of the Chassis 5
14 4 Preventative Measures Against Cable Fires 5
14 5 Fuse Overview 11
15 Fuel System 3
15 1 Fuel Filter 5
15 1 1 Fuel Separator (Preliminary Filter) 5
15 1 1 1 Fuel Separator − Emptying the Inspection Glass 5
15 1 1 2 Fuel Separator − Changing the Filter Element 7
15 1 2 Fuel Filter in the Diesel Engine 11
15 1 2 1 Fuel Filter in the Diesel Engine − Changing Filter Element 11
15 1 3 Fuel Filter of the Heating 13
15 1 3 1 Fuel Filter of the Heating − Changing the Filter Element 13
15 2 Fuel Tank − Draining Water and Deposits 15
15 3 Fuel System − Checking the Lines 15
15 4 Filling up 17
Index
036−2000−108_en 5
16 Cooling, Intake and Exhaust System 3
16 1 Cooling System 3
16 1 1 Cooling System − Visual Check 3
16 1 2 Cleaning the Cooling System 3
16 1 3 Checking the Coolant Level, Topping up If Required 5
16 1 4 Changing the Coolant 7
16 2 Intake System 11
16 2 1 Intake System − Visual Check 11
16 2 2 Replacing the Filter Element of the Air Filter 11
16 2 3 Cleaning the Filter Element 13
16 3 SCR System 15
16 3 1 Carrying out Visual Inspections of the SCR System 17
16 3 2 Safety Instructions when Handling AdBlue) 19
16 3 3 AdBlue) Tank 21
16 3 4 Pump Module 25
16 3 4 1 Pump Module − Filling the Compressed Air Reservoir 27
16 3 4 2 Pump Module − Replacing the AdBlue) Filter 29
16 3 4 3 Pump Module − Checking the AdBlue) Filter for Debris
Residue 31
16 3 5 SCR Catalytic Converter 33
16 3 6 SCR System − Draining the Compressed Air Tanks 35
16 3 7 SCR System − Air Drier: Replace Granulate Cartridge 35
17 Piston Rods 1
17 1 Exposed Chrome Surfaces − Applying Protective Grease 1
18 Crane Operator’s Cab 3
18 1 Check the Windscreen Washer System for Proper
Functioning 3
18 2 Fill up the Supply Tank of the Windscreen Washer System 3
18 3 Lubricating the Cab Tilt Cylinder 5
19 Crawler Chassis 3
19 1 Drive Gearbox 3
19 1 1 Transmission − Checking the Oil Level 3
19 1 2 Drive − Checking the Oil Level 5
19 1 3 Motor Flange − Checking the Oil Level 5
19 1 4 Transmission − Changing Oil 7
19 1 5 Drive − Changing Oil 9
19 1 6 Motor Flange − Changing the Oil 11
19 1 7 Cleaning the Bleeder Valves / Filters 13
19 1 8 Cleaning the Drive Gearbox 13
19 2 Lubricating the Idlers, Support and Track Rollers 15
19 3 Lubricating the Connecting Pins 15
19 4 Servicing the Hydraulic Cylinders on the Chassis 15
19 5 Tensioning the Track Group 17
19 6 Lubricating the Track Pins on the Track Group of the
Crawler−mounted Crane and Checking the Track Tension in
the Case of Running Noises 19
19 7 Checking the Screw Connections of the Drive Gearbox 21
19 8 Central Lubricating System 23
19 8 1 Component Parts 23
19 8 2 Function 23
19 8 3 Servicing the Central Lubricating System 25
19 8 4 Filling the Tank of the Central Lubrication System 27
19 8 5 Troubleshooting 29
Index
036−2000−108_en 6
20 Counterweight Dolly 3
20 1 Lubricate the Ball Bearing Slewing Ring 3
20 2 Lubricating the Ring Gear 3
20 3 Check the Screws of the Slewing Ring 5
20 4 Slewing Gear 7
20 4 1 Slew Gear Mechanism − Checking the Oil Level 7
20 4 2 Slew Gear Mechanism − Changing Oil 7
20 4 3 Slew Gear Mechanism − Checking the Disc Brake 9
20 4 4 Slew Gear Mechanism − Checking the Bolted Connections 11
20 4 5 Slew Gear Mechanism − Visual Inspection 11
20 5 Final Drive − Check the Oil Level 13
20 6 Final Drive − Replacing Oil 15
20 7 Tyres − Check the Air Pressure, Tread and Rims 19
20 8 Tyres − Checking the Wheel Nuts, Tightening if Required 21
20 9 Check Weld Seams for Cracks 23
21 Visual Checks 3
21 1 Visual Check − Superstructure and Crawler Chassis 3
21 2 Visual Checks on the Superlift Counterweight Supporting
Frame 3
21 3 Visual Check − Equipment 5
22 Inspections of the Crane 3
22 1 Recurrent Inspections of the Crane 3
22 1 1 Inspection of Load−bearing Steel Constructions 15
22 1 2 Inspection of the Disc Wheels (Rims) 57
22 1 3 Inspection of the Winches 59
22 1 3 1 Theoretical Service Life 61
22 1 3 2 Actual Operating Conditions 63
22 1 3 3 Determining the Operating Conditions (Load Spectrum) 63
22 1 3 4 Operating Hours of the Hoists per Inspection Interval 65
22 1 3 5 Determining the Spent Share of the Theoretical Service Life
of the Winches 67
22 1 3 6 Documentation 69
22 1 4 Load Hook 73
22 1 4 1 Inspection and Surveillance Measures 73
22 1 5 Inspection of the Sheaves 75
22 1 6 Inspection of the Ropes 77
22 1 7 Documentation 91
23 Central Lubricating System 3
23 1 Function 5
23 1 1 Setting the Interval and Operating Times 7
23 2 Service the Central Lubricating System 11
23 2 1 Filling the Tank of the Central Lubrication System 13
23 3 Troubleshooting 15