Terex Demag Crawler Crane CC2800-1 600T Maintenance Manual PDF

Terex Demag Crawler Crane CC2800-1 600T Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Terex Demag Crawler Crane CC2800-1 600T Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 328
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Terex Demag Crawler Crane CC2800-1 600T Maintenance Manual – PDF DOWNLOAD

Foreword
Index
1 Safety Instructions 3
1 1 General 3
1 2 Selection and Qualifications of Personnel 5
1 3 Particular Hazards 5
1 3 1 Dangers due to Crushing / Shearing 5
1 3 2 Dangers due to Reeling and Derricking 5
1 3 3 Dangers due to Slipping, Stumbling, Falling 5
1 3 4 Dangers due to Thermal Influences 7
1 3 5 Gas, Dust and Smoke 7
1 3 6 Dangers due to Residual Energy in the Hydraulic
System 7
1 4 Before Starting Lubrication and Maintenance Work 9
1 5 Undertaking Lubrication and Maintenance Tasks 13
1 6 Repairs 19
1 7 Recurrent Inspections of the Crane 21
1 8 Measures to Ensure Safe Operating Periods 35
1 8 1 General 35
1 8 2 Theoretical Service Life 37
1 8 3 Actual Operating Conditions 39
1 8 3 1 Determining the Operating Conditions
(Load Spectrum) 39
1 8 3 2 Operating Hours of the Hoists per Inspection Interval 41
1 8 4 Determining the Spent Share of the Theoretical
Service Life of the Winches 43
1 8 5 Documentation 45
2 Fuels and Lubricants 1
3 —
4 Lubrication and Maintenance Schedule 3
4 1 Initial Lubrication and Maintenance 3
4 2 Regular Routine Lubrication and Maintenance 3
4 3 Tips for Maintaining the Crane 5
4 4 Measures to Maintain the Crane: 5
4 5 List of Service Operations
8
5 Drive 3
5 1 Engine 3
5 2 Pump Distributor Gear — Checking the Oil Level 5
5 3 Pump Distributor Gear — Changing the Oil 7
5 4 Checking the Pump Distributor Gear for Leaks 7
5 5 Pump Distributor Gear —
Checking the External Screw Connections 9
Index
062–2003–151 2
6 Slew Ring Connection 3
6 1 Lubricating the Slew Ring Connection 3
6 2 Lubricating the Ring Gear 5
6 3 Checking the Screws of the Slewing Rim;
Operational Reliability of the Fixing Bolts 7
6 3 1 General 7
6 3 2 Checking the Torque of the Screws 7
7 Slew Gear 3
7 1 Slew Gear Mechanism, Checking the Oil Level 3
7 2 Slew Gear Mechanism, Changing the Oil 3
7 3 Slew Gear; Checking the Brake 5
7 4 Checking the Slew Gear Mechanism Screw Connections 7
7 5 Slew Gear Mechanism Visual Inspection 7
8 Hoists 3
8 1 Hoist 1 and 2 — Checking the Oil Level 3
8 2 Hoist 1 and 2 — Changing the Oil 5
8 3 Hoist 3 — Checking the Oil Level 9
8 4 Hoist Gear 3 — Changing the Oil 11
8 5 Reeving Winch — Checking the Oil Level 15
8 6 Reeving Winch — Checking the Oil 17
8 7 Hoists and Reeving Winch — Lubricating
the Rope Drum Bearings 19
8 8 Hoists and Reeving Winch; Checking the Brakes 19
8 9 Hoists and Reeving Winch — Checking and Re–tightening
the Screw Connections if Necessary 23
9 Luffing Gears 3
9 1 Luffing Gear 1 — Checking the Oil Level 5
9 2 Luffing Gear 1 — Changing the Oil 7
9 3 Luffing Gear 2 — Checking the Oil Level 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 — Checking the Brakes 17
9 7 Luffing Gears — Checking the Screw Connections
and Re–tightening if Necessary 23
10 Derricking Gear 3
10 1 Derricking Gear — Checking the Oil Level 3
10 2 Derricking Gear — Changing the Oil 5
10 3 Checking the Derricking Gear Brakes 9
10 4 Derricking Gear — Checking the Screw Connections
and Re–tightening if Necessary 15
Index
062–2003–151 3
11 Equipment 3
11 1 Maintaining the Hydraulic Cylinders on the Superstructure
and Equipment 3
11 2 Lubricating the Boom Bearings 5
11 3 Hook Blocks 7
11 3 1 Lubricating the Hook Blocks 7
11 4 Lubricating the Ropes 9
11 4 1 Cleaning the Ropes 11
11 5 Ropes 13
11 5 1 Checking and Replacing the Ropes if Necessary 15
11 5 2 General Information on Operation and Assembly 27
11 5 3 Transport 27
11 5 4 Storage 29
11 5 5 Mounting 29
11 6 Sheaves 41
11 6 1 Checking the Roller Bearings on the Sheaves 41
11 6 2 Checking the Sheaves 43
11 6 3 Replacing the Roller Bearing on the Sheaves 43
11 7 Checking the Main Boom and Fly Jib, A–frame and
Superlift Mast for Cracks in the Welds 45
11 8 Checking the Stay Bars, Bracing Rods and Mounting Rods 47
11 8 1 Checking the Stay Bars, Bracing Rods and Mounting Rods
for Cracks 51
11 8 2 Stay Bars, Bracing Rods and Mounting Rods — Checking
the Length 51
12 Hydraulic System 3
12 1 Hydraulic Oil Reservoir — Checking the Oil Level 3
12 2 Hydraulic Oil Reservoir —
Replacing the Return Oil 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 Accumulator Initial Gas Pressure 15
12 10 Hydraulic System —
Checking the Accumulator Initial Gas Pressure 17
12 11 Lower Luffing Mast Back Stops 21
12 11 1 Lower Luffing Mast Back Stops —
Checking the Oil Level 21
12 11 2 Lower Luffing Mast Back Stops — Changing the Oil 21
12 11 3 Checking the Lower Luffing Mast Back Stops for Leaks 23
12 11 4 Lower Luffing Gear Back Stops —
Checking the Screw Connections 23
Index
062–2003–151 4
13 Heating 3
13 1 Checking the System is Functioning Correctly 3
13 1 1 Checking the Fuses 5
13 1 2 Fault Diagnosis with the Heating Timer 5
13 2 Checking the Fuel Level 17
13 3 Checking the Water Level 19
13 4 Replacing the Heat Exchanger 19
13 5 Bleeding the heater 21
13 6 Air Conditioning Equipment (optional) 23
13 6 1 Switching on the Air Conditioning Equipment 23
13 6 2 Servicing the Air Conditioning Equipment 23
13 6 3 Having the Air Conditioning Equipment Checked 23
14 Electrical System 3
14 1 Checking the Lighting System 3
14 2 Checking the Battery Fluid Level 3
14 3 Checking the Limit Switches 3
14 4 Checking the Slip Ring Contacts on the Rope Winches and on
the Rotary Joint to the Undercarriage 3
14 5 Precautionary Measures Against Cable Fires 5
15 Fuel System 3
15 1 Draining Off Water and Residue From the Fuel Tank 3
15 2 Maintaining the Fuel Filter 3
15 3 Fuel System, Checking the Lines 5
16 Cooling, Air Intake and Exhaust System 3
16 1 Checking the Coolant Level and Topping Up if Necessary 3
16 2 Cleaning the Cooling System 5
16 3 Changing the Coolant 7
16 4 Cleaning and/or Replacing the Filter Element of the Air Filter 11
16 4 1 Dry Cleaning 13
16 4 2 Wet Cleaning 13
16 4 3 Checking the Element 15
16 5 Replacing the Safety Cartridge (Optional Equipment) 17
16 6 Exhaust System Visual Inspection 17
17 —
18 Crane Operator’s Cab 3
18 1 Checking the Windscreen Washing Assembly 3
18 2 Filling Up the Supply Tank of the Windscreen Washing Assembly 3
19 Undercarriage 3
19 1 Checking the Final Drive Oil Level 3
19 2 Changing the Oil in the Final Drive 5
19 3 Lubricating the Idlers, Bottom and Top Rollers 7
Index
062–2003–151 5
19 4 Lubricating the Connecting Pins 7
19 5 Maintaining the Hydraulic Cylinders on the Undercarriage 7
19 6 Tensioning the Crawler Track 9
19 7 Lubricating the Track Pins on the Track Typ Undercarriage and
Checking the Track Tension in the Case of Running Noises 11
19 8 Checking the Screw Connections and Re–tightening
if Necessary 13
19 9 Central Lubrication System 15
19 9 1 Component Parts 15
19 9 2 Operation 17
19 9 3 Setting the Interval and Operating Periods 19
19 9 4 Servicing Central Lubrication System 23
19 9 5 Filling the Tank of the Central Lubrication System 25
19 9 6 Troubleshooting 27
20 Counterweight carriage 3
20 1 Lubricating the Ball Bearing Slewing Rim 3
20 2 Lubricating the counterweight carriage 3
20 3 Final drive — Checking oil level 5
20 4 Final drive — Changing the oil 7
20 5 Tyres — Checking the air pressure, tread and rims 9
20 6 Tyres — Checking wheel nuts, tightening if required 11
20 7 Checking the Screw Connections 13
20 8 Checking the Welds for Cracks 13
21 Visual Inspections 3
21 1 Visual Inspection of the Superstructure and Crawler 3
21 2 Visual Inspections of the Superlift Counterweight Framework 3
21 3 Visual Inspection of the Equipment 5