Demag CC 2800-1 Crawler Crane Part 2 Lubrication and Maintenance Instructions PDF

Description

Demag CC 2800-1 Part 2 Lubrication and Maintenance Instructions

This is the complete Part 2: Lubrication and Maintenance Instructions for the Crane for the Demag CC 2800-1 crawler crane. It is the dedicated service volume that sits alongside the operating manual, and it is where the scheduled lubrication, routine maintenance and recurring inspection procedures for the whole machine are documented. Every chapter is written against the CC 2800-1 specifically, from the engine and pump distributor gear through the slew ring, hoists, luffing and derricking gears, hydraulics, undercarriage and counterweight dolly.

File Details

• Manual type: Lubrication and Maintenance Instructions (Part 2)
• Brand: Demag / Terex-Demag
• Model: CC 2800-1
• Language: English
• Page count: 510 pages
• File format: PDF
• Document numbers: 062-2002-200_en, 062-2010-200b_en, 062-2020-375_en, 062-2040-315_en, 062-2050-200c_en, 062-2060-289_en, 062-2070-200d_en, 062-2080-375_en, 062-2100-375_en, 062-2120-271h_en, 062-2130-315b_en, 062-2140-263a_en, 062-2150-254d_en, 062-2160-250c_en, 062-2170-200a_en, 062-2180-200a_en, 062-2190-213f_en, 062-2200-288a_en, 062-2210-200a_en, 062-2220-331c_en

Chapters Covered

• 1 Safety Instructions — general, personnel selection, particular hazards, before commencing work, carrying out work, repair work
• 2 Fuels and Lubricants — permitted fuels and lubricants, temperature ranges, grease and oil filling points
• 4 Lubrication and Maintenance Schedule — initial lubrication, regular routine lubrication, maintenance list
• 5 Drive — engine, pump distributor gear oil level and oil change, leak checks, external screw connections
• 6 Roller Bearing Slewing Rim — slew ring connection lubrication, ring gear lubrication, screw torque checks
• 7 Slew Gear — oil level, oil change, brake check, screw connections, visual inspection
• 8 Hoists — hoists 1, 2 and 3 oil level and oil change, receiving winch, rope drum bearings, brakes, limit switches
• 9 Luffing Gears — luffing gear 1 and 2 oil level and oil change, rope drum bearings, brake checks, screw connections
• 10 Derricking Gear — oil level, oil change, brake checks, screw connections
• 11 Equipment — hydraulic cylinders, boom bearings, hook blocks, ropes, sheaves, jib top section
• 12 Hydraulic System — oil reservoir, filters, oil change, bleeding, leaks, pressure hoses, hose couplings, accumulators, luffing mast back stops, outrigger cylinders
• 13 Heating and Air Conditioning — engine-independent heating, liquid gas heating, air conditioning servicing and error diagnosis
• 14 Electrical System — lighting, limit switches, slip ring contacts, cable fire precautions, fuse overview
• 15 Fuel System — fuel separator, fuel filter, fuel tank draining, refuelling procedures
• 16 Cooling, Intake and Exhaust System — coolant check, cooling system cleaning, cooling fluid change, air filter element
• 17 Piston Rods — exposed chrome surfaces protective grease
• 18 Crane Operator’s Cab — windscreen washing, supply tank, cab tilt cylinder lubrication
• 19 Undercarriage — final drive oil level and change, disc brake oil, idlers and track rollers, connecting pins, track tension, central lubricating system
• 20 Counterweight Dolly — slewing rim lubrication, ring gear, slew gear, final drive, travel drive, tyre pressure, wheel nuts, weld checks
• 21 Visual Checks — superstructure and crawler chassis, superlift counterweight frame, equipment
• 22 Examinations of the Crane — recurring inspections, load-bearing steel constructions, disc wheels, winches, theoretical service life, hooks, sheaves, ropes, documentation

The manual is organised around the maintenance intervals printed in the lubrication and maintenance schedule, so the technician can see exactly which task falls due at 10, 50, 250, 500, 1000 hours or annually. Each chapter then walks through the procedure for that component: how to check the oil level, how to drain and refill, how to verify the brake on a hoist, luffing or derricking gear, how to confirm the slew ring screw torque, how to bleed the hydraulic system, how to check the accumulator gas pressure, and how to handle the outrigger cylinders on the lower luffing mast and the fly jib. Safety callouts, torque tables and exploded component diagrams appear throughout, along with the fuel and lubricant specification tables that list the permitted products and the ambient and operating temperature ranges.

What This Manual Enables

With this document a maintenance technician can carry out the full scheduled service on a Demag CC 2800-1 without guesswork. The oil level checks for the pump distributor gear, slew gear, hoists, luffing gears and derricking gear are all documented with the exact plug, dipstick or inspection glass to use. The brake test procedures for the hoist, luffing and derricking winches are laid out step by step with the load conditions and the holding time needed to confirm the brake is sound. The hydraulic chapter gives the filter change sequences, the bleeding procedure, the hose replacement interval and the accumulator gas pressure check, while the undercarriage chapter covers final drive oil, disc brake oil, track tensioning with spacer sleeves and the central lubrication system fault-finding.

Because the CC 2800-1 is a large crawler crane, the cost of a service error or a missed brake check is high. Having the correct torque values — for example the slew rim M 56 screws at 12,000 Nm, the hoist gear housing M 24 at 1,000 Nm, or the counterweight dolly slew rim screws at 880 Nm — in front of you when the wrench is in your hand is what turns a risky job into a routine one. The recurring inspection chapter also explains how to calculate the used proportion of the theoretical service life of the winches from the load collective and operating hours, which is a legal requirement in many jurisdictions and a core part of the crane’s inspection documentation.

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Instant PDF Delivery

The manual is delivered as a PDF download immediately after payment. There is no shipping, no waiting for a courier and no physical book to keep track of. You can open the file on a laptop, tablet or phone in the workshop, print the pages you need for a specific job, or keep the full 510-page document on a memory stick in the tool cabinet. Whether you are servicing the slew ring, adjusting the track tension, changing the hydraulic oil or preparing the crane for its annual inspection, the relevant procedure and the supporting torque and capacity data are in the same file.