Terex Demag Crane CC 2500-1 Lubrication Manual – PDF DOWNLOAD

Description

Terex Demag Crane CC 2500-1 Lubrication Manual – PDF DOWNLOAD

FILE DETAILS:

Terex Demag Crane CC 2500-1 Lubrication Manual – PDF DOWNLOAD

Language : English
Pages : 512
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Terex Demag Crane CC 2500-1 Lubrication 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 from Entanglement and Dragging 5
1 3 3 Danger Due to Slipping, Tripping, Falling 5
1 3 4 Risks From Thermal Influences 7
1 3 5 Gas, Dust, Smoke 7
1 3 6 Risks From 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 Regular, Routine Lubrication and Maintenance 3
4 3 Tips on Maintenance of the Crane 5
4 4 Measures for Maintaining the Crane 5
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 the 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 Rim 3
6 1 Lubricating the Roller Bearer Slewing Rim 3
6 2 Lubricating the Ring Gear 5
6 3 Checking the Screws of the Slewing Rim 7
6 3 1 General 7
6 3 2 Checking the Torque of the Screws 7
6 4 Quick–Disconnect 11
7 Slew Gear 3
7 1 Slew Gear — Checking the Brake 5
7 2 Checking the Slew Gear Mechanism Screw Connections 7
7 3 Slew gear mechanism visual inspection 7
Index
059–2000 2
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 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 Retightening the
Screw Connections if Necessary 23
8 10 Hoist Limit Switch and Lower Limit Switch — Checking
Functionality 25
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 Derricking Gear — Lubricating the Rope Drum Bearings 7
10 4 Derricking Gear — Lubricate Sheaves 7
10 5 Checking the Derricking Gear Brakes 9
10 6 Derricking Gear — Checking the Screw Connections and
Retightening if Necessary 15
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 Block 7
11 3 1 Lubricating the Hook Blocks 7
11 4 Ropes 9
11 4 1 Lubricating the Ropes 11
11 4 2 Cleaning the Ropes 13
11 4 3 General Information on Operation and Assembly 13
11 5 Sheaves 29
11 5 1 Checking the Roller Bearings on the Sheaves 29
11 5 2 Checking the Sheaves 31
11 5 3 Lubricating the Sheave Bearing 31
Index
059–2000 3
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 Flexible Pressure Tubing 15
12 10 Hydraulic System — Changing 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 Back Stops 23
12 13 1 Lower Luffing Mast Back Stops — Checking the Oil Level 23
12 13 2 Bleeding Outrigger Cylinder Lower Luffing Mast —
Cylinder 25
12 13 3 Checking the Lower Luffing Mast Back Stops for Leaks 29
12 13 4 Lower Luffing Gear Back Stops —
Checking the Screw Connections 29
12 14 Outrigger Cylinder for Outrigger Strut LF 31
12 14 1 Support Cylinder for Support LF – Check Oil Level,
Deaerate Cylinder 31
12 14 2 Outrigger Cylinder for Outrigger Strut LF — Filling With Oil (After Repairs)
33
12 15 Outrigger Cylinder Fly Jib 35
12 15 1 Outrigger Cylinder Fly Jib — Checking for Leaks 35
12 15 2 Outrigger Cylinder Fly Jib — Checking the Oil Pressure 35
12 15 3 Outrigger Cylinder Fly Jib — Checking the Gas Pressure 35
12 15 4 Correcting the Oil and/or Gas Pressure and Filling the O
utrigger Cylinder 37
13 Heating and Air conditioning 3
13 1 Checking the System is Functioning Correctly 3
13 1 1 Checking the Fuses 5
13 1 2 Error Diagnosis with the Heating Timer 5
13 2 Checking the Water Level 17
13 3 Replacing the Heat Exchanger 17
13 4 Air Conditioning 19
13 4 1 Switching on the Air Conditioning Equipment 19
13 4 2 Servicing the Air Conditioning Equipment 19
13 4 3 Having the Air Conditioning Equipment Checked 23
13 4 4 Error Diagnosis for Condenser 23
13 4 5 Error Diagnosis for Heat Conditioning Unit 25
Index
059–2000 4
14 Electrical System 3
14 1 Checking the Lighting System 3
14 2 Checking the Limit Switches 3
14 2 1 Lower Limit Switch — Check Function 3
14 2 2 Hoist Limit Switch — Checking Functionality 3
14 3 Checking the Slip Ring Contacts on the Rope Winches and
on the Rotary Joint to the Undercarriage 3
14 4 Precautionary Measures Against Cable Fires 5
14 5 Fuse Overview 11
15 Fuel System 3
15 1 Fuel Filter — Emptying the Inspection Glass 5
15 2 Fuel Filter — Changing the Filter Element 5
15 3 Draining Off Water and Residue From the Fuel Tank 9
15 4 Fuel System, Checking the Lines 9
15 5 Refuelling With a Fuel Tank Filling System (Optional) 11
16 Cooling, Intake and Exhaust System 3
16 1 Check the Coolant and Top up as Necessary 3
16 2 Cleaning the Cooling System 5
16 3 Change Cooling Fluid 7
16 4 Change or Replace the Filter Element of the Air Filters 11
16 4 1 Replacing the Filter Element 11
16 4 2 Cleaning the Filter Element 13
16 5 Exhaust System Visual Inspection 15
17 Piston Rods 1
17 1 Exposed Chrome Surfaces — Applying Protective Grease 1
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
18 3 Lubricating the Cab Tilt Cylinder 5
Index
059–2000 5
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 Front Idlers, Track and Carrier Rollers 7
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 Type Undercarriage and
Checking the Track Tension in the Case of Running Noises 13
19 8 Checking the Screw Connections and Retightening if Necessary 15
19 9 Central Lubricating System 17
19 9 1 Component Parts 17
19 9 2 Function 17
19 9 3 Servicing Central Lubrication System 19
19 9 4 Filling the Tank of the Central Lubrication System 21
19 9 5 Troubleshooting 23
20 Counterweight Dolly 3
20 1 Lubricate Ball Bearing Slewing Rim 3
20 2 Lubricating the Ring Gear 3
20 3 Checking the Screws of the Slewing Rim 5
20 4 Slew Gear 7
20 4 1 Slew Gear Mechanism — Checking the Oil Level 7
20 4 2 Slew Gear Mechanism — Changing the Oil 7
20 4 3 Slew Gear Mechanism — Checking the Disc Brake 9
20 4 4 Checking the Slew Gear Mechanism Screw Connections 11
20 4 5 Slew Gear Mechanism Visual Inspection 11
20 5 Final Drive — Checking Oil Level 13
20 5 1 Drive Axle 13
20 5 2 Rigid Axle 15
20 6 Travel Drive — Replace Oil 17
20 6 1 Drive Axle 17
20 6 2 Rigid Axle 21
20 7 Lubricating the Axles 23
20 8 Check Tyre Air Pressure, Tread and Rims 25
20 9 Checking Tyre Wheel Nuts, Tightening if Required 27
20 10 Checking Welds for Cracks 29
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
Index
059–2000 6
22 Examinations of the Crane 3
22 1 Recurring Crane Inspections 3
22 1 1 Inspection of Load–Bearing Steel Constructions 17
22 1 2 Inspection of the Disc Wheels (Rims) 61
22 1 3 Inspection of the Winches 63
22 1 4 Hook 77
22 1 5 Inspection of the Sheaves 79
22 1 6 Inspection of the Ropes 81
22 1 7 Documentation 95
23 Central Lubricating System 3
23 1 Function 5
23 1 1 Setting the Interval and Operating Times 7
23 1 2 Initiation of an Additional Lubrication Impulse 11
23 2 Servicing Central Lubrication System 13
23 2 1 Filling the Tank of the Central Lubrication System 15
23 3 Troubleshooting 17

S.V 07/24