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

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

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

Language : English
Pages : 1396
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

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

Foreword 1
1 Safety instructions 3
1 1 General 3
2 −
3 Assembling and Dismantling the Crane 3
3 1 General 3
3 1 1 Bolt connections 3
3 1 2 Hydraulic Cylinders − Protecting the Piston Rods 5
3 1 3 Assembly Instructions 7
3 2 Assembling the crane −
Self assembly with the A−frame 9
3 2 1 General 9
3 3 Assembling the Superstructure 13
3 3 1 General 13
3 3 2 Assembly Procedure 13
3 4 Swinging the Crane Operator’s Cab into Operating
Position and Tilting 21
3 4 1 General 21
3 4 2 Swinging the Crane Operator’s Cab into the Operating Position 21
3 4 3 Tilting the Crane Operator’s Cab 23
3 5 Lifting and shifting of the A−frame into mounting position 25
3 6 Assembling the Central Ballast on the Carrier 27
3 6 1 General 27
3 6 2 Assembly Procedure with Auxiliary crane 27
3 7 Assembling the Track Carriers 29
3 7 1 General 29
3 7 2 Assembling the Left Track Carrier 31
3 7 2 1 General 31
3 7 2 2 Assembly Procedure for Left Crawler Track Carrier 33
3 7 3 Assembling the Right Track Carrier 37
3 7 3 1 General 37
3 7 3 2 Assembly Procedure for Right Crawler Track Carrier 39
3 7 4 Connecting the hydraulic lines via quick release coupling 45
3 8 Assembling the Counterweight 47
3 8 1 General 47
3 8 2 Assembly Sequence 49
3 9 Dismantling the crane 51
3 9 1 General 51
3 10 Dismantling the Counterweight 55
Contents
059−3000−080_en 2
3 11 Dismantling the Track Carriers 57
3 11 1 General 57
3 11 2 Dismantling the Hydraulic Lines 59
3 11 3 Supporting the Crane on Outriggers 61
3 11 4 Dismantling the Right Track Carrier 63
3 11 4 1 General 63
3 11 4 2 Disassembly Procedure 65
3 11 5 Dismantling the Left Track Carrier 69
3 11 5 1 General 69
3 11 5 2 Dismantling 71
3 12 Dismantling the Central Ballast on the Carrier 75
3 13 Folding the A−Frame into the Transport Position 77
3 13 1 General 77
3 14 Tilting and Swinging the Cab into the Transport Position 79
3 14 1 General 79
3 14 2 Tilting the Crane Operator’s Cab 79
3 14 3 Swinging the Crane Operator’s Cab into the Transport Position 81
3 15 Dismantling the Superstrucutre 83
3 15 1 General 83
3 15 2 Lifting off the Superstructure 83
Contents
059−3000−080_en 3
4 Assembling the Main Boom 3
4 1 General 3
4 2 Assembling and Fitting the Main Boom SH 5
4 2 1 Assembling Main Boom Combinations SH 7
4 2 2 Fitting Main Boom Combination SH 15
4 2 3 Assembling the Main Boom Stay Bars with the Combination SH 27
4 2 4 Fitting the Runner on the Connection Head 29
4 2 4 1 General 29
4 2 4 2 Assembly Procedure 31
4 2 5 Dismantling the Runner 35
4 2 6 Assembling the Auxiliary Bracing (Bracing Chains) for
the Combination SH −
Boom Lengths 72 m − 84 m 37
4 3 Assembling and Fitting the Main Boom SH/LH 39
4 3 1 Assembling Main Boom Combinations SH/LH 41
4 3 2 Fitting the Main Boom Combinations SH/LH 57
4 3 3 Assembling the Main Boom Stay Bars for
the Combination SH/LH 69
4 3 4 Fitting the Runner on the Main Boom SH/LH 71
4 3 4 1 General 71
4 3 4 2 Assembly Procedure 73
4 3 5 Dismantling the Runner 77
4 3 6 Assembling the Auxiliary Bracing (Bracing Chains) for
the Combination SH/LH 79
Contents
059−3000−080_en 4
5 Assembling the Main Boom and Fly Jib 3
5 1 General 3
5 2 Assembling and Fitting Fly Jib Combination SW 5
5 2 1 Assembling Main Boom Combination SH for Variant SW 7
5 2 2 Assembling Fly Jib Combinations for Variant SW 19
5 2 3 Fitting Main Boom and Fly Jib SW 27
5 2 4 Fitting the Runner 63
5 2 5 Assembling Stay Bars HA and HI and Bracing Rods WU for
the Combination SW 71
5 2 6 Assembly of the Auxiliary Bracing (Bracing Chains) on
the Main Boom (Combination SW) −
Boom Length 72 m 73
5 2 7 Assembly of the Auxiliary Bracing (Bracing Chains)
on the Fly Jib (Combination SW) −
Boom Lengths 60 m − 72 m 75
6 Assembling and Dismantling the Superlift 3
6 1 General 3
6 1 1 Bolt Connections 3
6 1 2 Hydraulic Cylinders − Protecting the Piston Rods 7
6 1 3 Assembly Instructions 9
6 2 Assembling and Fitting the Superlift Mast 11
6 2 1 General 11
6 3 Assembly of the Superlift mast with adjustment winch to
the counterweight support frame 17
6 3 1 Assembly of the Superlift mast with adjustment winch to
the counterweight support frame,
mast radius 10 5 m − 16 5 m,
SL counterweight radius 10 m − 16 m 17
6 3 1 1 Counterweight support frame and adjustment winch
(SL counterweight radius 10 m − 16 m) 21
6 3 2 Fitting the Superlift Mast 23
6 3 3 Assembly of the Support Rods and the Luffing Crossbar 27
6 3 3 1 Assembly of the support rods with cylinder 27
6 3 3 2 Assembling the Luffing Crossbar 27
6 3 4 Attachment of the Superlift counterweight with adjustment winch 29
6 4 Dismantle the Superlift equipment with adjustment winch facing
the counterweight support frame 37
6 4 1 General 37
6 4 2 Disassembly of the Superlift counterweight with adjustment winch 41
6 4 3 Dismantling of the Luffing Crossbar and the Support Rods 49
6 4 3 1 General 49
6 4 3 2 Dismantling the Support Rods 49
6 4 3 3 Dismantling the Luffing Crossbar 49
6 4 4 Dismantling the Superlift Mast 51
6 4 4 1 Dismantling the Hydraulic Lines for Luffing Gear 2 51
6 4 4 2 Setting Down the Superlift Mast 51
Contents
059−3000−080_en 5
7 Assembling the Main Boom with Superlift 3
7 1 General 3
7 2 Assembling and Fitting the SSL Superlift Combination 7
7 2 1 Assembling the SSL Main Boom Combinations 9
7 2 2 Fitting the SSL Main Boom Combination 21
7 2 2 1 Fitting Procedure on the Ground 21
7 2 2 2 Assembling the Stay Bars on the Main Boom 25
7 2 2 3 Erecting the Main Boom 27
7 2 3 Assembling the HA Stay Bars on the SSL Combination 31
7 2 4 Fitting the runner on the main boom SSL 33
7 2 4 1 General 33
7 2 5 Fitting the Runner on the Connection Head 35
7 2 6 Dismantling the Runner 39
7 3 Assembling and Fitting the SSL/LSL Main Boom 41
7 3 1 Assembling the SSL/LSL Main Boom Combinations 43
7 3 2 Fitting the SSL/LSL Main Boom Combination 63
7 3 2 1 Fitting Procedure on the Ground 63
7 3 2 2 Erecting the Main Boom 69
7 3 3 Assembling the HA Stay Bars for Combination SSL/LSL 73
7 3 4 Fitting the runner on the main boom SSL/LSL 75
7 3 4 1 General 75
7 3 5 Fitting the Runner on the Top Section 77
7 3 6 Dismantling the Runner 81
7 3 7 Assembling the Auxiliary Bracing for Combination SSL/LSL 83
7 3 7 1 Assembling the Auxiliary Bracing for the Combination
SSL/LSL − Boom Lengths 78 m and 84 m 83
7 3 7 2 Assembling the Auxiliary Bracing for the Combination
SSL/LSLH − Boom Lengths 90 m and 102 m 85
7 3 7 3 Assembly of the auxiliary bracing with the combination
SSL/LSL − boom lengths 96 m, 108 m, 114 m, 120 m and 126 m 87
7 3 8 Assembly of the auxiliary bracing 89
7 3 9 Assembly of the rope deflector 89
8 Assembling the Main Boom and Fly Jib with Superlift 3
8 1 General 3
8 2 Assembling and Fitting the Boom Combination SWSL 5
8 2 1 Assembling the Main Boom Combination for the Variant SWSL 7
8 2 2 Assembling the Fly Jib Combination for the Variant SWSL 27
8 2 3 Fitting the Main Boom and Fly Jib Combination SWSL 37
8 2 4 Fitting the Runner 71
8 2 5 Assembling the Stay Bars HA and HI and the Bracing Rods WU
for the Combination SWSL 79
8 2 6 Assembly of the auxiliary bracing (bracing chains) to the fly jib
(combination SWSL) 81
8 2 6 1 Assembly of the auxiliary bracing (bracing chains) on the fly jib
(combination SWSL) −
boom lengths 60 m − 72 m 81
8 2 6 2 Assembly of the Auxiliary Bracing (Bracing Chains) on the Fly Jib
(Combination SWSL) −
Boom Lengths 78 m − 84 m 83
Contents
059−3000−080_en 6
9 Reeving the Ropes 3
9 1 General 3
9 1 1 Spin Stabilizer 3
9 1 2 Load Lifting Equipment 5
9 1 3 Auxiliary Reeving Winch (Optional) 7
9 2 Reeving the Derricking Ropes 9
9 2 1 General 9
9 2 2 Table for Reeving the Derricking Ropes 9
9 3 Reeving the Luffing rope 11
9 3 1 Reeving the Luffing rope W1 11
9 3 1 1 General 11
9 3 1 2 Table for Reeving the Luffing Rope W1 11
9 3 2 Reeving the Luffing ropes W2 13
9 3 2 1 General 13
9 3 2 2 Table for reeving the luffing rope W2 13
9 4 Reeving the Hoist Ropes 15
9 4 1 Reeving the hoist rope − combination SH 15
9 4 2 Reeving the hoist rope − combination SH/LH 29
9 4 3 Reeving the hoist rope − combination SW 47
9 4 4 Reeving the hoist rope − combination SSL 65
9 4 5 Reeving the Hoist Ropes − Combination SSL/LSL 79
9 4 6 Reeving the Hoist Ropes − Combination SWSL 97
9 4 7 Reeving the hoist rope − combination SH + LF 115
9 4 8 Reeving the hoist rope − combination SH/LH + LF 127
9 4 9 Reeving the Hoist Ropes − Combination SSL + LF 141
9 4 10 Reeving the hoist rope − combination SSL/LSL + LF 157
Contents
059−3000−080_en 7
10 Erecting and Lowering the Boom System 3
10 1 General Instructions 3
10 1 1 Assembling the erecting device 5
10 2 Erecting Boom Variant SH 11
10 2 1 General Instructions 11
10 2 2 Erecting the boom variant SH, without WU rods on main boom,
without runner 13
10 2 2 1 Erecting boom variant SH, without WU rods on main boom,
without runner, with auxiliary crane 15
10 2 3 Erecting the boom variant SH, without WU rods on main boom,
with runner 17
10 2 3 1 Erecting boom variant SH, without WU rods on main boom,
with runner, with auxiliary crane 19
10 3 Erecting Boom Variant SH / LH 21
10 3 1 General Instructions 21
10 3 2 Erecting the boom variant SH / LH, without WU rods on main boom,
without runner 23
10 3 2 1 Erecting boom variant SH / LH, without WU rods on main boom,
without runner, with auxiliary crane 25
10 3 3 Erecting the boom variant SH / LH, without WU rods on main boom,
with runner 27
10 3 3 1 Erecting boom variant SH / LH, without WU rods on main boom,
with runner, with auxiliary crane 29
10 4 Erecting Boom Variant SW 33
10 4 1 General Instructions 33
10 4 2 Erecting Boom Variant SW, without Runner, without
Roller set on main boom 35
10 4 2 1 Erecting Boom Variant SW, without Runner, without Roller set
on main boom, with auxiliary crane 47
10 4 3 Erecting Boom Variant SW, with Runner, without Roller set
on main boom 59
10 4 3 1 Erecting Boom Variant SW, with Runner, without Roller set
on main boom, with auxiliary crane 69
10 4 4 Erecting Boom Variant SW, without Runner, with Roller set
and Hook block (4 9 t / 10 800 lbs) on main boom 79
10 4 4 1 Erecting Boom Variant SW, without Runner, with Roller set and Hook
block (4 9 t / 10 800 lbs) on main boom, with auxiliary crane 87
10 4 5 Erecting Boom Variant SW, with Runner, with Roller set and
Hook block (4 9 t / 10 800 lbs) on main boom 99
10 4 5 1 Erecting Boom Variant SW, with Runner, with Roller set and
Hook block (4 9 t / 10 800 lbs) on main boom,
with auxiliary crane 107
Contents
059−3000−080_en 8
10 5 Erecting Boom Variant SH + LF 117
10 5 1 General Instructions 117
10 5 2 Erecting Boom Variant SH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on the main boom,
without Roller set on main boom 119
10 5 2 1 Erecting Boom Variant SH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on the main boom,
without Roller set on main boom, with auxiliary crane 127
10 5 3 Erecting Boom Variant SH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
with Roller set and Hook block (4 9 t / 10 800 lbs) on Main boom 133
10 5 3 1 Erecting Boom Variant SH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on main boom,
with Roller set and Hook block (4 9 t / 10 800 lbs) on main boom,
with auxiliary crane 139
10 6 Erecting Boom Variant SH / LH + LF 145
10 6 1 General Instructions 145
10 6 2 Erecting Boom Variant SH / LH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on main boom 147
10 6 2 1 Erecting Boom Variant SH / LH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on main boom,
with auxiliary crane 153
10 6 3 Erecting Boom Variant SH / LH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on main boom,
with Hook block (4 2 t / 9 300 lbs) on main boom 159
10 6 3 1 Erecting Boom Variant SH/LH + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on main boom,
with Hook block (4 2 t / 9 300 lbs) on main boom,
with auxiliary crane 165
10 7 Erecting Boom Variant SSL 171
10 7 1 General Instructions 171
10 7 2 Erection procedure Boom variant SSL, without WU rods
on main boom, without Runner,
mast radius 14 m / 46 ft 173
10 7 3 Erection procedure Boom variant SSL,
without WU rods on main boom, without Runner,
mast radius 16 m / 52 5 ft 177
10 7 4 Erection procedure Boom variant SSL,
without WU rods on main boom, with Runner,
mast radius 14 m / 46 ft 179
10 7 5 Erection procedure Boom variant SSL,
without WU rods on main boom, with Runner,
mast radius 16 m / 52 5 ft 183
Contents
059−3000−080_en 9
10 8 Erecting Boom Variant SSL / LSL 185
10 8 1 General Instructions 185
10 8 2 Erection procedure Boom variant SSL / LSL,
without WU rods on main boom, without Runner,
mast radius 14 m / 46 ft 187
10 8 3 Erection procedure Boom variant SSL / LSL,
without WU rods on main boom, without Runner,
mast radius 16 m / 52 5 ft 191
10 8 4 Erection procedure Boom variant SSL / LSL,
without WU rods on main boom, with Runner,
mast radius 14 m / 46 ft 193
10 8 5 Erection procedure Boom variant SSL / LSL,
without WU rods on main boom, with Runner,
mast radius 16 m / 52 5 ft 197
10 9 Erecting Boom Variant SWSL 199
10 9 1 General Instructions 199
10 9 2 Erecting Boom Variant SWSL,
without Runner, without Roller set on Main boom, mast radius
14 m / 46 ft 201
10 9 3 Erecting Boom Variant SWSL, with Runner,
without Roller set on main boom 233
10 9 4 Erecting Boom Variant SWSL, without Runner, with Roller set
and Hook block (4 9 t / 10 800 lbs) on Main boom, mast radius
14 m / 46 ft 265
10 9 5 Erecting Boom Variant SWSL, with Runner, with Roller set
and Hook block (4 9 t / 10 800 lbs) on Main boom, mast radius
14 m / 46 ft 297
10 10 Erecting Boom Variant SSL + LF 329
10 10 1 General Instructions 329
10 10 2 Erecting Boom Variant SSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
without Roller set on Main boom,
mast radius 14 m / 46 ft 331
10 10 3 Erecting Boom Variant SSL + LF,
boom position LF 10 degrees, 20 degrees and
30 degrees,
without WU rods on Main boom,
without Roller set on Main boom,
mast radius 16 m / 52 5 ft 341
10 10 4 Erecting Boom Variant SSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom, with Roller set and Hook block
(4 9 t / 10 800 lbs) on Main boom,
mast radius 14 m / 46 ft 347
10 10 5 Erecting Boom Variant SSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom, with Roller set and Hook block
(4 9 t / 10 800 lbs) on Main boom,
mast radius 16 m / 52 5 ft 357
Contents
059−3000−080_en 10
10 11 Erecting Boom Variant SSL / LSL + LF 363
10 11 1 General Instructions 363
10 11 2 Erecting Boom Variant SSL / LSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
mast radius 14 m / 46 ft 365
10 11 3 Erecting Boom Variant SSL / LSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
mast radius 16 m / 52 5 ft 375
10 11 4 Erecting Boom Variant SSL / LSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
with Hook block (4 9 t / 10 800 lbs) on Main boom,
mast radius 14 m / 46 ft 381
10 11 5 Erecting Boom Variant SSL / LSL + LF,
boom position LF 10 degrees, 20 degrees and 30 degrees,
without WU rods on Main boom,
with Hook block (4 9 t / 10 800 lbs) on Main boom,
mast radius 16 m / 52 5 ft 391
10 12 Erecting Boom Variant LFVL 397
10 12 1 General Instructions 397
10 12 2 Erecting Boom Variant LFVL,
boom position LF 17 5 degrees,
without WU rods on Main boom,
without Roller set on Main boom,
mast radius 14 m / 46 ft 399
10 12 3 Erecting Boom Variant LFVL,
boom position LF 17 5 degrees,
without WU rods on Main boom,
without Roller set on Main boom,
mast radius 16 m / 52 5 ft 405
10 12 4 Erecting Boom Variant LFVL,
boom position LF 17 5 degrees,
without WU rods on Main boom, with Roller set and Hook block
(4 2 t / 9 300 lbs) on Main boom,
mast radius 14 m / 46 ft 409
10 12 5 Erecting Boom Variant LFVL,
boom position LF 17 5 degrees,
without WU rods on Main boom, with Roller set and Hook block
(4 2 t / 9 300 lbs) on Main boom,
mast radius 16 m / 52 5 ft 415
Contents
059−3000−080_en 11
11 −
12 −
13 Hydraulic Power Pack with Pin Locking Cylinder 3
13 1 General 3
13 2 Starting the Hydraulic Power Pack 7
13 3 Actuation of the Pin Locking Cylinder 7
13 4 Setting down the Hydraulic Power Pack 7
14 −
15 Assembling the Main Boom and Fly Jib LF 3
15 1 General 3
15 2 Assembling and Fitting the Fly Jib Combination LF
(Main boom SH) 5
15 2 1 Assembling the Main Boom Combination SH for the Variant LF 7
15 2 2 Assembling the Fly Jib Combination for the Variant LF
(Main Boom SH) 15
15 2 3 Fitting the Main Boom and Fly Jib Combination
SH + LF 21
15 2 4 Assembling the Main Boom Stay Bars with the Combination SH 45
15 2 5 Assembling the Auxiliary Bracing (Bracing Chains) for
the Combination SH − Boom Lengths 72 m − 84 m 47
15 3 Assembling and fitting the fly jib combination LF
(main boom SH/LH) 49
15 3 1 Assembling Main Boom Combinations SH/LH 51
15 3 2 Assembling Fly Jib Combination LF 67
15 3 3 Fitting the main boom and fly jib combination SH/LH + LF 79
15 3 4 Assembling the main boom stay bars with
the combination SH/LH 103
15 3 5 Assembling the Auxiliary Bracing (Bracing Chains) for
the Combination SH/LH 105
059−3000−080_en 12
18 Assembling the Main Boom and Fly Jib LF with Superlift 3
18 1 General 3
18 2 Assembling and Fitting the Fly Jib Combination LF
(Main Boom SSL) 7
18 2 1 Assembling the Main Boom Combination SSL for the Variant LF 9
18 2 2 Assembling the fly jib combinations LF
(main boom SSL) 21
18 2 3 Fitting the Main Boom and Fly Jib Combination SSL + LF 27
18 2 3 1 Fitting Procedure on the Ground 27
18 2 4 Assembling the HA Stay Bars on the SSL Combination 47
18 3 Assembling and fitting the fly jib combination LF
(main boom SSL/LSL) 49
18 3 1 Assembling the Main Boom Combination SSL / LSL for
the Variant LF 51
18 3 2 Assembling the fly jib combinations LF 71
18 3 3 Fitting the SSL/LSL Main Boom Combination 83
18 3 3 1 Fitting Procedure on the Ground 83
18 3 4 Assembling the HA Stay Bars for Combination SSL/LSL 103
18 3 5 Fitting the Auxiliary Bracing for Combinations SSL/LSL 105
18 3 5 1 Assembling the Auxiliary Bracing for the Combination
SSL/LSL − Boom Lengths 78 m and 84 m 105
18 3 5 2 Assembling the Auxiliary Bracing for the Combination
SSL/LSL − Boom Lengths 90 m and 102 m 107
18 3 5 3 Assembly of the auxiliary bracing with the combination
SSL/LSL − boom lengths 96 m, 108 m, 114 m, 120 m and 126 m 109
18 3 6 Assembly of the auxiliary bracing 111
18 3 7 Assembly of the rope deflector 111

S.V 07/24