Handing an AC 80-2 over to a new owner is easier when the paperwork travels with it. This all terrain crane drives on public roads and works on site with a telescopic boom. A workshop taking on a used crane that came without any documents is the buyer this set fits best, because one download gives the mechanics, the operator and the parts desk the same reference.
What this manual set helps you do
- Operate the crane safely by following the operator manual, which has the safety instructions and the steps for assembling and dismantling the crane, main boom, fly jib and superlift.
- Order the right parts from the parts manual, with assemblies such as chassis 8×6, boom, main boom extension and tires.
- Lubricate and inspect on schedule with the maintenance manual, including the maintenance list, recurrent inspections, fuels and lubricants, and the engine OM 501 LA.
- Trace hydraulic and electrical faults using the schematics.
- Check supporting details in the technical data, service information, training documents and component manuals.
Who this is for
A workshop or service company taking on a used AC 80-2 gets a full reference for inspection, maintenance and repair planning. A used crane dealer or exporter can hand the machine over with its documentation in one package.
FAQ
Q: What do I receive and how is it organised?
A: One download with 1,035 files (864 PDF) and 27,351 PDF pages in total, in English and German. The operator manual runs 18,960 pages in 478 files, the parts manual 1,411 pages in 2 files, and the maintenance manual 3,878 pages in 347 files. Schematics are 16 files, 138 pages.
Q: Which machine does it fit?
A: The Demag AC 80-2. The serial numbers printed on the main manual cover are 81844 and 81932.
Q: How does it help with a crane that arrived without paperwork?
A: You get the operator, parts, maintenance and schematic documents for the same model together. The parts catalogue (473 assemblies, 4702 part numbers, 430 drawings) is also included with the CDs and software.
Your crew can start work on the machine with the documents in hand on day one.
Does this manual fit your machine?
| Model |
Serial No. |
| AC 80-2 |
81844, 81932 |
The serial number shown is the one printed on the manual cover. Check the model and serial number on your machine's data plate before ordering.
📘 Show Index
Table of Contents:
Operator Manual Table of Contents
18,960 pages, 478 files
- Serial No. 81844, 81932 (13,924 pages)
- Manufacturer's Specifications
- Foreword
- Safety Instructions
- General
- Intended Use
- Operating Conditions and Computed Design of the Crane
- Structure of the Mobile Crane
- Serial Plate
- Safety Signs
- Overview
- Crane Operator's Cab
- Controls and Displays
- Control Lever Assignment
- Leaving the Cab
- Engine
- Checks before Starting
- Starting Procedure from the Crane Operator's Cab for Crane Operation
- Switching off
- Driving (Optional)
- Driving from Above from the Crane Operator's Cab
- Driving in Erect Mode
- Supporting the Crane on Outriggers from the Superstructure Cab (optional)
- Slewing
- Preparations for Slewing
- Slewing the Superstructure
- Braking the Superstructure
- Counterweight
- General
- Counterweight Designs
- Important Assembly Instructions
- Safety Equipment
- Electronic Crane Information System
- Limit Switch
- Maintenance, Repairs and Disposal
- Working Instructions
- Permitted wind speeds
- Load Tables and Wind Speed
- General notes on operation
- Publication 80-2-2000-772 (354 pages)
- Safety Instructions
- Crane Chassis
- Overview of the crane chassis
- Safety-relevant Components
- Chassis Number
- Driver's Cab
- Operator's Platform
- Dashboard installation (overview)
- Engine
- Checks before Starting
- Starting
- Switching off
- Driving the Crane
- Axle Loads and Transport Conditions
- Driving the Crane
- Dolly – Preparation (Optional)
- Drive
- Drive gearbox
- error diagnosis
- Distributor gear
- Brakes
- Braking System
- Service brake
- Parking brake
- Steering
- General System Description
- Safety Instructions
- Monitoring Functions for All Steering Programs
- Differential Locks
- Hydraulic Suspension
- Suspension Circuits
- Overall Level Adjustment
- Monitoring the Hydraulic Suspension
- Support
- Notes on supports
- Arrangement of the Controls for the Outriggers
- Before Extending the Outriggers
- Parking
- Leaving the Vehicle in Transport Condition
- Leaving the Crane in Configured Condition and with Outriggers Extended
- Tow-starting and Towing the Crane
- Towing start
- General Towing Regulations
- Towing the Crane Free on Soft Ground
- Manual 2 (420 pages)
- Safety Instructions
- Transporting the Crawler−mounted Crane
- General
- Dimensions and Transport Weights of the Main Components
- Dimensions and Transport Weights of the Boom System
- Assembling and Dismantling the Crane
- General
- Assembling the Crane
- Assemble the chassis outrigger
- Assembling the Main Boom
- General
- Assembling and Fitting the Main Boom SH
- Assembling and Fitting the Main Boom SH/LH
- Assembling the Main Boom and Fly Jib
- General
- Assembling and Fitting Fly Jib Combination SW
- Assembling and Dismantling the Superlift
- General
- Assembling and Fitting the Superlift Mast
- Fitting the Superlift Mast with Telescopic Connection to the
- Assembling the Main Boom with Superlift
- General
- Assembling and Fitting the SSL Superlift Combination
- Assembling and Fitting the SSL/LSL Main Boom
- Assembling the Main Boom and Fly Jib with Superlift
- General
- Assembling and Fitting the Boom Combination SWSL
- Reeving the Ropes
- General
- Reeving the Derricking Ropes
- Reeving the Luffing Ropes
- Erecting and Lowering the Boom System
- General
- Erecting Boom Variant SH
- Erecting the Boom Variant SH/LH
- Hydraulic Power Pack with Pin Locking Cylinder
- General
- Starting the Hydraulic Power Pack
- Actuation of the Pin Locking Cylinder
- Manual 3 (282 pages)
- Manufacturer's Specifications
- Foreword
- Safety Instructions
- Notes on Safety
- Operating Conditions and Calculated Design of the Crane
- Safety Regulations
- Structure of the Mobile Crane
- Serial Plate
- Diagram
- Crane Chassis
- Crane Symbols
- Indicator Light Symbols in the Crane Operator's Cab
- Switch and Button Symbols in the Crane Operator's Cab
- Crane Operator's Cab
- Control Elements in the Crane Operator's Cab
- Indicator Lights in the Crane Operator's Cab
- Engine
- Before Starting
- Starting Procedure from the Crane Operator's Cab for Superstructure Operation
- Points to Note following Starting
- Driving
- Driving on the Construction Site
- Driving in Erect Mode
- Supporting the Crane on Outriggers from the Superstructure Cab
- Slewing
- Preparations for Slewing
- Slewing the Superstructure
- Braking the Superstructure
- Counterweight
- Procedure for Fitting the Counterweight
- Allocation of Counterweights for the Various Configurations
- Safety Equipment
- Load Limit Device Console (LMB)(42)
- Input
- Hoist Limit Switch
- Notes on Operation
- General Notes on Operation
- Raising a Load Using Several Cranes
- Checking the Safety Measures
- Telescoping
- Telescoping the Main Boom
- Telescoping Procedure
- Luffing
- Raising and Lowering the Main Boom
- Raising and Lowering the Main Boom in High Range
- "Hoist 1" Hook Operation
- Raising and Lowering Load with Hoist 1
- Raising and Lowering the Load in High Range
- Hydraulic Manual Operation in case of an Emergency (Optional)
- Serial No. 81932 (1,636 pages)
- Manufacturer's Specifications
- Foreword
- Safety Instructions
- General
- Intended Use
- Operating Conditions and Computed Design of the Crane
- Structure of the Crane
- Serial Plate
- Safety Signs
- Overview
- Crane Operator's Cab
- Controls and Displays
- Control Lever Assignment
- Leaving the Cab
- Engine
- Checks before Starting
- Starting Procedure from the Crane Operator's Cab for Crane Operation
- Switching off
- Driving (Optional)
- Driving from Above from the Crane Operator's Cab
- Driving in Erect Mode
- Supporting the Crane on Outriggers from the Superstructure Cab (optional)
- Slewing the Superstructure
- Preparations for Slewing
- Initiating a Slewing Movement
- Braking the Superstructure
- Counterweight
- General
- Counterweight Designs
- Important Assembly Instructions
- Safety Equipment
- Electronic Crane Information System
- Limit Switch
- Maintenance, Repairs and Disposal
- Working Instructions
- Permitted wind speeds
- Load Tables and Wind Speed
- General notes on operation
- Crane Chassis
- Overview of the Crane Chassis
- Safety-relevant Components
- Chassis Number
- Driver's Cab
- Operator's Platform
- Dashboard Installation (Overview)
- Driving the Crane
- Axle Loads and Transport Conditions
- Driving the Crane
- Dolly – Preparation (Optional)
- Drive
- Drive Gearbox
- Error Diagnosis
- Distributor Gear
- Brakes
- Braking System
- Service Brake
- Parking Brake
- Steering
- General System Description
- Safety Instructions
- Monitoring functions for all steering programs
- Differential Locks
- Hydraulic Suspension
- Suspension Circuits
- Overall Level Adjustment
- Monitoring the Hydraulic Suspension
- Serial No. 81932 (1,412 pages)
- Manufacturer's Specifications
- Foreword
- Safety Instructions
- Structure of the Mobile Crane
- Crane operator's cab
- Engine
- Driving
- Slewing
- Counterweight
- Safety Equipment
- Crane Chassis
- Driver's Cab
- Driving – General Information
- Fitted
- Transmission
- Brakes
- Braking
- Steering
- Adjustment Work
- ”Construction Site Operation”
- “Tight cornering” during Road Travel
- “Construction Site Operation”
- “Manual Rear-axle Steering” (Steering figure “A”)
- “Tight cornering” (steering figure “B”)
- “Driving away from the wall” (steering figure “C”)
- “Diagonal steering” (steering figure “D” (crab walk))
- “Raising/lowering“ the lift axle (steering variant 8x6x6)
- axle(s)
- Differential Locks
- Hydraulic Suspension
- Outriggers
- (for Driving the Crane in Transport Condition)
- (for driving the Crane in Configured Condition)
- Parking
- Extended
- Towing the Crane and Towing the Crane to Start
- Automatic Transmission
- Heating and Ventilation
- Publication 80_2_1e (932 pages)
- Safety Instructions
- Operating Conditions and Calculated Design of the Crane
- Safety Regulations
- Catwalk
- Structure of the Mobile Crane
- Serial Plate
- Safety Signs
- Overview
- Crane Operator's Cab
- Control Elements in the Crane Operator's Cab
- Dashboard Installation
- Engine (Mercedes Benz OM 904 LA)
- Checks before Starting
- Starting Procedure
- Switching Off the Engine
- Driving (Optional)
- Driving from Above from the Crane Operator's Cab
- Driving in Erect Mode
- Supporting the Crane on Outriggers from the Superstructure Cab (optional)
- Crane Chassis
- Overview of Crane Chassis
- Serial Plates
- Driver's Cab
- Driver's Cab
- Dashboard Installation
- Engine
- Checks before Starting
- Starting
- Stopping the Engine
Parts Manual Table of Contents
1,411 pages, 2 files
- Publication 81637.1 (921 pages)
- SUPERSTRUCTURE WITH HG2
- MOUNTING PARTS
- SLEW RING
- HOIST GEARS
- CHASSIS 8X6
- MOUNTING PARTS
- DRIVE
- BRAKE SYSTEM
- BOOM
- MOUNTING BOOM
- MOUNTING TOP ROLLER
- MAIN BOOM EXTENSION
- BASIC CASE 9 M
- TOP SECTION CASE 9 M
- TRAVEL LOCK 17 M
- SAFETY ATTACHMENT, BOOM
- ELECTRIC MAIN BOOM
- CABLE DRUM MOUNTING
- DISTRIBUTION BOX
- SUPERSTRUCTURE OPTION
- ELECTRIC WIRING DIAGRAMM
- HEAD ROLLER
- AERODYNAMICAL SAFETY LIGHT
- CHASSIS OPTION
- UNDERRIDE GUARD, L.H. DRIVE
- HOOK BLOCK SUPPORT
- COVERING
- MACHINE-MAINTENANCE PARTS CHASSIS
- TOOL AND ACCESSORIES
- PAINTING/DECALS/STOP/PADS
- HOOK BLOCKS
- HOOK SUSPENSION
- HOOK BLOCK
- Publication 81932.1 (490 pages)
- SUPERSTRUCTURE STANDARD
- MOUNTING PARTS
- SLEW RING
- HOIST GEARS
- CHASSIS 8X6
- MOUNTING PARTS
- DRIVE
- BRAKE SYSTEM
- BOOM
- MAIN BOOM EXTENSION
- BASIC CASE 9 M
- TOP SECTION CASE 9 M
- TRAVEL LOCK 17 M
- SAFETY ATTACHMENT, BOOM
- ELECTRIC MAIN BOOM
- CABLE DRUM MOUNTING
- SUPERSTRUCTURE OPTION
- MOUNTING SPIN STABILIZER
- HEAD ROLLER
- AERODYNAMICAL SAFETY LIGTH
- CHASSIS OPTION
- COVERING
- COVERING R.H. AND REAR 20.5"
- OPERTION RANGE LIMITS
- TIRES
- HOOK BLOCKS / SINGLE LINES HOOK
- HOOK SUSPENSION
- HOOK BLOCK
Maintenance Manual Table of Contents
3,878 pages, 347 files
- Serial No. 81932 (716 pages)
- Foreword
- Safety Instructions
- General
- Selection and Qualifications of Personnel
- Particular Hazards
- Consumables and Capacities
- Lubrication and Maintenance Schedule
- Initial Lubrication and Maintenance
- Regular Routine Lubrication and Maintenance
- Tips for Maintaining the Crane
- Engine
- Inspection of the Engine
- Engine Quick Stop: Function Test
- Transmission
- Drive Gear – Checking and Topping Up the Oil Level
- Changing the Oil in the Drive Gearbox and Replacing the Filter
- Joint Shafts
- Flange Connections
- Lubricate the Joint Shafts
- Axles
- Checking and Tightening the Axle Fixings
- Lubricating the Axles
- Steering and Track Arm
- Steering
- Steering Components
- Lubricating the Steering Components
- Replacing the Hoses
- Brake and Air Pressure System
- Disc Brakes
- Checking the compressed-air brake system
- Draining Water from the Air Tank
- Wheels and Tyres
- Re-tightening the Wheel Nuts
- Tyres – Check Tyre Pressure, Tread Depth and for Signs of Damage
- Inspection of Disc Wheels (Rims)
- Hydraulic System
- Hydraulic Tank – Checking and Topping Up the Oil Level
- Hydraulic Tank – Filter
- Hydraulic Tank – Replacing the Aeration Filter
- Outriggers
- Electrical System
- Fuel System
- Air Intake and Cooling System
- Piston Rods
- Optional Equipment
- Visual Inspections
- Slew Ring
- Slew Gear
- Hoists
- Luffing Gear
- Main Boom, Rope Equipment, Devices
- Manual 2 (344 pages)
- Notes on Safety
- Maintenance Tasks
- Notes on Safety
- Recurrent Inspections of the Crane
- Measures to Ensure Safe Operating Periods
- of the Winches
- Fuels and Lubricants
- Capacities
- Lubrication and Maintenance Schedule
- Drive
- Transmission
- Replacing the Filter
- Joint Shafts
- Axles
- Steering
- Braking System
- Wheels and Tyres
- Checking for Damage
- Hydraulic System
- Preliminary Gas Tension
- Outriggers
- Electrical System
- Fuel System
- Air Intake and Cooling System
- Piston Rods
- Optional Equipment
- Correctly
- Replacing the Heat Exchanger
- Switching on the Hot Water Heating
- Checking and Replacing the Fuel Filter
- Visual Inspections
- Slew Ring
- Slew Gear
- Hoists
- Luffing Gear
- Equipment
- Retracking Ropes
- Inspect Rope Track Rollers
- Checking the Sheaves
- Sheaves – Checking the Roller Bearing
- Greasing Sliding Surfaces
- Telescopic Main Boom Extension (Optional)
- Greasing the Foot Bearing
- Telescopic Main Boom Extension (Optional)
- Greasing the Luffing Cylinder
- Checking the welding on the Telescopic Main Boom Extension
- for cracks (Optinal)
- Heating
- Publication 80_2_3e (274 pages)
- Foreword (Part 3)
- Contents (Part 3)
- Notes for the Operator
- Notes on Safety
- Maintenance Tasks
- Recurrent Inspections of the Crane
- Measures to Ensure Safe Operating Periods
- Fuels and Lubricants
- Capacities
- Lubrication and Maintenance Schedule
- Initial Lubrication and Maintenance
- Regular Routine Lubrication and Maintenance
- Maintenance List
- Drive
- Engine OM 501 LA
- Transmission
- Drive Gear – Checking and Topping Up the Oil Level
- Drive Gear – Changing the Oil and Replacing the intake Filter
- Joint Shafts
- Flange Connections
- Lubricating the Joint Shafts
- Axles
- Checking and Tightening the Axle Retaining Bolts
- Lubricating the Axles
- Steering and Track Arm
- Axle Drive – Checking and Topping Up the Oil Level
- Wheel Hub Drive – Checking and Topping Up the Oil Level
- Axle Drive – Changing the Oil
- Wheel Hub Drive – Changing the Oil
- Wheel Hub Bearing – Changing the Grease
- Suspension Cylinder – Lubricating the Swing Bearing
- Steering
- Steering Components
- Lubricating the Steering Components
- Replacing the Hoses
- Lubricating Independent Rear Axle Steering
- Electric-hydraulic Steering
- Braking System
- Check brake linings for wear
- Renew brake linings
- Replace brake drums
- Perform brake function check
- Check expanding cylinder
- Replace other brake parts
- Granulate Cartridge
- Draining Water from the Air Tanks
- Wheels and Tyres
- Tightening the Wheel Nuts
- Checking the Tyre Pressures
- Hydraulic System
- Hydraulic Tank – Checking and Topping Up the Oil Level
- Hydraulic Tank – Filter
- Hydraulic Tank – Replacing the Aeration Filter
- Changing the Hydraulic Oil
- Bleeding the Hydraulic System
- Preliminary Gas Tension
- Serial No. 81844, 81932 (2,544 pages)
- Manufacturer's Specifications
- Foreword
- Safety Instructions
- General
- Intended Use
- Operating Conditions and Computed Design of the Crane
- Structure of the Mobile Crane
- Serial Plate
- Safety Signs
- Overview
- Crane Operator's Cab
- Controls and Displays
- Control Lever Assignment
- Leaving the Cab
- Engine
- Checks before Starting
- Starting Procedure from the Crane Operator's Cab for Crane Operation
- Switching off
- Driving (Optional)
- Driving from Above from the Crane Operator's Cab
- Driving in Erect Mode
- Supporting the Crane on Outriggers from the Superstructure Cab (optional)
- Slewing
- Preparations for Slewing
- Slewing the Superstructure
- Braking the Superstructure
- Counterweight
- General
- Counterweight Designs
- Important Assembly Instructions
- Safety Equipment
- Electronic Crane Information System
- Limit Switch
- Maintenance, Repairs and Disposal
- Working Instructions
- Permitted wind speeds
- Load Tables and Wind Speed
- General notes on operation
Also in this set
- Schematics (16 files, 138 pages)
- Technical data (5 files, 22 pages)
- Service information (2 files, 21 pages)
- Assembly and installation (5 files, 8 pages)
- Diagnostic documents and software (1 file, 143 pages)
- Training documents (14 files, 2,661 pages)
- Component manuals (2 files, 109 pages)
- CDs and software (163 files)
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