Description

Terex Demag AC 650 Training Manual

If you’re wrenching on a Demag AC 650 without the factory training manual, you’re working blind. I’ve seen a tech guess on the tele cylinder preassembly torque and blow out the boom section seal. That’s a $15,000 mistake. This manual is 512 pages of OEM documentation — the same binder used in Terex Demag training centers. It’s not aftermarket fluff.

Telescoping System: Preassembly of the Tele Cylinder

The telescoping system section breaks down the boom from the sectional view to the tele cylinder preassembly. You get exploded views of Unimec 1 and Unimec 2, part lists, and the pinning and locking procedure. The preassembly tele cylinder pages (page 73 covers the electric circuit for the LPD proximity switches) are critical — if you skip the adjustment steps, the boom won’t extend properly. The manual includes the standard extension sequence and main boom pipes and hoses routing.

Hydraulic Superstructure: Solenoid Valves and Test Connections

Hydraulics are where most guys get lost. The manual dedicates pages to the hydraulic superstructure, including solenoid valves, telecylinder, luffing cylinder, and test connections for swing, H1, H2, and boom. If you’ve ever chased a pressure drop in the slew gear, the test connection diagram on page 2 of the hydraulic superstructure section lists the exact test points. You also get the list of PRVs and their settings. Know your test points.

Does the Manual Cover Crane Control Error Codes?

Yes. The crane control system section includes a service manual for the modular PDC (Programmable Drive Controller), interface descriptions, and the error code table. The error codes are split into E-type and S-type faults. Page 73 is part of the electric circuit for the SSL system, but the error code table is separate. You’ll find the codes in the ‘Functions superstructure’ chapter. If you’re getting a ‘Tele’ fault code, this manual tells you what the code means and which sensor to check.

E-type faults are listed on the error code table.

512 Pages of OEM Documentation — No Aftermarket Guesswork

I’ve wasted enough hours on aftermarket manuals that get the wiring colors wrong or skip the hydraulic schematic for the carrier. This training manual is original Terex Demag material. 512 pages cover the superstructure, carrier, telescoping system, hydraulic system, crane control, superlift options, and electrics. The carrier section alone includes the fuel system, cooling hydraulics, steering hydraulics (both standard and IRAS), outrigger linkage, suspension, and brake system. You get the cylinder preassembly drawings for the tele cylinder and luffing cylinder — not generic diagrams. If you work on other Terex Demag cranes, check the TEREX DEMAG CC 2500 Training Manual as well. For operators, the Demag AC 140 Simulator User Interface Manual covers the control interface for smaller models. If you need hoist instructions, see the DEMAG SpeedHoist D-SH Operating Instructions.

Carrier Systems: Steering, Brakes, and Outrigger Hydraulics

The carrier section is 11 pages of electric circuit diagrams for the chassis. You get steering hydraulics both standard and IRAS, outrigger hydraulics front and rear, and the brake system. The valve locations chapter lists the pressure settings (Druckeinstellungen UW) and solenoid valve functions. If you’re replacing a steering cylinder or bleeding the outrigger system, the hydraulic drawings save you from cross-threading fittings. Look at the electrical circuit diagrams for the chassis — they cover pages 1 through 12 with relay functions. The manual also covers the pneumatic steering system. The distribution gear section resembles a Manual Transmission layout. For fundamentals, you can read about Manual Transmission elsewhere.

FAQ: Four Questions About the AC 650 Training Manual

Does this manual include torque specifications?

Yes, for tele cylinder and connecting rod bolts.

Are the hydraulic schematics detailed enough for troubleshooting?

The manual contains multiple hydraulic diagrams for superstructure and carrier. It lists solenoid valves, pressure relief valves, test connections for H1, H2, slew gear, and swinging arm. You get pump views, filter locations, and cylinder assemblies. The outrigger hydraulics and steering hydraulics (standard and IRAS) are covered. Each drawing has a part number. For troubleshooting a non-functioning function, you can trace the circuit line by line.

How many pages are in the manual?

512 pages.

Is this a reprint or original OEM?

This is the original Terex Demag training document, not a copy or aftermarket version.

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