F110a 22
F110a 22
F110a 22
F 110A.22
use and maintenance
FROM SERIAL NUMBER *4455*
INDEX
1 INTRODUCTION
2 CLASSIFICATION OF THE CRANE MODEL
2.1 Generality
2.2 Hydraulic jibs
2.3 Technical data
3 CAPACITY PLATES
3.1 Generality
3.2 Capacity plates with lifting moment limiting device
3.3 Capacity plates with load limiting device
4 HYDRAULIC SCHEMATICS ( ) (version with lifting moment limiting device)
4.1 HYDRAULIC SCHEMATICS (version with load limiting device)
5 ELECTRIC SCHEMATICS
6 SAFETY NORMS
7 WARNING AND INSTRUCTIONS
7.1 Generality
7.2 Before operating
7.3 During operation
7.4 At the end of the operation (Prior to driving the vehicle)
7.5 Residual risks
8 IDENTIFICATION OF THE CRANE MODEL
8.1 Generality
8.2 Crane mark
9 CRANE NOMENCLATURE
9.1 Crane with ground controls on both sides
Crane with ground controls on both sides and with top seat controls by hand cables
9.2 Crane with top seat controls and with ground controls for outriggers
10 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES
10.1 Crane with ground controls on both sides
Crane with ground controls on both sides and with top seat controls by hand cables
10.2 Crane with top seat controls and with ground controls for outriggers
11 SUPPLEMENTARY BEAMS
11.1 Generality
11.2 Identification of the supplementary beams
12 TILTABLE OUTRIGGER RAMS
12.1 Manually tiltable outrigger rams
13 MANOEUVRES AND CONTROLS TO STABILIZE THE VEHICLE
13.1 Generality
13.2 Manual extension and re-entry of the outrigger supports
13.3 Manoeuvres for the manual extension of the double outrigger supports
13.4 Functions of control levers for stabilization
Edition ExtraCE 29.03.2006
13.5 Controls to stabilize the vehicle
14 CONTROLS TO OPERATE THE CRANE 1
14.1 Generality
14.2 Manoeuvres to unfold the crane into a working condition
14.3 Manoeuvres to fold the crane into the rest condition
14.4 Manoeuvres to unfold the crane "C" into a working condition (only for the crane version “C”)
14.5 Manoeuvres to fold the crane "C" into the rest condition (only for the crane version “C”)
14.6 Indicator of inner boom horizontal position (optional)
14.7 Third control station (optional)
15 MANOEUVRES OF THE CRANE LOADS (version with load limiting device)
Generality
16 MANOEUVRES OF THE CRANE LOADS (version with lifting moment limiting device)(optional)
16.1 Generality
16.2 Lifting moment limiting device “ELECTRONIC” (optional)
16.3 Control panels (optional)
16.4 Load handling (optional)
16.5 Lifting moment limiting device for two working sectors (optional)
16.6 Rotation limiting device (optional)
16.7 In the case of the appearance of the signal “ALARM” on the display of the control panel or of the
radio remote control or in case of an electrical failure (optional)
16.7.1 Diagnostic (Alarms/Input/Output) LME vers. 4-5 UC 01-7 (optional)
16.7.2 Temporary OVERIDE-Reactivation for the crane functions with standard distributor (optional)
16.7.3 OVERIDE-Reactivation lever for the crane functions (with Danfoss distributor) (optional)
16.8 XP device (if fitted, see the Use and Maintenance booklet)
16.8.1 Activation and instructions for use of the XP/V device (if fitted, see the Use and Maintenance booklet)
17 USE OF IMPLEMENTS
17.1 Generality
17.2 Hydraulic connections for implements - supplementary hoses
17.3 Oil cooler (heat exchanger)
18 MANUAL EXTENSIONS
18.1 Generality
18.2 Lifting moment limiting device “ELECTRONIC” for the manual extensions
(valid starting from the version 3.0 of the software)
19 CONTROLS TO OPERATE THE HYDRAULIC IMPLEMENTS OF THE CRANE
20 HYDRAULIC JIBS
20.1 Generality
20.2 Identification of the hydraulic jib
20.3 Nomenclature of the hydraulic jib
20.4 Manoeuvres to unfold the jib in working condition
20.5 Manoeuvres to fold the jib in rest condition
20.6 Operations to remove the hydraulic jib from the crane
20.7 Operations to mount the hydraulic jib on the crane
21 WINCH (if fitted)
21.1 Generality (version with lifting moment limiting device)
21.2 Winch for crane (version with lifting moment limiting device)
21.2.1 Winches equipped with a mechanical stroke end device (version with lifting moment limiting device)
21.3 Generality (version with load limiting device)
21.4 Winch for crane (version with load limiting device)
21.4.1 Winches equipped with a mechanical stroke end device (version with load limiting device)
22 MAINTENANCE INSTRUCTIONS
22.1 Generality
22.2 Timer
22.3 After every 8 working hours or at the end of every working day
22.4 After every 40 working hours or atfter every working week
22.5 After every 100 working hours or more frequently in case of more intensive utilisation
22.6 After every 500 working hours or after every 6 working months
22.7 After every 1000 working hours or after every working year
22.8 Complete overhaul of the crane is required when 10.000 working hours or 10 years'life are reached
22.9 Instructions for the dismantlement and the demolition of a FASSI crane
23 TABLE OF HYDRAULIC OIL AND LUBRICANTS CHARACTERISTICS
24 POSSIBLE FAULTS
24.1 Generality
24.2 Only operations which can be carried out by the user
24.3 Operations to be carried out only by a service center
25 INSTRUCTION AND WARNING PLATES
FASSI CRANE INDEX
GRU FASSI 1
This crane is the result of FASSI philosophy: ongoing research, rigorous testing, data
verification, and analysis of performances.
Many years of experience has allowed us to grant you the maximum safety of
operation together with the optimization of machine performances.
The fitment of the crane on the vehicle must be carried out in accordance with the
instructions given by FASSI in the manual for hydraulic crane fitting and the relevant
chassis manufacturers directives.
The Manufacturer declines all responsibility and guarantee if the fitting is entrusted to
workshops without sufficient technical capability to carry out the work in conformity.
Be sure that the unit has been installed, inspected and tested in accordance with the
local legal requirements.
As well as the principal safety norms, this manual contains a description of the crane
and the instructions for use and maintenance.
The following instructions refer to mobile cranes in general and must be inte- grated
with the manual for use supplied by the centre responsible for the crane fitting on
truck, vehicle or other type of structure.
Always conform to the safety norms and the instructions for use and mainte- nance
contained in the present manual in order to guarantee a long life to the crane.
NOTE
The original version of the present manual is in italian.
The spare parts catalogue for the crane can be viewed in the Internet
site: www.fassicat.com
2 CLASSIFICATION OF THE CRANE MODEL CLASSIFICATION OF
THE CRANE MODEL 2
2.1 Generality F 110A.22
The design of this crane has been carried out in respect of DIN 15018 norms, fatigue
test classification H1B3. The crane can operate, intermittently, with lifting devices
other than the hook. The dimensions and the capacity of the implements must be
proportioned with crane performances.
F 110A.22
Lifting Standard Hydraulic Rotation Rotation Working Pump Oil tank Crane Max. working
capacity reach extension arc torque pressure capacity capacity weight pressure
on the outrigger
( 140)
10,7 tm 8,10 m 3,70 m 390° 1,73 tm 30,0 MPa 30 l/min 60 l 1520 kg 47,1 daN\cm2
105,0 kNm 17,0 kNm
77.393 12.513 683,13 psi
26’6” 12’1” 4.351 7,93 15,85 3.351
lbf.ft ft/in ft/in lbs.ft psi gal/min gals lbs
CLASSIFICATION OF
THE CRANE MODEL 2.3
F 110A.22
3 CAPACITY PLATES CAPACITY PLATES
F 110A.22 3
3.1 Generality
The represented plates refer to the nominal design capacities.
CODE DESCRIPTION
CODE DESCRIPTION
CODE DESCRIPTION
CODE DESCRIPTION
DI341 DISTRIBUTOR
DV007 DEVIATOR
VA102 DOUBLE EFFECT BLOCK VALVE
VA185 SELECTOR VALVE
VA215 OIL FLOW CHECK VALVE
VA227 SEQUENCE VALVE
VA232 UNIDIRECTIONAL
VALVE
VA239 SIMPLE EFFECT BLOCK VALVE
VA247 OIL FLOW REGULATOR VALVE FOR ROTATION CYLINDER
4.1 HYDRAULIC SCHEMATICS HYDRAULIC
(version with load limiting SCHEMATICS 4.1
GR3
device)
Hydraulic schematic for crane - HCD4 distributor - ground controls - load limiting device
CODE DESCRIPTION
CODE DESCRIPTION
CODE DESCRIPTION
DI341 DISTRIBUTOR
DV003 DEVIATOR
DV007 DEVIATOR
FI870 FILTER (RETURN)
VA164 DOUBLE EFFECT BLOCK VALVE
VA209 SIMPLE EFFECT BLOCK VALVE
VA227 SEQUENCE VALVE
VA233 DOUBLE EFFECT BLOCK VALVE
VA239 SIMPLE EFFECT BLOCK VALVE
VA247 OIL FLOW REGULATOR VALVE FOR ROTATION CYLINDER
Hydraulic schematic for crane - versions HYDRAULIC
SCHEMATICS 4.1
GR3
CODE DESCRIPTION
DI341 DISTRIBUTOR
DV007 DEVIATOR
VA102 DOUBLE EFFECT BLOCK VALVE
VA185 SELECTOR VALVE
VA215 OIL FLOW CHECK VALVE
VA227 SEQUENCE VALVE
VA232 UNIDIRECTIONAL
VALVE
VA239 SIMPLE EFFECT BLOCK VALVE
VA247 OIL FLOW REGULATOR VALVE FOR ROTATION CYLINDER
5 ELECTRIC SCHEMATICS ELECTRIC SCHEMATICS
GR2_45»65_3_4_SE 5
Electric schematic for crane
N° DESCRIPTION
Check that the vehicle hand brake is on and that the wheels are chocked.
Stabilize the vehicle by the outrigger rams, making VERTICAL VERSION fig. 1
sure that:
- the lateral supports are fully extended;
- the wheels are in contact with the ground and the
suspension is not completely unloaded.
The vehicle/crane are not left unless the power take off is
disengaged and the load is on the ground.
Before driving the vehicle make sure that the outrig- gers are
fully retracted and re-entered, the safety taps closed and the
crane is in folded position.
HORIZONTAL VERSION
fig. 1a
7 WARNING AND INSTRUCTIONS SAFETY NORMS
7.1 Generality
GRU FASSI 7
The use of the crane is reserved to authorized personnel, instructed in advance, who
has to conform to the safety norms and instructions contained in the use manual
supplied with the crane. (See norms ISO 9926-1)
Warning plates, as well as instruction and operation plates must be replaced when no longer
readable or missing. See Paragraph 25 Instruction and warning plates.
To avoid hitting bridges or tunnels check and record the overall height of your crane in the
folded position or in laid position in the body or on the load. Always respect and pay
proper attention to road signs placed in proximity of such obstacles.
Make sure that control stations are properly lit so as to ensure safety while operating and
allow instruction plates to be visible.
Check that the working area is adequate and properly lighted for your crane.
Make sure that the hook is always free to rotate on its pin and that nothing obstructs
its vertical positioning.
Make sure that the pallet fork (if present) is con- nected
to the crane hook by means of a chain having at least
three (3) rings.
The control station on the top seat is provided with side safety guards; stay within
these guards.
Make sure that no one is within the working area of the crane.
(!) ATTENTION (!) WARNING AND
Avoid swinging the load above working and transit areas; any hidden
dan- ger situation must be audibly alarmed.
INSTRUCTIONS7.3
GRU FASSI
Avoid all those situations which may result in crushing during vehicle
sta- bilization, crane movement and load handling.
(In conformity with EN 349 standard the minimum safe working distances
to avoid crushing parts of the body)
Parts Minimum safe Figure Parts Minimum safe Figure
of the working of the working
Body distance mm Body distance mm
Hand
Wrist 100 Finger 25
Fist
The table indicates the minimum safety working distances concerning the various
parts of the body.
The figures illustrate circumstances which may turn out to be dangerous if you fail to
respect the minimum safe distances and if it is impossible to introduce lar- ger parts of
the body.
(!) ATTENTION (!)
For designated areas as: outrigger running towards rest position,
leaning and folding points of the booms in rest position, control platform
and swinnig column, top seat and running inner boom, where no carter
is pos- sible to be placed, please observe the shear and trapping hazard
stickers nearly placed.
5 8,0 - 10,7 Fresh breeze Small green branches bend, the surface of
waterways and lakes are wavy.
8 17,2 - 20,7 Storm wind Branches get broken, it's hard to walk.
9 20,8 - 24,4 Storm It damages houses (antennas and roof tiles
fall down)
Hook up the load, checking that it does not exceed the capacity indicated on the lifting diagram
specific to each load configuration.
Do not move the vehicle with the crane not in transport position and not with a load
suspended on the crane.
NOTE
Implements can be left mounted on the booms of the crane (or of the hydraulic jib)
only if the overall dimensions are respected; they must be suitably blocked to prevent
possible sideways movements.
If an accessory (fork, ...) is mounted, it must be tied down at all times during transport.
Make sure that the outrigger supports and rams are re-entered within the overall width
of the truck and locked by the safety devices.
Shearing, entrapment: the crane has a lot of parts in movement that it is impossible
to cover; therefore the operator shall always be aware of this residual risk and keep
clear from the parts in movement, particularly from the load; the operator is held
responsible not only for himself but also for those working in proximity of the crane
and for those who may draw closer even if not authorized.
Electricution: the crane is not insulated from electric contacts and therefore it is not
equipped to work under tension, even if the contact is accidental. Therefore be
compliant with the min clearance prescribed by the national directives in force.
Generally speaking the clearance from electric lines with a max tension of 38.000
volts should be at least 5 meters: Higher tensions require higher clearance to be
verified case by case together with competent technicians and with respect to the
environment conditions.
Manual extension overload: manual extensions are controlled by the moment
limiting device only under the conditions described in the relative chapter; the control
system of the manual extension overload must be activated by the operator as
described.
Accessories: be careful when assembling and disassembling the accessories
(extensions, buckets, baskets,…); first verify the weight, the securing systems and the
instructions for assembly and dismantlement; then appraise their barycentre and
provide for adequate provisional blocking systems in order to avoid sudden
movements.
(!) ATTENTION (!)
IF IN THE FOLDING CONDITION THE HOOK IS OUT OF TRUCK SIZE, IT
MUST BE TAKEN AWAY BEFORE TRAVELLING.
Particular operations: if you are required to operate under particular conditions not
illustrated in the manual of use and maintenance, analyse carefully the situation and
always refer to an authorised Fassi shop or to the Fassi technical support service or to
experienced operators before starting working.
8 IDENTIFICATION OF THE CRANE MODEL IDENTIFICATION OF
THE CRANE MODEL 8
8.1 Generality GRU FASSI
The exact crane model, serial number and description of implements will
enable FASSI Service Department to give a rapid and efficient response.
Identification data are marked on the plate DE5892, rivetted on the base
with personalized rivets FASSI. (fig. 2)
1
2
1 - Crane model 2
- Serial Number 3
3 - Year of manufacturing
fig. 2
1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Outrigger distributor
7. Outrigger double control
8. Distributor bank
9. Double control
10. Column
11. Inner ram
12. Inner boom
13. Outer ram
14. Outer boom
15. Booms extension rams
16. Extension boom sections
17. Lifting hook
18. Oil tank
19. Manual extensions (optional)
20. Seat (optional)
21. Hand-cables for crane (optional)
1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Outrigger distributor
7. Outrigger double control
8. Column
9. Seat
10. Distributor bank
11. Inner ram
12. Inner boom
13. Outer ram
14. Outer boom
15. Booms extension rams
16. Extension boom sections
17. Lifting hook
18. Oil tank
19. Manual extensions (optional)
fig. 5
10 NOMENCLATURE OF THE SAFETY NOMENCLATURE OF
AND PROTECTION DEVICES THE SAFETY AND
PROTECTION DEVICES
10
GR3_110
10.1 Crane with ground controls on both sides.
Crane with ground controls on
both sides and with top seat
controls by hand cables (on
request) (fig. 6).
Pos. Description
Supplementary beams are used in conjunction with the crane outriggers to ensure
the vehicle stability during load handling.
Ex. *145B070*0001
serial no. identification
code
fig. 8
Check that the outrigger rams are applied on a solid base; if necessary use larger
outrigger base plates (available on request) to avoid sinking.
When stabilization is complete the wheels of the vehicle must still be in contact with
the ground and the suspensions must not be fully unloaded.
Stabilize the crane so as to operate on a horizontal plane with a maximum tole- rance
of 1,5 degrees.
While loading, it may be necessary to vertically adjust the outrigger rams to prevent
an overload on the outriggers, then stabilize again.
While unloading, the outrigger rams may not be perfectly in contact with the ground
because of a rise in the suspension; it is therefore recommended to stabilize the vehicle
during operation to avoid an overturn.
13.2 Manual extension and re-entry of the SUPPLEMENTARY
outrigger supports BEAMS13.2
GR3_110
Always check that the outriggers locks, once in their rest posi-
tion, are locked in their seat by the safety devices, so as to
assure the impossibility of accidental movement.
fig. 10b
13.3 Manual extension and re-entry of the SUPPLEMENTARY
double outrigger supports BEAMS 13.3
GR3_110
By the same sequence, repeat the operations described to extend the other
supports.
(!) WARNING (!)
Keep hands clear of automatic stop device (levers A from the position of the fig. 11a to
the one of the fig. 11).
Always check that the outriggers locks, once in their rest position, are locked
in their seat by the safety devices, so as to assure the impossibility of
accidental movement.
C
NOTE
The graphic symbols illustrated hereunder are
marked on the plates affixed on the deviator
and indicate with the following symbolism fig. 12dfig. 12e
C
CD
Disengage the locking devices of the outrigger supports by putting the levers A
from the position of the fig. 11 to the one of the fig. 11a.
The stabilization has to be carried out with care and gradually keeping the vehicle in
horizontal levelled condition to prevent springs overloads and chassis torsions.
To operate the crane controls, after having completed the descent and stabilisa- tion
manoeuvres,
- Position lever D of oil diverter ( - S) on . fig. 13a
(!) Always check that the outrigger supports, once in their rest
position, are locked in their seat by the safety devices, so as to
assure the impossibility of accidental movement. (Fig. 11).
14 CONTROLS TO OPERATE THE CONTROLS TO
CRANE OPERATE THE CRANE
GR2_3_4
14
14.1 Generality
(!) WARNING (!)
Before operating the crane it is compulsory to set the outriggers. (Plate
DE6723 fig. 14)
The plates reported over each lever define their function in relation to their move-
ment.
fig. 14
VERSION WITH HORIZONTAL CONTROLS (ground controls or top CONTROLS TO OPERATE
seat controls THE CRANE 14.1
(!) ATTENTION (!) GR2_60»65_3_4
The sequence of the plates placed on the crane controls may be different.
Make sure that the lever you are going to operate correspond to the control you
selected.
CRANE IMPLEMENTS
CONTROLS CONTROLS
1 Additional function
When the operator is not present in the stand-up control station, the crane is allowed to
operate at its max rotation arc (which may differ from 180° indicated on plate
DE5643). In case the operator is not in the stand-up control station and the rotation arc
at the beginning reaches the position above the station, a red light starts flashing and a
buzzer starts ringing until the aforesaid rotation arc is maintained.
If you operate from the crane dual controls (maximum rotation arc allowed), take
extreme care when lowering the inner boom or while rotating the crane near the stand-
up control station, in order to prevent the crane booms from clashing against the
structure of the stand-up control station.
The column is fitted with a device that informs the driver through a sound/light signal
in the cab, that the inner boom max position allowed during lifting has been exceeded.
15.1 Generality
(!) Before manoeuvering the load, verify that the working area is suitable for
your crane.
The lifting curves of the capacity plate indicate the maximum load that the crane can
lift at a certain radius and at a certain height. To utilize the maximum capacity of the
crane, it is necessary to position the inner boom as indicated on the capacity plate. A
characteristic which permits the classification of cra- nes is their lifting capacity or
maximum lifting moment. The moment is defined by the value obtained from the
weight of the load to be lifted (kg) by its distan- ce (meters) from the centerline of
the crane rotation.
16.1 Generality
(!) Before manoeuvering the load, verify that the working area is suitable for
your crane.
The lifting curves of the capacity plate indicate the maximum load that the crane can
lift at a certain radius and at a certain height. To utilize the maximum capacity of the
crane, it is necessary to position the inner boom as indicated on the capacity plate.
During load handling, do not exceed the reach limits given, or the load indicated on
the above mentioned charts. If the limits are exceeded, the limiting device, allowing
all manoeuvres, which reduce the lifted load within the permitted reach limits and
forbid all other manoeuvres, will be immediately activated.
The pressure values detected in the lifting rams are turned into electric signals by the
transducers, and sent to the electronic logic of the device which deter- mines the
locking or unlocking of the controls concerned, according to the horizontal position of
the crane outer boom (mercury level switch); only the controls allowing a reduction of
the overload are enabled, while those increa- sing it are disabled.
The device features an electro-hydraulic control that does not allow the set value to be
exceed, by deactivating the controls (levers in neutral position) commanded by the
limiting device. When the controls are released (levers in neutral position) it's this
electronic logic that handles which manoeuvres are disabled, according to the position
of the crane outer boom and in overload condition, by sending electric signals to
special micro-switches placed on the elements of the distributor.
green, yellow and red led band signalling the load percentage as compared
to the capacity plate
Green light load between 0 and 90%
Yellow light load between 90 and 100%
Red light load higher than 100%
A
B - Display
C - Control buttons (4 control buttons) D - C BCH
“STOP” button
E - Audible alarm push button (danger) G D
F - Green warning light (electric on) G -
Control button for XP F
H - Control button for the temporary exclusion of E
the lifting moment limiting device
Layout of the control panel (fig. 18) (if fitted) placed on the double control side and on top fig. 17
seat (version with hand-cable controls)
D - “STOP” button
E - Audible alarm push button (danger)
F - Green warning light (electric on) G -
Control button for XP
H - Control button for the temporary exclusion of
the lifting moment limiting device
If the green warning light F comes on, it confirms that the electric circuit is active.
If the yellow led A comes on during load handling, 90% of the capacity (lifting
moment) has been reached.
If during operation the red led B comes on, the activation value of the lifting moment CONTROLS TO OPERATE
limiting device has been reached. THE CRANE16.3
Any hidden danger situation for persons must be audibly alarmed by pressing the push GR2_45»65_3_4_SE
button E.
When there are serious, imminent and dangerous conditions for persons and things
during load handling, operate on the STOP button, which isolates all crane functions.
When the electric feeding has been activated (after the version’s number of the
software) the pressure in the inner, outer ram and the jib and the percentage of load
on the winch are displayed.
In relation to the view chosen like standard, when you start the radio remote control
the pressure values are displayed in:
- ”bar” if on the display, on the left of the values, no symbol is present.
- ”daPsi” if on the display, on the left of the values, the symbol
* is present.
- By pushing the button the percentage values of pressure in the inner, outer ram
and the jib and the percentage of load on the winch are displayed. By pushing a
second time the button the pressure values in the inner, outer and jib rams
movement in the measurement unit non standard and the percentage of load on the
winch are displayed.
By pushing again the button you return to the initial display.
- By pushing the button one or more times you return to the initial display
(view of the pressure values).
If the fault cannot be resolved, you must immediately go to a FASSI autho- rised
Center after bringing the crane to its the rest position in relation to the conditions
explained in the paragraphes 15.7.2, 15.7.3.
All the eventual problems that the electronic device can have are shown on the display
of the control panel and they create the stop of all crane functions. The visualisation of
the alarm must be reset pushing the button l.m.l.d. exclusion on the main box control
panel, which bring again the display in the original screen showing the pressures only
if the problem has been solved. As consequen- ce of this, when appear an alarm
signal it is necessary to solve the problem because only in this case will be possible
to reset the display and reactivate the crane working.
ALARM CODES: CONTROLS TO
MESSAGES EXPLANATION
"STOP BOOM OUT" - warning for the interruption of the extension boom exit
because of a sudden variation of the cable tension.
"STOP JIB 25°" - warning of not permitted activation of the lifting functions
because of the activation of the maximum vertical opera-
tivity of the jib when it is complete with the 25° angle
increasing.
MESSAGES REMEDY
"WINCH OFF" Place the distributor bank lever controlling the winch in
neutral position.
"WINCH CAL.ERROR" See code 11.
"STOP BOOM OUT" Place the distributor bank lever controlling the extension
booms in neutral position. If the warning appears when the
winch cable lifting stroke end is not reached, place in any
case the lever in neutral position and then restart to operate.
"STOP BOOM UP" Lifting functions not available; are authorized only descent
functions.
To verify the right working of the differents input it is possible to use the display in
the "INPUT" menu.
16.7.2 Temporary OVERIDE-REACTIVATION for the CONTROLS TO
crane functions with standard distributor 16.7.2
OPERATE THE CRANE
GR2_45»65_3_4
- In case of an electrical failure or of the appearance of the signal “ALARM”
on the display B of the control panel of the lifting moment limiting device:
Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).
On the distributor it has been installed an electro-valve with a manual locking func- tion
(fig. 22) which allows to reactivate all the crane functions in case of absence of the
electric power. Only in these conditions it is permitted to remove the lead seal which
protects the device. Push the button and turn it into the clockwise sense (fig. 22a pos. 1-2);
the button stays in stable and closed position.
fig. 22
(!) When the electric power is restablished, remember to put the
button in its original position, turning it into the anti-clockwise
sense.
(fig. 22a pos. 3-4)
This activation prevents the operation of the lifting moment limiting devi-
ce, consequently, the operation under such conditions can involve an
overload condition. In such an emergency condition (where the lifting
moment limiting device has been disabled), the operator, who is respon-
sible for the machine safety, must:
- carefully consider the manoeuvres required to return to normal working
conditions: it is however compulsory to effect the re-entry of the
extension booms at first,
- calmly and carefully assess the type and scale of the hazards arising
from these manoeuvres and the possible reaction of the crane
(tipping over, frame overload, uncontrolled fall of the load due to a
hydraulic system overload etc.); fig. 22a
- make all movements as slowly as possible to reduce the
dynamic overload to the minimum.
After such emergency operations and prior to re-use of the crane, you must
immediately go to FASSI authorised Center for testing the structure and re-
sealing of the device.
Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).
On the distributor it has been installed an emergency tap lever (fig. 23) to be used in
the event of a black-out, electrical or hydraulic malfunctions.
Only In these situations it is permitted to remove the lead seal placed on the tap lever
and place it in the closed position.
After such emergency operations and prior to re-use of the crane, you must immediately
go to FASSI authorised Center for testing the structure and re-sea- ling of the device.
(!) Interferences with the valves or removal of the lead seal release the
FASSI GRU IDRAULICHE
from any responsibility and invalidate the warranty.
DE1679 DE1680
17 USE OF IMPLEMENTS USE OF IMPLEMENTS
GRU FASSI 17
17.1 Generality
The crane, in load condition H1B3, can be provided with implements such as:
- Manual extensions
- Winches
- Hydraulic extensions
- Personnel baskets
- Clam ‘shell buckets
- Augers
(!) When using an implement it is always necessary to check that its weight,
dimension and capacity is matched to the crane performances.
For further information please refer to FASSI GRU IDRAULICHE
Warning and norms for crane use also apply for hydraulic implement use.
Before using a personnel basket it is necessary to provide the crane with the safety
devices requested by the local norms in force, EN280 in Europe, and prior to use of
the crane it has to be tested and inspected in accordance with the local legal
requirements.
(!) When the crane is fitted with implements or laid on the truck body it is necessary to
check they are locked to assure the impossibility of accidental movements and that the
led signalling maximum obstruction in height (if fitted) confirms the cor rect
positioning of the crane.
(!) The crane can operate, intermittently and not continuously, with lifting
devices other than the hook, only on loose and light materials (not on scrap
iron).
NOTE
When using coupling unions it is necessary to verify that there is no trace of soil, curt
etc. on the unions and inside the seats so as to avoid the oil contami- nation and
consequently wear the tightening “ surface” of unions or ram seals.
The crane is equipped with an oil cooler (air-oil heat exchanger) to prevent damage
caused by an excessive increase of the oil temperature.
NOTE
When working in a low temperature climate, we recommend to bring the
hydraulic oil up to working temperature prior to starting work, This is
best done by operating the crane thru all its functions ram stroke end.
fig. 1 fig. 1
fig. 2 fig. 2
Use the "+" button to select JIB if in the actual configuration the manual exten-
sions are mounted on JIB or CRANE if the manual extensions are mounted on the
crane.
3. Message “M1 - M2 - M3” (fig. 3) USE OF IMPLEMENTS
After having pressed the above mentioned keys, the message illustrated in Fig. 3
will be displayed.
GR2_45»65_3_4_5_SE 18.2
fig. 3 fig. 3
At this point, through the "+" button, select the correct number of the manual exten- sion at
the moment in use (M stands for manual and 1, 2 and 3 indicate the number of the manual
extensions). Select the number of the manual extension you want; that number starts
blinking. You can select only the manual extensions that have been installed: i.e. if only
one manual extension is installed, by pressing the "+" key, only the M1extension will start
flashing. To confirm your choice, press once the “F1” key (control panel) or “ENTER”
(radio-remote control); you'll access the section dedicated to the system configuration.
fig. 4 fig. 4
If you press the "ENTER" key with the manual extensions mounted on the jib,
the screen of Fig. 4 will be displayed.
Therefore we can choose the most convenient configuration among the
following:
K1 Outer booms of the crane totally re-entered and jib extensions as you like K2
Outer booms of the crane as you like and jib extensions totally re-entered K3
Outer booms of the crane totally extended and jib extensions as you like K4
Outer booms of the crane as you like and jib extensions totally extended
Select the desired configuration using the * button to move among the various
options. Confirm your selection by pressing the “F1” (control panel) or “ENTER”
(radio-remote control) key. If the hydraulic jib boom is not at its stroke end, the
message at point 3 will be displayed; otherwise the message "F1 TO START" is
visualised.
fig. 5 fig. 5
6. Message “FC P3” (fig. 6) USE OF IMPLEMENTS
[paragraph to read only in case of manual extensions installed on Jib
and not on Crane]
GR2_45»65_3_4_5_SE 18.2
Note: do not hang any load on the hook.
This means that the jib outrigger must be positioned at its stroke end (if it is already
in that position this message won't appear), using the lever until the next screen is
displayed.
fig. 6 fig. 6
fig. 8 fig. 8
fig. 9 fig. 9
10. Message “LOAD OK” (fig. 10) USE OF IMPLEMENTS
This message confirms that the load does not exceed the lifting limits of the crane
and of the manual extension selected.
GR2_45»65_3_4_5_SE 18.2
fig. 10 fig. 10
selector on A “INDEX”
Figure C Figure D
For an overall view of the procedure, we attach the diagrams showing all the pas- sages
and messages that can be displayed during the procedure according to the various
situations that may take place.
The script "EXIT" in the block diagram allows to exit the procedure.
FURTHER MESSAGES
After releasing the lever in neutral position you can find the following messages
If you keep pressed the "F2" key “F2” on the control panel or “LMI” on the push- button
panel, it is possible to have an indicative evaluation of the weight applied on the hook (fig.
11).
fig. 11 fig. 11
fig. 12 fig. 12
b. “NO LOAD” (fig. 13)
USE OF IMPLEMENTS
In this case the load exceeds the max lifting value of the selected manual GR2_45»65_3_4_5_SE 18.2
extension (it could still be on the ground). Unhook the load since it cannot
be lifted using the selected manual extension. As in the preceding case, if you keep
pressed the "F2" key, it is possible to have an indicative evalua- tion of the weight
applied on the hook (fig. 11).
fig. 13 fig. 13
fig. 14 fig. 14
fig. 15 fig. 15
Electric schematic - crane with manual extensions USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18.2
Electric schematic - crane with jib and manual extensions on jib USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18.2
19 CONTROLS TO OPERATE THE USE OF IMPLEMENTS
HYDRAULIC IMPLEMENTS OF THE GR2_60»65_3_4_AS 19
CRANE
Jib Jib
Winch Bucket outer extension
boom booms
Make sure that the lever you are going to operate correspond to the control you
selected.
21 WINCH (if fitted) USE OF IMPLEMENTS
21.1 Generality
GRU FASSI 21
The winch is made of a drum that can rotate by means of a hydraulic motor, on a
structure fixed on the crane. The rotation of the drum on which the cable winds is
achieved by a hydraulic motor controlled by a safety check valve connected to the crane
circuit. A parking brake integrated to the motoreducer group hold the load in position
when the winch control lever is in neutral position.
Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
7. Block (double-triple......line) fig. 23
(!) On winches not equipped with cable layer, check the rewinding of
the cable on winch drum proceeds regularly and without
overlapping: it is suggested to rewind the cable only if it is
sufficiently taut.
Do not rotate the crane before the load is lifted. Lift the load vertically using the cable
and not the boom in order to avoid swinging the load. With the suspen- ded load rotate
slowly and with care checking the stability of the vehicle.
* * *
DOUBLE LINE TRIPLE LINE QUADRUPLE LINE
SINGLE LINE
*
CORRECT POSITION
FOR THE PULLEY AND
THE PULLEY BLOCK
21.3 Generality USE OF IMPLEMENTS
(version with load limiting device) GRU FASSI 21.3
The winch is made of a drum that can rotate by means of a hydraulic motor, on a
structure fixed on the crane. The rotation of the drum on which the cable winds is
achieved by a hydraulic motor controlled by a safety check valve connected to the crane
circuit. A parking brake integrated to the motoreducer group hold the load in position
when the winch control lever is in neutral position.
Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
7. Block (double-triple......line) Fig. 23
(!) On winches not equipped with cable layer, check the rewinding of
the cable on winch drum proceeds regularly and without
overlapping: it is suggested to rewind the cable only if it is
sufficiently taut.
Do not rotate the crane before the load is lifted. Lift the load vertically using the cable
and not the boom in order to avoid swinging the load. With the suspen- ded load rotate
slowly and with care checking the stability of the vehicle.
When the load exceeds the winch nominal load by 20% the exit of the exten- sion
boom sections is deactivated.
When unwinding, an electric device maintains at least three (3) turns of the lifting
cable wound around the winch drum on activation the following controls are
desactivated.
Manoeuvres not allowed:
- Winch rope descent
Manoeuvres allowed:
- all other movements
* * *
DOUBLE LINE TRIPLE LINE QUADRUPLE LINE
SINGLE LINE
*
CORRECT POSITION
FOR THE PULLEY AND
THE PULLEY BLOCK
22 MAINTENANCE INSTRUCTIONS MAINTENANCE
INSTRUCTIONS 22
22.1 Generality GRU FASSI
General lubrication and small repairs can be carried out by the user; repairs of a more
complicated nature must be carried out by authorized service person- nel.
Good maintenance and proper use are imperative to maintain efficient use and
guarantee the safety of the crane.
At least once a year you must take the crane to a Fassi Service Center for a check.
(!) Before disconnecting any hydraulic hoses, ensure that there is no pressure in the
hydraulic circuit. After removing hoses always mark them and their respective
ports on the crane. Faulty replacement can cause damage to the rams and to the
hydraulic circuit.
Any maintenance operation must be carried out with the crane power source turned
off. (in case of fixed mounting with hydraulic power pack, the electric motor has to be
turned off).
Do not place limbs, fingers or any other parts of anatomy into areas of the crane,
which present possibilities of shearing, without having blocked such parts of the crane.
Do not weld, drill or grind any part of the crane without the Manufacturer’s
authorisation.
Do not use the high pressure washing on the controls (deviators, distributors, double
controls, hand cable controls...), on the electronic components (boxes, control
panels...), on the tanks.
Never use detergents, petrolsol or inflammable liquids, always use non flam- mable or
non toxic liquids.
To avoid down time, it is recommended to periodically carry out the following checks.
22.2 Timer (fig. 29a) (if fitted) MAINTENANCE
INSTRUCTIONS 22.2
The control panel of the “electronic” lifting moment limiting device, placed next to GRU FASSI
the distributor of the crane, features an alphernumeric readout for displaying the date,
the activation time expressed in hours-minutes of the electric control panel ("Partial
Time" and "Total time") or the working time of the crane whilst being operated via
the control levers ("Work Time").
Press button C2 (clock/-) to have the current date visualized on display B. Fig. 29.
Partial time
How to view the partial time of the electric panel; which can be
reset.
- Keep button C2 (-) pressed until you read “Time” on
display B.
- Press button C1 (+) until you see "Partial time".
- Press button C3 (enter) to view the time.
Total time
How to view the total activation time of the electric panel; this cannot be reset.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C3 (enter) to visualize, for about 5 seconds, the total time
expressed in hours and minutes.
Work time
How to view the work time which is the actual time recorded whilst a crane
operating lever/function is being activated.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C1 (+) again to read "Work time" on the display.
- Press button C3 (enter) to view, for about 5 seconds the work time of the crane
expressed in hours and minutes.
22.3 After every 8 working hours or at the end of MAINTENANCE
every working day INSTRUCTIONS 22.3
- Check that all safety devices are efficient. GRU FASSI
- Check the level of the hydraulic oil in the tank.
- Check all the components of the hydraulic circuit for possible leaks.
- Check that the control and the oil diverter levers can easily be positioned; they
must show no signs of forcing.
- Check the condition of shackles, hooks, wire ropes and any other lifting equipment.
Clean the oil filter placed in the oil tank of the crane and if any, on the pump sec- tion
and pressure hoses.
NOTE The filters of fibre or paper can not be cleaned, they must be replaced. Cleaning of
the wire mesh filter on the tank (oil return to the oil-tank) fig. 31.
- Unscrew the security bolts of the filter cover 1 and remove it.
- Extract the cartridge, clean by flushing with a non flammable, non corrosive and non
toxic solvent (gas oil or other). Thoroughly dry the filter inside and out (do not use fig. 31
compressed air).
- Check if the cartridge has collapsed; if so, replace it!
- Remove the filter body 3 and clean it.
- Re-assemble the filter body and the cartridge: check the sealing of the ‘O’ ring 4-5-6;
in case, replace it!
NOTE Take care that no contaminated material passes into the tank. Replacement
of the filter on the delivery line (before the distributor) fig. 32.
- When the visual indicator becomes red, replace the cartridge.
- Unscrew with a suitable spanner the filter body (1) from the head (2).
fig. 32
- Remove the cartridge (3) and clean inside the holder (1).
- Insert a new cartridge and re-assemble the filter body into the head checking the seal
(4).
MAX MIN
Check the oil level in the tank with the crane in the folded position and with the outriggers
(crane and supplementary) fully re-entered. The oil level must not exceed the maximum or
be lower than the minimum (fig. 33).
Top up using hydraulic oil with the same characteristics as those indicated in the table at fig. 33
paragraph 23.
The following lubricators have been centralized and gathered in a case (fig. 33a)
positioned on the base (crane distributor side):
- rack guide shoe - rotation,
- upper and lower bush of the column - column support,
- rack group - column gear,
- column support group - pendulum beam.
Table of the tightening torques of the fixing rods of the crane on the vehicle
From “C0404 Kit for crane fixing”.
D. Fixing Tightening
rods torque = Nm
M22x1,5 300
M24x2,0 400
M27x2,0 600
M30x2,0 471
M33x2,0 1200
M39x3,0 1800
WITH SLEW RING
MAINTENANCE
- of the slew gear screws (bolts M20 Class 12.9: Thightening torque = 620 Nm)
WITH RACK
INSTRUCTIONS 22.6
- of the securing bolts for the ram pins and of all the other bolts and screws, where the GRU FASSI
tightening torque is not expressly indicated, consult the following table in order to find
it’s value according to the bolt diameter and class.
Table of the bolts tightening torque, in general, with average friction value (0,15)
and average-good tightening accuracy (C).
Check the guide shoe wear as it affects the sliding section tolerances; if the clearances are 3
considerable, damage to the rams and the structure may occur.
Clean the air filter placed in the top of the oil tank filter cap. Completely
(!) The waste oil and the filter cartridges MUST be disposed of by fig. 34
authorized persons.
(!) CAUTION DANGER (!)
On the outer boom there is a mercury capsule (mercury level switch) duly
protected and provided with the following warning stickers.
MERCURY IS EXTREMELY TOXIC. IN CASE OF REPLACEMENT AND/
OR SCRAPPING, DISPOSE OF OR RECYCLE THE CAPSULE CONTAI-
NING MERCURY WITH MAXIMUM CARE, AND IN ACCORDANCE WITH
THE NATIONAL REGULATIONS IN FORCE.
22.7 After every 1000 working hours or after MAINTENANCE
every working year 22.7
INSTRUCTIONS
GRU FASSI
Perform: Washing, Function Testing, Testing according to the
capacity plates
Check: Identification plates, Capacity plates
10.000 working hours, (i.e.: 10 years, 50 weeks a year, 20 hours a week, or 5 years, 50 weeks
a year, 40 hours a week)
or
a complete overhaul with in-depth structural inspection of the crane must be carried out by an
authorised service centre.
Completely release the residual pressure in the hydraulic circuits and then fully drain the oil
present in the circuits before starting the dismantlement of the relevant compo- nents. Be
careful not to let the oil drop on the ground, therefore collect it in special con- tainers, since
exhausted oil must be eliminated in compliance with the waste disposal rules in force.
Disable all the electric power supplies (batteries etc.) before dismantling the compo- nents of
the electric circuits.
23 TABLE OF HYDRAULIC OIL AND TABLE OF HYDRAULIC
LUBRICANTS CHARACTERISTICS OIL AND LUBRICANTS 23
CHARACTERISTICS
GRU FASSI
Use only GREASE NILEX EP1 of the firm NILS. NOTE: Do not ABSOLUTELY mix different
types of grease.
All grease used must be free from acid and resin, not hygroscopic and long-life such
as
BP GREASE LTX-EP1\EP2 or ELF EPEXA 1\2 ESSO BEACON EP1\EP2 or TEXACO EP1\
EP2 MOBIL EP1\EP2 or SIMILAR.
Classification ISO-L-CC
The most suitable here is a general-purpose lubricating oil with about SAE 30°
viscosity. A lubricating oil containing non-stick additives is recommen- ded if the
cables are expected to move quickly through the pulleys.
( ! ) WARNING ( ! )
Don’t use greases with solid particles as “Bisulphide of Molybdenum”
(not compatible with eventual teflon bushes).
24 POSSIBLE FAULTS POSSIBLE FAULTS
GRU FASSI 24
24.1 Generality
Many years experience of our product has allowed us to identify and classify the most
common faults which occur. In most cases it requires accurate hydraulic and electric
troubleshooting and simple rectification. In the following table we report the most fre- quent
inconveniences and our suggested remedies.
(!) Checking and adjustment of oil pressures of valve settings must be carried out by an
authorized service agent, under penalty of warranty forfeiture.
TO OPERATE THE CRANE FOR TOO LONGER PERIOD WITH THE OVERIDE
ACTIVATED MAY INVALIDATE THE CRANE WARRANTY.
The crane does not lift Non efficiency Replace the pump
the loads indicated on of the pump
the capacity plate
(main pressure or auxiliary) Check the pressure,
valves not properly adjust the valves or
adjusted, or worn replace them!
The crane does not Valves controlling the Adjust the valves
rotate properly rotation not adjusted
- WITH RACK: Wear of rotation guide shoe Replace the guide shoe
Wear of the seals Replace the seals
of the rotation cylinder
- WITH SLEW RING: Check the slew ring wear,
Wear of the slew ring
replace if necessary
Check the motore- ducer
Wear of the motoreducer group wear, replace if
group necessary
DE 4236
Instruction plate and safety norms
DE 6723
Warning plate to stabilize the vehicle before
using the crane
DE 1684A
Do not operate from the double control side, to
unfold or fold the crane
DE 4452A
Instruction plate to fold the crane
into the rest condition
INSTRUCTION AND
25
WARNING PLATES
GR3_080_110
DE 4491
Do not operate from the frontal position, to
extend the outrigger supports
DE 2100
Danger plate for crushing of lower limbs
DE 2735 DE 2316
Oil-diverter Outrigger control
control plate plate
Instruction plates to
stabilize the vehicle
INSTRUCTION AND
25
WARNING PLATES
GR3_080_110
DE 1681
Greasing points with brush
DE 1682
Greasing points at pressure
DE 1686
Do not walk or stop under a suspended load
DE 1683 / DE 2361
Do not operate in proximity of electric high-
tension lines
DE 6409A
Warning of shearing danger
INSTRUCTION AND
25
WARNING PLATES
GR3_080_110
DE 1679
Do not walk on...
DE 1680
Do not use water to estinguish fire
DE 4945
Warning of burn danger
DE 1067
Do not walk or stay under a suspended load and
for unauthorized persons to be within the
working area..
DE1067