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FASSI CRANE 1

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

use and maintenance


ORIGINAL INSTRUCTIONS

THANK YOU FOR SELECTING ONE OF FASSI CRANES.

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.

All this represents the core of FASSI quality system.

FASSI quality system is in conformity


with UNI EN ISO 9001:2000 (ISO
9001:2000)

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.

READ THIS MANUAL CAREFULLY prior to use or any maintenance. A few


minutes spent now could save time and labour later.

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.

2.2 Hydraulic jibs


Hydraulic jibs
Extension type Weight=kg Manual Weight=kg Manual Weight=kg Manual Weight=kg
L102 320 ML10 20 ------------------------ ------------------------

2.3 Technical data

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.

(!) WARNING (!)


If the capacities are downgraded or partially reduced (e.g. sector in front of vehicle
cab) capacity plates must be applied in line with the final test figures.

3.2 Capacity plates with lifting moment limiting device


CAPACITY PLATES
F 110A.22 3.2
CAPACITY PLATES
F 110A.22 3.2
CAPACITY PLATES
F 110A.22 3.2
CAPACITY PLATES
F 110A.22 3.2
CAPACITY PLATES
F 110A.22 3.2
3.3 Capacity plates with load limiting device CAPACITY PLATES
F 110A.22 3.3
CAPACITY PLATES
F 110A.22 3.3
CAPACITY PLATES
F 110A.22 3.3
CAPACITY PLATES
F 110A.22 3.3
4 HYDRAULIC SCHEMATICS HYDRAULIC
(version with lifting moment limiting device) 4
SCHEMATICS
GR3_110»150
Hydraulic schematic for crane - HCD4 distributor - ground controls - “electronic” lifting moment
limiting device (F110A from s.n. *4455* - F130A from s.n. *3333* - F150A from s.n. *3366*)

CODE DESCRIPTION

DI341 DISTRIBUTOR VA164 DOUBLE EFFECT BLOCK VALVE


DV003 DEVIATOR VA185 SELECTOR VALVE
DV007 DEVIATOR VA194 DOUBLE EFFECT BLOCK VALVE
EV128 ELECTROVALVE VA200 DOUBLE EFFECT BLOCK VALVE
EV117 ELECTROVALVE VA209 SIMPLE EFFECT BLOCK VALVE
FI870 FILTER (RETURN) VA215 OIL FLOW CHECK VALVE
M1/M2 GAUGE QUICK CONNECTION VA217 SEQUENCE VALVE
PR103 PRESSURE SWITCH VA227 SEQUENCE VALVE
RU975 FAUCET VA102 DOUBLE EFFECT BLOCK VALVE
TR002 PRESSURE TRANSDUCER VA239 SIMPLE EFFECT BLOCK VALVE
Hydraulic schematic for crane - HCD4 distributor - top seat controls - “electronic” lifting HYDRAULIC
moment limiting (F110A from s.n. *4455* - F130A from s.n. *3333* - F150A from s.n. *3366*)
4
SCHEMATICS
GR3_110»150

CODE DESCRIPTION

DI341 DISTRIBUTOR VA185 SELECTOR VALVE


DV003 DEVIATOR VA194 DOUBLE EFFECT BLOCK VALVE
DV007 DEVIATOR VA200 DOUBLE EFFECT BLOCK VALVE
EV128 ELECTROVALVE VA209 SIMPLE EFFECT BLOCK VALVE
EV117 ELECTROVALVE VA217 SEQUENCE VALVE
FI870 FILTER (RETURN) VA227 SEQUENCE VALVE
M1/M2 GAUGE QUICK CONNECTION VA102 DOUBLE EFFECT BLOCK VALVE
PR103 PRESSURE SWITCH VA239 SIMPLE EFFECT BLOCK VALVE
RU975 FAUCET VA247 OIL FLOW REGULATOR VALVE FOR ROTATION
TR002 PRESSURE TRANSDUCER CYLINDER
VA164 DOUBLE EFFECT BLOCK VALVE
Hydraulic schematic for crane - Danfoss distributor - “electronic” lifting moment limiting HYDRAULIC
(F110A from s.n. *5229* - F130A from s.n. *3780* - F150A from s.n. *3893*)
4
SCHEMATICS
GR3_110»150

CODE DESCRIPTION

DI341 DISTRIBUTOR VA148 ELECTRIC MAIN WITH BY PASS VALVE


DV003 DEVIATOR VA164 DOUBLE EFFECT BLOCK VALVE
DV007 DEVIATOR VA185 SELECTOR VALVE
EV124 ELECTROVALVE VA194 DOUBLE EFFECT BLOCK VALVE
FI776 FILTER (HIGH PRESSURE) VA200 DOUBLE EFFECT BLOCK VALVE
FI870 FILTER (RETURN) VA209 SIMPLE EFFECT BLOCK VALVE
M1/M2 GAUGE QUICK CONNECTION VA215 OIL FLOW CHECK VALVE
PR103 PRESSURE SWITCH VA227 SEQUENCE VALVE
RU975 FAUCET VA232 UNIDIRECTIONAL VALVE
RU978 FAUCET VA239 SIMPLE EFFECT BLOCK VALVE
TR002 PRESSURE TRANSDUCER VA257 SEQUENCE VALVE
Hydraulic schematic for crane - versions HYDRAULIC
4
SCHEMATICS
GR3_110»150

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

DI341 DISTRIBUTOR VA215 OIL FLOW CHECK VALVE


DV003 DEVIATOR VA227 SEQUENCE VALVE
DV007 DEVIATOR VA233 DOUBLE EFFECT BLOCK VALVE
FI870 FILTER (RETURN) VA239 SIMPLE EFFECT BLOCK VALVE
RU975 FAUCET
VA164 DOUBLE EFFECT BLOCK VALVE
VA194 DOUBLE EFFECT BLOCK VALVE
VA200 DOUBLE EFFECT BLOCK VALVE
VA209 SIMPLE EFFECT BLOCK VALVE
Hydraulic schematic for crane - HCD4 distributor - top seat controls - load limiting device HYDRAULIC
SCHEMATICS 4.1
GR3

CODE DESCRIPTION

DI341 DISTRIBUTOR VA233 DOUBLE EFFECT BLOCK VALVE


DV003 DEVIATOR VA239 SIMPLE EFFECT BLOCK VALVE
DV007 DEVIATOR VA247 OIL FLOW REGULATOR VALVE FOR ROTATION
FI870 FILTER (RETURN) CYLINDER
RU975 FAUCET
VA164 DOUBLE EFFECT BLOCK VALVE
VA194 DOUBLE EFFECT BLOCK VALVE
VA200 DOUBLE EFFECT BLOCK VALVE
VA209 SIMPLE EFFECT BLOCK VALVE
VA227 SEQUENCE VALVE
Hydraulic schematic for crane - Danfoss distributor - load limiting device HYDRAULIC
SCHEMATICS 4.1
GR3

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

ALIM ELECTRICAL FEED CABLE MAIN CONTROL PANEL


EV1 ELECTROVALVE FOR CRANE BLOCK
EV2 ELECTROVALVE FOR LIFTING MOMENT LIMITING DEVICE OF THE TWO WORKING ZONES
EV3 XP ELECTROVALVE
LP FLASHING
IP1/2/3 PROXIMITY MICROSWITCH FOR ROTATION CONTROL
LCV WINCH LOAD LIMITING DEVICE
LR ACTIVATION OF OVERLOAD BLOCK RED WARNING LIGHT
M1 MICROSWITCH ON THE DISTRIBUTOR (ROTATION)
M2 MICROSWITCH ON THE DISTRIBUTOR (INNER BOOM) M3
MICROSWITCH ON THE DISTRIBUTOR (OUTER BOOM)
M4 MICROSWITCH ON THE DISTRIBUTOR (CRANE EXTENSION BOOMS) M5
MICROSWITCH ON THE DISTRIBUTOR (JIB BOOM)
M6 MICROSWITCH ON THE DISTRIBUTOR (JIB EXTENSION BOOMS)
M7 MICROSWITCH ON THE DISTRIBUTOR (WINCH)
MS MERCURY LEVEL SENSOR ON THE OUTER BOOM
MV2 DRUM MICROSWITCH WINCH
P1 PRESSURE SWITCH FOR THE RE-ENTRY OF THE EXTENSION BOOMS
UCF MAIN CONTROL PANEL (FX000)
S1/2/3/… CONNECTORS
SAT1 DOUBLE CONTROL SIDE SATELLITE
SAT2 SATELLITE FOR 3° CONTROL STATION
SD1 SHUNT BOX 1
TP1 PRESSURE TRANSDUCER FOR INNER RAM TP2
PRESSURE TRANSDUCER FOR OUTER RAM TP3
PRESSURE TRANSDUCER FOR THE JIB RAM
6 SAFETY NORMS SAFETY NORMS
GR2_3_4_5 6
Strictly conform to the norms reported by the plates DE2499B (fig. 1) or DE4236
(fig. 1a) placed next to the controls, in order to avoid possible acciden- ts while
operating the crane.

Only authorized persons are allowed to operate the crane. The

crane must be used on firm, level ground.

Check that the vehicle hand brake is on and that the wheels are chocked.

Before every operation make sure that:


- no-one is within the working area of the crane;
- the safety devices are in place and operative;
- the minimum safe working distances from power lines are observed;
- the load is correctly slung and hooked.

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.

Use the crane in accordance with the use and maintenance


manual, making sure that:
- the load and radius are within the maximum limits
shown on the crane capacity plate;
- the crane is used progressively avoiding sudden load
movements
- swinging or dragging of the load is avoided;
- the load is lifted before rotating.

When using implements protect the crane working area with


a barrier.

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)

It is absolutely prohibited to walk or stop under a suspended load

It is prohibited for unauthorized persons to be within the working area. Under

no circumstances interfere with the safety and protection devices.

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.

Do not use the outriggers to raise the vehicle.

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.

7.2 Before operating


(!) ATTENTION (!)
Check that protections are in their place and that all safety devices are fitted
and active. (See norms ISO 9927-1)
DE1067
Keep the ladder and the control station on the top seat, clean; Normally, the seat can
tilt forward.

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.

Check the efficiency of the hook safety catch.

Carefully inspect the condition of ropes or chains. (if present)

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.

7.3 During operation


Take the vehicle fumes away from the working area by fitting an extension tube of a
suitable diameter and a right length to the exhaust system.
Do not run the engine in a indoor area without first making sure there is adequate ventilation.
When using the ladder to reach the control station on the top seat, avoid knocking
into the controls while going up or down the ladder.

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

Body 500 Head 300

Leg 180 Foot 120

Toes 50 Arm 120

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.

(!) ATTENTION (!)


Failure to respect the minimum safe distances may result in a safety
hazard and a deadly risk.
Remember that the stability of the unit (crane-vehicle) is only guaranteed by the
complete lateral extension of the outriggers and by the observance of the capa- city
plates.
Stabilize the vehicle on a horizontal plane with a maximum tolerance of 1,5 degrees.
Make sure that the outrigger rams rest on a solid base, if necessary use larger outrigger
base plates (available on request) to avoid sinking. If you adopt other means, make sure
that they are suitably sized for the load they must bear.
(!) ATTENTION (!) WARNING AND
Respect the safety distances from electric lines; the minimum distance
is, according to CEN norms, five (5) meters, except for otherwise
INSTRUCTIONS7.3
GRU FASSI
prescribed by national norms.
(!) ATTENTION (!)
Failure to respect the minimum safe distances may result in electrical hazards for
the operator and his assistants.
ELECTRICUTION:
General safety precautions for the operator and potential co-workers. If the crane hits an overhead
power line, do not touch the crane, the truck or the load.
Carefully evaluate the danger before moving. If you are closer than 10 meters from the crane, the
truck, the load or the electric line, move at least 10 meters away, by shuffling away with small
steps, in order to minimize the chance of getting a too high voltage diffe- rence between the
feet.
Warn others to stay away; call for help and contact the power company to de-energize the line: do
not attempt to assist someone in direct or indirect contact with the power line before the power
has been disabled: you run the risk of being electricuted yourself.
If you are in the truck cabin, stay inside without touching the vehicle body because it's
extremely hazardous to go out before the line is de-energised.
Help the electricuted person if you know the first-aid procedures, otherwise wait for the
paramedics to arrive.
(!) ATTENTION (!)
Do not utilize the crane during thunderstorms and with wind speed excee-
ding 13,8 m\s (50 km/h), maximum value of the Beaufort scale degree 6.
Indications about wind speed
Force of the wind Wind speed Classification Characteristics
Beaufort scale m/s

0 0,0 - 0,2 Calm Calm wind, smoke goes up quite


vertically
1 0,3 - 1,5 Light breeze Smoke reveals the direction of the wind,
2 1,6 - 3,3 one can feel the wind blowing, leaves
start fluttering.
3 3,4 - 5,4 Moderate breeze Leaves and branches are in constant
4 5,5 - 7,9 motion, small branches start fluttering.
Dust and papers dance on the ground.

5 8,0 - 10,7 Fresh breeze Small green branches bend, the surface of
waterways and lakes are wavy.

6 10,8 - 13,8 Near gale Big branches bend, wind whistles


through high-tension cables, it's
difficult to walk keeping the
umbrella open.
7 13,9 - 17,1 Moderate gale Trees sway, it's hard to walk

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)

(!) ATTENTION (!)


Carefully inspect the load rigging.

Hook up the load, checking that it does not exceed the capacity indicated on the lifting diagram
specific to each load configuration.

Make sure that the lifted load is balanced.


Avoid swinging the load above the control station; in cases where the load is too close, the
crane must be operated from the opposite side or with the radio-remote control.
When operating through a winch, lift the load vertically using the cable and not the booms in
order to avoid swinging the load.
Do not rotate the crane before the load is WARNING AND
lifted. INSTRUCTIONS7.4
GRU FASSI
Do not operate with sudden movemen- ts,
activate the controls with slow and
progressive movements; rotate slowly and
with care paying attention to the stability
of the vehicle.

With vertical lift, on hydraulic and


mechanical extension, rotate slowly in
order to avoid side-skidding.

(!) ATTENTION (!)


Do not utilize the crane for
pushpull (F), lateral (F) or sideways
(F) opera- tions.

(!) ATTENTION (!)


Crushing (F) or push (F) manoeu-
vres are not permitted.

(!) Never operate the outriggers


when the crane is loaded.

(!) ATTENTION (!)


The vehicle\crane must not be left
unless the load is on the ground,
the booms of the crane (and of the
hydraulic jib), are folded and laid
on a solid base and the power take-
off is disengaged.

Do not move the vehicle with the crane not in transport position and not with a load
suspended on the crane.

7.4 At the end of the operation (Prior to driving the vehicle)


Fold the crane.

If the booms of the crane (or of the


hydraulic jib) are to be laid on the body or
on the load, they must be suitably blocked
to prevent possible sideways movements.

Make sure that the indications about the


overall dimensions are respected.

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.

Disengage the power take off.


7.5 Residual risks WARNING AND
INSTRUCTIONS7.5
NOTE: This reasoned list does not carry the complete list of the residual risks, which GRU FASSI
are examined more in detail paragraph by paragraph in the manual under "(!)
ATTENTION (!)"; it is instead a way to exemplify to the operator the types of hazards
linked to the use of the crane, which basically involves a lifted load in movement.
Therefore we confirm you the following
It is absolutely forbidden to use the crane without having read and
understood the manual for use and maintenance and without having
being previously instructed by experienced personnel on all aspects of
safe crane operation.
Risk evaluation shall be followed by adequate provisions in order to
avoid risks and damages to people and things.
The crane operator shall be held directly responsible for the correct
operation of the crane also according to the jobsite conditions.
Overturn: the crane can overturn, thus hurting people and damaging things
specially in following conditions:
- if it is not correctly stabilized
- if the moment limiting device is disabled
- if the ground conditions at the jobsite are not stable enough with respect to the
dimensions of the outrigger base and/or of the additional base plate
- if you increase the design dynamic increasing the pump oil flow.
Moment limiting device: never try to bypass nor tamper with the moment limi-
ting device and the various safety systems installed on the crane. In such case the
operator shall be held responsible for the subsequent crane performan- ce. It is also
important to understand the alarm messages generated by the "moment limiting
device" and act consequently.
Control seat: before operating from the control seat the operator shall make sure
that he's safe from hazards (i.e. he stands clear of the load, there is a way of
escape,..). Otherwise he shall manoeuvre from a different control seat; if there is none
available, the crane should be equipped with a radio control or remote control in order
to allow the operator to operate the crane in absolute safety.
From the control seat the operator shall be able to visually inspect the whole working
area at all times. If it is not possible he shall team up with a co-worker able to control
the whole area; otherwise the crane shall be equipped with a radio control in order to
ensure the operator with the perfect position to see all potential hazards clearly at all
times. Naturally the operator shall also teach this eventually co-worker with the
scope of not harm each other with control commands.
Load rigging: carefully inspect the load rigging; the operator shall make sure that
the load is properly attached and balanced and that all unexpected move- ments are not
allowed. Be careful not to hit any potential impediments during the crane movements.
Jobsite conditions: prior to use always ascertain that the working area is free and
clear of potential obstacles to crane operations (people, building walls, balconies,
eaves, scaffoldings, tree branches, other lifting means or machines, electric lines,…).
This may hurt people, damage both the impediments and the crane, and provoke also
the crane overturn.
Make sure that there is no risk of elements falling on the operator or on the crane and
take the right precautions to prevent it.
Overload and/or fatigue: the crane can break down due to fatigue or overload:
- If it is misused (with cycles, loads or pump oil flow not pertinent to the crane class)
- If it is used for improper tasks (side, oblique or reversal pull)
- If it is used in poor jobsites (corrosive environment, too high or too low
temperature, foundry,… [see conditions of use])
- If the load exceeds the rated capacity indicated on the relevant plates
Wrong manoeuvring: the crane can fall break or overturn if the operator performs WARNING AND
a wrong manoeuvre due to the lack of familiarity with the opera- tion procedures
(see manual of use and maintenance) or due to inadequate psychophysical conditions:
INSTRUCTIONS7.5
GRU FASSI
we remind you that the directives in force impose a suitable training of the personnel
before using these types of machines and require an adequate psychophysical
condition to operate safely a lifting device that always implies the intrinsic danger of a
lifted load.
Weather conditions: too high or too low temperatures may damage the components
of the oleodynamic and electric circuits (See max and min conditions of use); it is
forbidden to operate the crane during a storm with lightning hazards, so we recommend
to fold it and put it to rest. Furthermore when the wind is too strong the crane can
overturn or break down.

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.

Breakdown of some sensors


The system "moment limiting device - intelligent type" is always monitored
during ignition (the system, after having activated the various circuits, checks the
presence of all the inputs for around 4 seconds) and then continuously monitors the
operation and the efficiency of the limiting device (approx. every 25 milliseconds).
For most of the components the system checks also the congruence of the incoming
signal with the one the system expects.

Maintenance: maintenance is particularly important; the lack of it may damage


things or hurt people.

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.

8.2 Crane mark

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

(!) UNDER NO CIRCUMSTANCES SHOULD THE


DATA MARKED ON THE PLATES BE ALTERED.
9 CRANE NOMENCLATURE CRANE
NOMENCLATURE 9
GR3_110
9.1 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. 4).
Pos. Description

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)

9.2 Crane with top seat controls and fig. 4

with ground controls for outriggers.


(fig. 5)
Pos. Description

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

1. Check valves for outrigger rams


2. Check valves for rotation control (flow regulators)
3. Check valve for inner ram
4. Check valve for outer ram
5. Check valve for booms extension rams
6. Lifting moment limiting device assembly (optional)
7. Control panels (optional)
8. Rotation limiting device (optional)
9. Main pressure valve (outriggers)
10. Main pressure valve (crane)
11. Auxiliary valves (crane)
12. Levers guard
13. Safety device for outriggers supports
14. Hook safety device
15. Safety device for extension booms
(only for the crane version “C”)

10.2 Crane with top seat controls and


with ground controls for
outriggers. (fig. 7)
Pos. Description fig. 6

1. Check valves for outrigger rams


2. Check valve for rotation control
3. Check valve for inner ram
4. Check valve for outer ram
5. Check valve for booms extension rams
6. Lifting moment limiting device assembly (optional)
7. Control panel (optional)
8. Rotation limiting device (optional)
9. Main pressure valve (outriggers)
10. Main pressure valve (crane)
11. Auxiliary valves (crane)
12. Levers guard
13. Safety device for outriggers supports
14. Hook safety device
15. Safety device for extension booms
(only for the crane version “C”)

Before crane use check that safety and protection


devices are fitted and active.

Under no circumstances interfere with the safety and pro-


tection devices.

Interference with the check valves and removal of the


lead seal remove the Manufacturer and invalidate the
warranty.

Use the ladder for the access to the top seat.


fig. 7
11 SUPPLEMENTARY BEAMS SUPPLEMENTARY
BEAMS 11
11.1 Generality GR3_110

Supplementary beams are used in conjunction with the crane outriggers to ensure
the vehicle stability during load handling.

outrigger ram outrigger extension Weight


Code stroke mm interaxis mm type kg
52185 550 2132 Fixed 115
56681 550 3558 Manual 250
115B073 450 3098 Manual 190
115B076 450 3098 Manual-Rotating-“H” 190
145B068 650 4142 Hydraulic-“H” variable 340
145B070 340 4142 Hydraulic-“H” variable 310

11.2 Identification of the supplementary beams


Identification data of the supplementary beam is
punched on the beam (fig. 8) in the following
sequence:

Ex. *145B070*0001
serial no. identification
code

fig. 8

12 TILTABLE OUTRIGGER RAMS


12.1 Manually tiltable outrigger ram
They are outrigger rams, which can be placed in a vertical (at 180°) or
inclined position (at 45°) to avoid obsticles on the truck frame. (fig. 9-9a)

To position the rams in a working condition.


- Supporting the ram, remove the check pin and the locking pin from
their positions; when the ram is in the vertical position, a stop prevents it
permits from overturning.
- Position, carefully, the ram in working condition, insert the locking pin
in its new position and secure it with the check pin (fig. 9a) fig. 9

To re-position the rams to the folded position.


- Remove the check pin and the locking pin from their position.
- Carefully position, the ram in a upward direction and support the
ram, insert the locking pin in its new position and secure it with the
check pin (fig. 9); if the ram is placed in a vertical position,
a rotation stop prevents overturning.

(!) The locking pin is held to the base structure by a chain


in order to prevent its loss.
fig. 9a
(!) The locking pin is constructed from special material
- do not replace it with a non original part
- your security depends on it
13 MANOEUVRES AND CONTROLS TO STABILIZE SUPPLEMENTARY
THE VEHICLE BEAMS 13
GRU FASSI
13.1 Generality
The outriggers rams prevent damaging stresses both to the frame and to the vehicle
suspensions on which the crane is mounted to and assure the stability of the unit
during load handling.

(!) ATTENTION (!)


Be very careful when stabilizing the vehicle; make sure that no one is or
transits in close proximity of the working area of the outriggers.

(!) ATTENTION (!) DE 6409A


The crane stability is maintained by the maximum extension of the
outrigger supports, by the solidity of the base underneath the plates of
the outrigger rams and by the observance of the capacity plates. To check
the maximum working pressure see Paragraph 2.3 Technical data

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

(!) ATTENTION (!)


To manoeuvre the supports hands must only grab the handles placed on the
outrigger rams.

- Disengage the locking devices of the outrigger supports by


putting the levers of the devices A and B from the position of
the fig. 10 to the one of the 10a.
- Pull, extending from the base the outrigger support.
- Position the lever of the device B downwards; the locking
loaded security device B remains disengaged.
- Pull, extending the outrigger support till the engaging of the pin
of the device B in its seat.
A B
- By the same sequence, repeat the operations described to extend
the other support.
fig. 10
(!) WARNING (!)
The engaging of the outriggers lock B ensures the complete
extension of the outrigger support (essential for the stability of
the complete crane vehicle unit) and the impossibility of acci-
dental movement.

(!) WARNING (!)


The complete extension of the outrigger support is visually
indicated by the yellow triangle which is found at the end of the
beam. (fig. 10b)

To re-enter the outriggers repeat the operations previously


described in reverse.
fig. 10a

(!) WARNING (!)


Keep hands clear of automatic stop device (levers A from the posi- tion
of the fig. 10a to the one of the fig. 10).

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

(!) ATTENTION (!)


To manoeuvre the supports hands must only grab the handles placed on the
outrigger rams.

- Disengage the locking devices of the outrigger supports by A


putting the levers of the devices A and B from the position of
the fig. 10 to the one of the 10a.
- Pull, extending from the base the outrigger support assembly (first and
second support).
- Position the lever of the device B downwards; the locking loaded
security device B remains disengaged.
- Pull, extending the outrigger support assembly, till the engaging
of the pin of the device B in its seat. B1
- Rotate the lever of the device B1 positioned on the first support, B
upwards; the spring loaded security pin will be disengaged from it’s
fig. 11
position.
- Pull, extending from the first support, the second support.
- Position the lever of the device B1 downwards; the locking loaded
security device B1 remains disengaged. A
- Pull, extending the second outrigger support till the engaging of the
pin of the device B1 which locates into its seat.

- By the same sequence, repeat the operations described to extend the B


other supports.

(!) WARNING (!) B1


The engaging of the outriggers lock B and B1 ensures the
complete extension of the outrigger support (essential for the
stability of the complete crane vehicle unit) and the impossibility of
accidental move- ment. fig. 11a
(!) WARNING (!)
The complete extension of the outrigger supports is visually indicated by
the yellow triangles which are found at the end of the beam and of the first
support (fig. 11b-11c)

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.

fig. 11b fig. 11c


13.4 Functions of control levers for stabilization SUPPLEMENTARY
BEAMS13.4
The controls to stabilize the vehicle are activated only from ground level and on GR3_110»150
both sides of the crane base.
fig. 12fig. 12a
Lever function D - C - CD
D= D=S
Lever D Control for deviator
crane-outriggers ( - S ).
(fig. 12-12a)

Levers C Control and dual control


for outrigger distributor
(fig. 12b-12c)

Levers CD Deviator control for selecting the fig. 12bfig. 12c


outrigger rams (outrigger-
extension); the position of the
select lever is guaranteed by an C
internal detent.
(fig. 12d-12e)

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

They indicate the position of the operator in C


relation to the vehicle and the crane. CD

C
CD

Control for deviator Positions of the deviator


crane-outriggers to control:
( - S) Outrigger rams (S)

Positions of the deviator to control: Outrigger


extension (E)
Outrigger rams (S)

Activation control for: Activation control for:


Outrigger rams Outrigger extension
Outrigger rams

See Paragraph 25 Instruction and warning plates.

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.

Position lever D of oil diverter ( - S) on S.


13.5 Controls to stabilize the vehicle SUPPLEMENTARY
BEAMS 13.5
The controls conform with the safety directives and enable the operator to acti- vate the GR3_110»150
lateral extension of the outrigger supports and rams only from the side where he can
visually check the operation.
Crane with outriggers manual extension and without supplementary outriggers

- Manual extension of the outrigger supports: See Paragraph 13.2.


- Outrigger ram descent; operate lever C.

Crane outrigger with manual or hydraulic extension and supplementary


outrig- gers

For manual extension of the outriggers


- Manual extension of the outrigger supports: See Paragraph 13.2.
- Outrigger ram control; position the lever CD on the corresponding position and
then, activate the lever C.

For hydraulic extension of the outriggers

(!) ATTENTION (!)


Operation of the crane outrigger supports must be from the control station
on that side; it is not allowed to operate outriggers on the opposite side of
the vehicle due to unseen dangers. DE4491
- Put the lever A of the outrigger security check from the position of the fig. 11 to the
one of the fig. 11a.
- Exit of the outrigger support; position the lever CD of the deviator on the corres-
ponding position and then, activate the lever C of the distributor or of the double A
control.
- Outrigger ram descent; position the lever CD on the corresponding position and
then, activate the lever C.

(!) ATTENTION (!)


During the stabilising operations, for each outrigger ram, it is recommen-
ded to DESCENT the outrigger as the last manoeuvre. fig. 13

(!) ATTENTION (!)


The complete extension of the outrigger supports is visually indicated by
the yellow triangles which are found at the end of the beam (and of the sup-
port if it’s supplied with extra double extension beams). (Fig. 11b).

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

Manoeuvres for re-entry of the crane outriggers and supplementary outrig-


gers within the overall vehicle width after crane use.

- Position lever D of oil diverter ( - S) on S. Repeat

by inverting the sequence of the operations.

(!) WARNING (!)


Keep hands clear of automatic stop device of the outrigger supports (Fig. 11).

(!) 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 crane and hydraulic implements can be manually operated with:


- ground controls on both sides or, on request
ground controls on both sides and
top seat controls by hand-cables;
- top seat controls.

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

Rotation Inner Outer Extension


boom boom booms Winch Bucket

IMPLEMENTS IMPLEMENTS IMPLEMENTS


CONTROLS CONTROLS CONTROLS
2 Additional functions 2 Additional functions 3 Additional functions

Jib Jib Rotator Bucket Jib JibWinch extension


outer extension outer booms
boom booms boom
(!) Operate the levers smoothly and gradually (!)
When carrying out simultaneous movements of two or more functions, also
related to pump flow and lever travel, it is possible that on reaching the
stroke end of a particular function, an increase in speed of the other
functions will occur.

(!) ATTENTION (!)


While exiting and folding the crane, you must operate from the
distributor side; it is forbidden to operate from the double
control side because of the overall dimensions of the booms.
(DE1684A fig.
15) fig. 15
14.2 Manoeuvres to unfold the crane into a working condition CONTROLS TO
OPERATE THE CRANE 14.2
The plate DE4452A indicates the sequence of the manoeuvres to be carried out to unfold GR2_3_4
and to fold the crane.

- Engage the power take off.


- Stabilize the vehicle (see details on Paragraph 13
“Manoeuvres and controls to stabilize the vehicle”).

(!) IT IS FORBIDDEN TO OPERATE FROM (!)


THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

By operating the corresponding levers:


- make sure that the extension booms and the outer ram are
closed;
- lift the inner boom over the horizontal line;
- open the outer boom to the “horizontal” position;

- position the hook on the vertical line above the load.

14.3 Manoeuvres to fold the crane into


the rest condition (see Plate
DE4452A)
(!) IT IS FORBIDDEN TO OPERATE FROM (!)
THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

By operating the corresponding levers:


- fold the extension booms to their stroke end;
- lift the inner boom to its stroke end;
- fold the outer boom to its stroke end;
- rotate the crane until the reference arrows coincide (on the column and
on the base);
- fold the inner boom to its stroke end; the rest locating pin locates into
its seat;
- re-position the outriggers to within the overall vehicle width as
described on Paragraph 13.

NOTE A safety device is installed on the outer boom of the crane


version "C" preventing the exit of the extension boom
sec- tions when the crane is in rest position.

14.4 Manoeuvres to unfold the crane "C" into a


working condition (only for the crane version C”)
(!) IT IS FORBIDDEN TO OPERATE FROM (!)
THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

By operating the corresponding levers:


- Lift the inner boom over the horizontal line.
- Open the outer boom to the “horizontal” position.
- Extend the extension boom sections; the hook of the safety device is free.
- Position the hook on the vertical line above the load.
14.5 Manoeuvres to fold the crane "C" into the rest condition CONTROLS TO
(only for the crane version “C”) OPERATE THE CRANE 14.5
GR2_3_4
(!) IT IS FORBIDDEN TO OPERATE FROM (!)
THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

By operating the corresponding levers:


- completely reenter the extension boom sections;
- lift the inner boom close to its stroke end;
- fold the outer boom to its stroke end;
- lower the inner boom until the hook of the safety device rests on the extension boom
sections;
- extend the extension boom sections until the hook is correctly positioned to be attached;
- do not insist on the control!
- rotate the crane until the reference arrows coincide (on the column and on the base);
- fold the inner boom to its stroke end; the rest locating pin locates into its seat;
- re-position the outriggers to within the overall vehicle width as described on
Paragraph 13.
14.6 Indicator of inner boom horizontal position CONTROLS TO
(on request) OPERATE THE CRANE 14.6
GR2_60»65_3_4
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 transport on road has been
exceeded.

14.7 Stand-up control station


This special fitting allows the operator to use the crane controls whilst standing in a
higher position, in order to have good vision of the working area.
The stand-up control station is constructed with a platform fixed on to the base of the
crane and with a control panel. The control point allows the manual ope- ration of the
crane controls through remote control cables or rigid rods.
On the control panel, further to the control levers and to the plates, we can find the
supplementary electric control panel (fig. 15 pos. 1).

Controls to operate the crane.


See paragraph 14 of the USE AND MAINTENANCE MANUAL for details of
“Controls to operate the crane”
See paragraphes 16 of the USE AND MAINTENANCE MANUAL for details of
“Lifting moment limiting device”

The operator's presence in the stand-up control station activates photo-


cell L (fig. 15) that automatically prevents the crane from rotating above
the station and activates the flashing of the green light in the different
control panels near the plate DE5775 (fig. 16b).
1
(!) ATENTION (!)
Before accessing the stand-up control station make sure
that the photocell L pilot-light (fig. 15) is turned on and
green; then check its correct functioning: if put your
hand in front of the photocell the pilot-light shall turn
yellow (thus enabling the limitation of the rotation path).
Besides, when entering the stand-up control station, L
before starting the crane operation, check that the limita-
tion of the rotation path is active, see the flashing of the
green light.
fig. 15
Always use the ladder fitted by the installer to gain access to
the control station; the side of the access to the platform is protected by chain link,
always replace the chain onto the structure of the platform after climbing up.
The instruction plate DE5643 reported on the selector, identifies the interven- tion CONTROLS TO
sectors of the device (fig. 16).
The operator's presence in the stand-up control station allows only a reduced rotation
OPERATE THE CRANE 14.7
GR2_60»65_3_4
of the crane, since it is not enabled to pass on the station.

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.

fig. 16 fig. 16b


15 MANOEUVRES OF THE CRANE CONTROLS TO
LOADS (version with load limiting OPERATE THE CRANE 15
GR2_45»65_3_4_AS_XS
device)

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.

Crane with load limiting device


During load handling, do not exceed the reach limits given, or the load indica- ted on
the above mentioned charts. If the limits are exceeded, the load limiting device,
permitting the slow descent of one of the two, or both, lifting rams (or if the jib is
fitted: the jib outer ram) will be immediately activated
16 MANOEUVRES OF THE CRANE LOADS CONTROLS TO
(version with lifting moment limiting OPERATE THE CRANE 16
GR2_45»65_3_4_AS_XS
device)

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.

Lifting moment limiting device


A characteristic which permits the classification of cranes is their lifting capa- city or
maximum lifting moment. The moment is defined by the value obtained from the
weight of the load to be lifted (kg) by its distance (meters) from the centerline of the
crane rotation.
The device called “lifting moment limiting device” preserves the crane structure from
overloads, as it prevents any movement which increases the value of the moment up to
the maximum established value.
16.2 "Electronic" lifting moment limiting device CONTROLS TO OPERATE
THE CRANE16.2
This device utilises an electro-hydraulic system managed by an electronic logic GR2_45»65_3_4_SE
that prevents any operation tending to cause an increase in the pressure induced by the
load in the lifting rams (inner, outer rams of the crane and of the hydraulic
extension, if fitted), up to the critical values. These values, which are not exceedable,
determine the intervention levels and provide the data for setting the device.

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.

(!) ATTENTION (!)


The presence of the lifting moment limiting device does not release the
user from the obligation to respect what is indicated on capacity plates
and lifting curves.

16.3 Control panels


Layout of the control panel (fig. 17), placed next to the distributor of the crane A -

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.

!NOTE! In the absence of electric power all crane functions will be


fig. 18
desactivated.

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.

Display on the control panel

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.

- For the use of the control button see Par. 22.2.

- By pushing the button one or more times you return to the initial display
(view of the pressure values).

- For the meaning of other messages see Par. 16.7.1 “Diagnostic”


16.4 Load handling CONTROLS TO

Manoeuvres of the crane


OPERATE THE CRANE 16.4
GRU FASSI
Fig. 20a-b e 20c-d illustrate the configurations of the crane (and of the eventual hydraulic
extension) with the manoeuvres allowed and not allowed
WITH HYDRAULIC JIB
by the device, in connection with the horizontal position of
the crane and extension outer booms.
(!) ATTENTION (!)
In the overload condition, if you simultaneously effect one
permitted and one non permitted manoeuvre you haven’t
movement. In the overload condition, before effecting a
permitted manoeuvre, it is necessary to return all the levers
to the neutral position. fig. 20a
(!) ATTENTION (!)
During load handling with the crane and with the WITHOUT HYDRAULIC JIB
crane and hydraulic jib, in vertical configuration or close, the operator must
strictly refer to the loads indicated on the capacity plates since the
limiting device shows to be not particularly sensitive with vertical lifts.
Crane with activated limiting device by the intervention of the crane or
the hydraulic jib (overload condition) and with outer boom of the crane above
the horizontal line fig. 20a-20b
fig. 20b
Manoeuvres not allowed:
- Inner boom descent
- Outer boom descent
- Extension of the crane extension boom sections (*)
- Lift and descent of the hydraulic jib
- Extension of the extension booms section of the jib
- Winch rope lift
- Movement of the hydraulic accessories (**)
NOTES: (*) If the overload condition has been activated by the hydraulic extension, the
extension of the crane boom sections is permitted.
(**) It is permitted only when coupled with permitted manoeuvres.
Manoeuvres allowed: all the manoeuvres that bring the load closer to the column and
therefore the overload
- Rotation in both directions WITH HYDRAULIC JIB
- Inner boom lift
- Outer boom lift
- Re-entry of the crane extension boom sections
- Re-entry of the jib extension boom sections
- Winch rope descent
Crane with activated limiting device by the intervention
of the crane or the hydraulic jib (overload condition)
and with outer boom of the crane under the
horizontal line fig. 20c-20d
Manoeuvres not allowed:
-- Inner boom lift
- Outer boom lift fig. 20d
- Extension of the crane extension boom sections (*)
- Lift of the hydraulic jib
- Extension of the extension booms section of the jib WITHOUT HYDRAULIC JIB
- Winch rope lift
- Movement of the hydraulic accessories (**)
NOTES: (*) If the overload condition has been activated by the hydraulic extension,
the extension of the crane boom sections is permitted.
(**) It is permitted only when coupled with permitted manoeuvres.
Manoeuvres allowed: all the manoeuvres that bring the load closer to the fig. 20c
column and therefore the overload
- Rotation in both directions
- Inner boom descent
- Outer boom descent
- Re-entry of the crane extension boom sections
- Descent of the hydraulic jib CONTROLS TO
- Re-entry of the extension booms section of the jib
- Winch rope descent
OPERATE THE CRANE 16.4
GRU FASSI
Crane with activated limiting device (overload condition) by the intervention
of the load limiter of the winch
Manoeuvres allowed:
- Rotation in both directions
- Re-entry of the crane extension boom sections
- Re-entry of the jib extension boom sections
- Winch rope descent
Manoeuvres not allowed:
- all other movements
Crane without load applied and activated limiting device
The limiting device may intervene also during loadless crane operation following a pres- sure
peak provoked by the attainment of the stroke end of the lifting ram at high speed. In this
condition, reactivation of the crane commands by performing one of the manoeuvres is allowed
by the system. If the limiting device intervenes when both the lifting rams are open and at stroke
end, and the crane extension booms are fully folded, it is not possible to reactivate the
commands, since the permitted manoeuvres (arm lifting and extension fully retracted) cannot
be carried out, because of the actual configuration of the crane (outer boom above the
horizontal). The device, in this case, allows the descent manoe- uvres since it verifies the it was a
peak pressure inside the lifting rams; the crane being loadless, thus these manoeuvres will be
allowed.
Temporised exclusion device of the lifting moment limiting device
The activation of the exclusion device is permitted when the limiting device is activated and
only in the case when it is impossible to carry out any of the allowed manoeuvres. This
generally occurs when handling heavy and bulky loads, with the outer boom above the
horizontal and the extension boom sections almost retracted.
(!) ATTENTION (!)
The activation of the exclusion system for the lifting moment limiting device
can ONLY be operated when the extension booms of the crane and of the
hydraulic jib (when fitted) are fully retracted.
The activation button of the excluding device, only in the case of the crane, are to
be activated as follows:
- retracted the crane extension booms until stroke end and momentarily pressurise;
- maintain the command for the extensions boom until the red led of the button LMI
placed on the control panel begins to flash;
- continue to keep the command for the extensions boom and press the exclusion device
button, the flashing red light becomes fixed;
- release the lever commanding the extensions booms.
The permitted manoeuvre is the descent of the outer boom in order to bring it under the
horizontal; remember that you have at your disposal five (5) seconds from the command
operation to carry out the descent. After such period of time, wait at least one (1) minute
in order to be allowed to carry out the manoeuvre once again.
The activation button of the excluding device, only in the case of the hydraulic jib,
are to be activated as follows:
- retracted the extensions booms of the hydraulic jib until stroke end and momentarily
pressurise;
- maintain the command for the extensions of the hydraulic jib boom until the red led of
the button LMI placed on the control panel begins to flash;
- release the lever commanding the extensions booms of the hydraulic jib;
- within 3 seconds from releasing the lever commanding the extensions booms of the
jib, retracted the extensions booms of the hydraulic jib until stroke end and
momentarily pressurise (the red led turns off as soon as the re-entry begins);
- maintain the command for the extensions boom until the red led of the button LMI
placed on the control panel begins to flash;
- continous to keep the command for the crane extensions boom press the
exclusion device button, the flashing red light becomes fixed;
- release the lever commanding the crane extensions booms.
The permitted manoeuvre is the descent of the outer boom in order to bring it under the
horizontal; remember that you have at your disposal five (5) seconds from the command
operation to carry out the descent. After such period of time, wait at least one (1) minute
in order to be allowed to carry out the manoeuvre once again.
(!) ATTENTION (!) CONTROLS TO
Activation of the exclusion device of the lifting moment limiting device. OPERATE THE CRANE 16.5
GRU FASSI
When the operator uses this device, it means that he wishes to over-
ride the lifting moment lifting device in order to make some manoeu-
vres (which would be impossible with the device active) that bring the
moment to within the maximum level, but involve an overload condition.
In such an emergency condition (where the lifting moment limiting devi-
ce has been disabled), the operator, who is the main responsible 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 exten-
sion 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.);
- make all movements as slowly as possible to reduce the
dynamic overload to the minimum.

16.5 Lifting moment limiting device for two


working sectors
In case of one sector of the working area with reduced stability of the vehicle (e.g.
sector in front of vehicle cab) the limiting device can be provided with a special
function which allows to operate with a reduction of the interven- tion level. The
reduction of the intervention level reduces the crane capacity values and this reduction
value is defined in the vehicle stability calculation. Consequently the working area is
divided in one sector (e.g. body side) where the crane works according to the capacity
plate values and another sector (e.g. cab side) where it works with reduced capacity
values. The device has conse- quently two intervention levels which are activated in
relation to the sector of the crane working area always securing the vehicle stability.

(!) ATTENTION (!)


If the rotation stops by going through the working zone where the crane can operate
according to the capacity plate values to the one where it can operate according to the
reduced values, it means that one of the following conditions is reached:
- rotation of a load bigger than the one admitted in the reduced sector defined in the
vehicle stability calculation;
- rotation without load applied but with (at least) one of the inner, outer rams of the
crane or the jib (if fitted) extended and pressurised at the stroke end.
The following manoeuvres are allowed:
- the opposite rotation
- the manoeuvres allowed by the limiting device in relation to the position of the
outer boom (positioned over or under the horizontal line).

16.6 Rotation limiting device


When a sector of the working area exists in which the stability is insufficient (for example
in the area in front of the cab) the permitted arc of rotation is limited by means of an
adjustable electro-hydraulic device which only allows operation within the safe area.
(Warning: persist in the operation!)
When exceeding the “safe area” the rotation limiting device only allowing:
- the opposite rotation
- the manoeuvres allowed by the limiting device in relation to the position of the
outer boom (positioned over or under the horizontal line).
If a reduction of capacity is necessary because of insufficient stability of the complete CONTROLS TO
unit, new capacity plates must be fixed giving the derated capacity in accordance with
the final stability test.
OPERATE THE CRANE 16.7
GRU FASSI

(!) ATTENTION (!)


Always check carefully that the vehicle is perfectly stable, paying special atten- tion to
the area immediately in front of the driver’s cabin as this is usually less stable.

16.7 In the case of the appearance of the signal “ALARM”


on the display of the control panel or of the
radioremote control or in case of an electrical failure.
In these cases, because of a fault, shown in the system, the crane is not func- tional
any more. The checks that the operator can effect to reactivate the crane functions are
the following:
- in case of an electrical failure check the connection of the feeding cables to the
battery;
- in case of the appearance of the signal “ALARM” on the display of the push-
button panel see Par. 15.7.1 and check if the fault can be resolved by the operator.

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.

16.7.1 Diagnostic (Alarms/Input/Output) LME vers. 4-5 UC 01-7


It is possible to install on the machine some operation improvements of the limiting
device not yet described here. For this purpose compare the released version of the
software installed on the machine (you can read it on the display when switching on)
with the one in this paragraph's heading. For further expla- nations please refer to
Fassi service network.

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

01 - electronic card alarm


16.7.1
OPERATE THE CRANE
GRU FASSI
02 - inner ram transducer alarm 04
- outer ram transducer alarm
06 - jib articulating ram transducer alarm 08 -
proximity sensor alarm (central one off) 09 -
proximity (lateral one off)
10 - mercury sensor level alarm (connector disconnected)
11 - mercury sensor level alarm (sensor defect)
12 - winch alarm
14 - microswitch on the inner ram distributor segment alarm
15 - microswitch on the outer ram distributor segment alarm
16 - microswitch on the jib articulating ram distributor segment alarm
17 - microswitch on the extension rams distributor segment alarm
18 - microswitch on the jib extension rams distributor segment alarm
19 - microswitch on the winch distributor segment alarm
20 - microswitch on the rotation distributor segment alarm
21 - 10A fuse alarm (fuse inside the main control panel protecting the
emergency circuit)
22 - winch stroke end device alarm

Only for crane with slew ring:

30 - inconsistency of the rotation lever movement alarm


31 - inconsistency of the inner ram lever movement alarm
32 - inconsistency of the outer ram lever movement alarm
33 - inconsistency of the crane extension ram lever movement alarm
34 - inconsistency of the jib articulating ram lever movement alarm
35 - inconsistency of the jib extension ram lever movement alarm
36 - inconsistency of the winch lever movement alarm
40 - CAN-BUS reading alarm on unit FX003
41 - CAN-BUS reading alarm on unit FX004
42 - CAN-BUS reading alarm on radio remote receiver unit

MESSAGES EXPLANATION

"WINCH OFF" - information for the activation of the winch up or down.

"WINCH CAL.ERROR" - flashing warning (10 seconds each minute); it appears


when the maximum detection of the winch adjustment with
load is exceeded.

"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.

"PLE" - activation of the speed reduction for the use of the


access platform.
What to do in case of alarm CONTROLS TO

CODE REMEDY 16.7.1


OPERATE THE CRANE
GRU FASSI
01 Take off the tension to the system and take on again the tension. If the
problem remains, take off the tension to the system again, take on the
tension and wait 12 minutes (12 minutes waiting time is a compulsory
condition and needs to be checked with a watch), take off the tension to the
system again, take on again the tension.
If the problem remains, you must immediately go to a FASSI
authorised Center.
02 Check the connector of the pressure transducer.
If the problem remains, you must immediately go to a FASSI
authorised Center.
04 See code 02.
06 See code 02.
08 Check if the red light on the proximity sensor is off and verify if the
metallic band is rightly positioned.
09 See code 08.
10 Check that the connector of the mercury sensor level is not damage. If the
problem remains, you must immediately go to a FASSI authorised
Center.
11 You must immediately go to a FASSI authorised Center.
12 See code 11.
14 See code 11.
15 See code 11.
16 See code 11.
17 See code 11.
18 See code 11.
19 See code 11.
20 See code 11.
21 Replace the 10A fuse at the nearest workshop after removing the
carter and the cover of the main panel FX000. (See electric
schematic Par. 5)
22 See code 11.

Only for crane with slew ring:

30 See code 11.


31 See code 11.
32 See code 11.
33 See code 11.
34 See code 11.
35 See code 11.
36 See code 11.
40 See code 11.
41 See code 11.
42 See code 11.

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)

(!) ATTENTION (!)


Activation of the reactivation button.

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.

16.7.3 OVERIDE - REACTIVATION lever for the


crane functions (with Danfoss distributor)
- 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 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.

(!) When the electric power is restablished, remember to put the


button in the opened position. fig. 23
(!) ATTENTION (!) CONTROLS TO
Activation of the emergency lever.
16.7.3
OPERATE THE CRANE
GR2_45»65_3_4
This activation prevents the operation of the lifting moment limiting device,
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 responsible 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 exten-
sion 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.);
- 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-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.

(!) ATTENTION (!)


The presence of the lifting moment limiting device does not release the
user from the obligation to respect what is indicated on capacity plates and
lifting curves.

(!) CAUTION DANGER (!)


On the outer boom there is a mercury capsule (mercury level switch) duly pro- tected and
provided with the following warning stickers.

MERCURY IS EXTREMELY TOXIC. IN CASE OF REPLACEMENT AND/OR


SCRAPPING, DISPOSE OF OR RECYCLE THE CAPSULE CONTAINING MER-
CURY WITH MAXIMUM CARE, AND IN ACCORDANCE WITH THE NATIONAL
REGULATIONS IN FORCE.

(!) ATTENTION (!)


Do not walk on the lever guards of the lifting moment limiting device posi-
tioned on the distributors or electric control panels. DE1679

Do not use water to estinguish fire! DE1680

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).

(!) ATTENTION (!)

In case of using the crane with lif-


ting devices other than the hook,
the access to the working area at
the persons must be prevented.

The dimensions and the capacity of the


implements must be proportio- ned with
crane performances.

(!) WARNING (!)


CRUSHING (F) OR PUSH (F) MANOEUVRES ARE NOT PERMITTED.
17.2 Hydraulic connections for implements - USE OF IMPLEMENTS
supple- mentary hoses. GRU FASSI 17.2
(!) WARNING (!)
To ensure that the control corresponds to the implement movement, hydraulic
connections are symmetrically fitted with coupling unions. Never invert such
positions: movements inversion as well as operating difficulties or unusual overload
with implement itself could occur.

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.

17.3 Oil cooler (heat exchanger)

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.

(!) WARNING (!)


The heat exchanger openings must be kept clear and clean. At no time should it be
covered.
18 MANUAL EXTENSIONS USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18
18.1 Generality
These are additional extensions, which are placed in the hydraulic extensions of the
crane and of the hydraulic jib and secured by locking pins.
Manual extensions have a maximum capacity independent from the crane confi-
guration as shown on the capacity plates.

(!) ATTENTION (!)


Manual extensions can be extracted from the rest position and be operative, once the
security pins have been removed, with the outer boom in sliding position.

(!) ATTENTION (!)


- Do not stand in front of stabilisers during operation!
Operate from a lateral position in respect of the extension movement of the manual
extensions; operation from the frontal position is dangerous.
- Verify that the area is suitable for this operation and there are no unauthorized
persons in the working area.
- Do not permit the extension to slide out at speed as this will damage the stroke end
stops.
- Do not try to align the holes (slots) for the locking pins with your fingers; always use
a suitable tool.
- When manual extensions are in place, fit the locking pins and secure them with
the check pins to prevent accidental escape.
(!) Always remember that when operating with implements, their tare weight must be
deducted from the capacity of the crane.

18.2 Lifting moment limiting device “ELECTRONIC”


for the manual extensions (valid starting from the
version 3.0 of the software)
HOW TO CONTROL THE LOAD HOOKED ON MANUAL EXTENSIONS.
This procedure aims to calculate the weight applied on the manual
extensions. It is necessary to apply the same procedure EVERY TIME you use
the manual extensions.
For its correct execution, follow meticulously the instructions reported HERE.
The extension limiting device IS NOT ALWAYS ACTIVE; on the contrary of
the crane limiting device, it responds about lifting a load only if
QUESTIONED, therefore only if you enable the procedure. Remember that
the procedure is manual. In any case always refer to the capacity plates of the
crane.
The limiting device for manual extensions, when interrogated, compares the
real weight applied on the lifting hook (inclusive of all the accessories
attached) with the value reported on the capacity plates. Such evaluation is
effective only during the execution of the procedure, therefore it is
prohibited to add weight or replace loads after the procedure is completed;
in such case the procedure shall be executed again from the start.
In the case one or more manual extensions are added or removed with
respect to the initial installation, it is COMPULSORY to have the crane initial
configura- tion file modified accordingly (See Authorised Shops).
Before activating the procedure, extend and lock by a pin not only the
manual extension you intend to use but also the preceding ones.
PANELS OF THE RADIO-REMOTE CONTROL USE OF IMPLEMENTS

Figure A (left side) Figure B (right side)


GR2_45»65_3_4_5_SE 18.2
selector on A
“+” “ENTE “INDEX
R” ”

HOW TO PREDISPOSE THE USE OF MECHANICAL EXTENSIONS ON


CRANE OR ON JIB
Note: In case of crane with slew ring and top seat, all the procedures
mentio- ned below can be executed from both the control panel and the
radio-remote control.

1. Initial display (Fig. 1)


Starting from the standard menu of the electronic lifting moment limiting device
displaying the pressures of the lifting rams (fig. 1), keep the “F1” key (control
panel), or the “+” and “ENTER” key (radio-remote control with the selector on
“A”, fig. A and B) pressed for some seconds.

fig. 1 fig. 1

2. Choice the installation of the manual extensions on Crane or on Jib. (Fig. 2)


If the crane features the installation of the manual extensions both on the crane and
on the jib, after the initial display, when you keep the “F1” (control panel) or “+”
and “ENTER” key pressed (radio-remote control), the program displays the message
illustrated in Figure 2.

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.

4. Message “K1 - K2 - K3 - K4” (fig. 4)


[paragraph to read only in case of manual extensions installed on Jib
and not on Crane]

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.

5. Message “FC P2” (fig. 5)


Note: do not hang any load on the hook.
This means that the outer ram 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. 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

7. Message “F1 TO START” or “F1 / ENTER START” (Fig. 7)


At this point the display will visualize the message "F1 TO START" (control panel) or
"F1/ENTER START" (radio-remote control). Press the "F1" (control panel) key or
"ENTER" (radio-remote control) to continue.

8. Message “UP P1” (see fig. 8) fig. 7 fig. 7


Note: do not hang any load on the hook.
It requires the activation of the inner boom lifting to eliminate an overpressure at the
lifting ram bottom (the manoeuvre is activated but the crane does not move since all
the movements are disabled).
Note: set the lever of the inner ram at its stroke end to simulate the lifting and keep
it like this for at least three seconds.

fig. 8 fig. 8

9. Message “START LOAD P1” (see Fig. 9)


Releasing the lever in neutral position the display visualises the message START
LOAD P1.
It requires the slow lifting of the load using the inner ram. This allows to haul it up
from the ground in order to calculate the weight which will be pointed out releasing
the lever in neutral position.

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

CLOSING OF THE PROCEDURE


All the crane functions will still be kept disabled. To start operating press
the “INDEX” key (control panel fig. 10, or radio-remote control fig. D always
with the selector in position “A” fig. C).

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

a. “PRESSURE ERROR” (see fig. 12)


It warns you that the system found an error in the pressures of the lifting
booms. The whole procedure must be restarted.

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

c. “NO SPEED” (fig. 14)


The load has been lifted too quickly; the whole procedure must be repeated from the
beginning. The "LMI" key on the push-button panel or "F2" key on the control
panel is disabled because it has not been possible to calculate the applied weight.
Press INDEX on the push-button panel or "F1" key on the control panel to exit the
procedure and go back to the standard operation. Put down the load on the ground
and repeat the whole procedure from the begin- ning.

fig. 14 fig. 14

d. “NO LOAD CRANE!” (fig. 15)


This message informs that the lifted load exceeds the max limit value of the
crane/jib, irrespective of the manual extensions, so that the load cannot be lifted in this
configuration due to the crane/jib overload. Also in this case the load must be either
removed or approached to the crane, and handled in a different way without using
the selected manual extension. Moreover the whole procedure must be repeated
from the beginning.

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

IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS


1 Additional function 2 Additional functions

Jib Jib
Winch Bucket outer extension
boom booms

IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS


2 Additional functions 3 Additional functions

Rotator Bucket Jib Jib Winch


outer extension
boom booms
The plates placed over each lever define their function in relation to their movement.

(!) ATTENTION (!)


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.
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.

Nomenclature of winch unit (fig. 23)

Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
7. Block (double-triple......line) fig. 23

(!) ATTENTION (!)


Check the condition of wire rope.

(!) 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.

21.2 Winch for crane


The identification data and the essential characteristics are marked on a plate fixed by
the manufacturer and used for the CE mark which testifies its confor- mity to the
Machine Directive (D.M.)

Manufacturer mark ...


Winch type ...
Serial number ...
Maximum line in N at the 4th layer...
Maximum speed in m/min ... or Maximum capacity pump l/min (!)

See operator winch manual supplied by the winches’ manufacturer.

The winch has a maximum capacity (which cannot be exceeded),


indicated by a plate, not related to the crane capacities which can also be
lower.
Consequently avoid to lift, with the winch, heavier loads than those allowed
by the crane capacity plate.
Note: We do not recommend using the winch with load moving (winch in
or out) at the same time as the extension booms or the crane
and hydraulic jib (if fitted), since it accelerates the wear of the
extension guide pads reducing their life to one third compared to
a standard application.
The couple limiter, installed on the winch structure, prevents that on the
cable, can be created a load major to the value of maximum line at the
4th layer, quiescing all the crane controls.
(!) Under no circumstances interfere with the limiter device adjustment.
21.2.1 Winches equipped with a mechanical stroke USE OF IMPLEMENTS
end device GRU FASSI 21.2.1
(!) ATTENTION (!)
The end stroke condition takes place when the block takes contact with the pulley
struc- ture.The operator must stop the manoeuvre before the block rotates the pulley
completely with consequent activation of the load cell on the winch. Such end stroke
device shall be used only under emergency conditions and not as a simple end
stroke interrupter.
The mechanical stroke end device combined with the winch limiter prevents the hook
bracket (or pulley/snatch block) from hitting the fixed pulley when lifting or when extending the
extension booms, and thus from damaging the cable.
When the winch limiter is activated, all the crane functions are disabled.
Manoeuvres allowed:
- Rotation in both directions
- Re-entry of the crane extension boom sections
- Re-entry of the extension booms sections of the jib
- Winch rope descent
Manoeuvres not allowed:
- all other movements
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. fig. 26
Manoeuvres not allowed:
- Winch rope descent
Manoeuvres allowed:
- all other movements
(!) ATTENTION (!)
Limit the exit speed of the extension rams when, during the lifting, the hook bracket (or pul-
ley/snatch block) is next to the fixed pulley, in order to avoid unnecessary stress to the cable.
(!) ATTENTION (!)
When the hook bracket (or pulley/snatch block, in case of double or triple line) and the fixed
pulley are very close, and the operator needs to manoeuvre in their proximity (i.e. operations like
load hook-up, arms folding, etc), we recommend to always stand side on with respect to the pulley
plan (never in front or at the back) and to operate the crane at a low speed, since the contact
(especially without load) can result in rapid and violent rotations of the hook group (from the
fig. 26 to the fig. 27).
(!) ATTENTION (!)
The end stroke condition takes place when the block takes contact with the pulley
struc- ture.The operator must stop the manoeuvre before the block rotates the pulley
fig. 27
completely with consequent activation of the load cell on the winch. Such end stroke
device shall be used only under emergency conditions and not as a simple end
stroke interrupter.

* * *
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.

Nomenclature of winch unit (Fig. 23)

Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
7. Block (double-triple......line) Fig. 23

(!) ATTENTION (!)


Check the condition of wire rope.

(!) 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.

21.4 Winch for crane


The identification data and the essential characteristics are marked on a plate fixed by
the manufacturer.

Manufacturer mark ...


Winch type ...
Serial number ...
Maximum line in N at the 4th layer...
Maximum speed in m/min ... or Maximum capacity pump l/min

(!) See operator winch manual supplied by the winches’ manufacturer.

The winch has a maximum capacity (which cannot be exceeded),


indicated by a plate, not related to the crane capacities which can also be
lower.
Consequently avoid to lift, with the winch, heavier loads than those allowed
by the capacity plate of the crane with the winch.
Note: We do not recommend using the winch with load moving (winch in or
out) at the same time as the extension booms or the crane and
hydraulic jib (if fitted), since it accelerates the wear of the extension
guide pads reducing their life to one third compared to a standard
application.
The cranes with winch feature a sensor that deactivates the exit of the
extension boom sections when the load on the winch exceeds the nominal load
by 20%. There is no other control on the maximum load lifting which is therefore
limited only by the lifting limit of the winch itself. In order not to overload the
winch, it is therefore for- bidden to lift a load attached to the winch cable using
the crane rams when the load exceeds the values indicated on the capacity plate
of the crane with winch.
21.4.1 Winches equipped with a mechanical stroke USE OF IMPLEMENTS
end device GRU FASSI 21.4.1
(!) ATTENTION (!)
The end stroke condition makes place when the block takes contact with
the pulley structure. The operator must stop the manoeuvre before the block
rotates the pulley completely. Such end stroke device shall be used only
under emergency conditions and not as a simple end stroke interrupter.

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

(!) ATTENTION (!)


Limit the exit speed of the extension rams when, during the lifting, the hook bracket
(or pulley/snatch block) is next to the fixed pulley, in order to avoid unnecessary stress fig. 26
to the cable.

(!) ATTENTION (!)


When the hook bracket (or pulley/snatch block, in case of double or triple line) and the
fixed pulley are very close, and the operator needs to manoeuvre in their proximity
(i.e. operations like load hook-up, arms folding, etc), we recom- mend to always stand
side on with respect to the pulley plan (never in front or at the back) and to operate the
crane at a low speed, since the contact (espe- cially without load) can result in rapid
and violent rotations of the hook group (from the fig. 26 to the fig. 27).

(!) ATTENTION (!)


The end stroke condition makes place when the block takes contact with
the pulley structure. The operator must stop the manoeuvre before the block
rotates the pulley completely. Such end stroke device shall be used only fig. 27
under emergency conditions and not as a simple end stroke interrupter.

* * *
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

To assure a long life to the crane, it is necessary to meticulously follow the


maintenance instructions.

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.

Spare parts must be original.

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.

Respect the information supplied for maintenance and technical assistance.

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 weld the fixing rods of the crane (see plate


DE1574 fig. 29)
TIRANTI:NON SALDARE! FIXING
When repairs to, or checks of, the hydraulic circuit and fig. 29
ROD:DO NOT WELD! TIRANTS:NE PAS
of the rams are carried out, it is very important not to
SOUDER! ZUGSCHRAUBEN: NICHT
use, or be in the proximity of, materials which can
damage the circuit or contaminate the hydrau- lic oil eg. SCHWEISSEN!
DE1574
metal shavings, sand or dust.

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").

How to view the date

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.

How to reset the "Partial time".

To start a new count perform the following:


- 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. Fig. 29a
- Press button C1 (+) again to read "Work time" on the
display.
- Press button C1 (+) again to read "Reset partial" on the
display.
- Press button C3 (enter) to read "Enter to confirm"
fig. 29a
on the display.
- Press button C3 (enter) again; the timer is reset and it
will start recording again.

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.

22.4 After every 40 working hours or after


every working week fig. 30
Check the tightening torque of the fixing rods of the crane (fig. 30).

See table at paragraph 22.5

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.

(!) WARNING (!)


At low temperatures, the grease shall not crystallize or, to be more precise, shall not
change its characteristics. At the effective operative temperature, the grease we
recommend shall have a fluidity at least equal to rating NLGI 0 or max. 1.

(!) WARNING (!)


Centralized lubrication shall not be used when room temperature is below fig. 33a
-10°C / -20°C.
All the lubricators mounted on the crane are protected by a plastic cap so to avoid the oil
contamination.
22.5 After every 100 working hours or more frequently MAINTENANCE
in case of more intensive utilisation INSTRUCTIONS 22.5
GRU FASSI
WITH RACK
Periodically grease the points indicated on the crane (fig. 34) WITH RACK
(and on the hydraulic jib, when fitted, fig. 35) paying particular
attention to the points not easily detected. For the sliding sections
of the outrigger supports and of the exten- sion booms guide shoes fig. 35
made from a special material have been fitted: to ease their
movement it is recommended to smear a light film of grease on
them, taking care that the surfaces of the extension booms are free
from impurities such as sand etc. Top up using hydraulic oil with
the same characteristics as those indicated in the table at paragraph
23.

WITH SLEW RING


fig. 34
Grease the slew gear to prevent friction during rotation and to
ensure that it is stable by preventing water (corrosion protection)
and contaminants from entering the bearings.
For a better internal distribution of
WITH SLEW RING
the grease it is advisable to rotate
the crane and grease it in such a
way as to see grease at the seals.
Top up using hydrau- lic oil with
the same characte- ristics as those
indicated in the table at paragraph
23. Grease the winch cable (if
fitted) after having first cleaned the
cable of any encrustation (grease
mixed with sand, dust, dirt etc.) The
lubricant used must guarantee a
good level of penetration in order to fig. 35a
lubricate both the inside and the
outside of the cable. Top up using
hydraulic oil with the same fig. 34a
characteristics as those indicated in
the table at para- graph 23.

22.6 After every 500 working hours or after every


6 working months
Check the tightening torque:
- of the fixing rods of the crane; consult the following table in order to find it’s
value according to the bolt diameter:

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).

From... “ELEMENTS DE FIXATION - ASSEMBLAGES VISSES” (AFNOR E 25-030 1984)

Diameter Class 8.8 Class 10.9 Class 12.9


Bolt = D Torque = Nm Torque = Nm Torque = Nm
3 1,06 1,56 1,83
4 2,44 3,58 4,19
5 4,83 7,10 8,30
6 8,30 12,30 14,30
8 20 29 35
10 40 59 69
12 69 102 119
14 111 163 191
16 173 255 298
18 239 352 412
20 339 499 584
22 466 685 802
24 584 858 1004
27 865 1271 1487
30 1173 1723 2016
33 1594 2342 2740
36 2046 3006 3517
39 2658 3905 4570
WITH SLEW RING
Check the rotation control motoreducer oil level. Fig. 34
- Remove the bleed plug (1) using a 22 mm Allen wrench.
- Remove the plug (2) using an 8 mm Allen wrench and the O-ring. 1
- Top up, if necessary, with the same type of oil as indicated in the table at Paragraph 23 via
the mouth (bleed plug). 2
- The correct level is reached when oil starts to escape from the threaded hole in plug (2).
- Check the state of wear of the O-rings (replace if necessary) and then return the plugs. The
lubrication oil can be drained completely by removing plug (3) using an 8 mm Allen
wrench.

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

replace the hydraulic oil and the filter cartridges.

(!) 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

Checklist in accordance with ISO 9927-1

Element Checks to be carried out:

Subframe Tightening torque of the fixing rods, wear


Structure and fixing rods and any deformation, actions
For crane with rack:
Base Lubrication, tightening torque of the rods,
Rack group, compensator wear and any deformation, actions
For crane with slew ring: Lubrication, tightening torque of the screws
Base wear and any deformation, actions
Slew ring group, compensator
Outriggers Greasing of extension supports, oil-leaks,
Supports, rams, base plates wear, actions, inspection of hoses
safety catches, hoses
Rotation cylinders Oil-leaks, chromium plating,
Cylinders, pistons, seals, any deformation, inspection of hoses
Column Lubrication, wear and any deformation, actions
Inner boom connection, outrigger
connection, pins, bushes
Inner boom Lubrication, wear and any deformation,
Pins, outrigger connections actions
Inner ram Oil-leaks, chromium plating,
Cylinder, rod, piston, seals, hoses any deformation, inspection of hoses
Outer boom Lubrication, wear and any deformation, actions
Pins, outrigger connections
Outer ram Oil-leaks, chromium plating, strains,
Cylinder, rod, piston, seals, hoses inspection of hoses
Extension booms Lubrication, wear and any deformation, actions
Guide shoes, pins, outrigger connections
Extension rams Oil-leaks, chromium plating,
Cylinder, rod, piston, seals, hoses any deformation, inspection of hoses
Hydraulic jib Lubrication, wear and any deformation, actions
Booms, pins, outrigger connections
Rams (hydraulic jib): Oil-leaks, chromium plating, any deformation,
Cylinder, rod, piston, seals, hoses inspection of hoses
Winch Lubrication, wear and any deformation, actions
Torque limiter, brake, rope slide guide,
cable, stroke end, pulleis
Distributors, deviators, valves Checking of the pressure, oil-leaks, wear and any
Control levers, forks, joints, deformation, actions,
fixing screws, lead seals
Lifting moment limiting device Checking of the pressure, oil-leaks
Valves, pressure switches, electrovalves
Power take-off, pump, oil-tank Pump capacity, checking of the pressure, oil change,
Filters, hoses replacement of filters, inspection of hoses
MAINTENANCE
Oil-pressure system Checking of the pressure, oil-leaks, INSTRUCTIONS 22.8
Hoses, hose protection devices inspection of hoses GRU FASSI
Implements for lifting Safety check, wear and any deformation, actions
Hooks, chains, cables, slings

Implements Oil-leaks, wear and any deformation,


Wallboard forks, buckets, rotators actions, inspection of hoses
Seat, third control station Access inspection,
Frame, fixing screws wear and any deformation, strains
Tele(radio)remote control Test

22.8 Complete overhaul of the crane is required


when 10.000 working hours or 10 years'
life are reached - i.e.:
When one of the limits indicated hereunder is reached:

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

10 years' life of the crane,

a complete overhaul with in-depth structural inspection of the crane must be carried out by an
authorised service centre.

22.9 Instructions for the dismantlement and the demolition


of a FASSI crane
INSTRUCTIONS FOR THE DISMANTLEMENT AND THE DEMOLITION OF A FASSI
CRANE
In case of demolition it is necessary to dismantle the whole machine and separate the diffe- rent
types of materials according to the respective waste disposals requirements.
The materials involved are the following:
- Ferrous materials: fabrications and mechanical components.
- Plastic materials: gaskets, belts, covers.
- Electric materials: windings, controls, electrovalves and similar.
- Oils and lubricants: hydraulic oil, lubricants for reducers, lubricating greases.
- For the truck follow the indications of the manufacturer
- Different material: Mercury (level sensor)
Take extreme care when slinging the components to be disassembled especially with respect
to their weight.

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

HYDRAULIC OIL WITH HIGH VISCOSITY: ISO-L-


HV
Minimal external maximal oil Gradation
temperature: temperature:
-35°C +45°C ISO VG 32
-20°C +75°C ISO VG 46

HYDRAULIC OIL WEAR RESISTANT: ISO-L-HM


Minimal external maximal oil Gradation
temperature: temperature:
-10°C +60°C ISO VG 32
+ 0°C +75°C ISO VG 46
+ 5°C +85°C ISO VG 68
+10°C +90°C ISO VG 100

GREASE (for centralized system)

Use only GREASE NILEX EP1 of the firm NILS. NOTE: Do not ABSOLUTELY mix different
types of grease.

GREASE (for slew ring, extension booms, outrigger supports...)

-30°C up to +130°CEP1 Gradation (cold climate)


EP2 Gradation (warm climate)

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.

HYDRAULIC OIL FOR MOTOREDUCER

Classification ISO-L-CC

Gradation EP ISO-VG 150

LUBRICATING OIL (for winch cable)

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.

BRILUBE 50 (BRITISH ROPES - BRINDON)

( ! ) 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.

(!) ATTENTION (!)


In the event that the crane ceases to operate and the code "alarm" with a number appears on the
Display B. Call your FASSI authorised service centre reporting the Alarm number with the
crane model and serial numbers. If the fault cannot be cleared follow the procedure in the chapter
"Controls to operate the crane" and overide the dump valve EVI.
THIS IS ONLY A TEMPORARY ACTION FOR EMERGENCIES, the crane should be
taken to a FASSI service centre for repair as soon as possible.

TO OPERATE THE CRANE FOR TOO LONGER PERIOD WITH THE OVERIDE
ACTIVATED MAY INVALIDATE THE CRANE WARRANTY.

24.2 Only operations which can be carried out by the user


Note: Any operation, other than those indicated hereunder, must be performed
only and exclusively by specialized personnel from an authorized support
centre, considering the potential residual risks.

FAULTS CAUSE REMEDIES


The crane does not Vehicle non in Stabilize the vehicle
rotate properly level position
Lack of lubrication - WITH RACK:
Grease the bushes and
the rotation guide shoe
- WITH SLEW RING:
Grease the slew ring and
the pinion gear- slew ring
group
The extension booms do Lack of lubrication Grease
not completely extend of the guide shoes the guide shoes
or work jerkily

Crane controls are Lack of Check the fuse,


not active electric energy the battery and
electric circuit

Winch stroke end See 21.2


active (if fitted)

The rotation limiting See 16.6


device is activated

Vibrations in Shortage of oil Check the level


crane operations and top up
if necessary
Obstructed filters
Clean or replace
the filter cartridge
Noteable decrease in Obstructed filters Clean or replace
movement speed the filter cartridge
24.3 Operations to be carried out only by an POSSIBLE FAULTS
authorized service center GRU FASSI 24.3

FAULTS CAUSE REMEDIES

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!

Ram seals are Replace the seals


not properly fitted
A boom of the crane does The safety check valve Replace the valve
not hold up the load and the ram is open
visually lowers
Oil leaks inside the ram Defective seals,
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

The extension booms do Wear of guide shoes Check the guide


not completely extend shoes wear, replace if
or work jerkily necessary

Vibrations in Non efficient pump Check the pump


crane operations

Noteable decrease in Non efficient pump Check the pump


movement speed
25 INSTRUCTION AND WARNING PLATES INSTRUCTION AND
25
WARNING PLATES
GR3_080_110

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

DE 2736 DE 2507 DE 2739

DE 2737 DE 2734 DE 2741

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

TIRANTI: NON SALDARE!


FIXING DO NOT WELD!
ROD: NE PAS
TIRANTS:
ZUGSCHRAUBEN:
SOUDER!
NICHT
DE 1574
Do not weld the
SCHWEISSEN!
DE1574 fixing rods

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

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