F195a 6
F195a 6
F195a 6
F 195A.22
use and maintenance
FROM SERIAL NUMBER *6001*
INDEX
1 INTRODUCTION
2 CLASSIFICATION OF THE CRANE MODEL
2.1 Generality
2.2 Hydraulic jibs (not available)
2.3 Technical data
3 CAPACITY PLATES
3.1 Generality
3.2 Capacity plates with lifting moment limiting device
4 HYDRAULIC SCHEMATICS (version with lifting moment 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 (not available)
13.3 Manoeuvres for the manual extension of the double outrigger supports (not available)
13.4 Functions of control levers for stabilization
13.5 Controls to stabilize the vehicle
13.5.1 Crane with hydraulic tiltable supports (with hydraulic motor) for outrigger rams
Edition 15.05.2006
14 CONTROLS TO OPERATE THE CRANE
14.1 Generality 1
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 (on request)
14.7 Stand-up control station (on request)
15 MANOEUVRES OF THE CRANE LOADS (version with load limiting device)(not available)
16 MANOEUVRES OF THE CRANE LOADS (version with lifting moment limiting device)
16.1 Generality
16.2 Lifting moment limiting device “ELECTRONIC”
16.3 Control panels
16.4 Load handling
16.5 Lifting moment limiting device for two working sectors
16.6 Rotation limiting device
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
16.7.1 Diagnostic (Alarms/Input/Output) LME vers. 4-5 UC 01-7
16.7.2 Temporary OVERIDE-Reactivation for the crane functions with standard distributor
16.7.3 OVERIDE-Reactivation lever for the crane functions (with Danfoss distributor)
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)
16.9 Use of the radio remote control (if fitted)
16.9.1 Scanreco control unit with linear levers (if fitted)
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 (not available)
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
20.8 Hydraulic jib articulated at 25 degrees with the automatic control (L515-L516)(not available)
20.9 Use of the hydraulic jib articulated at 25 degrees (not available on the L102 and on the L515-L516)
20.10 Crane with lifting moment limiting device and "pro link" (if fitted)
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)
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
Many years of experience has allowed us to grant you the maximum safety of ope-
ration together with the optimization of machine performances.
The fitment of the crane on the vehicle must be carried out in accordance with
the instructions given by FASSI in the manual for hydraulic crane fitting and the
relevant chassis manufacturers directives.
Be sure that the unit has been installed, inspected and tested in accordance
with the local legal requirements.
As well as the principal safety norms, this manual contains a description of the
crane and the instructions for use and maintenance.
The following instructions refer to mobile cranes in general and must be inte-
grated with the manual for use supplied by the centre responsible for the crane
fitting on truck, vehicle or other type of structure.
Always conform to the safety norms and the instructions for use and mainte-
nance contained in the present manual in order to guarantee a long life to the
crane.
NOTE
The original version of the present manual is in italian.
The spare parts catalogue for the crane can be viewed in the Internet
site: www.fassicat.com
2 CLASSIFICATION OF THE CRANE MODEL CLASSIFICATION OF
THE CRANE MODEL 2
2.1 Generality F 195A.22
The design of this crane has been carried out in respect of fatigue test classification H1B3 of the
EN12999 norm. The crane can operate, intermittently, with lifting devices other than the hook. The
dimensions and the capacity of the implements must be proportioned with crane performances.
F 195A.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
(Φ 200)
17,54 tm 8,30 m 4,00 m 400° 3,14 tm 29,2 MPa 45/65 l/min 180 l 2265 kg 32,4 daN\cm2
172,01 kNm 30,8 kNm
CLASSIFICATION OF
THE CRANE MODEL 2.3
F 195A.22
3 CAPACITY PLATES CAPACITY PLATES
F 195A.22 3
3.1 Generality
The represented plates refer to the nominal design capacities.
CODE DESCRIPTION
CODE DESCRIPTION
CODE DESCRIPTION
N° DESCRIPTION
Check that the vehicle hand brake is on and that the wheels are chocked.
Stabilize the vehicle by the outrigger rams, making VERTICAL VERSION fig. 1
sure that:
- the lateral supports are fully extended;
- the wheels are in contact with the ground and the
suspension is not completely unloaded.
The vehicle/crane are not left unless the power take off
is disengaged and the load is on the ground.
Warning plates, as well as instruction and operation plates must be replaced when
no longer readable or missing. See Paragraph 25 Instruction and warning plates.
To avoid hitting bridges or tunnels check and record the overall height of your crane
in the folded position or in laid position in the body or on the load. Always respect
and pay proper attention to road signs placed in proximity of such obstacles.
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.
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- INSTRUCTIONS 7.3
ger situation must be audibly alarmed. GRU FASSI
Avoid all those situations which may result in crushing during vehicle sta-
bilization, crane movement and load handling.
(In conformity with EN 349 standard the minimum safe working distances
to avoid crushing parts of the body)
Parts Minimum safe Figure Parts Minimum safe Figure
of the working of the working
Body distance mm Body distance mm
Hand
Wrist 100 Finger 25
Fist
The table indicates the minimum safety working distances concerning the
various parts of the body.
The figures illustrate circumstances which may turn out to be dangerous if you
fail to respect the minimum safe distances and if it is impossible to introduce lar-
ger parts of the body.
(!) ATTENTION (!)
For designated areas as: outrigger running towards rest position, leaning
and folding points of the booms in rest position, control platform and
swinnig column, top seat and running inner boom, where no carter is pos-
sible to be placed, please observe the shear and trapping hazard stickers
nearly placed.
5 8,0 - 10,7 Fresh breeze Small green branches bend, the surface
of waterways and lakes are wavy.
8 17,2 - 20,7 Storm wind Branches get broken, it's hard to walk.
9 20,8 - 24,4 Storm It damages houses (antennas and roof
tiles fall down)
Hook up the load, checking that it does not exceed the capacity indicated on the lifting
diagram specific to each load configuration.
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 WARNING AND
is lifted. INSTRUCTIONS 7.4
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.
Do not move the vehicle with the crane not in transport position and not with a
load suspended on the crane.
NOTE
Implements can be left mounted on the booms of the crane (or of the hydraulic
jib) only if the overall dimensions are respected; they must be suitably blocked to
prevent possible sideways movements.
If an accessory (fork, ...) is mounted, it must be tied down at all times during
transport.
Make sure that the outrigger supports and rams are re-entered within the overall
width of the truck and locked by the safety devices.
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.
fig. 2
1 - Crane model
2 - Serial Number
3 - Year of manufacturing
The crane must not be put into service within the European Community unless
the machine on which it is mounted also conforms with the prescribed Directive.
Ever change of use, modification or addition of accessories, not specified by this
manual must be affixed with a new CE mark in accordance with the Machinery
Directive.
A further metallic plate (fig. 3) fixed to the crane by the installer, quotes the
identifying data of the equipment and the final CE mark.
4 YEAR OF MOUNTING
fig. 3
1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Dual control for deviator crane-outriggers
7. Outrigger distributor
8. Outrigger double control
9. Distributor bank
10. Double control
11. Column
12. Inner ram
13. Inner boom
14. Outer ram
15. Outer boom
16. Booms extension rams
17. Extension boom sections
18. Lifting hook
19. Oil tank
20. Manual extensions (optional)
21. Seat (optional)
22. Hand-cables for crane (optional) fig. 4
1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Dual control for deviator crane-outriggers
7. Outrigger distributor
8. Outrigger double control
9. Column
10. Seat
11. Distributor bank
12. Inner ram
13. Inner boom
14. Outer ram
15. Outer boom
16. Booms extension rams
17. Extension boom sections
18. Lifting hook
19. Oil tank
20. Manual extensions (optional)
fig. 5
10 NOMENCLATURE OF THE SAFETY AND NOMENCLATURE OF
PROTECTION DEVICES
THE SAFETY AND
PROTECTION DEVICES
10
GR4_170»250
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
Pos. Description
VERSION 2
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 fig. 9
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.
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.
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.
13.4 Functions of control levers for stabilization SUPPLEMENTARY BEAMS
GR4_175_195_215_ 13.4
The controls to stabilize the vehicle are activated only from ground level and on 220_240_250_270
both sides of the crane base.
NOTE
The graphic symbols illustrated hereunder are marked on the plates (DE4486-
DE4487-DE4488) affixed next to the control stations and indicate with the fol-
lowing symbolism.
Lever C to control
outrigger support
or
outrigger ram
Controls for positioning the outriggers of the crane and the supplementary
beam.
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. A
Controls workable from the distributor side of the crane fig. 12 DE4486
Controls workable from the double control side of the crane fig. 13 DE4487
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 ( - E/S) on .
(!) 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).
13.3.1 Crane with hydraulic tiltable supports (with hydraulic SUPPLEMENTARY BEAMS
motor) for outrigger rams: GR4_175_195_215_ 13.5.1
220_240_250_270
(!) ATTENTION (!)
Be very careful during vehicle stabilization operation; make sure that there are
no obstacles preventing the rotation of the rams and that no one is or transi-
ts in close proximity of the working area of the outrigger rams.
- 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 ( -E/S) on E/S. DE4488 fig. 11b
fig. 11b
- By using the levers CD, the lever C and the valve taps, extend the outrigger
supports, rotate the outrigger rams putting in a working condition and lower
them till the complete stabilisation of the vehicle.
Example of using the levers CD, the lever C and the valve tap on the outrigger:
- extension of the outrigger support n°1
- activate the corresponding lever CD towards right (E1) and keep it in position;
- activate the lever C towards right to obtain the extension of the support;
- rotation of the outrigger ram n°1 from the rest position (fig. 15) to the
working condition (fig. 16)
- make sure that the tap R1 of the valve of the outrigger ram S1 is closed
(for the closed or opened position see fig. 12);
- before removing the pin 1 proceed as follows:
- activate the corresponding lever CD towards left (S1 R1) and keep it in
position;
- activate the lever C in the opposite direction to control the rotation and
take the ram S1 to its rest position so that the pin 1 is extractable;
- to remove the pin 1 rotate its handle B in the anticlockwise rotation after
disengaging the safety device F;
- to rotate the outrigger ram S1 proceed as follows:
- activate the corresponding lever CD towards left (S1 R1) and keep it in
position;
- activate the lever C in the opposite direction to control the rotation and
take the ram S1 to its working condition.
!!! ATTENTION !!!
Make sure that no one is or transits in close proximity of the working
area of the outriggers.
- insert the pin 1 in its new seat and lock it with a clockwise rotation (the safety SUPPLEMENTARY BEAMS
device F sets off automatically); GR4_175_195_215_ 13.5.1
220_240_250_270
(!) The locking pin 1 is constructed from special material
- do not replace it with a non original part
- your security depends on it
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
seat controls OPERATE THE CRANE 14.1
GR2_60»65_3_4
(!) 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.
(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.
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.
The lifting curves of the capacity plate indicate the maximum load that the
crane can lift at a certain radius and at a certain height. To utilize the maximum
capacity of the crane, it is necessary to position the inner boom as indicated
on the capacity plate. During load handling, do not exceed the reach limits
given, or the load indicated on the above mentioned charts. If the limits are
exceeded, the limiting device, allowing all manoeuvres, which reduce the lifted
load within the permitted reach limits and forbid all other manoeuvres, will be
immediately activated.
The pressure values detected in the lifting rams are turned into electric signals
by the transducers, and sent to the electronic logic of the device which deter-
mines the locking or unlocking of the controls concerned, according to the
horizontal position of the crane outer boom (mercury level switch); only the
controls allowing a reduction of the overload are enabled, while those increa-
sing it are disabled.
The device features an electro-hydraulic control that does not allow the set
value to be exceed, by deactivating the controls (levers in neutral position)
commanded by the limiting device. When the controls are released (levers in
neutral position) it's this electronic logic that handles which manoeuvres are
disabled, according to the position of the crane outer boom and in overload
condition, by sending electric signals to special micro-switches placed on the
elements of the distributor.
A - green, yellow and red led band signalling the load percentage as compared
to the capacity plate A
Green light load between 0 and 90%
Yellow light load between 90 and 100% C B
Red light load higher than 100% C
B- Display
G
H
C- Control buttons (4 control buttons) F
D- “STOP” button D
E- Audible alarm push button (danger) E
F- Green warning light (electric on)
G- Control button for XP fig. 17
H- Control button for the temporary exclusion
of the lifting moment limiting device
Layout of the control panel (fig. 18) (if fitted) placed on the double control side and
on top 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
fig. 18
If the green warning light F comes on, it confirms that the electric circuit is active.
If the yellow led A comes on during load handling, 90% of the capacity (lifting
moment) has been reached.
If during operation the red led B comes on, the activation value of the lifting CONTROLS TO
moment limiting device has been reached. OPERATE THE CRANE 16.3
GR2_45»65_3_4_SE
Any hidden danger situation for persons must be audibly alarmed by pressing
the push button E.
When there are serious, imminent and dangerous conditions for persons and
things during load handling, operate on the STOP button, which isolates all
crane functions.
When the electric feeding has been activated (after the version’s number of the
software) the pressure in the inner, outer ram and the jib and the percentage
of load on the winch are displayed.
In relation to the view chosen like standard, when you start the radio remote
control the pressure values are displayed in:
- ”bar” if on the display, on the left of the values, no symbol is present.
- ”daPsi” if on the display, on the left of the values, the symbol is present.
*
- By pushing the button the percentage values of pressure in the inner,
outer ram and the jib and the percentage of load on the winch are displayed.
By pushing a second time the button the pressure values in the inner,
outer and jib rams movement in the measurement unit non standard and the
percentage of load on the winch are displayed.
By pushing again the button you return to the initial display.
- By pushing the button one or more times you return to the initial display
(view of the pressure values).
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
OPERATE THE CRANE 16.7.1
01 - electronic card alarm 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
MESSAGES EXPLANATION
"STOP BOOM OUT" - warning for the interruption of the extension boom exit
because of a sudden variation of the cable tension.
"STOP JIB 25°" - warning of not permitted activation of the lifting functions
because of the activation of the maximum vertical opera-
tivity of the jib when it is complete with the 25° angle
increasing.
MESSAGES REMEDY
"WINCH OFF" Place the distributor bank lever controlling the winch in
neutral position.
"WINCH CAL.ERROR" See code 11.
"STOP BOOM OUT" Place the distributor bank lever controlling the extension
booms in neutral position. If the warning appears when
the winch cable lifting stroke end is not reached, place in
any case the lever in neutral position and then restart to
operate.
"STOP BOOM UP" Lifting functions not available; are authorized only descent
functions.
To verify the right working of the differents input it is possible to use the display
in the "INPUT" menu.
16.7.2 Temporary OVERIDE-REACTIVATION for the crane CONTROLS TO
functions with standard distributor OPERATE THE CRANE 16.7.2
GR2_45»65_3_4
- In case of an electrical failure or of the appearance of the signal “ALARM”
on the display B of the control panel of the lifting moment limiting device:
Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).
On the distributor it has been installed an electro-valve with a manual locking func-
tion (fig. 22) which allows to reactivate all the crane functions in case of absence of
the electric power. Only in these conditions it is permitted to remove the lead seal
which protects the device. Push the button and turn it into the clockwise sense (fig.
22a pos. 1-2); the button stays in stable and closed position.
fig. 22
(!) When the electric power is restablished, remember to put the button
in its original position, turning it into the anti-clockwise sense.
(fig. 22a pos. 3-4)
This activation prevents the operation of the lifting moment limiting devi-
ce, consequently, the operation under such conditions can involve an
overload condition. In such an emergency condition (where the lifting
moment limiting device has been disabled), the operator, who is respon-
sible for the machine safety, must:
- carefully consider the manoeuvres required to return to normal working
conditions: it is however compulsory to effect the re-entry of the extension
booms at first,
- calmly and carefully assess the type and scale of the hazards arising
from these manoeuvres and the possible reaction of the crane (tipping
over, frame overload, uncontrolled fall of the load due to a hydraulic
system overload etc.); fig. 22a
- make all movements as slowly as possible to reduce the dynamic
overload to the minimum.
After such emergency operations and prior to re-use of the crane, you must
immediately go to FASSI authorised Center for testing the structure and re-
sealing of the device.
Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).
On the distributor it has been installed an emergency tap lever (fig. 23) to be
used in the event of a black-out, electrical or hydraulic malfunctions.
Only In these situations it is permitted to remove the lead seal placed on the
tap lever and place it in the closed position.
(!) 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. OPERATE THE CRANE 16.7.3
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.
DE1679 DE1680
17 USE OF IMPLEMENTS USE OF IMPLEMENTS
GRU FASSI 17
17.1 Generality
The crane, in load condition H1B3, can be provided with implements such as:
- Manual extensions
- Winches
- Hydraulic extensions
- Personnel baskets
- Clam ‘shell buckets
- Augers
(!) When using an implement it is always necessary to check that its weight,
dimension and capacity is matched to the crane performances.
For further information please refer to FASSI GRU IDRAULICHE
Warning and norms for crane use also apply for hydraulic implement use.
Before using a personnel basket it is necessary to provide the crane with the
safety devices requested by the local norms in force, EN280 in Europe, and
prior to use of the crane it has to be tested and inspected in accordance with
the local legal requirements.
(!) When the crane is fitted with implements or laid on the truck body it is necessary
to check they are locked to assure the impossibility of accidental movements and
that the led signalling maximum obstruction in height (if fitted) confirms the cor
rect positioning of the crane.
(!) The crane can operate, intermittently and not continuously, with lifting
devices other than the hook, only on loose and light materials (not on
scrap iron).
NOTE
When using coupling unions it is necessary to verify that there is no trace of
soil, curt etc. on the unions and inside the seats so as to avoid the oil contami-
nation and consequently wear the tightening “ surface” of unions or ram seals.
The crane is equipped with an oil cooler (air-oil heat exchanger) to prevent
damage caused by an excessive increase of the oil temperature.
NOTE
When working in a low temperature climate, we recommend to bring the
hydraulic oil up to working temperature prior to starting work, This is
best done by operating the crane thru all its functions ram stroke end.
fig. 1 fig. 1
fig. 2 fig. 2
Use the "+" button to select JIB if in the actual configuration the manual exten-
sions are mounted on JIB or CRANE if the manual extensions are mounted on
the crane.
3. Message “M1 - M2 - M3” (fig. 3) USE OF IMPLEMENTS
After having pressed the above mentioned keys, the message illustrated in GR2_45»65_3_4_5_SE 18.2
Fig. 3 will be displayed.
fig. 3 fig. 3
At this point, through the "+" button, select the correct number of the manual exten-
sion at the moment in use (M stands for manual and 1, 2 and 3 indicate the number
of the manual extensions). Select the number of the manual extension you want; that
number starts blinking. You can select only the manual extensions that have been
installed: i.e. if only one manual extension is installed, by pressing the "+" key, only the
M1extension will start flashing. To confirm your choice, press once the “F1” key (control
panel) or “ENTER” (radio-remote control); you'll access the section dedicated to the
system configuration.
fig. 4 fig. 4
If you press the "ENTER" key with the manual extensions mounted on the
jib, the screen of Fig. 4 will be displayed.
Therefore we can choose the most convenient configuration among the
following:
K1 Outer booms of the crane totally re-entered and jib extensions as you like
K2 Outer booms of the crane as you like and jib extensions totally re-entered
K3 Outer booms of the crane totally extended and jib extensions as you like
K4 Outer booms of the crane as you like and jib extensions totally extended
Select the desired configuration using the * button to move among the various
options. Confirm your selection by pressing the “F1” (control panel) or “ENTER”
(radio-remote control) key. If the hydraulic jib boom is not at its stroke end, the
message at point 3 will be displayed; otherwise the message "F1 TO START" is
visualised.
fig. 5 fig. 5
6. Message “FC P3” (fig. 6) USE OF IMPLEMENTS
[paragraph to read only in case of manual extensions installed on Jib and GR2_45»65_3_4_5_SE 18.2
not on Crane]
Note: do not hang any load on the hook.
This means that the jib outrigger must be positioned at its stroke end (if it is
already in that position this message won't appear), using the lever until the
next screen is displayed.
fig. 6 fig. 6
fig. 7 fig. 7
8. Message “UP P1” (see fig. 8)
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
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 GR2_45»65_3_4_5_SE 18.2
crane and of the manual extension selected.
fig. 10 fig. 10
selector on A “INDEX”
Figure C Figure D
For an overall view of the procedure, we attach the diagrams showing all the pas-
sages and messages that can be displayed during the procedure according to the
various situations that may take place.
The script "EXIT" in the block diagram allows to exit the procedure.
FURTHER MESSAGES
After releasing the lever in neutral position you can find the following messages
If you keep pressed the "F2" key “F2” on the control panel or “LMI” on the push-
button panel, it is possible to have an indicative evaluation of the weight applied on
the hook (fig. 11).
fig. 11 fig. 11
fig. 12 fig. 12
b. “NO LOAD” (fig. 13) USE OF IMPLEMENTS
In this case the load exceeds the max lifting value of the selected manual GR2_45»65_3_4_5_SE 18.2
extension (it could still be on the ground). Unhook the load since it cannot
be lifted using the selected manual extension. As in the preceding case, if
you keep pressed the "F2" key, it is possible to have an indicative evalua-
tion of the weight applied on the hook (fig. 11).
fig. 13 fig. 13
fig. 14 fig. 14
fig. 15 fig. 15
Electric schematic - crane with manual extensions USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18.2
Electric schematic - crane with jib and manual extensions on jib USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18.2
19 CONTROLS TO OPERATE THE HYDRAULIC USE OF IMPLEMENTS
IMPLEMENTS OF THE CRANE GR2_60»65_3_4_AS 19
Jib Jib
Winch Bucket outer extension
boom booms
The plates placed over each lever define their function in relation to their movement.
Make sure that the lever you are going to operate correspond to the control you
selected.
21 WINCH (when fitted) USE OF IMPLEMENTS
GRU FASSI 21
20.1 Generality
The winch is made of a drum that can rotate by means of a hydraulic motor, on a
structure fixed on the crane. The rotation of the drum on which the cable winds is
achieved by a hydraulic motor controlled by a safety check valve connected to the
crane circuit. A parking brake integrated to the motoreducer group hold the load
in position when the winch control lever is in neutral position.
Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
fig. 23
7. Block (double-triple.... line)
(!) 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.
* * *
SINGLE LINE DOUBLE LINE TRIPLE LINE QUADRUPLE LINE
CORRECT POSITION
General lubrication and small repairs can be carried out by the user; repairs of
a more complicated nature must be carried out by authorized service person-
nel.
Good maintenance and proper use are imperative to maintain efficient use and
guarantee the safety of the crane.
At least once a year you must take the crane to a Fassi Service Center for a
check.
(!) Before disconnecting any hydraulic hoses, ensure that there is no pressure
in the hydraulic circuit. After removing hoses always mark them and their
respective ports on the crane. Faulty replacement can cause damage to
the rams and to the hydraulic circuit.
Any maintenance operation must be carried out with the crane power source
turned off. (in case of fixed mounting with hydraulic power pack, the electric
motor has to be turned off).
Do not place limbs, fingers or any other parts of anatomy into areas of the
crane, which present possibilities of shearing, without having blocked such
parts of the crane.
Do not weld, drill or grind any part of the crane without the Manufacturer’s
authorisation.
fig. 29
Do not weld the fixing rods of the crane (see plate
DE1574 fig. 29)
TIRANTI: NON SALDARE!
When repairs to, or checks of, the hydraulic circuit FIXING ROD: DO NOT WELD!
and of the rams are carried out, it is very important TIRANTS: NE PAS SOUDER!
not to use, or be in the proximity of, materials which ZUGSCHRAUBEN: NICHT SCHWEISSEN!
can damage the circuit or contaminate the hydrau- DE1574
lic oil eg. 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.
Press button C2 (clock/-) to have the current date visualized on display B. Fig. 29.
Partial time
Total time
How to view the total activation time of the electric panel; this cannot be reset.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C3 (enter) to visualize, for about 5 seconds, the total time
expressed in hours and minutes.
Work time
How to view the work time which is the actual time recorded whilst a crane
operating lever/function is being activated.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C1 (+) again to read "Work time" on the display.
- Press button C3 (enter) to view, for about 5 seconds the work time of the
crane expressed in hours and minutes.
22.3 After every 8 working hours or at the end of every MAINTENANCE
working day INSTRUCTIONS 22.3
GRU FASSI
- Check that all safety devices are efficient.
- Check the level of the hydraulic oil in the tank.
- Check all the components of the hydraulic circuit for possible leaks.
- Check that the control and the oil diverter levers can easily be positioned;
they must show no signs of forcing.
- Check the condition of shackles, hooks, wire ropes and any other lifting equipment.
Clean the oil filter placed in the oil tank of the crane and if any, on the pump sec-
tion and pressure hoses.
NOTE The filters of fibre or paper can not be cleaned, they must be replaced.
Cleaning of the wire mesh filter on the tank (oil return to the oil-tank) fig. 31.
- Unscrew the security bolts of the filter cover 1 and remove it.
- Extract the cartridge, clean by flushing with a non flammable, non corrosive fig. 31
and non toxic solvent (gas oil or other). Thoroughly dry the filter inside and out
(do not use 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).
fig. 33
Top up using hydraulic oil with the same characteristics as those indicated in the
table at 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.
WITH RACK
Periodically grease the points indicated on the crane (fig. WITH RACK
34) (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- fig. 35
sion booms guide shoes 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.
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) INSTRUCTIONS 22.6
WITH RACK GRU FASSI
- of the securing bolts for the ram pins and of all the other bolts and screws, where
the 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).
Clean the air filter placed in the top of the oil tank filter cap.
Completely replace the hydraulic oil and the filter cartridges. fig. 34
(!) The waste oil and the filter cartridges MUST be disposed of by
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 every MAINTENANCE
working year
INSTRUCTIONS 22.7
GRU FASSI
Perform: Washing, Function Testing, Testing according to the
capacity plates
Check: Identification plates, Capacity plates
10.000 working hours, (i.e.: 10 years, 50 weeks a year, 20 hours a week, or 5 years, 50
weeks a year, 40 hours a week)
or
a complete overhaul with in-depth structural inspection of the crane must be carried out by
the Manufacturer or by an authorised service centre.
Completely release the residual pressure in the hydraulic circuits and then fully drain
the oil present in the circuits before starting the dismantlement of the relevant compo-
nents. Be careful not to let the oil drop on the ground, therefore collect it in special con-
tainers, since exhausted oil must be eliminated in compliance with the waste disposal
rules in force.
Disable all the electric power supplies (batteries etc.) before dismantling the compo-
nents of the electric circuits.
23 TABLE OF HYDRAULIC OIL AND LUBRICANTS TABLE OF HYDRAULIC
CHARACTERISTICS
OIL AND LUBRICANTS
CHARACTERISTICS
23
GRU FASSI
All grease used must be free from acid and resin, not hygroscopic and
long-life such as
BP GREASE LTX-EP1\EP2 or ELF EPEXA 1\2
ESSO BEACON EP1\EP2 or TEXACO EP1\EP2
MOBIL EP1\EP2 or SIMILAR.
Classification ISO-L-CC
The most suitable here is a general-purpose lubricating oil with about SAE
30° viscosity. A lubricating oil containing non-stick additives is recommen-
ded if the cables are expected to move quickly through the pulleys.
( ! ) WARNING ( ! )
Don’t use greases with solid particles as “Bisulphide of Molybdenum”
(not compatible with eventual teflon bushes).
24 POSSIBLE FAULTS POSSIBLE FAULTS
GRU FASSI 24
24.1 Generality
Many years experience of our product has allowed us to identify and classify the most
common faults which occur. In most cases it requires accurate hydraulic and electric
troubleshooting and simple rectification. In the following table we report the most fre-
quent inconveniences and our suggested remedies.
(!) Checking and adjustment of oil pressures of valve settings must be carried out
by an authorized service agent, under penalty of warranty forfeiture.
TO OPERATE THE CRANE FOR TOO LONGER PERIOD WITH THE OVERIDE
ACTIVATED MAY INVALIDATE THE CRANE WARRANTY.
The crane does not lift Non efficiency Replace the pump
the loads indicated of the pump
on the capacity plate
(main pressure or auxiliary) Check the pressure,
valves not properly adjust the valves
adjusted, or worn or replace them!
A boom of the crane The safety check valve Replace the valve
does not hold up the load the ram is open
and 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: Wear of the slew ring Check the slew ring wear,
replace if necessary
Wear of the Check the motore-
motoreducer group ducer group wear,
replace if necessary
DE 4236
Instruction plate and safety norms
DE 6723
Warning plate to stabilize the vehicle before
using the crane
DE 1684A
Do not operate from the double control side,
to unfold or fold the crane
DE 4452A
Instruction plate to fold the
crane into the rest condition
INSTRUCTION AND
WARNING PLATES 25
GR4_175_195_215_220
240_250_270
DE 4491
Do not operate from the frontal position, to
extend the outrigger supports
DE 2100
Danger plate for crushing of lower limbs
Oil-diverter
control plate
DE 4488
Instruction plates
to stabilize the vehicle
DE 4486 DE 4487
INSTRUCTION AND
WARNING PLATES 25
GR4_175_195_215_220
240_250_270
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
WARNING PLATES 25
GR4_175_195_215_220
240_250_270
DE 1679
Do not walk on...
DE 1680
Do not use water to estinguish fire
DE 4945
Warning of burn danger
DE 1067
Do not walk or stay under a suspended load
and for unauthorized persons to be within the
DE1067 working area..