Fassi Crane Use and Maintenance Manual Translation of The Original Instructions UM002

1
FASSI CRANE USE AND MAINTENANCE MANUAL

Translation of the original instructions EN
UM002
(Amendment 00 - Edition 07/07/2014)
Index
Index
Chapter 1 – Introduction 8
1.1 – Introduction 8
1.2 – Use of manual 9
1.3 – Symbols used in the manual 10
1.4 – General nomenclature of FASSI crane and implements 10
1.5 – General procedure to operate the crane 11
Chapter 2 – General specifications 12
2.1 – Identification 12
CE marking 12
Icon legend (CE Declaration of conformity) 13
No CE marking 14
2.2 – Technical data 14
Classification and design standards 14
Technical features 14
Intended use of the lifting device according to its design 14
Forbidden use of the lifting device 15
Service and storage conditions 16
Noise emission values 17
Lifting capacity 18
Chapter 3 – Health and safet y instructions 25
3.1 – Personnel in charge 25

Use of personal protective equipment 25
3.2 – General instructions 26
3.3 – Crushing, trapping and shearing danger 27
Zones subjected to crushing, trapping and shearing danger 28
3.4 – Electric shock danger 29
3.5 – Burn danger 30
3.6 – Fall danger 30
3.7 – Noise emission danger 31
3.8 – Exhaust gas emission danger 31
3.9 – Danger due to unfavourable service conditions 31
3.10 – Danger related to the control station 32
3.11 – Danger related to working area 32
3.12 – Danger related to wrong operation 33
3.13 – Overturn danger 33
3.14 – Danger due to overload and fatigue of the crane 33
3.15 – Danger due to overload of manual extensions 34
3.16 – Danger related to lifting moment limiting device and safety devices 34
3.18 – Danger resulting from wrong securing of loads 35
3.19 – Danger related to crane transport 35
3.20 – Danger due to lacking or wrong maintenance 36
3.21 – Danger due to special working conditions 36
3.22 – Plate of instructions for safe use of the crane - Legend 37
2 UM002_Amendment 00 - Edition 07/07/2014

Index
Chapter 4 – Safet y devices and special functions 39
4.1 – Index of paragraphs as per crane equipment 39

4.2 – Safety devices 41
4.2.1 - STOP button 41
4.2.2 - FX900 electronic lifting moment limiting device 42
Generality 42
Working logic 42
Block due to overload 43
Lifting block (Angle control device for PROLINK) 45
Rotation block 45
Crane block by the attainment of the mechanical stroke end of the lifting ram. 45
Crane folded in transport position 45
Temporary exclusion of the lifting moment limiting device 46
Icon list 47
Icon flag list 50
Touchscreen control panel (if fitted) 51
Control panel for crane with top seat (if fitted) 52
Timer menu 56
User menu 57
GAS (Grab Automatic Shake) 57
Procedure to pass from radio remote to manual control mode (and vice versa) 58
Warnings and alarms 59
Messages 63
4.2.3 - Visual indicator (EN 12999: “Operational warning”) 65
4.2.4 - Rated capacity acoustic indicator 65
4.2.5 - Acoustic warning 65
4.2.6 - Angle control device for PROLINK 66
4.2.7 - Lifting moment limiting device for two working zones 67
4.2.8 - FSC (Fassi Stability Control) 68
FSC/S 68
FSC/S system display 75
4.2.9 - Inner boom horizontal position indicator 77
4.2.10 - CPM (Crane Position Monitoring) 77
4.3 – Special functions 78
4.3.1 - XP (Extra Power) 78
4.3.2 - PROLINK (Progressive Link) 79
4.3.3 - Exclusion tap for 7th/8th extension boom sections 79
4.3.4 - JDP (Jib Dual Power) 80
4.3.5 - JVC (Jib Vertical Control) 81
4.3.6 - FL (Full Lift) 82
4.3.7 - Oil cooler (heat exchanger) 82
Chapter 5 – Control systems 83
5.1 – Pictograms for crane and implement control 83

5.2 – Layout of crane and implement controls 84
5.2.1 - Horizontal layout order 84
5.2.2 - Layout order for radio remote control with joystick 84
Radio remote control - 6 functions with 3 joysticks 84
5.3 – Radio remote control 86
5.3.1 - RCH digital radio remote control 86
UM002_Amendment 00 - Edition 07/07/2014 3

Index
Radio remote control components 86

Radio remote control activation 88
Automatic frequency selection 88
Configuration of quick select buttons for supplementary functions 88
Cable connection 88
Radio remote control automatic switch-off 88
Radio remote control switch-off 89
5.3.2 - RCS digital radio remote control 89
Radio remote control components 89
Radio remote control activation 90
Automatic frequency selection 90
Configuration of quick select buttons for supplementary functions 91
Cable connection 91
Radio remote control automatic switch-off 91
Radio remote control switch-off 91
5.3.3 - Enabling outriggers and crane 92
5.3.4 - Controlling the outriggers 92
5.3.5 - Controlling the crane 94
5.4 – Top seat control station 95
5.4.1 - Controlling the crane 95
Chapter 6 – Setting up for crane operation 97
6.1 – Preliminary checks 97

6.1.1 - Checks on the crane 97
6.1.2 - Check of working area and service conditions 99
6.2 – Activating the crane 102
6.3 – Stabilizing the vehicle 102
6.3.1 - Outrigger nomenclature 102
6.3.2 - Instructions 103
6.3.3 - Enabling the outriggers 104
Hydraulically tiltable outrigger rams by chain 107
6.3.5 - Placing the vehicle in horizontal position 108
6.4 – Unfolding the crane into working position 109
6.4.2 - Enabling the crane 109
6.4.3 - Unfolding the crane into working position 110
Articulated folding crane 110
Chapter 7 – Crane operation 111
7.1 – Instructions 111

7.2 – Checking the load 113
7.3 – Hooking up or unhooking the load 113
7.4 – Handling the load 114
7.5 – Laying down the load 117
7.6 – In case of emergency 117
Chapter 8 – Folding the crane 118
8.1 – Instructions 118

8.2 – Folding the crane into transport position 118
8.2.1 - Articulated folding crane 118

Index
8.2.2 - Crane laid in transport position inside the vehicle body 119
8.3 – Reentering the outriggers 120
8.3.1 - Outrigger nomenclature 120
Hydraulically tiltable outrigger rams by chain 123
8.4 – Deactivating the crane 125
8.5 – Securing load and crane 125
Chapter 9 - Use of implements 126
9.1 – Generality 126

9.2 – Hydraulic connections implements - supplementary hoses 127
9.2.1 - Quick coupling connectors 127
9.2.2 - Quick coupling multiconnectors 128
Instructions for hydraulic implement connection 129
Instructions for hydraulic implement disconnection 129
9.3 – Controls to operate hydraulic implements 130
9.4 – Hydraulic extension 131
9.4.1 - Generality 131
9.4.2 - General nomenclature 131
9.4.3 - Technical specifications 132
9.4.4 - Health and safety instructions 132
9.4.5 - Safety devices 134
Locking device against the exit of extension boom sections 134
Locking system 134
Electronic lifting moment limiting device 134
9.4.6 - Setting up for hydraulic extension operation 135
Mounting the hydraulic extension 135
Placing the hydraulic extension into working position 136
9.4.7 - Hydraulic extension operation 137
9.4.8 - After hydraulic extension operation 138
Placing the hydraulic extension into transport position on the crane 138
Removing the hydraulic extension 139
9.4.9 - Maintenance and dismantling 139
9.5 – Manual extensions 140
Mechanical stroke end 142
Locking systems 142
Electronic check system for load hooked on manual extensions 143
9.5.6 - Setting up for manual extension operation 148
Instructions 148
Mounting the manual extensions 148
Extending the manual extensions 148
Mounting the hook on manual extensions 149
9.5.7 - Manual extension operation 150
9.5.8 - After manual extension operation 150
Instructions 150
Reentering the manual extensions 151

Index
Removing the manual extensions 151

9.6 – Winch system 152
Mechanical stroke end 154
Block due to activation of limiter and safety functions of the winch 154
Winch fail-safe negative brake 155
9.6.6 - Setting up for winch system operation 156
Working types 156
Mounting mobile pulleys and balance weight 157
Mounting the fixed pulleys on crane 158
Mounting the fixed pulleys on hydraulic extension 159
Mounting the fixed pulleys on manual extension 161
9.6.7 - During winch system operation 161
9.6.8 - After winch system operation 162
Chapter 10 – Maintenance 163
10.1 – Generality 163

10.2 – Checks and preventive maintenance 165
10.3 – Instructions for checks and preventive maintenance 168
10.3.1 - Lifting hook 168
Nomenclature 168
Hook 168
Ring 168
Functional check 169
10.3.2 - Winch 169
Nomenclature 169
Fail-safe negative brake 169
Rope 169
10.3.3 - Crane cleaning 170
10.3.4 - Base 170
10.3.5 - Rams 171
Nomenclature 171
Rod 171
10.3.6 - Slew ring 172
Nomenclature 172
Bolts and Screws 172
Rolling system 172
10.3.7 - Tank 173
Nomenclature 173
Oil level 173
Oil filter 173
Table of hydraulic oil characteristics 174
10.3.8 - Pump high pressure filter 174
10.3.9 - Lubrication 175
Compulsory periodic lubrication 176
Table of lubricant/grease characteristics 178

Index
Electronic lifting moment limiting device 179

Winch limiting devices 179
STOP button 180
Transducers and sensors 180
10.3.11 - Fixing rods, bolts and screws 182
10.4 – Checks and maintenance by the authorised FASSI service centre 183
10.5 – Crane dismantling and/or demolition 189
Chapter 11 – Failure conditions 190
11.1 – Outrigger control by radio 190

Examples of outrigger operation 192
11.2 – Crane control by radio - Distributor on the column 193
11.3 – Temporary override of crane functions 194
11.4 – Rupture of the crane pump 195

Chapter 1 — Introduction
Chapter 1 – Introduction
1.1 – Introduction
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 9001:2008 (ISO 9001:2008)
FASSI cranes conform with the European Standard EN12999:2011

(only for cranes with CE marking).
The crane fitment on the vehicle must be carried out by an authorised FASSI service centre in
accordance with the instructions given by FASSI in the manual for hydraulic crane mounting.
The Manufacturer declines any responsibility and disclaims all warranties if the fitment 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 are general and refer to loader cranes mounted on truck, vehicle or static
foundation, even for use in marine environment.
These instructions must be integrated with the manual for use supplied by the centre responsible for
the crane fitting on truck, vehicle or other type of structure.
Some of the options described in the use and maintenance manual are available on request; therefore
they may not be on your crane.
Read this manual carefully prior to activation, use, maintenance or any other operation.
A few minutes spent now could save time and labour later.
Always conform to the safety norms and the use and maintenance instructions contained in the
present manual in order to guarantee long life to the crane.
The original version of the present manual is in Italian.

The spare parts catalogue is available in electronic format on the website
www.fassicat.com.

1.2 – Use of manual

These instructions for use are an integral part of the device.
They must be stored during the entire life cycle of the device and kept on the vehicle.
The instructions for use and the enclosed technical documentation can’t replace any type of operator
training prescribed by the national directives.
FASSI is constantly involved in research and development of technologically advanced components

and instrumentation. This may involve deviations between the content of the instructions and the
device itself.
FASSI reserves the right to change specifications, pictures, use and maintenance
instructions without any notice.
In case of lacking, incomplete or wrong indications or descriptions, please contact a FASSI service
centre.
Schematics, images and photos in this manual are merely indicative and have only illustrative
function: they cannot be used in order to lodge complaints or make legal claims.
The current manual is copyrighted © by FASSI.
The copy, even partial, is possible only if authorised in written form by:
FASSI GRU S.p.A.

v. Roma, 110
24021 Albino (BG)
ITALY
These instructions are valid only for the crane model indicated on the cover of Appendix A and only
if they are completed by appendices and instructions of every equipment used with the device.
This manual may include references to equipment or implements which are not provided on your
crane.
Enclosed to this manual you can also find the “Interactive training” FASSI DVD.

1.3 – Symbols used in the manual

Inside the manual some ideograms are used in order to point out dangerous and forbidden situations
related to the device, as well as very important remarks for the crane operator.
Important remark or particularly interesting information for the operator.
Danger Attention: potential hazards for the operator and other persons.
Accidents (even serious) or injuries for the operator and other persons and damages to
the crane may occur if this warning is ignored.
Forbidden situation or operation. The non-observance of this prohibition may cause

accidents (even serious) for the operator and other persons, as well as damage to the
crane.
Ideogram used inside the pictures of the present manual to indicate allowed situations.
Ideogram used inside the pictures of the present manual to indicate forbidden situations.
1.4 – General nomenclature of FASSI crane and implements
1. Outrigger rams
2. Outrigger supports 8 10 11 12 13
3. Base beam
4. Base
5. Outrigger plate
6. Column 6 9
7. Inner ram 2 7 2
8. Inner boom
9. Outer ram 1 1 14
10. Outer boom 4 3
5
11. Extension boom sections
12. Boom extension rams
13. Manual extension 15
14. Hydraulic extension (jib)
15. Supplementary outrigger 16
16. Winch system

1.5 – General procedure to operate the crane

Respect the safety instructions included in the use and maintenance manual of crane and
implements.
Activate the crane

(Chapter 6 - Setting up for crane operation)
Enable the outriggers

Completely stabilize the crane

X>1.5°
Crane slope
X<1.5°
Enable the crane
Fold the outer boom and place the crane into working
position (Chapter 6 - Setting up for crane operation)
Lift and handle the load

(Chapter 7 - Crane operation)
Lay down the load

(Chapter 7 - Crane operation)
Fold the crane

(Chapter 8 - Folding the crane)

Reenter the outriggers

Disengage the power take-off

Check for the correct block of all the crane parts

Respect the maximum overall dimension in folded

position for transport (Chapter 8 - Folding the crane)

Chapter 2 — General specifications
Chapter 2 – General specifications
2.1 – Identification
CE marking
The CE mark indicates that the crane complies with safety and health requirements, as requested
by the Machinery Directive 2006/42/EC. The mark can be considered effective only if provided
together with a written declaration of conformity released by FASSI.
Identification data are indicated on the plate DE5891 (fig. 2.1), used for the CE mark.
1. Crane model
2. Serial number
1 3. Year of manufacture
2
3
Fig. 2.1
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.
In accordance with the Machinery Directive, every change of use, modification or addition of
implements not specified by this manual compels to renew the CE marking.
A further plate (fig. 2.2), which is fixed near the crane by the installer, quotes the
identifying data of the mounting and the final CE mark.
1. Name of the installer who

1 applied the final CE mark
2. Crane mark, model and serial
CRANE - MARK AND MODEL
SERIAL NUMBER 2 number
3. Vehicle mark, model and frame
3
VEHICLE - MARK AND MODEL
VEHICLE FRAME SERIAL NUMBER
number
YEAR OF MOUNTING
4 4. Year of mounting
Fig. 2.2
It is forbidden to alter the data marked on the plates.

Icon legend (CE Declaration of conformity)
Traversa
IT Gru Prolunga idraulica Radiocomando Verricello stabilizzatori Prolunga manuale Carrucola
supplementari
Remote control Boom extension
UK IE CY Loader crane 3rd boom Hoist Stabilizer Sheave
system manual
FR BE LU Grue de Système à Traverse Rallonge de flèche
3ème flèche Palan Poulie
CH chargement télécommande supplémentaire manuelle
DE AT LU Hydraulische Manuelle
Ladekran Funkfernsteuerung Winde Zusatzabstützungen Seilrolle
CH LI Knickverlängerung Armverlängerung
Afstandsbedienings- Mastverlenging,
NL Laadkraan 3e mast Hijsinrichting Stabilisator Katrolschijf
systeem handmatig
Grua industrial de Sistema controlo Braço extensível,
PT 3° braço Guincho Estabilizador Roldana
carga remoto manual
Prolonga Mando a distancia Estabilizadores
ES Grúa Cabrestante Prolonga manual Polea
hidráulica por radio suplementarios
Extra Manuell
SE Kran Jib Radiostyrning Vinsch Linhjul
stödbensbrygga förlängningsarm
Mekaaninen
FI Kuormausnosturi Jibipuomi Radio-ohjaus Vinssi Tukijalka Taittopyörästö
puominjatke
DK Lastekran 3.udskud Radiostyring Løft Støtteben Manuelt udskud Blok
Izlices
Distances vadības
LV Hidromanipulators 3-ā izlice Vinča Stabilizators pagarinājums, Bloks
sistēma
manuāls
Krovinių kėlimo Nuotolinio valdymo Mechaniškai
LT Papildoma strėlė Gervė Atrama Skriemulys
kranas sistema išilginama strėlė
Mehaaniline
EE Hüdrotõstuk 3 poom Ditants juhimine Vints Tugijalad (Vintsi) plokk
pikendus
Třetí hydraulické Výsuv ramene,
CZ Nakládací jeřáb Dálkové ovládání Zdvihadlo Podpěra Kladka
rameno manuální
Manuálne
SK Nakladací žeriav 3. výložník Dial’kové ovládanie Naviják Stabilizátor predĺženie Kladka
výložníka
Żuraw Ramię wysuwane
PL Bocian Sterowanie radiowe Wciągarka Podpory Zblocze
przeladunkowy ręcznie
Manipulativno Sistem daljinskega Teleskopski
SI Zglobna roka Vitel Stabilizator Škripec
dvigalo upravljanja podaljšek, ročni
Rádió távirányító Mechanikus
HU Önrakokó daru Lengőgém Emelőszerkezet Kitalpaló Görgő
rendszer gémtoldat
Extensie hidraulica Extensie manuala
RO Macara incarcator Telecomanda Troliu Stabilizator Scripete
brat brat
Haпpeчна rpeдa
Xидpaвлично Дистанционно
BG Kpaн Лебедка допълнителни Pъчно удължение Шайба
УдЪлжение упpaвление
cтaбилизатори
Uzaktan kumanda Manüel bom
TR Yükleyici vinç Üçüncü bom kaldırma Dengeleyici Kasnak
sistemi uzatma
Estenzjoni tal
MT Loader krejn 3 boom Sistema Motorizzata Arblu Stabbilizzatur Taljola
boom, Manwali
Tηλεσκοττική
3η τηλεσκοττικός Αττομακρυσμένο
EL Γερανός Avύψωση Σταθεροττοιητής προέκταση, Tροχαλία
βραχίονας σύστημα ελέγχου
χειροκίνητη
IS Hleðslukrani 3ja bóma Fjarstýring Spil Krana lappir handútdrag Svívill
Hydraulisk Teleskoparm
NO Lastebilkran Radio styring Vinsj Støtteben Skive
rorlenger manuell

No CE marking
Identification data of cranes for extra EC market are indicated on the plate DE5892 (fig. 2.3).
1. Crane model
2. Serial number
2
3
Fig. 2.3
2.2 – Technical data

Classification and design standards
The design of this crane has been carried out in respect of HC1/S2 (ex H1B3) classification, as
specified by the standard EN 12999.
Technical features
Refer to Appendix A of the present manual for the specific technical features of your crane.
Intended use of the lifting device according to its design
The non-conformity with the use instructions involves both hazards for the operator
and the persons in the vicinity and damages to crane and implements. This causes the
loss of every form of responsibility and warranty by FASSI.
It is allowed to use the crane and its implements in the load area indicated on the lifting diagrams
in order to lift, handle, keep suspended and release the loads.
It is permitted:
• to load and unload one’s own vehicle or other vehicles;

• to lift and keep suspended loads for mounting operations;
• to lift and handle loads with a hook;
• to occasionally use a bucket to lift and handle gravel or sand (the lifted and then released
load must not be higher than twice the weight of the lifting device).
Dimensions and capacity of other implements than the hook must be proportioned with crane
performances.
It is allowed to use the crane and its implements during load lifting and handling
operations only with stationary vehicle and under complete stability conditions.

Forbidden use of the lifting device
The non-conformity with the use instructions involves both hazards for the operator
and the persons in the vicinity and damages to crane and implements. This causes the
loss of every form of responsibility and warranty by FASSI.
It is prohibited:
• to use crane and implements for other aims than the ones indicated previously;
• to misuse the device;
• to unblock, hit or crush the loads;
• to push and drag the loads;
• to dig with buckets;
• to use crane and implements for wood or scrap iron;
• to use crane and implements in potentially explosive environments;
• to operate boom system or implements in strong currents, such as in a river;
• to fix loads to other points than the intended lifting attachments, which are represented
by the hook on the capacity plates;
• to carry out traction in every direction or vehicles towing;
• to use the hydraulic extension upside down (for instance with a platform working
under bridges);
• to move the vehicle with suspended load;
• to move the vehicle with the crane not in the expected transport configurations;
• to use crane and implements to lift or carry people.
Exception:
It is permitted to use work platforms (WP) to lift people only changing the end use
of the crane (Mobile Elevating Work Platform - MEWP) and after evaluation of its
conformity with the binding standards (EN 280) by a notified body.
In particular, the complete unit crane-vehicle with work platform (MEWP) is intended
only to move persons to working positions, where operations can be carried out from
the WP.
The possible combinations with WP and the relevant technical documentation are
available by all FASSI dealers.
In any case, it is prohibited to apply WP if a bucket or another implement other than
the hook are installed (or have been installed) on the crane.
If the vehicle is not completely stabilized, it may overturn. Working without proper
stabilization is forbidden.
If the use instructions of optional implements allow certain operations which are forbidden by the
current instructions, give always priority to the crane use instructions.

Service and storage conditions
The non-conformity with service conditions may cause both hazards for operator and
persons in the vicinity and damages to crane and things.
The crane is designed to be used in the temperature range indicated in the following table. If the
temperature range for crane operation is not included in these limits, the crane functionality may
be discontinuous and damages to the hydraulic and electrical systems may occur.
Temperature range for operation and storage of the crane

Temperature of the crane working environment -30°C to +50°C
Temperature of the crane storage environment -40°C to +70°C
In case of work in another temperature range than the one prescribed in the table, it is
compulsory to request FASSI specific authorization.
The crane must be used with wind speed lower than 13,8 m/s (50 Km/h - maximum value of
degree 6 of Beaufort scale) and in absence of thunderstorms.
Force of the wind Wind speed

Classification Characteristics
(Beaufort scale) (m/s)
Calm wind, smoke goes up quite
0 0,0 ÷ 0,2 Calm
vertically.
1 0,3 ÷ 1,5 Smoke reveals the direction of the wind,

Light breeze one can feel the wind blowing, leaves
2 1,6 ÷ 3,3 start fluttering.
3 3,4 ÷ 5,4 Leaves and branches are in constant

Moderate breeze motion, small branches start fluttering.
4 5,5 ÷ 7,9 Dust and papers dance on the ground.
Small green branches bend, the surface

5 8,0 ÷ 10,7 Fresh breeze
of waterways and lakes is wavy.
Big branches bend, wind whistles
6 10,8 ÷ 13,8 Near gale 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.
It damages houses (antennas and roof

9 20,8 ÷ 24,4 Storm
tiles fall down).
While working with the crane vertical up, it is recommended to consider the working
limit speed of the wind decreased of 5 km/h every 10 m height (refer to EN 1991-1-4).

The conditions of the ground or the support must be suitable to the maximum pressure exercised
by the device.
The value of the pressure exercised on the ground by the outriggers is indicated in the schedule
“Crane technical data” in Appendix A of the present manual (“Max. working pressure on the
outrigger Ø ... ”) and has to be compared with the below table.
Admitted pressure on the ground (Load capacity of the ground) - Ref. DIN 1054
A Made ground, not compacted artificially 0÷10 daN/cm2 = 0÷1 MPa
B Asphalt 20 daN/cm2 = 2 MPa
C Compact ground, not removed
1 Mud, peat, marshy ground 0 daN/cm2 = 0 MPa
2 Not compacted ground, adequately solid
From fine to middle sand 15 daN/cm2 = 1.5 MPa
From thick sand to gravel 20 daN/cm2 = 2 MPa
Shattered and compacted stones 25 daN/cm2 = 2.5 MPa
3 Compact ground
Wet 0 daN/cm2 = 0 MPa
Soft 4 daN/cm2 = 0.4 MPa
Compact 10 daN/cm2 = 1 MPa
Half-solid 20 daN/cm2 = 2 MPa
Hard (solid) 30 daN/cm2 = 3 MPa
4 Rock
Eroded 100 daN/cm2 = 10 MPa
Noise emission values
The risk due to noise is mainly caused by truck engine and auxiliary
hydraulic supply system. The installer must provide for the phonometric
assessment and the relevant declaration after mounting, according to the
reference norms in force where the crane is used.
Permanent low or short high noise emission levels damage the health of operators and
other persons in the working area.
Near the control stations of loader cranes installed on diesel engine vehicles, the noise emission
level depends on mounting and working conditions and it may reach the following values:
• 72 to 84 db(A) with low or high idling speed of the truck motor;

• 79 to 86 db(A) during crane operation;
• the maximum noise level ranges between 92 and 100 db(A).
While assessing the mounting, it is recommended to consider the minimum engine

speed.
If you use the radio remote control, it is recommended to work over 1 m far from the
vehicle engine.
In hazardous situations, it is compulsory to use the personal protective

equipment against noise.

Lifting capacity
It is forbidden to exceed the allowed limits of outreach and load represented on the
capacity plates.
Exceeding the allowed limits of outreach and load involves hazards of accidents (even
serious) for operator and persons in the vicinity, vehicle overturning and breaking of
crane components.
The specific design rated capacity plates of the crane are enclosed in Appendix A of the
present manual.
It is permitted to use the crane only in compliance with the lifting diagrams which are indicated
on the capacity plates.
Loads indicated on the capacity plates refer to crane without implements: so, prior to every lifting
operation, it is necessary to deduct the weight of the optional implements mounted on the crane
(e.g. manual extensions) from the load values represented on the plates.
Different hooks can be represented on the capacity plates. They are distinguished by different
colours (white and black) and their maximum allowed capacity is indicated in the label:
• a black hook is placed on the movable hook attachment of the crane/jib last hydraulic
extension boom;
• a white hook is placed on the movable hook attachment of the crane last hydraulic
extension boom + a black hook is placed on the movable hook attachment of the crane
sixth extension boom;
• a white + an optional black hook with different rated capacity are placed on the
movable hook attachment of the crane last hydraulic extension boom, according to the
maximum load to be lifted;

• a white hook is placed on the hook attachment of the manual extension (if fitted).
Always use a hook having the same or higher lifting capacity than the one of the load to be lifted
or handled.
The presence of the lifting moment limiting device does not exempt the operator from respecting
the lifting diagrams represented on the capacity plates.
When you use the hook attachment on the tip of the 6th extension boom section, it is compulsory
to close the exclusion tap for 7th/8th extension boom sections.
Before closing the exclusion tap, make sure the 7th and 8th extension boom sections are
completely reentered.
If JDP function is fitted, the exclusion tap is replaced by an electrovalve blocking the exit of the
extension boom sections, which can be activated by selecting the JDP icon from the control
station.
All the loads indicated on the capacity plates are considered to be valid after the positive
result of the stability test carried out by the final installer as per the standard EN 12999,
part 6.
In case of derated or partially decreased capacities (e.g. in the sector in front of the
vehicle cab), the operator must consider the plates defined after the final stability test
which is carried out by the installer.
The loads represented on the capacity plates for crane with winch can be lifted only
respecting the number of pulls specified in the plate.

Illustrative schematic for the capacity plate of a standard crane (fig. 2.4)
E
2
13
L
3
I 4
5
M
6
S I 7
C- 8
A
12
F 9
10
11
1. Crane model
2. Maximum design lifting moment
3. Maximum lifting capacity of crane/manual extension according to the hook
4. The plate loads refer to crane with XP device activated
5. HD (Hoist Drive) classification according to standard EN 12999 (for xhe-dynamic cranes)
6. The crane must be completely stabilized in order to lift and handle the plate loads
7. Lifting curves according to the outreach
8. Angle increase on crane provided with PROLINK
9. Crane maximum loads according to the outreach
10. Manual extension maximum loads
11. Manual extension weight
12. Inner boom angle in the crane plate configuration
13. Maximum loads allowed in vertical configuration

Illustrative schematic for the capacity plate of a crane with hydraulic extension
12
1
E
3
L
4
I
5
I M 6
-S
C
7
11
FA 8
10 9
1. Hydraulic extension-crane combination

3. Maximum lifting capacity of the crane with hydraulic extension or of the jib manual extension
according to the hook
4. The plate loads refer to crane with XP device activated
7. Angle increase on hydraulic extension provided with PROLINK
8. Hydraulic extension maximum loads according to the outreach
9. Maximum loads of jib manual extensions
10. Jib manual extension weight
12. Maximum loads that can be reached in the marked working areas

13
L E
I
I M
14
-S
A C
F
13. Capacity plate of hydraulic extension with JDP function
14. JDP function active only if 7th and 8th extension boom sections are reentered and blocked

Illustrative schematic for the capacity plate of a crane with winch
14 1
E
4
L
5
I
I M 6
-S
13
C
7
A
8
F
12 11 10 9
1. Crane model
3. Maximum lifting capacity of crane/manual extension with winch according to the hook
4. Winch maximum pull
7. Number of winch pulls (n=1 single, n=2 double, n=3 triple, n=4 quadruple, ...)
8. Maximum loads of crane with winch according to the outreach
9. Winch weight
10. Maximum loads of manual extensions with winch
11. Minimum distance between winch and first pulley
14. Maximum loads that can be reached in the marked working areas, in compliance with the
number of pulls specified on the plate

Illustrative schematic for the capacity plate of a crane with hydraulic extension and winch
1
14
2
3
4
E
5
L
6
I
I M
7
-S
C
8
FA 9
13 12 11
10
1. Hydraulic extension-crane combination

3. Maximum lifting capacity of crane with winch
4. Winch maximum pull
5. Number of winch pulls
8. Angle increase on hydraulic extension provided with PROLINK
9. Maximum loads of hydraulic extension with winch according to the outreach
10. Winch weight
11. Maximum loads of jib manual extensions with winch
12. Minimum distance between winch and first pulley
14. Maximum loads that can be reached in the marked working areas

Chapter 3 — Health and safety instructions
Chapter 3 – Health and safety instructions
3.1 – Personnel in charge

For the activation of this device the operator must:
• be authorised and previously trained about operation (refer to standard ISO 9926-1– Cranes –
Training of drivers – General);
• have knowledge of the content of the present manual;
• possess a certified professional training;
• have knowledge of the instructions of all the optional implements;
• be aware of the local standards and norms necessary to safely operate this device and its
implements;
• be physically and psychologically suitable;
• not be under the influence of alcohol or drugs;
• possess concentration skill and prove to be responsible and reliable;
• possess the requested qualifications as per the local laws;
• respect the minimum working age prescribed in the country of operation.
A high risk for the operator and persons in the vicinity occurs if the device is used by
an operator lacking of the proper qualifications, the necessary professional training,
the suitable psycho-physical condition and the knowledge of the present instructions.
The operator is the only person in charge of the lifting device and its implements, their
movements, the load movements and the whole working area of the crane.
Use of personal protective equipment
According to the hazardous situation, use the proper personal protective equipment during all the
operations with the device, such as:
• mounting,
• operation,
• cleaning and maintenance,
• repair,
• daily check.

3.2 – General instructions

This device is a working machine and must be used only by one operator. It has been built in
conformity with the safety norms and directives in force in the EU; anyway unforeseen hazards
could occur for persons, the device itself and other things.
It is prohibited for the operator to use the device if he is not able to guarantee his safety
and the safety of the other persons and things, as well as of the device itself.
Operate the device only for the tasks and in the service conditions that are allowed by the
present manual and the optional implement manuals.
It is forbidden to tamper with or remove safety and protection devices, plates, control
symbols, signals and warnings.
If capacity, warning, instruction or manoeuvre plates are lacking or not visible, please
contact a FASSI service centre for their replacement.
It is prohibited to move the vehicle with the crane not placed in one of the intended
transport configurations.
It is forbidden to move the vehicle with suspended load.
The operator must know exactly the weight he has to lift.
Some residual risks remain, as they cannot be completely foreseeable. They may endanger
the operator, the device and other persons and things, so it is necessary to be very careful
while unfolding and folding the crane, stabilizing and handling loads.
Some of the residual risks linked mainly to load lifting and handling are described in the
following paragraphs. Because of these risks, special attention is needed during operation.

3.3 – Crushing, trapping and shearing danger

The crane is provided with a lot of moving parts that cannot be covered. The operator must always
take into consideration this residual risk and avoid all the situations which may involve crushing,
trapping and shearing danger while stabilizing the vehicle, moving the crane and handling the load.
The operator is responsible for himself and all the persons who work near the crane or may come
close to it, even though not authorized.
It is compulsory to enclose the working area. No one shall stop or pass in the crane
working area. In this area it is forbidden to carry out other tasks.
It is prohibited to stop or pass under a suspended load.
In areas concerning:
• outriggers moving to transport position;

• top seat control station (if fitted) and inner boom movement;
• rest positioning points of the boom system moving to transport position
it is not possible to mount protections, so follow the adhesive plates for shearing, trapping
and crushing danger that are placed in the vicinity.

The minimum safety gaps related to parts of the human body are indicated in the following table.
The figures represent not dangerous situations if the minimum gaps are observed. In case of
crushing danger for different parts of the human body, consider the minimum gap requested for
the bigger part.
Minimum gaps to avoid crushing of parts of the human body (ref. EN 349)
Part of the Minimum gap Part of the Minimum gap

Figure Figure
body (mm) body (mm)
Body 500 Head 300
Leg 180 Foot 120
Foot fingers 50 Arm 120
Hand, wrist, fist 100 Hand finger 25
The non-observance of the minimum gaps may involve a grave risk or cause even serious
accidents.
Zones subjected to crushing, trapping and shearing danger
The image above represents the zones subjected to crushing, trapping and shearing
danger. It has only illustrative function and is not complete of all the possible crane
configurations.

3.4 – Electric shock danger

Keep the safety distance from high-voltage lines.
The minimum distance is seven (7) meters. For safe operation it is compulsory to follow
the current local regulations.
The non-observance of the minimum distance may produce an electric arc (even fatal) for
the operator and the persons in the vicinity.
It is absolutely prohibited to work under high-voltage lines. The crane is not insulated from
electric contacts and thus is not equipped for working under high-voltage lines, not even
for accidental contact.
It is absolutely prohibited to operate the crane during thunderstorms.
It is forbidden to operate the crane in case of wind gusts: the wires of electric lines could
swing and come into contact with the crane.
If the crane comes into contact with an electric line, follow this procedure:
• do not touch the crane, the vehicle or the load;

• prior to any movement, carefully consider the hazard. If you are closer than 10 meters from the
crane, the vehicle, the load or the electric line, move at least 10 meters away with small steps
in order to avoid an excessive electric potential difference between the feet;
• prevent anyone from coming close;
• call for help and ask somebody to de-energize the line;
• do not try to move an unfortunate before the power has been disengaged;
• if you are in the cab, stay inside without touching the bodywork: it is more dangerous if you go
out before the line is de-energized;
• help the electrocuted person if you know the first-aid procedures, otherwise wait for the
paramedics to arrive.

3.5 – Burn danger

During crane operation, oil and all the hydraulic system components reach high temperatures.
Do not touch hoses, pipes, quick coupling connectors and hydraulic system components while the
crane is working.
Where it is not possible to mount protections, follow the adhesive plates of burn danger
placed near the dangerous zones.
In order to avoid burns, the gas exhaust system must be covered or kept at a safe distance.
3.6 – Fall danger
It is forbidden to climb on the device.
It is forbidden to stand on the device (in case of top seat control station) while the vehicle
is moving.
To access the top seat control station (if fitted), always use the dedicated ladder. Pay attention in
order to avoid hitting the controls while ascending and descending. The ladder must be fitted and
correctly mounted by the installer, as per the current regulations.
There is higher risk of falls and accidents for the operator and persons in the vicinity in
case of snow, ice and dirt on controls, plates, support surfaces, steps and rises.

3.7 – Noise emission danger
Permanent low or short high noise emission levels damage the health of operators and
other persons in the working area.
In hazardous situations, it is compulsory to use the personal protective equipment

against noise.
While assessing the mounting, it is recommended to consider the minimum engine speed.
If you use the radio remote control, it is recommended to work over 1 m far from the
vehicle engine.
3.8 – Exhaust gas emission danger

Before starting the vehicle engine in an indoor space, ensure there is a proper ventilation.
Eject exhaust gases from the control station by using proper piping in diameter and length.
3.9 – Danger due to unfavourable service conditions

It is forbidden to operate the crane:
• during thunderstorms or at wind speed higher than 13,8 m/s (50 km/h - maximum value of
degree 6 of Beaufort scale; refer to paragraph 2.2 “Technical data”);
• at environmental temperatures below -30°C and over +50°C.
Too high or low temperatures may damage hydraulic and electric system components and
compromise the crane working.
If you use the crane in ice or snow condition, start the hydraulic system at the minimum engine
speed and let the oil circulate for some minutes, till its warming.
A wind gust may make an electric line swing and come into contact with the crane,
involving an electric shock danger.
A wind gust may cause loss of stability with consequent vehicle overturning and it may
seriously damage operator, persons in the vicinity and crane.
A risk of electric shock due to lightnings occurs in case of thunderstorms: in this situation
it is forbidden to operate the crane and it is compulsory to fold it into rest condition.

3.10 – Danger related to the control station

Before operating from the control station, carefully check there are no dangers (pay
attention to vicinity to the load, position of escapes, etc.).
The control station must be properly enlightened, in order to guarantee the safe working of the crane.
Load and working area must be clearly and fully visible to the operator. If this is not
possible, the operator must receive instructions (checking the communication efficacy) by
another operator who has the full view of the working area.
The operator must instruct his coworker so as to avoid mutual damage during manoeuvres.
movements, the load movements and the whole working area of the crane. Check the
coworker’s working conditions comply with the essential health, safety and welfare
requirements.
Controls, control stations, support surfaces, rises and steps to access the top seat control station (if
fitted) must be clear of snow, ice, dirt (oil, grease, etc.) and any object.
During indoor operation, exhaust gases of the vehicle engine must be correctly ejected.
3.11 – Danger related to working area

Carefully check the working area and assess the possible risks for operator, persons in
the vicinity and crane. In particular, pay attention to ground characteristics (see chapter
2 “General specifications”), clearance from scarps (see chapter 6 “Setting up for crane
operation”), vicinity of operator to the load, possible impacts against building walls,
balconies, gutters, scaffoldings, tree branches, other lifting devices or machines, electric
lines or anything that could interfere with the manoeuvres.
Operate the crane with adequate lighting to perform crane work safely (see EN 12464-1 and EN
12464-2 - Light And Lighting - Lighting Of Work Places).
Load and working area must be clearly and fully visible to the operator.
Take proper measures to avoid the risk that various elements fall on operator, crane or control
system.

3.12 – Danger related to wrong operation

The crane may get damaged and/or overturn if the operator carries out a wrong operation
due to lack of knowledge of the intended operating procedures and/or unsuitable
psychophysical conditions.
The current regulations prescribe a proper personnel training prior to safely operating similar
machines.
movements, the load movements and the whole working area of the crane.
It is forbidden to operate the crane in a psychophysical condition that is unsuitable for the
use of a lifting device.
3.13 – Overturn danger

The crane may overturn, involving a very high risk of damage and accidents for operator
and persons in the vicinity, especially under the following conditions:
• if it is not correctly stabilized;

• if you reenter or extend the outrigger supports without the crane being placed in
rest condition;
• if you deactivate or tamper with safety devices;
• if you stabilize on a ground that is not sufficiently resistant according to the dimensions
of the outrigger plate (see chapter 6 “Setting up for crane operation”);
• if you increase the design speeds and/or the rated flow of the pump;
• if you exceed the allowed limits of outreach and/or load that are represented on the
capacity plates;
• if you don’t respect the service conditions indicated in the current manual.
3.14 – Danger due to overload and fatigue of the crane

The crane can get damaged because of fatigue or overload, with very high risk of damage and
accidents for operator and persons in the vicinity, especially under the following conditions:
• if it is used differently from what is indicated in the present manual (for instance: exceeding the
maximum number of cycles pertinent to the crane class, or increasing the design speed and/
or the rated flow of the pump);
• if it is used for improper tasks (for instance: for side, oblique or reversal pull, for wood or scrap
iron);
• if it is operated in unsuitable service conditions (for instance: corrosive environment, too high
or too low temperature);
• if the intended capacity plates aren’t respected.
Use the crane only for the intended tasks and in the service conditions described in the
present instructions. Follow all the information indicated on the capacity plates.
In order to perform an ordinary and extra maintenance on the crane that guarantees its
functionality and safety, conform to the indications of chapter 10 “Maintenance” of this
manual.

3.15 – Danger due to overload of manual extensions

Manual extensions are controlled by the lifting moment limiting device only under the conditions
described in chapter 9 “Use of implements”.
The electronic check system for load hooked on manual extensions is not always active
(unlike the lifting moment limiting device of the crane), but it has to be activated by the
operator just to check if the load can be handled safely.
The presence of the lifting moment limiting device does not exempt the operator from
respecting the lifting diagrams represented on the capacity plates.
capacity plates.
serious) for operator and persons in the vicinity, vehicle overturning and breaking of crane
components.
Carefully read chapter 9 “Use of implements” prior to working with manual extensions.
3.16 – Danger related to lifting moment limiting device and safety

devices
For lifting moment limiting device and safety devices operation refer to chapter 4 “Safety devices
and special functions”.
The presence of the lifting moment limiting device does not exempt the operator from
respecting the lifting diagrams represented on the capacity plates.
It is forbidden to bypass, uninstall or tamper with the lifting moment limiting device and
all the safety systems fitted on the crane.
While operating the crane, pay attention to the alarms generated by the lifting moment limiting
device as well as the other safety devices and take the proper measures.
Perform a daily operational check of lifting moment limiting device and safety devices: replace the
damaged or broken components in order to work safely and obtain the maximum crane performances.
FASSI declines any responsibility if not allowed interventions are carried out on the lifting moment
limiting device or the safety systems.
3.17 – Danger related to use of implements
Pay special attention to assembly and disassembly of implements (extensions, buckets, baskets,
etc.): before these operations, check their weight, fixing systems and relevant assembly/disassembly
instructions. Evaluate the centre of gravity of implements and use the proper temporary fixing
systems to avoid unexpected movements.
Prior to working with implements, carefully read their use and maintenance instructions.

Loads indicated on the capacity plates refer to crane without implements: so, prior to
every lifting operation, it is necessary to deduct the weight of the optional implements
mounted on the crane (e.g. manual extensions) from the load values represented on the
plates.
Correctly insert the fixing devices during operation and transport.
Sling implements in order to avoid unexpected movements during their transport on the vehicle.
3.18 – Danger resulting from wrong securing of loads

Pay special attention to slinging loads during both handling and loading/unloading operations.
Make sure the load is well secured and balanced and unexpected movements are prevented.
During load movements, pay attention in order to avoid impacts against possible obstacles.
3.19 – Danger related to crane transport

After folding the crane and reentering the outriggers, correctly fix all the crane parts in
order to avoid the exit of extension boom sections and outriggers during transport. Check
also that the crane is correctly placed in the rest locating pins in order to avoid outer boom
fall and crane rotation.
In case of fittings where the crane lays in transport position inside the vehicle body or on
the load, it is compulsory to properly block possible movements of the boom system and
crane rotation.
High risk of accidents (even serious) occurs if crane and implements aren’t secured against
lateral movements and rotation.

Implements can be kept mounted on the extension boom sections of the crane (or of
the hydraulic extension) only if maximum allowed overall dimensions are observed and
implements are properly secured against possible uncontrolled movements.
Properly fix and balance the load, in order to avoid its fall from the vehicle during transport.
Take note of the vehicle (included load and implements) maximum dimensions. Observe
the maximum overall dimension in folded position for the transit under tunnels, bridges,
underpasses, power lines.
Observe the maximum allowed loads on the vehicle axles.
3.20 – Danger due to lacking or wrong maintenance

Maintenance is particularly important. If it is not carried out or it is performed in a wrong way, it may
involve serious damages to things or persons.
In chapter 10 “Maintenance” you find all the necessary operations to maintain your crane efficient
and avoid damages to things and persons due to crane bad working because of lacking or wrong
maintenance.
When you connect/disconnect any hydraulic pipe or hose, take proper preventative
measures to make sure there is no pressure in the system (even if the feeding is deactivated).
FASSI declines any responsibility for ruptures or damages to product, persons or things
due to a lack of maintenance.
3.21 – Danger due to special working conditions

If you need to work in special conditions which are not included in this manual, contact FASSI After
Sales department.

3.22 – Plate of instructions for safe use of the crane - Legend

The following plates, in vertical and horizontal version, are placed near the controls and have to be
strictly followed, in order to avoid possible accidents while operating the crane.
1. Only authorized persons are permitted to operate the crane.
2. The crane must be used on firm, level ground.
3. Check that the vehicle hand brake is on and that the wheels are chocked.
4. Before 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.
5. Stabilize the vehicle with the outriggers, making sure that:

• the lateral supports are fully extended;
• the wheels are in contact with the ground and the suspension is not completely unloaded;
• the outriggers safety taps, if present, are closed.
6. 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.
7. When using implements protect the working area with a barrier.
8. The vehicle/crane are not left unless the power take off is disengaged and the load is on the
ground.
9. Before driving the vehicle ensure that the outriggers are fully retracted and reentered, the safety
taps closed and the crane is in the folded position.

Carefully read the use and maintenance manual of crane and

implements prior to start up, operation, maintenance or any other
intervention on crane or implements.
It is obligatory to use the necessary personal protective equipment.
Make sure that loads and outreaches are within the maximum
limits shown on the capacity plate.
The crane must be completely stabilized in order to lift and handle

the loads indicated on the plate.
Pay maximum attention while stabilizing the vehicle; make sure

nobody stops or passes in proximity of the outrigger ram working
area.
Hand shearing danger because of moving parts (see paragraph

“Crushing, trapping and shearing danger”).
It is prohibited to operate from the side where the crane opens/

folds because of the overall dimensions of booms.
Keep the safety distance from electric lines. The minimum distance
is seven (7) meters, except for otherwise prescribed current local
regulations.
Prohibition of washing using high-pressure and direct water jets.

Chapter 4 — Safety devices and special functions
Chapter 4 – Safety devices and special functions
4.1 – Index of paragraphs as per crane equipment

Safety devices as per crane equipment
He-dynamic Xhe-dynamic
STOP button (paragraph 4.2.1)
FX900 electronic lifting moment

limiting device (paragraph 4.2.2)
Visual indicator (paragraph 4.2.3)
Rated capacity acoustic indicator

(paragraph 4.2.4)
Acoustic warning (paragraph 4.2.5)
Angle control device for PROLINK

(paragraph 4.2.6)
Lifting moment limiting device for 2 1 1
working zones (paragraph 4.2.7)
FSC (Fassi Stability Control) 2 2
(paragraph 4.2.8)
Inner boom horizontal position 3 3
indicator (paragraph 4.2.9)
CPM Crane Position Monitoring 4 4
(paragraph 4.2.10)
= compulsory for EC market

= standard
1 = for crane with FSC/S

2 = for crane with outriggers
3 = without FSC (compulsory for cranes in fixed and marine versions, if the installation is carried
out on boats used for inland waters or for inshore use)
4 = with FSC

Special functions as per crane equipment
He-dynamic Xhe-dynamic
XP (Extra Power) 1
(paragraph 4.3.1)
PROLINK (Progressive Link)
(paragraph 4.3.2)
Exclusion tap for 7th/8th
extension boom sections 1 1
(paragraph 4.3.3)
JDP (Jib Dual Power) 2 2
(paragraph 4.3.4)
JVC (Jib Vertical Control) 2 2
(par. 4.3.5)
FL (Full Lift)
(paragraph 4.3.6)
Oil cooler (heat exchanger)
(paragraph 4.3.7)
= standard
1 = standard according to the crane model

2 = standard according to the hydraulic extension-crane combination

4.2 – Safety devices

4.2.1 - STOP button
Crane control stations are provided with a STOP button that enables the immediate stop of all
crane movements.
In case of emergency, immediately release all the control levers and push the STOP button: in this
way, all the crane and supplementary functions are blocked.
If you push the STOP button and the crane doesn’t stop or other functions are still
active, high risk of accidents (even serious) occurs for the operator and other persons:
do not operate the crane and immediately contact an authorised FASSI service centre.
In conformity with standard EN 12999, it is not compulsory to fit the STOP button
on the control stations that are solely used for outrigger operation. In this case, by
operating the STOP button only crane and implements are affected, while outrigger
manoeuvres remain active: therefore it is necessary to pay special attention and make
sure nobody stops or passes in proximity of the outrigger ram working area.
Unblock the STOP button only if the crane can operate safely; high risk of even serious
accidents occurs if you unblock the STOP button before ensuring a safe crane operation.

4.2.2 - FX900 electronic lifting moment limiting device
Generality
The “crane lifting moment” is defined by the rated capacity (N) multiplied by the
outreach (m).
The FX900 electronic lifting moment limiting device si composed of an electronic system that
informs the operator about the loading conditions of the crane. It also blocks any operation
increasing the lifting ram pressure induced by load (in the crane inner and outer rams, and, if
fitted, in the hydraulic extension ram), over critical values that cannot be exceeded and that
determine the activation levels.
The presence of the lifting moment limiting device does not exempt the operator
from respecting the lifting diagrams represented on the capacity plates.
During load handling with crane or hydraulic extension in vertical configuration or

close to it, the operator must strictly refer to the loads indicated on the capacity
plates, since the limiting device could appear to be not particularly sensitive with
operations induced by vertical lifts.
Working logic
During crane operation, when you reach the value for the limiting device activation, the system
blocks any not-allowed control of crane and hydraulic extension (if fitted), according to the
working logic described in the following paragraphs; for winch, refer to the corresponding
paragraph in chapter 9 “Use of implements”.
The ADC system (Automatic Dynamic Control) - active only operating from radio
remote control - manages dynamics by limiting the stroke of the distributor control
levers, according to the pressure of lifting rams, while they are in operation. So, the
load handling speed decreases while approaching the activation level of the lifting
moment limiting device.
By using manual controls (ADC system not active), the pump flow is automatically
reduced, in order to prevent excessive dynamic stresses.
The ADC system is not active on controls for winch or implements other than
hydraulic extensions.
The ADC system manages an automatic variation in the crane movement speed,
even holding the radio remote control levers in the same position.

Block due to overload
According to the crane configuration, the safety device allows ( ) and forbids ( ) the following manoeuvres:
Inner Outer Exit of crane Reentry of Exit of jib Reentry of Hydraulic
Inner Outer Jib Winch
boom boom extension crane exten- Jib lift extension jib exten- Winch lift implement
boom lift boom lift descent descent
descent descent booms sion booms booms sion booms operation
1
Configuration A
1
Configuration B
1
Configuration C
UM002_Amendment 00 - Edition 07/07/2014

2 2 1
Configuration D
1
Configuration E
1
Configuration F
2 2 1
Configuration G
1
Configuration H
1
Configuration I
Note: configurations are represented on the following page
1 = forbidden manoeuvre, unless only the hydraulic extension is blocked

2 = forbidden manoeuvre, if the hydraulic extension is blocked
43
44
Allowed manoeuvres, according to the crane configuration:
Configuration A Configuration B Configuration C

Configuration D Configuration E Configuration F
Configuration G Configuration H Configuration I
In case of resettable alarm on sensors TI1 and TI2 (tilting sensors on outer and hydraulic extension boom), manoeuvres
are blocked, both above and under the horizontal line.
UM002_Amendment 00 - Edition 07/07/2014

Lifting block (Angle control device for PROLINK)
Refer to paragraph “Angle control device for PROLINK”.
Rotation block
According to the crane fitting, refer to paragraph “Lifting moment limiting device for two
working zones” or the one concerning FSC/S.
Crane block by the attainment of the mechanical stroke end of the lifting ram.
During load-less crane operations, the activation of the electronic lifting moment limiting
device may occur (blocking the crane) because of a pressure peak, due to the attainment at
high speed of the stroke end of the lifting ram.
In normal conditions, the crane can be reactivated by operating a manoeuvre which is allowed
by the system.
If the crane stops with extension boom sections completely in and inner and/or outer ram
extended at its stroke end, all crane movements are prevented.
In this configuration, the system still allows to operate descents, but immediately checks if
these manoeuvres cause a further increase of the lifting ram pressure induced by load; in this
case, the crane is definitively blocked.
Crane folded in transport position
If the crane is folded in transport position, all its movements are blocked, except for the outer
boom folding.
Therefore, when you turn on the crane, it is in block condition; on the main unit the message
CRANE FOLDED is displayed.
In order to solve this block condition and enable the crane unfolding, it is necessary to fold
the outer boom (as described in chapter 6 “Setting up for crane operation”): if the pressure
in the outer ram remains in a determined range for at least 2 seconds, the crane is effectively
considered at rest, the message CRANE FOLDED disappears and all the crane manoeuvres
are allowed.

Temporary exclusion of the lifting moment limiting device
In this condition:
• pressure induced by load close to the activation level of the lifting moment limiting device;
• extension boom sections completely reentered
while you lower the load with boom over the horizontal line, the effect due to the consequent
dynamic increase of pressure may activate the lifting moment limiting device. In this way, the
descent is blocked and it is impossible to place the load to the ground.
For this reason, a special function for the temporary exclusion of the lifting moment limiting
device is provided to complete the load lowering operation (as foreseen in the standard EN
12999).
In particular, with crane in block condition, it is necessary to maintain the reentry of its extension
boom sections until stroke end (operating from radio remote control: maintain the manoeuvre
till the message LMI and the icon flag appear on the display).
Then release the control lever for the extension boom section reentry and select the icon LMI
for the temporary exclusion of the lifting moment limiting device (operating from radio remote
control: if the procedure is correctly performed, the message ELMI and the icon flag
appear on the display).
Once the temporary exclusion of the lifting moment limiting device is activated, the operator
has 5 seconds at his disposal to complete the outer boom descent (operating from radio
remote control: as soon as the crane is out of the block condition, or once 5 seconds have
passed, the message ELMI and the icon flag disappear).
After the temporary exclusion of the lifting moment limiting device has been carried out, it is
necessary to wait at least one minute before repeating it.
The temporary exclusion of the lifting moment limiting device and the related
manoeuvres may undergo an overload condition and involve hazards of accidents
(even serious) for the operator and other persons, as well as damage to the crane.
In these conditions (with lifting moment limiting device deactivated), the operator,
who is the main responsible for the machine safety, must:
• carefully consider the operations he wants to carry out, in order to exit from
the emergency situation (in any case, with extension boom sections out, first
it is compulsory to operate their reentry);
• calmly and carefully assess the type and scale of the hazards arising from
these manoeuvres and the possible reaction of the crane (overturning, frame
overload, uncontrolled load descent due to hydraulic system overload, etc.);
• perform all movements as slowly as possible, to minimize the dynamic overload.

Icon list
Icons displayed on radio remote control
Engine start-up
Engine turning off
Increase of engine r.p.m.
Decrease of engine r.p.m.
Selection of outrigger/crane
Access to the user menu and confirmation (ENTER) in menus and
selections
Activation of the temporary exclusion of the LMLD (when possible) or
crane reactivation (in case of WARNING; in case of ALARM only after
the failure has been solved)
Activation/Deactivation of recycling valve
Activation/Deactivation of work lights
Activation/Deactivation of JDP function
Manual extension menu
Access to the timer menu or timer scrolling
Deactivation of electrovalve EV1
Icon flag scroll
Activation of DV output
Activation of supplementary output 1
...

Selection of the unit of measurement (bar, daPSI) or the percentage
(%) of the lifting capacity
Value increase or scrolling onwards in the menus
Value decrease or scrolling backwards in the menus
Activation/Deactivation of XP device or ICC function
Selection of the decreasing level of the general speed
Activation/Deactivation of the function switch
Grab Automatic Shake
Radio remote control test (RCS radio remote control)
Pixel test for the display (RCH radio remote control)

Activation/Deactivation of the
display backlight mode (RCS radio remote control)
Adjustment of display contrast
Activation of the display backlight
(RCH radio remote control)
mode
Icons displayed on touchscreen control panel
Engine start-up
Engine turning off
Access to the user menu

Activation/Deactivation of JDP function
Access to the timer menu
Icon flag scroll
...
Selection of radio remote or manual control

Icons displayed on control panel (cranes with top seat)
Engine start-up
Engine turning off
Activation/Deactivation of XP device
Selection of the decreasing level of the general speed
Activation/Deactivation of the function switch
Access to the timer menu or timer scrolling
Icon flag scroll
Grab Automatic Shake
...
Display test
Selection of radio remote or manual control
Activation/Deactivation of the display backlight mode

Icon flag list
Icon flags
The temporary exclusion of the LMLD can be activated: select the
icon/button LMI
Temporary exclusion of the LMLD activated
The oil cooler (heat exchanger) is working
Function switch activated
Manoeuvres activated with EV1 forced open or recycling valve activated
Maximum slope reached (with FSC/S stability control system)
Manual control mode activated
Radio remote control mode activated

Outrigger rams not in contact with the ground - L0 level (with FSC
stability control system)
Work platform detection (WP)
XP activated

Touchscreen control panel (if fitted)
The following screen has only illustrative function.
2 1
13
4 12
11
5
10
7 8 9
1. Graphic bar signalling the loading condition

2. Display of date and time
3. Display of working timers
4. Display of FSC levels
5. Display of activated functions
6. Icon bar
7. “<<<” button: movement to the left during icon selection
8. “>>>” button: movement to the right during icon selection
9. Icon Flag
10. Display of operating messages (WARNING, ALARM, etc.)
11. Oil temperature
12. Work lights activated
13. Display of crane configuration with pressure values, capacity percentages and angles
As there are no physical buttons, to select the item or icon it is sufficient to touch
them directly on the display.

Control panel for crane with top seat (if fitted)
2 1
3 10
4 9
5 6 7 8
1. 5-LED-band signalling the loading condition (green LED: capacity under 90%; orange
LED: capacity between 90% and 99%; red LED: 100% of the crane/hydraulic extension/
winch capacity in the working configuration)
2. Graphic display
3. “-” button: movement to the left during icon selection, value decrease or scrolling
backwards in the menus
4. “%/INDEX” button: used to select the unit of measurement (bar, daPSI) or the percentage
(%) of the lifting capacity, to display FSC levels, to go back to the previous menu from
the submenus (prolonged pressure), to move the cursor when entering a value in the
menu
5. Button for acoustic warning activation
6. Button for the selection of data and operating pages
7. Button to return to the main screen
8. STOP button (refer to paragraph 4.2.1)
9. “OK/ENTER” button: icon selection, access to the user menu or confirmation in menus
or selections
10. “+” button: movement to the right during icon selection, value increase or scrolling
backwards in the menus

Main screen (control panel on top seat)
1
2 12
3 17:27 27/05/2009
4 10 -96° -211° 26 11
9 6 11 28
6 8
5 7 9 10
1. Graphic bar signalling the loading condition

2. Icon bar
3. Display of working timers, date and time, or operating messages (WARNING, ALARM,
etc.)
4. Working pressure in the distributor bank
5. Pressure level or capacity percentage on inner boom
6. Crane angle
7. Pressure level or capacity percentage on outer boom
8. Hydraulic extension angle
9. Pressure level or capacity percentage on hydraulic extension
10. Capacity percentage on winch
11. Oil temperature
12. Icon flag

Crane operation display (control panel on top seat)
3 2 1 10
16
5 6 7 8 9
1. Hydraulic extension movement

2. Movement of crane extension boom sections
3. Alarm signal
4. Inner boom movement
5. Rotation
6. Outer boom movement
7. Capacity percentage
8. Hydraulic extension position (above or under the horizontal line)
9. Winch movement
10. Outer boom position (above or under the horizontal line)
You can enter this screen through prolonged pressure of the button .
The arrows indicating movement are highlighted on the display when the corresponding
operation is being carried out.
In case of overload or block in general, the forbidden manoeuvre is highlighted and flashing.
The display shows the highest capacity percentage between inner boom, outer boom,
hydraulic extension and winch; in case of block, it is highlighted and flashing.
If an alarm is detected, the danger sign appears in the upper left space of the display.

Scroll of displays (control panel on top seat)
By pressing the button , it is possible to scroll the displays, as indicated in the following
figures.
1. Capacity percentage on inner

17:27 27/05/2009 boom
16 9 2. Capacity percentage on outer
boom
3. Outer boom angle
1 2
4. Capacity percentage on
hydraulic extension
5. Hydraulic extension angle
6. Capacity percentage on winch
17:27 27/05/2009 7. Oil temperature
-25
3
17:27 27/05/2009
26
4
17:27 27/05/2009
-31
5
17:27 27/05/2009
2
6
17:27 27/05/2009
18
7

Timer menu
By selecting the icon (from radio remote control or panel on top seat: hold the confirmation
button pressed), it is possible to enter the timer menu and display:
Total and Partial - total / partial time the crane has been on (hours/minutes);
Work - crane working time from the lever operation (hours/minutes).
In addition to total, partial and work time, on the touchscreen panel display you can see also
the time related to each function.
UTILIZATION TIME
Total 9:14
Partial 1:38
Work 0:08
Reset Partial
Radio remote control or panel on top seat Touchscreen panel
To reset the partial time:
1. select Reset Partial;
2. when the confirmation message Enter to Confirm appears, press the message (from
touchscreen panel), the “OK/ENTER” button (from panel on top seat) or select the icon
(from radio remote control);
3. The message DONE! appears and signals the timer is reset.
Working timers, time and date can be displayed also on the main screen of the touchscreen
control panel.
To scroll timers on radio remote control or control panel on top seat, select the icon and
press (through simple pressure) the confirmation button.
17:27 27/05/2009 00009:14

1 -96° -211° 26 1 -96° -211° 26
9 6 11 28 9 6 11 28
Time and date Total activation time of the crane
LAVORO 00000:08 PARZ. 00001:38

1 -96° -211° 26 1 -96° -211° 26
9 6 11 28 9 6 11 28
Working time of the crane Partial activation time of the crane

User menu
To enter the user menu, select the icon (from touchscreen panel or radio remote control)
or hold “OK/ENTER” button pressed (from panel on top seat).
In the “Checking” menu you can find the submenus related to the different electronic units
installed in the circuit.
In the “Setting Menu” it is possible to open the submenus for the setting and/or modification
of program parameters, only after entering the access passwords (operation reserved to the
authorised FASSI service centre).
In the “Language” menu you can select the language to be used in the menu navigation.
In the “Press. Unit” menu you can choose the unit of measurement for pressure (bar or daPSI).
In the “Temp. Unit” menu you can choose the unit of measurement for temperature (°C or °F).
In the “Contrast” menu (if fitted) you can adjust the display brightness.
GAS (Grab Automatic Shake)
It is possible to use the Grab Automatic Shake function (only if the installer has activated it
and if you operate by radio remote control), by selecting the icon and at the same time
operating the lever for the grab opening.
This function involves quick adjustable movements, in order to gradually release the grab
content.
To stop movements, release the radio remote control lever or deselect the icon .

Procedure to pass from radio remote to manual control mode (and vice versa)
If you turn on the crane in radio mode and the radio remote control is turned off, the STOP
sign appears on the control panel display and crane operations are blocked.
If you press and hold the STOP sign (from touchscreen control panel) or the “OK/ENTER”
button (from panel on top seat), the STOP sign disappears and the word STOP appears on the
operating message line.
By turning on the radio remote control, the word STOP disappears and radio remote control
mode is enabled.
In order to pass from radio remote to manual control mode (crane operation through the
distributor levers), turn off the radio remote control handle and select the icon from the
control panel.
Instead, in order to pass from manual (crane operation through the distributor levers) to
radio remote control mode, turn on the radio remote control handle (the word STOP appears
on the operating message line) and select the icon from the control panel.
Once the icon is selected, choose (within 10 seconds) the radio or manual control mode:
from the touchscreen panel press the image related to the control mode; from the control
panel on top seat use the buttons “+” and “-”, then confirm by pressing the“OK/ENTER”
button.
According to the control mode you have selected, one of the following screens appears: you
must confirm it by pressing (within 10 seconds) the image (from touchscreen panel) or the
“OK/ENTER” button (from panel on top seat).
Radio remote control mode Manual control mode

If confirmations don’t occur within 10 seconds, procedures are cancelled.
If the control panel is not fitted, you can enable the manual control mode by using
the manual/radio switch placed on the carter covering the distributor on the column
(see paragraph 11.2 “Crane control by radio - Distributor on the column”).
Warnings and alarms
The diagnostic of FASSI electronic system detects and signals to the operator possible failure
conditions through numeric codes (which are shown on the radio or the control panel display)
and determines also the immediate block of the machine.
Failures are divided into two groups:
WARNING (W): warning, that can be reset

ALARM (A): alarm, that cannot be reset
In case of resettable warning, if you select the icon , the electronic system reactivates the
crane operation, as the failure condition doesn’t affect the machine safety (as a matter of fact,
by selecting the icon , the operator is aware of the failure on the crane and shall contact
as soon as possible an authorised FASSI service centre).
In addition to the numeric code on the display, the WARNING condition is also signalled by the
flashing red LED (if fitted) on radio remote control and control panel on top seat, that remains
flashing even after the selection of the icon .
In case of crane block due to overload, the resettable WARNING becomes non-resettable and
the message ALARM appears.
In case of non-resettable ALARM, the crane operation can be reactivated (by selecting the icon
), only if the failure has been solved, as the present condition affects the machine safety.
In addition to the numeric code on the display, the ALARM condition is also signalled by the
permanent red LED.
On the control panel on top seat, the red LED is the last of the 5-LED-band signalling
the loading condition, while on the radio remote control handle, the red LED (if
fitted) is the one signalling 100% of the capacity.
Any operation on the crane must be carried out in compliance with health and safety
requirements and by taking proper technical and organisational measures.
In case of emergency, refer to chapter 11 “Failure conditions” for the necessary

instructions to complete crane operations, before you go to an authorised FASSI
service centre.

FX900
Code Description Type Possible solutions
Corrupt data in EEPROM memory Turn off the power and turn on the
01 A
(parameters). crane again.
Pressure transducer value on inner ram out of
02 A
range.
Check the transducer connector is
Pressure transducer value on outer ram out of
04 A correctly inserted.
range.
06 Pressure transducer value on jib out of range. A
Angular sensor value on outer boom out of Check the angular sensor connector
11 A
range. is correctly inserted.
Check the load cell connector is
12 Value of the winch load cell out of range. A
correctly inserted.
Check the angular sensor connector
25 Angular sensor value on jib out of range. A
is correctly inserted.
Feeding tension value of the vehicle battery Recharge or replace the vehicle
26 A
below the minimum required. battery.
Inconsistency between the radio lever control
30 and the reading of the micro switch on the A
rotation distributor segment.
inner boom distributor segment.
outer boom distributor segment. Wait for some minutes, so that
Inconsistency between the radio lever control hydraulic oil can reach its working
and the reading of the micro switch on the temperature.
33 A
distributor segment for the crane extension
boom sections. Check that nobody in proximity
Inconsistency between the radio lever control has activated manual levers during
34 and the reading of the micro switch on the jib A operation with radio remote control.
boom distributor segment.
and the reading of the micro switch on the
35 A
distributor segment for the jib extension boom
sections.
winch distributor segment.
Failure of slave unit FX504A. During crane Check that the unit connectors are
working, the damage on the slave unit FX504A correctly inserted.
41 W/A
is indicated as WARNING. If you use radio Turn off the power and turn on the
options, the failure is indicated as ALARM. crane again.

FX900
Failure of slave unit FX504B. During crane
working, the damage on the slave unit
43 FX504B is indicated as WARNING. If you pass W/A
to outrigger operation, the failure is indicated
Check that the unit connectors are
as ALARM.
correctly inserted.
Failure of slave unit FX504C. During crane
Turn off the power and turn on the
working, the damage on the slave unit
crane again.
44 FX504C is indicated as WARNING. If you pass W/A
to outrigger operation, the failure is indicated
as ALARM.
45 Failure of slave unit FX450 (column) A
WDO relay on FX500/FX450 (base) controlled
60 A
closed with tension in but not out.
WDO relay on FX500/FX450 (base) controlled
61 A
open with tension in and out.
Output feeding tension under WDO on FX500/
crane again.
62 FX450 (base) detected also if there is a lack of A
main feeding tension of the WDO circuit.
Lack of the main feeding tension of the WDO
63 A
circuit on FX500/FX450 (base).
Timeout of Can messages reception from Contact an authorised FASSI service
70 A/W
digital tilting sensor. centre.
Timeout of Can message reception from If you deactivate the WARNING by
71 W
encoder of the outrigger 1. selecting the icon LMI, the system
Timeout of Can message reception from considers the outrigger supports as
72 W
encoder of the outrigger 2. completely reentered and activates
Timeout of Can message reception from the lower activation level of the
73 W
encoder of the outrigger 3. limiting device.
Timeout of Can message reception from Contact an authorised FASSI service
74 W
encoder of the outrigger 4. centre
Check the transducer connector is
90 Value of pressure transducer TP0 out of range. W
correctly inserted.
Check the sensor connector is
91 Value of temperature sensor TT out of range. W
correctly inserted.
Warning of stability danger: crane not in Place the crane into transport
99 transport position or not along the vehicle W position or along the vehicle body
body. and stabilize again.
200 Inner alarm of the FX504A optional unit. A
crane again.
WDO relay on FX504A controlled closed with
217 A
tension in but not out.
WDO relay on FX504A controlled open with
218 A
tension in and out.
Output feeding tension under WDO on FX504A
crane again.
219 detected also if there is a lack of main feeding A
tension of the WDO circuit.
220 A
circuit on FX504A.
230 Inner alarm of the FX504B optional unit. A
crane again.

FX900
WDO relay on FX504B controlled closed with
247 A
WDO relay on FX504B controlled open with
248 A
tension in and out.
Output feeding tension under WDO on FX504B
crane again.
249 detected also if there is a lack of main feeding A
tension of the WDO circuit.
250 A
circuit on FX504B.
260 Inner alarm of the FX504C optional unit. A
crane again.
WDO relay on FX504C controlled closed with
277 A
WDO relay on FX504C controlled open with
278 A
tension in and out.
Output feeding tension under WDO on
crane again.
279 FX504C detected also if there is a lack of main A
feeding tension of the WDO circuit.
280 A
circuit on FX504C.
WDO relay on FX450 (column) controlled
310 A
closed with tension in but not out.
WDO relay on FX450 (column) controlled open
311 A
with tension in and out.
Output feeding tension under WDO on FX450
crane again.
312 (column) detected also if there is a lack of A
main feeding tension of the WDO circuit.
313 A
circuit on FX450 (column).
Feeding tension value of the vehicle battery Recharge or replace the vehicle
316 A
below the minimum required. battery.
320 Failure of rotation encoder A
crane again.

Messages
DANGER!
It signals pressure detection in the transducer TP0 with electrovalve EV1 de-energized.
If the message remains, contact an authorised FASSI service centre.
It is forbidden to operate crane and implements if the limiting device is faulty or

tampered with.
WINCH OFF!
It signals the winch block caused by the rope being completely unwound.
Release the winch control lever.
WINCH CAL. ERROR

It signals (through a 1-minute-flashing every 10 minutes) the exceeding of the maximum
setting limit of the winch load cell.
Contact an authorised FASSI service centre.
STOP BOOM OUT

The exit of extension boom sections is not allowed because of the activation of the winch
mechanical stroke end.
Release the control lever for the exit of extension boom sections and then operate it to
partially reenter the extension boom sections.
STOP BOOM IN
The reentry of extension boom sections is not allowed because of the activation of JVC function.
Completely reenter the jib extension boom sections or lower the jib or outer boom until you
exit from the block condition.
STOP ROTATION
It signals the rotation block.
Operate rotation in the direction opposite to the one that caused the block.
STOP
It signals the STOP button has been pressed.
JIB OFF!
It appears if you operate the hydraulic extension control lever and its pressure transducer
and angular sensor are not connected.
Release the control levers and connect the pressure transducer and the angular sensor of
the hydraulic extension.
WARNING ANGLE!
It appears when you reach the vertical warning value of a crane or hydraulic extension
provided with PROLINK function.
Release the control levers.
MAX ANGLE CRANE!

It appears when you reach the maximum vertical value of a crane provided with PROLINK
function.

MAX ANGLE JIB!

It appears when you reach the maximum vertical value of a hydraulic extension provided
with PROLINK function.
CRANE FOLDED
It signals the crane folded in transport position. The only allowed operation is the outer
boom folding, until the message disappears.
NOT ALLOWED
It appears when XP is activated and you operate different levers at the same time.
Release the levers and then operate one lever at a time.
It appears also when you operate a manoeuvre which is not allowed.
Release the levers.
NO FEEDBACK SIGNAL
It may indicate a missing radio signal, problems in the transmission between unit and
antenna, or lack of crane feeding.
NO CODE!
It appears when you activate the ME icon without authorization, in order to start the special
procedure to check the load handled by manual extensions.
Press the INDEX button.
STABILITY STOP
It appears when you reach the maximum slope value of the crane during operation.
Approach the load to the column.
If this message appears immediately after the stabilization has been performed, crane
operation is not allowed: adjust the stabilization set-up by decreasing the slope.

4.2.3 - Visual indicator (EN 12999: “Operational warning”)
In compliance with safety regulations in force in EC countries, the crane is equipped with a visual
indicator (2 high-visibility flashing yellow lights) that warns persons in the vicinity that the crane
is in operation.
4.2.4 - Rated capacity acoustic indicator
In compliance with safety regulations in force in EC countries, the crane is equipped with an
acoustic indicator that (through an intermittent sound) warns persons in the vicinity when the
loading condition is between 90% and 99% of the crane/hydraulic extension/winch capacity in
the working configuration. When it reaches 100% of the capacity, the sound becomes continuous.
4.2.5 - Acoustic warning
In compliance with safety regulations in force in EC countries, the crane is equipped with an
acoustic warning that enables the operator to warn persons in the vicinity against dangerous
situations.

4.2.6 - Angle control device for PROLINK
If PROLINK function is available (see the corresponding paragraph), the crane is equipped with
an angle control device that prevents its outer boom and/or the hydraulic extension boom from
exceeding the maximum vertical value. The control is performed thanks to angle sensors placed
on the crane outer boom and the hydraulic extension boom (if fitted).
In case of manual control (from top seat), when the vertical warning value is reached, the control
device temporarily blocks every movement and activates (if fitted) the flashing red LED on radio
remote control and control panel on top seat, together with the message WARNING ANGLE! on
the display. In order to reactivate all the crane functions (except for the inner boom lift, that is
definitively blocked), it is sufficient to take back all the levers to neutral position. The message
WARNING ANGLE! disappears by lowering the boom under the warning value or by selecting the
LMI icon.
In case of control by radio, when the vertical warning value is reached, the control device slows
down the action of lifting rams.
When the maximum vertical value is reached (both with manual and radio remote control), the
control device activates the permanent red LED and the message MAX ANGLE CRANE! or MAX
ANGLE JIB!, according to the boom that has reached the limit.
Moreover, if the maximum vertical value is reached by the crane outer boom, the control device
blocks:
• the crane inner boom lift;

• the crane outer boom lift.
If the maximum vertical value is reached by the hydraulic extension boom, the control system
blocks:
• the crane inner boom lift;

• the crane outer boom lift;
• the hydraulic extension boom lift;
• the winch lift.
On cranes and hydraulic extensions fitted with PROLINK, the maximum vertical value might not
correspond to the lifting ram stroke end.

4.2.7 - Lifting moment limiting device for two working zones
If stability is reduced in a working sector (for instance in front of the vehicle cab), the lifting
moment limiting device for two working zones still enables to operate in that sector, but with a
reduced activation level, which is defined during the stability test of the vehicle.
Therefore, the working area is divided into two sectors: in one sector (e.g. vehicle body side),
the crane operates as per the capacity plate values; in the other sector (e.g. vehicle cab side), it
operates with derated capacity values.
So, the limiting device manages two activation levels (according to the working sector where the
crane operates) and the vehicle stability is always guaranteed.
In these conditions:
• manoeuvre of a bigger load than the one allowed in the derated load sector,
• lifting ram reaching its stroke end (1)
while the crane is passing from the working sector where it can operate with capacity plate values
to the sector where it can operate with derated capacity, the rotation is blocked and the allowed
operations are the following:
• crane rotation in the opposite direction;

• manoeuvres allowed by the electronic lifting moment limiting device.
(1) In case of block due to lifting ram reaching its stroke end, it is necessary to operate the
ram in block (signalled by the limiting device) in the opposite direction, so that the pressure is
discharged and it is possible to operate in the working sector with reduced activation level.
In case of overload with crane in “unstable” zone, the block of operations (except for rotation,
that isn’t stopped) occurs according to the working parameters of the electronic lifting moment
limiting device.
When the system starts and the crane is in “unstable” zone, rotation is blocked in both directions
if the pressure induced by the load is higher than the determined block pressure.
In case of derated or partially decreased capacities (e.g. in the sector in front of the
vehicle cab), the operator must consider the plates provided by the installer and defined
after the final stability test.
The presence of the lifting moment limiting device for two working zones does not
exempt the operator from respecting the lifting diagrams represented on the capacity
plates.
During load handling with crane or hydraulic extension in vertical configuration or close
to it, the operator must strictly refer to the loads indicated on the capacity plates, since
the limiting device could appear to be not particularly sensitive with operations induced
by vertical lifts.

4.2.8 - FSC (Fassi Stability Control)
The FSC system has been developed by FASSI in compliance with the Machinery Directive
2006/42/EC and the harmonized technical standard EN 12999, which require the stability control
to be included in the safety function of the lifting moment limiting device (for cranes having a
minimum capacity of 1000 kg or a minimum lifting moment of 40000 Nm).
This system is proposed in different variants, according to crane models (where the lifting moment
limiting device is fitted) and mountings.
FSC/S
The FSC/S system is available only on cranes provided with digital radio remote control,
hydraulically extendable outrigger supports and electronic lifting moment limiting device. It
allows crane operation only when all the outrigger rams are placed in working position in
contact with the ground.
The activation of the lifting moment limiting device occurs according to outrigger support
position and vehicle slope.
When you start to control the crane, the outrigger condition is no more considered;
so, during crane operation the outrigger placed opposite to the load, because of a
balance effect, may be no more in contact with the ground, without any crane block.
The system detects the left and right working areas of the vehicle body (1-4 and 2-3 - fig.
4.1) and manages the lifting moment limiting device for two working zones: “above body” (A)
and “above cab” (B) - fig. 4.2 (See paragraph “Lifting moment limiting device for two working
zones”).
Fig. 4.1 Fig. 4.2
During the passage from working zone “above body” to working zone “above cab”, the rotation
is blocked if the pressure induced by load is higher than the derated pressure for the activation
of the lifting moment limiting device.
The rotation block occurs also passing from a body side to the opposite one, where the
pressure for the activation of the lifting moment limiting device is lower than the pressure
induced by load. Rotation in the opposite direction is allowed, as well as all the manoeuvres
that are permitted by the electronic lifting moment limiting device.
If, after the execution of the stabilization, you start to control the crane and the lateral slope is

out of the limit, it isn’t possible to use the crane and the message STABILITY STOP appears
on the radio remote control and the panel display. In order to continue working, it is necessary
to adjust the stabilization set-up by decreasing the slope angle and re-entering within the
intended parameters of operation.
With FSC/S system, three working levels are available above the vehicle body: L1, “proportional”
L2 and L3.
In L1 working level: the pressure for the activation of the lifting moment limiting device is
derated (according to the stability test results); outrigger supports are completely reentered or
partially extended (less than half of their stroke); outrigger rams are placed in working position
in contact with the ground. The vehicle slope is not considered.
With FSC/SII, the crane works in L1 level with derated pressure when outrigger
supports are extended up to 25% of their maximum stroke.
In “proportional” L2 level, the activation of the lifting moment limiting device occurs when
the maximum intended slope is reached. The angle creating the block comes from a linear
calculation between minimum and maximum limit, according to the position of outrigger
supports. In this level, the outrigger supports are partially extended (at least half of their
stroke) and the outrigger rams are placed in working position in contact with the ground.
With FSC/SII, the crane works in “proportional” L2 level when outrigger supports
are partially extended from 25% to 99% of their maximum stroke.
If crane operation is carried out on a plane with downward slope (descent) and
under one of the following conditions:
• outrigger supports extended from 25% to 50% of their maximum stroke and
ground slope ≥ 2°
• outrigger supports extended from 50% to 99% of their maximum stroke and
ground slope ≥ 3°
a reduction of the crane movement speed occurs. This reduction is equal to the one
related to XP working (even for cranes without XP device).
If working conditions between downward and upward side are different, in the zone
“above body” the crane works as per the slowest condition.
XP speed
Standard speed XP speed
XP speed

In L3 working level, the activation of the lifting moment limiting device occurs when the
maximum intended slope is reached. In this level, the pressure for the activation of the lifting
moment limiting device is the rated one, the outrigger supports are completely extended; the
outrigger rams are placed in working position in contact with the ground.
The slope check is never active with crane above body; in this configuration the full
capacity of the crane is allowed.
When 80% of the maximum permitted slope is reached, the flashing icon flag appears on
the display and the rated capacity acoustic indicator emits an intermittent sound.
When you exceed 100% of the maximum allowed slope: the icon flag is permanent, the
permanent red LED (if fitted) on radio remote control and control panel on top seat turns
on, the rated capacity acoustic indicator emits a continuous sound, the message STABILITY
STOP appears on the display and the crane is blocked.
In working levels L2 and L3, if the block occurs during rotation, the crane is still
allowed to rotate in the opposite direction.
During crane reactivation, the red LED is on until the exit from the block condition and the icon
flag starts flashing as soon as the slope goes under 100%.
Depending on the crane configuration, the reactivation occurs as per the electronic lifting
moment limiting device working (see paragraph “Block due to overload”).
If you operate the crane by manual controls and lateral outriggers supports are not
completely extended, only L1 working level is available.
On both sides (right or left) of the working zone “above body”, the working level is determined
according to the less extended outrigger support (crane or supplementary outrigger).
“Above cab” level

L1 level
“Proportional” L2 level
L3 level

Crane use with outrigger rams not touching the ground (L0 level)
The crane use with outrigger rams not touching the ground is intended only for
maintenance or load-less operations: it is prohibited to lift and handle loads with
outriggers in level L0.
Generally, the crane is prevented from operation if its outrigger rams are not in contact with
the ground (level L0). In this condition, only the supplementary functions are active and the
icon flag is flashing.
Anyway, according to the crane mounting, it may be possible to set the L0 level through a
dedicated procedure to be carried out by an authorised FASSI service centre. In this way,
some manoeuvres can be activated even with outrigger rams not touching the ground.
According to the crane mounting, two different setting conditions can be defined by the
authorised FASSI service centre:
• for crane functionality limited to the vehicle body sector;

• for complete crane functionality (360°).
Functionality over the vehicle body Complete functionality (360°)
L0 enabled* L0 not enabled* - L0 enabled* L0 not enabled* -

(icon flag : no load can be lifted (icon flag : no load can be lifted
permanent) (icon flag : flashing) permanent) (icon flag : flashing)
• Reentry of crane • Reentry of crane
Allowed manoeuvres
extension boom sections All, except extension boom sections

• Reentry of jib extension for the exit of • Reentry of jib extension
All, limited to boom sections extension boom boom sections
the vehicle body • Supplementary functions sections, that • Supplementary functions
sector • Lift of the crane inner or is allowed only • Lift of the crane inner or
outer boom over the vehicle outer boom
• Descent of the crane body. • Descent of the crane
inner or outer boom inner or outer boom
If you operate a forbidden manoeuvre, the message NOT ALLOWED appears.

*Enabling procedure for L0 level
Once the setting procedure has been carried out by an authorised FASSI service centre,
the operator can enable the L0 working level, by following this procedure:
• if the hydraulic extension is fitted, completely reenter its extension

boom sections and hold the control lever (2 seconds);
• completely reenter (within 5 seconds) the crane extension boom

sections and hold the control lever (2 seconds);
• the crane functionality in L0 level is activated, when the icon flag

is permanently displayed.
The pressure limits for the activation of the lifting moment limiting device in L0 level
are defined by the installer during the setting procedure. When you reach those limits,
the system blocks rotation in both directions, as well as every operation increasing the
outreach. If the block occurs with crane or hydraulic extension above the horizontal line,
the lifting manoeuvres are prevented too.

ICC (Integrated Counter-weight Control)
“Stable” zone
(e.g. over the vehicle body)
While working from L2 to L3 level, this function controls the vehicle slope according
to the load variation on the body and adjusts the crane performances accordingly (up
to the reaching of the maximum angle or the block pressure of the lifting moment
limiting device).
“Unstable” zone
(e.g. over vehicle cab)
Angle of the crane outer boom/ By selecting the XP icon

hydraulic extension from the radio remote control:
• the message XP is shown on the display
• the working speed decreases
under 35° • the slope control is activated
• the lifting capacity is adapted to the one
allowed in the “stable” zone
• the message XP is shown on the display
(actually, ICC function is not active but it
above 35° is automatically activated when the boom
goes under 35°)
• the working speed decreases
The ICC function can be activated and work in “unstable” zone, only if the crane/
supplementary outriggers operate from L2 to L3 level and if the starting slope
towards the “unstable” zone is under 3°.

Stabilization procedure with FSC/S
START
Stabilize
Press INDEX button to display
the working levels (L1, L2, L3) or
the vehicle slope (X)
Enable the crane
Crane not in transport
position or not along the
Crane position vehicle body
Crane in transport position
or along the vehicle body
WARNING 099
Place the crane in transport position

or along the vehicle body
X+limX>5°
X+limX=?
Check not performed on
FSC/SII X+limX≤5°
STABILITY STOP
Crane is ready for operation
END
X: actual slope of the vehicle

limX: angle value defined during the FSC/S setting, according to the installation.

FSC/S system display
On radio remote control and control panel on top seat (if fitted) - “crane” mode
By pressing the INDEX button on the radio remote control or control panel, it is possible to
display the working levels.
1 - 4 L 1 * 2 - 3 L 3
The above display shows that side 1-4 is in L1 level, while side 2-3 is in L3 level. The star
indicates the side where the crane is placed (2-3). The absence of the star on both sides
means that the crane is on the vehicle body.
Sides 1-4 and 2-3 are represented on the plate placed near the outrigger controls (fig. 4.1).
For instance, in the following figure the crane is working in zone 1-4 and level L2. Zone 2-3
is set for the working level L1.
*1-4 L2 2-3 L1
With FSC/S system, by pressing the INDEX button it is possible to alternatively activate the
working level display and the one concerning the angle values of the vehicle.
X - 0 . 4 0 Y 1 . 2 5
On control panel on top seat (if fitted) - “outrigger” mode
Once outriggers have been enabled (see chapter 6 “Setting up for crane operation”), any
information about FSC system is displayed on the control panel.
For example:
a. Type of FSC fitted on the crane

a b. Outrigger rams 1-2 touching the
ground ( )
c. Working level (L1 on side 1-4)
d. Outrigger rams 3-4 touching the
b
ground ( )
c e e. Working level (L3 on side 2-3)
f f. Level indicator: for the correct machine
d
set-up the pointer must be inside the
inner rectangle

On touchscreen control panel (if fitted)
Once outriggers have been enabled (see chapter 6 “Setting up for crane operation”), any
information about FSC system is displayed on the control panel.
The represented configuration of crane, outriggers and sectors reflects the real conditions.
For example:
12 11
10
2
3
9
4
5 6 7 8
1. Position of outrigger rams

2. Position of outrigger supports
3. Side slope X and longitudinal slope Y
4. “” button: used to go back to the previous screen
5. Working level (side 2-3)
6. Percentage of allowed capacity (side 2-3)
7. Level indicator: it reflects the vehicle slope
8. Percentage of allowed capacity (side 1-4)
9. Outrigger number
10. Working level (side 1-4)
11. Type of FSC fitted on the crane
12. Percentage of allowed capacity (working zone “above cab”)
This screen is automatically displayed during stabilization and you can always see
it by selecting the icon .

4.2.9 - Inner boom horizontal position indicator
In compliance with safety regulations in force in EC countries, cranes which are not fitted with CPM
device may be provided with an inner boom horizontal position indicator. If the crane exceeds the
maximum height in transport position, the indicator signals it to the driver through an acoustic
and visual alarm (red LED), emitted by a panel (fig. 4.3) placed by the installer inside the vehicle
cab.
On cranes in fixed and marine versions, the inner boom horizontal position indicator is compulsory
if the installation is carried out on boats used for inland waters (such as rivers, canals and lakes),
as well as on boats for inshore use.
4.2.10 - CPM (Crane Position Monitoring)
In compliance with safety regulations in force in EC countries, the CPM device detects the correct
positioning of outrigger supports and the crane maximum height in transport condition.
If the crane exceeds the maximum height in transport position and if the outrigger supports
are not completely reentered within the vehicle overall dimension, the CPM device signals this
condition to the driver through an acoustic and visual alarm (red LED), emitted by a panel (fig.
4.3) placed by the installer inside the vehicle cab.
Fig. 4.3
Before driving the vehicle, make sure that outriggers are reentered within the vehicle
overall dimension, safety devices are locked and the crane is in transport position.

4.3 – Special functions

4.3.1 - XP (Extra Power)
On certain models, maximum performances are reached by activating the XP device, that ensures
safe operations by working on dynamic performances.
In order to activate/deactivate the XP device, select the icon .
The successful activation of the XP device is signalled by the message XP (on the displays of
radio remote control and control panel on top seat) or by the icon (on the display of the
touchscreen control panel).
In order to make the XP device deactivation effective, the crane control levers shall be
in neutral position.
On capacity plates graphically marked with , loads pertain to XP device

activated.
In case of cranes with free rotation or lifting moment limiting device for two working sectors in
“stable” zone, the activation of XP device involves:
• a reduction of the lifting and lowering speed of inner boom, outer boom and hydraulic
extension (if fitted). This enables to reach the maximum lifting capacity;
• a reduction of the rotation speed, without increasing the torque;
• a normal speed of hydraulic extension booms, bucket and rotator;
• normal speed and lifting capacity of winch.
On cranes fitted with lifting moment limiting device for two working sectors in “unstable” zone,
the activation of XP device involves only a speed reduction (in case of FSC/S, refer to paragraph
“ICC (Integrated Counterweight Control)”).
In case of XP device not activated and indication on display signalling that 90% of crane capacity
has been reached: if you activate the device, the indication may disappear. If you insist in the
manoeuvres increasing the lifting moment, the indication of 90% (and eventually 100%) might
be displayed again.
In case of XP device not activated and indication on display signalling that 100% of crane capacity
has been reached (block condition): if you activate the XP device the block may continue (in this
case it is necessary to reactivate the crane), or the indication of 100% may disappear (in this case
the crane controls are enabled). If you insist in the manoeuvres increasing the lifting moment, the
indication of 90% and 100% might be displayed again.
If the crane is equipped with FSC/S stability control system, you can activate the XP
device in working levels L2, L3 or working “above body”.

4.3.2 - PROLINK (Progressive Link)
Cranes provided with PROLINK can operate the outer boom and/or the hydraulic extension with
an increased angle upwards.
The tilt angle value of the outer boom and/or the hydraulic extension is represented on the
capacity plates.
In order to avoid the exceeding of the maximum vertical value, the crane is fitted
with an angle control device for PROLINK. While operating the crane or the hydraulic
extension, if you reach the maximum value vertical up, the device blocks every
dangerous movement.
The following figure shows the possible configurations of a crane fitted with hydraulic
extension and PROLINK function.
4.3.3 - Exclusion tap for 7th/8th extension boom sections
When you use the hook attachment on the tip of the 6th extension boom section, it is compulsory
to reenter the 7th and 8th extension boom sections and block their exit by closing the exclusion
tap (inserted between the 6th and 7th boom extension rams).
Open tap Closed tap
Before closing the exclusion tap, make sure the 7th and 8th extension boom sections
are completely reentered.
Open the tap to unlock the exit of the 7th and 8th extension boom sections.
If JDP function is fitted, the exclusion tap is replaced by an electrovalve blocking the
exit of the extension boom sections, which can be activated by selecting the JDP icon
from the control station (see paragraph 4.3.4 “JDP (Jib Dual Power)”).

4.3.4 - JDP (Jib Dual Power)
If fitted, JDP function enables to increase hydraulic extension performances by raising the block
pressure, according to the position of the crane extension boom sections.
In order to increase performances, this conditions are necessary:
• 7th and 8th extension boom sections reentered;

• crane in “stable” zone;
• XP device activated;
• icon selected.
When JDP is activated, you see the message JDP on the upper part of the display (on radio
remote control - fig. 4.4 - and panel on top seat) or the icon (on touchscreen panel display).
-1 -14 JDP 22C
% 15 8 12 0 0
Fig. 4.4
Select the icon again to deactivate the JDP function.
JDP function cannot be activated in “unstable” zone.
The following examples show possible situations where JDP function is not activated (after the
selection of the corresponding icon):
• 7th and 8th extension boom sections reentered and blocked, crane in “stable” zone but JDP
function not activated because the XP device is not activated;
-1 -14 22C
% 16 9 22 0 0
• 7th and 8th extension boom sections blocked, crane in stable zone, XP device activated but
JDP function not activated because 7th and 8th extension boom sections are not reentered;
-1 -14 XP 22C
% 15 8 20 0 0
In place of the exclusion tap for 7th/8th extension boom sections, by selecting the JDP
icon from the control station you activate a special electrovalve blocking the exit of the
7th and 8th extension boom sections.

4.3.5 - JVC (Jib Vertical Control)
When certain lifting values of crane and hydraulic extension are reached during vertical load
handling, the JVC control function prevents from operating the reentry of the crane extension
boom sections as first operation. This avoids possible lateral deformations.
If the system blocks the reentry of the crane extension boom sections and you operate the
corresponding control lever, the message STOP BOOM IN is displayed.
To reactivate the reentry of the crane extension boom sections, it is necessary:
• to completely reenter the jib extension boom sections and then (once the extension boom
sections are completely in) to keep for 2 seconds the control lever into position;
At low oil temperatures, the reentry of the crane extension boom sections may
occur even though the jib extension boom sections are not completely reentered.
Thus, it is necessary to start a Warm-up procedure (see paragraph 6.1.2 “Check
of working area and service conditions” of this manual).
or
• to lower hydraulic extension or outer boom until the exit from the block zone.
With JDP activated (7th and 8th extension boom sections reentered) no block occurs.

4.3.6 - FL (Full Lift)
The FL (Full Lift) system enables a “FAST” or “POWER” mode for operating the crane extension
boom sections.
The “POWER” mode (regenerative valve deactivated) enables to lift the maximum capacity loads
in the crane vertical configuration, by reducing the exit speed of the crane extension boom
sections.
The “FAST” mode (regenerative valve activated) enables to reach the maximum exit speed of the
extension boom sections.
It is possible to pass from “POWER” to “FAST” mode (and vice versa) by selecting the icon .
4.3.7 - Oil cooler (heat exchanger)
The oil cooler (air-oil heat exchanger) prevents the damaging effects caused by an excessive rise
of oil temperature.
The oil cooler is equipped of brush-less motor with integrated electronic management programme
and soft-start function, thanks to which the fan reaches its maximum speed slowly. In this way,
power peaks during start up and damages to the vehicle battery are prevented.
The fan speed is directly proportional to the temperature variation. Thus, at low oil temperatures
the fan runs slowly and saves energy. The start-up temperature can be set through the system
parameters, anyway the oil cooler doesn’t start with oil temperature lower than 20° C.
The oil cooler is also equipped with a self-cleaning automatic function, that enables the inversion
of the motor movement during operation. In particular, at the end of the working cycle of the oil
cooler, FASSI electronics sends a signal to the system and the fan inverts its rotation direction,
creating an outbound air flow, which removes dust from the radiant element.
Always assure the inbound/outbound air flow in/from the oil cooler.

Chapter 5 — Control systems
Chapter 5 – Control systems
5.1 – Pictograms for crane and implement control

Pictograms for crane and implement control
Inner boom Inner boom

Column rotation Column rotation
movement movement
(clockwise) (anti-clockwise)
(lift) (descent)
Outer boom Outer boom

Jib movement Jib movement
movement movement
(lift) (descent)
(lift) (descent)
Crane extension boom Crane extension boom

Implement rotation Implement rotation
movement movement
(clockwise) (anti-clockwise)
(exit) (reentry)
Winch movement Winch movement Bucket movement Bucket movement

(lift) (descent) (open) (close)
Jib extension boom Jib extension boom

movement movement
(exit) (reentry)

5.2 – Layout of crane and implement controls

In compliance with the standard EN 12999, the layout order of bi-directional controls must
follow the sequence of working functions from the base to the load.
5.2.1 - Horizontal layout order
The following sequence refers to articulated cranes and is valid from left to right or
conversely. The pictograms referring to implements are to be considered according to
what is fitted on the crane.
Standard crane Implements
5.2.2 - Layout order for radio remote control with joystick
The following sequences refer to articulated cranes. The pictograms referring to

implements are to be considered according to what is fitted on the crane.
Radio remote control - 6 functions with 3 joysticks
Left joystick Central joystick Right joystick

   
Left joystick Central joystick Right joystick
   
Left joystick Right joystick

5.3 – Radio remote control

Outriggers and crane can be operated by radio remote control. In case of working
anomalies, see paragraphs 11.1 “Outrigger control by radio” and 11.2 “Crane control by
radio - Distributor on the column”.
5.3.1 - RCH digital radio remote control
Radio remote control components
The control handle of RCH radio remote control is provided with a minimum of 6 and a maximum
of 8 linear levers. It is also supplied with a display to show information about crane operation.
The control handle can also be equipped with joystick controls for 6 or 8 functions.
The 8-function-control handle has two lateral 3-function-joysticks; the third function can be
operated by rotating the joystick knob.
1
3 1 2
3 2 4
Linear control handle Joystick control handle
1. Double display;
2. “RX” rotary function selector. It allows to select the icons displayed on the screen
and to activate/deactivate the crane functions. If you rotate it clockwise, you scroll
the icons left to right; anti-clockwise right to left. The icon selection is confirmed by
pressing the selector;
3. Battery status LED indicator: green flashing indicates the battery is charged; red flashing
(together with an acoustic signal) indicates the battery is almost empty and you need to
replace it (recharge the empty battery in the respective charger);
4. Levers/joysticks to control crane or outrigger functions;
5 7 10
8 11 12
9
Left side Right side Battery charger Receiver

5. Button for acoustic warning activation ;

6. “INDEX” button, used to display FSC levels, to go back to the previous menu from the
submenus (prolonged pressure), to move the cursor when entering a value in the menu
and to activate the display backlight mode;
7. Radio remote control start button ;
8. Identification key for the connection of control handle and antenna;
9. Socket for the connection of radio remote control serial cable (standard supplied: 10 m
long)
10. Quick select buttons for supplementary functions;
11. STOP button (refer to paragraph 4.2.1 “STOP button”);
12. Battery compartment;
15 16 17 18 19 20 21 22 23 24
14
25
13
26
Double display
When 90% of crane/hydraulic extension/winch capacity is reached, the widescreen

message “90%” appears for 5 seconds on the left display; then it disappears and
appears again in position 22.
When 100% of crane/hydraulic extension/winch capacity is reached, the widescreen

message “100%” appears for 5 seconds on the right display; then it disappears and
appears again in position 22.
13. Icons (for the icon list refer to chapter 4 “Safety devices and special functions”);
14. Capacity on inner ram, outer ram and hydraulic extension ram (if fitted);
15. Angular position of crane outer boom;
16. Angular position of hydraulic extension (if fitted);
17. JDP activated (if fitted);
18. XP or ICC activated (if fitted);
19. Capacity on the winch (if fitted);
20. Input oil temperature of the heat exchanger;
21. Working pressure in the distributor bank;
22. Indication that 90% and 100% of crane/hydraulic extension/winch capacity are reached;
23. Battery status indicator;
24. Radio signal quality indicator;
25. Icons related to the configurable quick select buttons for supplementary functions (placed
on the control handle right side);
26. Icon flag.
The second line on the display can also show particular crane conditions through messages
such as WARNING, ALARM, STOP ROTATION, etc.. In this case, all the data on the second line
momentarily disappear, till the crane control is restarted and they automatically appear again.

Radio remote control activation
• Insert a charged battery into the battery compartment.

• Unlock the STOP button on radio remote control.
• Press the radio remote control start button .
The radio remote control is ready for operation when the green LED in position 3 flashes.
Before starting work, always press the acoustic warning in order to warn the persons
in the vicinity.
Automatic frequency selection
RCH radio remote control is equipped with AFS (Automatic Frequency Selection) technology,
which provides many frequency ranges. When you turn on the radio remote control, the
system checks if the frequency used during last operation is available; if it is busy, the system
automatically finds an available one and saves it.
Configuration of quick select buttons for supplementary functions
• Press at least 2 of the supplementary function buttons and at the same time turn on the
control handle.
• Release the buttons.
• Turn the “RX” rotary function selector and choose the desired icon; press the quick select
button you want to combine with the selected icon.
• Repeat the previous operation to combine the other two buttons.
• At the end of the selection, turn off the control handle by pushing the STOP button.
Cable connection
In case of empty battery, interferences in the radio transmission or crane operation in

situations where the radio transmission is forbidden, the radio remote control can be easily
transformed into remote control via cable.
• Push the STOP button on radio remote control.

• Remove the protective coverings of sockets (indicated in the figure below) on radio remote
control and crane.
• Connect radio remote control and the receiver through the serial cable by using the screw
connector.
Radio remote control automatic switch-off
RCH radio remote control is equipped with automatic switch-off and it turns off about 15
minutes after entering the last command. This automatic switch-off is due to safety reasons
and it also lengthens the battery life.

Radio remote control switch-off
Push the STOP button.
5.3.2 - RCS digital radio remote control
Radio remote control components
The control handle of RCS radio remote control can be provided in “mini” version with 6
linear levers or in “maxi” version with 6 or 8 levers. It is also supplied with a display to show
information about crane operation.
As further option, the control handle can be equipped with joystick controls for 6 or 8
functions. The 8-function-control handle has two lateral 3-function-joysticks; the third
function can be operated by rotating the joystick knob.
1 1
2 2
3 4 3 4
5 6 7 8 5 6 7 8
Linear control handle Joystick control handle
1. Display;
2. Levers/joysticks to control crane or outrigger functions;
3. Quick select buttons for supplementary functions;
4. “RX” rotary function selector. It allows to select the icons displayed on the screen
and to activate/deactivate the crane functions. If you rotate it clockwise, you scroll
the icons left to right; anti-clockwise right to left. The icon selection is confirmed by
pressing the selector;
5. “INDEX” button, used to display FSC levels, to go back to the previous menu from the
submenus (prolonged pressure), to move the cursor when entering a value in the menu
and to activate the display backlight mode;
6. STOP button (refer to paragraph 4.2.1 “STOP button”);
7. Battery status LED indicator: green permanent LED indicates the battery is charged; red
flashing (together with an acoustic signal) indicates the battery is almost empty and you
need to replace it (recharge the empty battery in the respective charger);
8. Radio remote control start button / Acoustic warning activation button;
10
9
Left side Battery charger Receiver

9. Socket for the connection of radio remote control serial cable (standard supplied: 10 m
long);
10. Battery compartment;
14 15 16 17 18
19
90% 100%
13 7 9 JDP XP 20C 20
12 % 53 26 22 54 200 21
22
11 23
24
Display
11. Icons (for the icon list refer to chapter 4 “Safety devices and special functions”);
12. Capacity on inner ram, outer ram and hydraulic extension ram (if fitted);
13. Angular position of crane outer boom;
14. Orange light indicating that 90% of crane/hydraulic extension/winch capacity has been
reached;
15. Angular position of hydraulic extension (if fitted);
16. JDP activated (if fitted);
17. XP or ICC activated (if fitted);
18. Red light indicating that 100% of crane/hydraulic extension/winch capacity has been
reached; it can also signal alarms, warnings or particular crane conditions;
19. Capacity on the winch (if fitted);
20. Input oil temperature of the heat exchanger;
21. Working pressure in the distributor bank;
22. Icon flag
23. Battery status indicator;
24. Radio signal quality indicator.
Radio remote control activation
• Insert a charged battery into the battery compartment.

The radio remote control is ready for operation when green LED in position 7 is permanent on.
Before starting work, always press the acoustic warning button in order to warn the
persons in the vicinity.
Automatic frequency selection
RCS radio remote control is equipped with a special technology that

provides many frequency ranges. When you turn on the control handle, the
system places itself on the frequency used during last operation; if it is busy, the system
automatically selects the next available one.

Configuration of quick select buttons for supplementary functions
• Press at least 2 of the supplementary function buttons and at the same time turn on the
control handle.
• Release the buttons. The message “FAVOURITE CONFIGURATION” appears and confirms
the access to the button configuration menu.
• Turn the “RX” rotary function selector and choose the desired icon; press the quick select
button you want to combine with the selected icon.
• Repeat the previous operation to combine the other two buttons.
• At the end of the selection, turn off the control handle by pushing the STOP button.
Cable connection
In case of empty battery, interferences in the radio transmission or crane operation in

situations where the radio transmission is forbidden, the radio remote control can be easily
transformed into remote control via cable.
• Push the STOP button on radio remote control.

• Remove the protective coverings of sockets (indicated in the figure below) on radio remote
control and crane.
• Connect radio remote control and the receiver through the serial cable by using the screw
connector.
Radio remote control automatic switch-off
RCS radio remote control is equipped with automatic switch-off and it turns off about 5
minutes after entering the last command. This automatic switch-off is due to safety reasons
and it also lengthens the battery life.
Radio remote control switch-off
Push the STOP button.

5.3.3 - Enabling outriggers and crane
In order to enable the outriggers, operate the rotary selector placed on the radio remote control
and select the icon .
Rotary selector
The message OUTRIGGERS? appears on the display.
Confirm the selection by pressing simultaneously:
• (acoustic warning) and “INDEX” buttons (in case of RCH control handle);
• (start) and “INDEX” buttons (in case of RCS control handle).
The message OUTRIGGERS appears on the display.
In order to enable the crane, operate the rotary selector placed on the radio remote control and
select the icon .
The message CRANE? appears on the display.
The message CRANE appears on the display.
5.3.4 - Controlling the outriggers
Outriggers are numbered from 1 to 4, as shown for example in figure 5.1.
Fig. 5.1
On the selection controls of the outriggers letter E indicates hydraulically extendable outrigger
supports, letter S hydraulic outrigger rams and letter R the pivoting of the hydraulically tiltable
outrigger rams.

The crane is equipped on both sides with a consent button (represented in the following
figure). When you stabilize by radio remote control and you select the button, only the
exit of the outrigger support associated to that side is allowed, while the one on the
opposite side (not visible) is blocked.
Operate the selection lever or joystick, keep it into position and at the same time operate the
control.
Outrigger selection: examples of lever or joystick labels
1 2
1. Lever movement upwards: selection of outrigger support (E) - position 1;
lever movement downwards: selection of outrigger ram (S) - position 1.
2. Lever movement to the left: selection of outrigger support (E) - position 2;
lever movement to the right: selection of outrigger ram (S) - position 2.
Outrigger control: examples of lever or joystick labels
Lever movement upwards: exit of outrigger rams, exit of outrigger supports or

tilting of outrigger rams into working position;
lever movement downwards: reentry of outrigger rams, reentry of outrigger
supports or tilting of outrigger rams into transport position.

5.3.5 - Controlling the crane
The pictograms placed near the levers indicate their operating direction in relation to the controls
you want to perform (refer to paragraph 5.1 “Pictograms for crane and implement control”).
These pictograms are placed on different type labels, such as:
With linear-levers
With joystick
In case of third function operated by rotating the joystick knob
On the radio remote control it is possible to set up double function levers. In this case their labels
show double symbol.
Refer to paragraph 5.2 “Layout of crane and implement controls” for any explanation about the
sequence of labels.
Make sure that the lever you are going to operate corresponds to the control you want
to perform.

5.4 – Top seat control station

This special fitting allows the operator to control the crane whilst sitting in a higher position, in order
to have a better view of the working area.
The top seat control station allows the operation of crane controls through levers or radio remote
control (in this case, the control panel is fitted also with a supplementary STOP button).
To access the top seat control station, always use the dedicated ladder. Pay attention in order to
avoid hitting the controls while ascending and descending. The ladder must be fitted and correctly
mounted by the installer, as per the current regulations.
The operator’s presence on the top seat control station is detected by a sensor that automatically
activates the lever working.
5.4.1 - Controlling the crane

For crane operation by radio remote control, refer to paragraph 5.3 “Radio remote control”.
For crane operation by levers, consider the following instructions.
The labels are for example as the one shown in the following figure: position 1 represents the
operation which is associated to the lever movement indicated in position 2.
Refer to paragraph 5.2 “Layout of crane and implement controls” for any explanation about the
sequence of labels.
Make sure that the lever you are going to operate corresponds to the control you want
to perform.

Chapter 6 — Setting up for crane operation
Chapter 6 – Setting up for crane operation
6.1 – Preliminary checks

6.1.1 - Checks on the crane
Carry out the daily checks as prescribed in paragraph 10.2 “Checks and preventive
maintenance”.
Prior to starting operation with crane and implements, check their safety devices in
loadless condition and with reentered extension boom sections.
In particular, follow this procedure to check the STOP button working:
• operate any crane control: movements should perform without any problem;
• push the STOP button during crane operation: the crane should stop;
• operate again any crane control: no operation should be possible;
• unblock the STOP button: crane operations should perform without any problem.
If you push the STOP button and the crane doesn’t stop or other functions are still
active, high risk of accidents (even serious) occurs for the operator and other persons:
do not operate the crane and immediately contact an authorised FASSI service centre.
manoeuvres remain active: therefore it is necessary to pay special attention and make
sure nobody stops or passes in proximity of the outrigger ram working area.
Operating the crane with STOP button not working properly is a serious operator’s
negligence.
If you find any of the following defects on the crane:
• damages or cracks on components or weld joints;

• damages in the hydraulic system;
• oil cooling system not working properly;
• damages in the safety devices;
• loosened screws;
• unsecured pins;
• unusual noises;
• unusually quick or slow movements;
• failure of the control system;
• control levers not returning back automatically;
• faulty components, buttons, levers;
• damaged seals;
• malfunctioning of the hose tray system;
• missing protections;
• damaged ropes, chains and pulleys;
• faulty rope run;

• suitability of added components for the intended use not verified;

• excessive clearance between components (e.g. extension booms, joints, pins, etc.)
do not start the device or immediately stop it (refer to standard ISO 9927-1 – Cranes - Inspections-
General). Reactivation is possible only if the fault is solved and if safe working is guaranteed.
The list above could be incomplete: the operator must evaluate possible crane defects
and take proper measures.
Controls, control stations, support surfaces, rises and steps to access the top seat control station
(if fitted) must be clear of snow, ice, dirt (oil, grease, etc.) and any object.
Plates, control pictograms, signs and warnings must be clearly visible and identifiable.
The control station must be properly enlightened, in order to guarantee the safe working of the
crane.
If the crane is equipped with top seat control station, make sure the necessary access ladder is
fitted. Pay attention in order to avoid hitting the controls while ascending and descending.
The ladder must be fitted and correctly mounted by the installer, as per the current regulations.

6.1.2 - Check of working area and service conditions
The whole working area is considered to be high risk zone for accidents (even serious)
for the operator and other persons. The access to the working area by unauthorized
persons is prohibited.
To enclose the working area and signal the crane operation you can use: barriers, cones,
emergency lights, red and white stripe warning stickers, etc.
The working area must be properly enlightened, in order to guarantee the safe working of the
crane.
Load and working area must be clearly and fully visible to the operator. If this is not
possible, the operator must receive instructions (checking the communication efficacy) by
another operator who has the full view of the working area.
The operator must instruct his coworker so as to avoid mutual damage during manoeuvres.
movements, the load movements and the whole working area of the crane. Check the
coworker’s working conditions comply with the essential health, safety and welfare
requirements.


The minimum distance is seven (7) meters. For safe operation it is compulsory to follow the
current local regulations (refer to paragraph 3.4 “Electric shock danger”).
Evaluate the necessary space for crane and outrigger operation: movements must not be
obstructed by other objects.
The operator must know exactly the weight he has to lift.
The conditions of the ground or the support must be suitable to the maximum pressure
exercised by the device.
The value of the pressure exercised on the ground by the outriggers is indicated in the schedule
“Crane technical data” in Appendix A of the present manual (“Max. working pressure on the
outrigger Ø ... ”) and has to be compared with the below table.
Admitted pressure on the ground (Load capacity of the ground) - Ref. DIN 1054
A Made ground, not compacted artificially 0÷10 daN/cm2 = 0÷1 MPa
B Asphalt 20 daN/cm2 = 2 MPa
C Compact ground, not removed
1 Mud, peat, marshy ground 0 daN/cm2 = 0 MPa
2 Not compacted ground, adequately solid
From fine to middle sand 15 daN/cm2 = 1.5 MPa
From thick sand to gravel 20 daN/cm2 = 2 MPa
Shattered and compacted stones 25 daN/cm2 = 2.5 MPa
3 Compact ground
Wet 0 daN/cm2 = 0 MPa
Soft 4 daN/cm2 = 0.4 MPa
Compact 10 daN/cm2 = 1 MPa
Half-solid 20 daN/cm2 = 2 MPa
Hard (solid) 30 daN/cm2 = 3 MPa
4 Rock
Eroded 100 daN/cm2 = 10 MPa
If necessary, use larger outrigger plates (available on request) to avoid sinking.

Pay attention to the proximity of manhole covers, holes, etc.
Keep outriggers at a safety distance (at least 2 meters) from possible scarps.
Make sure that the temperature range for crane operation isn’t lower than -30°C and higher than
+50°C.
Check that the wind speed is lower than 13,8 m/s (refer to paragraph 2.2 “Technical data”).
It is absolutely forbidden to use the crane during thunderstorms or in unfavourable

climatic conditions.
If you use the crane in ice or snow condition, start the hydraulic system at the minimum engine
speed and let the oil circulate for some minutes, till its warming.
When you restart working in low temperature conditions, it is recommended that you
reentry a ram to its stroke end, in order to bring quite quickly hydraulic oil up to
working temperature.

6.2 – Activating the crane

Engage the power take off. Start the pump with adequate engine speed.
6.3 – Stabilizing the vehicle

6.3.1 - Outrigger nomenclature
Crane and supplementary outriggers (if fitted) may be composed of:
hydraulically extendable supports
the following types of rams

• not tiltable;
• hydraulically tiltable by chain.
III II I I II III
a. outrigger supports
I. first outrigger supports
II. second outrigger support
(if fitted)
b b III. third outrigger support
a a (if fitted)
b. outrigger rams
c. outriggers
c
Outriggers are numbered from 1 to 4, as shown for example in figure 6.1: outriggers 1 and 2 are
mounted on the crane, outriggers 3 and 4 indicate the supplementary outriggers.
Fig. 6.1
On the outrigger controls (selection and control) letter E indicates hydraulically extendable
outrigger supports, letter S hydraulic outrigger rams and letter R the pivoting of the hydraulically
tiltable outrigger rams.
Refer to the following paragraphs for details on the specific types of outrigger supports and rams.

6.3.2 - Instructions
Place yourself as close as possible to the loading and unloading area. Park the vehicle correctly
and check that the vehicle hand brake is on and that the wheels are chocked.
Working at short outreach guarantees safer operations and longer life to the crane.
The unit (crane-vehicle) stability is only ensured by the complete lateral extension
of outrigger supports, by outrigger rams properly touching the ground, by the base
solidity underneath the outrigger ram plates and by the observance of capacity plates.
Carry out stabilization carefully and gradually, keeping the vehicle as much as possible in horizontal
position, in order to prevent spring overloads and chassis torsions.
Pay special attention during stabilization and make sure there are no obstacles and that nobody
stops or passes in proximity of the outrigger ram working area. Ensure a full view of outrigger
movements, especially while working from the opposite side.
The non-observance of the minimum gaps may involve a grave risk or cause even
serious accidents (see paragraph 3.3 “Crushing, Trapping and shearing danger”).
Check that the vehicle wheels are always in contact with the ground and the suspension
is not completely unloaded. Do not lift the vehicle.
Control the outriggers from the side where you have the full view of the whole operating
area.

The crane is equipped on both sides with a consent button (represented in the following
figure). When you stabilize by radio remote control and you select the button, only the
exit of the outrigger support associated to that side is allowed, while the one on the
opposite side (not visible) is blocked.
During stabilization, the last manoeuvre to carry out on each outrigger ram must be
the ram descent.
If the crane is fitted with removable outrigger plates, place the outrigger rams into working
position (vertical downwards), then mount the plate (fig. 6.2 - position 1) by securing it with the
locking pin (fig. 6.2 - position 2) and the check pin (fig. 6.2 - position 3).
1
2
Fig. 6.2
Check the outrigger plates are in contact with the ground.
Make sure outrigger supports are well-greased, in order to ensure their correct working.
In order to place double or triple hydraulic outrigger supports from fully extended to
partially extended position, follow this procedure:
• completely reenter all the supports;
• partially extend the supports.
6.3.3 - Enabling the outriggers
Operate the rotary selector placed on the radio remote control and select the icon .
Rotary selector
The message OUTRIGGERS? appears on the display.
The message OUTRIGGERS appears on the display.

As general procedure, extend all the outrigger supports, place the tiltable outrigger rams (if fitted)
into working position (refer to the following paragraphs) and then extend all the outrigger rams
till they are solidly placed on the ground.
Fig. 6.3
In order to operate the outrigger, select the element you want to activate and at the same time
operate the control lever.
Outrigger selection: examples of lever labels

1
1. Lever movement
2. Selected element as per the lever movement: S (outrigger ram), R (tilting of
outrigger ram), E (outrigger support)
(e.g.: E1: outrigger support - position 1)
Outrigger control: examples of lever labels

1
1. Lever movement
2. Activation of the selected element as per the lever movement
Refer to the relevant paragraph of chapter 5 “Control systems” for the technical specifications
related to the control system.

The complete extension of outrigger supports is visually indicated by yellow triangles

near the edge of the beam (fig. 6.4) and the edge of supports (if they are multi-
extendable - fig. 6.5).
Fig. 6.4 Fig. 6.5
If the crane is fitted with tiltable outrigger rams, follow this operating procedure for
every outrigger.
1. Extend the outrigger support for about 1 meter
2. Place the tiltable outrigger ram into working

position (vertically towards the ground)
3. Extend the outrigger support completely
4. Extend the outrigger ram till it is solidly placed

on the ground

Hydraulically tiltable outrigger rams by chain
If the crane is fitted with hydraulically tiltable outrigger rams by chain, follow this procedure to
place them into working position.
• Partially extend the outrigger support.
• Make sure tap V1 (fig. 6.6) is closed to prevent the outrigger ram exit and open tap V2
(fig. 6.6) to unlock the pivoting of the ram.
• Operate the control lever to tilt the outrigger ram into transport position, in order to
pressurize the system and tighten the chain (fig. 6.7 - position 4).
• Remove the safety pin (fig. 6.6 - position 2a) from the seat (fig. 6.6 - position 3a).
• Remove the locking pin (fig. 6.6 - position 1a).
• Operate the control lever to tilt the outrigger ram into its working position (vertical
towards the ground): the rotation ram R (fig. 6.7) reenters and enables the pivoting of
the outrigger ram.
• In order to lock again the pivoting of the outrigger ram, line-up the seats for the insertion
of the locking pin (fig. 6.7 - position 1b) and secure the locking pin by inserting the safety
pin (fig. 6.7 - position 2b) in the seat (fig. 6.7 - position 3b).
• Close tap V2 (fig. 6.6).
3b
V2
1a
V1
2b
2a
1b 4
3a
Fig. 6.6 Fig. 6.7
Check the pivoting of the tiltable ram is properly locked.

Safety and locking pins are made of special material. Do not replace them with
others: your safety depends on it.
• Completely extend the outrigger support.
• Open tap V1 (fig. 6.6) to enable the outrigger ram exit.
• Exit the outrigger ram to its working position.
The previous procedure is described on the plate DE12934 here below.
6.3.5 - Placing the vehicle in horizontal position
Stabilize the vehicle on a horizontal plane with a maximum tilting angle of 1,5°.
Check the vehicle tilt on the level indicator. The bubble must be contained in the
internal circle, and in any case it shall not go out from the external circle (5°).
5°
1.5°
Carry out stabilization carefully and gradually, keeping the vehicle as much as possible in horizontal
position, in order to prevent spring overloads and chassis torsions.

6.4 – Unfolding the crane into working position

It is forbidden to operate near the overall dimensions of moving booms, as crushing,

trapping and shearing danger occurs. Thus, do not operate from the side where the
crane opens/folds.
Before unfolding the crane, make sure that:
• the securing devices of implements and manual/hydraulic extensions are correctly locked;
• the vehicle is properly stabilized;
• neither persons nor objects are in the crane working area;
• the operator has the full view of the working area.
6.4.2 - Enabling the crane
Operate the rotary selector placed on the radio remote control and select the icon .
The message CRANE? appears on the display.
The message CRANE appears on the display.

6.4.3 - Unfolding the crane into working position
Articulated folding crane
The sequence of operations to unfold (first line) and fold the crane (second line) is represented
on plates DE4452 (fig. 6.8) and DE13749 (with hydraulic extension fitted on the crane, see
chapter 9 “Use of implements”).
Fig. 6.8
To unfold the crane follow this procedure:
• fold the outer boom, making sure that extension boom sections are
reentered;
• lift the inner boom over the horizontal position;
• lift the outer boom to the horizontal position;
• exit the extension boom sections and position the hook on the vertical
line above the load.
The procedure here above is not necessary to unfold into working position a crane
laid in transport configuration inside the vehicle body.

Chapter 7 — Crane operation
Chapter 7 – Crane operation
7.1 – Instructions
movements, the load movements and the whole working area of the crane (refer to
chapter 3 “Health and safety instructions”).
Ensure no one stops or passes in the crane working area. Activate the acoustic warning
to warn persons in the vicinity and eventually make them go away from the danger zone.
The crane must be used only by one operator.
It is allowed to use the crane and its implements during load lifting and handling opera-
tions only with stationary vehicle and under complete stability conditions.
Use the crane only for the intended tasks and in the service conditions described in the
present instructions.
Follow the maximum capacities and the lifting diagrams which are indicated on the
capacity plates according to every working configuration.
Diagrams on capacity plates indicate the maximum load the crane can handle at a certain outreach
and height. In order to exploit the full lifting capacity of the crane, it is necessary to position the
inner boom at the angle represented on the capacity plate (fig. 2.4 - position 12).

It is forbidden to move the vehicle with suspended load.
During operations it is forbidden to leave the control station or to abandon the remote
control.
Before leaving the control station: place the load to the ground; reenter all the extension
boom sections and lay them on a solid and safe base; disengage the power take-off.
Secure the crane against not authorized activation.
Shearing and trapping risk remains in the area concerning top seat control station (if
fitted) and inner boom movement.
When you operate from the top seat, you must remain seated and keep all the body parts inside
the control station.
It is forbidden to leave the top seat control station while operating the crane.
accidents (see paragraph 3.3 “Crushing, Trapping and shearing danger”).
When you operate the winch, lift the load vertically using the rope and not the boom, in
order to avoid possible load dangerous swinging, boom instability and premature guide
shoe wear.
It is forbidden to operate the crane (with or without load) continuously and at full speed,
in order to avoid greater weak of components and shorter crane life.
If the vehicle is equipped with pneumatic suspensions, block them during crane operation.

7.2 – Checking the load

Carefully evaluate the load and its characteristics in order to choose the proper lifting
devices. You must know the precise weight to lift. Correctly sling the load and check the
proper working of lifting devices.
Make sure the hook is always unrestrained to pivot and vertically work.
Check the efficiency of the hook safety catch.
Carefully inspect the condition of ropes or chains (if fitted).
Make sure that the pallet fork (if fitted) is connected to the crane hook by means of a chain having
at least three (3) rings.
Carefully handle wet or icy loads, as this involves slipping danger.

Before lifting, it is compulsory to clean the load from ice or snow.
Make sure the load doesn’t exceed the capacity indicated on the capacity plates, according
to the related working configuration.
7.3 – Hooking up or unhooking the load

To hook up the load place the hook on the vertical line above the load centre of gravity.
Stop the crane movements and hook up the load.
Make sure the crane is not in operation when hooking up or unhooking the load. If it is
accidentally activated by others, high risk of accidents occurs for operator and persons in
the vicinity.
If a co-worker assists the operator:
• the co-worker can reach the working area only after the operator’s authorization;
• the co-worker can hook up or unhook the load only if the crane is not in operation and only
after the operator’s authorization;
• after hooking up or unhooking operation, the co-worker must immediately leave the working
area;

• it is under the operator’s responsibility to check that the coworker’s working conditions comply
with the essential health, safety and welfare requirements.
If the operator is not assisted by any co-worker, he must:
• turn off the crane;

• hook up or unhook the load;
• start the crane.
7.4 – Handling the load

Crane and implements can be operated by different control modes. They may be:
• by radio remote control;

• by top seat control station.
The labels are for example as the ones shown in the following figures:
1 2
On horizontal or vertical distributor

2
On linear-lever radio remote control
On joystick controls

In case of third function operated by rotating the joystick knob
Position 1 represents the crane operation which is associated to the lever movement indicated in
position 2.
On the radio remote control it is possible to set up double function levers. In this case their labels
show double symbol.
Examples of pictograms for crane and implement control
Inner boom Outer boom

Column rotation Jib movement
movement movement
(clockwise) (lift)
(lift) (lift)
Extension boom
Implement rotation Winch movement Bucket movement
movement
(clockwise) (descent) (open)
(exit)
Jib extension boom

movement
(reentry)

Do not rotate the crane before the hooked load is lifted. Rotate slowly and carefully, paying attention
to the stability of vehicle and load.
Make sure the lifted load is balanced.
While lifting and handling operations, keep the load continually checked and monitored.

The minimum distance from electric lines is seven (7) meters. For safe operation it is compulsory to
follow the current local regulations (refer to paragraph 3.4 “Electric shock danger”).
Operate the levers smoothly and gradually.

When operating at the same time two or more functions, by the stroke end of a function
an uncontrolled speed increase of the other functions may occur.
Rubbing of load or lifting devices on the crane booms is prohibited.
With vertical lift, especially with hydraulic and manual extensions, rotate slowly in order to avoid as
much as possible side-swinging.
Handle the load very carefully and avoid swinging and impacts.
Avoid quick movements and temporary stops, since they may cause the load swinging.
Check that the vehicle is always in contact with the ground.
It is forbidden to pass with suspended load where other persons transit or work. If
necessary, warn through acoustic signals against the possible danger.
It is forbidden to pass with suspended load over the control station.

While crane working, a high risk of accidents for operator and persons in the vicinity, as
well as of damage of the crane occurs if you notice damages or malfunctions and you
don’t stop operation.
In order to prevent overload on the outriggers, during vehicle loading it may be necessary to
vertically adjust the outrigger rams, so that load is distributed on suspensions.
While unloading, the outrigger ram plates may not be perfectly in contact with the ground because
of a rise of suspensions; it is therefore recommended to stabilize again to avoid an overturn.
These corrections in stabilization are allowed only under the following conditions:
• crane without load;

• reentered extension boom sections;
• crane with booms positioned over the vehicle body.
7.5 – Laying down the load

Lower the load without increasing the outreach.
The place where the load is laid down must be clear of obstacles.
Load must not be laid down on snow, ice, steep ground, holes, humps, etc.
Load must be laid down on even and solid ground.
Before unhooking the load from the crane, make sure it is firmly placed on the ground.
7.6 – In case of emergency

In case of emergency, immediately stop all the crane movements (see paragraph 4.2.1 “STOP
button”).
In case of emergency, it’s under the operator’s responsibility to evaluate if it is necessary to

stop crane and implement operations or if it is better to lay down the load and guarantee
the safety.

Chapter 8 — Folding the crane
Chapter 8 – Folding the crane
8.1 – Instructions
It is forbidden to operate near the overall dimensions of moving booms, as crushing,
trapping and shearing danger occurs. Thus, do not operate from the side where the crane
opens/folds.
accidents (see paragraph 3.3 “Crushing, trapping and shearing danger”).
8.2 – Folding the crane into transport position

If implements are fitted on the crane, refer to chapter 9 “Use of implements” and/or to the
specific instructions given by the implement manufacturer.
8.2.1 - Articulated folding crane
The sequence of operations to fold the crane (second line) is represented on plates DE4452
(fig. 8.1) and DE13749 (with hydraulic extension fitted on the crane, see chapter 9 “Use of
implements”).
Fig. 8.1

After unhooking the load, follow this procedure to fold the crane into transport position:
• completely reenter the extension boom sections;
• lift the inner boom almost to its stroke end;
• fold the outer boom to its stroke end;
• rotate the crane until the reference indicators on column and base
coincide;
• fold the inner boom to its stroke end;
• reenter the outriggers as described in paragraph 8.3 “Reentering the

outriggers”.
The plate of fig. 8.1 in the third line (first two frames) shows the checks to carry out while folding
the crane. According to the securing devices fitted on the crane, the operator must check:
• if the outer boom is locked on the column;
• if the inner boom is inserted in its seat on the base.
With crane in transport position, make sure the hook is within the vehicle overall
dimensions.
8.2.2 - Crane laid in transport position inside the vehicle body
In case of fittings where the crane lays in transport position inside the vehicle body or
on the load, it is compulsory to properly block possible movements of the boom system
and crane rotation.
High risk of accidents (even serious) occurs if crane and implements aren’t secured
against lateral movements and rotation.
The installer must equip the vehicle with rest locating pins and eventually provide operative
specifications for placing the crane in transport position.

8.3 – Reentering the outriggers

8.3.1 - Outrigger nomenclature
Refer to paragraph 6.3.1 “Outrigger nomenclature” for any explanation concerning nomenclature.
Pay special attention while reentering outriggers and make sure there are no obstacles and that
nobody stops or passes in proximity of the outrigger ram working area. Ensure a full view of
outrigger movements, especially while working from the opposite side. A residual risk of shearing,
trapping and crushing danger occurs in areas concerning outriggers moving to transport position.
Reenter the outrigger supports one at a time while checking every moving part. Ensure
a full view during each outrigger reentry operation.
Remove the removable outrigger plates (if fitted) before reentering the outrigger rams to transport
position.
Make sure outrigger supports are well-greased, in order to ensure their correct working.
Enable the outriggers following the instructions indicated in paragraph 6.3.3 “Enabling the
outriggers”.

As general procedure, completely reenter all the outrigger rams, then reenter the outrigger
supports and place the tiltable outrigger rams (if fitted) into transport position (vertical upwards
or inclined - refer to the following paragraphs).
Fig. 8.2
In order to operate the outrigger, select the element you want to activate and at the same time
operate the control lever.

1
1. Lever movement
2. Selected element as per the lever movement: S (outrigger ram), R (tilting of
outrigger ram), E (outrigger support)
(e.g.: E1: outrigger support - position 1)

1
1. Lever movement
2. Activation of the selected element as per the lever movement
Refer to the relevant paragraph of chapter 5 “Control systems” for the technical specifications
related to the control system.

If the crane is fitted with tiltable outrigger rams, follow this operating procedure for
every outrigger.
1. Reenter the outrigger ram completely
2. Reenter the outrigger support partially, as

indicated in phase 2 of the illustrative scheme
3. Place the tiltable outrigger ram into transport

position (vertical upwards or inclined)
4. Reenter the outrigger support completely
If the crane is fitted with hydraulically extendable outrigger supports, make

sure they reenter in this sequence: THIRD - SECOND - FIRST, in order to
avoid any damage to the internal chain system.
Make sure outrigger supports are well-greased, in order to ensure their

correct reentering sequence.

Hydraulically tiltable outrigger rams by chain
If the crane is fitted with hydraulically tiltable outrigger rams by chain, follow this procedure to
place them into transport position.
• Open tap V1 (fig. 8.3) to enable the outrigger ram reentry.
• Operate the control lever to completely reenter the ram.
• Partially reenter the outrigger support.
• Open tap V2 (fig. 8.3) to unlock the pivoting of the ram.
• Remove the safety pin (fig. 8.3 - position 2a) from the seat (fig. 8.3 - position 3a).
• Remove the locking pin (fig. 8.3 - position 1a).
Once the locking pin is removed, the outrigger ram swings to an inclined
position towards the ground, therefore a residual crushing risk occurs for
operator and persons in the vicinity. Do not stop in proximity of the outrigger
ram working area.
• Operate the control lever to tilt the outrigger ram into transport position (vertical upwards):
the rotation ram R (fig. 8.4) exits and enables the pivoting of the outrigger ram.
• In order to lock again the pivoting of the outrigger ram, line-up the seats for the insertion
of the locking pin (fig. 8.4 - position 1b) and secure the locking pin by inserting the safety
pin (fig. 8.4 - position 2b) in the seat (fig. 8.4 - position 3b).

3b
V2
1a
V1
2a 2b
1b
3a
Fig. 8.3 Fig. 8.4

Check the pivoting of the tiltable ram is properly locked.
Safety and locking pins are made of special material. Do not replace them with
others: your safety depends on it.
• Completely reenter the outrigger support.
The previous procedure is described on the plate DE12934 here below.

8.4 – Deactivating the crane

Disengage the power take off. Deactivate the pump.
8.5 – Securing load and crane

Fix all the crane parts and implements in order to avoid exit of extension boom sections and outriggers
during transport, outer boom fall and crane rotation.
In case of fittings where the crane lays in transport position inside the vehicle body or on
the load, it is compulsory to properly block possible movements of the boom system and
crane rotation.
High risk of accidents (even serious) occurs if crane and implements aren’t secured against
lateral movements and rotation.
Properly fix and balance the load, in order to avoid its fall from the vehicle during transport.
Implements can be kept mounted on the extension boom sections of the crane (or of the hydraulic
extension) only if maximum allowed overall dimensions are observed and implements are properly
secured against possible uncontrolled movements.
Take note of the vehicle (included load) maximum dimensions. Observe the maximum
overall dimension in folded position for the transit under tunnels, bridges, underpasses,
power lines and the maximum allowed loads on the vehicle axles.
Pay special attention to road signs.
If the crane is fitted with safety devices signalling the exceeding of overall dimensions,
pay always attention to the alarms emitted in the vehicle cab and take proper measures
to reenter within the overall dimensions.

Chapter 9 — Use of implements
Chapter 9 - Use of implements
9.1 – Generality
According to model and HC1/S2 (ex H1/B3) classification, the crane may be provided with the
following implements:
• manual extensions;
• winch;
• hydraulic extension;
• clamshell bucket;
• rotator;
• auger.
If the use instructions of implements allow certain operations which are forbidden by the current
instructions, give always priority to the crane use instructions.
Dimensions and capacity of other implements than the hook must be proportioned with crane
performances.
Loads indicated on the capacity plates refer to crane without implements: so, prior to every lifting
operation, it is necessary to deduct the weight of the optional implements mounted on the crane
(e.g. manual extensions) from the load values represented on the plates.
Implements can be kept mounted on the extension boom sections of the crane (or of the hydraulic
extension) only if maximum allowed overall dimensions are observed and implements are properly
secured against possible lateral movements.
Before operating implements (such as bucket, rotator and auger), it is necessary to refer
to an authorised FASSI service centre and check their suitability to the crane: as a matter
of fact, it could be necessary to derate the crane.

9.2 – Hydraulic connections implements - supplementary hoses

9.2.1 - Quick coupling connectors
In case of hydraulic connections fitted with quick coupling connectors, it is necessary to check
that there is no trace of soil, dirt, etc. on their surfaces and inside their seats. This prevents a
possible hydraulic oil contamination and a consequent quick wear of connector sealing surfaces
and ram seals.
In order to assure a correspondence between implement control and movement,

hydraulic connections are provided with symmetrically mounted quick coupling
connectors.
It is forbidden to invert their positions, as movement inversion as well as operating
difficulties or unusual overload with implement could occur.
Before connecting/disconnecting the quick coupling connectors of the hydraulic system,

take proper precautions in order to make sure there is no residual pressure (even if the
feeding is deactivated).
In order to depressurize the system, from the radio remote control handle select and
hold the icon pressed, then move the levers (the ones controlling the implement).
During crane operation, oil and all the hydraulic system components reach high
temperatures.
Use the proper personal protective equipment during operations on quick coupling
connectors.

9.2.2 - Quick coupling multiconnectors
Quick coupling multiconnectors ease connecting and disconnecting operations of hydraulic

implements (hydraulic extension, bucket, auger, etc.) and include electric and hydraulic connections.
They are also fitted with special protective caps to preserve fixed and mobile parts from impacts
and dirt. In particular, the cap for the fixed part is provided with an electric termination for the
hydraulic extension limiting device.
Quick coupling multiconnectors
10
1 6 3 4
2
6
9
5 9
8
5
7 7
Fixed part Mobile part
(placed on the tip of the crane hose trays) (connected to the hydraulic implement)
1. Fixed part of the quick coupling multiconnector

2. Protective cap for the fixed part
3. Mobile part of the quick coupling multiconnector
4. Protective cap for the mobile part
5. Guide pins
6. Hydraulic connections
7. Electric connections
8. Electric termination for the hydraulic extension limiting device
9. Safety system (to avoid an accidental disconnection)
10. Handle
Before connecting/disconnecting the quick coupling connectors of the hydraulic system,

take proper precautions in order to make sure there is no residual pressure (even if the
feeding is deactivated).
In order to depressurize the system, from the radio remote control handle select and
hold the icon pressed, then move the levers (the ones controlling the implement).
During crane operation, oil and all the hydraulic system components reach high
temperatures.
Use the proper personal protective equipment during operations on quick coupling
multiconnectors.

Instructions for hydraulic implement connection
Before connecting hydraulic implements, clean the coupling connector surfaces.
1 2 3
1. Insert the guide pins of the mobile part into the holes of the fixed part and approach the
mobile part till the two surfaces come in contact.
2. Move the handle towards the fixed part.
3. Insist on the handle movement, until its safety system button automatically clicks.
Instructions for hydraulic implement disconnection
4 5 6
4. Push the safety system button and at the same time move the handle towards the mobile
part.
5. Insist on the handle movement till its mechanical lock.
6. Exit the mobile part.
Cover fixed and mobile parts with the protective caps. For the fixed part, mount the
cap by moving the handle until the safety system button automatically clicks.

9.3 – Controls to operate hydraulic implements

you want to perform.
Make sure that the lever you are going to operate corresponds to the control you want to perform.
Examples of pictograms for implement control
Winch movement Bucket movement Implement rotation

(descent) (open) (clockwise)
Jib Jib extension boom

movement movement
(lift) (reentry)

9.4 – Hydraulic extension

9.4.1 - Generality
The hydraulic extension is a supplementary articulated boom that can be folded behind cab. It is
provided with one or more extension boom sections and it must be applied to the last extension
boom section of the crane.
On demand, manual extensions can be mounted on the hydraulic extension.
The hydraulic extension is mounted by inserting its connecting boom into the last crane extension
boom section and fixing it with locking pins.
The hydraulic connection to the supplementary hoses is made through quick coupling connectors
or multiconnectors.
FASSI hydraulic extensions must be used only in combination with FASSI cranes and vice versa,
according to the manufacturer’s specifications and the use and maintenance manual of the crane.
Each FASSI hydraulic extension can be mounted only on certain FASSI crane models.
You can find the possible combinations between crane and hydraulic extensions in
Appendix A of the use and maintenance manual.
9.4.2 - General nomenclature
1. Connecting boom
2. Locking pin
3. Hydraulic extension ram
4. Hydraulic extension boom
5. Boom extension rams
6. Extension boom sections
7. Manual extensions (if fitted)
8. Lifting hook

9.4.3 - Technical specifications
Loads that can be lifted and handled by the hydraulic extension are indicated on the corresponding
capacity plates for crane with hydraulic extension.
The use of manual extensions in combination with hydraulic extensions is allowed in conformity
with the warnings and instructions included in paragraph “Manual extensions” of the crane use
and maintenance manual.
Prior to every operation with the hydraulic extension, it is necessary to consider the
weight of optional implements mounted on the crane (e.g. manual extensions) and
deduct it from the load values represented on the plates.
Identification data of the hydraulic extension are indicated on the plates DE7066 (used for CE
mark) and DE7067 (used for extra EC markets).
For dispositions concerning service and storage conditions, refer to chapter 2 “General
specifications” of the crane use and maintenance manual, as the same instructions for
crane operation are valid for the hydraulic extension.
9.4.4 - Health and safety instructions
Refer to chapter 3 “Health and safety instructions” of the crane use and maintenance
manual, as the same instructions for crane operation are valid for the hydraulic extension.
For information and instructions in case of quick coupling connectors and multiconnectors,
refer to paragraph “Hydraulic connections implements - supplementary hoses” of the
crane use and maintenance manual.
During hydraulic extension operation, oil and all the hydraulic system components reach high
temperatures.
Do not touch hoses, pipes and quick coupling connectors/multiconnectors during hydraulic
extension operation.
Operating the hydraulic extension, it is forbidden to lift higher loads than the allowed
ones as per the capacity plates.
serious) for operator and persons in the vicinity, vehicle overturning and breaking of
crane and hydraulic extension components.

If you need to move a hydraulic extension, use suitable means according to its weight. During
this operation, the operator is directly responsible for the machine and his own safety. Use hook
attachment and connecting rods of the hydraulic extension as hooking points.
Follow the lifting scheme of the figure here below (ISO 3056).
β=45° 0.7·P 0.7·P
60°
1·P 1·P
Hydraulic extension having mass P
Example
In case of mass of hydraulic extension = 1000 kg and β=60°, the pull of each rope
must be higher than 1000 kg.

9.4.5 - Safety devices
Locking device against the exit of extension boom sections
Hydraulic extensions are equipped with a special automatic lock preventing their extension
boom sections from accidentally exiting during transport (in case of folded cranes in transport
position).
As a matter of fact, as hydraulic extensions are usually folded at rest on the crane outer boom
with their extension boom sections pointed downwards, the dynamic effects due to road
transport could cause their exit: the locking device solves this problem.
If it is not possible to place the hydraulic extension at rest in folded configuration,

place it inside the vehicle body.
Locking system
Hydraulic extensions are provided with a locking system composed of a locking and a check
pin (fig. 9.I.1 and 9.I.2). This system ensures an integral connection to the crane.
3 3
2
1
1
Fig. 9.I.1 Fig. 9.I.2
Electronic lifting moment limiting device
The electronic lifting moment limiting device mounted on the crane informs the operator about
the loading conditions of the hydraulic extension and manages its movements in case of
overload (block due to overload) or attainment of the maximum vertical limit (lifting block).
For any information about its working, refer to chapter 4 “Safety devices and special functions”
of the crane use and maintenance manual.

9.4.6 - Setting up for hydraulic extension operation
Mounting the hydraulic extension
While mounting the hydraulic extension on the crane, keep a safety distance in order
to avoid a crushing danger due to a possible loss of stability.
Carry out the mounting operations slowly and make sure the connecting boom
enters its seat smoothly.
By placing the hydraulic extension as showed in the figure and operating the control levers:
• place the crane extension boom sections at a proper distance from the connecting boom
of the hydraulic extension, in order to enable the lining-up manoeuvres and the connection
of hoses;
• if quick coupling connectors are fitted, connect the hydraulic extension hoses to the
hydraulic system according to the instructions of paragraph “Quick coupling connectors”
of the crane use and maintenance manual; if quick coupling multiconnectors are fitted,
follow the instructions of paragraph “Quick coupling multiconnectors” of the crane use and
maintenance manual;
• if quick coupling connectors are fitted, disconnect the electric cap from the socket placed
on the last crane extension boom section and connect the electric cable for the pressure
transducer;
• operate the rams of hydraulic extension and crane in order to line-up crane extension boom
sections and connecting boom; this enables to insert the connecting boom into the last
extension boom section;
• operate the crane extension boom sections (in case repeat the previous manoeuvre), until
the fixing holes are lined-up;
• insert the locking pin (fig. 9.I.1 - position 1) in the holes and secure it with the nut (fig. 9.I.1-
position 2) and the check pin (fig. 9.I.1 - position 3)
or (according to the locking system version)
insert the locking pin (fig. 9.I.2 - position 1) and the safety pin (fig. 9.I.2 - position 2) into
the seat (fig. 9.I.2 - position 3), securing them with the check pin (fig. 9.I.2 - position 4).
The locking pins are made of special material. Before crane and implement operation,
make sure they are in a good state of repair: in case of wear or damages, replace
them only with original FASSI spare parts. Your safety depends on it.
Check the locking pins are correctly inserted.
It is forbidden to operate the hydraulic extension if the locking pins are not correctly
inserted.

Placing the hydraulic extension into working position
The sequence of operations to unfold (first line) and fold (second line) the crane fitted with
hydraulic extension is represented on the plate DE13749.
In order to place the hydraulic extension into working position (starting from an articulated
crane that is folded in transport position), follow this procedure:
• fold the crane outer boom, making sure that extension boom sections
are reentered;
• fold the hydraulic extension;
• lift the crane inner boom over the horizontal position, in order to enable
the hydraulic extension unfolding;
• lift the crane outer boom to the horizontal position;
• unfold the hydraulic extension;
• exit the extension boom sections and position the hook on the vertical
line above the load.

9.4.7 - Hydraulic extension operation
The pictograms placed near the levers indicate their operating direction. The following figure
shows the symbols used to identify the hydraulic extension components; the arrow indicates the
direction of the corresponding movement.
Pictograms for hydraulic extension control
Jib extension boom movement Jib movement

(reentry) (lift)
Jib extension boom movement Jib movement

(exit) (descent)
Operating the hydraulic extension, it is forbidden to lift higher loads than the allowed
ones as per the capacity plates.
It is forbidden to operate the hydraulic extension in the configuration represented on

the left side of the following figure.

9.4.8 - After hydraulic extension operation
Placing the hydraulic extension into transport position on the crane
In order to place the hydraulic extension into transport position on the crane, follow this
procedure (indicated on the plate DE13749 - second line):
• completely reenter the jib extension boom sections;
• completely reenter the crane extension boom sections;
• lift the crane inner boom to its stroke end;
• fold the hydraulic extension to its stroke end;
• fold the crane outer boom to its stroke end;
• rotate the crane until the reference indicators on column and base
coincide;
• fold the crane inner boom to its stroke end;
• reenter the outriggers as described in paragraph 8.3 “Reentering the

outriggers” of the crane use and maintenance manual.
Make sure that the crane equipped with hydraulic extension and placed folded behind
cab doesn’t exceed the maximum overall dimension and weight for road transport.
If necessary, place the crane boom with hydraulic extension laid inside the vehicle
body, blocking any possible lateral movement.

Removing the hydraulic extension
By operating the control levers:
• place the hydraulic extension so that its two rest brackets lay on the ground or inside the
vehicle body (see the following figure);
• remove the locking and check pins;

• if quick coupling connectors are fitted, disconnect the hydraulic extension hoses from the
hydraulic system according to the instructions of paragraph “Quick coupling connectors”
of the crane use and maintenance manual; if quick coupling multiconnectors are fitted,
follow the instructions of paragraph “Quick coupling multiconnectors” of the crane use and
maintenance manual;
• if quick coupling connectors are fitted, disconnect the electric cable of the pressure
transducer: alarms 06 and 25 appear;
• put on the specific electric cap on the pressure transducer socket;
• select the LMI icon to reset alarms 06 and 25;
• reenter the crane extension boom sections in order to extract the connecting boom from
the crane.
Lay the hydraulic extension on a proper base and fix it to prevent any movement. If
you lay down the hydraulic extension in an unsuitable way, damages to persons and
device could occur. In case, use a pallet with closed surface.
Check the correct positioning of implements on the vehicle, in order to avoid unexpected
movements.
9.4.9 - Maintenance and dismantling
For instructions concerning maintenance and dismantling of the hydraulic extension, refer to
chapter 10 “Maintenance” of the crane use and maintenance manual.

9.5 – Manual extensions

9.5.1 - Generality
Manual extensions can be inserted in the last crane/jib extension boom section in order to increase
the machine outreach. Special FASSI locking pins enable their correct positioning and fixing.
Each FASSI manual extension can be mounted only on certain FASSI crane or hydraulic
extension models. You can find the possible combinations in Appendix A of the use and
maintenance manual.
6 2 5
1. Manual extension
4 2. Locking pin
3. Nut
4. Check pin
7
5. Safety pin
6. Mechanical stroke end devices
1
7. Guide shoes
2 8. Shackle
3
9. Hook
4
Fig. 9.M.1
The manual extension maximum capacity is indicated on the capacity plates.
This capacity is also indicated on the following plate, that is applied to manual extensions for EC
market.

1
2. Manual extension maximum capacity
2 3. Manual extension type

Operate manual extensions according to the maximum capacity indicated on the

capacity plates.
Prior to every operation with crane or hydraulic extension, it is necessary to consider

the weight of manual extensions. If they are mounted, deduct their weight from the
load values represented on the capacity plates.
crane operation are valid for manual extensions.
manual, as the same instructions for crane operation are valid for manual extensions.
The operator must know exactly the weight he has to lift: use the electronic check
system for the load hooked on manual extensions.
Before starting operation, make sure the locking pins are inserted and secured with the
check pins, in order to prevent an accidental exit.
Operating manual extensions, it is forbidden to lift higher loads than the allowed ones
as per the capacity plates.
It is possible to move manual extensions only if they weigh less than 20 kg, otherwise it is
necessary to use proper tools. The operator must choose the tool according to the manual
extension weight.
m < 20 kg m > 20 kg

Mechanical stroke end
Each manual extension is provided with a mechanical stroke end device that prevents its
accidental exit.
There are two possible versions of mechanical stroke end device, as per the following figures.
removable stroke end device fixed stroke end device
Locking systems
Each manual extension is provided with a locking and a check pin, in order to prevent its
accidental exit during transport and working.
There are two possible versions of locking system, as per fig. 9.M.2 and 9.M.3.
Fig. 9.M.2 - Version A Fig. 9.M.3 - Version B
The locking pins are made of special material. Before crane and implement operation,
make sure they are in a good state of repair: in case of wear or damages, replace
them only with original FASSI spare parts. Your safety depends on it.

Electronic check system for load hooked on manual extensions
The electronic check system for load hooked on manual extensions is not always
active (unlike the lifting moment limiting device of the crane), but it has to be
activated by the operator just to check if the load can be handled safely.
The presence of the electronic check system for load does not exempt the operator
from respecting the lifting diagrams represented on the capacity plates.
Once activated, the check system for load hooked on manual extensions compares the real
load hooked on manual extensions (included possible implements) with the admissible load.
This check only works while the operator is performing the dedicated procedure (1).
It is forbidden to add or replace loads once the check procedure has been performed.
If you add or remove one or more manual extensions from the original crane
installation, you must refer to an authorised FASSI service centre in order to update
the system as per the new configuration.
Prior to starting the load check procedure, extend the manual extensions as per the
sequence indicated on the capacity plate.
The check procedure enables to verify if a load can be handled when using manual extensions
on crane and/or hydraulic extension.
The procedure gives back the following information:
• admissible/not admissible load handling;

• approximate calculation of the load weight.

(1) Procedure to use the check system for load hooked on manual extensions
Select the icon .
Manual extensions mounted both on Manual extensions mounted only on

crane and hydraulic extension crane or only on hydraulic extension
When this screen is displayed:
MANUAL EXTENSIONS
Crane?
Jib?
select Crane or Jib, depending on whether

the manual extensions are mounted on
crane or hydraulic extension.
MANUAL EXTENSIONS
M1
M2
M3
select the number of extended manual extensions.
Manual extensions mounted on crane Manual extensions mounted on

hydraulic extension
MANUAL EXTENSIONS
Enter to confirm
confirm the message to continue.

MANUAL EXTENSIONS
K1
K2
K3
K4
select the extension boom section

configuration:
K1: crane extension booms reentered;
K2: crane extension booms reentered
and jib extension booms extended;
K3: crane extension booms extended
and jib extension booms reentered;
K4: crane and jib extension booms
extended.
MANUAL EXTENSIONS
Enter to confirm
MANUAL EXTENSIONS
P2 STROKE END
in load-less condition, lift the outer boom to its stroke end (operate the control even if
the ram is already at its stroke end).

Manual extensions mounted on crane Manual extensions mounted on

hydraulic extension
This screen is displayed:
MANUAL EXTENSIONS
JIB STROKE END
in load-less condition, lift the hydraulic

extension to its stroke end (operate the
control even if the ram is already at its
stroke end).
MANUAL EXTENSIONS
ENTER TO START
MANUAL EXTENSIONS
UP P1
operate the control lever to lift the inner boom, in order to eliminate any excess of
pressure (the operation does not produce any crane movement). When the lever returns
to neutral position, the system checks the inner ram pressure.
In case of irregularities, this screen is displayed:
MANUAL EXTENSIONS
PRESSURE ERROR
If irregularities with the inner ram pressure are detected, it is necessary to repeat the
procedure: go back to the main screen.

If no error is detected, the procedure continues with the request to lift the load.
MANUAL EXTENSIONS
START LOAD P1
Pv Memo
P. Max
Pv Memo displays the stored pressure value

P. Max displays the maximum allowed pressure value
Operate the inner boom and slowly lift the load from the ground.
• If the load value is admissible, this message is displayed:
MANUAL EXTENSIONS
LOAD OK
Load:
Load indicates the approximate weight in kg.
• If the load exceeds the maximum admissible value for the manual extension, this
message is displayed:
MANUAL EXTENSIONS
LOAD TOO HIGH
Load:
• If you lift the load too fast during the check procedure, this message is displayed:
MANUAL EXTENSIONS
TOO FAST
• If the load exceeds the maximum admissible value for the crane (inner ram overload),
this message is displayed:
MANUAL EXTENSIONS
CRANE OVERLOAD
When one of the above messages is displayed, the procedure is over.

9.5.6 - Setting up for manual extension operation
Instructions
Do not place limbs, fingers or any other part of your body into areas of the crane
where shearing danger occurs, without having arranged proper lock systems for
these areas.
It is forbidden to exit manual extensions too fast: this would cause damages to the
stroke end devices.
During operations to extend and reenter manual extensions, it is necessary to work

from a lateral position. Operating in front of the exit direction of manual extensions
is dangerous, therefore it is forbidden.
Make sure the area used to extend and reenter manual extensions is adequate and
suitable.
Extend the manual extensions according to the sequence and loads indicated on
capacity plates.
Mounting the manual extensions
Mounting must be performed by a competent person in a workmanlike manner: refer to an

authorised FASSI service centre.
Insert the manual extensions in the last crane/jib extension boom section by means of suitable
tools.
Mount the removable mechanical stroke end devices (if fitted) on the end of each manual
extension and secure the manual extension with the locking pins.
Extending the manual extensions
1. Orientate the outer boom downwards.

2. Exit the extension boom sections as long as the manual extensions you want to extend,
laying the last manual extension on the ground (in case, use a wooden plate between
manual extension and soil in order to avoid surface damage).
3. Unlock and extract the locking pin (fig. 9.M.1 - position 2) of the manual extension you want
to extend.
4. Slowly reenter the extension boom sections in order to enable the manual extension exit.
5. Once the manual extension is extended, according to the locking system:
Version A (fig. 9.M.2): insert the locking pin (fig. 9.M.1 - position 2) and secure it with
the nut (fig. 9.M.1 - position 3) and the check pin (fig. 9.M.1 - position 4);
Version B (fig. 9.M.3): insert the locking pin (fig. 9.M.1 - position 2) and secure it by
inserting the safety pin (fig. 9.M.1 - position 5) into its seat (fig. 9.M.3); secure the safety
pin with the check pin (fig. 9.M.1 - position 4).
6. Repeat above-mentioned operations 3, 4 and 5 for each manual extension you want to
extend.
7. Mount the hook.
Do not try to line-up the holes/slots for the locking pin insertion with your fingers;
always use a suitable tool.
Check all the locking pins are correctly inserted and the manual extensions properly
secured.
Mounting the hook on manual extensions
There are three possible types of hook attachment on manual extensions, as per the following
figures.
Mount the hook according to the type of attachment that is fitted on the manual extension.
2 3 2
2 3 1
2
1 3
3
1
1
Make sure all the locking pins (position 1), nuts (position 3) and check pins (position
2) are correctly mounted.

9.5.7 - Manual extension operation
It is allowed to operate manual extensions only in compliance with the maximum capacity
indicated on the capacity plates.
The operator must know exactly the weight he has to lift: use the electronic check
system for the load hooked on manual extensions.
The electronic check system for load hooked on manual extensions is not always active
(unlike the lifting moment limiting device of the crane), but it has to be activated by the
operator just to check if the load can be handled safely.
Loads indicated on the capacity plates refer to crane without implements: so, prior to
every lifting operation, it is necessary to deduct the weight of manual extensions from
the load values represented on the plates.
9.5.8 - After manual extension operation
Instructions
Slowly reenter manual extensions. Do not place limbs, fingers or any other part of
your body into areas of the crane where shearing danger occurs, without having
arranged proper lock systems for these areas.
During operations to extend and reenter manual extensions, it is necessary to work

from a lateral position in order to prevent possible impacts.

Reentering the manual extensions
1. Remove the hook.

2. Orientate the outer boom downwards.
3. Lay the last manual extension on the ground (in case, use a wooden plate between manual
extension and soil in order to avoid surface damage).
4. Unlock and extract the locking pin (fig. 9.M.1 - position 2) of the manual extension you want
to reenter.
5. Slowly extend the extension boom sections in order to enable the manual extension reentry.
6. Once the manual extension is reentered, according to the locking system:
Version A (fig. 9.M.2): insert the locking pin (fig. 9.M.1 - position 2) and secure it with
the nut (fig. 9.M.1 - position 3) and the check pin (fig. 9.M.1 - position 4);
Version B (fig. 9.M.3): insert the locking pin (fig. 9.M.1 - position 2) and secure it by
inserting the safety pin (fig. 9.M.1 - position 5) into its seat (fig. 9.M.3); secure the safety
pin with the check pin (fig. 9.M.1 - position 4).
7. Repeat above-mentioned operations 4, 5 and 6 for each manual extension you want to
reenter.
Do not try to line-up the holes/slots for the locking pin insertion with your fingers;
always use a suitable tool.
Check all the locking pins are correctly inserted and the manual extensions properly
secured.
Removing the manual extensions
The removal of manual extensions must be performed by a competent person in a workmanlike

manner: refer to an authorised FASSI service centre.
In order to carry out the operation, sling and support the manual extensions, then remove the
mechanical stroke end devices (if removable) and extract the manual extensions by means of
proper tools.
For instructions concerning maintenance and dismantling of manual extensions, refer to chapter
10 “Maintenance” of the crane use and maintenance manual.

9.6 – Winch system

9.6.1 - Generality
The winch system is composed of a rotating drum fixed to a structure which is integrally connected
to the crane and of lifting devices.
A hydraulic motor (controlled by a safety check valve that is connected to the crane circuit)
enables the rotation of the drum on which the rope winds.
When the winch control lever is in neutral position, the load is kept in position by a fail-safe
negative brake integrated into the motoreducer unit.
Prior to winch operation, read the use and maintenance instructions provided by the
manufacturer.
1. Winch
2. Rope
3. Fixed pulley
4. Balance weight/
Rope stretcher
5. Hook
6. Transmission pulley
7. Mobile pulley
Winch identification data and technical features are indicated on a metallic plate. It is applied
on the winch by its manufacturer and is used for CE mark, according to the Machinery Directive.
The identification data on the plate are the following:
6
1. Manufacturer’s name
1 2. Winch type
3 3. Serial number
2
5. Winch weight
6. Rope diameter
5
7
7. Maximum pull at the datum layer
8. Datum layer
8
Moreover, the following adhesive plate is applied on pulleys for EC market.
1. Pulley code
1 2. Pulley weight
2 3. Pulley maximum capacity
4

Each FASSI pulley can be used only in combination with certain winch models, which in
turn can be mounted only on certain FASSI crane models.
You can find the possible combinations crane - winch in Appendix A of the use and
maintenance manual.
crane operation are valid for the winch system.
manual, as the same instructions for crane operation are valid for the winch system.
The capacity plates for crane with winch indicate the maximum load that can be lifted
by a crane provided with winch system in the different working configurations (n=1
single pull, n=2 double pull, n=3 triple pull, n=4 quadruple pull).
capacity plates for crane with winch. Exceeding the allowed limits of outreach and load
involves hazards of accidents (even serious) for operator and persons in the vicinity,
vehicle overturning and breaking of crane components.
It is forbidden to exit the crane/jib extension boom sections when the load is lifted by
the winch.
During lifting operation with balance weight or mobile pulley next to the fixed pulley,
reduce the exit speed of extension boom sections in order to prevent stresses on the
rope.
The locking pins are made of special material. Do not replace them with others: your
safety depends on it.

Mechanical stroke end
The stroke end condition occurs when mobile pulley or balance weight come in contact with
the fixed pulley structure (the following figures show the parts coming in contact).
Prior to starting a lifting manoeuvre, carefully check quotas and overall dimensions.
Single pull Double pull Triple pull Quadruple pull

(n=1) (n=2) (n=3) (n=4)
Fig. 9.V.1 shows a normal working situation.

Fig. 9.V.2 shows the activation of the mechanical stroke end device.
Fig. 9.V.1 Fig. 9.V.2
Block due to activation of limiter and safety functions of the winch
The activation of the winch limiter due to overload blocks the following manoeuvres:
• inner boom lift and descent;

• outer boom lift and descent;
• hydraulic extension (if fitted) lift and descent;
• exit of crane extension boom sections;
• exit of extension boom sections of the hydraulic extension (if fitted);
• lift of the winch rope.
The block caused by winch rope totally unwound prevents this manoeuvre:
• descent of the winch rope.

The extension boom section block due to winch overload (with winch capacity and crane angle
over certain parameters) prevents the following manoeuvres:

• exit of extension boom sections of the hydraulic extension (if fitted).
The block due to activation of the mechanical stroke end device prevents the following
manoeuvres:
• hydraulic extension (if fitted) lift and descent;

• exit of extension boom sections of the hydraulic extension (if fitted);
• lift of the winch rope.
Winch fail-safe negative brake
For any information about the integrated fail-safe negative brake, refer to the use and
maintenance instructions provided by the winch manufacturer.

9.6.6 - Setting up for winch system operation
Working types
In fig. 9.V.3 you can find the mounting scheme of fixed pulley, balance weight and mobile
pulley in case of single, double, triple and quadruple pull.
Single pull Double pull Triple pull Quadruple pull

(n=1) (n=2) (n=3) (n=4)
Fig. 9.V.3

Mounting mobile pulleys and balance weight
According to the working type, mount mobile pulley or balance weight as per the following
figures: insert the locking pins (position 1) and secure them with nut and check pins (position
2).
1 2
1
n=1 n=2
2 1 2 1
2
2
1
1
n=3 n=4
Prior to starting operation, check the locking pins are inserted and secured by their
check pins.
The loads represented on the capacity plates for crane with winch can be lifted only
respecting the number of pulls specified in the plates.

Mounting the fixed pulleys on crane
Mount the fixed pulley by the hook attachment and the middle guide pulley (if fitted), by
inserting the locking pins (position 1) and securing them with nut and check pins (position 2).
fixed pulley
1
2
2
1
middle guide pulley

Mounting the fixed pulleys on hydraulic extension
If the hydraulic extension is fitted, mount fixed pulley, transmission pulleys and balance weight
as per the following figures, by inserting the locking pins (position 1) and securing them with
nut and check pins (position 2).
2 1 2
1
fixed pulley balance weight
1 2
2
1 1
transmission pulley transmission pulley
1
2
2
1
transmission pulley transmission pulley

1
2
2
1
1
transmission pulley fixed and transmission pulleys
1
2
2
1
middle guide pulley

(in case of manual extensions)
check pins.

Mounting the fixed pulleys on manual extension
A bracket adapter (position 3) is fitted on certain manual extensions: it must be mounted as

per the following figure.
check pins.
9.6.7 - During winch system operation
The pictograms placed near the levers indicate their operating direction.
Pictograms for winch control
Winch movement Winch movement

(descent) (lift)
Do not rotate the crane before the hooked load is lifted.
Lift the load vertically using the rope and not the boom, in order to avoid possible load
dangerous swinging, boom instability and premature guide shoe wear.
With suspended load, rotate slowly and carefully, paying attention to the vehicle stability..
When balance weight or mobile pulley are very close to the fixed pulley and you have
to work in their vicinity, place yourself laterally and not in front or behind the pulley and
operate at slow speed, since the contact (especially without load) may result in abrupt
movements of the hook group (fig. 9.V.4 and 9.V.5).

Fig. 9.V.4 Fig. 9.V.5
Operating the winch, it is forbidden to lift higher loads than the allowed ones as per the
relevant capacity plates.
Check that the rope rewinding on winch drum occurs regularly and without overlapping.
It is suggested that you rewind the rope only if it is taut enough.
For the proper rope rewinding on winch drum, the distance between winch and first
pulley shall correspond at least to the one represented on the capacity plates.
Prior to operation, check there are no wear signs on the rope.
9.6.8 - After winch system operation
Prior to folding the crane into transport position, remove all the pulleys by extracting locking and
check pins.
Completely rewind the rope on winch drum, checking the operation occurs properly.
In some cases, still observing the maximum overall dimension for transport, it is
possible to fold the crane without removing the fixed pulley (fig. 9.V.6) and by fixing
the winch hook to the specific outer boom bracket (fig. 9.V.6 - position 1).
Fig. 9.V.6
For instructions concerning maintenance and dismantling of the winch system, refer to chapter
10 “Maintenance” of the crane use and maintenance manual.

Chapter 10 — Maintenance
Chapter 10 – Maintenance
10.1 – Generality
In this chapter you can find the check and planned maintenance programme of a FASSI crane,
together with the detailed instructions concerning maintenance operations. Good maintenance and
correct use are essential to ensure and safeguard the crane functionality and safety.
In order to ensure long life for the crane, it is necessary to scrupulously follow instructions and
maintenance programmes of this chapter.
At least once a year you must take the crane to an authorised FASSI service centre for a
check.
Each crane is provided with a “Check register” where you must record all the checks and ordinary
and extra maintenance operations you carry out on the crane.
FASSI declines any responsibility for ruptures or damages to product, persons or things
due to a lack of check and maintenance.
If you repair or replace any crane component, you must use original FASSI spare parts. In this way
only you can ensure a constant and regular crane working and avoid early warranty rescission.
While repairing or checking hydraulic system and rams, don’t use or approach materials that may
damage the system or contaminate the hydraulic oil (hemp filaments, oakum, metal shavings, sand
and powdered materials, etc.).
All maintenance operations must be carried out with stationary machine, turned off engines
and depressurized hydraulic system.
In order to depressurize the system, from the radio remote control handle select and hold
the icon pressed, then move the levers.
During maintenance operations, do not place limbs, fingers or any other part of your
body into areas of the crane where shearing, cutting, crushing, trapping or impact danger
occurs, without having arranged proper lock systems for these areas.
During maintenance operations pay special attention because of burn danger due to
possible hot components.

It is forbidden to carry out on the crane welding, drilling, grinding or any other action that
is not described among maintenance operations, without FASSI authorization.
In the following paragraphs you can find check and maintenance lists for operator, competent
personnel and FASSI authorised service centre (ISO 9927), as well as necessary instructions for
operations carried out by operator and competent personnel (for instructions related to the operations
performed by the service centre, refer to the installation manual).
Icon legend for check and maintenance lists:
Operator’s checks
Checks and preventive maintenance by the competent personnel (ISO 12480-1)
Maintenance by the authorised FASSI service centre
Visual check
Functional check
Cleaning
Lubrication
Replenish / Replacement
Nondestructive check
The operator is not allowed to carry out maintenance operations that are reserved to
authorised FASSI service centres.

10.2 – Checks and preventive maintenance
Daily checks
Time required: 15 minutes
In case of
Element Description
anomalies (1)
Check the functionality of hook and its safety devices.
Go to an authorised
Lifting hook Visually check the physical integrity of hook and its service centre or
(ISO 17440) components, to make sure there are no surface damages and replace the hook.
excessive deformations.
Carry out a general check of cleaning conditions and make Clean crane and
sure there are no foreign substances (dust, ice, snow, grease, accessories
oil, etc.). (§ 10.3.3).
Crane and Carry out a general functional check to make sure there are
accessories no malfunctioning, irregular noises and movements.
Carry out a general check of the physical integrity, to
make sure there are no lacking, damaged or unsuitable
components.
Visually check the physical integrity of the metal structure,
Metal carpentry
paying special attention to weld joints (absence of breaks, Go to an authorised
(2)
cracks, paint flaking, cuts, incisions, etc.). service centre.
Bolts and screws
Visually check that threaded connections are not loosened.
(2)
Winch rope Visually check the physical integrity of the rope segment in
(ISO 4309) use (§ 10.3.2).
Hydraulic system
Visually check there are no oil leakages.
(2)
Visually check the oil level in the tank by the specific indicator Replenish the
Tank
(§ 10.3.7). lacking oil.
Check by the specific indicators that there is no obstruction in Replace the filter
Filters
the pump high pressure filter (§ 10.3.8). (§ 10.3.8).
Check the safety system functionality (§ 10.3.10).
Check that protections and ladder for top seat control station Go to an authorised
Safety devices are fitted. service centre.
Check that removable locking devices are fitted and well-
functioning.
Warning Visually check the physical integrity of warning and capacity
plates. Go to an authorised
and capacity
service centre.
plates, use and Check the use and maintenance manual is provided.
maintenance Visually check that warning and capacity plates are clean and Clean warning and
manual readable. capacity plates.
Carry out a general check for the correct working of
Transducers and
transducers and sensors (check the conformity between crane
sensors (2)
configuration and sensor output).
Visually check the physical integrity of control levers. Go to an authorised
service centre.
Control levers (2) Manually check the operating fluidity of control levers.
Check that control levers automatically return to neutral
position without any problem.

Weekly checks and preventive maintenance

(Before the following operations, carry out the daily checks)
In case of
Element Description
anomalies (1)
Clean the hook
Check that the hook safety device and its spring are clean. safety device and its
Lifting hook
spring.
(ISO 17440)
Check and detect the critical dimensions of hook and its
components, according to § 10.3.1.
Visually check the physical integrity of the rope segment in Go to an authorised
Winch rope use (considering besides 5 turns around the drum). Check service centre.
(ISO 4309) there are no broken wires, deformations, flattening, corrosion,
wrinkles, etc. (§ 10.3.2).
Clean the oil cooler
Oil cooler/
Visually check the cleaning conditions of the oil cooler. blowing air (do not
heat exchanger
disassemble).
Dissolve and remove impurities on ram rods. Rub the
Rams (2) surface using an industrial oil-soaked cloth (use low viscosity
protective oil - see § 10.3.5).
Lubricate crane and its components according to the planned
Lubrication
lubrication programme (§ 10.3.9).
Lubricate extension
Visually check the lubrication of extension boom sections and
Lubrication boom sections and
guide shoes.
guide shoes.
Quarterly checks and preventive maintenance

(Before the following operations, carry out daily checks and weekly
checks/preventive maintenance)
In case of
Element Description
anomalies (1)
Go to an authorised
Slew ring Visually check the wear condition of slew ring seals.
service centre.
Carry out a careful visual check of the physical integrity of the
Metal carpentry metal structure, paying special attention to structural weld
(2) joints (absence of breaks, cracks, paint flaking, cuts, incisions,
etc.)
Visually check the physical integrity of the ram cylinder, Go to an authorised
making sure there are no deformations. service centre.
Rams (2)
Visually check the surface covering of ram rods, making sure
there are no deformations.
Visually check the physical integrity of the outrigger ram plate.
Check the joint
Outrigger rams lubrication - Go
Manually check that the outrigger ram plate is free to move.
to an authorised
service centre.

Quarterly checks and preventive maintenance

(Before the following operations, carry out daily checks and weekly
checks/preventive maintenance)
In case of
Element Description
anomalies (1)
Visually check there are no surface damages, such as cracks,
Seat incisions, cuts or crevices, abrasions on frame, structure and
seat.
Bolts and screws Go to an authorised
Visually check the physical integrity of bolts and screws.
(2) service centre.
Visually and manually check there are no clearances in the
Pivot points (2) pivot points, paying special attention to self-locking ring nuts
(1) and snap rings (1).
Visually check the physical integrity of winch and its
components (cable gland, pulleys, etc.).
Carry out a functional check of winch and its components
Winch
(cable gland, pulleys, etc.).
Carry out a test to check that load is kept in position by the
brake (§ 10.3.2).
Visually check hydraulic system and its components, verifying Go to an authorised
their physical integrity and the absence of corrosion, cracks, service centre.
Hydraulic system cuts, abrasions, disjunctions, lacerations and other surface
(2) damages.
Visually check hydraulic system and its components, making
sure there are no oil leakages.
Manually check that the tap switches smoothly.
Tank Replace the
Visually check there is no filter obstruction (§ 10.3.7).
cartridge (§ 10.3.7).
Visually check the physical integrity of greasing kit and grease
Grease nipples (2)
nipple (§ 10.3.9).
Electric and
Visually check the physical integrity of electric and electronic Go to an authorised
electronic devices
equipment. service centre.
(2)
Transducers and Check the physical integrity of the metal reader for proximity
sensors (2) sensor.
Lubrication
Clean crane and its implements using suitable products
Crane cleaning
(§ 10.3.3).
Every 100 hours (Work Time) of utilization of each

component / quarterly
In case of
Element Description
anomalies (1)
Lubrication
(1) The described operations must be carried out by competent personnel (ISO 12480-1).
(2) See the list of components in paragraph 10.4 “Checks and maintenance by the authorised FASSI
service centre”.

10.3 – Instructions for checks and preventive maintenance

10.3.1 - Lifting hook
Nomenclature
The hook is the crane part in direct contact with load. In order to ensure its proper working
condition, it is necessary to check and record its correct functionality and also its wear and
deformation conditions.
2 1. Ring
2. Pin
3
3. Safety device
4. Hook
4
Fig. 10.1 Fig. 10.2
Hook
Deformations
Measure the hook opening (measure D1 - fig. 10.2) and check permanent deformation
doesn’t exceed 10% of the value detected during the first measurement.
Wear condition
Measure the thickness of the hook lower part (measure E - fig. 10.2) and check that it
doesn’t decrease over 5% of the original value detected during the first measurement. No
gaps or discontinuity shall be found on the hook surfaces subject to wear.
If the component is over-deformed or worn, you must demolish and scrap it.
Ring
Deformations
Measure the major axis of the ring (measure B - fig. 10.2) and check that permanent
deformation doesn’t exceed 10% of the value detected during the first measurement.
Wear condition
Measure the thickness of the hook ring (measure R - fig. 10.2) and check that it doesn’t
decrease over 5% of the original value detected during the first measurement. No gaps or
discontinuity shall be found on the hook surfaces subject to wear.

If the component is over-deformed or worn, you must demolish and scrap it.
Functional check
• Check that the hook safety device properly returns to its position.
• Carry out a functional check of the bearing by swivelling the hook in respect of the ring.
10.3.2 - Winch
Nomenclature
5 1. Hydraulic motor and

safety check valve
2. Drum
1 3. Reduction unit
4. Frame
5. Rope
3
4
Fail-safe negative brake
A brake is fitted on the winch, in order to hold load while at rest.
To check the brake correct working, follow this procedure:
1. place the crane in horizontal configuration as per the capacity plate, with one extension
boom section out and observing the minimum distance between winch and first pulley;
2. lift the rated load by the winch a few centimetres from the ground, with single pull
increased of 5%;
3. turn off the vehicle engine;
4. operate the winch lift and descent control levers;
5. hold the load in position (at least 5 minutes);
6. if the load doesn’t sink, the brake working is correct.
If load moves excessively, go to an authorised FASSI service centre.
Rope
For any detail about rope maintenance, refer to the use and maintenance instructions provided
by the winch manufacturer.

10.3.3 - Crane cleaning
Wash the crane using a high-pressure water jet and cleaners in compliance with binding norms.
Do not use clothes that could scratch or damage the crane surfaces.
Crane cleaning must be carried out with:

• crane stabilized or placed in transport position;
• power take-off disengaged;
• engine turned off;
• hydraulic system depressurized.
It is forbidden to use high-pressure washing on crane controls (deviators, distributors,

control levers, etc.), electrical components (boxes, control panels, etc.), tanks and ram
rods.
It is forbidden to use detergents such as petrol and flammable cleaning solvents or

liquids. Choose and use non-flammable and nontoxic cleaning solvents.
10.3.4 - Base
Fixing rods integrally connect crane and vehicle, in order to avoid disconnections and corresponding
movements that could be dangerous and compromise the crane functionality.
Loosened or damaged bolts may cause unexpected breaks and serious consequences
for persons and/or things.
Controlling the fixing rods enables to find possible loosenings and to avoid malfunctioning and/
or dangers.

In order to control the fixing rods:
• visually check if there are signs of rubbing, scratches and traces due to movements of
screwed and bolted parts;
• manually check if bolts and screws are loosened.
10.3.5 - Rams
Nomenclature
1. Rod
2. Cylinder
2
Rod
In order to ensure the correct working of rams and safeguard them from corrosion, their rods
must be clear of impurities and protected by an oily film.
Preventive maintenance must be carried out in a very dry place.
1. Dissolve and remove with clean water any remains of salt, sand and production material,
as well as any other impurity on the rods.
2. Let rods dry in the open air.
3. Soak an industrial cloth (that leaves no remains) in low viscosity protective oil and rub
the whole rod surface.
Do not use steam cleaners or high-pressure water jets.
For oil characteristics, see paragraph 10.3.9.

10.3.6 - Slew ring
Nomenclature
4
3
5
2 1. Gear
2. Outer ring
1
3. Inner ring
4. Screws connecting slew ring and
base
5. Screws connecting slew ring and
column
6. Lubrication points
Bolts and Screws
Checking that bolts and screws on the slew ring are tightened avoids possible loosenings that
may cause inefficiency of the rolling system and possible breaks of the tightening system.
In order to control bolts and screws:
• visually check if there are signs of rubbing, scratches and traces due to movements of
screwed and bolted parts;
• manually check if bolts and screws are loosened.
Rolling system
The complete lubrication of the rolling system enables to reduce friction, to seal and protect
from corrosion. So, it is recommended that you lubricate every 100 working hours, using the
specific points signalled on the slew ring, so that grease comes out along the whole edge of
protective seals.
In order to ease grease distribution on bearings, it is suggested that you rotate the slew ring
while greasing. Any grease in excess coming out must be carefully removed.
For grease characteristics, see paragraph 10.3.9.

10.3.7 - Tank
Nomenclature
1. Tap
2
4 2. Tank
3. Oil filter
4. Indicator for oil level monitoring
Oil level
Check the oil level in the tank using the specific indicator shown in the figure above. This check
must be carried out with cold oil, crane in transport position, all outrigger rams reentered and
vehicle in horizontal position: oil must remain between maximum and minimum level signs.
If oil is under the minimum level, replenish it.

If oil is above the maximum level, go to an authorised FASSI service centre.
Oil filter
The filter holds in its cartridge all the solid particles that oil gathers along the hydraulic circuit.
If you don’t remove these solid particles, premature component wear may occur.
2
3
1
1. Head
2. Cap
3. Spring
4 4. Cartridge
5. Filter case
According to the planned maintenance programme, open and clean the filter, then replace the
cartridge following this procedure:
• unscrew the cap fixing screws and remove cap and spring (if fitted);
• remove the cartridge;
• clean the inner part of the filter case using a non-flammable cleaning solvent;
• insert a new cartridge and the spring (if fitted);
• check the wear condition of seals (in case of excessive wear replace them) and screw
again the cap on the head.

Table of hydraulic oil characteristics
High viscosity hydraulic oil: ISO-L-HV

Outdoor minimum Gradation
Oil maximum temperature
temperature
-35° C +45° C ISO VG 32
-20° C +75° C ISO VG 46
Wear resistant hydraulic oil: ISO-L-HM

Outdoor minimum Gradation
Oil maximum 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
10.3.8 - Pump high pressure filter
The filter holds in its cartridge all the solid particles that oil gathers along the hydraulic circuit. If
you don’t remove these solid particles, premature component wear may occur.
1
1. Head
2. Obstruction indicator
3. Cartridge
3
4. Seal
4 5. Filter case
The solid particles held by the filter must be periodically removed from the cartridge in order to
prevent a decrease of the machine performances.
A chromatic obstruction indicator signals when it is necessary to replace the cartridge: when
from green it becomes red, open and clean the filter, then replace the cartridge following this
procedure:
• unscrew the filter case from the head;

• remove the cartridge;
• clean the inner part of the filter case using a non-flammable cleaning solvent;
• insert a new cartridge;
• check the wear condition of seals (in case of excessive wear replace them) and insert again
the filter case in the head;
• mount again head and filter case.

10.3.9 - Lubrication
In order to ensure that mobile components of crane and implements correctly work, it is necessary
to grease or lubricate the different parts according to the following table.
Lubricating points are indicated on crane and implements by specific symbols. For example, their
positioning is represented in the following figures. In particular:
This symbol indicates that a This symbol indicates that

grease nipple is fitted in order a lubricating point is fitted.
to lubricate the component. Lubrication must be carried
Lubrication must be carried out directly on the component,
out using a pump or a suitable using specific instruments (e.g.
grease gun. brushes, grease rollers, clothes,
etc.).
Crane with slew ring
Before lubrication, remove old grease or lubricant, dirt and impurities.

During lubrication, it is suggested that you move components slowly, in order to better
and uniformly distribute the lubricant.
Apply grease till it comes out.
After lubrication, remove grease in excess.

Compulsory periodic lubrication
Group Subgroup Element Maintenance frequency

Every 100 working hours /
Slew ring Rolling system
quarterly (§10.3.6)
Slew ring Gear Weekly
Inner boom Ram Rod
Outer boom Ram Rod
Extension boom sections Ram Rod

Weekly (§ 10.3.5)
Jib Ram Rod
Jib extension boom
Ram Rod
sections
Outrigger rams Ram Rod
Column Pivot points Bushes
Inner boom Linkage system Bushes
Inner boom Pivot points Bushes
Inner boom Ram Bushes
Outer boom Outer boom
Outer boom Linkage system Bushes
Outer boom Pivot points Bushes
Outer boom Inner guide shoes
Outer boom Ram Bushes

Extension boom
Extension boom sections
sections
Quarterly
Extension boom sections Guide shoes
Jib Jib
Jib Linkage system Bushes
Jib Pivot points Bushes
Jib Inner guide shoes
Jib Connecting boom Guide shoes
Jib Ram Bushes

Jib extension boom Jib extension boom
sections sections
Jib extension boom
Guide shoes
sections
Manual extensions Guide shoes

Group Subgroup Element Maintenance frequency

Outrigger supports Outrigger supports
Outrigger supports Guide shoes
Outrigger rams Plate and pivot joint Quarterly
Winch Fixed pulley
Winch Transmission pulley
Winch Winch rope Quarterly (§ 10.3.2)

Table of lubricant/grease characteristics
Lubricating oil (for motoreducer unit)

Classification Gradation
ISO-L-CC EP ISO-VG 150
Lubricating oil (for winch rope)

The most suitable here is a general-purpose lubricating oil with about SAE 30° viscosity. A lubricating oil
containing sticky additives is recommended if ropes are expected to move quickly through the pulleys.
BRILUBE 50 (BRITISH ROPES - BRINDON)
Grease
(for slew ring, extension boom sections, outrigger supports, gears, pins, bushes, hook)
Temperature Gradation
EP1 (cold climate)
-30° C up to +130° C
EP2 (hot climate)
For slew ring, extension boom sections, outrigger supports, pins, bushes and hook use
NILEX grease by NILS firm.
For gears use NILEX or CETAL grease by NILS firm.
Alternatively, you can use acid- / resin-free, not hygroscopic and long-life greases, with the following
characteristics.
Characteristics of NILEX grease

(for slew ring, extension boom sections, outrigger supports, gears, pins, bushes, hook)
Soap-thickener: aluminium complex
Base oil viscosity at 40° C (DIN 51562): min. 800 mm2/s
4 balls Shell test - welding load (DIN 51350 T4): min. 3000 N
Corrosion protection (DIN 51802): degree 0/0
Classification (DIN 51502): KP 2P-20
Solid additives-free
Avoid use of spray and/or solvent based products
Characteristics of CETAL grease (for gears)

Soap-thickener: aluminium complex
Base oil viscosity at 40° C (DIN 51562): min. 500 mm2/s
4 balls Shell test - welding load (DIN 51350 T4): min. 5000 N
Corrosion protection (DIN 51802): degree 0/0
Classification (DIN 51502): OGF 0S-30
Graphite solid additive
It is forbidden to mix different types of grease.
It is forbidden to use greases with solid particles as Molybdenum disulfide (not

compatible with eventual Teflon bushes).

Electronic lifting moment limiting device
Place the crane over the vehicle body, in load-less condition and with extension boom sections
reentered.
Check the electronic lifting moment correct working.
If the electronic lifting moment limiting device blocks the crane (with rated capacity acoustic
indicator and LEDs turned on) and it is not allowed to exit extension boom sections and lower
inner/outer boom and hydraulic extension, it means that the lifting device is correctly working.
Otherwise, go to an authorised FASSI service centre.
Winch limiting devices
Procedure to check the correct working of the winch lifting couple limiter
On cranes fitted with winch, follow this procedure to check the correct working of the winch
lifting couple limiter:
1. place the crane in the configuration represented on the capacity plate;

2. slowly rewind the rope with single pull (n=1), in load-less condition and with
counterweight and hook only;
3. when the counterweight touches the fixed pulley, the winch lift shall stop and the oil
pressure detected by TP0 shall not exceed the maximum working pressure indicated
in the schedule “Crane technical data” in Appendix A. All movements of the crane /
hydraulic extension (if fitted) are prevented, except for the reentry of extension boom
sections and winch descent.
If the winch lifting couple limiter does not work correctly, go to an authorised FASSI service
centre.
Procedure to check the correct working of the stroke end device for winch rope
totally unwound
In order to check the correct working of the stroke end device for winch rope totally
unwound, follow this procedure:
1. place the crane with outer boom in horizontal position and inner boom in such a way
that the winch is as close as possible to the ground.
2. push the stroke end device (see figure below) by means of suitable tools.
3. holding the stroke end device pushed, operate the exit of extension boom sections.
If the operation is blocked, it means that the stroke end device for winch rope totally
unwound is correctly working.
If the stroke end device for winch rope totally unwound does not work correctly, go to an
authorised FASSI service centre.

STOP button
In order to check the STOP button correct working, follow this procedure:
• operate any crane control: movements should perform without any problem;
• push the STOP button during crane operation: the crane should stop;
• operate again any crane control: no operation should be possible;
• unblock the STOP button: crane operations should perform without any problem.
If you push the STOP button and the crane doesn’t stop or other functions are
still active, high risk of accidents (even serious) occurs for the operator and other
persons: do not operate the crane and immediately contact an authorised FASSI
service centre.
manoeuvres remain active: therefore it is necessary to pay special attention and
make sure nobody stops or passes in proximity of the outrigger ram working area.
Operating the crane with STOP button not working properly is a serious operator’s
negligence.
Transducers and sensors
The general check for the correct working of transducers and sensors (whose list is at the end
of paragraph 10.4) must be carried out to verify the conformity between sensor/transducer
output and real value of the detected measure.
Carry out this check every day during normal crane work: if you find any inconsistencies
between output signal and real detected value, go to an authorised FASSI service centre.
Examples of inconsistency between output signal and real detected value:
1. Transducer: tilting sensors of outer boom and hydraulic extension.

2. Transducer: Fassi Stability Control sensors.
3. Transducer: pressure transducers.
1. Tilting sensors of outer boom and hydraulic extension
With reference to the crane configuration shown in the picture, the following are examples
of tilting sensor inconsistency:
• angle detected by the outer boom tilting sensor: 0° or under 0°;

• angle detected by the hydraulic extension tilting sensor: 0
° or above 0°.

2. Fassi Stability Control sensors
In case of crane fitted with FSC/S and stabilized as shown in the figure (outrigger rams
touching the ground in correspondence to the black circles), the following are examples
of inconsistency:
• sensor signalling L0 working level;

• sensor signalling L3 working level on one/both side(s);
• sensor signalling L1 working level on both sides.
3. Pressure transducers
In case of crane operation with load close to the one represented on the capacity plate,
the pressure transducers shall detect a value close to the one indicated in the schedule
“Crane technical data” in Appendix A.
If one/all pressure transducer(s) detect very low values, there is an inconsistency
between detected measure and real value.

10.3.11 - Fixing rods, bolts and screws
Check that bolts are tightened: if it is not specifically indicated, their tightening torque must be
obtained from this table, according to their diameter and class.
Table of the bolt tightening torque, in general, with average friction value (0,15)
and average-good tightening accuracy (C).
(”Eléments de fixation - assemblages vissés” - AFNOR E 25-030 1984)
Tightening torque (Nm)
Bolt diameter
Class 8.8 Class 10.9 Class 12.9
M3 1,06 1,56 1,83
M4 2,44 3,58 4,19
M5 4,83 7,10 8,30
M6 8,30 12,30 14,30
M8 20 29 35
M10 40 59 69
M12 69 102 119
M14 111 163 191
M16 173 255 298
M18 239 352 412
M20 339 499 584
M22 466 685 802
M24 584 858 1004
M27 865 1271 1487
M30 1173 1723 2016
M33 1594 2342 2740
M36 2046 3006 3517
M39 2658 3905 4570
Fixing rod diameter Tightening torque

(Nm)
M16x1,5 125
M18x1,5 150
M20x1,5 250
M22x1,5 300
M24x2,0 400
M27x2,0 600
M30x2,0 900
M33x2,0 1200
M39x3,0 1800

10.4 – Checks and maintenance by the authorised FASSI service

centre
Checks and maintenance after the first 50 hours (Work

time) of crane utilization
In case of
Element Description
anomalies
Restore the tightening torque of bolts and screws on the
motoreducer according to the manufacturer’s instructions and
check their integrity.
Replace hot lubricant oil in the reduction unit.
Motoreducer Visually check the general cleaning conditions of reduction unit Clean the reduction
(slew ring) and caps. unit.
Clean the inner part of the reduction unit using new oil.
Visually check the physical integrity of bolts and screws on the Replace / repair the
motoreducer. component.
Replace the brake oil.
Restore the tightening torque according to the specific
Slew ring
instructions (*).
Winch Replace the hot lubricant oil in the winch reduction unit.
Restore the tightening torque of fixing rods, according to the
Base
specific instructions (*).
Yearly checks and maintenance / after relevant

modifications, repairs or long periods of non-utilization
In case of
Element Description
anomalies
Check the wear condition of bearing using nondestructive
methods (vibrations, noise analysis, etc.).
Check there are no cracks and other surface damages using
Replace / repair the
suitable methods (e.g. penetrating liquids, ultrasound, etc.).
component.
Check there are no cracks and other surface damages on
the ring, using suitable methods (e.g. penetrating liquids,
Lifting hook
ultrasound, etc.).
(ISO 17440)
Restore the tightening torque of the nut connecting hook and
ring, according to § 10.3.11.
Lubricate the
Visually check if the bearing is lubricated.
bearing.
Visually check the physical integrity of nut and threaded part Replace / repair the
of the hook. component.
Restore the tightening torque of fixing rods, according to the
Base
Visually check there are no deformations on metal carpentry.
Metal carpentry Visually check the physical integrity of the metal structure, Replace / repair the
(2) paying special attention to weld joints (absence of breaks, component.
cracks, paint flaking, cuts, incisions, etc.).
Bolts and screws Restore the tightening torque of bolts and screws, according
(2) to the specific instructions (*).


In case of
Element Description
anomalies
Check valve setting
Check the movement speed of the crane.
Functional check and pump flow.
of the crane Check the valve
Carry out a lifting test with capacity plate loads.
setting.
Carry out a test to check the winch lifting moment as per the Check the valve
capacity plate. setting.
Winch Go over the rope carrying out a magnet-inductive testing Replace / repair the
(ISO 4309). component.
Replace hot lubricant oil in the winch reduction unit.
Motoreducer Check the crane rotational power.

(slew ring) Visually check the physical integrity of the hydraulic motor.
Jib extension component.
boom sections
Visually check the physical integrity of stroke end devices.
and manual
extensions
Restore the tightening torque of ring nuts.
Rams (2) Visually check that ram seals withstand the maximum working Replace / repair the
pressures. component.
Restore the tightening torque of hydraulic system connections.
Visually check and make sure pipes withstand the maximum
working pressures and there is no deformation or leakage.
Pipes and hoses Visually check and make sure hoses withstand the maximum
of hydraulic working pressures and there is no deformation, swelling or
system leakage.
component.
Visually check there are no cracks, cuts, abrasions, wrinkles or
flattening on pipes and hoses.
Check the expiry date of hoses (in any case, 5 years from date
of manufacture).
Restore the tightening torque of hydraulic system connections.
Visually check and make sure hoses (high pressure and
Pump return) withstand the maximum working pressures and there
is no deformation, swelling or leakage.
Check the expiry date of hoses (in any case, 5 years from date
component.
of manufacture).
Integrated Check functionality and physical integrity of the override
assembly system.
Clean the fan using compressed air. The jet direction must be
Oil cooler/ parallel to the winglets in order to avoid possible damages.
heat exchanger Replace / repair the
Visually check the physical integrity of the fan.
component.


In case of
Element Description
anomalies
Visually check the physical integrity of hose protection chain
and its pivot joints.
Visually check there is no oil leakage from the ram.
component.
Visually check the surface covering of ram rods, making sure
there are no deformations.
Outrigger Restore the lubrication of ram rods.
supports Dissolve and remove impurities on ram rods. Rub the
surface using an industrial oil-soaked cloth (use low viscosity
protective oil).
Visually check the physical integrity of the ram cylinder,
making sure there are no deformations.
Visually check and make sure ram seals withstand the
maximum working pressures.
Crane-outrigger
Manually check that the deviator switches smoothly.
deviator
Carry out a functional test of the lifting moment limiting
device. Replace / repair the
Safety devices component.
Carry out a functional test of the winch limiter.
Radio remote Check the connectivity between radio remote control and
control crane main unit.
Radio receiver
Check the connectivity between antenna and crane main unit.
antenna
Electric wirings Check physical integrity and wear condition of electric cables.
Self-locking ring
Restore the tightening torque of self-locking ring nuts.
nuts (2)
Lead and other
Check the physical integrity of lead and other seals.
seals (2) Replace / repair the
Visually check the height of guide shoes and that they ensure component.
Guide shoes (2)
a correct parallel alignment.
Carry out the valve
Distributors Check that maximum working pressures are reached.
setting.
Ten-yearly checks and maintenance
In case of
Element Description
anomalies
Column Clean the inner part of the joint using suitable products.
Check there are no deformations on metal carpentry using
suitable methods.
Metal carpentry Check there are no internal or external (but barely detectable
(2) by a visual check) damages in/on metal carpentry and weld Replace / repair the
joints, using suitable methods (ultrasound, x-rays, penetrant component.
liquids, magnetoscope, etc.).
Check the valve setting and make sure there is no load loss of
Valves (2)
oil while circulating.

Ten-yearly checks and maintenance
In case of
Element Description
anomalies
Visually check wear condition of bushes and coaxiality of Replace / repair the
Bushes (2)
rotating components. component.
Hydraulic system
Clean the inner part of the hydraulic system using new oil.
(2)

component / yearly
In case of
Element Description
anomalies
Visually check the grease quantity in the drum support Restore the grease
transmission bearing. quantity.
Winch Visually check the physical integrity of the winch, making sure
there are no surface damages, such as cracks, incisions, cuts,
abrasions and covering loss. Replace / repair the
Visually check the physical integrity of bolts and screws on component.
the winch and restore their tightening torque according to the
manufacturer’s instructions.
Visually check the general cleaning conditions of reduction unit Clean the reduction
Motoreducer and caps. unit.
(slew ring) Restore the tightening torque of bolts and screws on
motoreducer according to the manufacturer’s instructions.
Visually check the physical integrity of bolts and screws on
Slew ring slew ring and restore their tightening torque according to the
component.

component / yearly
In case of
Element Description
anomalies
Check the clearance between outer and inner ring according
to the specific instructions (*). Replace / repair the
Slew ring
Visually check physical integrity and wear condition of the slew component.
ring gear.
Replace the brake oil.
Motoreducer
(slew ring)

Every 2000 hours (Total Time) of utilization of each

component / yearly
In case of
Element Description
anomalies
Oil Completely replace the crane hydraulic oil.

component / every ten years
In case of
Element Description
anomalies
Visually check physical integrity and wear condition of the Replace / repair the
motoreducer pinion. component.
Replace all bearings and outer seal rings.
Motoreducer Replace / repair the
Carefully check all the reduction unit seals.
(slew ring) component.
Check the bearing lubrication. Restore the lubricant.
Check the wear condition of the reduction unit gears.
component.
As per the specific component expiry date (in any case, 5

years from date of manufacture)
In case of
Element Description
anomalies
Hydraulic system
Replace hoses.
hoses
Pump Replace hoses.
(*) Refer to the crane installation manual.

(2) The elements indicated in the check and maintenance lists refer to the following components:
Metal carpentry Transducers and sensors Bolts and screws

• Base • FSC • Column
• Column • Pressure transducers • Inner boom
• Inner boom • Tilting sensor on outer boom • Outer boom
• Linkage system on inner • Micro switch for 7th - 8th • Jib
boom extension boom sections in • Outrigger supports
• Outer boom • Inductive proximity sensors: • Outrigger rams
• Linkage system on outer –– inner boom horizontal • Crane distributor
boom position indicator • Outrigger distributor
• Extension boom sections –– sensor for rams on the • Radio receiver antenna
• Jib ground • Seat
• Linkage system on jib Rams • Winch
• Jib extension boom sections • Inner boom • Slew ring (§ 10.3.6)
• Manual extension • Outer boom • Fixing rods
• Outrigger supports • Extension boom sections
• Winch and pulleys • Jib Valves
• Jib extension boom sections • Column
Control levers • Outrigger rams • Inner boom
• Crane-outrigger deviator • Outer boom
• Ground control station Grease nipples • Extension boom sections
• Radio remote control • Column • Jib
• Top seat control station • Inner boom • Jib extension boom sections
• Outer boom • Outrigger rams
Valve lead seals • Jib • Winch
• Column • Outrigger supports
• Inner boom Circlips, self-locking ring nuts, • Motoreducer (slew ring)
• Outer boom pivot points • Integrated assembly
• Extension boom sections • Rams
• Jib • Column
• Jib extension boom sections • Inner boom Guide shoes
• Winch • Outer boom • Outer boom
• Outrigger supports • Extension boom sections • Extension boom sections
• Outrigger rams • Jib • Jib
• Motoreducer (slew ring) • Jib extension boom sections • Jib connecting boom
• Valves • Jib extension boom sections
• Integrated assembly Bushes • Manual extensions
• Rams • Outrigger supports
Distributors • Inner boom
• Crane distributor • Outer boom Hydraulic system
• Outrigger distributor • Jib • Hoses
• Pipes
Electric/electronic devices • Rams
• FX main unit • Distributors
• Radio remote control • Tank
• Radio receiver • Valves
• Oil cooler (heat exchanger)

10.5 – Crane dismantling and/or demolition
For crane dismantling and/or demolition, refer to an authorised FASSI service centre.
In case of demolition it is necessary to dismantle the whole machine and separate the different types
of materials according to the respective waste disposals requirements.
The materials are the following:
• Iron materials: carpentry and mechanical components;

• Plastic materials: seals, belts, protections;
• Electric materials: windings, controls, electrovalves and similar;
• Oils and lubricants: hydraulic oil, lubricants for reduction units, lubricating greases;
• For the vehicle follow the manufacturer’s instructions;
• Different material: mercury (level sensor).
Take extreme care when slinging components to be disassembled, paying special attention
to their weight.
Completely discharge the residual pressure and then fully drain the oil in the hydraulic
systems before starting the dismantlement of components. Be careful not to let the oil
drop on the ground: collect it in special containers.
Exhausted oil must be disposed of in compliance with the binding waste disposal norms.
Deactivate all the electric power supplies (batteries, etc.) before dismantling the electric
circuit components.

Chapter 11 — Failure conditions
Chapter 11 – Failure conditions
Tampering with check valves and/or breaking of safety seals don’t ensure a correct
working of the crane safety devices: therefore these operations release FASSI from any
responsibility and invalidate the warranty.
In this situation, the operator is directly responsible for operations and machine safety.
11.1 – Outrigger control by radio

In case of working anomalies of radio remote control, levers on control handle may be useless. So,
it may be necessary to operate outriggers directly from their distributor.
In this emergency situation, make sure that nobody stops or passes in proximity of the
outrigger ram working area, neither from the operator’s side nor from the opposite one.
In order to operate the outrigger distributor, fasten the selection screw completely (fig. 11.1 -
position 1).
Fig. 11.1
Fig. 11.2
Refer to paragraph 6.3.1 “Outrigger nomenclature” for any explanation concerning nomenclature.

Horizontal
distributor
Then control the outriggers directly from the distributor, by using the two threadless levers.
1 2
1. Lever movement upwards: selection of outrigger support (E);

lever movement downwards: selection of outrigger ram (S).
2. Lever movement upwards: selection of outrigger support (E);
lever movement downwards: selection of outrigger ram (S) or tilting of
outrigger ram (R).
1 2
1. Lever movement upwards: exit of outrigger rams (S) or supports (E);
lever movement downwards: reentry of outrigger rams (S) or supports (E).
2. Lever movement upwards: exit of outrigger rams (S), exit of outrigger
supports (E) or tilting of outrigger rams into working position (R);
lever movement downwards: reentry of outrigger rams (S), reentry of
outrigger supports (E) or tilting of outrigger rams into transport position (R).
In order to reactivate the crane functions, unscrew the selection screw (fig. 11.1 - position 1).
Once the emergency operations are completed, immediately go to an authorised FASSI

service centre for any necessary repair.

Examples of outrigger operation
• Extension of outrigger support - position 2 (E2)
• Exit of outrigger ram - position 2 (S2)
• Reentry of outrigger ram - position 2 (S2)
• Reentry of outrigger support - position 2 (E2)

11.2 – Crane control by radio - Distributor on the column

In case of working anomalies of radio remote control, levers on control handle may be useless:
immediately contact an authorised FASSI service centre.
If a particular danger occurs for persons or things, it is possible to carry out some emergency
operations from the distributor placed on the crane column: reduce the outreach, lay down the load
and, if possible, place the crane in transport position in the vehicle body. If there are not suitable
safety conditions, immediately contact an authorised FASSI service centre.
In order to use the distributor on the column, it is necessary to:
• remove the carter shown in fig. 11.3 - position 1;

• enable the manual control mode by using the manual/radio switch (fig. 11.3 - position 2) or by
selecting the icon , if the control panel is fitted (refer to chapter 4, paragraph “Procedure to
pass from radio remote to manual control mode (and vice versa)”);
• operate the crane by using the threadless lever.
Control layout
implements
2
standard crane
Fig. 11.3
If you use the distributor on the column, pay special attention to moving parts (such as
crane booms, rams and column), where higher crushing, trapping and shearing danger
occurs.

The labels are for example as the one shown in the following figure: position 1 represents the
operation which is associated to the lever movement indicated in position 2.
1 2
Make sure that the lever you are going to operate corresponds to the control you want to
perform.
If failure occurs and you cannot reach the distributor in a safe way, it is not possible to
operate an emergency control (as it occurs when the hydraulic system is broken or there
is no oil feeding to the distributor). In this situation you must contact an authorised FASSI
service centre.
11.3 – Temporary override of crane functions

In case of working anomalies of the lifting moment limiting device or irreversible crane block, it is
necessary to deactivate all the safety devices by operating the override system.
In order to reach the tap (fig. 11.5 - position 1), remove the yellow plate (fig. 11.4 - position 1) from
the carter placed on the distributor. Remove the safety seal and turn the tap clockwise.
1
1
Fig. 11.4 Fig. 11.5
It is forbidden to work once the safety seals have been removed.
Only in case of working anomalies of the lifting moment limiting device or irreversible
crane block, it is possible to remove the seal on the override system and deactivate the
safety devices.

The temporary exclusion of the lifting moment limiting device and the related manoeuvres
may undergo an overload condition and involve hazards of accidents (even serious) for the
operator and other persons, as well as damage to the crane.
In these conditions (with lifting moment limiting device deactivated), the operator, who is
the main responsible for the machine safety, must:
• carefully consider the operations he wants to carry out, in order to exit from the
emergency situation (in any case, with extension boom sections out, first it is
compulsory to operate their reentry);
• calmly and carefully assess the type and scale of the hazards arising from these
manoeuvres and the possible reaction of the crane (overturning, frame overload,
uncontrolled load descent due to hydraulic system overload, etc.);
• perform all movements as slowly as possible, to minimize the dynamic overload.
Once the emergency operations are completed and prior to other crane operations,
immediately go to an authorised FASSI service centre to check the structure and seal the
device.
Tampering with check valves and breaking of safety seals release FASSI from any
responsibility and invalidate the warranty.
11.4 – Rupture of the crane pump

In case of rupture of the crane pump, immediately turn off the vehicle engine, close the pump tap
and contact an authorised FASSI service centre.

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1

FASSI CRANE USE AND MAINTENANCE MANUAL

Chapter 2 – General specifications 12

Chapter 3 – Health and safet y instructions 25

3.1 – Personnel in charge 25

2 UM002_Amendment 00 - Edition 07/07/2014

Chapter 4 – Safet y devices and special functions 39

4.1 – Index of paragraphs as per crane equipment 39

Chapter 5 – Control systems 83

5.1 – Pictograms for crane and implement control 83

UM002_Amendment 00 - Edition 07/07/2014 3

Radio remote control components 86

Chapter 6 – Setting up for crane operation 97

6.1 – Preliminary checks 97

Chapter 7 – Crane operation 111

7.1 – Instructions 111

Chapter 8 – Folding the crane 118

8.1 – Instructions 118

4 UM002_Amendment 00 - Edition 07/07/2014

Chapter 9 - Use of implements 126

9.1 – Generality 126

UM002_Amendment 00 - Edition 07/07/2014 5

Removing the manual extensions 151

Chapter 10 – Maintenance 163

10.1 – Generality 163

6 UM002_Amendment 00 - Edition 07/07/2014

Electronic lifting moment limiting device 179

Chapter 11 – Failure conditions 190

11.1 – Outrigger control by radio 190

UM002_Amendment 00 - Edition 07/07/2014 7

All this represents the core of FASSI quality system.

FASSI quality system is in conformity with

FASSI cranes conform with the European Standard EN12999:2011

The original version of the present manual is in Italian.

8 UM002_Amendment 00 - Edition 07/07/2014

1.2 – Use of manual

FASSI is constantly involved in research and development of technologically advanced components

The current manual is copyrighted © by FASSI.

FASSI GRU S.p.A.

UM002_Amendment 00 - Edition 07/07/2014 9

1.3 – Symbols used in the manual

Important remark or particularly interesting information for the operator.

Forbidden situation or operation. The non-observance of this prohibition may cause

1.4 – General nomenclature of FASSI crane and implements

10 UM002_Amendment 00 - Edition 07/07/2014

1.5 – General procedure to operate the crane

Activate the crane

Enable the outriggers

Completely stabilize the crane

Lift and handle the load

Lay down the load

Fold the crane

Enable the outriggers

Reenter the outriggers

Disengage the power take-off

Check for the correct block of all the crane parts

Respect the maximum overall dimension in folded

UM002_Amendment 00 - Edition 07/07/2014 11

Chapter 2 – General specifications