F800/900XP.22 - FASCAN International, Inc.
Contents
1. TEO It is absolutely prohibited to walk or stop under a ee suspended load and for unauthorized persons to within the working area Avoid swinging the load above the control station DE 1686 in cases where the load is too close the crane must be operated from the opposite side It is absolutely prohibited to load or unload under or in proximity of electric lines The minimum distance from electric lines 15 according to CEN norms SEWEBS 5 meters except for otherwise prescribed by national norms For cranes with top seat controls it is necessary to use a ladder to reach the control station When operating from the top seat stay within its side safety guards Ll pl Do not rotate the crane befo re the load is lifted do not operate with sudden movements activate the con trols with slow and pro gressive movements Rotate slowly and with care paying attention to the Stability of the vehicle With vertical lift on hydraulic and mechanical extension rotate slowly in order to avoid side skidding Do not move the vehicle if a load is suspended on the crane Do not utilize the crane for pushpull lateral or sideways operations Under no circumstances interfere with the safety and protection devices The vehicle crane are not left unless the power take off is disengaged and the load is on the grou2. 5 3 3 Q Ed gt pars EQ lad INA Pare cC EA T 5B IVA vare SBIVA ie m i jane i i 1 et 22 54 25 52 2522222 222442 aliae J 4 4 12 22 777774 Ld LETNA LETRA D1132 HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 44 800 900XP HYDRAULIC AND ELECTRIC SCHEMATICS Hydraulic schematic for crane Danfoss distributor L804 lifting moment limiting devi ce intelligent type 2000008 89 200008 se I H 2H9VH 944 X 3 3MVINTN3Tdd S U11332 1833A D2v Id N 1 TVA Mmm 1 E I o 1 BP SSI TWA deg a picco See bLao ILLE sca L1 lt gt E3 4 ME E SERE eye ine aent at ant aea m 24 TINA 4 45 HYDRAULIC AND yA ELECTRIC SCHEMATICS F 800 900XP VARIANTE 2 Hydraulic schemati
3. B When the XP device is active remember that The crane rotates with a decreased speed without increasing the rotation capacity the maximum load that the crane can rotate remains unchanged The Extension and Retraction of the extension rams and if fitted the Up Down stroke of the winch and The Extension and Retraction of the hydraulic jib are all possible without any reduction in speed they produce negligible dynamic effect On cranes with a lifting moment limiting device for double working zones manoeuvres within the unstable area are slower without any increase in the lifting capacity How to use the XP device The XP device can be activated by the crane operator before or during manoeuvres to handle the load For example it can be used to exploit the reduction in the speed when moving a load that must be positioned with precision to exploit the variation in the lifting moment limiting device adjustment parameters to exit from a critical situation when moving the load yellow light or activation of the lifting moment limiting with the red light and block Switching on the XP device after the yellow light has come on the light goes off insisting with the manoeuvres that increase the lifting moment you get the yellow and red lights again Switching on the XP device after the red light has come on lifting moment limiting device block A The block continues the crane must be reset by r
4. Check for leaks when the pump is activated MAINTENANCE INSTRUCTIONS F 800 900XP Cleaning of the filter on the delivery line before the distributor fig 44 Unscrew with an hexagonal spanner 30 mm the body filter pos 1 from the head pos 2 Remove the cartridge pos 3 and clean it as previously indicated Check if the cartridge has crumbled up in case replace it Re assemble checking the seal pos 4 on the filter body Screw the filter body into the head Check for leaks when the pump is activated Check the oil level in the tank with the crane in the folded position and with the outriggers crane and supplemen tary fully re entered The oil level must be within the maximum and minimum markings fig 45 Top up using hydraulic oil with the same characteristics as those indica ted in the table on page 47 After every 100 working hours or more frequently in case of more intensive utilisation 36 Periodically grease the points indicated on the crane paying parti cular attention to the points not easily detected Guide shoes made from a special material have been fitted to allow the crane extension boom sections the hydraulic booms and the outrigger supports to slide freely To ease their move ment it is recommended to smear a light film of grease on them taking care that the surfaces of the extension boom sec tions are free from impurities such as sand etc Use
5. The particular configuration of the radio remote control allows to control 6 functions distributor segment of the crane through 6 keys To control a higher number of functions 7 or 8 it is necessary to operate on proper selectors fig 34a which allows at some keys the order of a double function The ideogramms placed on the side of each radio remote control key and on each lever on the emergency control determine the working of the levers in relation to the movement to effect EMERGENCY CONTROLS Turn the selector swicth fig 35 on the Manual Radio panel to Manual fig 35 WARNING The control lever NOT assembled on the distributor must only be used to manoeu vre the crane if the electricity supply is cut off The column controls must only be used in an emergency and only to bring the crane to its rest position During emergency manoeuvres the operator should be assisted by a second trained person who can intervene if necessary 27 CONTROLS TO OPERATE THE CRANE F 800 900XP 28 WARNING The operator must pay particular attention to his working position and safety when using the crane Particular care is needed when turning the crane due to obstacles around the column driver s cabin back of the truck The operation of the distributor segment functions for the control of the crane and of the possible hydraulic accesso ries are obtained by operating properly the radi
6. entrusted to workshops without sufficient technical capability to carry out the work in conformity Every change of use modification or addition of accessories must be affixed with a new CE mark in accordance with the Machinery Directive As well as the principal safety norms this manual contains a description of the crane and the instructions for use and maintenance Equipment other than Fassi must be supplied with its own use manual The crane must only be operated by responsible persons previously instructed and authorized THANK YOU FOR SELECTING ONE OF OUR CRANES SAFETY NORMS This symbol draws your attention on the points concerning safety It means WARNING BE CAREFUL IT CONCERNS YOUR SAFETY ATTENTION READ THIS MANUAL CAREFULLY prior to use of the crane or any maintenance A few minutes spent now could save time and labour later Be sure that the unit has been installed inspected and tested in accordance with the local legal requirements To operate the crane it is necessary to fully understand its working safety and warranty norms Warning plates as well as instruction and operation plates must be repla ced when no longer readable or missing See chapters A B Check that protections are in their place and that all safety devices are fitted and active Do not run the engine in a indoor area without first making sure there is adequate ventilation Fit a suitable extension tube to the vehicle
7. 12 9 Diameter D Torque Torque Nm Torque Nm 3 1 1 6 183 Bolt Class 8 8 Class 10 9 Class 12 9 mE Nm Nm mE Nm 6 830 1230 1430 27 805 171 1487 8 2 2 3 3 473 t2 216 10 40 59 69 33 1594 2342 24 12 69 442 19 36 204 3006 357 From ELEMENTS DE FIXATION ASSEMBLAGES VISSES AFNOR E 25 030 AGOSTO 1984 m 25 28 _ 239 352 412 Check the rotation control motoreducer oil level Remove the bleed plug 1 using a 22 mm Allen wrench Remove the plug 2 using an 8 mm Allen wrench and the O ring Top up if necessary with the same type of oil as indicated on page 47 via the mouth bleed plug The correct level is reached when oil starts to escape from the threaded hole in plug 2 Check the state of wear of the O rings replace if necessary and then return the plugs The lubrication oil can be drained completely by removing plug 3 using an 8 mm Allen wrench Check the guide shoe wear as it affects the sliding section tolerances if the clearances are considerable damage to the rams and the structure may occur Replace the oil filter cartridges Clean the air filter placed in the top of the oil tank filter cap Completely replace the hydraulic oil i The waste oil must be disposed of by authorized persons 36a NIB INSTRUCTIONS I CAUTION DANGER t F 800 900XP On t
8. 900XP Electric schematic for crane arc of free rotation an 7 29 AY Tad U 13 m tx 19 D8 17 NZ e 0 S aa 4 5 0 m g gt u u te as a oO r a gt Lact i 1 1 Dy 4 I I ex 0 1 gt E a I gt ZAW gt F DoD 2 Gi a ccu cci Sua ae aN a a ere SEQUENZA 9 Y M 19 Tad 234 1 69 0 03 38 CODE DESCRIPTION ALIM FEED MAIN CONTROL PANEL FUSE PROTECTION FUSE 10A DR ELECTRIC ROTATIONING DISTRIBUTOR AV ACOUSTIC ALARM D3 POLARITY PROTECTION DIODE D4 D5 LIFTING MOMENT LIMITING DEVICE DIODES D6 D7 LAMPS TEST DIODES D8 D9 NOT BACK DIODES EV2 ELECTROVALVE FOR CRANE LIFTING BLOCK EV3 ELECTROVALVE FOR CRANE DESCENTS BLOCK EV6 EMERGENCY ELECTROVALVE MS MERCURY SLOPE SENSOR ON OUTER BOOM IPB PROMISSITY SENSOR VALVE RB RELE STOP SIGNAL 1 BLOCK LATE CAPACITOR MR3 BLOCK LATE RELAY 1 90 LOAD PRESSURE DETECTOR LB WHITE WARNING LIGHT LG1 YELLOW WARNING LIGHT FOR MAIN CONTROL PANEL 90 LOAD REACHING
9. LG2 YELLOW WARNING LIGHT FOR DOUBLE CONTROL SATELLITE 90 LOAD REACHING LR1 RED WARNING LIGHT FOR MAIN CONTROL PANEL BLOCK LR2 RED WARNING LIGHT FOR DOUBLE CONTROL SATELLITE BLOCK LP ADDITIONAL FLASHING PE1 MAIN CONTROL PANEL EMERGENCY BUTTON PE2 DOUBLE CONTROL SATELLITE EMERGENCY BUTTON PC1 ACOUSTIC WARNING BUTTON FOR MAIN CONTROL PANEL PC2 ACOUSTIC WARNING BUTTON FOR DOUBLE CONTROL SATELLITE SAT2 DOUBLE CONTROL SIDE SATELLITE SE SEQUENCE SHUNT BOX MSE SEQUENCE MICRO EV10 SEQUENCE ELECTROVALVE AR1 CRANE WINDING AR2 EXTENSION WINDING LCV WINCH LOAD LIMITING DEVICE MV1 PULLEY MICRO WINCH MV2 DRUM MICRO WINCH MR4 WINCH RELAY EV9 WINCH DESCENT BLOCK ELECTROVALVE EV11 MAIN LIFTING BLOCK ELECTROVALVE SAT EC ELECTRICONTROLLER SATELLITE CABLE SAT RADIO RADIO REMOTE CONTROL SATELLITE CABLE HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 39 Electric schematic for crane limited arc rotation HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 0 2 0 C 0 0 0 0 D 0 0 1 1 UE 605608608 IIE 69 US Fom 259004006 2 WB SE LZR eas EE 22 8 0 1 1 lz 22 E B poxT e9 1 8 po D 4 sN E E 51 A21 Li Ej 2 i NT 8 0 rA 14 i lt b d 01 x
10. LIMITING DEVICE MV1 PULLEY MICRO WINCH MV2 DRUM MICRO WINCH MR4 WINCH RELAY EV9 WINCH DESCENT BLOCK ELECTROVALVE EV11 MAIN LIFTING BLOCK ELECTROVALVE SAT EC ELECTRICONTROLLER SATELLITE CABLE SAT RADIO RADIO REMOTE CONTROL SATELLITE CABLE HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 43 jHOonnvsgi na is i 15583125 581469 i ms PIX F3 JMVININIIddNS SATAVAL 83 kas s p L 4 L 2 4 4 4 1 1 1 1 Lo 1 5 5 ET SEI IIIS 8 3 1555 23 14 1 i 1 Hydraulic schematic for crane Danfoss distributor L604 lifting moment limiting device 1 i i 1 MAE jus A HEH E T x E EEr 1 x TTE 4 1 2 A Leak k tn nl esi st ss a si a i K 4 s Ss LE 1 1 tu 11 1 li o Le Led 1
11. OEE ENE DELTE VALVOLE tions also related to pump flow and lever travel it is possible that DI BLOCCO on reaching the stroke end of a particular function an increase in WARNING BEFORE OPERATING THE CRANE speed of the other functions will occur IT IS COMPULSORY TO EXTEND THE OUTRIGGERS AND SHUT THE BLOCK VALVE TAPS WARNING While exiting and folding the crane you must operate from the distributor BVENT EST TE 1 OBLIGATOIRE DE EN FONCTION LES side it is forbidden to operate from the double control side because of gsm the overall dimensions of the booms DE1684A fig 34a VALVES DE BLOCAGE ACHTUNG VOR INBETRIEBNAHME DES KRANS The crane and the possible hydraulic accessories are operated through propor tional radio remote control subjugate to a distributore which the manual order is 850 to be used only in case of emergency DE319 HETRONIC RADIO REMOTE CONTROL fig 34 Complete of key linears joystick proportional for the crane and the functions of starting turning off the motor the emergency stop system the start the warning horn and starting spy system WARNING First read the instructions given in the User s Manual supplied by the Manufacturer before using the remote control to avoid improper use Activation of the radio remote control Turn the selector swicth fig 35 on the Manual Radio panel to Radio
12. The rotation of the drum on which the cable winds is achieved by a hydraulic motor pos 2 connected to the circuit by means of hoses in case of fittings or hoses brake the stop of the rotation is guaranteed by a safety check valve pos 4 A parking brake integrated to the motoreducer group pre vents the rotation on the drum held of the winch load in position when the control function is not activated lever N in neutral position The winch is identified by a plate fig 38a indicating the essential data and fixed by the manufacturer Manufacturer mark Winch type Serial number Maximum line in N at the 4th layer Maximum speed in m min See operator winch manual supplied by the winches manufacturer The winch has a maximum capacity indicated by a plate not related to the crane capacities which can also be lower Consequently avoid to lift with the winch heavier loads than those allowed by the crane capacity plate The couple limiter installed on the winch structure prevents that on the cable can be created a load major to the value of maximum line at the 4th layer quiescing all the crane controls Under no circumstances interfere with the limiter device adjustment Do not rotate the crane before the load is lifted rotate slowly and with care the suspended load checking the stability of the vehicle The presser cable always keeps the cable in tension easing the regular rewin ding a
13. a grease with the same characteristics indicated in the table on page 47 Grease the fifth wheel to prevent friction during rotation and to ensure that it is stable by preventing water corrosion protec tion and contaminants from entering the bearings We recommend greasing this with the crane rotating and making sure that the grease overflows from the fifth wheel seals Use a grease with the same characteristics indicated in the table on page 47 Grease the winch cable if fitted after having first cleaned the cable of any encrustation grease mixed with sand dust dirt etc The lubricant used must guarantee a good level of penetration in order to lubricate both the inside and the outside of the cable Use a grease with the same characteristics indicated in the table on page 47 MAINTENANCE INSTRUCTIONS F 800 900XP After every 500 working hours Check the tightening torque of the fixing rods of the crane Tightening torque for fixing rods M39x3 1800 Nm of the slew gear screws Tightening torque for bolts M20 Class 12 9 620 Nm of the securing bolts for the ram pins and of all the other bolts and screws where the tightening torque is not expressly indicated consult the following table in order to find it s value according to the bolt diameter and class Table of the bolts tightening torque with average friction value 0 15 and ave rage good tightening accuracy type C Bolt Class 8 8 Class 10 9 Class
14. 2 3 11 m 1 2 11 1 1 1 1 1 41 1 1 1 1 23 kir Ds 01139 FAA ZNSNOAS 22 61 Ness 1 61 E 79 ND t Tan lt 40 CODE DESCRIPTION ALIM FEED MAIN CONTROL PANEL FUSE PROTECTION FUSE 10A DR ELECTRIC ROTATIONING DISTRIBUTOR AV ACOUSTIC ALARM D1 D2 ROTATION CONSENT DIODES D3 POLARITY PROTECTION DIODE D4 D5 LIFTING MOMENT LIMITING DEVICE DIODES D6 D7 LAMPS TEST DIODES D8 D9 NOT BACK DIODES EV2 ELECTROVALVE FOR CRANE LIFTING BLOCK EV3 ELECTROVALVE FOR CRANE DESCENTS BLOCK EV6 EMERGENCY ELECTROVALVE EV7 CLOCKWISE ROTATION BLOCK ELECTROVALVE EV8 ANTICLOCKWISE ROTATION BLOCK ELECTROVALVE IP1 CLOCKWISE ROTATION PROXIMITY IP2 ANTICLOCKWISE ROTATION PROXIMITY SDP SEAT PROXIMITY SHUNT BOX MR CLOCKWISE ROTATION RELAY MR2 ANTICLOCKWISE ROTATION RELAY MS MERCURY SLOPE SENSOR ON OUTER BOOM IPB PROMISSITY SENSOR VALVE RB RELE STOP SIGNAL C1 BLOCK LATE CAPACITOR MR3 BLOCK LATE RELAY 1 90 LOAD PRESSURE DETECTOR LB WHITE WARNING LIGHT 61 YELLOW WARNING LIGHT FOR MAIN CONTROL PANEL 90 LOAD REACHING LG2 YELLOW WARNING LIGHT FOR DOUBLE CONTROL SATELLITE 90 LOAD REACHING LR1 RED WARNING LIGHT FOR MAIN CONTROL PANEL BLOCK LR2 RED
15. 7 7a 7b and the eventual hydraulic extension indicate the manoeuvres which are allowed and not allowed by the device in connection with the horizontal position of the crane and extension outer booms When the moment is reduced it resets automatically the manoeuvres blocked by the device are released N B There is a delay of 4 seconds after the moment reduction before the reset can occur in order to safeguard the stabi 14 lity of the device Lifting moment limiting device for two working areas When a sector of the working area exists in which the stability is insufficient for example in the area in front of the cab the permitted arc of rotation is limi ted by means of an adjustable electro hydraulic device which allows operation with a reduced value of the intervention level The reduction of the intervention level reduces the crane capacity values and this reduction value is defined in the vehicle stability calculation Consequently the working area is divided one sector e g body side where the crane works according to the capacity plate values and another sector e g cab side where it works with reduced capacity values The device has consequently two intervention levels which are activated in relation to the sector of the crane working area always securing the vehicle sta bility WARNING If the rotation stops by going through the working zone where the crane can operate according to the capacity p
16. Check valve for booms extension rams Lifting moment limiting device assembly Parachute valves Board of control limiter on column Rotation limiting device Main pressure valve crane outriggers Main pressure valve crane Auxiliary valves crane Safety device for outriggers supports Hook safety device Remote control audible alarm emergency stop button STOP Visual gauge yellow red light activation of the limiting device WARNING First read the instructions given in the User s Manual supplied by the Manufacturer before using the remote control to avoid improper use Before crane use check that safety and protection devices are fitted and active Under no circumstances interfere with the safety and protection devices Interference with the check valves and removal of the lead seals remove the Manufacturer and invalidate the warranty SAFETY AND PROTECTION RAY DEVICES F 800 900XP 157 1 fig 6 ann LIFTING MOMENT LIMITING DEVICE AND CONTROL CONTROL PANELS F 800 900XP PANELS A characteristic which permits the classification of cranes is their lifting capa city or maximum lifting moment The moment is defined by the value obtained from the product of the load to be lifted in kg by its distance in meters from the centerline of the crane rotation The device called lifting moment limiting device preserves the crane structu re from
17. DIODE D4 D5 LIFTING MOMENT LIMITING DEVICE DIODES D6 D7 LAMPS TEST DIODES D8 D9 NOT BACK DIODES EV1 ELECTROVALVE FOR LIMITING GENERAL PRESSION EV2 ELECTROVALVE FOR CRANE LIFTING BLOCK EV3 ELECTROVALVE FOR CRANE DESCENTS BLOCK EV4 ELECTROVALVE FOR LIFTING MOMENT LIMITING DEVICE FOR TWO WORKING ZONES EV6 EMERGENCY ELECTROVALVE EV7 CLOCKWISE ROTATION BLOCK ELECTROVALVE EV8 ANTICLOCKWISE ROTATION BLOCK ELECTROVALVE IP1 CLOCKWISE ROTATION PROXIMITY IP2 ANTICLOCKWISE ROTATION PROXIMITY SDP SEAT PROXIMITY SHUNT BOX MR CLOCKWISE ROTATION RELAY MR2 ANTICLOCKWISE ROTATION RELAY MS MERCURY SLOPE SENSOR ON OUTER BOOM IPB PROMISSITY SENSOR VALVE RB RELE STOP SIGNAL C1 BLOCK LATE CAPACITOR MR3 BLOCK LATE RELAY 1 90 LOAD PRESSURE DETECTOR P3 THRUST METER CONSENT ROTATION LB WHITE WARNING LIGHT LG1 YELLOW WARNING LIGHT FOR MAIN CONTROL PANEL 90 LOAD REACHING LG2 YELLOW WARNING LIGHT FOR DOUBLE CONTROL SATELLITE 90 LOAD REACHING LR1 RED WARNING LIGHT FOR MAIN CONTROL PANEL BLOCK LR2 RED WARNING LIGHT FOR DOUBLE CONTROL SATELLITE BLOCK EP ADDITIONAL FLASHING PE1 MAIN CONTROL PANEL EMERGENCY BUTTON PE2 DOUBLE CONTROL SATELLITE EMERGENCY BUTTON 1 ACOUSTIC WARNING BUTTON FOR MAIN CONTROL PANEL PC2 ACOUSTIC WARNING BUTTON FOR DOUBLE CONTROL SATELLITE SAT2 DOUBLE CONTROL SIDE SATELLITE SE SEQUENCE SHUNT BOX MSE SEQUENCE MICRO EV10 SEQUENCE ELECTROVALVE AR1 CRANE WINDING AR2 EXTENSION WINDING LCV WINCH LOAD
18. E MANUF YEAR fig 2 24021 ALBINO BG ITALY 39 35 755020 The model the version of the crane the year of manu facturing and the serial number are stamped on the base fig 3 in the following sequence F800 900XP 22 0 7 01 bk serial no year of manufacturing version 23 24 25 26 27 model 1I H Identilication UNDER NO CIRCUMSTANCES SHOULD THE ig plate DATA MARKED ON THE PLATE AND PUNCHED ON THE BASE BE ALTERED It is essential to give the correct crane model and serial number when you contact the Service and Parts Department The exact crane model serial number and description of implements will enable FASSI Service Department to give a rapid and efficient response A further metallic plate fig 4 fixed to the crane by the installer quotes the identifying data of the equipment and the final CE mark 1 of the installer who applied the final CE mark 2 Crane mark model and serial number MODEL 3 Vehicle mark model and chassis number 2 4 Year of mounting TECHNICAL DATA F 800 900XP 22 TECHNICAL DATA The design of this crane has been carried out in respect of DIN 15018 norms fatigue test classification H1B3 The crane can operate intermittently with lifting devices other than the hook The dimensions and the capacity of the implements must be proportioned with crane performances F 800 900XP 22 Lifting Standard Hydraulic Rota
19. FASSI CRANE Chapter II IV V VI VII VIII XII XIII XIV XV 800 900XP 22 use and maintenance Edition CE 15 01 98 Valid from serial no 0162 INDEX INTRODUCTION SAFETY NORMS INSTRUCTIONS FOR CRANE USE IDENTIFICATION OF THE CRANE MODEL TECHNICAL DATA CRANE NOMENCLATURE SAFETY AND PROTECTION DEVICES LIFTING MOMENT AND ROTATION LIMITING DEVICE VISUAL INDICATORS XP CR DEVICE CONTROLS TO STABILIZE THE VEHICLE CONTROLS TO OPERATE THE CRANE USE OF IMPLEMENTS MAINTENANCE INSTRUCTIONS POSSIBLE FAULTS HYDRAULIC AND ELECTRIC SCHEMATICS OIL AND LUBRICANT CHARACTERISTICS INSTRUCTION AND WARNING PLATES CAPACITY PLATES page 2 page 3 page 6 page page 8 page 10 page 12 page 14 page 19 page 27 page 31 page 34 page 37 page 38 page 47 page 48 page 51 FASSI CRANE F 800 900 22 use and maintenance INTRODUCTION F 800 900XP 22 This instruction manual describes the FASSI CRANE F800 900XP 22 The crane which conforms to the Machines Directive D M 89 392 and successive amendments 91 368 and 93 44 must not be put into service within the European Community unless the machine on which it is moun ted also conforms with the prescribed Directive The fitment must be carried out in accordance with the instructions given by the Manufacturer in the manual for hydraulic crane fitting The Manufacturer declines all responsibility and guarantee if the fitting is
20. G PLATES F 800 900XP DE 1679 Do not walk on DE 1680 Do not use water to extinguish fire TIRANTI NON SALDARE FIXING ROD WELD TIRANTS NE PAS SOUDER ZUGSCHRAUBEN NICHT SCHWEISSEN DE 1574 Do not weld the fixing rods 90 CAPACITY PLATES CAPACITY PLATES F 800 900XP 22 For cranes and manual extensions The represented plates refer to the nominal design capacities WARNING If the capacities are downgraded or partially reduced e g sector in front of vehicle cab capacity plates must be applied in line with the final test figures cmm GAU IDRAULICHE F800 22 12 Pmax22 000kg 11 0 12 34 5 6 7 8 9 811111111 s h Da A 2242 18095 10095 ko N us 11 90 m 267 veas 91 CAPACITY PLATES F 800 900XP 22 IDRAULICHE 900 22 9 Pmax 22 000 kg 9 Pmax 8 205 52
21. RNING First read the instructions given in the User s Manual supplied by the Manufacturer before using the remote control to avoid improper use Any hidden danger situation for persons must be audibly alarmed When there are serious imminent and dangerous conditions for persons and things during load handling operate on the emergency stop button 1 which isolates all crane functions ATTENTION The presence of the lifting moment limiting device does not release the user from the obligation to respect what is indicated on capacity plates and lifting curves XP CR CE DEVICE The XP device works on the principle of an increase in the lifting capacity of the crane with a reduction in the dynamic effect achieved with a reduction in the speed of the movements ACTIVATION OF THE XP DEVICE You operate on the SLOW FAST selector Q fig 10 placed on the radio remote on the SLOW position With the selector set on this posi tion you have the electric signals of the strokes of the radio remote control keys they St So come modified and interpreted from the electric controlers of lt fig 10 the crane distributor segment which limits the strokes obtai al ning the reduction of the speed movements of the crane WARNING The capacity plates relevant to the XP device are marked F900XP LIFTING MOMENT LIMITING DEVICE AND WARNING NTROL PANEL EAD
22. WARNING LIGHT FOR DOUBLE CONTROL SATELLITE BLOCK LP ADDITIONAL FLASHING PE1 MAIN CONTROL PANEL EMERGENCY BUTTON PE2 DOUBLE CONTROL SATELLITE EMERGENCY BUTTON 1 ACOUSTIC WARNING BUTTON FOR MAIN CONTROL PANEL PC2 ACOUSTIC WARNING BUTTON FOR DOUBLE CONTROL SATELLITE SAT2 DOUBLE CONTROL SIDE SATELLITE SE SEQUENCE SHUNT BOX MSE SEQUENCE MICRO EV10 SEQUENCE ELECTROVALVE 1 CRANE WINDING AR2 EXTENSION WINDING LCV WINCH LOAD LIMITING DEVICE MV1 PULLEY MICRO WINCH MV2 DRUM MICRO WINCH MR4 WINCH RELAY EV9 WINCH DESCENT BLOCK ELECTROVALVE EV11 MAIN LIFTING BLOCK ELECTROVALVE SAT EC ELECTRICONTROLLER SATELLITE CABLE SAT RADIO RADIO REMOTE CONTROL SATELLITE CABLE HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 41 cu ZE v3 a2 1 1 8 5 x 0 oO on 1 4 1 2 01130 1 5 2 ce FE 61 61 65 70 TD OA Ss e 61 O I I M 1 4 K L O O LLI HYDRAULIC AND ELECTRIC SCHEMATICS F 800 900XP 42 CODE DESCRIPTION ALIM FEED MAIN CONTROL PANEL FUSE PROTECTION FUSE 10A DR ELECTRIC ROTATIONING DISTRIBUTOR AV ACOUSTIC ALARM D1 D2 ROTATION CONSENT DIODES D3 POLARITY PROTECTION
23. c for crane versions 1 double motor riducer 2 F800 900XP 27 3 hydraulic rotating stabilizers SC GRU IDRAULICHE 900003 TRAVERSA GRU VARIANTE 3 VARIANTE 1 TABLE OF HYDRAULIC OIL AND LUBRICANTS CHARACTERISTICS HYDRAULIC OIL WITH HIGH VISCOSITY ISO L HV Minimal external maximal oil temperature temperature 35 C 45 C Gradation ISO VG 32 20 C 75C Gradation ISO VG 46 HYDRAULIC OIL WEAR RESISTANT ISO L HM Minimal external maximal oil temperature temperature 10C 60C Gradation ISO VG 32 75 Gradation ISO VG 46 5C 85C Gradation ISO VG 68 10C 90C Gradation ISO VG 100 GREASE Consistency NLGI BEACON EP 2 BEACON HYDRAULIC OIL FOR MOTOREDUCER Classification ISO L CC Gradation EP ISO VG 150 GREASE for slew ring 30 C up to 130 C EP2 Gradation All grease used must be free from acid and resin not hydroscopic and long life such as BP GREASE LTX EP2 ELF 2 ESSO BEACON 2 or SIMILAR LUBRICATING OIL for winch cable The most suitable here is a general purpose lubricating oil with about SAE 30 viscosity A lubricating oil containing non stick additives is recommended if the cables are expected to move quickly through the pulleys BRILUBE 50 BRITISH ROPES BRINDON 1 WARNING Don t use greases with solid particles as Bisulphide of Molybdenu
24. crane radio remote control proportional Hetronic Fig 5 Pos Description 1 Outrigger rams 2 Outrigger supports with lateral hydraulic extension 3 Base 4 Slew ring 5 Rotation motoreducer 6 Oil diverter crane outriggers 7 Double control for oil diverter crane outriggers 8 Multi purpose outriggers oil diverter 9 Double control for multi purpose outriggers oil diverter 10 Column 11 Distributore electric hyadraulic crane 12 Inner rams 13 Inner boom 14 Outer ram 15 Outer boom 16 Booms extension rams 1 Extension boom sections 18 Manual extensions optional 19 Lifting hook 20 Oil tank 21 Receive switchboard radio remote control 22 Radio remote control transmitting console 10 CRANE NOMENCLATURE F 800 900XP n 1 End W 1 H 1 E Am o IT SSE b Sw Sd 127 ui E iT fig 5 22 21 12 SAFETY AND MIB PROTECTION DEVICES F 800 900XP SAFETY AND PROTECTION DEVICES Version with ground controls for outriggers and controlers of the crane radio remote control proportional Hetronic Fig 6 Pos Description N O O1 OQ N gt 230185 WN O Tap and check valve for outrigger rams Check valves for rotation control Check valve for inner rams Check valve for outer ram
25. disengaged and the load is on the ground 9 Before driving the vehicle ensure that the outriggers are fully retracted and re entered the safety taps closed and the crane is in the folded position Instruction plate and safety norms ATTENZIONE PRIMA DI AZIONARE LA GRU E OBBLIGATORIO METTERE IN OPERA GLI STABI LIZZATORI E CHIUDERE RUBINETTI DELLE VALVOLE DI BLOCCO WARNING BEFORE OPERATING THE CRANE IT IS COMPULSORY TO EXTEND THE OUTRIGGERS AND SHUT THE BLOCK VALVE TAPS ATTENTION AVANT D UTILISER LA GRUE IL EST OBLIGATOIRE DE METTRE EN FONCTION LES STABILISATEURS ET FERMER LES ROBINETS DES VALVES DE BLOCAGE ACHTUNG VOR INBETRIEBNAHME DES KRANS MUESSEN DIE ABSTUETZUNGEN AUSGEFAHREN UND DIE ABSPERRVENTILE GESCHLOSSEN WERDEN DE318 DE 2406 Instruction plates to stabilize the vehicle DE2407 DE 2407 48 DE 319 Warning plate to stabilize the vehi cle before using the crane DE 2589 DE2589 Instruction plates to stabilize and adjust hydraulically the vehicle _ DE2590 DE 2590 DE 1686 DE 1684A Do not operate from the double control side to unfold or fold the crane DE 1684A DE 1681 Greasing points with brush DE 1682 Greasing points at pressure DE 1686 Do not walk or stop under a suspended load DE 1683 Do not operate in proximity of electric high tension lines INSTRUCTION AND WARNING PLATES F 800 900XP 49 INSTRUCTION AND WARNIN
26. ditions calmly and carefully assess the type and scale of the hazards arising from these manoeuvres and the possible reaction of the crane tipping over frame overload uncontrolled fall of the load due to a hydraulic system overload etc make all movements as slowly as possible to reduce the dynamic overload to the minimum LIFTING MOMENT LIMITING DEVICE AND CONTROL PANELS F 800 900XP fig 8 15 LIFTING MOMENT VII LIMITING DEVICE AND CONTROL PANELS F 800 900XP 16 DE 1680 Only In these situations it is permitted to remove the lead seals placed on the tap lever and place it in the closed position After such emergency operations and prior to re use of the crane you must immediately go to FASSI authorised Center for testing the structu re and re sealing of the device Interferences with the valves or removal of the lead seals release the Manufacturer from any responsibility and invalidate the warranty Control panel of the limiting device Layout of the control panel fig 9 positioned on the column next to the distributor pos 1 Emergency stop button STOP 2 Audible alarm push button danger 3 Orange warning light 90 of the capacity has been reached 4 Red warming light activation of the limiting device 5 White warning light power on 6 Fuse If the white warning light 5 comes on it confirms that the electric circuit is active and the push butto
27. e pin in its new seat and secure with the check pin Select the support E1 positioning the lever C on E1 Operate the lever to control the re entry of the support E1 CONTROLS TO STABILIZE THE VEHICLE F 800 900XP fig 28 fig 29 fig 30 fig 31 29 E SIRE Select the ram S4 positioning the lever on S4 F 800 900XP Operate the lever to control the re entry of the ram S4 Select the support E4 positioning the lever C on E4 Operate the lever to control the re entry of the outrigger support E4 N B The lever if in other positions does not allow any operations as a security device keeps it in free position Always check that the outriggers supports once in their rest position are locked in their seat by the safety devices so as to assure the impossibility of fig 33 accidental movements Fig 16 It is compulsory to close the outriggers rams valves taps before moving the truck Fig 17 fig 16c 26 CONTROLS TO OPERATE THE CRANE EH F 800 900XP WARNING Before operating the crane it is compulsory to set the outriggers and to shut the safety check valve taps This coincides with that indicated on the plate DE319 placed on the outrig gers Fig 34 Operate the levers smoothly and gradually ATTENZIONE PRIMA DI AZIONARE LA GRU i E OBBLIGATORIO METTERE IN OPERA GLI STABI When carrying out simultaneous movements of two or more func E
28. ector swicth fig 35 on the Manual Radio panel to Radio Operate lever re entry to ensure that the outer boom sections are completely re entered Before lifting the inner boom be sure that the outer ram is closed operate the lever H re entry function Lift the inner boom over the horizontal line by operating lever G fig 34a Open the outer boom to the horizontal position by operating lever H Eventually extend the booms of the crane by operating lever I Position the hook on the vertical line above the load operating lever F rotation CONTROLS TO OPERATE to fold the crane into the rest THE CRANE condition F 800 900XP IT IS FORBIDDEN TO OPERATE FROM THE DOUBLE CONTROL SIDE Operate from ground control distributor side Fold the extension boom sections to their stroke end lever 1 Lift the inner boom to its stroke end lever Fold the outer boom to its stroke end lever Operate the rotation control lever F until the arrows placed on the base and on the slew ring coincide Fold the inner boom to its stroke end lever the rest locating pin lines up with its seat ES um ET M s W CIE fig 34a Lift and re enter the outriggers to within the overall vehicle width as described in the chapter IX When all manoeuvres are complete check that the taps of the outrigger ram valves are c
29. ent possibilities of shearing without having blocked such parts of the crane Do not weld drill or grind any part of the crane without the Manufacturer s authorisation Do not weld the fixing rods of the crane see plate DE1574 fig 41 TIRANTI NON SALDARE FIXING ROD NOT WELD TIRANTS NE PAS SOUDER ZUGSCHRAUBEN NICHT SCHWEISSEN fig 41 When repairs to or checks of the hydraulic circuit and of the rams are carried out it is very important not to use or be in the proximity of mate rials which can damage the circuit or contaminate the hydraulic oil eg metal shavings sand or dust Do not use the high pressure washing on the controls deviators and double controls distributor on the slewing ring on the electronic components boxes control panels on the tanks Never use detergents petrolsol or inflammable liquids always use non flammable or non toxic liquids To avoid down time it is recommended to periodically carry out the fol lowing checks MAINTENANCE INSTRUCTIONS F 800 900XP At the end of every working day Check that all safety devices are efficient Check the level of the hydraulic oil in the tank Check the hoses fittings and all the components of the hydraulic circuit for possible leaks Check that the oil diverter E S and the double controls levers can be moved easily Check that the multi purpose oil diverter and double control levers can be moved easily and re
30. ers 2 E S Fig 20 22 Lever C Multifunction deviator for selecting and operating the supports and the outrigger rams of the crane as well as the supplementary outriggers Fig 20 22 WARNING Be very careful during vehicle stabilization operation make sure i e that there no obstacles preventing the rotation of the rams O il and that no one is or transits in close proximity of the working area of the outriggers Position lever D of oil diverter crane outriggers Z E S on E S Fig 20 22 Disengage the locking devices of the outrigger supports by putting the levers A from the position of the fig 16 to the one of the fig 16a Open all the taps of the valves placed on the outrigger rams fig 17 Double oil diverter control side fig 19 20 DE2590 Select the outrigger support E2 positioning the lever C of the multifunction deviator on E2 Operate the lever to extend the support E2 Select the outrigger ram S2 positioning the lever C on S2 Make sure that the ram valve tap S2 is closed fig 23 Open the valve tap on the rack ram belonging to the outrigger rotation device fig 24 Remove the check pin and release the pin fig 25 Use lever C to control the rotation and take the ram S2 to its working position nsert the pin in its new seat and secure with the check pin fig 26 Close the tap on the rack ram valve and open the tap of the outrig
31. es Lack of electric energy Winch end stroke active The rotation limiting device is activated Shortage of oil Obstructed filters Obstructed filters Remedies Stabilize the vehicle Grease the slew ring Grease the guide shoes Check the fuse the battery and electric circuit See Chapter XI See Chapter VIII Check the level and top if necessary Clean or replace the filter cartridge Clean or replace the filter cartridge Operations to be carried out by a service center Faults The crane does not lift the loads indicated on the capacity plate A boom of the crane does not hold up the load and visually lowers The crane does not rotate properly The extension booms do not completely extend or work jerkily Vibrations in crane operations Noteable decrease in movement speed Cause Non efficiency of the pump Main pressure valve not properly adjusted blocked or out of service Ram seals are not properly fitted The safety check valve of the ram is open Oil leaks inside the ram Valve controlling the rotation not adjusted Wear of guide shoes Non efficient pump Non efficient pump Remedies Replace the pump Check the pressure adjust the valve Replace the seals Replace the valve Defective seals replace them Adjust the valve Check the guide shoes wear replace if necessary Check the pump Check the pump 3 HYDRAULIC AND ELECTRIC SCHEMATICS F 800
32. etracting the extension rams with hydraulic jib act on the retraction of the jib extension rams B The red light switches off and the yellow lights usually comes on the crane controls are enabled Insisting with the manoeuvres that increase the lifting moment you get the yellow and red lights again 18 CONTROLS TO STABILIZE THE VEHICLE The outriggers rams prevent harmful stresses both to the frame and to the vehicle suspensions on which the crane is mounted and assure the stability of the unit during load handling Supplementary beams Supplementary beams supplementary outriggers are used in conjunction with the crane outriggers to ensure the vehicle stability during load handling Supplementary outrigger ram extension max beam code stroke integrals 7508055 520 5770 mm hydraulic extension 7508054 340 5770 mm hydraulic extension 750B053 520 mm 6870 mm double hydraulic extension 750B043 340 mm 6870 mm double hydraulic extension Identification data of the supplementary beam are punched on the beam fig 11 in the following Punching sequence Example 7 serial identification code ATTENTION The crane stability is only guaranteed by the maximum lateral extension of the outrigger supports of the crane and supplementary outriggers if fitted Be very careful during vehicle stabilization operation make sure that no one is or transits in close proximity of the working area of t
33. ever to control the re entry of the ram 1 Select the support E1 positioning the lever C on E1 Operate the lever to control the re entry of the support E1 Select the ram S4 positioning the lever on S4 Operate the lever to control the re entry of the ram S4 Select the support E4 positioning the lever C on E4 Operate the lever to control the re entry of the support E4 N B The lever if in other positions does not allow any operations as a security device keeps it in free position Always check that the outriggers supports once in their rest position are locked in their seat by the safety devices so as to assure the impossibility of accidental movements Fig 16 It is compulsory to close the outriggers rams valves taps before moving the truck Fig 17 Adjustable supports manual for the outrigger rams on request and only for cranes without integrated sub frame Outrigger rams which allow to be rested in an inclined position when obstructions on the vehicle chassis prevent their vertical stowability They are supports with articulation to be put between the outrigger supports and rams the fixed part is screwed to the outrigger supports and the mobile one to the outrigger rams After the extension of the lateral outrigger supports place the outrigger ram in a working condition as follows Remove the check pin and the locking pin from their posi tion fig 18 hand carrying the ra
34. evice keeps it in free position ATTENTION During the stabilisation operations for each outrigger ram it is recommended to DESCENT the outrigger as last manoeuvre ATTENTION The complete extension of the outrigger supports is visually indicated by the yellow triangles which are found at the end of the beam and the first outrigger support Fig 16b 16 c The stabilization has to be carried out with care and gradually keeping the vehicle in horizontal levelled condition to prevent springs overloads and chassis torsions After having completed the descent and the stabilisation manoeuvres close the taps of the valves placed on the outrigger rams Enable the crane by taking lever D controlling the crane outrig gers oil diverter E S to position 2 fig 20a 22a Manoeuvres for re entry of the crane outriggers and supple mentary outriggers within the overall vehicle width after crane use Position lever D of oil diverter crane outriggers 2 E S on E S Fig 20 22 Open all the taps of the valves placed on the outrigger rams of the supplementary beam fig 17 WARNING Under no circumstances put the hands on the locking devices of the outrigger supports the device re hook lever A from position of fig 16b to fig 16 is automatic Oil diverter double control side fig 19 20 DE2590 Select the outrigger ram S2 positioning the lever C on S2 Open the valve tap on the
35. exhaust pipe to take the fumes away from the working area Stabilize the vehicle by means of the outrigger rams checking that they rest on a solid base if in doubt use special larger outrigger base plates available on request See chapter IX Level the crane so as it is always operated on a horizontal plane Check that the taps of the outrigger rams safety check valves are closed Never operate the outriggers when the crane is loaded Remember that the stability of the unit crane vehicle is only guaranteed by the maximum lateral extension of the outriggers Should visibility be insufficient make sure that control stations are properly lighted so as to ensure safety while operating control functions and allow rea ding of the plates Before manoeuvering a load check that the working area is adequate and properly lighted for your crane Make sure that the hook is always free to rotate on its pin and that nothing obstructs its vertical positioning Check the efficiency of the hook safety catch SAFETY NORMS F 800 900XP SAFETY NORMS Carefully inspect the load rigging and the a IE F 800 900XP condition of ropes or chains Make sure that the lifted load is balanced The pallet fork must be connected to the crane hook by means of a chain having at least 3 rings Hook up the load checking that it does not exceed the capacity indicated on the lifting diagram specific to each load configuration
36. face of unions WARNING ensure that the control corresponds to the implement movement hydraulic connections are symmetrically fitted with coupling unions Never invert such positions movements inversion as well as operating difficulties could occur fig 40 33 34 MAINTENANCE INSTRUCTIONS F 800 900XP MAINTENANCE INSTRUCTIONS To assure a long life to the crane it is necessary to meticulously follow the instructions General lubrication and small repairs can be carried out by the user repairs of a more complicated nature must be carried out by authorized service personnel Spare parts must be original Good maintenance and proper use are imperative to maintain efficient use and guarantee the safety of the crane At least once a year you must take the crane to a Fassi Service Center for a check Before disconnecting any hydraulic hoses ensure that there is no pressure in the hydraulic circuit After removing hoses always mark them and their respective ports on the crane Faulty replacement can cause damage to the rams and to the hydraulic circuit Respect the information supplied for maintenance and technical assistance Any maintenance operation must be carried out with the crane power source turned off in case of fixed mounting with hydraulic power pack the electric motor has to be turned off Do not place limbs fingers or any other parts of anatomy into areas of the crane which pres
37. ger ram valve S2 fig 27 fig 22a Again use lever C to lower the ram S2 Select the support E3 positioning the lever C on E3 23 CONTROLS TO STABILIZE THE VEHICLE F 800 900XP Operate the lever to extend the support E3 Select the ram S3 positioning the lever C on S3 Operate the lever to control the ram descent S3 N B The lever if in other positions does not allow any operations as a security device keeps it in free position Oil diverter side fig 21 22 DE2589 Select the support E1 positioning the lever C on E1 Operate the lever to extend the support E1 Select the ram 1 positioning the lever C on 1 Make sure that the ram valve tap 1 is closed fig 28 Open the valve tap on the rack ram fig 29 Remove the check pin and release the pin fig 30 Use lever C to control the rotation and take the ram 1 to its working position Insert the pin in its new seat and secure with the check pin fig 31 Close the tap on the rack ram valve fig 32 Open the tap of the outrigger ram valve 1 fig 33 Again use lever C to lower the ram 1 Select the support E4 positioning the lever C on E4 Operate the lever to extend the support E4 Select the ram S4 positioning the lever on S4 Operate the lever to control the ram descent S4 N B The lever if in other positions does not allow any operations as a security d
38. he outer boom there is a mercury capsule mercury level switch duly pro tected and provided with the following warning stickers Contiene mercurio smaltire secondo le leggi in vigore H beseitingen so wie gesetzlich Es hat quecksilber bitte Mercury inside scrap following laws in force Contient du mercure recycler selon les lois en vigueuer MERCURY IS EXTREMELY TOXIC INCASE OF REPLACEMENT AND OR SCRAPPING DISPOSE OF OR RECYCLE THE CAPSULE CONTAINING MERCURY WITH MAXIMUM CARE AND IN ACCORDANCE WITH THE NATIONAL REGULATIONS IN FORCE 360 POSSIBLE FAULTS POSSIBLE FAULTS F 800 900XP c XIII Many years experience of our product has allowed us to identify and classify the most common faults which occur In most cases it requires accurate hydraulic and electric troubleshooting and simple rectification In the following table we report the most fre quent inconveniences and our suggested remedies Checking and adjustment of oil pressures of valve settings must be carried out by an authorized service agent under penalty of warranty forfeiture Operations which can be carried out by the user Faults The crane does not rotate properly The extension booms do not completely extend or work jerkily Crane controls are not active Vibrations in crane up operations Noteable decrease in movement speed Cause Vehicle non in level position Lack of lubrication Lack of lubrication of the guide sho
39. he outriggers Check that they are applied on a solid base the plate pressure of the rams Is 70 daN cm on a plate which diameter is 210 mm If needed use the special base plates on request When stabilization is complete the wheels of the vehicle must still be in contact with the ground and the suspensions must not be fully unloaded Level the crane so as to operate on a horizontal plane The controls to stabilize the vehicle are activated only on ground level and on both sides of the crane base CONTROLS TO STABILIZE THE VEHICLE F 800 900XP 19 CONTROLS TO STABILIZE THE VEHICLE F 800 900XP C am T DE2406 The controls to stabilize the vehicle are in conformity with the safety directives and enable the operator to activate the lateral extension of the outriggers outrigger supports and rams only from the side where he can visually check the operation The special construction concept of the outrigger control group which combines the functions of an 8 positions deviator with those of a distributor segment allows to use the control lever for selecting and operating the supports and the outrigger rams selection support or ram is effected like on a deviator by positioning the lever on the corresponding position indi cated by the function schematic plates DE2406 and DE2407 or DE2589 and DE2590 for cranes with a adjustable hydrau lic outriggers available on request placed on the c
40. icle by the outrigger rams making sure that the lateral supports are fully extended the wheels are in contact with the ground and the suspension is not completely unloaded outriggers safety taps are closed 6 Use the crane in accordance with the use and maintenance manual making sure that the load and radii 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 load is lifted before rotating 7 When using implements protect the crane working area with a barrier 8 The vehicle crane are not left unless the power take off is disenga ged and the load is on the ground 9 Before driving the vehicle make sure that the outriggers are fully retracted and re entered the safety taps closed and the crane is in folded position FASSI GRU IDRAULICHE SpA 24071 ALBINO TALY 48 2 INSTRUCTIONS FOR SAFE USE OF THE CRANE GRU IDRAULICHE Tel 39 35 77 64 00 Fax 39 35 75 50 20 1 Only authorized persons are permitied to operate the crane 6 Use the crane in accordance with the use and maintenance manual making 2 The crane must be used on firm level ground sure that the load and radius are within the maximum limits shown on 3 Check that the vehicle hand brake is on and that the wheels are chocked the crane capacity plate 4 Before operati
41. ioning the lever C on S3 Operate the lever to control the ram descent S3 N B The lever if in other positions does not allow any operations as a security device keeps it in free position Oil diverter side fig 14 15 DE2406 CONTROLS TO STABILIZE THE VEHICLE Select the support E1 positioning the lever C on E1 F 800 900XP Operate the lever to extend the support E1 Select the ram 1 positioning the lever C on 1 Operate the lever to control the ram descent 1 Select the support E4 positioning the lever on E4 Operate the lever to extend the support E4 Select the ram S4 positioning the lever C on S4 Operate the lever to control the ram descent S4 N B The lever if in other positions does not allow any operations as a security device keeps it in free position ATTENTION During the stabilisation operations for each outrigger ram it is recommended to DESCENT the outrigger as last manoeuvre ATTENTION The complete extension of the outrigger supports is visually indicated by the yellow triangles which are found at the end of the beam and the first outrigger support Fig 16b 16 c The stabilization has to be carried out with care and gradually keeping the vehicle in horizontal levelled condition to prevent springs overloads and chassis torsions After having completed the descent and stabilisation manoeu vres close the taps of the valves placed on the
42. late values to the one where it can operate according to the reduced values it means that one of the following conditions is reached manoeuvre of a load bigger than the one admitted in the reduced sector defined in the vehicle stability calculation manoeuvre without load with at least one of the inner outer rams of the crane or the jib if fitted extended till the stroke end The only one allowed manoeuvre is the crane rotation in the reversed sense and consequently an action which respectively allows to reduce the moment or to re enter the inner ram s the crane outer ram the jib outer ram EMERGENCY tap lever fig 8 Each device is fitted with an emergency tap lever to be used in the event of a black out electrical or hydraulic malfunctions or whenever the lifting moment limiting device makes it impossible to use any controls when handling a load this may occur when the exten sion booms are fully folded and the load is particularly heavy and bulky WARNING When the operator uses this device it means that he wishes to override the lifting moment limiting device in order to make some manoeuvres which would be impossible with the device active that bring the moment to within the maximum level but involve an overload condition In such an emergency condition where the lifting moment limiting device has been disabled the operator must carefully consider the manoeuvres required to return to normal working con
43. losed Fig 17 If there are accessories placed on the load or the back of the truck make sure that these are secured to avoid any sideways movement Tele radio remote control by request The HETRONIC radio remote control in the cases of unloaded battery or fig 17 presence of interference on the transmission by radio or use of the crane in determine applications where the transmission by radio is forbidden it is easily transformable in tele radio remote control using a connection cable supplied by request Activation of the tele radio remo te control Connect by cable the radio remo te control to the connector fixed on the plinth of the crane fig 37 Connect the flying connector of the delay cable to the switchboard fig 37a The use of the cable of prolongs it is necessary to operate with the same procedure of connection Turn the selector swicth fig 35 on the Manual Radio panel to Radio ATTENTION To restore the radio remote control it is necessary to disconnect the fig 37a cable from the console and the swit chboard 30 CONTROLS TO OPERATE THE CRANE F 800 900XP Load manoeuvres Before manoeuvering the load verify that the working area is suitable for your crane The lifting curves of the capacity plate indicate the maximum load that the crane can lift at a certain radius and at a certain height To utilize the maximum capacity of the crane it is necessa
44. m OIL AND LUBRICANT CHARACTERISTICS F 800 900XP 47 INSTRUCTION AND WARNING PLATES F 800 900XP FASSI GRU IDRAULICHE SpA 24021 ALBINO ITALY dei Carmelitani 2 E Tel 39 35 77 64 00 Fax 39 35 75 50 20 INSTRUCTION AND WARNING PLATES INSTRUCTIONS FOR SAFE USE 0F 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 suspensien is not completely unloaded the outriggers safety taps are closed DE 1771 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
45. m Carefully position the ram insert the locking pin in its new seat and secure it with the check pin fig 18a To re position the rams in folded condition Remove the check pin and the locking pin from their posi tion Carefully rotate the ram in a upward direction insert the locking pin in its new seat and secure it with the check pin The locking pin is constructed from special material do not replace it with a non original part your security depends on it Adjustable supports hydraulic control for the outrigger rams on request and only for cranes without integrated sub frame These are hinged supports with a mechanical hydraulic device for resting the outrigger rams at 180 upwards if there are obstructions on the vehicle chassis CONTROLS TO STABILIZE These should be placed between the outrigger supports and the F 800 900XP c IX rams the fixed part if screwed to the outrigger supports and the moving part to the outrigger rams L Controls for positioning the hydraulic adjustable outriggers and the supplementary beam The extension and re entering of the support and outrigger rams indicated on the fig 19 21 coincide with what indicated on the pla tes DE2590 and DE2589 placed on the base in proximity of the con trol stations The symbols reported at side of each lever indicate the operating levers in relation to their movement Lever function D C Lever D Deviator crane outrigg
46. n panel functions are enabled INOTE In the absence of electric power all crane functions will be desactivated If the orange warning light 3 comes on during load handling 90 of the capacity lifting moment has been reached If during operation the red warning light 4 comes on the activation value of the lifting moment limiting device has been reached Any hidden danger situation for persons must be audibly alarmed by pressing the push button 2 When there are serious imminent and dangerous conditions for persons and things during load handling operate on the emergency stop button 1 which isolates all crane functions ATTENTION Do not walk on the electric control panels or on the lever guards of the lifting moment limiting device positioned on the distributors Plate DE1679 Do not use water to estinguish fire Plate DE1680 VISUAL INDICATOR YELLOW RED LIGHT Fig 9a On the radio remote control it is not possible to have the visual signals of intervention of the load limiting device The crane is furnished of visual indicator signals which has to be located in a visible position on the crane structure or on the truck indicates with yellow light 90 of the capacity lifting moment has been reached red light the activation value of the lifting moment limiting device has been reached LIFTING MOMENT LIMITING DEVICE AND CONTROL PANELS F 800 900XP c VIII 6 1 4 fig 9 fig 9 WA
47. nd At the end of the job and prior to driving the vehicle the crane must be folded If the booms are to be laid on the body or on the load they must be blocked to prevent possible sideways movements Outrigger rams must be lifted and re entered within the overall width of the truck and safety devices locked Check that the taps of the outrigger rams safety check valves are closed Disengage the power take off To avoid hitting bridges or tunnels check and record the overall height of your crane in the folded position or in laid position in the body or on the load Always respect and pay proper attention to road signs placed in proximity of such obstacles SAFETY NORMS F 800 900XP mni PER INSTRUCTIONS FOR CRANE USE F 800 900XP The use of the crane is reserved to authorized personnel instructed in advance who has to strictly conform to the safety norms and instructions contained in the instruction manual supplied with the crane 1 Only authorized persons are allowed to operate the crane 2 Thecrane must be used on firm level ground 3 Check that the vehicle hand brake is on and that the wheels are chocked 4 Before every operation make sure that no one is within the working area of the crane the safety devices are in place and operative the minimum safe working distances from power lines are observed the load is correctly slung and hooked 5 Stabilize the veh
48. nd without overlappings on the drum On winches not equipped with presser cable check the rewinding of the cable on winch drum proceeds regularly and without overlapping it is suggested not to rewind the cable if it is not sufficiently taut According to the actual norms the winches must be provided with safety device That adopted one uses an electrohydraulic technology where a signal given by a microswitch controls the quiescing and the reactivation of crane controls through an electrovalve The adopted device prevents that the lifting with the winch or in the booms extension rams exit crane or hydraulic extension the cable hook or the block takes contact with the pulley structure inthe unwinding the cable is completely wound from the winch drum three turns must be wound at least causing the controls quiescing To reactivate the controls the lever fig 26 27 28 winch control must be acti USE OF IMPLEMENTS vated controlling F 800 900XP the descent of the cable if the device operation is happened in the lifting with the winch or in exit with the booms extension rams the lifting of the cable if the operation is happened in the unwinding of the same one In the phase of lifting or exit of booms extension rams the control of the position about the cable hook or about the block as regards the pulley structure is obtained through a microswitch which lever is kept in position by a chain balance weigh
49. o remote control key As said before certain keys allowes to the con trol after selection two different functions Observe the disposition of controls which appears on the radio remote control the fig 36a represents the possible combinations of the controls and the numbering of the levers is given as reference The fig 36b represents the manual control of the crane and eventual accessories in emergency conditions Lever function Crane controls F Rotation motoreducer control G Inner ram control H Outer ram control Outer booms section rams control Lever function L M N Hydraulic implements controls L First hydraulic implement control M Second hydraulic implement control N Third hydraulic implement control Always remember that the number of levers for hydraulic implements controls changes upon the type of fittings as follows 1lever winch control 2 levers jib outer ram jib extension rams control 3 levers jib outer ram jib extension rams and winch control Manoeuvres to unfold the crane into a working condition fig 36 IT IS FORBIDDEN TO OPERATE FROM THE DOUBLE CONTROL SIDE Operate from ground control distributor side Engage the power take off Stabilize the vehicle as described in the chapter IX and position lever D of the deviator crane outriggers S E on Turn the sel
50. on make sure that the crane is used progressively avoiding sudden load movements no one is within the working area of ihe crane gt swinging or dragging of the load is avoided the safety devices are in place and operative the load is lifted before rotating the minimum safe working distances from power lines are observed NN the load is correctly slung and hooked 7 When using implements protect ihe working area with a barrier I 8 The vehicle crane are not left unless the power take off is 5 Stabilize the vehicle with the outriggers making sure that I the lateral supports are fully Ended 9 disengaged and the load is on the ground the wheels are in contact with the ground and the suspension is not 9 Before driving the vehicle ensure that the outriggers are fully retracted completely unloaded and re entered the safety taps closed and the crane is in the folded the safety taps are closed pesition THESE INSTRUCTIONS FOR THE USE OF THE CRANE COINCIDE WITH THOSE OF THE PLATE DE1771 FIG 1 PLACED NEXT TO THE CRANE IDENTIFICATION OF IDENTIFICATION OF THE CRANE MODEL THE CRANE MODEL F 800 900XP Essential data for the identification of the crane given on the plate DE1661 used for the CE mark and fixed to the base Fig 2 1 Crane model 2 Serial Number 3 Year of manufacturing GRU MODELLO 1 CRANE MODEL N DI SERIE 2 SERIAL NUMBER ANNO DI COSTRUZION
51. ontrols The control is effected by operating the lever like on a distri butor the stability of the selected position is guaranteed by an internal device The extension and re entering of the support and outrigger rams indicated on the fig 12 14 coincide with what indicated on the plates DE2407 and DE2406 placed in dual side position on the base The symbols reported at side of each lever indicate the operating levers in relation to their movement Lever function D C Lever D Deviator crane outriggers 2 E S Fig 13 15 Lever C Multifunction deviator for selecting and operating the supports and the outrigger rams of the crane as well as the supplementary outriggers Fig 13 15 Position lever D of oil diverter crane outriggers 2 E S on E S Fig 13 15 Open all the taps of the valves placed on the outrigger rams fig 17 Disengage the locking devices of the outrigger supports by putting the levers A from the position of the fig 16 to the one of the fig 16a Double oil diverter control side fig 12 13 DE2407 Select the outrigger support E2 positioning the lever C of the multifunction deviator on E2 Operate the lever to extend the support E2 Select the outrigger ram S2 positioning the lever on 82 Operate the lever to control the ram descent 82 Select the support E3 positioning the lever C on E3 Operate the lever to extend the support E3 Select the ram S3 posit
52. outrigger rams Enable the crane by taking lever D controlling the crane outriggers oil diverter 2 E S to position Z 13a 15a Manoeuvres for re entry of the crane outriggers and supple mentary outriggers within the overall vehicle width after crane use Position lever D of oil diverter crane outriggers 2 5 Fig 13 15 Open all the taps of the valves placed on the outrigger rams fig 17 WARNING Under no circumstances put the hands on the locking devices of the outrigger supports The device re hook lever A from position of fig 16b to fig 16 is automatic Oil diverter double control side fig 12 13 DE2407 Select the outrigger ram S2 positioning the lever C 82 Operate the lever to control the re entry of the ram 82 Select the outrigger support E2 positioning the lever on 2 Operate the lever to control the re entry of the support E2 Select the ram S3 positioning the lever C on S3 Operate the lever to control the re entry of the ram S3 Select the support E3 positioning the lever C on E3 Operate the lever to control the re entry of the support E3 CONTROLS TO STABILIZE THE VEHICLE F 800 900XP N B The lever if in other positions does not allow any operations as a security device keeps it in free position Oil diverter side fig 14 15 DE2406 Select the ram 1 positioning the lever C on 1 Operate the l
53. overloads as it prevents any movement which increases the value of the moment up to the maximum established value This device is fitted close to the distributor whose specific functions it uses It utilises an electrohydraulic technology preventing any movement which cau ses an increase in the pressure induced by the load in the inner and outer rams of the crane and in the outer ram for the hydraulic extension if fitted up to the critical values which have been established in the structural test These values which are non exceedable determine the intervention levels and provide the data for setting the device The condition of intervention is operated by the position in connection with the horizontal position of the crane outer boom on which the electronic signal position mercury level switch is read by a special electrovalve This determines the controls of the locking or unlocking resetting of the controls concerned The lifting moment limiting device concernes the fol lowing manoeuvres Inner boom descent the inner boom lift is controlled by the general main pressure valve of the distributor Outer boom lift Outer boom descent Extension of extension boom sections Winch rope if fitted hydraulic extension is fitted extension outer boom lift Extension outer boom descent Extension of the jib extension booms section The crane configurations fig
54. placed in the crane outer booms and secured by pins and check pins they have a maxi mum capacity indicated on the plate independent from the crane configura tion WARNING Manual extensions are not protected by the lifting moment limiting device Before lifting the load make sure that its weight does not exceed the Capacity indicated on the plate Manual extensions can be extracted from the rest position and be operative once the security pins have been removed with the outer boom in sliding position Verify that the area is suitable for this operation and there are no unauthorized persons in the working area Do not permit the extension to slide out at speed as this will damage the stroke end stops Do not try to align the holes slots for the locking pins with your fingers always use a Suitable tool Always remember that when operating with implements their tare weight must be deducted from the capacity of the crane When manual extensions are in place fit the locking pins and secure them with the check pins to prevent accidental escape 31 32 USE OF IMPLEMENTS F 800 900XP fig 38 Mossa as gana 5 foro 98004 Y citrate Vetoesto mer P 5 014010 mor B n nin T3 Xe O Winch fig 38 The winch is made of a drum pos 1 that can rotate by means of a hydraulic engine pos 2 on a structure pos 3 fixed on the crane i e under the outer boom
55. ram 82 Make sure that the valve tap belonging to the rack ram is closed Operate the lever to control the re entry of the ram 82 Remove the check pin and release the pin Close the tap on the ram valve 82 Open the tap of the rack ram valve Use lever C to control the rotation and take the ram S2 to its rest position Insert the pin in its new seat and secure with the check pin Select the support E2 positioning the lever C on E2 Operate the lever to control the re entry of the support E2 Select the ram S3 positioning the lever C on S3 Operate the lever to control the re entry of the ram S3 Select the support E3 positioning the lever C on E3 Operate the lever to control the re entry of the support E3 N B The lever if in other positions does not allow any operations as a security device keeps it in free position Oil diverter side fig 21 22 DE2589 Select the ram S1 positioning the lever C on 1 Operate the lever to control the re entry of the ram 1 Open the valve tap on the ram 1 Make sure that the valve tap belonging to the rack ram is closed Operate the lever C to control the re entry of the ram S1 Remove the check pin and release the pin Close the tap on the outrigger ram valve Open the tap of the rack ram valve Use lever C to control the rotation and take the ram S1 to its rest position nsert th
56. ry to position the inner boom as indicated on the capacity plate During load handling do not exceed the reach limits given or the load indicated on the above mentioned charts If the limits are exceeded the load limiting device allowing all manoeuvres which reduce the lifted load within the permitted reach limits and forbid all other manoeuvres will be immediately activated The presence of the lifting moment limiting device does not release the user from the observance of the capacity plates and lifting curves WARNING Always check carefully that the vehicle is perfectly stable paying spe cial attention to the area immediately in front of the driver s cabin which is usually less stable USE OF IMPLEMENTS USE OF IMPLEMENTS F 800 900XP The crane can be provided with implements such as Manual extensions Winches Hydraulic extensions Personnel baskets When using an implement it is always necessary to check that its weight dimension and capacity is matched to the crane performances Warning and norms for crane use also apply for hydraulic implement use Before using a personnel basket it is necessary to provide the crane with the safety devices requested by the local norms in force Prior to use of the crane it has to be tested and inspected in accordance with the local legal requirements Manual extensions Manual extensions are additional boom sections which are
57. t assem bled free on the cable In the quiescing of the crane the keeping in position of the micro switch lever becomes impossible with the consequent quiescing of controls To put the crane in rest position it is necessary to operate in this way withdraw the flying drive it is assembled on the cable of the cable winder from the pin placed near the microswitch placed on the pulley assembled on the booms extension rams In case it is a crane with hydraulic extension it is necessary to detach the cable of the cable winder placed on the crane from the pin of the second cable winder assembled on the extension Release the cable from all support rings placed on the booms letting that it winds free in the cable winder Insert the flying drive in the pin placed in the cable winder Fig 39 This operation gets active all crane controls to complete the rest position operations Please remember that after stabilizing the vehicle and placing the crane in working position it is compulsory to reset the functionality of end stroke device otherwise the cable could be damaged Hydraulic connections between implements and hoses fitted on exten sion boom section Fig 40 In case of hoses connection to implements through coupling unions it is necessary to verify that there is no trace of soil curt etc on the unions and inside the seats so as to avoid the oil contamination and consequen tly wear the tightening sur
58. tion Rotation Working Pump Oil tank Crane Max working capacity reach extension arc torque pressure capacity capacity weight pressure on the outrigger 210 82 2 tm 8 00m 3 55m 360 6 74tm 32 0 MPa 801 2501 6350 kg 70 daN cm 806 4 kNm 66 14 F800 900XP 22 7707 25 3 41457 1577 O j SBRACCIO MAX REACH MAX BRAS MAX MAXIMALE REICHWEITE M ify 1241 F800 900XP 22 2518 B z 964 3 2 i 855 2 16 2242 74 7192 25 7 530 1 2485 87 1150 3 9 480 355 171 1326 4 47 PESO GRU SERBATOIO RIFORNITO STABILIZZATORI STANDARD POIDS DE LA GRUE AVEC RESERVOIR VIDE STABILISATION STANDARD KRANGEWICHT MIT LEEREM TANK UND STANDARDABSTUTZUNG 580 1 11 MASSIMA ALTEZZA SOTTOGANCIO HAUTEUR MAXIMUM SOUS CROCHET MAXIMUM HOOKING POSITION MAXIMALHOEHE BIS KRANHAKEN CO 1247 TECHNICAL DATA F 800 900XP 22 KAY CON TUBAZIONI SUPPLEMENTARI WITH SUPPLEMENTARY HOSES AVEC TUYAUTERIE SUPPLEMENTAIRE MIT ZUSAETZLICHEN SCHLAEUCHEN DIMENSIONI E POSIZIONE BARICENTRO POIDS DIMENSIONS ET POSITION DU BARYCENTRE WEIGHT DIMENSIONS AND BARYCENTRE POSITION GEWICHTE ABMESSUNG UND POSITION DES KRANSCHWERPUNKTS F 800 900XP B NOMENCLATURE CRANE NOMENCLATURE Version with ground controls for outriggers and controlers of the
59. turn freely to neutral position Check the condition of shackles hooks wire ropes and any other lifting equip ment After the first 40 hours use Check the tightening torque of the fixing rods of the crane Fig 42 Tightening torque for the rods M 39x3 1800 Nm fig 42 After every working week Clean the oil filters in the crane tank at the intake before the pump and immediately after the pump If the hydraulic circuit of the crane is connected to a tipper a remote oil tank may be fitted in this case the filter will be found in this tank Cleaning of the filter on the tank oil return from the distributor fig 43 Remove the filter cover pos 1 by unscrewing the three security bolts Remove the spring and extract the filter cartridge pos 2 during this operation take care that no contaminated material passes into the tank Clean the cartridge by flushing with a non flammable and non toxic solvent Thoroughly dry the filter inside and out with compressed air Remove the filter holder from the filter body pos 3 a hose is attached to its base clean and reassemble checking the sealing O rings pos 4 internal seal between cartridge and pos 5 holder and external seal between holder and body Re assemble the filter cartridge into its holder re assemble the spring and the filter cover pos 6 check the sealing of the O ring under the filter cover Re fit the three security bolts
Download Pdf Manuals
Related Search