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F 700A/800AXP.26 - FASCAN International, Inc.

1. RADIO REMOTE CONTROL IS MOBILE BEFORE STARTING MANOEUVRING OF THE VRING OF THE STABILISERS WITH THE RADIO REMOTE CONTROL THE OPERA STABILISERS WITHTHE RADIO REMOTE CONTROL TOR SHALL MAKE SURE THAT THEIR MOVEMENTS ARE FULLY VISIBLE DE5842 THE OPERATOR SHALL MAKE SURE THAT THEIR MOVEMENTS ARE FULLY VISIBLE ATTENTION DE5842 Selection crane outriggers ATTENTION You can select whether to control the crane or the outrigger functions using the buttons placed on the remote control as follows To operate the outriggers position the A B selector pos 5 on A and the selector E S 2 pos 1 on ES then press together the left confirmation button OK pos 2 and the right confirmation button OK pos 6 for joy stick controls pos 7 for linear controls Outriggers appears on the display When turning on the remote control asks for selector confirmation E S 7 on display to con firm press contemporarily the two left right OK confirmation buttons pos 2 and pos 6 for joy stick controls pos 7 for linear controls Functions of the controls on the push button panel of the transmitting console The first 5 control levers LINEAR PUSH BUTTON PANEL SCANRECO on the push button fig 10 panel beginning on the DISAS right have two plates WT because they can con trol through the selec tor E S 2 5 functions of the crane or the func tions for stabilization Hereunder are rep
2. Plastic materials gaskets belts covers Electric materials windings controls electrovalves and similar Oils and lubricants hydraulic oil lubricants for reducers lubricating greases For the truck follow the indications of the manufacturer Different material Mercury level sensor Take extreme care when slinging the components to be disassembled especially with respect to their weight Completely release the residual pressure in the hydraulic circuits and then fully drain the oil present in the circuits before starting the dismantlement of the relevant compo nents Be careful not to let the oil drop on the ground therefore collect it in special con tainers since exhausted oil must be eliminated in compliance with the waste disposal rules in force Disable all the electric power supplies batteries etc before dismantling the compo nents of the electric circuits MAINTENANCE INSTRUCTIONS RES GRU FASSI CHARACTERISTICS GRU FASSI 23 OF HYDRAULIC 23 TABLE OF HYDRAULIC OIL AND LUBRICANTS HYDRAULIC OIL WITH HIGH VISCOSITY ISO L HV Minimal external maximal oil Gradation temperature temperature 35 C 45 ISO VG 32 20 C 75 C ISO VG 46 HYDRAULIC OIL WEAR RESISTANT ISO L HM Minimal external maximal oil Gradation temperature temperature 10 C 60 C ISO VG 32 0 75 ISO VG 46 5 C 85 C ISO VG 68 10 C 90 C ISO VG 100 GREASE for centralized system Use only GR
3. USE OF IMPLEMENTS GR4_5 20 10 21 WINCH when fitted 20 1 Generality The winch is made of a drum that can rotate by means of a hydraulic motor a structure fixed on the crane The rotation of the drum on which the cable winds is achieved by a hydraulic motor controlled by a safety check valve connected to the crane circuit A parking brake integrated to the motoreducer group hold the load in position when the winch control lever is in neutral position Nomenclature of winch unit fig 23 Pos Description Winch Cable Fixed pulley Balance weight Hook Transmission pulley Block double triple line fig 23 pU d ATTENTION D Check the condition of wire rope On winches not equipped with cable layer check the rewinding of the cable on winch drum proceeds regularly and without overlapping it is suggested to rewind the cable only if it is sufficiently taut Do not rotate the crane before the load is lifted Lift the load vertically using the cable and not the boom in order to avoid swinging the load With the suspen ded load rotate slowly and with care checking the stability of the vehicle 21 2 Winch for crane The identification data and the essential characteristics are marked on a plate fixed by the manufacturer and used for the CE mark which testifies its confor mity to the Machine Directive D M Manufacturer mark Winch type number Maximum line in N at the 4
4. CONTROLS TO Functions of the controls on the push button panel of the transmitting console IS OPERATE THE CRANE GR5 LINEAR PUSH BUTTON PANEL SCANRECO ACCESSORY CONTROLS CRANE CONTROLS PAA DISPLAY RED LED 10096 YELLOW LED 90 socket for serial cable SELECTOR E S 2 fig 10 eeh and stop button radio startin STOP and audible alak gers E S or of the crane 9 GAS 2 control button selector for the use of the outrig T OK A Er _ exclusion push button for the lifting s control button moment limitin oment limiting device GAS x y SWitching of the selector for the use of the 9 10 function free H K oh or selector for the use of the crane control button Standard starting the engine selector for the use of the right con control button turning off trol panel in configuration A or B g a engine gt OPERATE THE CRANE Functions of the controls on the push button panel of the transmitting console CONTROLS TO PUSH BUTTON PANEL SCANRECO WITH JOY STICK GR5 DISPLAY RED LED 90 YELLOW LED 90 socket for Serial cable SELECTOR E S 2 fig 10a radio turning off and stop button STOP radio starting and audible alarm E S 8 control button selector for the use of the outrig OK gers E S or of the crane 9 RPM GAS B OK ENTER exclusion
5. button to select JIB if in the actual configuration the manual extensions are mounted on JIB or CRANE if the manual extensions are mounted on the crane After having pressed the above mentioned keys the message illustrated in GR2_45 60 3 4 5 3 Message M1 M2 fig 3 USE OF DEE Fig 3 will be displayed NTE EH 2 Em fig 3 fig 3 At this point through the button select the correct number of the manual extension at the moment in use M stands for manual and 1 2 and 3 indicate the number of the manual extensions Select the number of the manual extension you want that number starts blinking You can select only the manual extensions that have been installed i e if only one manual extension is installed by pressing the only the M1extension will start flashing To confirm your choice press once the F1 key control panel or ENTER radio remote control you ll access the section dedicated to the system confi guration 4 Message K2 K4 fig 4 paragraph to read only in case of manual extensions installed on Jib and not on Crane fig 4 If you press the ENTER key with the manual extensions mounted on the jib the screen of Fig 4 will be displayed Therefore we can choose the most convenient configuration among the following K1 Outer booms of the crane totally re entered and jib extensions as you like K2 Outer booms of the crane as you like a
6. tion and pressure hoses NOTE The filters of fibre or paper can not be cleaned they must be replaced Cleaning of the wire mesh filter on the tank oil return to the oil tank fig 31 Unscrew the security bolts of the filter cover 1 and remove it Extract the cartridge clean by flushing with a non flammable non corrosive and non toxic solvent gas oil or other Thoroughly dry the filter inside and out do not use compressed air Check if the cartridge has collapsed if so replace it Remove the filter body 3 and clean it Re assemble the filter body and the cartridge check the sealing of the O ring 4 5 6 in case replace it NOTE Take care that no contaminated material passes into the tank Replacement of the filter on the delivery line before the distributor fig 32 When the visual indicator becomes red replace the cartridge Unscrew with a suitable spanner the filter body 1 from the head 2 Remove the cartridge 3 and clean inside the holder 1 Insert a new cartridge and re assemble the filter body into the head checking the seal 4 Check the oil level in the tank with the crane in the folded position and with the Outriggers crane and supplementary fully re entered The oil level must not exceed the maximum or be lower than the minimum fig 33 Top up using hydraulic oil with the same characteristics as those indicated in the table at paragraph 23 The following lubricators have
7. 380 kg 27 70 29 60 m PL 31 AL 21 DE 5489 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device E ma GRU IDRAULICHE E L505 F700A 26 444kNm PT 4000 kg d o Bee 20215240 a EH 26 30 d 55 RL 36 SL 25 a 5 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device L5051F800AXP 26 9 Pmax 4000 kg gen m 1 deser 24 7 1145 26 30 E d 55 36 SL 25 28 10 29 90 B eae mg c g SE lh lk CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device L506 F 7004 26 Na Kn RL 36 SL 25 29 90 31 10 A la Ad K ler Bag d d f CO PE Kas lz jo kag CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device m GRU IDRAULICHE L5061F800AXP 26 8220 180011515 1370 dude m 16 80 19 00 20 50 21 85 23 25 24 80 26 40 SL WS CA 2810 29 90 31 70 m CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device y 4000 kg
8. Any maintenance operation must be carried out with the crane power source turned off in case of fixed mounting with hydraulic power pack the electric motor has to be turned off Do not place limbs fingers or any other parts of anatomy into areas of the crane which present possibilities of shearing without having blocked such parts of the crane Do not weld drill or grind any part of the crane without the Manufacturer s authorisation fig 29 Do not weld the fixing rods of the crane see plate DE1574 fig 29 TIRANTI NON SALDARE FIXING ROD NOT WELD When repairs to or checks of the hydraulic circuit and of the rams are carried out it is very important TIRANTS NE PAS SOUDER not to use or be in the proximity of materials ZUGSCHRAUBEN NICHT SCHWEISSEN 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 distributors double controls hand cable controls on the electronic components boxes control panels on the tanks Never use detergents petrolsol or inflammable liquids always use non flam mable or non toxic liquids To avoid down time it is recommended to periodically carry out the following checks INSTRUCTIONS En 22 2 Timer fig 29a if fitted GRU FASSI The control panel of the electronic lifting moment limiting device placed next to the distributor of the c
9. DI778 DISTRIBUTOR VA164 DOUBLE EFFECT BLOCK VALVE DV018 DEVIATOR VA175 BLOCK VALVE FAUCET DV019 DEVIATOR VA185 SELECTOR VALVE FI782 OIL FILTER HIGH PRESSURE VA187 BLOCK VALVE FAUCET FI854 OIL FILTER RETURN VA200 DOUBLE EFFECT BLOCK VALVE NI1006 SPECIAL STRAIGHT PIPE FITTING M VA215 OIL FLOW CHECK VALVE RU976 FAUCET VA232 UNIDIRECTIONAL VALVE 90002 OIL COOLER HEAT EXCHANGER VA246 REGENERATIVE VALVE 90001 OIL COOLER HEAT EXCHANGER VA249 UNIDIRECTIONAL VALVE 5 ELECTRIC SCHEMATICS Electric schematic for crane LP M1 M2 M3 M4 M5 MG M7 ELECTRIC SCHEMATICS GR5 fe Tr nr F600 F1000A JI e eva i Hm Cv106 CN8 2 9242322934233 CN8 1 CN5 2 CN4 2 4 1 HE ETC CN3 1 CN3 2 CNe mg CN14 Le eet P3 Pl DUI E pm 133355 21 EVR d A bech 5 EVE IN EVG d DI Evsan EVS3IN EVEA HY CV003 2 CV006 1 CV003 004 001 1 ALIM 2 Nr DESCRIPTION ALIM GENERAL FEEDING ALIMI SHUNT BOX ON THE COLUMN ALIM2 SHUNT BOX ON THE BASE D1 D10 CONNECTORS FOR DANFOSS MODULUS DR ELECTRIC ROTATING DISTRIBUTOR EM EMERGENCY ELECTROVALVE F
10. Light breeze Smoke reveals the direction of the 1 wind one can feel the wind blowing leaves start fluttering Moderate breeze Leaves and branches are in constant motion small branches start fluttering Dust and papers dance on the ground 1 2 3 4 5 8 0 10 7 Fresh breeze Small green branches bend the surface of waterways and lakes are wavy 10 8 13 8 Near gale Big branches bend wind whistles through high tension cables it s difficult to walk keeping the umbrella open 13 9 171 Moderate gale Trees sway it s hard to walk 17 2 20 7 Branches get broken it s hard to walk 20 8 24 4 Storm It damages houses antennas and roof tiles fall down ATTENTION Carefully inspect the load rigging Hook up the load checking that it does not exceed the capacity indicated on the lifting diagram specific to each load configuration Make sure that the lifted load is balanced Avoid swinging the load above the control station in cases where the load is too close the crane must be operated from the opposite side or with the radio remote control WARNING AND INSTRUCTIONS GRU FASSI WARNING AND 7 4 INSTRUCTIONS GRU FASSI When operating through a winch lift the load vertically using the cable and not the booms in order to avoid swinging the load Do not rotate the crane before the load is lifted Do not operate with sudden movemen ts activate the controls with slow and progres
11. Z EIS of the push button panel on 2 Manoeuvres for re entry of the crane outriggers and supplementary outrig gers within the overall vehicle width after crane use Hepeat by reversing the sequence of the operations effected for the stabilisation of the vehicle ATTENTION Keep hands clear of automatic stop device of the outrigger supports Fig 12 Always check that the outrigger supports once in their rest position are locked in their seat by the safety devices so as to assure the impossibility of accidental movement Fig 12 13 3 2 Crane with hydraulic tiltable supports WITH CHAIN for outrigger rams ATTENTION Be very careful during vehicle stabilization operation make sure that there are no obsta cles preventing the rotation of the rams and that no one is or transits in close proxi mity of the working area of the outriggers Disengage the locking devices of the outrigger supports by putting the levers A from the position of the fig 12 to the one of the fig 12a Position lever D of oil diverter 2 E S on E S Position selector EIS of the push button panel on E S Byusing the levers CD the lever C and the valve taps extend the outrigger supports rotate the outrigger rams putting in a working condition and lower them till the complete stabilisation of the vehicle Example of using the levers CD the lever C and the valve tap on the outrigger and the valve tap on the control r
12. the rest locating pin locates into its seat re position the outriggers to within the overall vehicle width as described on Paragraph 13 Es S At lt wc AU FEI 12073 5 LK von ei M LS TG E a 4 by ALE 2 27 m fig 18 16 MANOEUVRES OF THE CRANE LOADS 161 Generality 1 Before manoeuvering the load that the working area is Suitable for your crane The lifting curves of the capacity plate indicate the maximum load that the crane can lift at a certain radius and at a certain height To utilize the maximum capacity of the crane it is necessary to position the inner boom as indicated on the capa city plate the coloured symbols on the inner boom and column must coincide 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 devi ce allowing all manoeuvres which reduce the lifted load within the permitted reach limits and forbid all other manoeuvres will be immediately activated On the crane has been installed an electronic system to automatically control the maximum speed for moving the booms in relation to the load applied With low loads the control system allows the use of the nominal capacity of the pump while the oil capacity available for the moving is automatically and pro gressively reduced at the increased loads The manoeuvres affected by this
13. 3 29 CONTROLS OPERATE THE CRANE Generality Manoeuvres to unfold the crane into a working condition Manoeuvres to fold the crane into the rest condition MANOEUVRES OF THE CRANE LOADS version with load limiting device not available GE OF THE CRANE LOADS version with lifting moment limiting device enerality Lifting moment limiting device ELECTRONIC Control panel Load handling Lifting moment limiting device for two working sectors Rotation limiting device In the case of the appearance of the signal ALARM on the display of the control panel or of the radio remote control or in case of an electrical failure Diagnostic Alarms Input Output LME vers 4 5 UC 01 7 Temporary OVERIDE Reactivation for the crane functions in case of the appearance of the signal ALARM on the display of the push button panel Temporary OVERIDE Reactivation for the crane functions in case of an electrical failure out of order of the radio remote control or of the appearance of the signal ALARM on the display of the push button panel in this case we cannot reactivate the crane functions XP device if fitted see the Use and Maintenance booklet Activation and instructions for use of the XP V device if fitted see the Use and Maintenance booklet IMC and ADC devices if fitted see the Use and Maintenance booklet USE OF IMPLEMENTS Generality Hydraulic connections for implements supplementary hoses Oil cooler heat excha
14. 5 RL dy RL 36 SL 25 29 90 31 70 m F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device NEN ee _ GRU IDRAULICHE L516 2800 26 ges Am Pmax 4000 kg NG 177111 nA ase IA CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device Bae rm co GRU IDRAULICHE L414 F700A 26 9 Pmax 2000kg 1max 2000 a e NN Se EEN We m 22 EE T Ge ees ge d x ami moe ima E SC er o o IN m 530 230 kg 21 80 29 70 m PL 31 QL 21 3 v20 145 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device L414 F700A 26 9 2000 kg imax 2000 aan ler o lo IN SC GE ph 31 QL 21 3 250 CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device GRU IDRAULICHE L505 F700A 26 116 30 4 2 6 m Sen Oy Ay 192 2050 2 23 30 670 500 400 Kg 28 20 30 00 31 85 OL 55 RL 36 SL 25 v20 145 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device GRU IDRAULICHE L505 F700A 26 zech T Ji Ph 55 AL 36
15. ATTENTION Failure to respect the minimum safe distances may result in electrical hazards for the ope rator and his assistants ELECTRICUTION General safety precautions for the operator and potential co workers If the crane hits an ove rhead power line do not touch the crane the truck or the load Carefully evaluate the danger before moving If you are closer than 10 meters from the crane the truck the load or the electric line move at least 10 meters away by shuffling away with small steps in order to minimize the chance of getting a too high voltage difference between the feet Warn others to stay away call for help and contact the power company to de energize the line do not attempt to assist someone in direct or indirect contact with the power line before the power has been disabled you run the risk of being electricuted yourself If you are in the truck cabin stay inside without touching the vehicle body because it s extremely hazardous to go out before the line is de energised Help the electricuted person if you know the first aid procedures otherwise wait for the parame dics to arrive ATTENTION Do not utilize the crane during thunderstorms and with wind speed exceeding 13 8 mis 50 km h maximum value of the Beaufort scale degree 6 Indications about wind speed Force of the wind Wind speed Classification Characteristics Beaufort scale m s 0 0 0 2 Calm Calm wind smoke goes up quite vertically 0
16. INSTRUCTIONS 71 Generality The use of the crane is reserved to authorized personnel instructed in advance who has to conform to the safety norms and instructions contained in the use manual supplied with the crane See norms ISO 9926 1 It is absolutely prohibited to walk or stop under a suspended load It is prohibited for unauthorized persons to be within the working area Under no circumstances interfere with the safety and protection devices Warning plates as well as instruction and operation plates must be replaced when no longer readable or missing See Paragraph 25 Instruction and warning plates Do not use the outriggers to raise the vehicle To avoid hitting bridges or tunnels check and record the overall height of your crane in the folded position or in laid position in the body or on the load Always respect and pay proper attention to road signs placed in proximity of such obstacles 7 2 Before operating ATTENTION Check that protections are in their place and that all safety devices are fitted and active See norms ISO 9927 1 Keep the ladder and the control station on the top seat clean normally the seat can tilt forward Make sure that control stations are properly lit so as to ensure safety while opera ting and allow instruction plates to be visible Check that the working area is adequate and properly lighted for your crane Make sure that the hook is always free to rotate on its pin and that not
17. If during operation the red led placed on the side of the display comes on the activation value of the lifting moment limiting device has been reached Visual indicator yellow red light The control unit was up to 90 loading a graduated band of led lights to show the increased load upon reach 90 a yellow led will be illuminated upon rea ching 100 and activation of the lifting moment limiting device a red led will be illuminated The visual indicator located on the crane is shown in fig 19 Any hidden danger situation for persons must be audibly warned by pressing the push button of the audible alarm on radio and audible alarm push button When there are serious imminent and dangerous conditions for persons and things during load handling operate on the STOP button which isolates all crane functions and activate the intermittent audible alarm push button 16 4 Load handling CONTROLS TO OPERATE THE CRANE KSE Manoeuvres of the crane GRU FASSI Fig 20a b e 20c d illustrate the configurations of the crane and of the eventual hydraulic extension with the manoeuvres allowed and not allowed by the device in connection with the horizontal position WITH HYDRAULIC JIB of the crane and extension outer booms ATTENTION In the overload condition if you simultaneously effect one permitted and one non permitted manoeuvre you haven t movement In the overload condition before effecting a permitted manoeuvre it is neces
18. In the event that the crane ceases to operate and the code alarm with a number appears on the Display B Call your FASSI authorised service centre reporting the Alarm number with the crane model and serial numbers If the fault cannot be cleared follow the procedure in the chapter Controls to operate the crane and overide the dump valve EVI THIS IS ONLY A TEMPORARY ACTION FOR EMERGENCIES the crane should be taken to a FASSI service centre for repair as soon as possible TO OPERATE THE CRANE FOR TOO LONGER PERIOD WITH THE OVERIDE ACTIVATED MAY INVALIDATE THE CRANE WARRANT Y 24 2 Only operations which can be carried out by the user Note Any operation other than those indicated hereunder must be performed only and exclusively by specialized personnel from an authorized support centre considering the potential residual risks The crane does not Vehicle non Stabilize the vehicle rotate properly in level position Lack of lubrication WITH RACK Grease the bushes and the rotation guide shoe WITH SLEW RING Grease the slew ring and the pinion gear slew ring group The extension booms Lack of lubrication Grease do not completely extend of the guide shoes the guide shoes or work jerkily Crane controls are Lack of Check the fuse not active electric energy the battery and electric circuit Winch stroke end See 21 2 active if fitted The rotation limiting See 16 6 device is activated Vibrations in Shortage of oil Check the l
19. LOAD Ks EXIT LOAD Kg EXIT INDEX 20 HYDRAULIC JIBS 20 1 Generality The hydraulic jibs foldable behind the cab are additional booms with articulation and with one or more extension booms to be fitted to the last extension boom of the crane on request the manual extensions can be installed on the extension booms of the jib NOTE The weights reported in the table are indicative and can vary in relation to the fittings The are fitted by means of the insertion of the extension connecting boom into the crane extension boom the fixing to the crane is obtained through locking pins The hydraulic connection to the supplementary functions of the crane is through quick couplings Warnings and norms for crane utilisation apply also for hydraulic jibs use ATTENTION The loads shown on the capacity plates which concern the configuration of the crane with hydraulic jib refer to the hydraulic jib and consequently they are the same whether the crane has its extension booms retracted or extended Warnings and norms for manual extensions are indicated at Paragraph 18 ATTENTION It is recommended to employ lifting means adequate to the weight of the load and radius of the extensions during this operation the operator is responsible for the machine safety The slings or the cables used for handling the load should have the adequate capacity and length try to avoid the load overtur ning by hav
20. SL 25 v30 250 CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device L506 F700A 26 42000 116 00 RL SL kg 1200 11070 970 885 810 730 9000145 di SL 25 3 v20 145 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device GRU L506 F700A 26 Mmax 313kNm gt 2000 3 Tmax 2000 dan n 1203 15 95 He RL 36 SL 25 250 CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device ONG OW 4 Mmax 304kNm 9 Pmax 20000 Tmax 2000 dan n 1 kg 1220 5 RL SL 500 440 kg 30 00 31 80 m RL 36 SL 25 4 HYDRAULIC SCHEMATICS HYDRAULIC SCHEMATICS GR5_700_800XP Hydraulic schematic for crane Danfoss distributor electronic lifting moment limiting device L41 L60 I I q I I CECHA 281 CODE DESCRIPTION DI776 DISTRIBUTOR VA184 SENSOR VALVE DI778 DISTRIBUTOR VA185 SELECTOR VALVE DV018 DEVIATOR VA194
21. Year of mounting O fig 3 UNDER NO CIRCUMSTANCES SHOULD THE DATA MARKED ON THE PLATES BE ALTERED 9 9 1 Pos ON Oo oS Ee 19 CRANE NOMENCLATURE CRANE M NOMENCLATURE Controls for crane and outriggers through push button panel of the radio remote control fig 4 Description Outrigger rams Outrigger supports Base Slew ring Rotation motoreducer Deviator crane outriggers Dual control for deviator crane outriggers Integrated group for outrigger controls Electric hydraulic distributor for crane Column Inner ram Inner boom Outer ram Outer boom Booms extension rams Extension boom sections Lifting hook Oil tank Manual extensions optional Heat exchanger Receive radio remote control Push button panel transmitting console of the radio remote control 2 22 18 i ml LEM 5 f FH LI 2 4 i S du Ee 2 54 11 TONG CPI e 2 n la j ENS 4 1 i o 5 8 6 fig 4 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES GR5 10 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES 10 1 Controls for crane and outriggers through push button panel of the radio remote control fig 5 Pos X Description Check valves for outrigger rams Check valves for rotation control flow regulators Check valve for inner ram Check valve for outer ra
22. articulating ram lever movement alarm 35 inconsistency of the jib extension ram lever movement alarm 36 inconsistency of the winch lever movement alarm 40 CAN BUS reading alarm on unit FX003 41 CAN BUS reading alarm on unit FX004 42 CAN BUS reading alarm on radio remote receiver unit MESSAGES EXPLANATION WINCH OFF information for the activation of the winch up or down WINCH CAL ERROR flashing warning 10 seconds each minute it appears when the maximum detection of the winch adjustment with load is exceeded STOP BOOM OUT warning for the interruption of the extension boom exit because of a sudden variation of the cable tension STOP JIB 25 warning of not permitted activation of the lifting functions because of the activation of the maximum vertical opera tivity of the jib when it is complete with the 25 angle increasing PLE activation of the speed reduction for the use of the access platform CONTROLS INE OPERATE THE CRANE GRU FASSI What to do in case of alarm CODE 01 02 04 08 09 10 22 REMEDY Take off the tension to the system and take on again the tension If the problem remains take off the tension to the system again take on the tension and wait 12 minutes 12 minutes waiting time is a compulsory condition and needs to be checked with a watch take off the tension to the system again take on again the tension If the problem remains you must immediately go
23. been centralized and gathered in a case fig 33a positioned on the base crane distributor side rack guide shoe rotation upper and lower bush of the column column support rack group column gear column support group pendulum beam 1 WARNING At low temperatures the grease shall not crystallize or to be more precise shall not change its characteristics At the effective operative temperature the grease we recommend shall have a fluidity at least equal to rating NLGIO or max 1 WARNING Centralized lubrication shall not be used when room temperature is below fig 33a 10 C 20 C All the lubricators mounted on the crane are protected by a plastic cap so to avoid the oil contamination 22 5 After every 100 working hours or more frequently in GRU FASSI case of more intensive utilisation WITH RACK Periodically grease the points indicated on the crane fig 34 and on the hydrau lic jib when fitted fig 35 paying particular attention to the WITH RACK points not easily detected For the sliding sections of the outrigger supports and of the extension booms guide shoes made from a special material have been fitted to ease their movement it is recommended to smear a light film of grea se on them taking care that the surfaces of the extension booms are free from impurities such as sand etc Top up using hydraulic oil with the same characteristics as those indicated in t
24. been solved As consequence of this when appear an alarm signal it is necessary to solve the problem because only in this case will be possible to reset the display and reactivate the crane working ALARM CODES CONTROLS TO OPERATE THE CRANE BIN GRU FASSI 01 electronic card alarm 02 inner ram transducer alarm 04 outer ram transducer alarm 06 jib articulating ram transducer alarm 08 proximity sensor alarm central one off 09 proximity lateral one off 10 mercury sensor level alarm connector disconnected 11 mercury sensor level alarm sensor defect 12 winch alarm 14 microswitch on the inner ram distributor segment alarm 15 microswitch on the outer ram distributor segment alarm 16 microswitch on the jib articulating ram distributor segment alarm 17 microswitch on the extension rams distributor segment alarm 18 microswitch on the jib extension rams distributor segment alarm 19 microswitch on the winch distributor segment alarm 20 microswitch on the rotation distributor segment alarm 21 fuse alarm fuse inside the main control panel protecting the emergency circuit 22 winch stroke end device alarm Only for crane with slew ring 30 inconsistency of the rotation lever movement alarm 31 inconsistency of the inner ram lever movement alarm 32 inconsistency of the outer ram lever movement alarm 33 inconsistency of the crane extension ram lever movement alarm 34 inconsistency of the jib
25. driving the vehicle ensure that the outriggers are fully retracted and completely unloaded ATTENZIONE PRIMA DI AZIONARE LA GRU E OBBLIGATORIO METTERE IN OPERA GLI STABILIZZATORI WARNING BEFORE OPERATING THE CRANE IT IS COMPULSORY TO EXTEND THE OUTRIGGERS ATTENTION AVANT D UTILISER LA GRUE IL EST OBLIGATOIRE DE METTRE EN FONCTION LES STABILISATEURS ACHTUNG VOR INBETRIEBNAHME DES KRANS MUESSEN DIE ABSTUETZUNGEN AUSGEFAHREN ATENCION ANTES DE ACCIONAR LA GRUA ES OBLIGATORIO ESTABILIZAR EL VEH CULO ANTES DE UTILIZAR A GRUA E OBRIGATORIO COLOCAR EM FUNCIO NAMENTO OS ESTABILIZADORES DE2327 re entered the safety taps closed and the crane is in the folded position DE 4236 Instruction plate and safety norms DE 2327 Warning plate to stabilize the vehicle before using the crane DE 4452A Instruction plate to fold the crane into the rest condition INSTRUCTION P158 WARNING PLATES GR5 DE 4491 Do not operate from the frontal position to extend the outrigger supports NV DE 2100 TS C Danger plate for crushing of lower limbs DE 2100 Instruction plates to stabilize the vehicle 88858589 288249 INSTRUCTION WARNING PLATES Wade GR5 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 o
26. failure In these cases because of a fault shown in the system the crane is not func tional any more The checks that the operator can effect to reactivate the crane functions are the following in case of an electrical failure check the connection of the feeding cables to the battery in case of the appearance of the signal ALARM on the display of the push button panel see Par 15 7 1 and check if the fault can be resolved by the operator If the fault cannot be resolved you must immediately go to a FASSI authori sed Center after bringing the crane to its the rest position in relation to the conditions explained in the paragraphes 15 7 2 15 7 3 16 7 1 Diagnostic Alarms Input Output LME vers 4 5 UC 01 7 It is possible to install on the machine some operation improvements of the limiting device not yet described here For this purpose compare the released version of the software installed on the machine you can read it on the display when switching on with the one in this paragraph s heading For further expla nations please refer to Fassi service network All the eventual problems that the electronic device can have are shown on the display of the control panel and they create the stop of all crane functions The visualisation of the must be reset pushing the button l m l d exclusion on the main box control panel which bring again the display in the original screen showing the pressures only if the problem has
27. 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 its value according to the bolt diameter and class Table of the bolts tightening torque in general with average friction value 0 15 and average good tightening accuracy C From ELEMENTS DE FIXATION ASSEMBLAGES VISSES AFNOR E 25 030 1984 M Class 8 8 Class 10 9 Bolt Nm Torque Nm Torque Nm 1 56 3 58 7 10 111 584 ___ 2658 WITH SLEW RING Check the rotation control motoreducer oil level Fig 34 Remove the bleed plug 1 using a 22 mm Allen wrench Remove the plug 2 using an 8 mm Allen wrench and the O ring Top up if necessary with the same type of oil as indicated in the table at Paragraph 23 via the mouth bleed plug The correct level is reached when oil starts to escape from the threaded hole in plug 2 Checkthe 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 Clean the air filter placed in the top of the oil tank filter cap Completely replace the hydraulic oil and the filter cartridges fig 34 The waste
28. position of the crane outer boom mercury level switch only the controls allowing a reduction of the overload are enabled while those increasing it are disabled The device features an electro hydraulic control that does not allow the set value to be exceed by deactivating the controls levers in neutral position commanded by the limiting device When the controls are released levers in neutral position it s this electronic logic that handles which manoeuvres are disabled according to the position of the crane outer boom and in overload condition by sending elec tric signals to special micro switches placed on the elements of the distributor ATTENTION The presence of the lifting moment limiting device does not release the user from the obligation to respect what is indicated on capacity plates and lifting curves CONTROLS TO OPERATE THE CRANE IBI GR5 CONTROLS OPERATE THE CRANE GR5 16 3 Control panel The control devices are insered in the push button panel of the radio remote control For the picture list of the push button panel of the radio see Controls to opera te the crane If the warning light over the on radio button comes on it confirms that the con trol unit has been activated INOTE In the absence of electric power all crane functions will be desactivated If during operation the yellow led placed on the side of the display comes on 90 of the rated capacity has been reached
29. prevent damage caused by an excessive increase of the oil temperature NOTE When working in a low temperature climate we recommend to bring the hydraulic oil up to working temperature prior to starting work This is best done by operating the crane thru all its functions ram stroke end WARNING The heat exchanger openings must be kept clear and clean At no time should it be covered 18 MANUAL EXTENSIONS USE OF IMPLEMENTS GR2 45 60 3 4 5 18 1 Generality These are additional extensions which are placed in the hydraulic extensions of the crane and of the hydraulic jib and secured by locking pins Manual extensions have a maximum capacity independent from the crane confi guration as shown on the capacity plates ATTENTION Manual extensions can be extracted from the rest position and be operative once the security pins have been removed with the outer boom in sliding position ATTENTION Do not stand in front of stabilisers during operation Operate from a lateral position in respect of the extension movement of the manual extensions operation from the frontal position is dangerous Verify that the area is suitable for this operation and there are no unauthorized persons in the working area not permit the extension to slide out at speed as this will damage the stroke end stops Donottry to align the holes slots for the locking pins with your fingers always use a suitable tool Whe
30. the working area of the outriggers ATTENTION The crane stability is maintained by the maximum extension of the outrigger supports by the solidity of the base underneath the plates of the outrigger rams and by the observance of the capacity plates To check the maximum working pressure see Paragraph 2 3 Technical data Check that the outrigger rams are applied on a solid base if necessary use larger outrigger base plates available on request to avoid sinking When stabilization is complete the wheels of the vehicle must still be in contact with the ground and the suspensions must not be fully unloaded Stabilize the crane so as to operate on a horizontal plane with a maximum tole rance of 1 5 degrees While loading it may be necessary to vertically adjust the outrigger rams to pre vent an overload on the outriggers then stabilize again While unloading the outrigger rams may not be perfectly in contact with the ground because of a rise in the suspension it is therefore recommended to stabi lize the vehicle during operation to avoid an overturn SUPPLEMENTARY BEAMS GRU FASSI Ve DE 6409 DE 6409 5 The controls to stabilize the vehicle are activated only from the push button panel of GR5 the transmitting console 13 2 Functions of control levers for stabilization SUPPLEMENTARY ATTENTION D ATTENTION SINCE THE RADIO REMOTE CONTROL IS MOBILE BEFORE STARTING 5
31. to a FASSI authorised Center Check the connector of the pressure transducer If the problem remains you must immediately go to a FASSI authorised Center oee code 02 oee code 02 Check if the red light on the proximity sensor is off and verify if the metallic band is rightly positioned oee code 08 Check that the connector of the mercury sensor level is not damage If the problem remains you must immediately go to a FASSI authorised Center You must immediately go to a FASSI authorised Center oee code 11 oee code 11 oee code 11 oee code 11 oee code 11 oee code 11 oee code 11 oee code 11 Replace the 10A fuse at the nearest workshop after removing the carter and the cover of the main panel FX000 See electric schematic Par 5 oee code 11 Only for crane with slew ring 30 See code 11 31 See code 11 32 See code 11 39 See code 11 34 See code 11 35 See code 11 36 See code 11 40 See code 11 41 See code 11 42 See code 11 MESSAGES REMEDY WINCH OFF Place the distributor bank lever controlling the winch in neutral position WINCH CAL ERROR See code 11 STOP BOOM OUT Place the distributor bank lever controlling the extension booms in neutral position If the warning appears when the winch cable lifting stroke end is not reached place in any case the lever in neutral position and then restart to operate STOP BOOM UP Lifting functions not available are authorized onl
32. who is responsible for the machine safety must carefully consider the manoeuvres required to return to normal working conditions it is however compulsory to effect the re entry of the extension booms at first CONTROLS TO OPERATE THE CRANE GR5 CONTROLS INE OPERATE THE CRANE GR5 calmly and carefully assess the type and scale of the hazards arising from these manoeuvres and the possible reaction of the crane tipping over frame overload uncontrolled fall of the load due to a hydraulic system overload etc make all movements as slowly as possible to reduce the dynamic overload to the minimum After such emergency operations and prior to re use of the crane you must immediately go to a FASSI authorised Center for testing the structure and re sealing of the device 0 Interferences with the valves or removal of the lead seal release the FASSI GRU IDRAULICHE from any responsibility and invalidate the warranty ie PO199 PO188 In case of an electrical failure all the control levers of the push button panel of the radio remote and the emergency control cannot be used and then it is necessary operate directly the distributor fig 22 For the access to the distributor remove the cover 2 fig 22 by unscrewing the five fixing screws The column controls must only be used in an emergency and only to bring the crane to its rest p
33. within the overall width of the truck and locked by the safety devices Disengage the power take off 7 5 Residual risks Note This reasoned list does not carry the complete list of the residual risks which are examined more in detail paragraph by paragraph in the manual under ATTENTION 1 it is instead way to exemplify to the operator the types of hazards linked to the use of the crane which basically involves a lifted load in movement Therefore we confirm you the following It is absolutely forbidden to use the crane without having read and under stood the manual for use and maintenance and without having being pre viously instructed by experienced personnel on all aspects of safe crane operation Risk evaluation shall be followed by adequate provisions in order to avoid risks and damages to people and things The crane operator shall be held directly responsible for the correct ope ration of the crane also according to the jobsite conditions Overturn the crane can overturn thus hurting people and damaging things specially in following conditions if it is not correctly stabilized if the moment limiting device is disabled if the ground conditions at the jobsite are not stable enough with respect to the dimensions of the outrigger base and or of the additional base plate if you increase the design dynamic increasing the pump oil flow Moment limiting device never try to bypass nor tamper with the moment lim
34. 5 0001 serial no identification code fig 6 12 TILTABLE OUTRIGGER RAMS n 12 1 Manually tiltable outrigger rams Outrigger rams are allowed to be stored in an inclined position when obstruc tions on the vehicle chassis prevent their vertical stowability These hinged supports are placed between the outrigger supports and the rams the fixed part is screwed to the supports while the mobile part is screwed to the rams fig 9 9a To place the rams in a working condition Supporting the ram remove the check pin and the locking pin from their positions Position carefully the ram in working condition insert the locking pin in its new position and secure it with the check pin To re position the rams to the folded position Remove the check pin and the locking pin Position the ram in a upward direction and supporting the ram insert the locking pin in its new position 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 fig Ya 13 MANOEUVRES AND CONTROLS TO STABILIZE THE VEHICLE 131 Generality The outriggers rams prevent damaging stresses both to the frame and to the vehicle suspensions on which the crane is mounted to and assure the stability of the unit during load handling Be very careful when stabilizing the vehicle make sure that no one is or transits in close proximity of
35. DOUBLE EFFECT BLOCK VALVE DV019 DEVIATOR VA232 UNIDIRECTIONAL VALVE EV124 ELECTROVALVE VA239 SIMPLE EFFECT BLOCK VALVE EV125 ELECTROVALVE VA246 REGENERATIVE VALVE FI782 OIL FILTER HIGH PRESSURE VA249 UNIDIRECTIONAL VALVE FI854 OIL FILTER RETURN VA256 OIL FLOW REGULATOR VALVE FOR ROTATION M1141 MOTOREDUCER CYLINDER PR103 PRESSURE SWITCH VA259 ELECTRIC REGENERATIVE VALVE 24V RU976 FAUCET VA260 ELECTRIC REGENERATIVE VALVE 12V RU978 FAUCET VA263 DOUBLE EFFECT BLOCK VALVE TR002 PRESSURE TRANSDUCER VA262 SIMPLE EFFECT BLOCK VALVE VA148 ELECTRIC MAIN WITH BY PASS VALVE 90002 OIL COOLER HEAT EXCHANGER VA149 ELECTRIC MAIN WITH BY PASS VALVE 50001 OIL COOLER HEAT EXCHANGER HYDRAULIC SCHEMATICS Hydraulic schematic for crane versions 13 GR5_700_800XP FIM I1 CEEYA lizer E OD 0 22 mc TO mc uo O0 2200 M CH CG 431 o EK 2o CH 0 co or WU X o 0 m 43 Lr Lu Hydraulish drehbare stabilisatoren Hydraulic rotation stab Bomba de flujo variable LIO version LIO version Version L10 Mit Verstel Flow variable pump Pompe d bit variable Version 110 2 Stabilizzatori a rotazione idraulica 3 Pompa a portata variabile 1 Versione 110 CODE DESCRIPTION DI776 DISTRIBUTOR TR001 PRESSURE TRANSDUCER
36. DRAULICHE Tel 39 35 77 64 00 Fax 39 35 75 50 20 VERTICAL VERSION fig 1 FASSI GRU IDRAULICHE SpA FAS GIL 24021 aveino ITALIA Via dei Carmelitani 2 GRU IDRAULICHE Tel 39 35 77 64 00 Fax 39 35 75 50 20 INSTRUCTIONS FOR SAFE USE OF THE CRANE 7 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 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 o
37. E CRANE MODEL IDENTIFICATION m THE CRANE MODEL 8 1 Generality GRU FASSI The exact crane model serial number and description of implements will enable FASSI Service Department to give a rapid and efficient response 8 2 Crane mark The CE indicates that the crane complies with the Machines Directive D M 98 37 it can be considered effective only with a written declaration of conformity enclosed The crane affixed with the CE mark is supplied with a lifting moment limiting device to preserve the crane structure from overloads MATRICOLA SERIAL NUMBER ANNO Di COSTRUZIONE MANUF YEAR FASSI GRU S p A Identification data are marked on the plate DE5891 used for the CE mark fig 2 and rivetted on the base with personalized rivets FASSI 1 Crane model 2 Serial Number 3 Year of manufacturing The crane must not be put into service within the European Community unless the machine on which it is mounted also conforms with the prescribed Directive Ever change of use modification or addition of accessories not specified by this manual must be affixed with a new CE mark in accordance with the Machinery Directive A further metallic plate fig 3 fixed to the crane by the installer quotes the identifying data of the equipment and the final CE mark 1 Name of the installer who 1 applied the final CE mark 2 Crane mark model and serial number 3 Vehicle mark model and chassis number 4
38. EASE NILEX EP1 of the firm NILS NOTE Do not ABSOLUTELY mix different types of grease GREASE for slew ring extension booms outrigger supports 30 C up to 130 C EP1 Gradation cold climate EP2 Gradation warm climate All grease used must be free from acid and resin not hygroscopic and long life such as BP GREASE LTX EP1 EP2 or ELF EPEXA 1 2 ESSO BEACON EP1 EP2 or TEXACO EP1 EP2 MOBIL EP1 EP2 or SIMILAR HYDRAULIC OIL FOR MOTOREDUCER Classification ISO L CC Gradation EP ISO VG 150 LUBRICATING OIL for winch cable The most suitable here is a general purpose lubricating oil with about SAE 30 viscosity A lubricating oil containing non stick additives is recommended if the cables are expected to move quickly through the pulleys BRILUBE 50 BRITISH ROPES BRINDON WARNING Don t use greases with solid particles as Bisulphide of Molybdenum not compatible with eventual teflon bushes 24 POSSIBLE FAULTS 24 1 Generality Many years experience of our product has allowed us to identify and classify the most common faults which occur In most cases it requires accurate hydraulic and electric troubleshooting and simple rectification In the following table we report the most fre quent inconveniences and our suggested remedies Checking and adjustment of oil pressures of valve settings must be carried out by an authorized service agent under penalty of warranty forfeiture ATTENTION
39. FASSI CRANE F 700A 800AXP 26 use and maintenance FROM SERIAL NUMBER 1001 INDEX 1 INTRODUCTION CLASSIFICATION OF THE CRANE MODEL Generality Hydraulic jibs Technical data CAPACITY PLATES Generality Capacity plates with lifting moment limiting device HYDRAULIC SCHEMATICS ELECTRIC SCHEMATICS SAFETY NORMS WARNING AND INSTRUCTIONS Generality Before operating During operation At the end of the operation Prior to driving the vehicle Residual risks IDENTIFICATION OF THE CRANE MODEL Generality Crane mark CRANE NOMENCLATURE 9 1 Controls for crane and outriggers through push button panel of the radio remote control 10 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES 10 1 Controls for crane and outriggers through push button panel of the radio remote control 11 SUPPLEMENTARY BEAMS 11 1 Generality 11 2 Identification of the supplementary beams 12 TILTABLE OUTRIGGER RAMS 12 1 Manually tiltable outrigger rams 13 MANOEUVRES AND CONTROLS TO STABILIZE THE VEHICLE 13 1 Generality 13 2 Functions of control levers for stabilization 13 8 Controls to stabilize the vehicle 13 3 1 Crane with fixed or manually tiltable supports for outrigger rams 13 3 2 Crane with hydraulic tiltable supports WITH CHAIN for outrigger rams GO Po gt Ro 20 10 21 2 21 2 1 22 22 1 22 2 22 3 22 4 22 9 22 6 22 22 8 22 9 23 24 24 1 24 2 24
40. OF HYDRAULIC OIL AND LUBRICANTS CHARACTERISTICS POSSIBLE FAULTS Generality Only operations which can be carried out by the user Operations to be carried out only by a service center INSTRUCTION AND WARNING PLATES FASSI CRANE onus use and maintenance ORIGINAL INSTRUCTIONS THANK YOU FOR SELECTING ONE OF FASSI CRANES This crane is the result of FASSI philosophy ongoing research rigorous testing data verification and analysis of performances Many years of experience has allowed us to grant you the maximum safety of operation together with the optimization of machine performances All this represents the core of FASSI quality system FASSI quality system is in conformity with UNI EN ISO 9001 2000 ISO 9001 2000 FASSI cranes conform with the European Norm EN12999 The fitment of the crane on the vehicle must be carried out in accordance with the instructions given by FASSI in the manual for hydraulic crane fitting and the relevant chassis manufacturers directives The Manufacturer declines all responsibility and guarantee if the fitting is entrusted to workshops without sufficient technical capability to carry out the work in conformity Be sure that the unit has been installed inspected and tested in accordance with the local legal requirements As well as the principal safety norms this manual contains a description of the crane and the instructions for use and maintenance The following instructions refer to
41. OR CRANE BLOCK EV2 ELECTROVALVE FOR LIFTING MOMENT LIMITING DEVICE OF THE TWO WORKING ZONES EV3 XP ELECTROVALVE EV ELECTROVALVE FOR PRESSURE REDUCTION OF REGENERATIVE EXTENSION EXIT EV5 REGENERATIVE ELECTROVALVE 2 EVDEV ELECTROVALVE FOR ELECTRIC DEVIATOR CRANE OUTRIGGERS GO _EVEt 2 3 4 EXTENSION ELECTROVALVE EVG GENERAL ELECTROVALVE FOR OUTRIGGER DISTRIBUTOR Sa EVR RE ENTRY ELECTROVALVE OUTRIGGERS EXTENSIONS AAS EVS1 2 3 4 OUTRIGGER ELECTROVALVE SG G EXIT ELECTROVALVE OUTRIGGERS EXTENSIONS 003 DANFOSS CONTROL UNIT 004 OUTRIGGER CONTROL UNIT ee IP1 2 3 PROXIMITY MICROSWITCH FOR ROTATION CONTROL GC LCV WINCH LOAD LIMITING DEVICE OHE LG 90 LOAD YELLOW WARNING LIGHT SS LP FLASHING LR ACTIVATION OF OVERLOAD BLOCK RED WARNING LIGHT GIN Vu AT MICROSWITCH THE DISTRIBUTOR CI 5 MS MERCURY LEVEL SENSOR ON THE OUTER BOOM Els MVI PULLEY MICROSWITCH FOR WINCH FITTED ONLY ON THE ELECTRIC STROKE END SLEW DRUM MICROSWITCH WINCH 2 P PRESSURE SWITCH FOR THE RE ENTRY OF THE EXTENSION BOOMS AO 5 SELECTOR FOR ACTIVATING SECOND MS FOR THE HYDRAULIC JIB AT 25 RADIO RECEIVER OF THE RADIO REMOTE CONTROL TP1 PRESSURE TRANSDUCER FOR INNER RAM TP2 PRESSURE TRANSDUCER FOR OUTER RAM TP3 PRESSURE TRANSDUCER FOR THE JIB RAM UCF GENERAL CONTROL PANEL FX000 6 SAFETY NORMS Strictly conform to the norms reported by the plates DE2499B fig 1 or SAFETY NORMS GR234 5 DE4236 fig 1a placed next to th
42. USE THE CAPACITY PLATE POUR LES CHARGES UTILISER L ABAQUE DE CHARGE PARA LAS CARGAS UTILIZAR LA TARGETA DE CAPACIDADES FUR DIE LASTEN SIND DIE TRAGLASTDIAGRAMME ZU BENUTZEN _________ DES153 20 10 Crane with lifting moment limiting device and pro link if fitted The cranes fitted with pro link can operate the outer boom and the hydraulic jib with an increased angle of about 15 degrees In order to prevent the booms from exceeding the maximum angle over the horizontal line generally 80 degrees the crane is fitted with a suitable safety device Safety device for pro link The safety device receives the signals about the inclination of the outer boom of the crane and of the hydraulic jib and transmits them to the limiting system that controls the manoeuvres the significant values are the first and the second angle limit alfa and alfa2 respectively about 70 and 80 degrees from the horizontal line Function of the safety device controlling the articulation pro link When the first angle limit alfa1 is reached the safety device temporarily stops all movements and activates the flashing red light Warning angle is displayed on the screen In order to reactivate all the crane functions except for the lifting of the inner boom that in this case is definitely disabled just put the all the levers in neu tral position Press the LMI button to remove the message Warning angle it will disappear when the temporary block angle al
43. am for the tiltable support extension of the outrigger support n 1 activate the lever CD n 1 in the direction of E by keeping activated the lever CD n 1 activate the lever C in the opposite direction 5 condition fig 15 GR5 make sure that the tap R1 of the valve of the outrigger ram S1 is closed for the closed or opened position see fig 14 open the tap R2 of the valve of the control ram for the tiltable support to remove the pin 2 proceed as follows activate the lever CD n 1 in the direction of S by keeping activated the lever CD n 1 activate the lever C in the opposite direction to control the rotation and take the ram S1 to its rest position so that the pin 2 is extractable lift the parking pin 1 safety until it is released and remove from its seat the pin 2 to rotate the outrigger ram S1 proceed as follows activate the lever CD n 1 in the direction of S by keeping activated the lever CD n 1 activate the lever C in the opposite direction till the requested extension of the outrigger ram S1 SUPPLEMENTARY rotation of the outrigger ram 1 from the rest position fig 13 to the working ATTENTION Make sure that no one is or transits in close proximity of the working area of the outriggers manually complete the rotation by positioning the ram vertically insert the pin 2 in its new seat and lock it with the parking pin 1 safety close the tap R2 of the valve of th
44. bilization of the vehicle ATTENTION Keep hands clear of automatic stop device of the outrigger supports Fig 12 Always check that the outrigger supports once in their rest position are locked in their seat by the safety devices so as to assure the impossibility of accidental movement Fig 12 14 CONTROLS TO OPERATE THE CRANE 14 1 Generality WARNING Before operating the crane it is compulsory to set the outriggers Plate DE2327 fig 16 ATTENZIONE PRIMA DI AZIONARE LA GRU E OBBLIGATORIO METTERE OPERA STABILIZZATCRI WARNING BEFORE OPERATING THE CRANE IT IS COMPULSORY TO EXTEND THE OUTRIGGERS ATTENTION AVANT D UTILISER LA GRUE IL EST OBLIGATOIRE DE METTRE EN FONCTION LES STABILISATEURS ACHTUNG VOR INBETRIEBNAHME DES KRANS MUESSEN DIE ABSTUETZUNGEN AUSGEFAHREN Radio remote control The crane and hydraulic implements can be operated through propor tional radio remote control subjugate to a distributore which the manual order is to be used only in case of emergency ATENCI N ANTES DE ACCIONAR LA GRUA ES OBLIGATORIO ESTABILIZAR EL VEHICULO ANTES DE UTILIZAR A GRUA OBRIGAT RIO COLOCAR EM FUNCIO NAMENTO OS ESTABILIZADORES DE2327 Display on the push button panel of the radio remote control When you start the radio remote control fig 10 the pressure in the inner outer ram and the jib and the percentage of load on the winch are disp
45. cedure and go back to the standard operation Put down the load on the ground and repeat the whole procedure from the begin ning d NO LOAD CRANE Fig 15 This message informs that the lifted load exceeds the max limit value of the crane jib irrespective of the manual extensions so that the load cannot be lifted in this configuration due to the crane Jib overload Also in this case the load must be either removed or approached to the crane and handled in a different way without using the selected manual extension Moreover the whole procedure must be repeated from the beginning fig 13 USE OF IMPLEMENTS GR2 45x60 3 4 5 2 Electric schematic crane with manual extensions dea A con ENTER c3 ch MI M2 M3 LET CENTER FC P2 FI TO START FI ENTER START CENTER UP Pl PRESSURE ERROR START LOAD LINDEX LOAD OK NO SPEED mE mm CEL INDEX Coa NO LOAD CRANE NO LOAD EXIT INDEX NO LOAD Ke LOADOK Ke EXIT EXIT Diosc E gt USE OF IMPLEMENTS GR2_45 60_3 4 5 Electric schematic crane with jib and manual extensions on jib Selettore su con ENTER e yp MI M2 M3 ENTER R K3 K4 ENTER FC P2 P3 21 TO START START CENTER UP P1 PRESSURE ERROR START LOAD EXIT INDEX LOAD OK NO SPEED EXIT INDEX NO LOAD CRANE NO LOAD EXIT INDEX NO
46. cerns the alarms in the use and maintenance manual and follow the written instructions GRU CHE FOR THE LOADS USE THE CAPACITY PLATE POUR LES CHARGES UTILISER L ABAQUE DE CHARGE PARA LAS CARGAS UTILIZAR LA TARGETA DE CAPACIDADES FUR DIE LASTEN SIND DIE TRAGLASTDIAGRAMME ZU BENUTZEN ES 20 9 Use of the hydraulic jib articulated at 25 degrees USE OF a 209 not available on the L102 and on the L515 L516 GR4_5 FO This device permits to arrange the hydraulic jib with its movement ram fully opened or in standard configuration fig 1 or articulated at 25 degrees upwards in relation to the outer boom of the crane fig 2 fig 1 fig 2 Procedure to change from the standard configuration to the 25 degrees s one re enter the extension booms put the hook attack of the hydraulic jib on ground remove the check pin the nut and extract the pin P lower the inner or the outer boom of the crane slowly until that the holes of the adapter A for the new configuration line up to those of the connecting boom insert the pin P in its new seat screw the nut and mount the check pin Use for the selector for configuration On the cranes equipped with jib articulated at 25 degrees is installed a safety device which activated through the selector of the fig 3 prevents the verticalising of the jib further than the value reported on the capacity plates position of the selector when the jib is in
47. comes on the crane controls are enabled Acting with the manoeuvres that increase the lifting moment you get the yellow and red warning lights again 16 9 IMC AND ADC DEVICES The IMC Integrated Machine Control device is an electronic brain that pro cesses real time information coming from the peripheral sensors and from the crane electro hydraulic systems therefore it allows control of all functions and movements with precision fluidity and safety The ADC Automatic Dynamic Control device controls the dynamics of the movements providing the maximum speed available subject to the applied load 17 USE OF IMPLEMENTS USE OF IMPLEMENTS GRU FASSI 171 Generality The crane in load condition H1B3 can be provided with implements such as Manual extensions Winches Hydraulic extensions Personnel baskets Clam shell buckets Augers 1 When using an implement it is always necessary to check that its weight dimension and capacity is matched to the crane performances For further information please refer to FASSI GRU IDRAULICHE Warning and norms for crane use also apply for hydraulic implement use Before using a personnel basket it is necessary to provide the crane with the safety devices requested by the local norms in force EN280 in Europe and prior to use of the crane it has to be tested and inspected in accordance with the local legal requirements When the crane is fitted with implements or laid on
48. details of Controls to operate the crane See paragraphes 16 of the USE AND MAINTENANCE MANUAL for details of Lifting moment limiting device The activation of the XP device on cranes with free rotation or with rotation limiting device produces anincrease in the capacity of the crane areduction in the speed of rotation without increasing the torque areduction in the speed of lifting and lowing the inner boom outer boom and of the jib boom when fitted speed of the extension booms bucket and the rotator allows normal speed and lifting capacity of the winch CONTROLS ILR OPERATE THE CRANE GR5 XP The activation of the XP device on cranes with lifting moment limiting device for two sectors produces inthe stable zone working area the same effect for crane with free rotation inthe unstable zone working area a reduction in the speed without the increase in capacity Activation of the XP device when the 90 of the capacity has been reached the yellow light on the led band of the push button panel goes off allowing the manoeuvres that increase the lifting moment you then have the repeat of the yellow led band and red led band of the warning lights again Activation of the XP device after the lifting moment limiting device block A The block continues the crane must be reset B The red led band of the warning light switches off and the yellow led band of the warning light usually
49. e control system of the manual extension overload must be activated by the ope rator as described Accessories be careful when assembling and disassembling the accessories extensions buckets baskets first verify the weight the securing systems and the instructions for assembly and dismantlement then appraise their barycentre and provide for adequate provisional blocking systems in order to avoid sudden movements ATTENTION If in the folding condition the hook is out of truck size it must be taken away before travelling Breakdown of some sensors The system moment limiting device intelligent type is always monitored during ignition the system after having activated the various circuits checks the presence of all the inputs for around 4 seconds and then continuously monitors the operation and the efficiency of the limiting device approx every 25 milliseconds For most of the components the system checks also the congruence of the incoming signal with the one the system expects Maintenance maintenance is particularly important the lack of it may damage things or hurt people Particular operations if you are required to operate under particular conditions not illustrated in the manual of use and maintenance analyse carefully the situa tion and always refer to an authorised Fassi shop or to the Fassi technical sup port service or to experienced operators before starting working 8 IDENTIFICATION OF TH
50. e control ram for the tiltable support The locking pin 2 is constructed from special material do not replace it with a non original part your security depends on it descent of the outrigger ram n 1 open the tap R1 of the valve of the outrigger ram 1 activate the lever CD n 1 in the direction of S by keeping activated the lever CD n 1 activate the lever C in the opposite direction till the requested extension of the outrigger ram S1 close the tap R1 of the valve of the outrigger ram S1 ATTENTION The complete extension of the outrigger supports is visually indicated by the yellow triangles which are found at the end of the beam and of the support if it s supplied with extra double extension beams Fig 12b 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 ATTENTION During the stabilising operations for each outrigger ram it is recommended to DESCENT the outrigger as the last manoeuvre To operate the crane controls after having completed the stabilisation manoeuvres Position lever D of oil diverter 2 E S on 2 Position selector 7 E S of the push button panel on ee Manoeuvres for re entry of the crane outriggers and supplementary outriggers within the overall vehicle width after crane use Repeat by inverting the sequence of the operations effected for the sta
51. e controls in order to avoid possible acci dents while operating the crane Only authorized persons are allowed to operate the crane The crane must be used on firm level ground Check that the vehicle hand brake is on and that the wheels are chocked Before every operation make sure that no one is within the working area of the crane the safety devices are in place and operative the minimum safe working distances from power lines are observed the load is correctly slung and hooked otabilize the vehicle 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 Use the crane in accordance with the use and maintenance manual making sure that the load and radius are within the maximum limits shown on the crane capacity plate the crane is used progressively avoiding sudden load movements swinging or dragging of the load is avoided the load is lifted before rotating When using implements protect the crane working area with a barrier The vehicle crane are not left unless the power take off is disengaged and the load is on the ground Before driving the vehicle make sure that the outriggers are fully retracted and re entered the safety taps clo sed and the crane is in folded position HORIZONTAL VERSION FASSI GRU IDRAULICHE SpA ipe a FERREA GRU I
52. e end of the lifting ram at high speed In this condition reactivation of the crane commands by performing one of the manoeuvres is allowed by the system If the limiting device intervenes when both the lifting rams are open and at stroke end and the crane extension booms are fully folded it is not possible to reac tivate the commands since the permitted manoeuvres arm lifting and extension fully retracted cannot be carried out because of the actual configuration of the crane outer boom above the horizontal The device in this case allows the descent manoeuvres since it verifies the it was a peak pressure inside the lifting rams the crane being loadless thus these manoeuvres will be allowed Temporised exclusion device of the lifting moment limiting device The activation of the exclusion device is permitted when the limiting device is activated and only in the case when it is impossible to carry out any of the allowed manoeuvres This generally occurs when handling heavy and bulky loads with the outer boom above the horizontal and the extension boom sections almost retracted ATTENTION The activation of the exclusion system for the lifting moment limiting device can ONLY be operated when the extension booms of the crane and of the hydraulic jib when fitted are fully retracted The activation button of the excluding device only in the case of the crane are to be activated as follows retracted the crane extension booms
53. ector in front of vehicle cab capacity plates must be applied in line with the final test figures 3 1 1 Capacity plates with lifting moment limiting device EL GRU IDRAULICHE F700A 26 9 21500 kg 8 2800 kg R 128 5 101 T 70 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device a cee GRU IDELAULICHE Pmax 21500 kg Pmax SC 7 NS 128 5 101 T 70 CAPACITY PLATES F 700A 800AXP 26 KAB 3 1 1 Capacity plates with lifting moment limiting device PASSI GRU IDRAULICHE F700A 26 y Pmax _ 6000 kg 2000 dan 6000 5715 4830 3860 1940 9 55 1 R128 5 101 T 70 v20 145 CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device Pmax 9000 kg 1max 3000 8028 S 101 70 v30 250 3 1 1 Capacity plates with lifting moment limiting device GRU IDRAULICHE L414 F 700A 26 Pmax 4000kg a m ih PL 31 QL 21 CAPACITY PLATES F 700A 800AXP 26 KAB CAPACITY PLATES F 700A 800AXP 26 3 1 1 Capacity plates with lifting moment limiting device m EH Se EE IDRAULICHE 4 496kNm y Pmax 4000 kg Se m 18001920 20652230D400 150
54. evel crane operations and top up if necessary Obstructed filters Clean or replace the filter cartridge Noteable decrease in Obstructed filters Clean or replace movement speed the filter cartridge POSSIBLE FAULTS GRU FASSI 2 POSSIBLE FAULTS 24 PSI GRU FASSI Operations to be carried out only by an authorized service center 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 WITH RACK WITH SLEW RING The extension booms do not completely extend or work jerkily Vibrations in crane operations Noteable decrease in movement speed Non efficiency of the pump main pressure or auxiliary valves not properly adjusted or worn Ram seals are not properly fitted The safety check valve the ram is open Oil leaks inside the ram Valves controlling the rotation not adjusted Wear of rotation guide shoe Wear of the seals of the rotation cylinder Wear of the slew ring Wear of the motoreducer group Wear of guide shoes Replace the pump Check the pressure adjust the valves or replace them Replace the seals Replace the valve Defective seals replace them Adjust the valves Replace the guide shoe Replace the seals Check the slew ring wear replace if necessary Check the motore ducer group wear replace if necessary Check the guide shoes wear re
55. f electric high tension lines DE 2361 Do not operate in proximity of electric high tension lines INSTRUCTION AND P158 WARNING PLATES GR5 DE 1679 Do not walk on DE 1680 Do not use water to estinguish fire TIRANTI NON SALDARE FIXING ROD DO NOT WELD DE 1574 TIRANTS NE PAS SOUDER Do not weld the fixing rods ZUGSCHRAUBEN NICHT SCHWEISSEN
56. f the pressure oil change Filters hoses replacement of filters inspection of hoses Checking of the pressure oil leaks system Checking of the pressure oil leaks Hoses hose protection devices inspection of hoses Implements for lifting Safety check wear and any deformation actions Hooks chains cables slings Implements Oil leaks wear and any deformation Wallboard forks buckets rotators actions inspection of hoses Seat third control station Access inspection Frame fixing screws wear and any deformation strains 22 8 Complete overhaul of the crane is required when 10 000 working hours or 10 years life are reached i e When one of the limits indicated hereunder is reached 10 000 working hours e 10 years 50 weeks a year 20 hours a week or 5 years 50 weeks a year 40 hours a week Or 10 years life of the crane a complete overhaul with in depth structural inspection of the crane must be carried out by the Manufacturer or by an authorised service centre 22 9 Instructions for the dismantlement and the demolition of a FASSI crane INSTRUCTIONS FOR THE DISMANTLEMENT AND THE DEMOLITION OF A FASSI CRANE In case of demolition it is necessary to dismantle the whole machine and separate the diffe rent types of materials according to the respective waste disposals requirements The materials involved are the following Ferrous materials fabrications and mechanical components
57. fa1 is no longer exceeded When the second angle limit alfa2 is reached the safety device definitively stops all lifting movements and activates the fixed red light Max angle crane or Max Angle jib are displayed according to which boom has reached the limit The outer booms of the crane and of the hydraulic jib can reach both the alfa1 tem porary block and alfa2 definitive block limits independently from the position of the other booms But if one of these two booms reaches the second limit alfa2 this condition evidently stops any other lifting Only if neither the crane outer boom nor the hydraulic jib reach the first angle limit alfa1 the inner boom can attain its max limit alfa2 that is its mechanic stroke end Folding the crane When you fold the crane the outer boom is positioned with an angle that generally exceeds the second limit alfa2 this is because the safety device pro link never disables the descent of the inner and outer booms At this point the inner boom lifting is not permitted To unfold the crane just turn off the system when you turn it on the message Crane Folded is displayed At this point the only manoeuvre allowed is the folding of the outer boom we recommend to perform this manoeuvre on all the cranes in order to ensure a correct and safe crane unfolding if you activate it for some seconds the message Crane Folded will disappear and all the manoeuvres will be reactivated
58. he various situations that may take place The script EXIT in the block diagram allows to exit the procedure FURTHER MESSAGES After releasing the lever in neutral position you can find the following messages If you keep pressed the F2 key F2 on the control panel or LMI on the push but ton panel it is possible to have an indicative evaluation of the weight applied on the hook fig 11 NINE TED LY we 3 fig 11 fig 11 PRESSURE ERROR see fig 12 It warns you that the system found an error in the pressures of the lifting booms The whole procedure must be restarted fig 12 fig 12 USE OF IMPLEMENTS b NO LOAD fig 13 GR2_45 60 3 4 5 In this case the load exceeds the max lifting value of the selected manual extension it could still be on the ground Unhook the load since it cannot be lifted using the selected manual extension As in the preceding case if you keep pressed the F2 key it is possible to have an indicative evalua tion of the weight applied on the hook fig 11 NTER BE fig 13 NO SPEED fig 14 The load has been lifted too quickly the whole procedure must be repeated from the beginning The LMI key on the push button panel or F2 key on the control panel is disabled because it has not been possible to calculate the applied weight Press INDEX on the push button panel or F1 key on the con trol panel to exit the pro
59. he table at paragraph 23 WITH SLEW RING Grease the slew gear to prevent friction during rotation and to ensure that it is stable by preventing water corrosion protection and contaminants from entering the bearings For a better internal distribution of the grease it is advisable to rotate the crane and grease it WITH SLEW RING in such a way as to see grease at the seals Top up using hydraulic oil with the same cha racteristics as those indicated in the table at paragraph 23 Grease the winch cable if fit ted 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 Top up using hydraulic oil with the same cha racteristics as those indicated in the table at paragraph 23 22 6 After every 500 working hours or atfter every 6 working months Check the tightening torque ofthe fixing rods of the crane consult the following table in order to find it s value according to the bolt diameter Table of the tightening torques of the fixing rods of the crane on the vehicle From C0404_ kit for crane fixing D Fixing Tightening rods torque Nm M22x1 5 300 M24x2 0 400 am Ng WITH SLEW RING MAINTENANCE of the slew gear screws bolts M20 Class 12 9 Thightening torque 620 Nm INSTRUCTIONS PAS WITH RACK GRU FASSI
60. hing obstructs its vertical positioning Check the efficiency of the hook safety catch Carefully inspect the condition of ropes or chains if present Make sure that the pallet fork if present is connected to the crane hook by means of a chain having at least three 3 rings 7 3 During operation Take the vehicle fumes away from the working area by fitting an extension tube of a suitable diameter and a right length to the exhaust system Do not run the engine in a indoor area without first making sure there is adequate ventilation When using the ladder to reach the control station on the top seat avoid knocking into the controls while going up or down the ladder The control station on the top seat is provided with side safety guards stay within these guards Make sure that no one is within the working area of the crane SAFETY NORMS GRU FASSI WARNING VARY INSTRUCTIONS GRU FASSI ATTENTION Avoid swinging the load above working and transit areas any hidden dan ger situation must be audibly alarmed Avoid all those situations which may result in crushing during vehicle stabi lization crane movement and load handling In conformity with EN 349 standard the minimum safe working distances to avoid crushing parts of the body Parts Minimum safe Figure of the working Body distance mm Parts Minimum safe Figure of the working Body distance mm Body 500 Head 300 Nag Toe
61. i ting device and the various safety systems installed on the crane In such case the operator shall be held responsible for the subsequent crane performan ce It is also important to understand the alarm messages generated by the moment limiting device and act consequently Control seat before operating from the control seat the operator shall make sure that he s safe from hazards i e he stands clear of the load there is a way of escape Otherwise he shall manoeuvre from a different control seat if there is none available the crane should be equipped with a radio control or remote control in order to allow the operator to operate the crane in absolute safety From the control seat the operator shall be able to visually inspect the whole working area at all times If it is not possible he shall team up with a co worker able to control the whole area otherwise the crane shall be equipped with a radio control in order to ensure the operator with the perfect position to see all potential hazards clearly at all times Naturally the operator shall also teach this eventually co worker with the scope of not harm each other with control commands Load rigging carefully inspect the load rigging the operator shall make sure that the load is properly attached and balanced and that all unexpected move ments are not allowed Be careful not to hit any potential impediments during the crane movements Jobsite conditions prior to use always a
62. in rapid and violent rotations of the hook group from the fig 26 to the fig 27 ATTENTION The end stroke condition takes place when the block takes contact with the pulley structu re The operator must stop the manoeuvre before the block rotates the pulley completely with consequent activation of the load cell on the winch Such end stroke device shall be used only under emergency conditions and not as a simple end stroke interrupter DOUBLE LINE QUADRUPLE LINE CORRECT POSITION FOR THE PULLEY AND THE PULLEY BLOCK INSTRUCTIONS 22 MAINTENANCE INSTRUCTIONS Ga 22 GRU FASSI 22 1 Generality To assure a long life to the crane it is necessary to meticulously follow the maintenance instructions General lubrication and small repairs can be carried out by the user repairs of a more complicated nature must be carried out by authorized service person nel Spare parts must be original Good maintenance and proper use are imperative to maintain efficient use and guarantee the safety of the crane At least once a year you must take the crane to a Fassi Service Center for a check Before disconnecting any hydraulic hoses ensure that there is no pressure in the hydraulic circuit After removing hoses always mark them and their respective ports on the crane Faulty replacement can cause damage to the rams and to the hydraulic circuit Respect the information supplied for maintenance and technical assistance
63. ing one length passed through itself and the other one through the hook 20 2 Identification of the hydraulic jib The model the version of the crane the year of construction and the serial number are stamped on the hydraulic jib fig 28 in the following sequence L102 03 001 A model I B year of construction A B C serial number 20 3 Nomenclature of the hydraulic jib Pos Description Connecting boom Locking pins Jib outer ram Jib outer boom Boom extension rams Extension booms Manual extension on request Lifting hook NOO OI BAON USE OF IMPLEMENTS 4 5 0 USE OF IMPLEMENTS 20 4 Manoeuvres to unfold the jib working condition Operate as described to put the crane in working condition paragraph 14 2 By operating the corresponding levers open the outer boom of the jib extend the jib outer boom sliding sections position the hook on the centerline of the load 20 5 Manoeuvres to fold the jib in rest condition By operating the corresponding levers re enter the hydraulic sections of the jib and of the crane lift the inner boom to its stroke end re enter the outer boom of the jib and of the crane to its stroke end operate as described to fold the crane in rest position WARNING Always check and record the overall height of the crane in the folded position or in laid position in the body or on the load Al
64. interrupter The mechanical stroke end device combined with the winch limiter prevents the hook bracket or pulley snatch block from hitting the fixed pulley when lifting or when extending the extension booms and thus from damaging the cable When the winch limiter is activated all the crane functions are disabled Manoeuvres allowed Rotation in both directions Re entry of the crane extension boom sections Re entry of the extension booms sections of the jib Winch rope descent Manoeuvres not allowed all other movements When unwinding an electric device maintains at least three 3 turns of the lifting cable wound around the winch drum on activation the following controls are desactivated Manoeuvres not allowed Winch rope descent Manoeuvres allowed all other movements ATTENTION Limit the exit soeed of the extension rams when during the lifting the hook bracket or pul ley snatch block is next to the fixed pulley in order to avoid unnecessary stress to the cable ATTENTION When the hook bracket or pulley snatch block in case of double or triple line and the fixed pulley are very close and the operator needs to manoeuvre in their proximity i e operations like load hook up arms folding etc we recommend to always stand side on with respect to the pulley plan never in front or at the back and to operate the crane at a low speed since the contact especially without load can result
65. ions and prior to re use of the crane you must immediately go to a FASSI authorised Center for reactivation of the crane functions and re sealing of the device Interferences with the valves or removal of the lead seal release the FASSI GRU IDRAULICHE from any responsibility and invalidate the warranty 16 7 3 Temporary OVERIDE REACTIVATION for the crane functions in case of an electrical failure out of order of the radio remote control or of the appearance of the signal ALARM on the display of the push button panel in this case we cannot reactivate the crane functions On the distributor it has been installed an emergency lever to be used in the event of a black out electrical or hydraulic malfunctions Only In these situations it is permitted to remove the lead seal placed on the tap lever and place it in the closed position For the access to the tap lever remove the cover 1 fig 21 placed under the pro tection guard of the distributor by unscrewing the two fixing screws 10 mm hexa gonal spanner When the electric power is restablished remember to put the lever in the opened position ATTENTION Activation of the emergency lever This activation prevents the operation of the lifting moment limiting device consequently the operation under such conditions can involve an overload condition In such an emergency condition where the lifting moment limi ting device has been disabled the operator
66. ition lever D of oil diverter 2 E S on E S fig 12b Position selector 2 E S of the push button panel on E S you read outriggers on the display By using the levers CD and the lever extend the outrigger supports and lower the outrigger rams till the complete stabilisation of the vehicle Example of using the levers CD and the lever C extension of the outrigger support nA activate the lever CD n11 in the direction of E by keeping activated the lever CD n 1 activate the lever C in the opposite direction descent of the outrigger ram n 1 SUPPLEMENTARY 1331 activate the lever CD in the direction of S BEAMS by keeping activated the lever CD n41 activate the lever C in the opposite GR5 direction ATTENTION The complete extension of the outrigger supports is visually indicated by the yellow triangles which are found at the end of the beam and of the support if it s supplied with extra double extension beams Fig 12b 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 ATTENTION During the stabilising operations for each outrigger ram it is recommended to DESCENT the outrigger as the last manoeuvre To operate the crane controls after having completed the stabilisation manoeuvres Position lever D of oil diverter 2 E S on 2 Position selector
67. layed In relation to the view chosen like standard when you start the radio remote control the pressure values are displayed in bar if on the display on the left of the values no symbol is present daPsi if on the display on the left of the values the symbol is present By pushing the button the percentage values of pressure in the inner outer ram and the jib and the percentage of load on the winch are displayed By pushing a second time the button m the pressure values in the inner outer and jib rams movement in the measurement unit non standard and the percentage of load on the winch are displayed By pushing again the button you return to the initial display For the use of the control button see Par 22 2 By pushing the button one or more times you return to the initial display view of the pressure values For the meaning of other messages see Par 16 7 1 Diagnostic You can select whether to control the crane or the outrigger functions using the buttons placed on the remote control as follows To operate the crane position the selector pos 5 on A and the selector EXS 2 pos 1 on then press together the left confirmation button OK pos 2 and the right confirmation button OK pos 6 for joy stick controls pos 7 for linear controls Crane appears on the display When turning on the remote control asks for selector confirmation E S 2 on display to confirm pre
68. lic system overload etc make all movements as slowly as possible to reduce the dynamic overload to the minimum 16 5 Lifting moment limiting device for two working sectors In case of one sector of the working area with reduced stability of the vehicle e g sector in front of vehicle cab the limiting device can be provided with a special function which allows to operate with a reduction of the 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 in one sector e g body side where the crane works according to the capacity plate values and another sector e g cab side where it works with reduced capacity values The device has consequently two intervention levels which are activated in relation to the sec tor of the crane working area always securing the vehicle stability ATTENTION If the rotation stops by going through the working zone where the crane can operate according to the capacity plate values to the one where it can operate according to the reduced values it means that one of the following conditions is reached rotation of a load bigger than the one admitted in the reduced sector defined in the vehicle stability calculation rotation without load applied but with at least one of the inner outer rams of the crane or the jib if fitted extended and pressuri
69. lic connections for implements supple mentary hoses operate the outer ram of the jib and the inner ram of the crane in order to align the extension booms of the crane and the first boom of the jib thus allowing their connection eventually repeat the previous operation until the fixing holes are aligned working on the extension booms of the crane insert the lock pin into the fixing holes and secure it with the check pin 20 8 Hydraulic jib articulated at 25 degrees with the USE OF S 205 automatic control L515 L516 GR5 This device permits to arrange the hydraulic jib articulated at 25 degrees upwards in relation to the outer boom of the crane with the auto matic control of the verticalising maximum limit ATTENTION If during the utilization the verticalising limit value of the hydraulic jib 80 degrees over the horizontal line has been reached the safety device intervenes preventing every further verticalising Manoeuvres not allowed with the intervention of the safety device lift of the inner boom lift of the outer boom lift of the jib mouvement boom Manoeuvres allowed all other movements Device control The device is continously monitored therefore an eventual fault causes an alarm signal on the control panels and stop the three prevented movements see above leaving all other movements free At this point it is necessary to read the alarm message and the paragraph which con
70. m Check valve for booms extension rams Lifting moment limiting device assembly Control panel Rotation limiting device Main pressure valve outriggers 10 Main pressure valve crane 11 Auxiliary valves crane 12 Safety device for outrigger supports 13 Hook safety device 14 Exclusion tap lever 15 Visual indicator yellow red light SO O Oo a E 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 seal remove the Manufacturer and invalidate the warranty Use the ladder for the access to the top seat 14 BU H d G A t D D 1 2 1148 E Ip B zd Ts EE M E H 1 1 KSE GE 1 581 HI 2 fig 5 11 SUPPLEMENTARY BEAMS SUPPLEMENTARY BEAMS GR5 700 800XP hh 11 1 Generality Supplementary beams are used in conjunction with the crane outriggers to ensure the vehicle stability during load handling Code outrigger ram outrigger extension Weight stroke mm interaxis mm type kg 750B055 520 5770 Hydraulic H variable 750B054 340 5770 Hydraulic H variable 11 2 Identification of the supplementary beams Identification data of the supplementary beam is punched on the beam fig 6 in the following sequence Ex 750B05
71. m continuous 90 kNm l min 479 549 52 11 388 66 327 4 786 21 13 26 42 66 04 14 804 1029 77 psi Ibf ft ft in ft in Ibs ft psi gal min gals Ibs 4575 15 2990 8710 3260 10 8 ST 700 CLASSIFICATION OF THE CRANE vone PA F 700A 800AXP 26 CLASSIFICATION OF WA THE CRANE MODEL F 700A 800AXP 26 ST 700 GALU IDRAULICHE R 865 2 10 ks 265 10 lo 3200 10 6 9 2240 74 ee 3050 10 8490 27 10 Gm 2555 B 5 705 2 4 md INR nt a R KX INIM d i fadi kho 1500 4 11 2000 6 7 F700A 22 F700A 23 F700A 24 8 00 28 1157 MEZZERIA TIRANTI FIXING ROD CENTER DISTANCE LIGNE MEDIANE TIRANTS ABMESSUNG DER BEFESTIGUNGSBRIDEN DISTANCIA ENTRE ESPARRAGOS LINHA MEDIANA DOS TIRANTES GANCIO HOOK MASSIMA ALTEZZA SOTTOGANCIO HAUTEUR MAXIMUM SOUS CROCHET MAXIMUM HOOKING POSITION MAXIMALHOEHE BIS KRANHAKEN M XIMA ALTURA DEBAJO DEL GANCHO ALTURA LIVRE M XIMA DEBAIXO DO GANCHO ST 700 3 CAPACITY PLATES CAPACITY PLATES 700A 800AXP 26 31 Generality The represented plates refer to the nominal design capacities WARNING If the capacities are downgraded or partially reduced e g s
72. mobile cranes in general and must be inte grated with the manual for use supplied by the centre responsible for the crane fitting on truck vehicle or other type of structure READ THIS MANUAL CAREFULLY prior to use or any maintenance A few minutes spent now could save time and labour later Always conform to the safety norms and the instructions for use and mainte nance contained in the present manual in order to guarantee a long life to the crane NOTE The original version of the present manual 15 in italian The spare parts catalogue for the crane can be viewed in the Internet site www fassicat com 2 CLASSIFICATION OF THE CRANE MODEL 21 Generality The design of this crane has been carried out in respect of fatigue test classifi cation H1B3 of the EN12999 norm The crane can operate intermittently with lifting devices other than the hook The dimensions and the capacity of the implements must be proportioned with crane performances 2 2 Hydraulic jibs Extension type Weight kg Manual Weight kg 1414 _ 850 PL41 32 04 2 22 80 L516 1400 10151 80 RL51 2 3 Technical data F 700A 800AXP 26 Lifting Standard Hydraulic Rotation Rotation Working Pump Oil tank Crane Max working capacity reach extension arc torque pressure capacity capacity weight pressure on the outrigger 210 66 3 tm 16 15m 11 80 m 360 9 17tm 33 0 MPa 80 100 250 6715kg 71 0 daN cm 650 40 kN
73. moved with respect to the initial installation it is COMPULSORY to have the crane initial configura tion file modified accordingly See Authorised Shops Before activating the procedure extend and lock by a pin not only the manual extension you intend to use but also the preceding ones USE OF IMPLEMENTS PANELS OF THE RADIO REMOTE CONTROL GR2 45 60 3 4 5 Figure A left side Figure B right side selector on A HOW TO PREDISPOSE THE USE OF MECHANICAL EXTENSIONS ON CRANE OR ON JIB Note In case of crane with slew ring and top seat all the procedures mentio ned below can be executed from both the control panel and the radio remote control 1 Initial display Fig 1 Starting from the standard menu of the electronic lifting moment limiting device displaying the pressures of the lifting rams fig 1 keep the F1 key control panel or the and ENTER key radio remote control with the selector on A fig N and B pressed for some seconds 5 101 8 1 1 2 Choice the installation of the manual extensions on Crane or on Jib Fig 2 lf the crane features the installation of the manual extensions both on the crane and on the jib after the initial display when you keep the F1 control panel and ENTER key pressed radio remote control the program displays the message illustrated in Figure 2 ENTER sax fig 2 fig 2 Use the
74. n manual extensions are in place fit the locking pins and secure them with the check pins to prevent accidental escape Always remember that when operating with implements their tare weight must be deducted from the capacity of the crane 18 2 Lifting moment limiting device ELECTRONIC for the manual extensions valid starting from the version 3 0 of the software HOW TO CONTROL THE LOAD HOOKED ON MANUAL EXTEN SIONS This procedure aims to calculate the weight applied on the manual extensions It is necessary to apply the same procedure EVERY TIME you use the manual extensions For its correct execution follow meticulously the instructions reported HERE The extension limiting device IS NOT ALWAYS ACTIVE on the contrary of the crane limiting device it responds about lifting a load only if QUESTIONED the refore only if you enable the procedure Remember that the procedure is manual In any case always refer to the capacity plates of the crane The limiting device for manual extensions when interrogated compares the real weight applied on the lifting hook inclusive of all the accessories attached with the value reported on the capacity plates Such evaluation is effective only during the execution of the procedure therefore it is prohibited to add weight or replace loads after the procedure is completed in such case the procedure shall be executed again from the start In the case one or more manual extensions are added or re
75. nd jib extensions totally re entered K3 Outer booms of the crane totally extended and jib extensions as you like K4 Outer booms of the crane as you like and jib extensions totally extended Select the desired configuration using the button to move among the various options Confirm your selection by pressing the F1 control panel or ENTER radio remote control key If the hydraulic jib boom is not at its stroke end the message at point 3 will be displayed otherwise the message F1 TO START is visualised 5 Message FC P2 fig 5 Note do not hang any load on the hook This means that the outer ram must be positioned at its stroke end if it is already in that position this message won t appear using the lever until the next screen is displayed fig 5 USE OF IMPLEMENTS 6 GR2 45 60 3 4 5 fig 7 Message FC P3 fig 6 paragraph to read only in case of manual extensions installed on Jib and not on Crane Note do not hang any load on the hook This means that the jib outrigger must be positioned at its stroke end if it is already in that position this message won t appear using the lever until the next screen is displayed fig 6 Message F1 TO START or 1 ENTER START Fig 7 At this point the display will visualize the message F1 TO START control panel or F1 ENTER START radio remote control Press the F1 control panel key or ENTER radio remote control to c
76. nger MANUAL EXTENSIONS Generality Lifting moment limiting device ELECTRONIC for the manual extensions valid starting from the version 3 0 of the software if fitted CONTROLS TO OPERATE THE HYDRAULIC IMPLEMENTS OF THE CRANE not available HYDRAULIC JIBS Generality Identification of the hydraulic jib Nomenclature of the hydraulic jib Manoeuvres to unfold the jib in working condition Manoeuvres to fold the jib in rest condition Operations to remove the hydraulic jib from the crane Operations to mount the hydraulic jib on the crane Hydraulic jib articulated at 25 degrees with the automatic control L515 L516 Use of the hydraulic jib articulated at 25 degrees not available on the L102 and on the L515 L516 Crane with lifting moment limiting device and pro link if fitted WINCH if fitted Generality Winch for crane Winches equipped with a mechanical stroke end device MAINTENANCE INSTRUCTIONS Generality Timer After every 8 working hours or at the end of every working day After every 40 working hours or atfter every working week After every 100 working hours or more frequently in case of more intensive utilisation After every 500 working hours or after every 6 working months After every 1000 working hours or after every working year Complete overhaul of the crane is required when 10 000 working hours or 10 years life are reached Instructions for the dismantlement and the demolition of a FASSI crane TABLE
77. oil and the filter cartridges MUST be disposed of by authorized persons CAUTION DANGER On the outer boom there is a mercury capsule mercury level switch duly Es hat quecksilber bitte protected and provided with the following warning stickers MERCURY 15 EXTREMELY TOXIC IN CASE OF REPLACEMENT Mercury inside scrap following laws in force AND OR SCRAPPING DISPOSE OF OR RECYCLE THE CAPSULE Contient du mercure recycler selon les lois en vigueuer CONTAINING MERCURY WITH MAXIMUM CARE AND IN ACCORDAN CE WITH THE NATIONAL REGULATIONS IN FORCE le leggi in vigore beseitingen so wie gesetzlich PIYA INSTRUCTIONS GRU FASSI 22 After every 1000 working hours or after every working year Perform Washing Function Testing Testing according to the capacity plates Check Identification plates Capacity plates Checklist in accordance with 150 9927 1 Subframe Tightening torque of the fixing rods wear Structure and fixing rods and any deformation actions For crane with rack Base Lubrication tightening torque of the rods Rack group compensator wear and any deformation actions For crane with slew ring Base Lubrication tightening torque of the screws Slew ring group compensator wear and any deformation actions Outriggers Greasing of extension supports oil leaks Supports rams base plates wear actions inspection of hoses safety catches hoses Rotation cylinders Oil leaks chr
78. omium plating Cylinders pistons seals any deformation inspection of hoses Column Lubrication wear and any deformation actions Inner boom connection outrigger connection pins bushes Inner boom Lubrication wear and any deformation Pins outrigger connections actions Inner ram Oil leaks chromium plating Cylinder rod piston seals hoses any deformation inspection of hoses Outer boom Lubrication wear and any deformation actions Pins outrigger connections Outer ram Oil leaks chromium plating strains Cylinder rod piston seals hoses inspection of hoses Extension booms Lubrication wear and any deformation actions Guide shoes pins outrigger connections Extension rams Oil leaks chromium plating Cylinder rod piston seals hoses any deformation inspection of hoses Hydraulic jib Lubrication wear and any deformation actions Booms pins outrigger connections Rams hydraulic jib Oil leaks chromium plating any deformation Cylinder rod piston seals hoses inspection of hoses Lubrication wear and any deformation actions Winch Torque limiter brake rope slide guide cable stroke end pulleis Distributors deviators valves Control levers forks joints fixing screws lead seals Checking of the pressure oil leaks wear and any deformation actions Lifting moment limiting device Valves pressure switches electrovalves Power take off pump oil tank Pump capacity checking o
79. ontinue fig 7 Message UP P1 see fig 8 Note do not hang any load on the hook It requires the activation of the inner boom lifting to eliminate an overpressure at the lifting ram bottom the manoeuvre is activated but the crane does not move since all the movements are disabled Note set the lever of the inner ram at its stroke end to simulate the lifting and keep it like this for at least three seconds fig 8 Message START LOAD P1 vedere Fig 9 Releasing the lever in neutral position the display visualises the message START LOAD P1 It requires the slow lifting of the load using the inner ram This allows to haul it up from the ground in order to calculate the weight which will be pointed out releasing the lever in neutral position This message confirms that load does not exceed the lifting limits of the GR2 45 60 3 4 5 10 Message LOAD OK fig 10 USE OF IMPLEMENTS crane and of the manual extension selected RR BY fig 10 fig 10 CLOSING OF THE PROCEDURE All the crane functions will still be kept disabled To start operating press the INDEX key control panel fig 10 or radio remote control fig D always with the selector in position A fig C selettore su Figure Figure D For an overall view of the procedure we attach the diagrams showing all the passa ges and messages that can be displayed during the procedure according to t
80. operate the crane 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 certain movements The XP device can be used not just to increase the capacity crane but to exploit the reduction in the speed when moving a load that must be posi tioned with precision and to exploit the variation in the lifting moment limiting device adjustment parameters to exit from a critical situation when moving the load overcoming of the 90 or intervention of the lifting moment limiting device ATTENTION The rating plates relevant to the XP device are marked F XP 16 8 1 Activation and instructions for use of the XP V device You operate the XP device only from the console of the radio remote control by using the appropriate selector fig 22a SCANRECO RADIO REMOTE CONTROL RScanreco radio remote control You operate on the XP ON XP OFF selector fig 22a on the XP ON position The activation of the XP device is indicated with the mark XP displayed up on the right of the control panel WARNING It is recommended to release the crane controls levers of the control console in neutral position before activating or desactivating the XP fig 22a device because of the variation of speed is considerable and immediate carefully operate the controls See paragraph 14 of the USE AND MAINTENANCE MANUAL for
81. orted SELECTOR the plates which corre EIS D spond to the stabiliza tion functions radio turning off radio starting and stop button STOP and audible alarm LEVERS CD LEVER C PUSH BUTTON PANEL SCANRECO WITH JOY STICK The three control joy fig 10a sticks on the push but DISPLAY ton panel have two plates because they can control through the selector E S 7 the functions of the crane or the functions for Stabilization Hereunder are repor ted the plates which ESO correspond to the sta bilization functions radio turning off pista 4 radio starting and stop button STOP and audible alarm LEVERS CD LEVER C 5 132 7 Selector EIS 2 Selector for the use of the crane or the outriggers GR5 Levers CD Controls to select the outrigger supports and rams Levers C Control of the selected outrigger support or ram MANOEUVRES OF THE OUTRIGGER RAMS IN CASE OF AN ELECTRICAL FAILURE In case of an electrical failure electrical or hydrau lic malfunctions you cannot use the selectors on the push button panel and so it is necessary to operate directly the integrated group of the outrig ger control fig 11 after removing the protection PICTURE LIST fig 11 G electrovalve for main bypass U electrovalve for the ram descent and extension of the outrigger supports R electrovalve for the ram re entry and retraction of the outrigger supports E1 E2 E3 E4 electro
82. osition Be very careful at the manoeuvre of rotation because of the residual danger of crushing During emergency manoeuvres the operator when it is possible should be assisted by a second trained person who can interve ne if necessary Eg positioning the lever D of the deviator 2 5 E S by using then the deviator crane outriggers like interruption control of emergency ATTENTION The presence of the lifting moment limiting device does not relea se the user from the obligation to respect what is indicated on capacity plates and lifting curves CAUTION DANGER On the outer boom there is a mercury capsule mercury level switch duly protected and provided with the following warning stickers Contiene mercurio smaltire secondo le leggi in vigore H d Es hat quecksilber bitte 7 beseitingen so wie gesetzlich 2 Mercury inside scrap following laws in force Contient du mercure recycler selon les lois vigueuer Mercury is extremely toxic In case of replacement and or scrapping dispo se of or recycle the capsule containing mercury with maximum care and in accordance with the national regulations in force ATTENTION Do not walk on DE1679 Do not use water to estinguish fire DE1680 16 8 XP DEVICE CONTROLS TO OPERATE THE CRANE This device can be activated only through the push butoon panel of the radio GR5 XP remote control see Par HO Controls to
83. place if necessary Non efficient pump Check the pump Non efficient pump Check the pump 25 INSTRUCTION AND WARNING PLATES INSTRUCTION AND FASSI GRU IDRAULICHE SpA WARNING PLATES ade GR5 24021 ALBINO BG ITALIA dei Carmelitani 2 INSTRUCTIONS FOR SAFE USE OF THE CRANE Tel 39 35 77 64 00 Fax 39 35 75 50 20 1 Only authorized persons are permitted to operate the crane 5 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 operation make sure that no one is within the working area of the crane the safety devices are in place and operative the crane is used progressively avoiding sudden load movements swinging or dragging of the load is avoided the load is lifted before rotating the minimum safe working distances from power lines are observed 7 When using implements protect the working area with a barrier the load is correctly slung and hooked 8 The vehicle crane are not left unless the power take off is 5 Stabilize the vehicle with the outriggers making sure that disengaged and the load is on the ground the lateral supports are fully extended the wheels are in contact with the ground and the suspension is not 9 Before
84. push button for the selector enter for control an lifting moment limiting device GAS X y switching of the selector for the use of the 9 10 function free XP XP ON Selector for the use of the crane selector various times for control zi standard or XP starting the engine selector for the use of the right 008 selector index return for control B control panel in configuration del turning the engine orB GR5 CONTROLS TO OPERATE THE CRANE 14 2 Manoeuvres to unfold the crane into a working condition The plate DE4452A indicates the sequence of the manoeuvres to be carried out to unfold and to fold the crane Engage the power take off Stabilize the vehicle see details on Paragraph 13 Manoeuvres and controls to stabilize the vehicle By operating the corresponding levers make sure that the extension booms and the outer ram are closed lift the inner boom over the horizontal line open the outer boom to the horizontal position position the hook on the vertical line above the load 14 3 Manoeuvres to fold the crane into the rest condition see plate DE4452A By operating the corresponding levers fold the extension booms to their stroke end lift the inner boom to its stroke end fold the outer boom to its stroke end rotate the crane until the arrows coincide on the base and on the slew ring fold the inner boom to its stroke end
85. r boom of the crane under the horizontal line fig 20c 20d Manoeuvres not allowed Inner boom lift Outer boom lift Extension of the crane extension boom sections 5 Lift of the hydraulic jib Extension of the extension booms section of the jib Winch rope lift Movement of the hydraulic accessories fig 20d NOTES Ifthe overload condition has been activated by the hydraulic extension the extension of the crane boom sections is permitted Itis permitted only when coupled with permitted manoeuvres Manoeuvres allowed all the manoeuvres that bring the load closer to the column and therefore the overload Rotation in both directions Inner boom descent Outer boom descent Re entry of the crane extension boom sections CONTROLS OPERATE THE CRANE GRU FASSI Descent of the hydraulic jib Re entry of the extension booms section of the jib Winch rope descent Crane with activated limiting device overload condition by the intervention of the load limiter of the winch Manoeuvres allowed Rotation in both directions Re entry of the crane extension boom sections Re entry of the jib extension boom sections Winch rope descent Manoeuvres not allowed all other movements Crane without load applied and activated limiting device The limiting device may intervene also during loadless crane operation following a pressu re peak provoked by the attainment of the strok
86. rane features an alphernumeric readout for displaying the date the activation time expressed in hours minutes of the electric control panel Partial Time and Total time or the working time of the crane whilst being operated via the control levers Work Time How to view the date Press button C2 clock to have the current date visualized on display B Fig 29 Partial time How to view the partial time of the electric panel which can be reset Keep button C2 pressed until you read Time on display Press button C1 4 until you see Partial time Press button C3 enter to view the time fig 29a How to reset the Partial time To start a new count perform the following Keep button C2 pressed until you read Time on display B Press button C1 to read Partial time on the display Press button C1 again to read Total time eem mm ra on the display fig 29a E B RI Press button C1 again to read Work time IDEAS on the display Temm ST EE Press button C1 again to read Reset partial on the display Press button C3 enter to read Enter to confirm on the display Press button C3 enter again the timer is reset and it will start recording again Total time How to view the total activation time of the electric panel this cannot be reset Keep button C2 pressed until you read Time on display B Press button
87. s 50 120 7 N IN Hand Wrist 100 25 Fist The table indicates the minimum safety working distances concerning the various parts of the body The figures illustrate circumstances which may turn out to be dangerous if you fail to respect the minimum safe distances and if it is impossible to introduce larger parts of the body ATTENTION For designated areas as outrigger running towards rest position leaning and folding points of the booms in rest position control platform and swinnig colu mn top seat and running inner boom where no carter is possible to be placed please observe the shear and trapping hazard stickers nearly placed ATTENTION Failure to respect the minimum safe distances may result in a safety hazard and a deadly risk Remember that the stability of the unit crane vehicle is only guaranteed by the complete lateral extension of the outriggers and by the observance of the capacity plates Stabilize the vehicle on a horizontal plane with a maxi mum tolerance of 1 5 degrees Make sure that the outrig ger rams rest on a solid base if necessary use larger outrigger base plates available on request to avoid sinking If you adopt other means make sure that they are suitably sized for the load they must bear ATTENTION Respect the safety distances from electric lines the minimum distance is according to CEN norms five b meters except for otherwise prescribed by national norms
88. sary to return all the levers to the neutral position ATTENTION During load handling with the crane and with the crane and hydraulic jib in vertical configuration or close the operator must strictly refer to the loads indicated on the capacity plates since the limiting device shows to be not particularly sensitive with vertical lifts Crane with activated limiting device by the intervention of the crane or the hydraulic jib overload condition and with outer boom of the crane above the horizontal line fig 20a 20b Manoeuvres not allowed Inner boom descent Outer boom descent Extension of the crane extension boom sections 5 Lift and descent of the hydraulic jib Extension of the extension booms section of the jib Winch rope lift Movement of the hydraulic accessories NOTES Ifthe overload condition has been activated by the hydraulic extension the extension of the crane boom sections is permitted It is permitted only when coupled with permitted manoeuvres Manoeuvres allowed all the manoeuvres that bring the load closer to the column and therefore the overload Rotation in both directions Inner boom lift Outer boom lift Re entry of the crane extension boom sections Re entry of the jib extension boom sections Winch rope descent WITH HYDRAULIC JIB Crane with activated limiting device by the intervention of the crane or the hydraulic jib overload condition and with oute
89. scertain that the working area is free and clear of potential obstacles to crane operations people building walls balconies eaves scaffoldings tree branches other lifting means or machines electric lines This may hurt people damage both the impedi ments and the crane and provoke also the crane overturn Make sure that there is no risk of elements falling on the operator or on the crane and take the right precautions to prevent it Overload and or fatigue the crane can break down due to fatigue or overload If it is misused with cycles loads or pump oil flow not pertinent to the crane class f it is used for improper tasks side oblique or reversal pull f itis used in poor jobsites corrosive environment too high or too low temperature foundry see conditions of f the load exceeds the rated capacity indicated on the relevant plates WARNING AND INSTRUCTIONS 7 5 GRU FASSI WARNING AND TAGS INSTRUCTIONS GRU FASSI Wrong manoeuvring the crane can fall break or overturn if the operator performs a wrong manoeuvre due to the lack of familiarity with the opera tion procedures see manual of use and maintenance or due to inadequate psychophysical conditions we remind you that the directives in force impose a suitable training of the personnel before using these types of machines and require an adequate psychophysical condition to operate safely a lifting device that always implies the intrin
90. sed at the stroke end The following manoeuvres are allowed the opposite rotation the manoeuvres allowed by the limiting device in relation to the position of the outer boom positioned over or under the horizontal line 16 6 Rotation limiting device When a sector of the working area exists in which the stability is insufficient for example in the area in front of the cab the permitted arc of rotation is limited by means of an adjustable electro hydraulic device which only allows operation within the safe area Warning persist in the operation When exceeding the safe area the rotation limiting device only allowing the opposite rotation the manoeuvres allowed by the limiting device in relation to the position of the outer boom positioned over or under the horizontal line CONTROLS TO OPERATE THE 8 GRU FASSI CONTROLS OPERATE THE CRANE GRU FASSI lf a reduction of capacity is necessary because of insufficient stability of the complete unit new capacity plates must be fixed giving the derated capacity in accordance with the final stability test ATTENTION Always check carefully that the vehicle is perfectly stable paying special atten tion to the area immediately in front of the driver s cabin as this is usually less stable 16 7 Inthecase of the appearance of the signal ALARM on the display of the control panel or of the radioremote control or in case of an electrical
91. sic danger of a lifted load Weather conditions too high or too low temperatures may damage the com ponents of the oleodynamic and electric circuits See max and min conditions of use it is forbidden to operate the crane during a storm with lightning hazar ds 50 we recommend 10 fold it and put it to rest Furthermore when the wind 15 too strong the crane can overturn or break down Shearing entrapment the crane has a lot of parts in movement that it is impossible to cover therefore the operator shall always be aware of this resi dual risk and keep clear from the parts in movement particularly from the load the operator is held responsible not only for himself but also for those working in proximity of the crane and for those who may draw closer even if not autho rized Electricution the crane is not insulated from electric contacts and therefo re it is not equipped to work under tension even if the contact is accidental Therefore be compliant with the min clearance prescribed by the national directives in force Generally speaking the clearance from electric lines with a max tension of 38 000 volts should be at least 5 meters Higher tensions requi re higher clearance to be verified case by case together with competent tech nicians and with respect to the environment conditions Manual extension overload manual extensions are controlled by the moment limiting device only under the conditions described in the relative chapter th
92. sive movements rotate slowly and with care paying attention to the Stability of the vehicle With vertical lift on hydraulic and mechanical extension rotate slowly in order to avoid side skidding ATTENTION Do not utilize the crane for pushpull F lateral F or sideways F opera tions ATTENTION Crushing F or push F ma noeu vres are not permitted Never operate the outriggers when the crane is loaded ATTENTION The vehicle crane must not be left unless the load is on the ground the booms of the crane and of the hydraulic jib are folded and laid on a solid base and the power take off is disengaged Do not move the vehicle with the crane not in transport position and not with a load suspended on the crane 7 4 Atthe end of the operation Prior to driving the vehicle Fold the crane If the booms of the crane or of the hydraulic jib are to be laid on the body or on the load they must be suitably blocked to prevent possible sideways movements Make sure that the indications about the overall dimensions are respected NOTE Implements can be left mounted on the booms of the crane or of the hydraulic jib only if the overall dimensions are respected they must be suitably blocked to prevent possible sideways movements If an accessory fork is mounted it must be tied down at all times during tran sport Make sure that the outrigger supports and rams are re entered
93. ss together the two left right OK confirmation buttons pos 2 and pos 6 for joy stick controls pos 7 for linear controls Tele radio remote control The radio remote control in the case of a discharged battery or in the presence of interferen ce in the radio transmission or use of the crane in situations where the transmission by radio is forbidden it is easily transformed to cable remote control using a connecting cable Activation of the tele radio remote control Connect by cable the remote control to the socket fixed on the base of the crane fig 17 WARNING First read the instructions given in the User s Manual supplied by the Manufacturer before using the remote control to avoid improper use The plates shown on the side of each push button panel lever of the radio remote control and on each lever on the emergency control determine the operation of the levers in relation to the movement of the crane ATTENTION The sequence of the plates placed on the crane controls may be different Make sure that the lever you are going to operate correspond to the control you selected Operate the levers smoothly and gradually When carrying out simultaneous movements of two or more functions also related to pump flow and lever travel it is possible that on reaching the stroke end of a particular function an increase in speed of the other functions will occur CONTROLS TO OPERATE THE CRANE GR5
94. standard configuration position of the selector when the jib is articulated at 25 degrees USE OF IMPLEMENTS PURSE 5 ATTENTION This device is not automatic and so it is compulsory to position the selector of the fig 3 on the configuration standard or at 25 degrees which you want to use ATTENTION Before using in the configuration of the jib articulated at 25 degrees verify that the device is efficient When the selector is positioned for the configuration at 25 degrees the safety device is activated If during the utilization the verticalising limit value has been reached the safety device intervenes Manoeuvres not allowed with the intervention of the safety device lift of the inner boom lift of the outer boom lift of the jib mouvement boom Manoeuvres allowed all other movements When the selector is positioned for jib in standard configuration the safety device is disactivated ATTENTION It is forbidden to use the crane with hydraulic extension articulated at 25 degrees without enabling the corresponding safety device fig 3 since when the vertical disposition angles of the jib extension are higher than those of the standard configuration the extension boom sections of the crane and of the hydraulic jib can generate a very dangerous situation because they are not designed to work with the reverse actions PER CARICHI UTILIZZARE TARGA PORTATE FOR THE LOADS
95. system are rotation lift and descent of the inner boom lift and descent of the outer boom exit of the extension booms of the crane lift and descent of the jib when fitted exit of the extension booms of the jib when fitted Lifting moment limiting device A characteristic which permits the classification of cranes is their lifting capacity or maximum lifting moment The moment is defined by the value obtained from the weight of the load to be lifted kg by its distance meters from the centerline of the crane rotation The device called lifting moment limiting device preserves the crane structure from overloads as it prevents any movement which increases the value of the moment up to the maximum established value 16 2 Electronic lifting moment limiting device This device utilises an electro hydraulic system managed by an electronic logic that prevents any operation tending to cause an increase in the pressure induced by the load in the lifting rams inner outer rams of the crane and of the hydraulic extension If fitted up to the critical values These values which are not exceeda ble determine the intervention levels and provide the data for setting the device The pressure values detected in the lifting rams are turned into electric signals by the transducers and sent to the electronic logic of the device which determines the locking or unlocking of the controls concerned according to the horizontal
96. th layer Maximum speed in m min or Maximum capacity pump l min See operator winch manual supplied by the winches manufacturer The winch has a maximum capacity which cannot be exceeded indicated by a plate not related to the crane capacities which can also be lower Consequently avoid to lift with the winch heavier loads than those allowed by the crane capacity plate Note We do not recommend using the winch with load moving winch in or out at the same time as the extension booms or the crane and hydraulic jib if fitted since it accelerates the wear of the extension guide pads reducing their life to one third compared to a standard application The couple limiter installed on the winch structure prevents that on the cable can be created a load major to the value of maximum line at the 4th layer quiescing all the crane controls 5 Under no circumstances interfere with the limiter device adjustment USE OF IMPLEMENTS GRU FASSI USE OF IMPLEMENTS GRU FASSI fig 27 21 2 1 Winches equipped with a mechanical stroke end device ATTENTION The end stroke condition takes place when the block takes contact with the pulley structu re The operator must stop the manoeuvre before the block rotates the pulley completely with consequent activation of the load cell on the winch Such end stroke device shall be used only under emergency conditions and not as a simple end stroke
97. the truck body it is necessary to check they are locked to assure the impossibility of accidental movements and that the led signalling maximum obstruction in height if fitted confirms the correct positioning of the crane The crane can operate intermittently and not continuously with lifting devices other than the hook only on loose and light materials not on scrap iron ATTENTION In case of using the crane with lifting devices other than the hook the access to the working area at the persons must be pre vented The dimensions and the capacity of the implements must be pro portioned with crane performan ces WARNING CRUSHING F OR PUSH F MANOEUVRES ARE NOT PERMITTED USE OF IMPLEMENTS GRU FASSI 17 2 Hydraulic connections for implements supple mentary hoses WARNING To ensure that the control corresponds to the implement movement hydraulic connections are symmetrically fitted with coupling unions Never invert such positions movements inversion as well as operating difficulties or unusual overload with implement itself could occur NOTE When using coupling unions it is necessary to verify that there is no trace of soil curt etc on the unions and inside the seats so as to avoid the oil contami nation and consequently wear the tightening surface of unions or ram seals 17 3 Oil cooler heat exchanger The crane is equipped with an oil cooler air oil heat exchanger to
98. to read Partial time on the display Press button again to read Total time on the display Press button C3 enter to visualize for about 5 seconds the total time expressed in hours and minutes Work time How to view the work time which is the actual time recorded whilst a crane operating lever function is being activated Keep button C2 pressed until you read Time on display B Press button C1 4 to read Partial time on the display Press button again to read Total time on the display Press button again to read Work time on the display Press button C3 enter to view for about 5 seconds the work time of the crane expressed in hours and minutes INSTRUCTIONS working day GRU FASSI Check that all safety devices are efficient Check the level of the hydraulic oil in the tank Check all the components of the hydraulic circuit for possible leaks Check that the control and the oil diverter levers can easily be positioned they must show no signs of forcing Check the condition of shackles hooks wire ropes and any other lifting equipment 22 3 After every 8 working hours or at the end of every PA 22 4 After every 40 working hours or atfter every working week Check the tightening torque of the fixing rods of the crane fig 30 See table at paragraph 22 5 Clean the oil filter placed in the oil tank of the crane and if any on the pump sec
99. trol panel begins to flash continous to keep the command for the crane extensions boom press the exclusion device button the flashing red light becomes fixed release the lever commanding the crane extensions booms The permitted manoeuvre is the descent of the outer boom in order to bring it under the horizontal remember that you have at your disposal five 5 seconds from the command operation to carry out the descent After such period of time wait at least one 1 minute in order to be allowed to carry out the manoeuvre once again ATTENTION Activation of the exclusion device of the lifting moment limiting device When the operator uses this device it means that he wishes to override the lifting moment lifting 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 devi ce has been disabled the operator who is the main responsible for the machine safety must carefully consider the manoeuvres required to return to normal working conditions it is however compulsory to effect the re entry of the exten sion booms at first calmly and carefully assess the type and scale of the hazards arising from these manoeuvres and the possible reaction of the crane tipping over frame overload uncontrolled fall of the load due to a hydrau
100. until stroke end and momentarily pressurise maintain the command for the extensions boom until the red led of the button LMI placed on the control panel begins to flash continue to keep the command for the extensions boom and press the exclusion device button the flashing red light becomes fixed release the lever commanding the extensions booms The permitted manoeuvre is the descent of the outer boom in order to bring it under the horizontal remember that you have at your disposal five 5 seconds from the command operation to carry out the descent After such period of time wait at least one 1 minute in order to be allowed to carry out the manoeuvre once again The activation button of the excluding device only in the case of the hydraulic jib are to be activated as follows retracted the extensions booms of the hydraulic jib until stroke end and momentarily pressurise maintain the command for the extensions of the hydraulic jib boom until the red led of the button LMI placed on the control panel begins to flash release the lever commanding the extensions booms of the hydraulic jib within 3 seconds from releasing the lever commanding the extensions booms of the jib retracted the extensions booms of the hydraulic jib until stroke end and momentarily pressurise the red led turns off as soon as the re entry begins maintain the command for the extensions boom until the red led of the button LMI placed on the con
101. utriggers are fully retracted and re entered the safety taps closed and the crane is in the folded position fig 1a INSTRUCTIONS FOR SAFE USE OF THE CRANE 7 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 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 re entered the safety taps closed and the crane is in the folded position 7 WARNING AND
102. valve of the extension rams 51 52 53 54 electrovalve of the outrigger rams T electric deviator of the crane outriggers fig 11a Example re entry of the outrigger ram 1 tighten the T screw fig 11a remove the lead seal placed on the electrovalve G general push the button and then turn it clockwise fig 11b pos 1 2 the button stays in the closed position Unscrew the knurled screw of the electrovalve 51 of the outrigger Push with an appropriate metal tip and in the direction of the arrow F the slider of the spool R general to re enter the ram Re screw the knurled screw of the electrovalve 51 of the outrigger Put the button of the electrovalve G back to its original position by turning it anti clockwise fig 11b pos 3 4 to reactivate the crane functions loosen the T screw to the previous position see fig 11 After such emergency operations and prior to re use of the crane you must immediately go to a FASSI authorised Center for the repair of the fault and re sealing of the device Interferences with the valves or removal of the lead seal release the FASSI GRU IDRAULICHE from any responsibility and invalidate the warranty 13 3 Controls to stabilize the vehicle 13 3 1 Crane with fixed or manually tiltable supports for outrigger rams Disengage the locking devices of the outrigger supports by putting the levers A from the position of the fig 12 to the one of the fig 12a Pos
103. ways respect and pay proper attention that the load and dimension limits are in conformity with the road regulations 20 6 Operations to remove the hydraulic jib from the crane By operating the corresponding levers re enter the jib outer booms sliding sections to their stroke end extend the crane outer ram to its stroke end extend of at least 1 1 5 m the crane outer booms sliding sections re enter the outer ram of the jib and the inner ram of the crane to obtain the two rest brackets of the jib either lay on the ground or on the truck body or if possible on a specific rest trestle remove screwing the locking pins re enter the outer booms sliding sections of the crane to free the first boom of the crane jib disconnect the jib from the hydraulic circuit of the crane operating on the quick couplings Assure that the hydraulic jib is adequately stripped to avoid side turnover 20 7 Operations to mount the hydraulic jib on the crane By operating the corresponding levers place the extension on the vehicle or on the ground in the direction of the movement of the extension booms extend the crane outer ram to its stroke end and position the extension booms of the crane not too close to the first boom of the jib in order to allow the lining up manoeuvres and the connection of the hoses connect the jib hoses to the hydraulic plant through coupling unions following indications of Paragraph 17 2 Hydrau
104. y descent functions To verify the right working of the differents input it is possible to use the display in the INPUT menu 16 7 2 Temporary OVERIDE REACTIVATION for the crane functions in case of the appearance of the signal ALARM on the display of the push button panel Note If the alarm doesn t involve components which control the distributor it is possible to re close the crane using the push button panel of the radio remote conirol ATTENTION These manoeuvres can be effected where the lifting moment limiting device has been disabled and then can involve an overload condition In such an emer gency condition the operator who is responsible for the machine safety must carefully consider the manoeuvres required to return to normal working condi tions it is however compulsory to effect the re entry of the extension booms at first calmly and carefully assess the type and scale of the hazards arising from these manoeuvres and the possible reaction of the crane tipping over frame overload uncontrolled fall of the load due to a hydraulic system overload etc make all movements as slowly as possible to reduce the dynamic overload to the minimum Reactivation of the crane functions using the push button panel of the radio Keeping pressed the exclusion push button of the limiting device on the push button panel operate on the lever of the movement to be effected After such emergency operat

F 700A/800AXP.26 - FASCAN International, Inc.

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