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FASSI CRANE 1

F 60A.21
use and maintenance
FROM SERIAL NUMBER *0775*

INDEX
1 INTRODUCTION
2 CLASSIFICATION OF THE CRANE MODEL
2.1 Generality
2.2 Hydraulic jibs (not available)
2.3 Technical data
3 CAPACITY PLATES
3.1 Generality
3.1.1 Capacity plates with load limiting device
3.1.2 Capacity plates with lifting moment limiting device (optional)
4 HYDRAULIC SCHEMATICS ( ) (version with lifting moment limiting device)
4.1 HYDRAULIC SCHEMATICS (version with load limiting device)
5 ELECTRIC SCHEMATICS
6 SAFETY NORMS
7 WARNING AND INSTRUCTIONS
7.1 Generality
7.2 Before operating
7.3 During operation
7.4 At the end of the operation (Prior to driving the vehicle)
7.5 Residual risks
8 IDENTIFICATION OF THE CRANE MODEL
8.1 Generality
8.2 Crane mark
9 CRANE NOMENCLATURE
9.1 Version with ground controls for crane and outriggers
Version with top seat controls for crane by hand cables
10 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES
10.1 Version with ground controls for crane and outriggers
Version with top seat controls for crane by hand cables
11 SUPPLEMENTARY BEAMS
11.1 Generality
11.2 Identification of the supplementary beams
12 TILTABLE OUTRIGGER RAMS
12.1 Manually tiltable outrigger rams
13 MANOEUVRES AND CONTROLS TO STABILIZE THE VEHICLE
13.1 Generality
13.2 Manual extension and re-entry of the outrigger supports

Edition ExtraCE 07.03.2006

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13.3 Manoeuvres for the manual extension of the double outrigger supports
13.4 Functions of control levers for stabilization 1
13.5 Controls to stabilize the vehicle
14 CONTROLS TO OPERATE THE CRANE
14.1 Generality
14.2 Manoeuvres to unfold the crane into a working condition
14.3 Manoeuvres to fold the crane into the rest condition
14.4 Manoeuvres to unfold the crane "C" into a working condition (only for the crane version “C”)
14.5 Manoeuvres to fold the crane "C" into the rest condition (only for the crane version “C”)
14.6 Indicator of inner boom horizontal position (optional)
14.7 Third control station (optional)
15 MANOEUVRES OF THE CRANE LOADS (version with load limiting device)
15.1 Generality
16 MANOEUVRES OF THE CRANE LOADS (version with lifting moment limiting device)
16.1 Generality
16.2 Lifting moment limiting device “ELECTRONIC” (optional)
16.3 Control panels (optional)
16.4 Load handling (optional)
16.5 Lifting moment limiting device for two working sectors (optional)
16.6 Rotation limiting device (optional)
16.7 In the case of the appearance of the signal “ALARM” on the display of the control panel or
of the radio remote control or in case of an electrical failure (optional)
16.7.1 Diagnostic (Alarms/Input/Output) LME vers. 4-5 UC 01-7 (optional)
16.7.2 Temporary OVERIDE-Reactivation for the crane functions with standard distributor (optional)
16.7.3 OVERIDE-Reactivation lever for the crane functions (with Danfoss distributor) (optional)
16.8 XP device (if fitted, see the Use and Maintenance booklet)
16.8.1 Activation and instructions for use of the XP/V device
(if fitted, see the Use and Maintenance booklet)
17 USE OF IMPLEMENTS
17.1 Generality
17.2 Hydraulic connections for implements - supplementary hoses
17.3 Oil cooler (heat exchanger)
18 MANUAL EXTENSIONS
18.1 Generality
18.2 Lifting moment limiting device “ELECTRONIC” for the manual extensions
(valid starting from the version 3.0 of the software)
19 CONTROLS TO OPERATE THE HYDRAULIC IMPLEMENTS OF THE CRANE
20 HYDRAULIC JIBS (not available)
21 WINCH (if fitted)
21.1 Generality (version with lifting moment limiting device)
21.2 Winch for crane
21.2.1 Winches equipped with a mechanical stroke end device
21.3 Generality (version with load limiting device)
21.4 Winch for crane
21.4.1 Winches equipped with a mechanical stroke end device
22 MAINTENANCE INSTRUCTIONS
22.1 Generality
22.2 Timer
22.3 After every 8 working hours or at the end of every working day
22.4 After every 40 working hours or atfter every working week
22.5 After every 100 working hours or more frequently in case of more intensive utilisation
22.6 After every 500 working hours or after every 6 working months
22.7 After every 1000 working hours or after every working year
22.8 Complete overhaul of the crane is required when 10.000 working hours or 10 years'
life are reached
22.9 Instructions for the dismantlement and the demolition of a FASSI crane
23 TABLE OF HYDRAULIC OIL AND LUBRICANTS CHARACTERISTICS
24 POSSIBLE FAULTS
24.1 Generality
24.2 Only operations which can be carried out by the user
24.3 Operations to be carried out only by a service center
25 INSTRUCTION AND WARNING PLATES
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FASSI CRANE INDEX

GRU FASSI 1

Use and maintenance

ORIGINAL INSTRUCTIONS

THANK YOU FOR SELECTING ONE OF FASSI CRANES.

This crane is the result of FASSI philosophy: ongoing research, rigorous

testing, data verification, and analysis of performances.

Many years of experience has allowed us to grant you the maximum safety of
operation together with the optimization of machine performances.

All this represents the core of FASSI quality system.

FASSI quality system is in conformity with

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

The fitment of the crane on the vehicle must be carried out in accordance with
the instructions given by FASSI in the manual for hydraulic crane fitting and the
relevant chassis manufacturers directives.

The Manufacturer declines all responsibility and guarantee if the fitting is

entrusted to workshops without sufficient technical capability to carry out the
work in conformity.

Be sure that the unit has been installed, inspected and tested in accordance
with the local legal requirements.

As well as the principal safety norms, this manual contains a description of the
crane and the instructions for use and maintenance.

The following instructions refer to mobile cranes in general and must be inte-
grated with the manual for use supplied by the centre responsible for the crane
fitting on truck, vehicle or other type of structure.
Some of the options described in the use and maintenance manual are availa-
ble only on request; therefore they may not be on your crane.

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

minutes spent now could save time and labour later.
Always conform to the safety norms and the instructions for use and mainte-
nance contained in the present manual in order to guarantee a long life to the
crane.

NOTE
The original version of the present manual is in italian.

The spare parts catalogue for the crane can be viewed in the Internet
site: www.fassicat.com
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2 CLASSIFICATION OF THE CRANE MODEL CLASSIFICATION OF

THE CRANE MODEL 2
2.1 Generality F 60A.21

The design of this crane has been carried out in respect of DIN 15018 norms,
fatigue test classification H1B3. The crane can operate, intermittently, with
lifting devices other than the hook. The dimensions and the capacity of the
implements must be proportioned with crane performances.

2.2 Hydraulic jibs (not available)

2.3 Technical data

F 60A.21
Lifting Standard Hydraulic Rotation Rotation Working Pump Oil tank Crane Max. working
capacity reach extension arc torque pressure capacity capacity weight pressure
on the outrigger
(Φ 140)

6,0 tm 5,50 m 1,62 m 370° 1,12 tm 25,5 MPa 20 l/min 60 l 725 kg 31,5 daN\cm2
58,9 kNm 11,02 kNm
43.398 18’0” 5’3” 8.101 3.698 psi 5,28 15,85 1.598 lbs 456,87 psi
lbf.ft ft/in ft/in lbs.ft gal/min gals
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CLASSIFICATION OF
THE CRANE MODEL 2.2
F 60A.21
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3 CAPACITY PLATES CAPACITY PLATES

F 60A.21 3
3.1 Generality
The represented plates refer to the nominal design capacities.

(!) WARNING (!)

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

3.2 Capacity plates with lifting moment limiting device

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CAPACITY PLATES
F 60A.21 3.2
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CAPACITY PLATES
F 60A.21 3.3

3.3 Capacity plates with load limiting device

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CAPACITY PLATES
F 60A.21 3.3
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CAPACITY PLATES
F 60A.21 3.3
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4 HYDRAULIC SCHEMATICS HYDRAULIC

SCHEMATICS 4
F 60A
Hydraulic schematic for crane - HCD4 distributor - ground controls - “electronic”
lifting moment limiting device

CODE DESCRIPTION

DV003 DEVIATOR VA102 DOUBLE EFFECT BLOCK VALVE

EV128 ELECTROVALVE VA185 SELECTOR VALVE
EV117 ELECTROVALVE VA200 DOUBLE EFFECT BLOCK VALVE
FI870 FILTER (RETURN) VA213 SIMPLE EFFECT BLOCK VALVE
M1/M2 GAUGE QUICK CONNECTION VA215 OIL FLOW CHECK VALVE
PR103 PRESSURE SWITCH VA217 SEQUENCE VALVE
RU975 FAUCET VA239 SIMPLE EFFECT BLOCK VALVE
TR001 PRESSURE TRANSDUCER
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Hydraulic schematic for crane - Danfoss distributor - “electronic” lifting moment HYDRAULIC
limiting device SCHEMATICS 4
F 60A

CODE DESCRIPTION

DV003 DEVIATOR VA102 DOUBLE EFFECT BLOCK VALVE

EV124 ELECTROVALVE VA148 ELECTRIC MAIN WITH BY PASS VALVE
FI776 FILTER (HIGH PRESSURE) VA185 SELECTOR VALVE
FI870 FILTER (RETURN) VA200 DOUBLE EFFECT BLOCK VALVE
M1/M2 GAUGE QUICK CONNECTION VA213 SIMPLE EFFECT BLOCK VALVE
PR103 PRESSURE SWITCH VA227 SEQUENCE VALVE
RU971 FAUCET VA232 UNIDIRECTIONAL VALVE
RU975 FAUCET VA239 SIMPLE EFFECT BLOCK VALVE
TR001 PRESSURE TRANSDUCER VA247 OIL FLOW REGULATOR VALVE FOR ROTATION
CYLINDER
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4.1 HYDRAULIC SCHEMATICS HYDRAULIC

(version version with load limiting device)

SCHEMATICS 4.1
F 60A

Hydraulic schematic for crane - HCD3M distributor - ground controls - load limi-
ting device

CODE DESCRIPTION

DV003 DEVIATOR VA215 OIL FLOW CHECK VALVE

FI870 FILTER (RETURN) VA239 SIMPLE EFFECT BLOCK VALVE
PR103 PRESSURE SWITCH
RU975 FAUCET
VA102 DOUBLE EFFECT BLOCK VALVE
VA200 DOUBLE EFFECT BLOCK VALVE
VA213 SIMPLE EFFECT BLOCK VALVE
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Hydraulic schematic for crane - Danfoss distributor - load limiting device HYDRAULIC
SCHEMATICS 4.1
F 60A

CODE DESCRIPTION

DV003 DEVIATOR
FI870 FILTER (RETURN)
RU975 FAUCET
VA102 DOUBLE EFFECT BLOCK VALVE
VA200 DOUBLE EFFECT BLOCK VALVE
VA213 SIMPLE EFFECT BLOCK VALVE
VA222 OIL FLOW CHECK VALVE
VA227 SEQUENCE VALVE
VA239 SIMPLE EFFECT BLOCK VALVE
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5 ELECTRIC SCHEMATICS ELECTRIC SCHEMATICS

GR2_45»65_3_4_SE 5
Electric schematic for crane

N° DESCRIPTION

ALIM ELECTRICAL FEED CABLE MAIN CONTROL PANEL

EV1 ELECTROVALVE FOR CRANE BLOCK
EV2 ELECTROVALVE FOR LIFTING MOMENT LIMITING DEVICE OF THE TWO WORKING ZONES
EV3 XP ELECTROVALVE
LP FLASHING
IP1/2/3 PROXIMITY MICROSWITCH FOR ROTATION CONTROL
LCV WINCH LOAD LIMITING DEVICE
LR ACTIVATION OF OVERLOAD BLOCK RED WARNING LIGHT
M1 MICROSWITCH ON THE DISTRIBUTOR (ROTATION)
M2 MICROSWITCH ON THE DISTRIBUTOR (INNER BOOM)
M3 MICROSWITCH ON THE DISTRIBUTOR (OUTER BOOM)
M4 MICROSWITCH ON THE DISTRIBUTOR (CRANE EXTENSION BOOMS)
M5 MICROSWITCH ON THE DISTRIBUTOR (JIB BOOM)
M6 MICROSWITCH ON THE DISTRIBUTOR (JIB EXTENSION BOOMS)
M7 MICROSWITCH ON THE DISTRIBUTOR (WINCH)
MS MERCURY LEVEL SENSOR ON THE OUTER BOOM
MV2 DRUM MICROSWITCH WINCH
P1 PRESSURE SWITCH FOR THE RE-ENTRY OF THE EXTENSION BOOMS
UCF MAIN CONTROL PANEL (FX000)
S1/2/3/… CONNECTORS
SAT1 DOUBLE CONTROL SIDE SATELLITE
SAT2 SATELLITE FOR 3° CONTROL STATION
SD1 SHUNT BOX 1
TP1 PRESSURE TRANSDUCER FOR INNER RAM
TP2 PRESSURE TRANSDUCER FOR OUTER RAM
TP3 PRESSURE TRANSDUCER FOR THE JIB RAM
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6 SAFETY NORMS SAFETY NORMS

GR2_3_4_5 6
Strictly conform to the norms reported by the plates DE2499A (fig. 1) or
DE1771A (fig. 1a) placed next to the 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.

Stabilize the vehicle by the outrigger rams, making VERTICAL VERSION fig. 1
sure that:
- the lateral supports are fully extended;
- the wheels are in contact with the ground and the
suspension is not completely unloaded.

Use the crane in accordance with the use and maintenance

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

When using implements protect the crane working area

with a barrier.

The vehicle/crane are not left unless the power take off
is disengaged and the load is on the ground.

Before driving the vehicle make sure that the outrig-

gers are fully retracted and re-entered, the safety taps
closed and the crane is in folded position.

HORIZONTAL VERSION fig. 1a

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7 WARNING AND INSTRUCTIONS SAFETY NORMS

GRU FASSI 7
7.1 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

DE1067
(!) 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
operating and allow instruction plates to be visible.

Check that the working area is adequate and properly lighted for your crane.

Make sure that the hook is always free to rotate on its pin and that nothing
obstructs its vertical positioning.

Check the efficiency of the hook safety catch.

Carefully inspect the condition of ropes or chains. (if

present)

Make sure that the pallet fork (if present) is con-

nected to the crane hook by means of a chain
having at least three (3) rings.

7.3 During operation

Take the vehicle fumes away from the working area by fitting an extension tube
of a suitable diameter and a right length to the exhaust system.
Do not run the engine in a indoor area without first making sure there is adequate
ventilation.

When using the ladder to reach the control station on the top seat, avoid
knocking into the controls while going up or down the ladder.

The control station on the top seat is provided with side safety guards; stay
within these guards.

Make sure that no one is within the working area of the crane.
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(!) ATTENTION (!) WARNING AND

Avoid swinging the load above working and transit areas; any hidden dan- INSTRUCTIONS 7.3
ger situation must be audibly alarmed. GRU FASSI
Avoid all those situations which may result in crushing during vehicle sta-
bilization, crane movement and load handling.

(In conformity with EN 349 standard the minimum safe working distances
to avoid crushing parts of the body)
Parts Minimum safe Figure Parts Minimum safe Figure
of the working of the working
Body distance mm Body distance mm

Body 500 Head 300

Leg 180 Foot 120

Toes 50 Arm 120

Hand
Wrist 100 Finger 25
Fist

The table indicates the minimum safety working distances concerning the
various parts of the body.
The figures illustrate circumstances which may turn out to be dangerous if you
fail to respect the minimum safe distances and if it is impossible to introduce lar-
ger parts of the body.
(!) ATTENTION (!)
For designated areas as: outrigger running towards rest position, leaning
and folding points of the booms in rest position, control platform and
swinnig column, top seat and running inner boom, where no carter is pos-
sible to be placed, please observe the shear and trapping hazard stickers
nearly placed.

Remember that the stability of the unit (crane-vehicle) is only guaranteed by the
complete lateral extension of the outriggers and by the observance of the capa-
city plates.
Stabilize the vehicle on a horizontal plane with a maximum tolerance of 1,5
degrees. Make sure that the outrigger rams rest on a solid base, if necessary use
larger outrigger base plates (available on request) to avoid sinking. If you adopt
other means, make sure that they are suitably sized for the load they must bear.

(!) ATTENTION (!)

Failure to respect the minimum safe distances may result in a safety
hazard and a deadly risk.
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(!) ATTENTION (!) WARNING AND

Respect the safety distances from electric lines; the minimum distance is, INSTRUCTIONS 7.3
according to CEN norms, five (5) meters, except for otherwise prescribed GRU FASSI
by national norms.
(!) ATTENTION (!)
Failure to respect the minimum safe distances may result in electrical hazards for the
operator and his assistants.
ELECTRICUTION:
General safety precautions for the operator and potential co-workers. If the crane hits an
overhead power line, do not touch the crane, the truck or the load.
Carefully evaluate the danger before moving. If you are closer than 10 meters from the
crane, the truck, the load or the electric line, move at least 10 meters away, by shuffling
away with small steps, in order to minimize the chance of getting a too high voltage diffe-
rence between the feet.
Warn others to stay away; call for help and contact the power company to de-energize the
line: do not attempt to assist someone in direct or indirect contact with the power line before
the power has been disabled: you run the risk of being electricuted yourself.
If you are in the truck cabin, stay inside without touching the vehicle body because it's
extremely hazardous to go out before the line is de-energised.
Help the electricuted person if you know the first-aid procedures, otherwise wait for the
paramedics to arrive.
(!) ATTENTION (!)
Do not utilize the crane during thunderstorms and with wind speed excee-
ding 13,8 m\s (50 km/h), maximum value of the Beaufort scale degree 6.
Indications about wind speed
Force of the wind Wind speed Classification Characteristics
Beaufort scale m/s

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

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

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

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

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

8 17,2 - 20,7 Storm wind Branches get broken, it's hard to walk.
9 20,8 - 24,4 Storm It damages houses (antennas and roof
tiles fall down)

(!) ATTENTION (!)

Carefully inspect the load rigging.

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

Make sure that the lifted load is balanced.

Avoid swinging the load above the control station; in cases where the load is too close,
the crane must be operated from the opposite side or with the radio-remote control, if fit-
ted. When operating through a winch, lift the load vertically using the cable and not
the booms in order to avoid swinging the load.
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Do not rotate the crane before the load WARNING AND

is lifted. INSTRUCTIONS 7.4
GRU FASSI
Do not operate with sudden movemen-
ts, activate the controls with slow and
progressive movements; rotate slowly
and with care paying attention to the
stability of the vehicle.

With vertical lift, on hydraulic and

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

(!) ATTENTION (!)

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

(!) ATTENTION (!)

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

(!) Never operate the outriggers

when the crane is loaded.

(!) ATTENTION (!)

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

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

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

Fold the crane.

If the booms of the crane (or of the

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

Make sure that the indications about

the overall dimensions are respected.

NOTE
Implements can be left mounted on the booms of the crane (or of the hydraulic
jib) only if the overall dimensions are respected; they must be suitably blocked to
prevent possible sideways movements.

If an accessory (fork, ...) is mounted, it must be tied down at all times during
transport.
Make sure that the outrigger supports and rams are re-entered within the overall
width of the truck and locked by the safety devices.

Disengage the power take off.

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7.5 Residual risks WARNING AND

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

Shearing, entrapment: the crane has a lot of parts in movement that it is

impossible to cover; therefore the operator shall always be aware of this residual
risk and keep clear from the parts in movement, particularly from the load; the
operator is held responsible not only for himself but also for those working in
proximity of the crane and for those who may draw closer even if not authorized.

Electricution: the crane is not insulated from electric contacts and therefore it is
not equipped to work under tension, even if the contact is accidental. Therefore
be compliant with the min clearance prescribed by the national directives in
force. Generally speaking the clearance from electric lines with a max tension
of 38.000 volts should be at least 5 meters: Higher tensions require higher
clearance to be verified case by case together with competent technicians and
with respect to the environment conditions.

Manual extension overload: manual extensions are controlled by the moment

limiting device only under the conditions described in the relative chapter; the
control system of the manual extension overload must be activated by the
operator as described.

Accessories: be careful when assembling and disassembling the accessories

(extensions, buckets, baskets,…); first verify the weight, the securing systems
and the instructions for assembly and dismantlement; then appraise their
barycentre and provide for adequate provisional blocking systems in order to
avoid sudden movements.
(!) ATTENTION (!)
IF IN THE FOLDING CONDITION THE HOOK IS OUT OF TRUCK SIZE, IT
MUST BE TAKEN AWAY BEFORE TRAVELLING.

Breakdown of some sensors

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

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

things or hurt people.

Particular operations: if you are required to operate under particular conditions

not illustrated in the manual of use and maintenance, analyse carefully the
situation and always refer to an authorised Fassi shop or to the Fassi technical
support service or to experienced operators before starting working.
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8 IDENTIFICATION OF THE CRANE MODEL IDENTIFICATION OF

THE CRANE MODEL 8
GRU FASSI
8.1 Generality
The exact crane model, serial number and description of implements will
enable FASSI Service Department to give a rapid and efficient response.

8.2 Crane mark

Identification data are marked on the plate DE5892, rivetted on the

base with personalized rivets FASSI. (fig. 2)
1

2
1 - Crane model
2 - Serial Number 3
3 - Year of manufacturing
fig. 2

(!) UNDER NO CIRCUMSTANCES SHOULD THE DATA

MARKED ON THE PLATES BE ALTERED.
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9 CRANE NOMENCLATURE CRANE

NOMENCLATURE 9
GR2_60»65
9.1 Version with ground controls for crane and
outriggers. (fig. 4)
Version with top seat controls (fig. 4a) for crane by
hand cables (optional)
Pos. Description

1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Distributor for crane-outriggers
6. Double control for crane-outriggers
7. Deviator control for selecting the rams
8. Column
9. Inner ram
10. Inner boom
11. Outer ram
12. Outer boom
13. Booms extension rams
14. Extension boom sections
15. Lifting hook
16. Oil tank
17. Manual extensions (optional)
18. Seat (optional)
19. Hand-cables from top seat (optional)

18
19

10

13

fig. 4a
11
12

8
9
16
7
14
4
2
7
6
4

17 1
3
15 2 5
1
fig. 4
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10 NOMENCLATURE OF THE SAFETY AND NOMENCLATURE OF

PROTECTION DEVICES
THE SAFETY AND
PROTECTION DEVICES
10
GR2_60»65
10.1 Version with ground controls for crane and
outriggers. (fig. 5)
Version with top seat controls (fig. 5a) for crane by
hand cables (optional)
Pos. Description

1. Check valves for outrigger rams

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

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.
7 11

5
4

fig. 5a

3
12

8 2
7
2 1

12

11
1
13 11

7 6
9-10 fig. 5
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11 SUPPLEMENTARY BEAMS SUPPLEMENTARY

BEAMS 11
11.1 Generality GR2_60»65

Supplementary beams are used in conjunction with the crane outriggers to

ensure the vehicle stability during load handling.

outrigger ram outrigger extension Weight

Code
stroke mm interaxis mm type kg
48019 440 1860 Fixed 60
48018 440 2500 Manual 80

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. *48019*0001

serial no.
identification code

fig. 6
12 TILTABLE OUTRIGGER RAMS

12.1 Manually tiltable outrigger rams

They are outrigger rams, which can be placed in a vertical, upwards, or incli-
ned position (at 30°) to avoid obsticles on the truck frame. (fig. 7-7a)

To position the rams in a working condition

(!) ATTENTION (!)
- If the ram is placed in a vertical position, a rotation stop F
prevents overturning to the opposite direction. F
- Before extracting the check pin and the locking pin to lower the
ram, check the position of the rotation stop F to prevent the ram
falling to the opposite side of the stop. Supporting the ram, fig. 7
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. (fig. 7a)

To re-position the rams to the folded position

- Remove the check pin and the locking pin from their position.
- Carefully position, the ram in a upward direction and support the
ram, insert the locking pin in its new position and secure it with the
check pin (fig. 7); if the ram is placed in a vertical position, a rotation
stop F prevents overturning.
fig. 7a
(!) The locking pin is held to the outrigger support by a chain
in order to prevent its loss.

(!) The locking pin is constructed from special material

- do not replace it with a non original part
- your security depends on it
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13 MANOEUVRES AND CONTROLS TO STABILIZE SUPPLEMENTARY

THE VEHICLE
BEAMS 13
GRU FASSI

13.1 Generality
The outriggers rams prevent damaging stresses both to the frame and to the
vehicle suspensions on which the crane is mounted to and assure the stability
of the unit during load handling.

(!) ATTENTION (!)

Be very careful when stabilizing the vehicle; make sure that no one is or
transits in close proximity of the working area of the outriggers.
DE 6409A
(!) 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

prevent an overload on the outriggers, then stabilize again.

While unloading, the outrigger rams may not be perfectly in contact with the
ground because of a rise in the suspension; it is therefore recommended to
stabilize the vehicle during operation to avoid an overturn.
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13.2 Manual extension and re-entry of the outrigger supports SUPPLEMENTARY BEAMS
GR2_60»65 13.2
(!) ATTENTION (!)
To manoeuvre the supports hands must only grab the handles placed on the
outrigger rams.
- Disengage the locking devices of the outrigger supports by
putting the levers of the devices A and B from the position of
the fig. 8 to the one of the 8a.
- Pull, extending from the base the outrigger support.
- Position the lever of the device B downwards; the locking loaded
security device B remains disengaged.
- Pull, extending the outrigger support till the engaging of the
pin of the device B in its seat. B A
fig. 8
- By the same sequence, repeat the operations described to
extend the other support.
(!) ATTENTION (!) B
The engaging of the outriggers lock B ensures the complete extension
of the outrigger support (essential for the stability of the complete
crane vehicle unit) and the impossibility of accidental movement.
(!) ATTENTION (!)
The complete extension of the outrigger support is visually indicated
by the yellow triangle which is found at the end of the beam. (fig. 8b) A
fig. 8a
To re-enter the outriggers repeat the operations previously described
in reverse.
(!) ATTENTION (!)
Keep hands clear of automatic stop device (lever A of the fig. 8).

Always check that the outriggers locks, once in their rest position, are
locked in their seat by the safety devices, so as to assure the impossi-
bility of accidental movement.

fig. 8b
13.3 Manual extension and re-entry of the double
outrigger supports
(!) ATTENTION (!) A
To manoeuvre the supports hands must only grab the handles placed on the
outrigger rams.
- Disengage the locking device of the outrigger supports by putting the
levers of the devices A and B from the position of the fig. 9 to the one
of the 9a.
- Pull, extending from the base the outrigger support assembly (first and
second support).
B
- Position the lever of the device B downwards; the locking loaded security fig. 9
device B remains disengaged.
- Pull, extending the outrigger support assembly, till the engaging of the
pin of the device B in its seat.
- Rotate the lever of the device B1 positioned on the first support, upwards; A
the spring loaded security pin will be disengaged from it’s position.
- Pull, extending from the first support, the second support.
- Position the lever of the device B1 downwards; the locking loaded security
device B1 remains disengaged. B1
- Pull, extending the second outrigger support till the engaging of the pin
of the device B1 which locates into its seat. B
- By the same sequence, repeat the operations described to extend the fig. 9a
other supports.
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(!) ATTENTION (!) SUPPLEMENTARY BEAMS

The engaging of the outriggers lock B and B1 ensures the complete exten- GR2_60»65 13.4
sion of the outrigger support (essential for the stability of the complete crane
vehicle unit) and the impossibility of accidental movement.
(!) 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
first support (fig. 8b-9b)
By the same sequence, repeat the operations described to extend the
other supports.
(!) ATTENTION (!)
Keep hands clear of automatic stop device (lever A of the fig. 9).
Always check that the outriggers locks, once in their rest position, are locked
in their seat by the safety devices, so as to assure the impossibility of acci-
dental movement.

13.4 Functions of control levers for stabilization

The controls to stabilize the vehicle are activated only from
ground level and on both sides of the crane base.

Lever function C - CD
Levers C Outrigger rams control DISTRIBUTOR SIDE DOUBLE CONTROL SIDE
distributor for the crane
and for the supplemen-
tary outriggers.
Fig. 10-11

Levers CD Deviator control for selec-

ting the outrigger rams
(outrigger-extension); the
position of the select lever C
is guaranteed by an inter- C
nal detent. fig. 10 fig. 11
Fig. 10b-11b

The controls of the outrigger rams,

indicated in the fig. 10a-11a coincide
with the plates DE3706 and DE3705
placed on the base, next to the con-
trol stations.

The symbols and the graphics indi- CD

cate the operating levers C and CD CD
in relation to their movement.
fig. 10b fig. 11b

fig. 10a fig. 11a

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13.4 Controls to stabilize the vehicle SUPPLEMENTARY BEAMS

GR2_60»65 13.4
(!) ATTENTION (!)
When controlling from the opposite side of the vehicle (it is not possible
visually to check the operation) it is compulsory make sure that no one
is or transits in close proximity to the outriggers.

- Manual extension of the outrigger supports: See Paragraph 13.2 or 13.3.

Note: When the outrigger ram is placed in a vertical or inclined position it
is necessary to position it in a working position during the extension of the
support.
- Outrigger ram descent: position the lever CD on the corresponding position
and then, activate the lever C.
(!) ATTENTION (!)
During the stabilising operations, for each outrigger ram, it is recommen-
ded to DESCENT the outrigger as the last manoeuvre.
(!) 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. 8b).
The stabilization has to be carried out with care and gradually keeping
the vehicle in horizontal levelled condition to prevent springs overloads A
and chassis torsions.
Manoeuvres for re-entry of the crane outriggers and supplemen-
tary outriggers within the overall vehicle width after crane use.
Repeat by inverting the sequence of the operations.
(!) ATTENTION (!)
Keep hands clear of automatic stop device (lever A of the fig. 8c).
fig. 8c
(!) 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. 8c).
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14 CONTROLS TO OPERATE THE CRANE CONTROLS TO

OPERATE THE CRANE
GR2_3_4
14
14.1 Generality
(!) WARNING (!)
Before operating the crane it is compulsory to set the outriggers. (Plate
DE6723 fig. 14)

The crane and hydraulic implements can be manually operated with:

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

The plates reported over each lever define their function in relation to their move-
ment.

fig. 14
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VERSION WITH HORIZONTAL CONTROLS (ground controls or top CONTROLS TO

seat controls OPERATE THE CRANE 14.1
GR2_60»65_3_4
(!) ATTENTION (!)
The sequence of the plates placed on the crane controls may be different.

Make sure that the lever you are going to operate correspond to the control
you selected.

CRANE CONTROLS IMPLEMENTS CONTROLS

1 Additional function

Rotation Inner Outer Extension

boom boom booms Winch Bucket

IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS

2 Additional functions 2 Additional functions 3 Additional functions

Jib Jib Rotator Bucket Jib Jib Winch

outer extension outer extension
boom booms boom booms

(!) Operate the levers smoothly and gradually (!)

When carrying out simultaneous movements of two or more functions,
also related to pump flow and lever travel, it is possible that on reaching
the stroke end of a particular function, an increase in speed of the other
functions will occur.

(!) ATTENTION (!)

While exiting and folding the crane, you must operate from the
distributor side; it is forbidden to operate from the double control
side because of the overall dimensions of the booms. (DE1684A fig.
15) fig. 15
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14.2 Manoeuvres to unfold the crane into a working condition CONTROLS TO

OPERATE THE CRANE 14.2
The plate DE4452A indicates the sequence of the manoeuvres to be carried out to
GR2_3_4
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”).

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

THE DOUBLE CONTROL SIDE

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

By operating the corresponding levers:

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

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

14.3 Manoeuvres to fold the crane into the

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

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

By operating the corresponding levers:

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

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

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

14.4 Manoeuvres to unfold the crane "C" into a

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

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

By operating the corresponding levers:

- Lift the inner boom over the horizontal line.
- Open the outer boom to the “horizontal” position.
- Extend the extension boom sections; the hook of the safety device is free.
- Position the hook on the vertical line above the load.
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14.5 Manoeuvres to fold the crane "C" into the rest condition CONTROLS TO

(only for the crane version “C”)

OPERATE THE CRANE 14.5
GR2_3_4
(!) IT IS FORBIDDEN TO OPERATE FROM (!)
THE DOUBLE CONTROL SIDE

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

By operating the corresponding levers:

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

(on request)
OPERATE THE CRANE 14.6
GR2_60»65_3_4

The column is fitted with a device that informs the driver through a sound/light
signal in the cab, that the inner boom max position allowed during transport on
road has been exceeded.

14.7 Stand-up control station

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

Controls to operate the crane.

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

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

cell L (fig. 15) that automatically prevents the crane from rotating above
the station and activates the flashing of the green light in the different
control panels near the plate DE5775 (fig. 16b).

(!) ATENTION (!) 1

Before accessing the stand-up control station make sure
that the photocell L pilot-light (fig. 15) is turned on and
green; then check its correct functioning: if put your
hand in front of the photocell the pilot-light shall turn
yellow (thus enabling the limitation of the rotation path).
Besides, when entering the stand-up control station,
before starting the crane operation, check that the limita-
tion of the rotation path is active, see the flashing of the
L
green light. fig. 15

Always use the ladder fitted by the installer to gain access to

the control station; the side of the access to the platform is protected by chain
link, always replace the chain onto the structure of the platform after climbing
up.
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The instruction plate DE5643 reported on the selector, identifies the interven- CONTROLS TO
tion sectors of the device (fig. 16). OPERATE THE CRANE 14.7
The operator's presence in the stand-up control station allows only a reduced GR2_60»65_3_4
rotation of the crane, since it is not enabled to pass on the station.

When the operator is not present in the stand-up control station, the crane is
allowed to operate at its max rotation arc (which may differ from 180° indicated
on plate DE5643). In case the operator is not in the stand-up control station
and the rotation arc at the beginning reaches the position above the station, a
red light starts flashing and a buzzer starts ringing until the aforesaid rotation
arc is maintained.
If you operate from the crane dual controls (maximum rotation arc allowed),
take extreme care when lowering the inner boom or while rotating the crane
near the stand-up control station, in order to prevent the crane booms from
clashing against the structure of the stand-up control station.

The column is fitted with a device that informs the driver through a sound/light
signal in the cab, that the inner boom max position allowed during lifting has
been exceeded.

fig. 16 fig. 16b

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15 MANOEUVRES OF THE CRANE LOADS CONTROLS TO

(version with load limiting device)

OPERATE THE CRANE 15
GR2_45»65_3_4_AS_XS

15.1 Generality
(!) Before manoeuvering the load, verify that the working area is suitable
for your crane.

The lifting curves of the capacity plate indicate the maximum load that the
crane can lift at a certain radius and at a certain height. To utilize the maximum
capacity of the crane, it is necessary to position the inner boom as indicated
on the capacity plate. A characteristic which permits the classification of cra-
nes is their lifting capacity or maximum lifting moment. The moment is defined
by the value obtained from the weight of the load to be lifted (kg) by its distan-
ce (meters) from the centerline of the crane rotation.

Crane with load limiting device

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

(version with lifting moment limiting device)

OPERATE THE CRANE 16
GR2_45»65_3_4_AS_XS

16.1 Generality
(!) Before manoeuvering the load, verify that the working area is suitable
for your crane.

The lifting curves of the capacity plate indicate the maximum load that the
crane can lift at a certain radius and at a certain height. To utilize the maximum
capacity of the crane, it is necessary to position the inner boom as indicated
on the capacity plate. During load handling, do not exceed the reach limits
given, or the load indicated on the above mentioned charts. If the limits are
exceeded, the limiting device, allowing all manoeuvres, which reduce the lifted
load within the permitted reach limits and forbid all other manoeuvres, will be
immediately activated.

Lifting moment limiting device

A characteristic which permits the classification of cranes is their lifting capa-
city or maximum lifting moment. The moment is defined by the value obtained
from the weight of the load to be lifted (kg) by its distance (meters) from the
centerline of the crane rotation.
The device called “lifting moment limiting device” preserves the crane structure
from overloads, as it prevents any movement which increases the value of the
moment up to the maximum established value.
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16.2 "Electronic" lifting moment limiting device CONTROLS TO

OPERATE THE CRANE 16.2
This device utilises an electro-hydraulic system managed by an electronic GR2_45»65_3_4_SE
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 exceedable, determine the intervention levels and provide the data for
setting the device.

The pressure values detected in the lifting rams are turned into electric signals
by the transducers, and sent to the electronic logic of the device which deter-
mines the locking or unlocking of the controls concerned, according to the
horizontal position of the crane outer boom (mercury level switch); only the
controls allowing a reduction of the overload are enabled, while those increa-
sing it are disabled.

The device features an electro-hydraulic control that does not allow the set
value to be exceed, by deactivating the controls (levers in neutral position)
commanded by the limiting device. When the controls are released (levers in
neutral position) it's this electronic logic that handles which manoeuvres are
disabled, according to the position of the crane outer boom and in overload
condition, by sending electric signals to special micro-switches placed on the
elements of the distributor.

(!) ATTENTION (!)

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

16.3 Control panels

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

A - green, yellow and red led band signalling the load percentage as compared
to the capacity plate A
Green light load between 0 and 90%
Yellow light load between 90 and 100% C B
Red light load higher than 100% C
B- Display
G
H
C- Control buttons (4 control buttons) F
D- “STOP” button D
E- Audible alarm push button (danger) E
F- Green warning light (electric on)
G- Control button for XP fig. 17
H- Control button for the temporary exclusion
of the lifting moment limiting device

Layout of the control panel (fig. 18) (if fitted) placed on the double control side and
on top seat (version with hand-cable controls)

D- “STOP” button
E- Audible alarm push button (danger)
F- Green warning light (electric on)
G- Control button for XP
H- Control button for the temporary exclusion
of the lifting moment limiting device
fig. 18
If the green warning light F comes on, it confirms that the electric circuit is active.

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

desactivated.

If the yellow led A comes on during load handling, 90% of the capacity (lifting
moment) has been reached.
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If during operation the red led B comes on, the activation value of the lifting CONTROLS TO
moment limiting device has been reached. OPERATE THE CRANE 16.3
GR2_45»65_3_4_SE
Any hidden danger situation for persons must be audibly alarmed by pressing
the push button E.

When there are serious, imminent and dangerous conditions for persons and
things during load handling, operate on the STOP button, which isolates all
crane functions.

Display on the control panel

When the electric feeding has been activated (after the version’s number of the
software) the pressure in the inner, outer ram and the jib and the percentage
of load on the winch are displayed.

In relation to the view chosen like standard, when you start the radio remote
control the pressure values are displayed in:
- ”bar” if on the display, on the left of the values, no symbol is present.
- ”daPsi” if on the display, on the left of the values, the symbol is present.
*
- By pushing the button the percentage values of pressure in the inner,
outer ram and the jib and the percentage of load on the winch are displayed.
By pushing a second time the button the pressure values in the inner,
outer and jib rams movement in the measurement unit non standard and the
percentage of load on the winch are displayed.
By pushing again the button you return to the initial display.

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

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

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

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16.4 Load handling CONTROLS TO

OPERATE THE CRANE 16.4
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 necessary to return all the
levers to the neutral position.
fig. 20a
(!) ATTENTION (!)
During load handling with the crane and with the WITHOUT HYDRAULIC JIB
crane and hydraulic jib, in vertical configuration or close, the operator must
strictly refer to the loads indicated on the capacity plates since the limiting
device shows to be not particularly sensitive with vertical lifts.
Crane with activated limiting device by the intervention of the crane or the
hydraulic jib (overload condition) and with outer boom of the crane above the
horizontal line fig. 20a-20b
Manoeuvres not allowed:
- Inner boom descent fig. 20b
- Outer boom descent
- Extension of the crane extension boom sections (*)
- Lift and descent of the hydraulic jib
- Extension of the extension booms section of the jib
- Winch rope lift
- Movement of the hydraulic accessories (**)
NOTES: (*) If the overload condition has been activated by the hydraulic extension, the
extension of the crane boom sections is permitted.
(**) It is permitted only when coupled with permitted manoeuvres.
Manoeuvres allowed: all the manoeuvres that bring the load closer to the column and
therefore the overload
- Rotation in both directions
WITH HYDRAULIC JIB
- Inner boom lift
- Outer boom lift
- Re-entry of the crane extension boom sections
- Re-entry of the jib extension boom sections
- Winch rope descent
Crane with activated limiting device by the intervention
of the crane or the hydraulic jib (overload condition)
and with outer boom of the crane under the horizontal
line fig. 20c-20d
Manoeuvres not allowed:
-- Inner boom lift
- Outer boom lift
- Extension of the crane extension boom sections (*)
fig. 20d
- Lift of the hydraulic jib
- Extension of the extension booms section of the jib
WITHOUT HYDRAULIC JIB
- Winch rope lift
- Movement of the hydraulic accessories (**)
NOTES: (*) If the overload condition has been activated by the hydraulic
extension, the extension of the crane boom sections is permitted.
(**) It is permitted only when coupled with permitted manoeuvres.
Manoeuvres allowed: all the manoeuvres that bring the load closer to the
column and therefore the overload fig. 20c
- Rotation in both directions
- Inner boom descent
- Outer boom descent
- Re-entry of the crane extension boom sections
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- Descent of the hydraulic jib CONTROLS TO

- Re-entry of the extension booms section of the jib OPERATE THE CRANE 16.4
- Winch rope descent GRU FASSI
Crane with activated limiting device (overload condition) by the intervention
of the load limiter of the winch
Manoeuvres allowed:
- Rotation in both directions
- Re-entry of the crane extension boom sections
- Re-entry of the jib extension boom sections
- Winch rope descent
Manoeuvres not allowed:
- all other movements
Crane without load applied and activated limiting device
The limiting device may intervene also during loadless crane operation following a pres-
sure peak provoked by the attainment of the stroke end of the lifting ram at high speed. In
this condition, reactivation of the crane commands by performing one of the manoeuvres
is allowed by the system. If the limiting device intervenes when both the lifting rams are
open and at stroke end, and the crane extension booms are fully folded, it is not possible
to reactivate the commands, since the permitted manoeuvres (arm lifting and extension
fully retracted) cannot be carried out, because of the actual configuration of the crane
(outer boom above the horizontal). The device, in this case, allows the descent manoe-
uvres since it verifies the it was a peak pressure inside the lifting rams; the crane being
loadless, thus these manoeuvres will be allowed.
Temporised exclusion device of the lifting moment limiting device
The activation of the exclusion device is permitted when the limiting device is activated
and only in the case when it is impossible to carry out any of the allowed manoeuvres.
This generally occurs when handling heavy and bulky loads, with the outer boom
above the horizontal and the extension boom sections almost retracted.
(!) ATTENTION (!)
The activation of the exclusion system for the lifting moment limiting device
can ONLY be operated when the extension booms of the crane and of the
hydraulic jib (when fitted) are fully retracted.
The activation button of the excluding device, only in the case of the crane, are
to be activated as follows:
- retracted the crane extension booms until stroke end and momentarily pressurise;
- maintain the command for the extensions boom until the red led of the button LMI
placed on the control panel begins to flash;
- continue to keep the command for the extensions boom and press the exclusion
device button, the flashing red light becomes fixed;
- release the lever commanding the extensions booms.
The permitted manoeuvre is the descent of the outer boom in order to bring it under
the horizontal; remember that you have at your disposal five (5) seconds from the
command operation to carry out the descent. After such period of time, wait at least
one (1) minute in order to be allowed to carry out the manoeuvre once again.
The activation button of the excluding device, only in the case of the hydraulic jib,
are to be activated as follows:
- retracted the extensions booms of the hydraulic jib until stroke end and momentarily
pressurise;
- maintain the command for the extensions of the hydraulic jib boom until the red
led of the button LMI placed on the control panel begins to flash;
- release the lever commanding the extensions booms of the hydraulic jib;
- within 3 seconds from releasing the lever commanding the extensions booms of
the jib, retracted the extensions booms of the hydraulic jib until stroke end and
momentarily pressurise (the red led turns off as soon as the re-entry begins);
- maintain the command for the extensions boom until the red led of the button
LMI placed on the control panel begins to flash;
- continous to keep the command for the crane extensions boom press the
exclusion device button, the flashing red light becomes fixed;
- release the lever commanding the crane extensions booms.
The permitted manoeuvre is the descent of the outer boom in order to bring it under
the horizontal; remember that you have at your disposal five (5) seconds from the
command operation to carry out the descent. After such period of time, wait at least
one (1) minute in order to be allowed to carry out the manoeuvre once again.
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(!) ATTENTION (!) CONTROLS TO

Activation of the exclusion device of the lifting moment limiting device. OPERATE THE CRANE 16.5
GRU FASSI
When the operator uses this device, it means that he wishes to over-
ride the lifting moment lifting device in order to make some manoeu-
vres (which would be impossible with the device active) that bring the
moment to within the maximum level, but involve an overload condition.
In such an emergency condition (where the lifting moment limiting devi-
ce has been disabled), the operator, who is the main responsible for the
machine safety, must:
- carefully consider the manoeuvres required to return to normal working
conditions: it is however compulsory to effect the re-entry of the exten-
sion booms at first,
- calmly and carefully assess the type and scale of the hazards arising
from these manoeuvres and the possible reaction of the crane (tipping
over, frame overload, uncontrolled fall of the load due to a hydraulic
system overload etc.);
- make all movements as slowly as possible to reduce the dynamic
overload to the minimum.

16.5 Lifting moment limiting device for two working

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

(!) ATTENTION (!)

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

16.6 Rotation limiting device

When a sector of the working area exists in which the stability is insufficient (for
example in the area in front of the cab) the permitted arc of rotation is limited by
means of an adjustable electro-hydraulic device which only allows operation within
the safe area. (Warning: persist in the operation!)
When exceeding the “safe area” the rotation limiting device only allowing:
- the opposite rotation
- the manoeuvres allowed by the limiting device in relation to the position of the
outer boom (positioned over or under the horizontal line).
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If a reduction of capacity is necessary because of insufficient stability of the CONTROLS TO

complete unit, new capacity plates must be fixed giving the derated capacity in OPERATE THE CRANE 16.7
accordance with the final stability test. GRU FASSI

(!) ATTENTION (!)

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

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

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

If the fault cannot be resolved, you must immediately go to a FASSI autho-

rised Center after bringing the crane to its the rest position in relation to the
conditions explained in the paragraphes 15.7.2, 15.7.3.

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

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

All the eventual problems that the electronic device can have are shown on the
display of the control panel and they create the stop of all crane functions. The
visualisation of the alarm must be reset pushing the button l.m.l.d. exclusion on
the main box control panel, which bring again the display in the original screen
showing the pressures only if the problem has been solved. As consequen-
ce of this, when appear an alarm signal it is necessary to solve the problem
because only in this case will be possible to reset the display and reactivate
the crane working.
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ALARM CODES: CONTROLS TO

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

Only for crane with slew ring:

30 - inconsistency of the rotation lever movement alarm

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

MESSAGES EXPLANATION

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

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

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

"STOP BOOM OUT" - warning for the interruption of the extension boom exit
because of a sudden variation of the cable tension.

"STOP JIB 25°" - warning of not permitted activation of the lifting functions
because of the activation of the maximum vertical opera-
tivity of the jib when it is complete with the 25° angle
increasing.

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

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

OPERATE THE CRANE 16.7.1
CODE REMEDY GRU FASSI
01 Take off the tension to the system and take on again the tension. If the
problem remains, take off the tension to the system again, take on the
tension and wait 12 minutes (12 minutes waiting time is a compulsory
condition and needs to be checked with a watch), take off the tension
to the system again, take on again the tension.
If the problem remains, you must immediately go to a FASSI
authorised Center.
02 Check the connector of the pressure transducer.
If the problem remains, you must immediately go to a FASSI
authorised Center.
04 See code 02.
06 See code 02.
08 Check if the red light on the proximity sensor is off and verify if
the metallic band is rightly positioned.
09 See code 08.
10 Check that the connector of the mercury sensor level is not damage.
If the problem remains, you must immediately go to a FASSI
authorised Center.
11 You must immediately go to a FASSI authorised Center.
12 See code 11.
14 See code 11.
15 See code 11.
16 See code 11.
17 See code 11.
18 See code 11.
19 See code 11.
20 See code 11.
21 Replace the 10A fuse at the nearest workshop after removing
the carter and the cover of the main panel FX000. (See electric
schematic Par. 5)
22 See code 11.

Only for crane with slew ring:

30 See code 11.

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

MESSAGES REMEDY

"WINCH OFF" Place the distributor bank lever controlling the winch in
neutral position.
"WINCH CAL.ERROR" See code 11.
"STOP BOOM OUT" Place the distributor bank lever controlling the extension
booms in neutral position. If the warning appears when
the winch cable lifting stroke end is not reached, place in
any case the lever in neutral position and then restart to
operate.
"STOP BOOM UP" Lifting functions not available; are authorized only descent
functions.

To verify the right working of the differents input it is possible to use the display
in the "INPUT" menu.
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16.7.2 Temporary OVERRIDE-REACTIVATION for the CONTROLS TO

crane functions with standard distributor

OPERATE THE CRANE 16.7.2
GR2_45»65_3_4
- In case of an electrical failure or of the appearance of the signal “ALARM”
on the display B of the control panel of the lifting moment limiting device:

Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).

On the distributor it has been installed an electro-valve with a manual locking func-
tion (fig. 22) which allows to reactivate all the crane functions in case of absence of
the electric power. Only in these conditions it is permitted to remove the lead seal
which protects the device. Push the button and turn it into the clockwise sense (fig.
22a pos. 1-2); the button stays in stable and closed position.
fig. 22
(!) When the electric power is restablished, remember to put the button
in its original position, turning it into the anti-clockwise sense.
(fig. 22a pos. 3-4)

(!) ATTENTION (!)

Activation of the reactivation button.

This activation prevents the operation of the lifting moment limiting devi-
ce, consequently, the operation under such conditions can involve an
overload condition. In such an emergency condition (where the lifting
moment limiting device has been disabled), the operator, who is respon-
sible for the machine safety, must:
- carefully consider the manoeuvres required to return to normal working
conditions: it is however compulsory to effect the re-entry of the extension
booms at first,
- calmly and carefully assess the type and scale of the hazards arising
from these manoeuvres and the possible reaction of the crane (tipping
over, frame overload, uncontrolled fall of the load due to a hydraulic
fig. 22a
system overload etc.);
- make all movements as slowly as possible to reduce the dynamic
overload to the minimum.

After such emergency operations and prior to re-use of the crane, you must
immediately go to FASSI authorised Center for testing the structure and re-
sealing of the device.

16.7.3 OVERRIDE - REACTIVATION lever for the crane

functions (with Danfoss distributor)
- In case of an electrical failure or of the appearance of the signal “ALARM”
on the display B of the control panel of the lifting moment limiting device:

Firstly remove the protection guard. Then unscrew the fixing screws (13 mm
hexagonal spanner).

On the distributor it has been installed an emergency tap lever (fig. 23) to be
used in the event of a black-out, electrical or hydraulic malfunctions.
Only In these situations it is permitted to remove the lead seal placed on the
tap lever and place it in the closed position.

(!) When the electric power is restablished, remember to put the button
fig. 23
in the opened position.
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(!) ATTENTION (!) CONTROLS TO

Activation of the emergency lever. OPERATE THE CRANE 16.7.3
GR2_45»65_3_4
This activation prevents the operation of the lifting moment limiting device,
consequently, the operation under such conditions can involve an overload
condition. In such an emergency condition (where the lifting moment limiting
device has been disabled), the operator, who is responsible for the machine
safety, must:
- carefully consider the manoeuvres required to return to normal working
conditions: it is however compulsory to effect the re-entry of the exten-
sion booms at first,
- calmly and carefully assess the type and scale of the hazards arising from
these manoeuvres and the possible reaction of the crane (tipping over,
frame overload, uncontrolled fall of the load due to a hydraulic system
overload etc.);
- make all movements as slowly as possible to reduce the dynamic overload
to the minimum.

After such emergency operations and prior to re-use of the crane, you must
immediately go to FASSI authorised Center for testing the structure and re-sea-
ling of the device.

(!) Interferences with the valves or removal of the lead seal release the
FASSI GRU IDRAULICHE
from any responsibility and invalidate the warranty.

(!) ATTENTION (!)

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

(!) CAUTION DANGER (!)

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

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

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

(!) ATTENTION (!)

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

Do not use water to estinguish fire! DE1680

DE1679 DE1680
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17 USE OF IMPLEMENTS USE OF IMPLEMENTS

GRU FASSI 17

17.1 Generality
The crane, in load condition H1B3, can be provided with implements such as:

- Manual extensions
- Winches
- Hydraulic extensions
- Personnel baskets
- Clam ‘shell buckets
- Augers

(!) When using an implement it is always necessary to check that its weight,
dimension and capacity is matched to the crane performances.
For further information please refer to FASSI GRU S.p.a.

Warning and norms for crane use also apply for hydraulic implement use.

Before using a personnel basket it is necessary to provide the crane with the
safety devices requested by the local norms in force, EN280 in Europe, and
prior to use of the crane it has to be tested and inspected in accordance with
the local legal requirements.

(!) When the crane is fitted with implements or laid on the truck body it is necessary
to check they are locked to assure the impossibility of accidental movements and
that the led signalling maximum obstruction in height (if fitted) confirms the cor
rect positioning of the crane.

(!) The crane can operate, intermittently and not continuously, with lifting
devices other than the hook, only on loose and light materials (not on
scrap iron).

(!) ATTENTION (!)

In case of using the crane with lif-

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

The dimensions and the capacity of

the implements must be proportio-
ned with crane performances.

(!) WARNING (!)

CRUSHING (F) OR PUSH (F) MANOEUVRES ARE NOT PERMITTED.
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17.2 Hydraulic connections for implements - supple- USE OF IMPLEMENTS

mentary hoses. GRU FASSI 17.2

(!) WARNING (!)

To ensure that the control corresponds to the implement movement, hydraulic
connections are symmetrically fitted with coupling unions. Never invert such
positions: movements inversion as well as operating difficulties or unusual
overload with implement itself could occur.

NOTE
When using coupling unions it is necessary to verify that there is no trace of
soil, curt etc. on the unions and inside the seats so as to avoid the oil contami-
nation and consequently wear the tightening “ surface” of unions or ram seals.

17.3 Oil cooler (heat exchanger) (if fitted)

The crane is equipped with an oil cooler (air-oil heat exchanger) to prevent
damage caused by an excessive increase of the oil temperature.

NOTE
When working in a low temperature climate, we recommend to bring the
hydraulic oil up to working temperature prior to starting work, This is
best done by operating the crane thru all its functions ram stroke end.

(!) WARNING (!)

The heat exchanger openings must be kept clear and clean. At no time should
it be covered.
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18 MANUAL EXTENSIONS USE OF IMPLEMENTS

GR2_45»65_3_4_5_SE 18
18.1 Generality
These are additional extensions, which are placed in the hydraulic extensions of
the crane and of the hydraulic jib and secured by locking pins.
Manual extensions have a maximum capacity independent from the crane confi-
guration as shown on the capacity plates.

(!) ATTENTION (!)

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

(!) ATTENTION (!)

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

18.2 Lifting moment limiting device “ELECTRONIC” for

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

GR2_45»65_3_4_5_SE 18.2
Figure A (left side) Figure B (right side)

selector on A “+” “ENTER” “INDEX”

HOW TO PREDISPOSE THE USE OF MECHANICAL EXTENSIONS ON CRANE

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

1. Initial display (Fig. 1)

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

fig. 1 fig. 1

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

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

fig. 2 fig. 2

Use the "+" button to select JIB if in the actual configuration the manual exten-
sions are mounted on JIB or CRANE if the manual extensions are mounted on
the crane.
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3. Message “M1 - M2 - M3” (fig. 3) USE OF IMPLEMENTS

After having pressed the above mentioned keys, the message illustrated in GR2_45»65_3_4_5_SE 18.2
Fig. 3 will be displayed.

fig. 3 fig. 3

At this point, through the "+" button, select the correct number of the manual exten-
sion at the moment in use (M stands for manual and 1, 2 and 3 indicate the number
of the manual extensions). Select the number of the manual extension you want; that
number starts blinking. You can select only the manual extensions that have been
installed: i.e. if only one manual extension is installed, by pressing the "+" key, only the
M1extension will start flashing. To confirm your choice, press once the “F1” key (control
panel) or “ENTER” (radio-remote control); you'll access the section dedicated to the
system configuration.

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

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

fig. 4 fig. 4
If you press the "ENTER" key with the manual extensions mounted on the
jib, the screen of Fig. 4 will be displayed.
Therefore we can choose the most convenient configuration among the
following:
K1 Outer booms of the crane totally re-entered and jib extensions as you like
K2 Outer booms of the crane as you like and jib extensions totally re-entered
K3 Outer booms of the crane totally extended and jib extensions as you like
K4 Outer booms of the crane as you like and jib extensions totally extended
Select the desired configuration using the * button to move among the various
options. Confirm your selection by pressing the “F1” (control panel) or “ENTER”
(radio-remote control) key. If the hydraulic jib boom is not at its stroke end, the
message at point 3 will be displayed; otherwise the message "F1 TO START" is
visualised.

5. Message “FC P2” (fig. 5)

Note: do not hang any load on the hook.
This means that the outer ram must be positioned at its stroke end (if it is
already in that position this message won't appear), using the lever until the
next screen is displayed.

fig. 5 fig. 5
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6. Message “FC P3” (fig. 6) USE OF IMPLEMENTS

[paragraph to read only in case of manual extensions installed on Jib and GR2_45»65_3_4_5_SE 18.2
not on Crane]
Note: do not hang any load on the hook.
This means that the jib outrigger must be positioned at its stroke end (if it is
already in that position this message won't appear), using the lever until the
next screen is displayed.

fig. 6 fig. 6

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

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

fig. 7 fig. 7
8. Message “UP P1” (see fig. 8)
Note: do not hang any load on the hook.
It requires the activation of the inner boom lifting to eliminate an overpressure at
the lifting ram bottom (the manoeuvre is activated but the crane does not move
since all the movements are disabled).
Note: set the lever of the inner ram at its stroke end to simulate the lifting
and keep it like this for at least three seconds.

fig. 8 fig. 8

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

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

fig. 9 fig. 9
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10. Message “LOAD OK” (fig. 10) USE OF IMPLEMENTS

This message confirms that the load does not exceed the lifting limits of the GR2_45»65_3_4_5_SE 18.2
crane and of the manual extension selected.

fig. 10 fig. 10

CLOSING OF THE PROCEDURE

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

selector on A “INDEX”

Figure C Figure D
For an overall view of the procedure, we attach the diagrams showing all the pas-
sages and messages that can be displayed during the procedure according to the
various situations that may take place.

The script "EXIT" in the block diagram allows to exit the procedure.

FURTHER MESSAGES
After releasing the lever in neutral position you can find the following messages

If you keep pressed the "F2" key “F2” on the control panel or “LMI” on the push-
button panel, it is possible to have an indicative evaluation of the weight applied on
the hook (fig. 11).

fig. 11 fig. 11

a. “PRESSURE ERROR” (see fig. 12)

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

fig. 12 fig. 12
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b. “NO LOAD” (fig. 13) USE OF IMPLEMENTS

In this case the load exceeds the max lifting value of the selected manual GR2_45»65_3_4_5_SE 18.2
extension (it could still be on the ground). Unhook the load since it cannot
be lifted using the selected manual extension. As in the preceding case, if
you keep pressed the "F2" key, it is possible to have an indicative evalua-
tion of the weight applied on the hook (fig. 11).

fig. 13 fig. 13

c. “NO SPEED” (fig. 14)

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

fig. 14 fig. 14

d. “NO LOAD CRANE!” (fig. 15)

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

fig. 15 fig. 15
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Electric schematic - crane with manual extensions USE OF IMPLEMENTS

GR2_45»65_3_4_5_SE 18.2
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Electric schematic - crane with jib and manual extensions on jib USE OF IMPLEMENTS
GR2_45»65_3_4_5_SE 18.2
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19 CONTROLS TO OPERATE THE HYDRAULIC USE OF IMPLEMENTS

IMPLEMENTS OF THE CRANE GR2_60»65_3_4_AS 19

IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS

1 Additional function 2 Additional functions

Jib Jib
Winch Bucket outer extension
boom booms

IMPLEMENTS CONTROLS IMPLEMENTS CONTROLS

2 Additional functions 3 Additional functions

Rotator Bucket Jib Jib Winch

outer extension
boom booms

The plates placed over each lever define their function in relation to their movement.

(!) ATTENTION (!)

The sequence of the plates placed on the crane controls may be different.

Make sure that the lever you are going to operate correspond to the control you
selected.
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21 WINCH (if fitted) USE OF IMPLEMENTS

GRU FASSI 21
21.1 Generality
The winch is made of a drum that can rotate by means of a hydraulic motor, on a
structure fixed on the crane. The rotation of the drum on which the cable winds is
achieved by a hydraulic motor controlled by a safety check valve connected to the
crane circuit. A parking brake integrated to the motoreducer group hold the load
in position when the winch control lever is in neutral position.

Nomenclature of winch unit (fig. 23)

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

(!) ATTENTION (!)

Check the condition of wire rope.

(!) On winches not equipped with cable layer, check the rewinding of the
cable on winch drum proceeds regularly and without overlapping: it
is suggested to rewind the cable only if it is sufficiently taut.

Do not rotate the crane before the load is lifted. Lift the load vertically using the
cable and not the boom in order to avoid swinging the load. With the suspen-
ded load rotate slowly and with care checking the stability of the vehicle.

21.2 Winch for crane

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

Manufacturer mark ...

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

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

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

by a plate, not related to the crane capacities which can also be lower.
Consequently avoid to lift, with the winch, heavier loads than those allowed
by the crane capacity plate.
Note: We do not recommend using the winch with load moving (winch in
or out) at the same time as the extension booms or the crane and
hydraulic jib (if fitted), since it accelerates the wear of the extension
guide pads reducing their life to one third compared to a standard
application.
The couple limiter, installed on the winch structure, prevents that on the
cable, can be created a load major to the value of maximum line at the
4th layer, quiescing all the crane controls.
(!) Under no circumstances interfere with the limiter device adjustment.
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21.2.1 Winches equipped with a mechanical stroke end USE OF IMPLEMENTS

device GRU FASSI 21.2.1

(!) ATTENTION (!)
The end stroke condition takes place when the block takes contact with the pulley struc-
ture. The operator must stop the manoeuvre before the block rotates the pulley completely
with consequent activation of the load cell on the winch. Such end stroke device shall be
used only under emergency conditions and not as a simple end stroke interrupter.
The mechanical stroke end device combined with the winch limiter prevents the hook
bracket (or pulley/snatch block) from hitting the fixed pulley when lifting or when extending
the extension booms, and thus from damaging the cable.
When the winch limiter is activated, all the crane functions are disabled.
Manoeuvres allowed:
- Rotation in both directions
- Re-entry of the crane extension boom sections
- Re-entry of the extension booms sections of the jib
- Winch rope descent
Manoeuvres not allowed:
- all other movements
When unwinding, an electric device maintains at least three (3) turns of the lifting cable
wound around the winch drum on activation the following controls are desactivated.
Manoeuvres not allowed: fig. 26
- Winch rope descent
Manoeuvres allowed:
- all other movements
(!) ATTENTION (!)
Limit the exit speed of the extension rams when, during the lifting, the hook bracket (or pul-
ley/snatch block) is next to the fixed pulley, in order to avoid unnecessary stress to the cable.
(!) ATTENTION (!)
When the hook bracket (or pulley/snatch block, in case of double or triple line) and the fixed
pulley are very close, and the operator needs to manoeuvre in their proximity (i.e. operations
like load hook-up, arms folding, etc), we recommend to always stand side on with respect to
the pulley plan (never in front or at the back) and to operate the crane at a low speed, since
the contact (especially without load) can result in rapid and violent rotations of the hook
group (from the fig. 26 to the fig. 27).
(!) ATTENTION (!)
The end stroke condition takes place when the block takes contact with the pulley struc-
ture. The operator must stop the manoeuvre before the block rotates the pulley completely fig. 27
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.

* * *
SINGLE LINE DOUBLE LINE TRIPLE LINE QUADRUPLE LINE

CORRECT POSITION

* FOR THE PULLEY AND

THE PULLEY BLOCK
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21.3 Generality USE OF IMPLEMENTS

(version with load limiting device) GRU FASSI 21.3

The winch is made of a drum that can rotate by means of a hydraulic motor, on a
structure fixed on the crane. The rotation of the drum on which the cable winds is
achieved by a hydraulic motor controlled by a safety check valve connected to the
crane circuit. A parking brake integrated to the motoreducer group hold the load
in position when the winch control lever is in neutral position.

Nomenclature of winch unit (Fig. 23)

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

(!) ATTENTION (!)

Check the condition of wire rope.

(!) On winches not equipped with cable layer, check the rewinding of the
cable on winch drum proceeds regularly and without overlapping: it
is suggested to rewind the cable only if it is sufficiently taut.

Do not rotate the crane before the load is lifted. Lift the load vertically using the
cable and not the boom in order to avoid swinging the load. With the suspen-
ded load rotate slowly and with care checking the stability of the vehicle.

21.4 Winch for crane

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

Manufacturer mark ...

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

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

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

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

device GRU FASSI 21.4.1

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

When the load exceeds the winch nominal load by 20% the exit of the exten-
sion boom sections is deactivated.

When unwinding, an electric device maintains at least three (3) turns of the
lifting cable wound around the winch drum on activation the following controls
are desactivated.
Manoeuvres not allowed:
- Winch rope descent
Manoeuvres allowed:
- all other movements

(!) ATTENTION (!)

Limit the exit speed of the extension rams when, during the lifting, the hook fig. 26
bracket (or pulley/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 recom-
mend to always stand side on with respect to the pulley plan (never in front or
at the back) and to operate the crane at a low speed, since the contact (espe-
cially without load) can result in rapid and violent rotations of the hook group
(from the fig. 26 to the fig. 27).

(!) ATTENTION (!)

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

* * *
SINGLE LINE DOUBLE LINE TRIPLE LINE QUADRUPLE LINE
CORRECT POSITION

* FOR THE PULLEY AND

THE PULLEY BLOCK
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22 MAINTENANCE INSTRUCTIONS MAINTENANCE

INSTRUCTIONS 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.

Any maintenance operation must be carried out with the crane power source
turned off. (in case of fixed mounting with hydraulic power pack, the electric
motor has to be turned off).

Do not place limbs, fingers or any other parts of anatomy into areas of the
crane, which present possibilities of shearing, without having blocked such
parts of the crane.

Do not weld, drill or grind any part of the crane without the Manufacturer’s
authorisation.
fig. 29
Do not weld the fixing rods of the crane (see plate
DE1574 fig. 29)
TIRANTI: NON SALDARE!
When repairs to, or checks of, the hydraulic circuit FIXING ROD: DO NOT WELD!
and of the rams are carried out, it is very important TIRANTS: NE PAS SOUDER!
not to use, or be in the proximity of, materials which ZUGSCHRAUBEN: NICHT SCHWEISSEN!
can damage the circuit or contaminate the hydrau- DE1574
lic oil eg. metal shavings, sand or dust.

Do not use the high pressure washing on the controls (deviators, distributors,
double controls, hand cable controls...), on the electronic components (boxes,
control panels...), on the tanks.

Never use detergents, petrolsol or inflammable liquids, always use non flam-
mable or non toxic liquids.

To avoid down time, it is recommended to periodically carry out the following

checks.
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22.2 Timer (fig. 29a) (if fitted) MAINTENANCE

INSTRUCTIONS 22.2
The control panel of the “electronic” lifting moment limiting device, placed GRU FASSI
next to the distributor of the crane, features an alphernumeric readout for
displaying the date, the activation time expressed in hours-minutes of the
electric control panel ("Partial Time" and "Total time") or the working time of
the crane whilst being operated via the control levers ("Work Time").

How to view the date

Press button C2 (clock/-) to have the current date visualized on display B. Fig. 29.

Partial time

How to view the partial time of the electric panel; which

can be reset.
- Keep button C2 (-) pressed until you read “Time” on
display B.
- Press button C1 (+) until you see "Partial time".
- Press button C3 (enter) to view the time.

How to reset the "Partial time".

To start a new count perform the following:

- Keep button C2 (-) pressed until you read "Time" on
display B.
- Press button C1 (+) to read "Partial time" on the
display.
- Press button C1 (+) again to read "Total time" on the
display. Fig. 29a
- Press button C1 (+) again to read "Work time" on
the display.
- Press button C1 (+) again to read "Reset partial" on
the display.
- Press button C3 (enter) to read "Enter to confirm" fig. 29a
on the display.
- Press button C3 (enter) again; the timer is reset and
it will start recording again.

Total time

How to view the total activation time of the electric panel; this cannot be reset.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C3 (enter) to visualize, for about 5 seconds, the total time
expressed in hours and minutes.

Work time

How to view the work time which is the actual time recorded whilst a crane
operating lever/function is being activated.
- Keep button C2 (-) pressed until you read "Time" on display B.
- Press button C1 (+) to read "Partial time" on the display.
- Press button C1 (+) again to read "Total time" on the display.
- Press button C1 (+) again to read "Work time" on the display.
- Press button C3 (enter) to view, for about 5 seconds the work time of the
crane expressed in hours and minutes.
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22.3 After every 8 working hours or at the end of every MAINTENANCE

working day INSTRUCTIONS 22.3
GRU FASSI
- Check that all safety devices are efficient.
- Check the level of the hydraulic oil in the tank.
- Check all the components of the hydraulic circuit for possible leaks.
- Check that the control and the oil diverter levers can easily be positioned;
they must show no signs of forcing.
- Check the condition of shackles, hooks, wire ropes and any other lifting equipment.

22.4 After every 40 working hours or after every

fig. 30
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-
tion and pressure hoses.

NOTE The filters of fibre or paper can not be cleaned, they must be replaced.

Cleaning of the wire mesh filter on the tank (oil return to the oil-tank) fig. 31.
- Unscrew the security bolts of the filter cover 1 and remove it.
- Extract the cartridge, clean by flushing with a non flammable, non corrosive fig. 31
and non toxic solvent (gas oil or other). Thoroughly dry the filter inside and out
(do not use compressed air).
- Check if the cartridge has collapsed; if so, replace it!
- Remove the filter body 3 and clean it.
- Re-assemble the filter body and the cartridge: check the sealing of the ‘O’ ring
4-5-6; in case, replace it!

NOTE Take care that no contaminated material passes into the tank.

Replacement of the filter on the delivery line (before the distributor) fig. 32.
- When the visual indicator becomes red, replace the cartridge.
- Unscrew with a suitable spanner the filter body (1) from the head (2). fig. 32
- Remove the cartridge (3) and clean inside the holder (1).
- Insert a new cartridge and re-assemble the filter body into the head checking
the seal (4). MAX
MIN
Check the oil level in the tank with the crane in the folded position and with the
outriggers (crane and supplementary) fully re-entered. The oil level must not
exceed the maximum or be lower than the minimum (fig. 33).
fig. 33
Top up using hydraulic oil with the same characteristics as those indicated in the
table at paragraph 23.

The following lubricators have been centralized and gathered in a case (fig. 33a)
positioned on the base (crane distributor side):
- rack guide shoe - rotation,
- upper and lower bush of the column - column support,
- rack group - column gear,
- column support group - pendulum beam.

(!) WARNING (!)

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

(!) WARNING (!)

Centralized lubrication shall not be used when room temperature is below fig. 33a
-10°C / -20°C.
All the lubricators mounted on the crane are protected by a plastic cap so to avoid
the oil contamination.
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22.5 After every 100 working hours or more frequently in MAINTENANCE

case of more intensive utilisation

INSTRUCTIONS 22.5
GRU FASSI

WITH RACK
Periodically grease the points indicated on the crane (fig. WITH RACK
34) (and on the hydraulic jib, when fitted, fig. 35) paying
particular attention to the points not easily detected. For the
sliding sections of the outrigger supports and of the exten- fig. 35
sion booms guide shoes made from a special material have
been fitted: to ease their movement it is recommended to
smear a light film of grease on them, taking care that the
surfaces of the extension booms are free from impurities
such as sand etc. Top up using hydraulic oil with the same
characteristics as those indicated in the table at paragraph
23.

WITH SLEW RING

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

22.6 After every 500 working hours or after every 6

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

Table of the tightening torques of the fixing rods of the crane on the vehicle
From “C0404 Kit for crane fixing”.

D. Fixing Tightening
rods torque = Nm
M22x1,5 300
M24x2,0 400
M27x2,0 600
M30x2,0 471
M33x2,0 1200
M39x3,0 1800
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WITH SLEW RING MAINTENANCE

- of the slew gear screws (bolts M20 Class 12.9: Thightening torque = 620 Nm) INSTRUCTIONS 22.6
WITH RACK GRU FASSI
- of the securing bolts for the ram pins and of all the other bolts and screws, where
the tightening torque is not expressly indicated, consult the following table in order
to find it’s value according to the bolt diameter and class.

Table of the bolts tightening torque, in general, with average friction value (0,15) and
average-good tightening accuracy (C).

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

Diameter Class 8.8 Class 10.9 Class 12.9

Bolt = D Torque = Nm Torque = Nm Torque = Nm
3 1,06 1,56 1,83
4 2,44 3,58 4,19
5 4,83 7,10 8,30
6 8,30 12,30 14,30
8 20 29 35
10 40 59 69
12 69 102 119
14 111 163 191
16 173 255 298
18 239 352 412
20 339 499 584
22 466 685 802
24 584 858 1004
27 865 1271 1487
30 1173 1723 2016
33 1594 2342 2740
36 2046 3006 3517
39 2658 3905 4570
WITH SLEW RING
Check the rotation control motoreducer oil level. Fig. 34 1
- 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 2
via the mouth (bleed plug).
- The correct level is reached when oil starts to escape from the threaded hole in plug (2).
- Check the state of wear of the O-rings (replace if necessary) and then return the plugs.
The lubrication oil can be drained completely by removing plug (3) using an 8 mm
Allen wrench.
3
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 oil and the filter cartridges MUST be disposed of by
authorized persons.
(!) CAUTION DANGER (!)
On the outer boom there is a mercury capsule (mercury level switch) duly
protected and provided with the following warning stickers.
MERCURY IS EXTREMELY TOXIC. IN CASE OF REPLACEMENT AND/
OR SCRAPPING, DISPOSE OF OR RECYCLE THE CAPSULE CONTAI-
NING MERCURY WITH MAXIMUM CARE, AND IN ACCORDANCE WITH
THE NATIONAL REGULATIONS IN FORCE.
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22.7 After every 1000 working hours or after every MAINTENANCE

working year
INSTRUCTIONS 22.7
GRU FASSI
Perform: Washing, Function Testing, Testing according to the
capacity plates
Check: Identification plates, Capacity plates

Checklist in accordance with ISO 9927-1

Element Checks to be carried out:

Subframe Tightening torque of the fixing rods, wear

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

Implements Oil-leaks, wear and any deformation,

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

22.8 Complete overhaul of the crane is required

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

10.000 working hours, (i.e.: 10 years, 50 weeks a year, 20 hours a week, or 5 years, 50
weeks a year, 40 hours a week)

or

10 years' life of the crane,

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

22.9 Instructions for the dismantlement and the demolition

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

Completely release the residual pressure in the hydraulic circuits and then fully drain
the oil present in the circuits before starting the dismantlement of the relevant compo-
nents. Be careful not to let the oil drop on the ground, therefore collect it in special con-
tainers, since exhausted oil must be eliminated in compliance with the waste disposal
rules in force.

Disable all the electric power supplies (batteries etc.) before dismantling the compo-
nents of the electric circuits.
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23 TABLE OF HYDRAULIC OIL AND LUBRICANTS TABLE OF HYDRAULIC

CHARACTERISTICS
OIL AND LUBRICANTS
CHARACTERISTICS
23
GRU FASSI

HYDRAULIC OIL WITH HIGH VISCOSITY: ISO-L-HV

Minimal external maximal oil Gradation

temperature: temperature:
-35°C +45°C ISO VG 32
-20°C +75°C ISO VG 46

HYDRAULIC OIL WEAR RESISTANT: ISO-L-HM

Minimal external maximal oil Gradation

temperature: temperature:
-10°C +60°C ISO VG 32
+ 0°C +75°C ISO VG 46
+ 5°C +85°C ISO VG 68
+10°C +90°C ISO VG 100

GREASE (for centralized system)

Use only GREASE NILEX EP1 of the firm NILS.

NOTE: Do not ABSOLUTELY mix different types of grease.

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

-30°C up to +130°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 recommen-
ded if the cables are expected to move quickly through the pulleys.

BRILUBE 50 (BRITISH ROPES - BRINDON)

( ! ) WARNING ( ! )
Don’t use greases with solid particles as “Bisulphide of Molybdenum”
(not compatible with eventual teflon bushes).
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24 POSSIBLE FAULTS POSSIBLE FAULTS

GRU FASSI 24
24.1 Generality
Many years experience of our product has allowed us to identify and classify the most
common faults which occur. In most cases it requires accurate hydraulic and electric
troubleshooting and simple rectification. In the following table we report the most fre-
quent inconveniences and our suggested remedies.

(!) Checking and adjustment of oil pressures of valve settings must be carried out
by an authorized service agent, under penalty of warranty forfeiture.

(!) ATTENTION (!)

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

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

24.2 Only operations which can be carried out by the user

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

FAULTS CAUSE REMEDIES

The crane does not Vehicle non 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 level

crane operations and top up
if necessary

Obstructed filters Clean or replace

the filter cartridge

Noteable decrease in Obstructed filters Clean or replace

movement speed the filter cartridge
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24.3 Operations to be carried out only by an authorized POSSIBLE FAULTS

service center GRU FASSI 24.3

FAULTS CAUSE REMEDIES

The crane does not lift Non efficiency Replace the pump
the loads indicated of the pump
on the capacity plate
(main pressure or auxiliary) Check the pressure,
valves not properly adjust the valves
adjusted, or worn or replace them!

Ram seals are Replace the seals

not properly fitted

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

The crane does not Valves controlling the Adjust the valves
rotate properly rotation not adjusted

- WITH RACK: Wear of rotation guide shoe Replace the guide shoe
Wear of the seals Replace the seals
of the rotation cylinder

- WITH SLEW RING: Wear of the slew ring Check the slew ring wear,
replace if necessary
Wear of the Check the motore-
motoreducer group ducer group wear,
replace if necessary

The extension booms Wear of guide shoes Check the

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

Vibrations in Non efficient pump Check the pump

crane operations

Noteable decrease in Non efficient pump Check the pump

movement speed
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25 INSTRUCTION AND WARNING PLATES INSTRUCTION AND

WARNING PLATES 25
GR2_60»65

DE 1771A
Instruction plate and safety norms

DE 6723
Warning plate to stabilize the vehicle before
using the crane

DE 1684A
Do not operate from the double control side,
to unfold or fold the crane

DE 4452A
Instruction plate to fold the crane
into the rest condition
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INSTRUCTION AND
WARNING PLATES 25
GR2_60»65

DE 4945A
Warning of burn danger

DE 6409A
Warning of shearing danger

DE 4491
Do not operate from the frontal position, to
extend the outrigger supports

DE 2100
Danger plate for crushing of lower limbs

DE 3706 DE 3705 PO156

Instruction plates
to stabilize the vehicle
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INSTRUCTION AND
WARNING PLATES 25
GR2_60»65

DE 1067
Do not walk or stay under a suspended load
and for unauthorized persons to be within the
DE 1067 working area

DE 1681
Greasing points with brush

DE 1682
Greasing points at pressure

DE 1686
Do not walk or stop under a suspended load

DE 1683 / DE 2361
Do not operate in proximity of electric high-
tension lines
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INSTRUCTION AND
WARNING PLATES 25
GR2_60»65

DE 1679
Do not walk on...

DE 1680
Do not use water to estinguish fire

TIRANTI: NON SALDARE!

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