Fassi Crane: Use and Maintenance
Fassi Crane: Use and Maintenance
F 360SE.24
use and maintenance
INDEX
Edition 25.08.2004
1
FASSI CRANE
INTRODUCTION
cI F 360SE.24
F 360SE.24
use and maintenance
The fitment must be carried out in accordance with the instructions given
by the Manufacturer in the manual for hydraulic crane fitting.
2
SAFETY NORMS SAFETY NORMS
F 360SE c II
(!) This symbol draws your attention on the points concerning safety.
It means: WARNING! BE CAREFUL!
IT CONCERNS YOUR SAFETY!
!ATTENTION!
READ THIS MANUAL CAREFULLY prior to use of the crane or any maintenance.
A few minutes spent now could save time and labour later. Be sure that the
unit has been installed, inspected and tested in accordance with the local
legal requirements.
Check that protections are in their place and that all safety devices are fitted
and active.
Do not run the engine in a indoor area without first making sure there is
adequate ventilation. Fit a suitable extension tube to the vehicle exhaust pipe
to take the fumes away from the working area.
Stabilize the vehicle checking that they 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.
Should visibility be insufficient, make sure that control stations are properly
lighted so as to ensure safety while operating control functions and allow rea-
ding of the plates.
Avoid swinging the load above the control station; any hidden danger situation
must be audibly alarmed.
Avoid all those situations which may result in crushing during crane stabilization,
movement and load handling.
The table reports the minimum safe working distances to avoid crushing parts
of the body.
Hand
Wrist 3,94 Finger 0,98
Fist
In conformity with “EN 349” Standard the minimum safe working distances to avoid cru-
shing parts of the body.
NOTE: Failure to respect the minimum safe distances may result in a
deadly risk for the operator and his assistants.
4
Maintain safe clearances from electrical lines SAFETY NORMS
and apparatus. You must allow for boom sway, F 360SE c II
rock or sag and electrical line and loadline
swaying. This lifting device does not provide
protection from contact with or proximity to an
electrically charged conductor. You must main-
tain a clearance of at least 10 feet between
any part of the crane, loadline or load and any
electrical line or apparatus carrying up to
50.000 volts. One foot additional clearance is
required for every additional 30.000 volts or
less.
NOTE: Failure to respect the minimum safe distances may result in electrical
hazards for the operator and his assistants.
(!) ATTENTION (!)
Do not utilize the crane with wind speed exceeding 12,5 m\s (value 6 of the
Beaufort scale).
Indications about wind speed
5
SAFETY NORMS For cranes with top seat controls, it is necessary to use a ladder and a cat
c II F 360SE walk to reach the control station.
When operating from the top seat, stay within its side safety guards.
The vehicle\crane must not be left unless the load is on the ground, the booms of
the crane are folded and laid on a solid base and the power take-off is disengaged.
At the end of the job and prior to driving the vehicle the crane must be folded.
If the booms are to be laid on the body or on the load, they must be blocked to
prevent possible sideways movements.
NOTE Implements can be left mounted on the booms of the crane only if the
overall dimensions are respected.
Make sure that the outrigger rams are lifted and the supports re-
entered within the overall width of the truck.
3 — Check that the vehicle hand brake is on and that the wheels are chocked.
6 — Use the crane in accordance with the use and maintenance manual,
making sure that:
— the load and radius are within the maximum limits shown on the
crane capacity plate;
— the crane is used progressively avoiding sudden load movements;
— swinging or dragging of the load is avoided;
— the load is lifted before rotating.
7 — When using implements protect the crane working area with a barrier.
8 — The vehicle/crane are not left unless the power take off is disengaged
and the load is on the ground.
9 — Before driving the vehicle make sure that the outriggers are fully retracted
and re-entered, and the crane is in folded position.
fig. 1
THESE INSTRUCTIONS FOR THE USE OF THE CRANE COINCIDE WITH THOSE OF
THE PLATE DE2676 (FIG. 1) PLACED NEXT TO THE CRANE.
7
IDENTIFICATION OF IDENTIFICATION OF THE CRANE MODEL
c IV THE CRANE MODEL
F 360SE
The exact crane model, serial number and description of implements will
enable FASSI Service Department to give a rapid and efficient response.
Identification data of the crane are marked on the plate DE2141 and fixed on
the base.
1 — Crane model
1 2 — Serial Number
2 3 — Year of manufacturing
8
TECHNICAL DATA
TECHNICAL DATA cV
F 360SE
The design of this crane has been carried out in respect of DIN 15018 norms,
fatigue test classification H1B3 .
(!) The crane can operate, intermittently, with lifting devices other
than the hook.
The dimensions and the capacity of the implements must be
proportioned with crane performances.
F 360SE.24
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 500)
(Φ 1’7”)
26,6 tm 18,30 m 9,94 m 420° 4,69 tm 30,0 MPa 60+60 l/min 250 l 4680 kg 120 psi
260,86 kNm 45,99 kNm
192398 lbf.ft 60’0” 32’7” 420° 33923 lbf.ft 4351 psi 15,85+15,85 66,04 gals 10318 lbs 8,3 daN/cm2
gal/min
F 360SE.24
ST 331
9
TECHNICAL DATA
cV F 360SE
F 360SE
ST 331
10
TECHNICAL DATA
F 360SE cV
F 360SE
ST 331
11
CRANE CRANE NOMENCLATURE (fig. 2)
c VI NOMENCLATURE
F 360SE
Pos. Description
1 - Outrigger rams
2 - Outrigger supports
3 - Base
4 - Rotation cylinders
5 - Column
6 - Inner ram
7 - Inner boom
8 - Outer ram
9 - Outer boom
10 - Booms extension rams
11 - Extension boom sections
12 - Deviator crane - outriggers
13 - Outrigger distributors
14 - Outrigger transmission
15 - Ladder and cat walk
16 - Seat and control station
17 - Manual and foot controls (crane distributors)
18 - Supplementary hoses (hydraulic implements)
19 - Oil tank
20 - Heat exchanger (available on request)
12
CRANE
NOMENCLATURE c VI
F 360SE
fig. 2
13
SAFETY AND SAFETY AND PROTECTION DEVICES (fig. 3)
c VII PROTECTION
DEVICES
F 360SE
Pos. Description
1 - Check valves for outrigger rams
2 - Check valve for rotation control
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
7 - Parachute valves (lifting moment limiting device)
8 - Main pressure valves (outrigger distributor)
9 - Main pressure and auxiliary valves (crane distributors)
10 - Carter for outer ram
11 - Carter for hose protection devices
12 - Carter for booms extensions ram check valve
13 - Handle
14 - Emrgency tap (lifting moment limiting device)
15 - Seat with device indicating the operator presence
16 - Heat exchanger (available on request)
(!) Before crane use check that safety and protection devices are fitted
and active.
(!) Under no circumstances interfere with the safety and protection devices.
(!) Interference with the check valves and removal of the lead seals remove
the Manufacturer and invalidate the warranty.
(!) For the access to the top seat use a ladder and a cat walk.
14
SAFETY AND
PROTECTION c VII
DEVICES
F 360SE
fig. 3
15
LIFTING MOMENT
c VIII LIMITING DEVICE
LIFTING MOMENT LIMITING DEVICE
F 360SE
A characteristic which permits the classification of cranes is their lifting capa-
city or maximum lifting moment. The moment is defined by the value obtained
from the product of the load to be lifted (in lbs) by its distance (in ft) from the
centerline of the crane rotation.
The device called “lifting moment limiting device” preserves the crane structu-
re from overloads, as it prevents any movement which increases the value of
the moment up to the maximum established value.
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.
(!) Interferences with the valves or removal of the lead seal release the
FASSI GRU IDRAULICHE
from any responsibility and invalidate the warranty.
DE1679
(!) 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.
17
CONTROLS CONTROLS TO STABILIZE THE VEHICLE
c IX TO STABILIZE
THE VEHICLE
F 360SE The outriggers rams prevent harmful stresses both to the frame and to the
vehicle suspensions on which the crane is mounted and assure the stability of
the unit during load handling.
Be very careful during vehicle stabilization operation; make sure that no one is
or transits in close proximity of the working area of the outriggers.
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 tolerance
of 1,5 degrees.
The controls to stabilize the vehicle are activated only on ground level and on
both sides of the crane base.
fig. 9
The extension and re-entering of the support and outrigger rams indicated on the
fig. 9-10 coincide with what indicated on the plates DE2600 and DE2601 placed
next to the control stations.
The symbols and the graphics of the plates define the vehicle side from which
you operate and indicate the operating levers in relation to their movement.
On the plate DE2600 is also reported the oil diverter (placed on the side of the
base beam, on the left side of the vehicle) with the position of the lever for - E/S
control (E=extensions, S=outriggers).
fig. 11 fig. 12
18
- Position lever D of oil diverter - E/S, (placed on the beam of the crane base, CONTROLS
on the left side of the vehicle), on E/S (extensions - outriggers). TO STABILIZE c IX
THE VEHICLE
F 360SE
Extension of the outrigger support E1
- Operate the lever E1 to extend the support.
Extension of the outrigger support E2
- Operate the lever E2 to extend the support.
Descent of the outrigger ram S1
- Operate the lever S1 to lower the ram.
Descent of the outrigger ram S2
- Operate the lever S2 to lower the ram.
Unfold the crane into a working condition, positioning lever D of oil diverter
crane-outriggers ( - E/S) on . fig. 9.
(!) Under no circumstances interfere with the device indicating the operator
presence which is fitted on the seat of the control station.
19
CONTROLS CONTROLS TO OPERATE THE CRANE
cX TO OPERATE
THE CRANE
F 360SE (!) WARNING (!)
Before operating the crane it is compulsory to set the outriggers
This coincides with that indicated on the plate DE2327 placed on the outriggers.
(Fig. 14)
(!) Operate the levers smoothly and gradually. When carrying out simulta-
neous 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 parti-
cular function, an increase in speed of the other functions will occur.
The control station is on the top seat, the crane and the hydraulic implements are
controlled from the distributors placed on the left and on the right side of the ope-
rator and are manually activated by means joystick or levers (in relation to the
distributor type) and foot controls.
(!) The device indicating the operator presence which is fitted on the seat
fig. 14 of the control station prevents the activation of the hydraulic working of
the two distributors before the operator sits down at the control station.
20
Right side of the control station CONTROLS
TO OPERATE cX
Respect to the operator (left to right) we activate, by means of foot controls, the pallet- THE CRANE
fork and by means of joystick, the outer boom and the pallet-fork rotator. F 360SE
The foot control activates the pallet-fork:
pushing with the foot tip, we control the opening of the pallet-fork.
pushing with the heel, we control the closure.
The joystick controls the outer boom and the pallet-fork:
forwards, controlling the descent of the outer boom;
towards, controlling the ascent.
on the right, controlling the clockwise rotation;
on the left, controlling the counterclockwise rotation.
(!) Properly changing the angle of the operating direction of the joy-stick,
it is possible to simultaneously control both functions.
Load manoeuvres
(!) Before manoeuvering the load, verify that the working area is
suitable for your crane.
The lifting curves of the capacity chart indicate the maximum load that the
crane can lift at a certain radius and at a certain height.
(!) Always remember that when operating with implements, their tare
weight must be deducted from the capacity of the crane.
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
lifting moment limiting device, allowing all manoeuvres, which reduce
the lifted load within the permitted reach limits and forbid all other
manoeuvres, will be immediately activated.
(!) The presence of the lifting moment limiting device does not release
the user from the observance of the capacity chart.
22
USE OF IMPLEMENTS USE OF IMPLEMENTS
F 360SE c XI
OIL COOLER (HEAT EXCHANGER)
The crane (available on request) can be equipped with an oil cooler (air-oil heat
exchanger) to prevent damage caused by an excessive increase of the oil tempe-
rature.
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.
HYDRAULIC ACCESSORIES
- Fork rotator
- Pallet-fork
(!) When using an implement it is always necessary to check that its weight,
dimension and capacity is matched to the crane performances.
(!) Warning and norms for crane use also apply for hydraulic implement use.
(!) Always remember that when operating with implements, their tare weight
must be deducted from the capacity of the crane.
23
MAINTENANCE MAINTENANCE INSTRUCTIONS
c XII INSTRUCTIONS
F 360SE
To assure a long life to the crane, it is necessary to meticulously follow the
instructions.
General lubrication and small repairs can be carried out by the user; repairs of a
more complicated nature must be carried out by authorized service personnel.
At least once a year you must take the crane to a Fassi Service Center for a
check.
Good maintenance and proper use are imperative to maintain efficient use
and guarantee the safety of the crane.
(!) Before disconnecting any hydraulic hoses, ensure that there is no pressure
in the hydraulic circuit.
After removing hoses always mark them and their respective ports on the crane.
Faulty replacement can cause damage to the rams and to the hydraulic circuit.
Any maintenance operation must be carried out with the crane power source tur-
ned 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. 17
Do not weld the fixing rods of the crane
(DE1574 fig. 17)
TIRANTI: NON SALDARE!
When repairs to, or checks of, the hydraulic
FIXING ROD: DO NOT WELD! circuit and of the rams are carried out, it is
TIRANTS: NE PAS SOUDER! very important not to use, or be in the
proximity of, materials which can damage
ZUGSCHRAUBEN: NICHT SCHWEISSEN! the circuit or contaminate the hydraulic oil
DE1574
eg. metal shavings, sand or dust.
Never use detergents, petrolsol or inflammable liquids, always use non flam-
mable or non toxic liquids.
When cleaning the exchanger (if fitted) direct the jet of water or air parallely to
the fins in order not to damage them; protect the electric motor adequately.
Where needed use a cleaning product which does not eat into the alluminium
of the radiant group.
24
MAINTENANCE
INSTRUCTIONS c XII
F 360SE
Check the hoses fittings and all the components of the hydraulic circuit for
possible leaks.
Check that the crane controls (levers and foot) and the outrigger controls
(levers) can be moved easily and return freely to neutral position.
Check the condition of shackles, hooks, wire ropes and every eventually used
equipment.
fig. 18
Clean the oil filter placed in the oil tank of the crane and if any, on the pump
section and pressure hoses.
Cleaning of the wire mesh filter on the tank (oil return to the oil-tank) fig. 19.
2
- Unscrew the security bolts of the filter cover 1 and
remove it.
- Extract the cartridge, clean by flushing with a non flammable,
non corrosive and non toxic solvent (gas oil or other).
Thoroughly dry the filter inside and out (do not use 4
compressed air).
- Check if the cartridge has collapsed; if so, replace it! 3
- 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!
5
NOTE
Take care that no contaminated material passes into the tank.
fig. 19
25
MAINTENANCE Replacement of the filter on the delivery line (before the distributor) fig. 20
c XII INSTRUCTIONS
- When the visual indicator becomes red, replace the cartridge.
F 360SE
- Unscrew with a suitable spanner the filter body (1) from the head (2).
- Remove the cartridge (3) and clean inside the filter body (1).
- Insert a new cartridge and re-assemble the filter body into the head
(check the sealing (4)).
Note!
The following lubricators have been centralized and gathered in a case posi-
tioned on the base (crane distributor side):
- rack guide shoe - rotation,
fig. 20 - upper and lower bush of the column - column support,
- rack group - column gear,
- column support group - pendulum beam.
For the sliding sections of the outrigger supports and of the extension booms guide
shoes made from a special material have been fitted: to ease their movement it is
recommended to smear a light film of grease on them, taking care that the surfaces of
the outrigger supports and inner and extension booms are free from impurities such
as sand etc.
For the sliding sections of the carter of the outer ram and ease their movement it is
recommended to smear a light film of grease on the guide-shoes.
Use a grease with the same characteristics indicated in the table at paragraph N0.
26
MAINTENANCE
INSTRUCTIONS c XII
F 360SE
D. Fixing Tightening
rods torque = inch-pound force
M22x1,5 2655
fig. 22
M24x2,0 3540
M27x2,0 5310
M30x2,0 4169
M33x2,0 10620
M39x3,0 15931
- of the securing bolts for the ram pins and of all the other bolts and screws,
where the tightening torque is not expressly indicated, consult the following
table in order to find it’s value according to the bolt diameter and class.
Table of the bolts tightening torque with average friction value (0,15) and average-
good tightening accuracy (C).
Bolt inch Class 8.8 Class 10.9 Class 12.9 Bolt inch Class 8.8 Class 10.9 Class 12.9
Diameter = D Torque = inch- Torque = inch- Torque = inch- Diameter = D Torque = inch- Torque = inch- Torque = inch-
pound force pound force pound force pound force pound force pound force
0,118 9,4 13,8 16,2 0,787 3000 4416 5169
0,157 21,6 31,7 37,1 0,866 4124 6063 7098
0,197 42,7 62,8 73,5 0,945 5169 7594 8886
0,236 73,5 109 126 1,063 7656 11249 13161
0,315 177 257 310 1,181 10382 15250 17843
0,394 354 522 611 1,299 14108 20728 24251
0,472 611 903 1053 1,417 18108 26605 31128
0,551 982 1443 1690 1,535 23525 34562 40448
0,630 1531 2257 2637 From “ELEMENTS DE FIXATION - ASSEMBLAGES VISSES”
0,709 2115 3115 3646 (AFNOR E 25-030 AGOSTO 1984)
Check the guide shoe wear as it affects the sliding section tolerances; if the clea-
rances 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.
or
27b
POSSIBLE FAULTS POSSIBLE FAULTS
c XIII F 360SE
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 frequent inconveniences and our suggested remedies.
(!) Checking and adjustment of oil pressures of valve settings must be carried
out by an authorized service agent, under penalty of warranty forfeiture.
Operations which can be carried out by the user.
Faults Cause Remedies
The crane does not rotate Vehicle non in level position Stabilize the vehicle
properly Lack of lubrication Grease the bushes
The extension booms do Lack of lubrication of the Grease the guide shoes
not completely extend or guide shoes
work jerkily
Crane controls are not Lack of electric energy Check the fuse, the bat-
active with the operator tery and electric circuit
at the control station The device indicating the Check the circuit of the
operator presence on the device indicating the
top seat is activated operator presence on
the top seat
Vibrations in crane Shortage of oil Check the level and
operations top up if necessary
Obstructed filters Clean or replace the filter
cartridge
Noteable decrease in Obstructed filters Clean or replace the filter
movement speed cartridge
CODE DESCRIPTION
29
HYDRAULIC AND Hydraulic schematic for crane - two Danfoss distributors - lifting moment limiting
c XIV ELECTRIC SCHEMATICS device “intelligent” type
F 360SE
SYMBOL DESCRIPTON
30
HYDRAULIC AND
ELECTRIC SCHEMATICS c XIV
F 360SE
Electric schematic for crane - two standard distributors - free rotation
CODE DESCRIPTION
31
HYDRAULIC AND Electric schematic for crane - two Danfoss distributors - free rotation
c XIV ELECTRIC SCHEMATICS
F 360SE
CODE DESCRIPTION
32
HYDRAULIC AND
Unifilar schematic - standard distributor - free rotation - seat box ELECTRIC SCHEMATICS c XIV
F 360SE
33
HYDRAULIC AND Electric schematic for crane - terminal strip - seat box
c XIV ELECTRIC SCHEMATICS
F 360SE
34
TABLE OF HYDRAULIC OIL AND TABLE OF HYDRAULIC
LUBRICANTS CHARACTERISTICS OIL AND LUBRICANTS c XV
CHARACTERISTICS
F 360SE
HYDRAULIC OIL WITH HIGH VISCOSITY: ISO-L-HV
All grease used must be free from acid and resin, not hygroscopic and long-
life such as
BP GREASE LTX-EP1\EP2 or ELF EPEXA 1\2
ESSO BEACON EP1\EP2 or TEXACO EP1\EP2
MOBIL EP1\EP2 or SIMILAR.
Classification ISO-L-CC
The most suitable here is a general-purpose lubricating oil with about SAE
30° viscosity. A lubricating oil containing non-stick additives is recommended
if the cables are expected to move quickly through the pulleys.
( ! ) WARNING ( ! )
Don’t use greases with solid particles as “Bisulphide of Molybdenum”
(not compatible with eventual teflon bushes).
35
INSTRUCTION AND
INSTRUCTION AND WARNING PLATES
A WARNING PLATES
F 360SE
DE 2676
Instruction plate and safety norms
DE 2327
Warning plate to stabilize the vehicle
before using the crane
Instruction plates
to stabilize the vehicle
DE 2600 DE 2601
DE 2497 DE 2498
Warning plates to make sure that no one
is or transits in close proximity of the outriggers
36
INSTRUCTION AND
WARNING PLATES
F 360SE
A
DE 2868
DE 3953
DE 1067
Do not walk or stay under a suspended
load and for unauthorized persons to be
DE1067 within the working area.
DE 2100
Danger plate for crushing of lower limbs
37
INSTRUCTION AND
A WARNING PLATES
F 360SE
DE 1686
Do not walk or stop under a suspended
load
DE 1683
Do not operate in proximity of electric
high-tension lines
DE 2361
Do not operate in proximity of electric
DE2361
high-tension lines
DE 1679
Do not walk on...
DE 1680
Do not use water to estinguish fire
38
INSTRUCTION AND
WARNING PLATES
F 360SE
A
DE 1681
Greasing points with brush
DE 1682
Greasing points at pressure
39
CAPACITY PLATES CAPACITY PLATES
B F 360SE.24
For cranes and manual extensions.
! WARNING !
40