FASSI CRANE cI

F 390SE.24
use and maintenance

INDEX

Chapter I INTRODUCTION page 2

II SAFETY NORMS page 3
III INSTRUCTIONS FOR CRANE USE page 7
IV IDENTIFICATION OF THE CRANE MODEL page 8
V TECHNICAL DATA page 9
VI CRANE NOMENCLATURE page 12
VII SAFETY AND PROTECTION DEVICES page 14
VIII LIFTING MOMENT LIMITING DEVICE page 16
IX CONTROLS TO STABILIZE THE VEHICLE page 18
X CONTROLS TO OPERATE THE CRANE page 21
XI USE OF IMPLEMENTS page 24
XII MAINTENANCE INSTRUCTIONS page 25
XIII POSSIBLE FAULTS page 30
XIV HYDRAULIC AND ELECTRIC SCHEMATICS page 31
XV OIL AND LUBRICANT CHARACTERISTICS page 34
A INSTRUCTION AND WARNING PLATES page 35
B CAPACITY PLATES page 38

Edition 02.07.2003 1
 FASSI CRANE
INTRODUCTION
cI F 390SE.24

F 390SE.24
use and maintenance

This instruction manual describes the FASSI CRANE F390SE.24.

The fitment must be carried out in accordance with the instructions given
by the Manufacturer in the manual for hydraulic crane fitting.

The Manufacturer declines all responsibility and guarantee if the fitting is

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

As well as the principal safety norms, this manual contains a description

of the crane and the instructions for use and maintenance.

The crane must only be operated by responsible persons, previously

instructed and authorized.

THANK YOU FOR SELECTING ONE OF OUR CRANES.

2
SAFETY NORMS SAFETY NORMS
F 390SE 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.

To operate the crane it is necessary to fully understand its working, safety

and warranty norms.

Check that protections are in their place and that all safety devices are fitted
and active.

Warning plates, as well as instruction and operation plates must be replaced

when no longer readable or missing. (See chapters A - B)

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.

Level the crane so as it is always operated on a horizontal plane; check that the
angle of inclination of the vehicle always does not exceeds five (5°) in any direction.

Never operate the outriggers when the crane is loaded.

Remember that the stability of the unit (crane-vehicle) is only guaranteed by

the fully lateral extension of the outriggers.

Should visibility be insufficient, make sure that control stations are properly
lighted so as to ensure safety while operating control functions and allow rea-
ding of the plates.

Before manoeuvering a load check that the

working area is adequate and properly lighted for
your crane.

Make sure that the hook is always free to rotate

on its pin and that nothing obstructs its vertical
positioning.

Check the efficiency of the hook safety catch.

3
 SAFETY NORMS Carefully inspect the load rigging and the con-
c II F 390SE dition of ropes or chains.
Make sure that the lifted load is balanced.

Hook up the load, checking that it does not

exceed the capacity indicated on the lifting
diagram specific to each load configuration.

It is absolutely prohibited to walk or stop under a suspended load and for

unauthorized persons to be within the working area.
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.

Parts Minimum safe Figure Parts Minimum safe Figure

of the working of the working
Body distance inch Body distance inch

Body 19,68 Head 11,81

Leg 7,09 Foot 4,72

Toes 1,97 Arm 4,72

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 390SE 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 elec-
trical 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.

Do not utilize the crane with stormy weather or with wind speed exceeding
12,5 m\s (value 6 of the Beaufort scale).

Indications about wind speed

Force of the Wind speed Classification Characteristics

wind m/s
Beaufort scale

0 0,0 - 0,2 Calm Calm wind, smoke

goes up quite vertically

1 0,3 - 1,5 Light breeze Smoke reveals the

2 1,6 - 3,3 direction of the wind,
one can feel the wind
blowing, leaves start
fluttering.

3 3,4 - 5,4 Moderate breeze Leaves and branches

4 5,5 - 7,9 are in constant 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 35,43 - 45,28 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)

5
 SAFETY NORMS For cranes with top seat controls, it is necessary to use a ladder and a cat
c II F 390SE walk to reach the control station.
When operating from the top seat, stay within its side safety guards.

Do not rotate the crane before the load

is lifted, do not operate with sudden
movements, 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 push-
pull (F), lateral (F) or sideways (F)
operations.

Do not move the vehicle if a load is

suspended on the crane.

Under no circumstances interfere with the safety and protection devices.

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.

THE FORK MUST BE TIED DOWN AT ALL TIMES

DURING TRANSPORT

Make sure that the outrigger rams are lifted and the supports re-
entered within the overall width of the truck.

Disengage the power take off.

To avoid hitting bridges or tunnels check and record the overall

height of your crane in the folded position or in laid position in the
body or on the load. Always respect and pay proper attention to
road signs placed in proximity of such obstacles.

6
INSTRUCTIONS FOR CRANE USE INSTRUCTIONS
FOR CRANE USE c III
F 390SE
The use of the crane is reserved to authorized personnel, instructed in
advance, who has to strictly conform to the safety norms and instruc-
tions contained in the instruction manual supplied with the crane.

1 — Only authorized persons are allowed to operate the crane.

2 — The crane must be used on firm, level ground.

3 — Check that the vehicle hand brake is on and that the wheels are chocked.

4 — Before every operation make sure that:

— no-one is within the working area of the crane;
— the safety devices are in place and operative;
— the minimum safe working distances from power lines are observed;
— the load is correctly slung and hooked.

5 — Stabilize the vehicle by the outrigger rams, making sure that:

— the lateral supports are fully extended;
— the wheels are in contact with the ground and the suspension is not
completely unloaded;

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 390SE
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
2 — Serial Number
3 — Year of manufacturing
1
2
3

fig. 2

(!) UNDER NO CIRCUMSTANCES SHOULD THE DATA MARKED

ON THE PLATE BE ALTERED.

8
TECHNICAL DATA TECHNICAL DATA
F 390SE.24 cV
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 390SE.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 1’8”)

28 tm 24,04 m 15,68 m 430° 6,79 tm 29,0 MPa 60 l/min 240 l 6200 kg 9 daN/cm2
274,7 kNm 66,59 kNm
202524 lbf.ft 78’10” 51’5” 430° 49117 lbf.ft 4206 psi 15,85 63,4 gals 13670 lbs 130 psi
gal/min

PESO GRU CON SERBATOIO NON RIFORNITO, STABILIZZATORI STANDARD

WEIGHT OF THE CRANE WITH EMPTY TANK, STANDARD STABILIZATION
kg 6.200
POIDS DE LA GRUE AVEC RESERVOIR VIDE, STABILISATION STANDARD
lbs 13.670
KRANGEWICHT MIT LEEREM TANK UND STANDARDABSTUETZUNG

F 390SE.24
ST 390
9
 TECHNICAL DATA
cV F 390SE

F 390SE
ST 390

10
 TECHNICAL DATA
F 390SE F 390SE.24 cV

MASSIMA ALTEZZA SOTTOGANCIO.

HAUTEUR MAXIMUM SOUS CROCHET.
MAXIMUM HOOKING POSITION.
MAXIMALHOEHE BIS KRANHAKEN

ST 390
11
 CRANE CRANE NOMENCLATURE (fig. 3)
c VI NOMENCLATURE
F 390SE
Pos. Description

1 - Outrigger rams
2 - Outrigger supports
3 - Base
4 - Rotation cylinders
5 - Column
6 - Inner ram
7 - Inner boom
8 - Inner booms extension rams
9 - Inner extension boom sections
10 - Outer ram
11 - Outer boom
12 - Booms extension rams
13 - Extension boom sections
14 - Deviator crane - outriggers
15 - Outrigger distributors
16 - Ladder and cat walk
17 - Seat and control station
18 - Crane distributors (manual and foot controls)
19 - Supplementary hoses (hydraulic implements)
20 - Oil tank

12
 CRANE
NOMENCLATURE c VI
F 390SE

12 8

10

11 18 17
18
fig. 3

5 6
16
19
20
13
16

16

15
2
4 1
3
1 15
14

13
 SAFETY AND SAFETY AND PROTECTION DEVICES (fig. 4)
c VII PROTECTION
DEVICES
F 390SE
Pos. Description

1 - Check valves for outrigger rams

2 - Check valve for rotation control
3 - Check valve for inner ram
4 - Check valve for inner booms extension rams
5 - Check valve for outer ram
6 - Check valve for booms extension ram
7 - Lifting moment limiting device assembly
8 - Parachute valves (lifting moment limiting device)
9 - Main pressure valves (outrigger distributors)
10 - Main pressure and auxiliary valves (crane distributors)
11 - Carter for outer ram
12 - Carter for hose protection devices
13 - Carter for booms extensions ram check valve
14 - Handles
15 - Emrgency tap (lifting moment limiting device)
16 - Seat with device indicating the operator presence
17 - 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 390SE

12
6

13 11
5 4
16
8 14 10
fig. 4

10
7

12

15

1
17

15
 LIFTING MOMENT
c VIII LIMITING DEVICE
LIFTING MOMENT LIMITING DEVICE
F 390SE
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.

Lifting moment limiting device “INTELLIGENT TYPE”

This device is fitted close to the distributor, whose specific functions it uses. It
utilises an electrohydraulic technology, preventing any movement which cau-
ses an increase in the pressure induced by the load in the inner and outer
rams of the crane, up to the “critical values” which have been established in
the structural test. These values, which are non-exceedable, determine the
intervention levels and provide the data for setting the device. The condition of
intervention is operated by the position, in connection with the horizontal posi-
tion, of the crane outer boom, on which the electronic signal position (mercury
level switch) is read by a special electrovalve. This determines the controls of
the locking or unlocking (resetting) of the controls concerned.

(!) 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
MERCURY WITH MAXIMUM CARE, AND IN ACCORDANCE WITH THE
NATIONAL REGULATIONS IN FORCE.

The lifting moment limiting device concernes the following

manoeuvres:

— Inner boom descent; the inner boom lift is controlled

by the general main pressure valve of the distributor.
— Extension of the inner extension boom sections.
— Outer boom lift.
fig. 5
— Outer boom descent.
— Extension of extension boom sections.

The crane configurations (fig. 5-6) indicate the manoeuvres

which are allowed and not allowed by the device, in connec-
tion with the horizontal position of the crane and extension
outer booms. When the moment is reduced, it resets automa-
tically (the manoeuvres blocked by the device are released).
fig. 6 N.B.: There is a delay of four (4) seconds after the moment
reduction before the reset can occur in order to safeguard
the stability of the device.

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

desactivated.
16
EMERGENCY tap lever fig. 7 LIFTING MOMENT
LIMITING DEVICE c VIII
Each device is fitted with an emergency tap lever to be used in the event of a F 390SE
black-out, electrical or hydraulic malfunctions or whenever the lifting moment
limiting device makes it impossible to use any controls when handling a load
(this may occur when the extension booms are fully folded and the load is
particularly heavy and bulky).

(!) WARNING (!)

When the operator uses this device, it means that he wishes to

override the lifting moment limiting device in order to make some
manoeuvres (which would be impossible with the device active)
that bring the moment to within the maximum level, but involve an
overload condition. In such an emergency condition (where the lif-
ting moment limiting device has been disabled), the operator must:

— carefully consider the manoeuvres required to return to

normal working conditions; fig. 7
— 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.

Only in these situations it is permitted to remove the lead seals placed

on the tap lever and place it in the closed position.

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

(!) Interferences with the valves or removal of the lead seals release the
Manufacturer from any responsibility and invalidate the warranty.

(!) 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.

(!) ATTENTION (!)

Do not walk on the electric control panels (plate DE1679)

Do not use water to estinguish fire! (plate DE1680)

DE1679 DE1680

17
 CONTROLS CONTROLS TO STABILIZE THE VEHICLE
c IX TO STABILIZE
THE VEHICLE
F 390SE The outriggers rams prevent harmful stresses both to the frame and to the vehicle
suspensions on which the crane is mounted and assure the stability of the unit
during load handling.

Supplementary beams
Supplementary beams (supplementary outriggers) are used in conjunction with the
crane outriggers to ensure the vehicle stability during load handling.

Supplementary outrigger ram extension max.

beam code stroke interaxis

390B054 520 mm 4984 mm hydraulic extension

Identification data of the supplementary beam are punched on the beam (fig. 8) in the
following sequence:
fig. 8
Example *390B054*0001

serial no.

identification code

(!) ATTENTION (!)

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.
(!) ATTENTION (!)
The crane stability is only guaranteed by the maximum lateral extension of the outrigger
supports and by the solidity of the base underneath the plates of the outrigger rams. To
check the maximum working pressure see Chapter V “Technical data”
When stabilization is complete the wheels of the vehicle must still be in contact with
the ground and the suspensions must not be fully unloaded.
Level the crane so as to operate on a horizontal plane.
Description of the controls to stabilize the vehicle
The controls to stabilize the vehicle are activated only on ground level and are
placed on the crane base; they are in conformity with the safety directives and
enable the operator to activate the lateral extension of the outriggers (outrigger
supports and rams) only from the side where he can visually check the operation.
Lever function (oil-diverter side) Fig. 9
- D Deviator crane/outriggers control ( - E/S)
- E2 Outrigger extension control E2 crane
- S2 Outrigger ram control S2 crane
- E3 Outrigger extension control E3 supplementary
outriggers
- S3 Outrigger ram control S3 supplementary outriggers
Lever function (oil tank side) Fig. 10
fig. 9
- E1 Outrigger extension control E1 crane
- S1 Outrigger ram control S1 crane
- E4 Outrigger extension control E4 supplementary
outriggers
- S4 Outrigger ram control S4 supplementary outriggers

The extension and re-entering of the support and

outrigger rams indicated on the fig. 9-10 coincide
with what indicated on the plates DE 3771 and
DE3772 placed next to the control station. fig. 10
18
The symbols and the graphics of the plates define the side of the vehicle from which CONTROLS
we operate and indicate the operating levers in relation to their movement. TO STABILIZE c IX
THE VEHICLE
Controls for positioning the hydraulic outriggers of the crane and of the F 390SE
supplementary beam.

Special base plates (detachable)

The outrigger rams of the crane and of the supplementary

outriggers they are supplied with base plates which can be
fastened to the ram stems through jaw securing devices.

Fastening of the base plate

- Place the base plate underneath the ram, remove the fig. 11 fig. 11a
check pin and open the anchor jaws. (fig. 11-11a)
- Operate the corresponding lever S to control the descent
of the ram until the ball joint touches the seat cut in the
base plate; closethe jaws and secure them in their seat
with the check pin. (fig. 11b-11c)

Removal of the base plate

- Release the check pin and open the anchor jaws.
- Operate the corresponding lever S to control the re-entry
of the ram. fig. 11b fig. 11c
- Close the jaws, secure them with the check pin and remove the base plate.

(!) For the safety and for the encumbrances we recommend to remove the plates
before putting the rams to the rest position; special handles are featured for
the plates handling and the opening and closing of the securing device (jaws).
fig. 14 fig. 13
(!) WARNING (!)
Keep clean the ball joint heads of the outrigger rams and
the seats cut in the base plates to avoid their deterioration.
Controls workable from the oil-diverter side fig.11-13
DE3771
Position lever D of oil diverter ( -E/S) on E/S. fig. 14
Extension of the outrigger support E2 ( )
- Operate the lever E2 to extend the outrigger support.
Descent of the outrigger ram S2 ( ) and fastening of the base plate fig. 11
(see par. "Special base plates").
- Operate the lever S2 to lower the outrigger ram.
Extension of the outrigger support E3 (supplementary outriggers).
- Operate the lever E3 to extend the support.
Descent of the outrigger ram S3 (supplementary outriggers) and fastening of the
base plate (see par. "Special base plates").
- Operate the lever S3 to lower the ram.

Controls workable from the oil tank side fig. 12-15 DE3772
The lever D of oil diverter ( -E/S) must be positioned on E/S; if it’s the case re-
position it. fig. 12 fig. 15
Extension of the outrigger support E1 ( ).
- Operate the lever E1 to extend the outrigger support.
Descent of the outrigger ram S1 ( ) and fastening of the
base plate (see par. "Special base plates").
- Operate the lever S1 to lower the ram.
Extension of the outrigger support E4 (supplementary outriggers)
- Operate the lever E4 to extend the support.
Descent of the outrigger ram S4 (supplementary outriggers)
and fastening of the base plate (see par. "Special base plates").
- Operate the lever S4 to lower the outrigger ram.

19
 CONTROLS (!) ATTENTION (!)
c IX TO STABILIZE The complete extension of the outrigger supports is visually indicated by the
THE VEHICLE yellow triangles which are found at the end of the beam and the first outrigger
F 390SE support. (Note: the pictures are related to the oil-diverter side) (fig. 16-16a)
The stabilization has to be carried out with care and gradually keeping the
vehicle in horizontal levelled condition to prevent
springs overloads and chassis torsions.

(!) ATTENTION (!)

During the stabilisation operations, for each outrigger
ram, it is recommended to DESCENT the outrigger as
last manoeuvre.
Enable the crane by taking lever D controlling the crane/outrig-
fig. 16 fig. 16a gers oil-diverter ( - E/S) to position . fig. 14a DE3771
Manoeuvres for re-entry of the crane outriggers and supplementary outriggers
within the overall vehicle width after crane use.
Controls workable from the oil-diverter side fig. 11-13 DE3771
Position lever D of oil diverter ( - E/S) on E/S
Re-entry of the outrigger ram S2 ( ) and removal of the base plate (see par. "Special
base plates").
- Operate the lever S2 to control the re-entry (at stroke end) of the outrigger ram.
Re-entry of the outrigger support E2 ( ).
- Operate the lever E2 to control the re-entry of the outrigger support.
fig. 14a
Re-entry of the outrigger ram S3 (supplementary outriggers) and removal of the base
plate (see par. "Special base plates").
- Operate the lever S3 to control the re-entry (at stroke end) of the outrigger ram.
Re-entry of the outrigger support E3 (supplementary outriggers).
- Operate the lever E3 to control the re-entry of the support.
Controls workable from the oil tank side fig. 12-15 DE3772
The lever D of oil diverter ( - E/S) must be positioned on E/S; if it’s the case re-position it.
Re-entry of the outrigger ram S1 ( ) and removal of the base plate (see par. "Special
base plates").
- Operate the lever S1 to control the re-entry (at stroke end) of the outrigger ram.
Re-entry of the outrigger support E1 ( ).
- Operate the lever E1 to control the re-entry of the outrigger support.
Re-entry of the outrigger ram S4 (supplementary outriggers) and removal of the base
plate (see par. "Special base plates").
- Operate the lever S4 to control the re-entry (at stroke end) of the outrigger ram.
Re-entry of the outrigger support E4 (supplementary outriggers).
- Operate the lever E4 to control the re-entry of the support.

(!) WARNING (!)

Due to the particular characteristic of the hydraulic circuit (double circuit with
two pumps), the distributor placed on the right of the top seat (extension
booms, outer boom and pallet-fork) is alimented by one pump also with the
oil-diverter - E/S on E/S.
The distributor controls are disacticated by a device indicating the operator
presence which prevents the control activation before the operator sits down
at the control station.

(!) Under no circumstances interfere with the device indicating the operator
presence which is fitted on the seat of the control station.

20
 CONTROLS
CONTROLS TO OPERATE THE CRANE TO STABILIZE cX
THE VEHICLE
(!) WARNING (!) F 390SE
Before operating the crane it is compulsory to set the outriggers

This coincides with that indicated on the plate DE2327 placed on the outrig-
gers. (fig. 17)

(!) Operate the levers smoothly and gradually.

When carrying out simultaneous movements of two or more func-
tions, 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.

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 operator and are activated by means levers (manually) and foot controls.

(!) The device indicating the operator presence which is fitted on the seat
of the control station prevents the activation of the hydraulic working of fig. 17
the two distributors before the operator sits down at the control station.

The left distributor, respect to the operator,

controls four functions (left to right):
- Pallett-fork rotator
- Inner ram
- Rotation of the crane
- Extension of the inner booms

The right distributor, respect to the opera-

tor, controls three functions (left to right):
- Exit of the extension boom sections fig. 18a
- Outer boom
- Pallett-fork

The symbols on the plate DE3690, placed on the sup-

port handle in front of the operator, identify the left and
right side of the control station, define the lever func-
tion and foot controls in relation to the movement to be
effected. fig. 18-18a

Left side of the control station

Respect to the operator (left to right) we activate, by

means of levers, the pallet-fork rotator and the inner
boom and, by means of foot controls, the rotation of
the crane and the extension of the inner booms. fig. 18

The first lever controls the mouvement of the pallet-fork rotator

forwards: clockwise rotation
towards: counterclockwise rotation.

The second lever controls the mouvement of the inner boom

forwards, controlling the descent
towards, controlling the ascent

The left foot control activates the rotation of the crane

Pushing with the foot tip: clockwise rotation
Pushing with the heel: counterclockwise rotation. fig. 18b

The center foot control activates the extension of the inner booms
Pushing with the foot tip, we control the exit of the inner booms
Pushing with the heel, we control the re-entry of the inner booms
21
 CONTROLS Right side of the control station
c IX TO OPERATE
THE CRANE
Respect to the operator (left to right) we activate, by means of foot controls,
F 390SE
the exit of the extension boom sections and, by means of levers, the outer
boom and the pallet-fork.

fig. 18c The right foot control activates the exit of the extension boom sections
Pushing with the foot tip, we control the exit of the extension boom sections
Pushing with the heel, we control the re-entry of the extension boom sections.

The first lever controls the mouvement of the outer boom

forwards, controlling the descent
towards, controlling the ascent.

The lever controls the mouvement of the pallet-fork

forwards, controlling the closure
towards, controlling the opening.

Manoeuvres to unfold the crane into a working condition

- Engage the power take off.

- Stabilize the vehicle as described on page 16.
- Before lifting the inner boom, be sure that the outer ram is open.
- Lift the inner boom over the horizontal line, close the outer boom and
eventually extend the booms of the crane.
- Operate on the crane rotation to position the fork on the vertical line above
the load, operate on the pallet-fork rotation control for the correct orientation
of the fork.

Manoeuvres to fold the crane into the rest condition

- Open the outer boom to its stroke end.

- Re-enter the extension boom sections.
- Operate the rotation control of the crane and fold the inner boom, paying
attention to the crane boom position on the body. It is necessary during
this operation to orientate the pallet-fork position to avoid obstacles on the
body or the load.
- Lift and re-enter the outriggers as previously described.
- Disengage the power take off.

(!) THE FORK MUST BE TIED DOWN AT ALL TIMES DURING TRASPORT.

22
Load manoeuvres CONTROLS
TO STABILIZE cX
THE VEHICLE
(!) Before manoeuvering the load, verify that the working area is suitable F 390SE
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 indica-
ted 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.

(!) ACTION OF INNER BOOM TELESCOPE EXTENSIONS CAN ALWAYS BE

ACTIVATED WHEN INNER BOOM IS ABOVE 45°, ON THE CONTRARY,
BELOW 45° IT CAN BE ACTIVATED ONLY IF THE PRESSURE OF THE
INNER RAMS IS LESS THAN 200 BAR.

To increase the hydraulic available reach always activate first the extension sec-
tions of the inner boom (ONLY WHEN ABOVE 45 DEGREES) and afterward those of
the outer boom: follow the inverted sequence to reduce the hydraulic reach
(ALWAYS KEEPING IN MIND THAT THE “Inner Boom Telescope” MUST ONLY BE
OPERATED ABOVE 45 DEGREES).

23
 USE OF IMPLEMENTS USE OF IMPLEMENTS
c XI F 390SE
OIL COOLER (HEAT EXCHANGER)

The crane is equipped with an oil cooler (air-oil heat exchanger) to prevent dama-
ge 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.

HYDRAULIC ACCESSORIES

The crane can be provided with implements such as:

- 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.

Hydraulic connections between implements and hoses fitted on the

extension boom section of the crane.

(!) In case of hoses connection to implements through coupling unions it is

necessary to verify that there is no trace of soil, curt etc. on the unions
and inside the seats so as to avoid the oil contamination and consequen-
tly wear the tightening “ surface of unions.

(!) 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 could occur.

24
MAINTENANCE INSTRUCTIONS MAINTENANCE
INSTRUCTIONS c XII
F 390SE
To assure a long life to the crane, it is necessary to meticulously follow the instructions.
General lubrication and small repairs can be carried out by the user; repairs of a
more complicated nature must be carried out by authorized service personnel.
Spare parts must be original.
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.
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). fig. 19

Do not place limbs, fingers or any other parts of anatomy

into areas of the crane, which present possibilities of TIRANTI: NON SALDARE!
shearing, without having blocked such parts of the crane. FIXING ROD: DO NOT WELD!
Do not weld, drill or grind any part of the crane without TIRANTS: NE PAS SOUDER!
the Manufacturer’s authorisation. ZUGSCHRAUBEN: NICHT SCHWEISSEN!
DE1574
Do not weld the fixing rods of the crane (DE1574 fig. 19).
When repairs to, or checks of, the hydraulic circuit and of the rams are carried out, it is
very important not to use, or be in the proximity of, materials which can damage the
circuit or contaminate the hydraulic oil eg. metal shavings, sand or dust.
Do not use high pressure washers on the controls (deviators, distributors, double
controls, hand cable controls), on the electronic components (boxes, control
panels), on the oil cooler (if fitted), on the tank.
Never use detergents, petrolsol or inflammable liquids, always use non flamma-
ble 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.
To avoid down time, it is recommended to periodically carry out the following
checks.

At the end of every working day

Check that all safety devices are efficient.

Check the level of the hydraulic oil in the tank.
Check the hoses fittings and all the components of the hydraulic circuit for
possible leaks.
Check that the oil-diverter - E/S lever can be moved easily.
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.
25
 MAINTENANCE
c XII INSTRUCTIONS
F 390SE

After the first 40 hours use

Check the tightening torque of the fixing rods of the crane.

(fig. 20)

Tightening torque for the rods M33x2 = 1200 Nm

fig. 20

After every working week

Clean the oil filter placed in the oil tank of the crane and if any, on the pump sec-
tion and pressure hoses.
6 NOTE The filters of fibre or paper can not be cleaned, they must be replaced.
1
Cleaning of the wire mesh filter on the tank (oil return to the oil-tank) fig. 21
- Unscrew the security bolts of the filter cover 1 and remove it.
2 - Extract the cartridge, clean by flushing with a non flammable 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
4 - Re-assemble the filter body and the cartridge: check the sealing of the ‘O’ ring 4-5-6;
in case, replace it!
3 NOTE Take care that no contaminated material passes into the tank.

Replacement of the filter on the delivery line (before the distributor) fig. 22
When the visual indicator becomes red, replace the cartridge.
5 - 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)).
fig. 21
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 MAX
not exceed the maximum or be lower than the mini-
mum (fig. 23). MIN

Top up using hydraulic oil with the same characteri-

stics as those indicated in the table at page 33. fig. 23

Note! The following lubricators have been centralized and gathered in a case
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,
fig. 22 shall not change its characteristics.
At the effective operative temperature, the grease we recommend shall have a flui-
dity at least equal to rating NLGI 0 or max. 1.
(!) WARNING (!)
Centralized lubrication shall not be used when room temperature is below -
10°C / -20°C.
26
For the sliding sections of the outrigger supports and of the extension booms guide shoes MAINTENANCE
made from a special material have been fitted: to ease their movement it is recommended INSTRUCTIONS c XII
to smear a light film of grease on them, taking care that the surfaces of the outrigger sup- F 390SE
ports and inner and extension booms are free from impurities such as sand etc. For the sli-
ding 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 page 33.

After every 500 working hours

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

- 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 Class 8.8 Class 10.9 Class 12.9 Bolt Class 8.8 Class 10.9 Class 12.9
Diameter = D Torque = Nm Torque = Nm Torque = Nm Diameter = D Torque = Nm Torque = Nm Torque = Nm
3 1,06 1,56 1,83 20 339 499 584
4 2,44 3,58 4,19 22 466 685 802
5 4,83 7,10 8,30 24 584 858 1004
6 8,30 12,30 14,30 27 865 1271 1487
8 20 29 35 30 1173 1723 2016
10 40 59 69 33 1594 2342 2740
12 69 102 119 36 2046 3006 3517
14 111 163 191 39 2658 3905 4570
16 173 255 298 From “ELEMENTS DE FIXATION - ASSEMBLAGES VISSES”
18 239 352 412 E 25-030 AGOSTO 1984

Check the guide shoe wear as it affects the sliding section tolerances; if the clearan-
ces 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.
(!) 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 CONTAINING MER-
CURY WITH MAXIMUM CARE, AND IN ACCORDANCE WITH THE NATIONAL
REGULATIONS IN FORCE.
27
 MAINTENANCE
c XII INSTRUCTIONS
F 390SE

After every working year

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

Base Lubrication, tightening torque of the rods,

Rack 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,

Inner boom connection, outrigger actions
connection, pins, bushes

Inner boom Lubrication, wear and any deformation,

Pins, outrigger connections actions

Inner ram Oil-leaks, chromium plating,

Cylinder, rod, piston, any deformation, inspection of hoses
seals, hoses

Outer boom Lubrication, wear and any deformation,

Pins, outrigger connections actions

Outer ram Oil-leaks, chromium plating, strains,

Cylinder, rod, piston, seals, inspection of hoses
hoses

Extension booms Lubrication, wear and any deformation,

Guide shoes, pins, actions
outrigger connections

Extension rams Oil-leaks, chromium plating,

Cylinder, rod, piston, seals, any deformation, inspection of hoses
hoses

Hydraulic jib Lubrication, wear and any deformation,

Booms, pins, outrigger connections actions

Rams (hydraulic jib): Oil-leaks, chromium plating,

Cylinder, rod, piston, seals, any deformation, inspection of hoses
hoses

Winch Lubrication, wear and any deformation,

Torque limiter, brake, actions
rope slide guide, cable, stroke end,
pulleis
27a
 MAINTENANCE
Distributors, deviators, valves Checking of the pressure, oil-leaks,
Control levers, forks, joints, wear and any deformation, actions,
INSTRUCTIONS c XII
F 390SE
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,

Filters, hoses oil change, replacement of filters,
inspection of hoses

Oil-pressure system Checking of the pressure, oil-leaks,

Hoses, hose protection devices inspection of hoses

Implements for lifting Safety check, wear and any deformation,

Hooks, chains, cables, slings actions,

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

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 the Manufacturer or by an authorised service centre.

27b
 POSSIBLE FAULTS POSSIBLE FAULTS
c XIII F 390SE
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 rotation
group
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
Operations to be carried out by a service center.
Faults Cause Remedies
The crane does not lift Non efficiency of the Replace the pump
the loads indicated on pump
the capacity plate (main pressure or auxiliary) Check the pressure,
valves not properly adjust the valves or
adjusted, or worn replace them
Ram seals are not properly Replace the seals
fitted
A boom of the crane does The safety check valve of Replace the valve
not hold up the load and the ram is open
visually lowers Oil leaks inside the ram Defective seals, replace
them
The crane does not rotate Valves controlling the Adjust the valves
properly rotation not adjusted
Wear of the seals of the Replace the seals
rotation cylinder
The extension booms do Wear of guide shoes Check the guide
not completely extend or shoes wear,
work jerkily replace if necessary
Vibrations in crane Non efficient pump Check the pump
operations
Noteable decrease in Non efficient pump Check the pump
movement speed
28
HYDRAULIC AND ELECTRIC SCHEMATICS HYDRAULIC AND
ELECTRIC SCHEMATICS c XIV
F 390SE
Hydraulic schematic for crane - two Danfoss distributors - lifting moment limiting
device “intelligent” type

CODE DESCRIPTION

EV109 ELECTROVALVE VA209 SIMPLE EFFECT BLOCK VALVE

M1/M GAUGE QUICK CONNECTION VA224 LIFTING MOMENT LIMITING DEVICE VALVE
RU971 FAUCET VA225 LEVEL SENSOR VALVE
VA102 DOUBLE EFFECT BLOCK VALVE VA227 SEQUENCE VALVE
VA177 ANTIBURST VALVE FOR LIFTING RAMS VA232 UNIDIRECTIONAL VALVE
VA185 SELECTOR VALVE VA247 DOUBLE EFFECT BLOCK VALVE
VA194 DOUBLE EFFECT BLOCK VALVE

29
 HYDRAULIC AND Hydraulic schematic for crane - outriggers and outrigger extensions
c XIV ELECTRIC SCHEMATICS
F 390SE

CODE DESCRIPTION

DI490 DISTRIBUTOR
DV011 DEVIATOR
FI776 FILTER
FI854 FILTER
RU976 FAUCET
VA239 SIMPLE EFFECT BLOCK VALVE

30
Electric schematic for crane - two Danfoss distributors - free rotation HYDRAULIC AND
ELECTRIC SCHEMATICS c XIV
F 390SE

CODE DESCRIPTION

ALIM FEED MAIN CONTROL PANEL

C1 CONDENSOR FOR BLOCK DELAY
D3 POLARITY PROTECTION DIODE
D4 LIMITING DEVICE DIODE
D5 LIMITING DEVICE DIODE
EV1 EMERGENCY ELECTROVALVE
EV2 ELECTROVALVE FOR LIFTING BLOCK
EV3 ELECTROVALVE FOR DESCENT BLOCK
F1 PROTECTION FUSE 5A
IPB PROXIMITY SENSOR VALVE
MS MERCURY LEVEL SENSOR ON THE OUTER BOOM
MSG MICROSWITCH FOR OPERATOR PRESENCE ON TOP-SEAT
R1 RELAY FOR BLOCK DELAY
R2 RELAY FOR OPERATOR PRESENCE ON TOP-SEAT
RB STOP SIGNAL RELAY
RNA EMERGENCY RADIO REMOTE CONTROL RELAY

31
 OIL AND LUBRICANT
c XIV CHARACTERISTICS
OIL AND LUBRICANT CHARACTERISTICS
F 390SE
TABLE A

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

Consistency: NLGI BEACON EP 2 - BEACON 3

( ! ) WARNING ( ! )
Don’t use greases with solid particles as “Bisulphide of Molybdenum”.

32
INSTRUCTION AND WARNING PLATES INSTRUCTION AND
WARNING PLATES
F 390SE
A

DE 2676
Instruction plate and safety norms

DE 2327
Warning plate to stabilize the vehicle
before using the crane

Instruction plates
DE 3771 to stabilize the vehicle DE 3772

DE 3690

Crane controls plate

33
 INSTRUCTION AND
A WARNING PLATES
F 390SE

DE 1067
Do not walk or stay under a suspended
load and for unauthorized persons to be
within the working area.
DE1067

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
DE2361 Do not operate in proximity of electric
high-tension lines

DE 2100
Danger plate for crushing of lower limbs
34
 INSTRUCTION AND
WARNING PLATES
F 390SE
A

DE 1679
Do not walk on...

DE 1680
Do not use water to estinguish fire

DE 1681
Greasing points with brush

DE 1682
Greasing points at pressure

TIRANTI: NON SALDARE!

FIXING ROD: DO NOT WELD!
TIRANTS: NE PAS SOUDER!
ZUGSCHRAUBEN: NICHT SCHWEISSEN
DE1574
DE 1574

Do not weld the fixing rods

35
 CAPACITY PLATES CAPACITY PLATES
B F 390SE.24
For cranes and manual extensions.

The represented plates refer to the nominal design capacities.

! WARNING !

If the capacities are downgraded or partially reduced (e.g. sector in front of

vehicle cab) capacity plates must be applied in line with the final test figures.

36