FASSI CRANE 1

F 190AC.24
use and maintenance
FROM SERIAL NUMBER *4316*

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
3.2 Capacity plates with lifting moment limiting device
4 HYDRAULIC SCHEMATICS (version with lifting moment limiting device) ( )
5 ELECTRIC SCHEMATICS (version with lifting moment limiting device) ( )
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 Crane with distributor on the column
9.2 Crane with ground controls on both sides
Crane with ground controls on both sides and with top seat controls by hand cables
9.3 Crane with top seat controls and with ground controls for outriggers
10 NOMENCLATURE OF THE SAFETY AND PROTECTION DEVICES
10.1 Crane with distributor on the column
10.2 Crane with ground controls on both sides
Crane with ground controls on both sides and with top seat controls by hand cables
10.3 Crane with top seat controls and with ground controls for outriggers
11 SUPPLEMENTARY BEAMS
11.1 Generality
11.2 Identification of the supplementary beams
12 TILTABLE OUTRIGGER RAMS (not available)
13 MANOEUVRES AND CONTROLS TO STABILIZE THE VEHICLE
13.1 Generality
13.2 Functions of control levers for stabilization with horizontal distributor
13.2.1 Functions of control levers for stabilization with vertical distributor
13.2.2 Functions of control levers for stabilization with radio-remote control
13.3 Controls to stabilize the vehicle
13.4 Manually tiltable outrigger rams
13.5 Crane with hydraulic tiltable supports (with hydraulic motor) for outrigger rams

Edition 16.04.2008
14 CONTROLS TO OPERATE THE CRANE
14.1 Generality 1
14.2 Radio-remote control
14.2.1 Use of the radio-remote control
14.2.2 Push-button panel of the radio remote control “RCH”
14.2.3 Push-button panel of the radio remote control “SCANRECO”
14.2.4 Icon legend
14.3 Emergency station from the column (if accessible)
14.4 Manoeuvres to unfold the crane into a working condition
14.5 Manoeuvres to fold the crane into the rest condition
14.6 Manoeuvres to unfold the crane “C” into a working condition (only for the crane version C)
14.7 Manoeuvres to fold the crane “C” into the rest condition (only for the crane version C)
14.8 Indicator of inner boom horizontal position (optional)
14.9 Stand-up control station (if fitted)
15 MANOEUVRES OF THE CRANE LOADS (version with load limiting device) (not available)
16 MANOEUVRES OF THE CRANE LOADS (version with lifting moment limiting device) ( )
16.1 Generality
16.2 Lifting moment limiting device “EVOLUTION” (LMEV) and automatic dynamic control (ADC)
16.3 Control panels of the lifting moment limiting device
16.4 Load handling
16.4.1 “Block due to overload condition”
16.4.2 “Winch off”
16.4.3 “Lifting block” (Pro link)
16.4.4 Other functional characteristics
16.4.5 Visual indicator yellow/red light
16.5 Lifting moment limiting device for two working sectors
16.6 Rotation limiting device
16.7 Setting menu
16.8 Diagnostic: alarms and warnings
16.8.1 Temporary OVERIDE-Reactivation for the crane functions
16.9 XP device (if fitted)
16.9.1 Activation and instructions for use of the XP/CR device (if fitted)
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 (see “Setting Menù”)
19 CONTROLS TO OPERATE THE HYDRAULIC IMPLEMENTS OF THE CRANE
20 HYDRAULIC JIBS (not available)
20.1 Generality
20.2 Identification of the hydraulic jib
20.3 Nomenclature of the hydraulic jib
20.4 Manoeuvres to unfold the jib in working condition
20.5 Manoeuvres to fold the jib in rest condition
20.6 Operations to remove the hydraulic jib from the crane
20.7 Operations to mount the hydraulic jib on the crane
20.8 Hydraulic jib articulated at 25 degrees with the automatic control (L515-L516)(not available)
20.9 Use of the hydraulic jib articulated at 25 degrees (not available on the L102 and on the L515-L516)
(not available)
20.10 Crane with lifting moment limiting device and "Pro link" (if fitted)
21 WINCH (if fitted)
21.1 Generality (version with lifting moment limiting device)
21.2 Winch for crane (version with lifting moment limiting device)
21.2.1 Winches equipped with a mechanical stroke end device (version with lifting moment limiting device)
22 MAINTENANCE INSTRUCTIONS
22.1 Generality
22.2 After every 8 working hours or at the end of every working day
22.3 After every 40 working hours or after every working week
22.4 After every 100 working hours or more frequently in case of more intensive utilisation
22.5 After every 500 working hours or after every 6 working months
22.6 After every 1000 working hours or after every working year
22.7 Complete overhaul of the crane is required when 10.000 working hours or 10 years'life are reached
22.8 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
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 ope-
ration together with the optimization of machine performances.

All this represents the core of FASSI quality system.

FASSI quality system is in conformity with

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

FASSI cranes conform with the European Norm EN12999

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

The Manufacturer declines all responsibility and guarantee if the fitting is

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

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

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

The following instructions refer to 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
2 CLASSIFICATION OF THE CRANE MODEL CLASSIFICATION OF
THE CRANE MODEL 2
2.1 Generality F 190AC.24

The design of this crane has been carried out in respect of fatigue test classification H1B3 of the
EN12999 norm. The crane can operate, intermittently, with lifting devices other than the hook. The
dimensions and the capacity of the implements must be proportioned with crane performances.

2.2 Hydraulic jibs (not available)

2.3 Technical data

F 190AC.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 200)

16,70 tm 10,94 m 6,99 m 400° 3,05 tm 28,0 MPa 40 l/min 120 l 2420 kg 31,7 daN\cm2
163,8 kNm 29,9 kNm
CLASSIFICATION OF
THE CRANE MODEL 2.3
F 190AC.24
3 CAPACITY PLATES CAPACITY PLATES
F 190AC.24 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

CAPACITY PLATES
F 190AC.24 3.2
4 HYDRAULIC SCHEMATICS HYDRAULIC
SCHEMATICS 4
(version with lifting moment limiting device) GR4_190 - EVOLUTION
Hydraulic schematic for crane - Danfoss S800 distributor - “electronic” lifting moment
limiting device - CE

CODE DESCRIPTION

DI787 DISTRIBUTOR VA148 MAIN PRESSURE VALVE WITH ELECTRIC ACTIVATION

DV020 DEVIATOR VA185 SELECTOR VALVE
EV124 ELECTROVALVE VA265 DOUBLE EFFECT BLOCK VALVE
FI776 OIL FILTER (HIGH PRESSURE) VA264 SIMPLE EFFECT BLOCK VALVE
FI870 OIL FILTER (RETURN) VA215 OIL FLOW CHECK VALVE
M1/M2 GAUGE QUICK CONNECTION VA227 SEQUENCE VALVE
PR103 PRESSURE SWITCH VA232 UNIDIRECTIONAL VALVE
RU976 FAUCET VA233 DOUBLE EFFECT BLOCK VALVE
RU978 FAUCET VA239 SIMPLE EFFECT BLOCK VALVE
TR002 PRESSURE TRANSDUCER VA257 SEQUENCE VALVE
VA146 MAIN PRESSURE VALVE WITH ELECTRIC ACTIVATION
Hydraulic schematic for crane - versions HYDRAULIC
SCHEMATICS 4
GR4_190 - EVOLUTION

CODE DESCRIPTION

DI779 COMPENSATED FLOW CONTROL VALVE VA232 UNIDIRECTIONAL VALVE

DV016 FLOW REGULATOR VALVE VA233 DOUBLE EFFECT BLOCK VALVE
DV020 DEVIATOR VA247 OIL FLOW REGULATOR VALVE FOR ROTATION
VA185 SELECTOR VALVE CYLINDER
VA227 SEQUENCE VALVE VA266 REGENERATIVE VALVE
5 ELECTRIC SCHEMATICS ELECTRIC SCHEMATICS
EVOLUTION 5
Electric schematic for crane

SYMBOL DESCRIPTION

ALIM FX800 GENERAL FEEDING TEMP1+SC SENSOR ACTIVATION WARMTH EXCHANGING DEVICE
FARI ACTIVATION WORK LIGHTS TI1 SENSOR OF CORNER ON SECUNDARY ARM
EV1 ELECTROVALVE FOR CRANE BLOCK TI2 SENSOR OF CORNER ON HYDRAULIC JIBS
EV2 ELECTROVALVE DOUBLE LIMITING DEVICE TP0 PRESSURE TRANSDUCER FOR DISTRIBUTOR
EV3 XP ELECTROVALVE TP1 PRESSURE TRANSDUCER FOR INNER RAM
EV4 ELECTROVALVE FOR PRESSURE REDUCTION OF TP2 PRESSURE TRANSDUCER FOR SECONDARY RAM
REGENERATIVE EXTENSION EXIT TP3 PRESSURE TRANSDUCER FOR THE
EV5 REGENERATIVE ELECTROVALVE JIB RAM
FX800 CENTRAL PROCESSING UNITY IP4 SENSOR OF PROXIMITY CONTROL STATION
FX801/A/G USER PANEL PROTECTION
IP1/2/3 PROXIMITY MICROSWITCH FOR ROTATION CONTROL FTC PHOTOCELL OPERATOR PRESENCE ON CONTROL
LCV WINCH LOAD LIMITING DEVICE STATION
LG YELLOW LIGHT 90% DF FLOW DEVIATOR (FOR VERSIONS FROM
LP LUMINOUS TOWER GROUND AND FROM SEAT)
LR RED LIGHT 100% FX804 CONTROL UNITY EXTENSIONS/STABILIZERS
MV2 RUN END WINCH ALIM FX804 FEEDING FX804
OPTION OPTIONS EVE1…EVE4 ELECTROVALVE FOR CONTROL EXTENSION 1…
PLE CONTACT FOR PLATFORM EXTENSION 4
RC RECEIVER OF THE RADIO EVS1…EVS4 ELECTROVALVE FOR CONTROL STABILIZER 1…
MAN SELECTOR REMOTE/MANUAL FOR CRANE USE WITH STABILIZER 4
RADIO OR MANUAL EVR / EVU ELECTROVALVE FOR CONTROL EXIT/RETURN
FX002/1/2 WINCH LOAD LIMITING DEVICE EXTENSIONS/STABILIZERS
S3 CONNECTION SENSOR HYDRAULIC JIB EVDEV ELECTROVALVE FOR CONTROL ELECTRICIAL
CONNECTING DEVICE DEVIATING DEVICE CRANE/STABILIZERS
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

7 WARNING AND INSTRUCTIONS WARNING AND
INSTRUCTIONS 7
7.1 Generality GRU FASSI

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
and maintenance manual supplied with the crane. (See norms ISO 9926-1).

It is 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.

Do not run the engine in a indoor area without first making sure there is adequa-
te ventilation. 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.
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.
The crane must be activated only in the stability conditions. Park the vehicle cor-
rectly and insert the parking brake.

7.2 Before operating

(!) ATTENTION (!)
Make sure that the protections are in their place and that all the safety devi-
ces are fitted and active (See norms ISO 9927-1).

Keep the ladder and the control station on the top seat clean (if present).
Normally, the seat can be tilt forward.

Make sure that control stations, the instruction plates and the loading charts
are properly lit and visible, so as to ensure safety while operating.

Pay attention to not crash against the control station on the top seat (if fitted)
during manoeuvres.

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 connected to the crane hook by
means of a chain having at least three (3) rings.
7.3 During operation WARNING AND
INSTRUCTIONS 7.3
GRU FASSI
Locate and delimit the working area.

Make sure that no one is within the working area of the crane. Do not stop and
do not pass in the delimited area.

Choose the correct control position, making sure to have the complete visibility of
the working area.

Stabilize the vehicle on a horizontal plane with a maximum tolerance of 1,5

degrees. Check the vehicle inclination on the levelness indicator. The bubble must
be contained in the internal circle, and in any case it doesn't must to come out from
the external circle.

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 (!)

The stability of the unit (crane-vehicle) is only guaranteed by the complete
lateral extension of the outriggers and by the observance of the capacity
plates.

The values of the support force F are indicated in the table at paragraph "2.3 Technical
Data". Just as an indication it's enclosed the below table.

ADMITTED PRESSURE ON THE GROUND (Load capacity of the ground) - Rif. DIN 1054
A Made ground, not compacted artificially 0 - 10 daN/cm²
B Asphalt 20 daN/cm²
C Compact ground, not removed
1. Mud, peat, marshy ground 0 daN/cm²
2. Not compacted ground, adequately solid
From fine to middle sand 15 daN/cm²
From thick sand to gravel 20 daN/cm²
Shattered and compacted stones 25 daN/cm²
3. Compact ground
Wet 0 daN/cm²
Soft 4 daN/cm²
Compact 10 daN/cm²
Half - solid 20 daN/cm²
Hard (solid) 30 daN/cm²
4. Rock
Eroded 100 daN/cm²
 (!) ATTENTION (!) WARNING AND
Carefully inspect the load rigging. INSTRUCTIONS 7.3
GRU FASSI
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.

(!) ATTENTION (!)

Avoid swinging the load above working and transit areas. Any hidden dan-
ger situation must be audibly alarmed. 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 fitted).

During the loading and unloading operations it is prohibited to leave the control sta-
tion or the control at a distance.
Activate the controls with slow and progressive movements. Move the load with
the greatest caution, and avoid swingings and collisions. Avoid the rapid displace-
ments and the temporary stops, since they can cause the load swinging.

Do not rotate the crane before the load is lifted. 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 (!)
Handle the wet or frozen load with the maximum attention: it exists the
skidding danger. It's obligatory to clean the load from the ice or the snow
before lifting.

When operating through a winch, lift the load vertically using the cable and
not the booms in order to avoid swinging the load.

The crane must be used exclusively to lift loads.

It is prohibited to unblock, hit, pull or drag the loads.
It is prohibited the lateral traction or the vehicles drawing.

(!) ATTENTION (!)

Do not utilize the crane for pushpull (F), lateral (F) or sideways (F)
operations.
Crushing (F) or push (F) manoeuvres 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 when the crane is not in transport position.
Do not move the vehicle with a load suspended on the crane.

(!) ATTENTION (!)

Avoid working conditions which present danger for the operator and the per-
sons present in the action area of the crane, the outriggers or the load.
- CRUSHING DANGER / SHEARING DANGER WARNING AND
Avoid all those situations which may result in crushing during vehicle stabiliza- INSTRUCTIONS 7.3
tion, crane movement and load handling. GRU FASSI

The table indicates the minimum safety working distances concerning the
various parts of the body. The figures illustrate circumstances which may turn
out to be dangerous if you fail to respect the minimum safe distances and if it is
impossible to introduce larger parts of the body.
(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

Foot 120
Leg 180

Toes 50 Arm 120

Hand
Wrist 100 Finger 25
Fist

(!) ATTENTION (!)

Failure to respect the minimum safe distances may result in a safety
hazard and a deadly risk.
(!) 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.
- ELECTROCUTION DANGER
General safety precautions for the operator and potential co-workers.

(!) ATTENTION (!)

Respect the safety distances from electric lines; the minimum distance is,
according to CEN norms, five (5) meters, except for otherwise prescribed
by national norms. Failure to respect the minimum safe distances may result in
electrical hazards for the operator and his assistants.

If the crane comes into contact with an electric line, it's necessary to follow the next
procedure:
- 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 WARNING AND
extremely hazardous to go out before the line is de-energised. INSTRUCTIONS 7.3
- Help the electricuted person if you know the first-aid procedures, otherwise wait for the GRU FASSI
paramedics to arrive.

(!) ATTENTION (!)

A wind gust can cause the swinging of an electric line.
Do not utilize the crane during thunderstorms and when wind speed excee-
ding 13,8 m\s (50 km/h), maximum value of the Beaufort scale degree 6.

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)

- BURN DANGER
During the oil flow in the hydraulic circuit, the oil and all the components of the circuit
reach high temperatures.
It's necessary to verify the temperature of every hydraulic component before to touch it,
for to avoid burns.

- USE TEMPERATURE AND CRANE STORING

The crane is designed for the utilization at ambient temperature included in the below
table. If the ambient temperature of utilization is not included in the indicated limits, the
crane functionality can be compromised.
Temperatures too high or too low can damage the components of the oleody-
namic and electric circuit, and compromise the crane functioning.
If the crane is used in the presence of ice or snow, it's necessary to start the hydraulic
system at the minimum speed of the motor. It's necessary to do circulate the oil for some
minutes, until to its heating.

(!) ATTENTION (!)

It's obligatory to clean the load from the ice or the snow before lifting.
USE TEMPERATURE AND CRANE STORING
Temperature of the working ambient of the crane -30°C to +50°C
Temperature of the storage ambient of the crane -40°C to +70°C

(!) ATTENTION (!)

If you work at ambient temperature different from that prescribed in the table,
it's obligatory to request the specific authorization to the FASSI GRU.
7.4 At the end of the operation (Prior to driving the vehicle) WARNING AND
INSTRUCTIONS 7.4
GRU FASSI
Unhook the load, and make re-enter the crane booms.

Fold the crane.

Make the re-enter of the outrigger cylinders one at a time, checking every single
organ in motion. The operator must have a full visibility during every operation of
re-entry of the stabilization organs.
Make sure that the outrigger supports and rams are re-entered within
the overall width of the truck and locked by the safety devices.

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 res-
pected.

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.

Disengage the power take off.

Fix the load adequately, to avoid the fall of the load from the vehicle during
march.

(!) ATTENTION (!)

After having closed the crane, and having do the re-enter of the outriggers,
it's necessary to fix all the crane organs, to avoid the booms or outriggers exit
during the vehicle march.
Hook all the fixing devices correctly.

(!) ATTENTION (!)

Annotate the maximum dimensions of the vehicle, included the possible tran-
sported load. Respect the greatest height of volume for the transit below the
tunnels, bridges, subways, tension lines and the maximum axial loads con-
sented from the vehicle.
7.5 Residual risks WARNING AND
INSTRUCTIONS 7.5
Utilize the crane only for the provided aims by the Use and Maintenance manual. GRU FASSI
It is prohibited the crane utilization for differents aims to those indicated in the
Use and Maintenance manual.

(!) ATTENTION (!)

It is prohibited the crane utilization not by qualified staff.
The operator is responsible for the machinery, its movements, the load
movement and all the working area of the crane.

Therefore it's necessary the maximun attention in all the phases of the crane ope-
ning and closing, of stabilization and of the load handling, it exist a series of resi-
dual risks, not predictable completely, which can create danger for the employed
in the crane handling
In the below list are indicated some residual risks, that have as danger a relie-
ved and in movement load, which request particular attention during the working
period.

MOMENT LIMITING DEVICE

Never try to bypass nor tamper with the moment limiting device and the
various safety systems installed on the crane. In such case the operator shall
be held responsible for the subsequent crane performance. 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 is
safe from hazards (i.e. stand clear of the load, make sure that 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, must 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. The operator shall also teach this even-
tually 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 movements are
not allowed. Be careful not to hit any potential impediments during the crane
movements.
If the load sticks out of the maximum volumes of the vehicle, the operator must
make sure of the new maximum dimensions of volume, to avoid collisions with
the tunnels, the subways, the bridges and the electric lines.
JOBSITE CONDITIONS
Enclose the working zone. Prior to use, make sure 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 WARNING AND
The crane can break down due to fatigue or overload: INSTRUCTIONS 7.5
- If it is misused (with cycles, loads or pump oil flow not pertinent to the crane class) GRU FASSI
- 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
Utilize the crane only for the provided aims by the Use and Maintenance manual.
It is prohibited the crane utilization for differents aims to those indicated in the
Use and Maintenance manual.

WRONG MANOEUVRING
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.
The crane can fall break or overturn if the operator performs a wrong manoeu-
vre, due to the lack of familiarity with the operation procedures or due to inade-
quate psychophysical conditions.

WEATHER CONDITIONS
Too high or too low temperatures may damage the components of the oleody-
namic and electric circuits. 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.
In the chapter "7.3 During operation" are indicated the utilization limits for the
temperature, the wind loads and the annexed danger (electrocution, collisions,
etc.).

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.
In the chapter "7.3 During operation" are indicated the utilization limits for the
ground consistency and the load capacity of the ground.

SHEARING, ENTRAPMENT
The crane has a lot of parts in movement that it is impossible to cover.
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
for himself and also for those working people in proximity of the crane, and for
those who may draw closer even if not authorized.
ELECTRICUTION WARNING AND
The crane is not insulated from electric contacts and therefore it is not equipped INSTRUCTIONS 7.5
to work under tension, even if the contact is accidental. Therefore be compliant GRU FASSI
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.
The operator must consider the ambiental conditions: a wind gust can cause
the crane swinging, and so a contact with the electric lines.
The minimum distance of safety can differ according to typ of the electric line.
It's obligatory to respect the regulation in force in the country of use for to can
operate in safety.

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.
It's prohibited to overload the extensions over the indicated limits in the capaci-
ty plates.
In the chapter "3 Capacity plates" are indicated the maximum capacity of the
manual extensions.

ACCESSORIES
Be careful when assembling and disassembling the accessories (extensions,
buckets, baskets,…): verify the weight, the securing systems and the instruc-
tions for assembly and dismantlement, then appraise their barycentre and
provide for adequate provisional blocking systems in order to avoid sudden
movements.

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.
It's obligatory to replace the damaged or spoilt components for to work with
safety, and for to obtain the best performances of the crane.

MAINTENANCE
Maintenance is particularly important: the lack of it may damage things or hurt
people.
In the chapter "22 Maintenance instructions" are described all the operations
for to maintain efficient your crane, and to avoid serious damages to things and
persons caused by the crane malfunction for the scarce or null maintenance.

(!) ATTENTION (!)

The FASSI GRU declines every responsability for the spoilts, the breakin-
gs or the damages caused by the maintenance failing.

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.
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

The CE indicates that the crane complies with the Machines

Directive (D.M.) 98/37; it can be considered effective only with a
written declaration of conformity enclosed.
The cranes with the CE mark and the capacity superior to 1000 1
kg and/or the lifting moment superior to 40KMm is supplied with
a lifting moment limiting device, that preserves the structure from 2
possible overloads. 3

Identification data are marked on the plate DE5891 used for the CE
mark (fig. 2) and rivetted on the base with personalized rivets FASSI. fig. 2

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

The crane must not be put into service within the European Community unless
the machine on which it is mounted also conforms with the prescribed Directive.
Ever change of use, modification or addition of accessories, not specified by this
manual must be affixed with a new CE mark in accordance with the Machinery
Directive.

A further metallic plate (fig. 3) fixed to the crane by the installer, quotes the
identifying data of the equipment and the final CE mark.
1

1- Name of the installer who

applied the final CE mark
2- Crane mark, model and
serial number
CRANE - MARK AND MODEL
3- Vehicle mark, model and 2 SERIAL NUMBER
chassis number
TRUCK - MARK AND MODEL
4- Year of mounting 3 TRUCK FRAME SERIAL NUMBER

4 YEAR OF MOUNTING
fig. 3

(!) ATTENTION (!)

It is forbidden to alter the data marked on the plates.
9 CRANE NOMENCLATURE CRANE
NOMENCLATURE 9
GR4 - EVOLUTION
9.1 Crane with distributor on the column

Pos. Description

1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Dual control for deviator crane-outriggers
7. Outrigger distributor
8. Outrigger double control
9. Distributor bank
10. Column
11. Inner ram
12. Inner boom
13. Outer ram
14. Outer boom
15. Booms extension rams
16. Extension boom sections
17. Lifting hook
18. Oil tank
19. Manual extensions (optional)
9.2 Crane with ground controls on both sides. CRANE

Crane with ground controls on both

NOMENCLATURE 9.2
GR4 - EVOLUTION
sides and with top seat controls by
hand cables (on request)(fig. 1)
Pos. Description

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

fig. 1
9.3 Crane with top seat controls and with
ground controls for outriggers (fig. 2)
Pos. Description

1. Outrigger rams
2. Outrigger supports
3. Base
4. Rotation cylinders
5. Deviator crane-outriggers
6. Dual control for deviator crane-outriggers
7. Outrigger distributor
8. Outrigger double control
9. Column
10. Seat
11. Distributor bank
12. Inner ram
13. Inner boom
14. Outer ram
15. Outer boom
16. Booms extension rams
17. Extension boom sections
18. Lifting hook
19. Oil tank
20. Manual extensions (optional)

fig. 2
10 NOMENCLATURE OF THE SAFETY AND NOMENCLATURE OF

PROTECTION DEVICES
THE SAFETY AND
PROTECTION DEVICES
10
GR4 - EVOLUTION

10.1 Crane with distributor on the column

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
7. Control panels
8. Rotation limiting device
9. Main pressure valve (outriggers)
10. Main pressure valve (crane)
11. Auxiliary valves (crane)
12. Safety device for outriggers supports
13. Hook safety device
14. Safety device for extension booms (only for the crane version “C”)

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.

10.2 Crane with ground controls on both sides. NOMENCLATURE OF

Crane with ground controls on both

THE SAFETY AND
PROTECTION DEVICES
10.2
sides and with top seat controls by GR4_170»250
hand cables (on request)(fig. 1)
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
7. Control panels
8. Rotation limiting device
9. Main pressure valve (outriggers)
10. Main pressure valve (crane)
11. Auxiliary valves (crane)
12. Levers guard
13. Safety device for outriggers supports
14. Hook safety device
15. Safety device for extension booms
(only for the crane version “C”)

10.3 Crane with top seat controls and

with ground controls for outriggers
(fig. 2)
Pos. Description

1. Check valves for outrigger rams fig. 1

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. Control panel
8. Rotation limiting device
9. Main pressure valve (outriggers)
10. Main pressure valve (crane)
11. Auxiliary valves (crane)
12. Levers guard
13. Safety device for outriggers supports
14. Hook safety device
15. Safety device for extension booms
(only for the crane version “C”)

Before crane use check that safety and protection devices

are fitted and active.

Under no circumstances interfere with the safety and pro-

tection 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.

fig. 2
11 SUPPLEMENTARY BEAMS SUPPLEMENTARY BEAMS
GR4 - EVOLUTION 11
11.1 Generality
Supplementary beams are used in conjunction with the crane outriggers to
ensure the vehicle stability during load handling.

outrigger ram outrigger extension Weight

Code type kg
stroke mm interaxis mm
210803ME 455(C)/560(L) 3100 manually-“H” variable 130
210802ME 455(C)/560(L) 3600 manually-“H” variable 162
290800HE 340(C)/550(L) 4100 Hydraulic-“H” variable 320
540800HE 330(C)/510(L) 5000 Hydraulic-“H” variable 550

11.2 Identification of the supplementary beams

Identification data of the supplementary beam is stamped on the plate DE6839
(fig. 1).

fig. 1

DE6839
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.
13.2 Functions of control levers for stabilization with SUPPLEMENTARY

horizontal distributor
BEAMS 13.2
GR4 - EVOLUTION

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

GRAPHIC SYMBOLS (See Paragraph 25 Instruction and warning plates)

The graphic symbols illustrated hereunder are marked on the plates (DE6251-DE6252-
DE4496-DE4489) affixed next to the control stations and indicate with the following sym-
bolism.

They indicate the position of the operator in

relation to the vehicle and the crane.

Lever CD for selecting Levers D

outrigger ram Deviator -E/S
or
outrigger support

Lever C to control
outrigger support
or
outrigger ram

fig. 1a fig. 1b
Lever function D - CD - C

Levers D Control for deviator

crane-outriggers ( - E\S ). CD
(fig. 1a) C

Levers CD Control for selecting the

supports or the outrigger D
rams. (fig. 1b)

Levers C Control for the support or C

the outrigger ram selected
(fig. 1b) D

Gripping the levers, the "multifunction" control

CD
group adopted allows to select and manoe-
uvre the outrigger support or the ram. The
function happens through simultaneous ope-
ration of the selecting lever CD and the con-
trol lever C.

Exemple
To select the support E2 or the outrigger ram S2
- Position the lever CD (corresponding to outrigger support E2 and to outrigger
ram S2) on E2 or S2 and keep it in position.
To carry out the operation
- Operate lever C to activate the exit/re-entry of outrigger support E2 or the
descent/lift of outrigger ram S2
13.2.1 Functions of control levers for stabilization SUPPLEMENTARY

with vertical distributor

BEAMS
GR4 - EVOLUTION
13.2.1
The controls to stabilize the vehicle are activated only from ground level and on
both sides of the crane base.

GRAPHIC SYMBOLS (See Paragraph 25 Instruction and warning plates)

The graphic symbols illustrated hereunder are marked on the plates (DE4486-
DE4487-DE4488) affixed next to the control stations and indicate with the fol-
lowing symbolism.

They indicate the position of the operator in

relation to the vehicle and the crane.

Lever CD for selecting Levers D

outrigger ram Deviator -E/S
or
outrigger support

Lever C to control
outrigger support
or
outrigger ram

Lever function D - CD - C fig. 2a -2b

CD
Levers D Control for deviator
crane-outriggers ( - E\S ).
(fig. 2a)

Levers CD Control for selecting the

supports or the outrigger
rams. (fig. 2b)
C
Levers C Control for the support or
the outrigger ram selected
(fig. 2b) CD

The "multifunction" control group adopted allows

to select and manoeuvre the outrigger support or
the ram, through simultaneous operation of the
selecting lever CD and the control lever C.

Exemple
To select the support E2 or the outrigger ram S2
- Position the lever CD (corresponding to outrigger support E2 and to outrigger
ram S2) on E2 or S2 and keep it in position.
To carry out the operation C
- Operate lever C to activate the exit/re-entry of outrigger support E2 or the
descent/lift of outrigger ram S2
13.2.2 Functions of control levers for stabilization with SUPPLEMENTARY

radio-remote control
BEAMS
GR4 - EVOLUTION
13.2.2
The controls to stabilize the vehicle with radio-remote control are activated
only from the push-button panel of the transmitting-console.

(!) ATTENTION (!)

Before starting manoeuvring of the stabilisers with the radio remote control, the
operator shall make sure that their movements are fully visible.

- RCH PUSH-BUTTON PANEL

You can select whether to control the outrigger functions using the buttons pla-
ced on the remote control as follows:
- Position the rotating selector on the icon . "?outriggers?" appears on
the display.
- Confirm the operation pressing contemporarily the left buttons "CLACSON"
and "INDEX". "outriggers" appears on the display.

You can select whether to control the crane functions using the buttons placed
on the remote control as follows:
- Position the rotating selector on the icon . "?crane?" appears on the
display.
- Confirm the operation pressing contemporarily the left buttons "CLACSON"
and "INDEX". The indications of the crane load appear on the display.

LINEAR PUSH-BUTTON PANEL (fig.3) LINEAR PUSH-BUTTON PANEL fig. 3

The first 5 control levers on the push-button panel (beginning on the
right) have two plates because they can control 5 functions of the ROTATING
DISPLAY
crane or the functions for stabilization. SELECTOR
Hereunder are reported the plates indicating the stabilization fun-
ctions for every lever. CLACSON

LEVERS CD LEVER C

INDEX
C

CD

PUSH-BUTTON PANEL WITH JOYSTICK (fig.3a)

The three control joy-sticks on the push-button panel have two PUSH-BUTTON PANEL WITH JOY-STICK fig. 3a
plates because they can control the functions of the crane or
DISPLAY
the functions for stabilization. ROTATING
Hereunder are reported the plates indicating the stabilization CLACSON SELECTOR
functions for the joystick.
CD

C
LEVERS CD LEVER C

INDEX

Rotating selector Selector of the icons on the display.

Leve CD Controls for the selection of the outrigger supports and
of the outrigger rams.
Leva C Control of the selected outrigger support or ram.
 SUPPLEMENTARY
- SCANRECO PUSH-BUTTON PANEL BEAMS
GR4 - EVOLUTION
13.2.2
You can select whether to control the outrigger functions using the buttons pla-
ced on the remote control as follows:
- Position the rotating selector on the icon . "?outriggers?" appears on
the display.
- Confirm the operation pressing contemporarily the buttons "INDEX" and
"IGNITION". "?outriggers?" appears on the display.

You can select whether to control the crane functions using the buttons placed
on the remote control as follows:
- Position the rotating selector on the icon . "?crane?" appears on the
display.
- Confirm the operation pressing contemporarily the buttons "INDEX" and
"IGNITION". The indications of the crane load appear on the display.

LINEAR PUSH-BUTTON PANEL (fig.4)

The first 5 control levers on the push-button panel (beginning on the LINEAR PUSH-BUTTON PANEL fig. 4
right) have two plates because they can control 5 functions of the crane
or the functions for stabilization.
CD C
Hereunder are reported the plates indicating the stabilization func- DISPLAY
tions for every lever.

LEVERS CD LEVER C

INDEX
ROTATING
SELECTOR
IGNITION

Rotating selector Selector of the icons on the display.

Leve CD Controls for the selection of the outrigger supports and
of the outrigger rams.
Leva C Control of the selected outrigger support or ram.
 SUPPLEMENTARY
MANOEUVRES OF THE OUTRIGGER RAMS IN CASE OF AN ELE- BEAMS
GR4 - EVOLUTION
13.2.2
CTRICAL FAILURE

In case of an electrical failure, electrical malfunctions, you cannot

use the selectors on the push-button panel and so it is necessa-
ry to operate directly the outrigger distributor bank (fig. 5).
In such an emergency condition, the operator shall make sure
that no one is within or passing in close proximity to the working
area of the outriggers, neither from the operator side nor from the
opposite side. The operator shall be able to visually see the CD

whole working area at all times. If it is not possible he shall team up

with a co-worker (i.e. located on the opposite side of the crane) in a
way not to harm each other while manoeuvring the outriggers (i.e.
disengage of the locking devices of the outrigger supports, see fig.
6-6a). To operate with the distributor bank use the two levers
without thread in equipment.

PICTURE LIST (fig. 5):

Levers CD Controls to select the outrigger supports and rams. C
Levers C Control of the selected outrigger support or ram.
T Electric deviator of the crane-outriggers (fig. 5a) CD C

Example: re-entry of the outrigger ram S1

- tighten the T screw (fig. 5a)
- activate the corresponding lever CD towards "S1" and keep it in
position.
- activate the lever C to control the descent of the ram.
- to reactivate the crane functions loosen the T screw, to the previous
position (see fig. 5a)

After such emergency operations and prior to re-use of the crane,

you must immediately go to a FASSI authorised Center for the fig. 5
repair of the fault and re-sealing of the device.

(!) ATTENTION (!)

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

fig. 5a

fig. 6 fig. 6a
13.3 Controls to stabilize the vehicle SUPPLEMENTARY
BEAMS
GR4 - EVOLUTION
13.3
The controls conform with the safety directives and enable the operator to acti-
vate the lateral extension of the outrigger supports and rams only from the side
where he can visually check the operation.

Controls for positioning the outriggers of the crane and the supplementary beam.
Disengage the locking devices of the outrigger supports by putting the levers A A
from the position of the fig. 7 to the one of the fig. 8.

Controls workable from the distributor side of the crane fig. 9 and fig. 9a

horizontal distributor fig. 9 vertical distributor

fig. 7

Position lever D of oil-diverter ( -E/S) on E/S.

How to exit the outrigger support E2 (crane)

- Operate the corresponding lever CD towards "E2" and keep it
in position.
- Operate the lever C to exit the outrigger support.

How to descent the outrigger ram S2 (crane)

- Operate the corresponding lever CD towards "S2" and keep it fig. 8
in position.
- Operate the lever C to descent the outrigger ram.

How to exit the outrigger support E3 (supplementary outriggers) fig. 9a

- Operate the corresponding lever CD towards "E3" and keep it
in position.
- Operate the lever C to exit the outrigger support.

How to descent the outrigger ram S3 (supplementary outriggers)

- Operate the corresponding lever CD towards "S3" and keep it in position.
- Operate the lever C to descent the outrigger ram.
(!) ATTENTION (!)
Operation of the crane outrigger supports must be from the control station
on that side; it is not allowed to operate outriggers on the opposite side of
the vehicle due to unseen dangers. DE4491 (fig. 11)

Controls workable from the double control side of the crane fig. 10 e fig. 10a

vertical distributor fig. 11

horizontal distributor fig. 10

How to exit the outrigger support E1 (crane)

- Operate the corresponding lever CD towards "E1" and keep it
in position.
- Operate the lever C to exit the outrigger support.

How to descent the outrigger ram S1 (crane)

- Operate the corresponding lever CD towards "S1" and keep it
in position.
- Operate the lever C to descent the outrigger ram.

fig. 10a
How to exit the outrigger support E4 (supplementary outriggers) SUPPLEMENTARY BEAMS
- Operate the corresponding lever CD towards "E4" and keep it in position. GR4 - EVOLUTION 13.3
- Operate the lever C to exit the outrigger support.

How to descent the outrigger ram S4 (supplementary outriggers)

- Operate the corresponding lever CD towards "S4" and keep it in position.
- Operate the lever C to descent the outrigger ram.

(!) 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. 12)

The stabilization has to be carried out with care and gradually keeping the vehi-
cle in horizontal levelled condition to prevent springs overloads and chassis tor-
sions.

(!) ATTENTION (!)

During the stabilising operations, for each outrigger ram, it is recommen- fig. 12
ded to DESCENT the outrigger as the last manoeuvre.

To operate the crane controls, after having completed the descent and stabilisa-
tion manoeuvres,
- Position lever D of oil diverter ( - E/S) on . (Fig. 1)

Manoeuvres for re-entry of the crane outriggers and supplementary outriggers

within the overall vehicle width after crane use.
Position lever D of oil diverter ( - E/S) on E/S. (Fig. 1)

How to lift the outrigger ram S

- Operate the corresponding lever CD towards "S" and keep it in position.
- Operate the lever C to lift the outrigger ram. (Fig. 2)

How to re-enter the outrigger support E

- Operate the corresponding lever CD towards "E" and keep it in position.
- Operate the lever C to re-enter the support. (Fig. 2)

(!) ATTENTION (!)

Keep hands clear of automatic stop device of the outrigger supports.
(Fig. 7-8).
Always check that the outrigger supports, once in their rest position, are loc-
ked in their seat by the safety devices, so as to assure the impossibility of
accidental movement. (Fig. 7-8).
13.4 Manually tiltable outrigger rams SUPPLEMENTARY BEAMS
GR4 - EVOLUTION 13.4
Outrigger rams are allowed to be stored in an inclined position, when obstructions on
the vehicle chassis prevent their vertical stowability. These hinged supports are pla-
ced between the outrigger supports and the rams; the fixed part is
screwed to the supports while the mobile part is screwed to the rams.
(fig 13-13a)
To place the rams in a working condition. (fig. 13)
- Supporting the ram, remove the check pin and the locking pin
from their positions.
- Position, carefully, the ram in working condition, insert the locking
pin in its new position and secure it with the check pin (fig. 13a)
To re-position the rams to the folded position.
- Remove the check pin and the locking pin.
- Position, the ram in a upward direction and supporting the
ram, insert
- the locking pin in its new position and secure it with the check pin fig. 13a
fig. 13
(!) ATTENTION (!)
The locking pin is constructed fromspecial material. Do not replace it with a
non original part: your security depends on it.

13.5 Crane with hydraulic tiltable supports (with hydraulic

motor) for outrigger rams:

(!) ATTENTION (!)

Be very careful during vehicle stabilization operation; make sure that there fig. 16
are no obstacles preventing the rotation of the rams and that no one is or
transits in close proximity of the working area of the outrigger rams.
- Disengage the locking devices of the outrigger supports by putting the horizontal distributor
levers A from the position of the fig. 14 to the one of the fig. 15.

- Position lever D of oil diverter ( -E/S) on E/S.

fig. 17

fig. 18

vertical distributor

fig. 14 fig. 15

Controls workable from the distributor side of the crane

fig. 17 DE6340; fig. 17a DE5263

Controls workable from the double control side of the crane

fig. 18 DE6341; fig. 18a DE5264

- By using the levers CD, the lever C and the valve taps (fig. 16), extend the
outrigger supports, rotate the outrigger rams putting in a working condition
and lower them till the complete stabilisation of the vehicle. (Fig. 19-20)

fig. 17a fig. 18a

Example of using the levers CD, the lever C and the valve tap on the outrigger: SUPPLEMENTARY BEAMS
- extension of the outrigger support n°1 GR4 - EVOLUTION 13.5
- activate the corresponding lever CD towards "E1" and keep it in position;
- activate the lever C towards right to obtain the extension of the support.
- rotation of the outrigger ram n°1 from the rest position (fig. 13) to the
working condition (fig. 13a)
- make sure that the tap R1 of the valve of DISTRIBUTOR SIDE DISTRIBUTOR SIDE
the outrigger ram S1 is closed (for the
closed or opened position see fig. 16);
- before removing the pin 1 proceed as
follows:
- activate the corresponding lever CD
towards "S1 R1" and keep it in
position;
- activate the lever C in the opposite
direction to control the rotation and take
the ram S1 to its rest position so that
the pin 1 is extractable;
- to remove the pin 1 rotate its handle B
in the anticlockwise rotation after
disengaging the safety device F; DE 5733
- to rotate the outrigger ram S1 proceed as
follows:
DOUBLE CONTROL SIDE
- activate the corresponding lever CD
towards "S1 R1" and keep it in fig. 19
position;
- activate the lever C in the opposite
direction to control the rotation and take
the ram S1 to its working condition. DOUBLE CONTROL SIDE

(!) ATTENTION (!)

Make sure that no one is or transits in close
proximity of the working area of the outrig-
gers.

- insert the pin 1 in its new seat and lock it

with a clockwise rotation (the safety device DE 5734
F sets off automatically);

(!) ATTENTION (!)

The locking pin 1 is constructed from special material do not replace it with
a non original part. Your security depends on it.

- descent of the outrigger ram n°1 B

- open the tap R1 of the valve of the outrigger ram S1; F 1
- activate the corresponding lever CD towards "S1 R1" and keep it in
position; fig. 20
- activate the lever C in the opposite direction till the requested extension of
the outrigger ram S1;
- close the tap R1 of the valve of the outrigger ram S1.

(!) ATTENTION (!)

The complete extension of the outrigger supports is visually indicated by
the yellow triangles which are found at the end of the beam (and of the sup-
port if it’s supplied with extra double extension beams). (Fig. 12).

The stabilization has to be carried out with care and gradually keeping the vehicle
in horizontal levelled condition to prevent springs overloads and chassis torsions.

(!) ATTENTION (!)

During the stabilising operations, for each outrigger ram, it is recommended
to DESCENT the outrigger as the last manoeuvre.
To operate the crane controls, after having completed the stabilisation manoeu- SUPPLEMENTARY BEAMS
vres, GR4 - EVOLUTION 13.5
- Position lever D of oil diverter ( - E/S) on .
- Position selector ( - E/S) of the push-button panel on .

Manoeuvres for re-entry of the crane outriggers and supplementary outrig-

gers within the overall vehicle width after crane use.

- Repeat by inverting the sequence of the operations effected for the stabiliza-
tion of the vehicle.

(!) ATTENTION (!)

Keep hands clear of automatic stop device of the outrigger supports. (Fig. 7-8).
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. 7).
14 CONTROLS TO OPERATE THE CRANE CONTROLS TO
OPERATE THE CRANE 14
GR4 - EVOLUTION
14.1 Generality
(!) WARNING (!)
Before operating the crane it is compulsory to set the outriggers. (Plate
DE6723 fig. 1)

The crane and hydraulic implements can be manually operated with:

- with the radio-remote control
- with controls from the emergency station from the column (if accessible)
- ground controls on both sides.

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

fig. 1
14.2 Radio-remote control CONTROLS TO
OPERATE THE CRANE 14.2
GR4 - EVOLUTION
14.2.1 Use of the radio-remote control
(!) ATTENTION (!)
First read the instructions given in the User's Manual supplied by the
Manufacturer before using the remote control to avoid improper use.

The plates shown on the side of each push-button panel lever of the radio remote
control determine the operation of the levers in relation to the movement of the
crane.

(!) ATTENTION (!)

The sequence of the plates placed on the crane controls may be different.
Make sure that the lever you are going to operate corresponds to the control
you selected.

(!) ATTENTION (!)

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 stro-
ke end of a particular function, an increase in speed of the other functions
will occur.

- TELE-RADIO REMOTE CONTROL

The radio remote control, in the case of a discharged battery or in the presence of
interference in the radio transmission, or use of the crane in situations where the
transmission by radio is forbidden, can be easily transformed into tele-radio remote
control.
Connect the push-button panel and the socket, indicated by the DE6998 plate (fig.
2), placed on the base with the serial cable (supplied with the radio remote control).
The battery of the push-button panel may be left (even if it will not be charged).
Turn push-button panel on, using the ignition key (fig 5).
fig. 2
If the remote radio control does not work, you can use the emergency distributor to
put down the load on the ground. Read attentively paragraph 16.8.1, before using it.
14.2.2 Push-button panel of the radio-remote control "RCH" CONTROLS TO
OPERATE THE CRANE
GR4 - EVOLUTION
14.2.2
The push-button panel of the radio remote control "RCH" in its standard configu-
ration, features 6 linear levers (but it can allocate up to 8) and a display where it is
possible to visualize information about the use of the crane.

Optionally, the push-button panel can be supplied with joystick controls with 6 or
8 functions. The 8-function version features two side joysticks with 3 functions; the
third function is available through the rotation of the joystick head.

- LINEAR PUSH-BUTTON PANEL

A B

F
C D

H
G
E

fig. 3

- PUSH-BUTTON PANEL WITH JOYSTICK

A B

F
C D

G
H
E

fig. 4

Each push-button panel element is identified with letters of the alphabet as shown
in figures 3,4,5,6,7: check the list down below to get the meaning of each element.
A) Graphic Display visualizing the pressure on the lifting rams, alarms, various
information and icons for the selection of the different menus (For transla-
tions see graphic panel).
B) Function selector with rotary movement "RX" to select the icons of the
program menus (see the icon legend, par. 14.2.4). Press on the selector to
confirm the choice.
C) Yellow light indicating that the crane exceeds 90% of its capacity.
D) Red light indicating that the crane exceeds 100% of its capacity, and the
activation of the lifting moment limiting device. It can signal too alarms,
warnings or particular conditions of the crane.
E) Battery condition visual indicator. Correct functioning (charged battery) CONTROLS TO
is indicated by a green flashing. Red flashing with audible bleep indicates OPERATE THE CRANE
GR4 - EVOLUTION
14.2.2
that the battery is almost discharged and needs to be replaced.
F) Activation push-button for acoustic alarm.
G) Button “INDEX” used:
a) To start again to “Initial Menu”, getting out from the under menus.
b) To do the scroll of the alarms. At every pressure, it will be visualized the
following alarm, if fitted.
c) To move with the cursor towards right, if you are inserting a PIN.
d) To activate the retrolighting on the display (the retrolighting will switch off
automatically. The extinction time is planed out in the SW FX800).
H) Levers/joystick for crane control.
I) Socket for radio remote control serial cable. Standard radio remote control
is supplied with 10mt-long serial cable connecting the push-button panel
with the socket on the base.
L) Push-button panel ignition key. When the key is in "0" position, the push-
button panel is off, when in "1" position, the push-button panel is on (the
emergency button must be released).
M) Mushroom-shaped emergency button.
N) Battery.

F G M
N

I L

fig. 5 fig. 6 fig. 7

Check the list down below to get the meaning of the elements identified with letters
of the alphabet as they are displayed when turning on the push-button panel, as
shown in figure 8.

1 a. Load on the crane lifting rams, expressed in percentage.

1 b. Pressure in the crane lifting rams, expressed in bars.
1 c. Pressure in the crane lifting rams, expressed in daPsi*.
2. Crane angle monitored by the angle sensor placed on the outer boom.
3. Hydraulic extension angle monitored by the angle sensor placed on
extension arm (the extension is not present in this case).
4. Space for messages.
5. Load on the winch (if fitted), expressed in percentage.
6. Oil temperature monitored by the temperature sensor.
7. Pressure in the hydraulic distributor .
8. Icons.
9. Flags.

The second line of the display can indicate too particular conditions of the crane
through messages like WARNING, ALARM, STOP ROTATION, etc.
In this case, all the data on the second line disappear at the moment and will reap-
pear automatically when the crane control is taken again.

fig.8
14.2.3 Push-button panel of the radio-remote control CONTROLS TO

"SCANRECO"
OPERATE THE CRANE
GR4 - EVOLUTION
14.2.3
The push-button panel of the radio remote control "SCANRECO" in its standard
configuration, features 6 linear levers (but it can allocate up to 8) and a display
where it is possible to visualize information about the use of the crane.

- LINEAR PUSH-BUTTON PANEL

H
C

E F G

fig. 9

Each push-button panel element is identified with letters of the alphabet as shown
in figures 9 - 10 - 11 - 12 - 13 : check the list down below to get the meaning of
each element.

A) Display.
B) Linear levers to control the crane functions.
C) Short cut buttons 1, 2 and 3. These can be paired with any of the virtual
buttons (VB).
D) Rotary selector. Using this selector, icons in the program menu can be
selected. Clockwise rotation selects icons to the right, anti clockwise rota-
tion selects icons to the left.
E) Button “INDEX” used:
a) To start again to “Initial Menu”, getting out from the under menus.
b) To do the scroll of the alarms. At every pressure, it will be visualized the
following alarm, if fitted. I J
c) To move with the cursor towards right, if you are inserting a PIN.
d) To activate the retrolighting on the display (the retrolighting will switch off
automatically. The extinction time is planed out in the SW FX800).
fig. 10
F) Emergency push-button.
G) Light showing the battery status. Green permanent light means that the
battery is working correctly (charged). Red flashing light means that the
battery is discharged and needs to be replaced.
H) Activation button. Press once to start up the radio remote control.
I) Yellow light indicating that the crane exceeds 90% of its capacity.
J) Red light indicating that the crane exceeds 100% of its capacity, and the
activation of the lifting moment limiting device. It can signal too alarms, K
warnings or particular conditions of the crane.
K) Battery.
fig. 11
L) Connection point to the cable that serves to connect the radio remote con- CONTROLS TO
trol to the electronic unit installed on the crane. The radio remote control is OPERATE THE CRANE
GR4 - EVOLUTION
14.2.3
supplied with a 10 m. length serial cable to connect the radio remote con-
trol to the electronics present on the crane.

M N P Q

R S L

fig. 12

fig. 13

M) Angular position of the crane, read by the angular sensor applied on

the outer boom.
N) Angular position of the hydraulic extension. If the hydraulic extension isn't
present, no value will be visualized. If the hydraulic jib is present but not
attached, it will be visualized “---“.
P) Load percentage on the winch.
Q) The oil temperature, read by the temperature sensor applied on the heat
exchanger.
R) Load indication on: the inner ram, the outer ram, the hydraulic extension (if
fitted).
S) Working pressure in the distributor bank.
T) Virtual Button VB.

- FIRST ACTIVATION OF THE RADIO REMOTE CONTROL AND PROCEDURE

OF AUTOLEARNING
When the radio remote control is installed, and in case it is required to be replaced,
the following procedure is required before it is operated:
1. Insert the battery in the radio remote control.
2. Connect the radio remote control to the crane through the serial cable.
3. Switch on electrically the crane, and after approx. 15 seconds (when the
electronics is activated completely) push and keep pushed the button “ON”
on the radio remote control until the display shows the inscription
“Learnmode OK. Please power off”. Switch off the radio remote control.
Switch off the crane.
4. Remove the serial cable and switch the radio remote control on again.
5. Wait for approx. ten (10) seconds.
6. Electrically feed the crane to put the electronic card under tension (FX800);
the radio remote control display will show “updating Gui version”.
7. Wait approx. three (3) minutes to allow loading of all the icons on the
display. When the display shows “Icons updated please power off”, switch
off and restart the radio remote control panel.
8. The crane can now be operated
- CONFIGURATION OF SUPPLEMENTARY BUTTONS AND COMBINATION CONTROLS TO
OF THE ICONS (VIRTUAL BUTTONS) OPERATE THE CRANE
GR4 - EVOLUTION
14.2.3
1. Insert the battery in the radio remote control and switch on electrically the
crane.
2. Push and keep pushed two of the three buttons of supplementary activation
and switch on the radio remote control with the button “ON”. Appears the
inscription “FAVORITE CONFIGURATION” that confirms the entry in the
menu of buttons combination.
3. Move with the rotary selector on the icon requested and push the physical
button 1, 2 or 3 according to the button that you want to combine to that
icon.
4. Repeat the operation to assign the functions of the other two buttons.
5. To confirm the assignment of the buttons functions, it's necessary to
switch off and relight the radio remote control.

The combination physical button/virtual button can be modified at any time simply
repeating all the procedure previously indicated.

- RE-START OF THE RADIO REMOTE CONTROL

If, when switching on the radio remote control after its first activation, problems con-
cerning icon representation on the display appear, proceed in the following way:
1. Switch on the radio remote control panel.
2. Push at the same time the "E" and "H" buttons (fig.9).
3. The radio remote control display will show “updating”.
4. Wait approx. three (3) minutes to allow loading of all the icons on the
display. When the display shows “Icons updated please power off”, switch
off and restart the radio remote control panel.
5. The crane can now be operated.
14.2.4 Icon legend CONTROLS TO
OPERATE THE CRANE
GR4 - EVOLUTION
14.2.4
- RADIO REMOTE CONTROL DISPLAY AND GRAPHIC PANEL
ENTER
+ (to increase values when modifying the parameters or to navigate the
menus in progression).
- (to decrease values when modifying the parameters or to navigate the
menus in regression).
Activation of the procedure for the temporary exclusion of the lifting
moment limiting device, and for the reset of the messages "alarm"
and "warning".
Modification of the values displayed: pressure in Bar, load in %,
pressure in dapsi, crane angle in degrees, (jib angle) in degrees, oil
temperature.
Clock activation and access to the timer menu.
Activation/disactivation "XP" device.
Activation of the load check procedure on manual extensions
(only on the graphic display).
To increase truck's engine r.p.m.
To decrease truck's engine r.p.m.
Starting the truck engine.
Turning off the truck engine.
Decrease in crane general speed (each selection reduces speed by
the percentage set in the parameter visualised on "Lnn").
Selection of the 9°/10° function on the radio remote control.
Visualization of active "flag" icons in addition to the one selected.
Lighting working lights.
Activation of the supplementary exit 0.
Activation of the supplementary exit 1.
Activation of the supplementary exit 2.
Activation of the supplementary exit 3.
Activation of the supplementary exit 4.
Activation of the supplementary exit 5.
Activation of the supplementary exit 6.
Activation of the supplementary exit 7.
Activation of the supplementary exit 8.
Activation of the supplementary exit 9.
Activation of electric regeneration.
Activation of the electric deviator of flow.
Activation of JDP (Jib Dual Power).
De-energizing of the EV1 electrovalve without hinding the levers move-
ment to unload the pipes pressure.
Passage from crane control to stabilizers and vice versa.

- ICONS VALID ONLY FOR MENU OF THE PANEL GRAPHIC REGULATION

Upon activation the setting menu of the graphic panel is displayed
(lightness, contrast, etc.).
Access to the setting menu.
Keyboard blockage.
Contrast regulation.
Lighting retrolighting.
Visualisation of the software release.
Modification of load values from % to Bar on crane layout.
Visualization state of the lever, the control and the position of the
electric modules
- ICONS VALID ONLY FOR MENU OF THE RADIO REMOTE CONTROL CONTROLS TO
REGULATION OPERATE THE CRANE
GR4 - EVOLUTION
14.2.4
Entry of the diagnostics levers, buttons and radio remote control menu.
Lighting retrolighting.
Contrast regulation.
- "FLAG": WARNING ICONS NOT SELECTABLE WITH SELECTOR "RX"
Warning icon indicating the activation condition of the general
speed reduction.
Icon signalling 90% load capacity.
Icon signalling that load capacity exceeds 100% (activation of the
moment limiting device).
Downgrade to level 1.
Downgrade to level 2.
Icon signalling the activation of the procedure for the temporary.
exclusion of the lifting moment limiting device.
Icon signalling the activation of the photocell located on the control
station on the top seat (operator is present) or the regenerative activation
on crane with slew ring.
Icon signalling oil temperature in the tank (only on graphic panel
and on cranes fitted with heat exchanger).
Icon indicating the activation of the manoeuvre with EV1 forced at rest
(open) or the regenerative activation on F240B.
Icon indicating the activation of the 9° and 10° function.
Icon signalling the activation of the procedure of the manual jibs.
- INFORMATION MESSAGES
STOP ROTATION The "ROTATION STOP" is activated
MAX ANGLE CRANE The "LIFTING STOP" is activated by the crane angle
sensor
MAX ANGLE JIB The "LIFTING STOP" is activated by the hydraulic
jib angle sensor
STOP BOOM OUT The "WINCH STOP" is activated by the boom out
stop
NOT ALLOWED The manoeuvre is not allowed
WARNING ANGLE Warning upon reaching the "lifting block"
activation angle (only on graphic display)
CRANE FOLDED The crane is folded
STOP The emergency stop button is pressed
JIB OFF! The hydraulic jib is not electrically connected; it's
not possible to maneuvre it
BATTERY LOW! The FX800 battery is getting low
WINCH CAL. ERROR The winch limiting device is not correctly calibrated,
repeat the calibration as soon as possible.
WINCH OFF! Intervention of the "WINCH OFF" caused by the
rope being completely unwound
START ENGINE Starting the truck engine
STOP ENGINE Turning off the truck engine
WARNING ROTATION IP4 cuts out without the operator presence on third
control station
NEW PVED Noticed an exchange module to plan on the Can Bus
line
DANGEROUS Noticed a pressure on TP0 with manoeuvre blocked
and EV1 de-energized
UPDATING Updating GUI version in progress
WARNING VB Buttons state on the radio remote control not corre-
sponding to the one of Fx800
STOP INNER BOOM Intervention of “main descent block” for the
interference with truck cab
14.3 Emergency station from the column (if accessible) or CONTROLS TO

control station (version with load limiting device)

OPERATE THE CRANE
GR4 - EVOLUTION
14.3
(!) ATTENTION (!)
The sequence of the plates placed on the crane controls may be diffe-
rent. Make sure that the lever you are going to operate correspond to the
control you selected.

CRANE CONTROLS

Rotation Inner Outer Extension

boom boom booms

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

Jib Jib Winch

Rotator Bucket outer extension
boom booms

(!) ATTENTION (!)

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.
(!) 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. (DE6400 fig.
14) fig. 14

DE 6409A
VERSION WITH HORIZONTAL CONTROLS (ground controls or top CONTROLS TO
seat controls) OPERATE THE CRANE 14.3
GR4 - EVOLUTION
(!) ATTENTION (!)
The sequence of the plates placed on the crane controls may be diffe-
rent. 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

(!) ATTENTION (!)

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.

(!) 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
14.4 Manoeuvres to unfold the crane into a working condition CONTROLS TO
OPERATE THE CRANE 14.4
GR4 - EVOLUTION
The plate DE4452A indicates the sequence of the manoeuvres to be carried out
to unfold and to fold the crane.

- Engage the power take off.

- Stabilize the vehicle (see details on
Paragraph 13 “Manoeuvres and controls
to stabilize the vehicle”).

(!) ATTENTION (!)

It is forbidden to operate near the booms in
mouvement. 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.

14.5 Manoeuvres to fold the crane into the

rest condition (see Plate DE445 2A)
(!) ATTENTION (!)
It is forbidden to operate near the booms in
mouvement. 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.

(!) ATTENTION (!)

If the hook goes out of size with the crane folded it must be
taken of before starting the truck.
 (!) ATTENTION (!) CONTROLS TO
A safety device is installed on the outer boom of the crane version "C" pre- OPERATE THE CRANE
GR4 - EVOLUTION
14.6
venting the exit of the extension boom sections when the crane is in rest
position.

14.6 Manoeuvres to unfold the crane "C" into a working

condition (only for the crane version C”)
(!) ATTENTION (!)
It is forbidden to operate near the booms in mouvement.
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.

14.7 Manoeuvres to fold the crane "C" into the rest condition
(only for the crane version “C”)
(!) ATTENTION (!)
It is forbidden to operate near the booms in mouvement.
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;
- reenter the extension boom sections and suitions and suitably lock them in
place by means of the hook;
- 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.

(!) ATTENTION (!)

If the hook goes out of size with the crane folded it must be taken of
before starting the truck.

14.8 Indicator of inner boom horizontal position

(on request)
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.
14.9 Stand-up control station (if fitted) CONTROLS TO
OPERATE THE CRANE 14.9
GR4 - EVOLUTION
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.

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 that automatically prevents the crane from rotating above the sta-
tion and activates the flashing of the green light in the different control
panels near the plate DE5775 (fig. 16b).

(!) ATTENTION (!)

Before accessing the stand-up control station make sure that the photo-
cell L pilot-light is turned on and green. Then check its correct functio-
ning, putting 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 limitation of the rotation path is active (see the flashing of
the green light).

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.
The instruction plate DE5643 reported on the selector identi-
fies the intervention sectors of the device (fig. 16).
The operator's presence in the stand-up control station allows
only a reduced 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 sta- L
tion, 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), CONTROLS TO
take extreme care when lowering the inner boom or while rotating the crane OPERATE THE CRANE
GR4 - EVOLUTION
14.9
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. 16b

fig. 16
16 MANOEUVRES OF THE CRANE LOADS CONTROLS TO OPERATE
THE CRANE 16
GR4_5 - EVOLUTION
16.1 Generality
(!) ATTENTION (!)
Before manoeuvring 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
centreline 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.

(!) 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.

16.2 Lifting moment limiting device "EVOLUTION"

(LMEV) and automatic dynamic control (ADC)
This device utilises an electro-hydraulic system managed by an electronic
logic that prevents any operation tending to cause an increase in the pressure
induced by the load in the lifting rams (inner, outer rams of the crane and of
the hydraulic extension, if fitted), up to the critical values. These values, which
are not 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 hori-
zontal position of the crane outer boom; only the controls allowing a reduction
of the overload are enabled, while those increasing it are disabled.
The device features an electro-hydraulic control that does not allow the set
value to be exceeded, by deactivating the controls commanded by the limi-
ting 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.

The ADC device (if fitted) can be activated only through the radio remote
control. It controls the dynamics of the movements by limiting the distributor
control levers run according to the pressure of the hinged rams in movement,
thus providing the maximum speed available subject to the applied load. When
using manual controls (therefore the ADC system is not enabled), the oil capa-
city is automatically reduced in order to avoid excessive dynamic solicitations.

(!) ATTENTION (!)

The ADC device is not active on winch controls and on accessories other
than the hydraulic jibs.
Practically the speed of the load movement decreases as the interven-
tion limit of the lifting moment limiting device approaches.
Any movement (ram) (including the rotation) acts on all the movements, exclusive CONTROLS TO OPERATE
of the re-entry/exit of the boom sections (provided that this speed is too low). THE CRANE 16.3
GR4_5 - EVOLUTION
(!) ATTENTION (!)
This control of the dynamics and therefore of speed engenders a varia-
tion of the movement speed of the crane also without varying the posi-
tion of the control levers. (For instance when putting down on the ground
the load hanged on the winch, the crane movement gradually accelerates
even if the control lever of the radio remote control is kept unchanged).

16.3 Control panels of the lifting moment limiting

device (if fitted)
There are three types of control panels: Graphic, Alphanumeric or Basic.

GRAPHIC PANEL

Refer to fig. 1 to identify the various components of the panel:

1 Green, yellow and red led band signalling the load percentage as com-
pared to the capacity plate. Green light load between 0 and 90%. Yellow
light load between 90 and 100%. Red light load higher than 100% (acti-
vation of the lifting moment limiting device).
2 Graphic Display visualizing the pressure on the lifting rams, alarms,
various information and icons for the selection of the different menus.
3 Mushroom-shaped emergency button (always active).
4 "INDEX" push-button to program or select menus.
5 Audible alarm push button (see instructions and warnings).
6 Control button for the temporary exclusion of the lifting moment limiting
device, and for the reset of the messages "alarm" and "warning".
7 Function selector with rotary movement "RX" to select the icons of the
program menus (see the icon legend, par. 14.2.3). Press on the selec-
tor to confirm the choice.
8 Red led light-flashing for "warning" or fixed for "alarm".
Led lights 4-6. If led lights 4 and 6 are flashing the panel is not enabled
(emergency excluded); contemporarily press on push-buttons 4 and 6
to activate it.

fig. 1
ALPHANUMERIC PANEL CONTROLS TO OPERATE
THE CRANE 16.3
Refer to fig. 2 to identify the various components of the panel: GR4_5 - EVOLUTION

1. Green, yellow and red led band signalling the load percentage as com-
pared to the capacity plate. Green light load between 0 and 90%.
Yellow light load between 90 and 100%. Red light load higher than 100%
(activation of the lifting moment limiting device).
2. Alphanumeric Display visualizing the pressure on the lifting rams, alarms,
various information and icons for the selection of the different menus.
3. Mushroom-shaped emergency button (always active).
4. Push-button to select the use of buttons 5, 6, 7, 8, 9 in configuration
"A" or "B". If the light is on, the "A" mode is enabled, if the light is off,
the "B" mode is enabled.
5A. Control button for the temporary exclusion of the lifting moment limiting
device, and for the reset of the messages "alarm" and "warning".
6A. "XP" device push-button.
7A. Audible alarm push button (see instructions and warnings).
8A. Push-button to modify the values displayed: pressure in Bar, load in %,
pressure in dapsi, crane angle in degrees, jib angle in degrees, oil tem-
perature.
9A. Button for the clock activation and to access the timer menu (see timer
16.7).
5B. + button (to increase values when modifying the parameters or to navi-
gate the menus in progression).
6B. - button (to decrease values when modifying the parameters or to navi-
gate the menus in regression).
7B. "INDEX" push-button to program or to select menus.
8B. "ENTER" button used to program or to select menus.
9B. F2 button (actually not in use).
10. Red light-flashing for "warning" or fixed for "alarm".
Led lights 4-6. If led lights 4 and 6 are flashing the panel is not enabled
(emergency excluded); contemporarily press on push-buttons 4 and 6
to activate it.

fig. 2
BASIC PANEL CONTROLS TO OPERATE
THE CRANE 16.3
Refer to fig. 3 to identify the various components of the panel: GR4_5 - EVOLUTION

1 Green, yellow and red led band signalling the load percentage as com-
pared to the capacity plate. Green light load between 0 and 90%.
Yellow light load between 90 and 100%. Red light load higher than 100%
(activation of the lifting moment limiting device). The red light can also
signal "warning" if flashing, or "alarm" if fixed.
2 Orange light signalling that the XP device is enabled.
3 Mushroom-shaped emergency button (always active).
4 Green light signalling tension in he panel; if flashing, it indicates the
presence of the operator in the third control station.
5 Control button for the temporary exclusion of the lifting moment limiting
device, and for the reset of the messages "alarm" and "warning".
6 "XP" device push-button.
7 Audible alarm push button (see instructions and warnings).
2-4 Lights 2-4 are flashing during the exclusion procedure of the lifting moment
limiting device.

fig. 3
16.4 Load handling CONTROLS TO OPERATE
THE CRANE 16.4
Any block condition requiring the distributor unloading does not allow the use of GR4_5 - EVOLUTION
hydraulic accessories (bucket, rotator, …); these could however be activated when
coupled with permitted manoeuvres.

16.4.1 "Block due to overload condition"

According to the type of block and to the crane configuration, the only manoeuvres
permitted are the ones allowing a reduction of the overload, as follows:

Crane in overload condition with outer boom and hydraulic jib under the hori-
zontal line

Manoeuvres not allowed

- Inner boom lift

- Outer boom lift
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Hydraulic jib lift (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom under the horizontal line and
hydraulic jib horizontal

Manoeuvres not allowed

- Inner boom lift

- Outer boom lift
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom under the horizontal line and
hydraulic jib over the horizontal line

Manoeuvres not allowed

- Inner boom lift

- Outer boom lift
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Hydraulic jib descent (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom horizontal and hydraulic jib under
the horizontal line

Manoeuvres not allowed

- Inner boom lift (only if the overload is created by the hydraulic jib)
- Outer boom lift (only if the overload is created by the hydraulic jib)
- Exit of the crane extension boom sections (if the overload is created by the jib
ram, it can still operate)
- Hydraulic jib lift (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)
Crane in overload condition with outer boom and hydraulic jib horizontal CONTROLS TO OPERATE
THE CRANE 16.4.1
Manoeuvres not allowed GR4_5 - EVOLUTION

- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom horizontal and hydraulic jib over
the horizontal line

Manoeuvres not allowed

- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Hydraulic jib descent
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom over the horizontal line and
hydraulic jib under the horizontal line

Manoeuvres not allowed

- Inner boom lift (only if the overload is created by the hydraulic jib)
- Inner boom descent
- Outer boom lift (only if the overload is created by the hydraulic jib)
- Outer boom descent
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Hydraulic jib lift (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom over the horizontal line and
hydraulic jib horizontal

Manoeuvres not allowed

- Inner boom descent

- Outer boom descent
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)

Crane in overload condition with outer boom and hydraulic jib over the horizontal line

Manoeuvres not allowed

- Inner boom descent

- Outer boom descent
- Exit of the crane extension boom sections (if the overload is created by the
hydraulic jib, it can still operate)
- Hydraulic jib descent (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch lift (if crane is equipped with)
Note: In case of alarm to be reset on sensors Tl1 and Tl2 (inclinometers on outer
boom and extension boom), not knowing the crane configuration, the block is activated
on manoeuvres both above and under the horizontal line.
(!) ATTENTION (!)
During load handling with the crane and with the crane and hydraulic jib, in vertical
configuration or close, the operator must strictly refer to the loads indicated on the
capacity plates since the limiting device shows to be not particularly sensitive with
vertical lifts.
16.4.2 "Winch off" (when fitted) CONTROLS TO OPERATE
THE CRANE 16.4.2
GR4_5 - EVOLUTION
Crane in overload condition by the intervention of the load limiter of the winch

Manoeuvres not allowed

- Clockwise/anticlockwise rotation
- Inner boom lift/descent
- Outer boom lift/descent
- Exit of the crane extension boom sections
- Hydraulic jib lift/descent (if crane is equipped with)
- Exit of the jib extension boom sections (if crane is equipped with)
- Winch rope lift

Crane in overload condition for winch rope totally unwound

Manoeuvres not allowed

- Winch rope descent

16.4.3 "Lifting block" (Prolink)

Function of the safety device controlling the articulation "Prolink"
When the first angle limit alfa1 is reached, the safety device temporarily stops all
movements and activates the flashing red light; "Warning angle" is displayed on
the screen. In order to reactivate all the crane functions (except for the lifting of the
inner boom that in this case is definitely disabled) just put the all the levers in neu-
tral position. Press the LMI button to remove the message "Warning angle" (it will
disappear when the temporary block angle alfa1 is no longer exceeded).
When the second angle limit alfa2 is reached, the safety device definitively stops
all lifting movements and activates the fixed red light; "Max angle crane" or "Max
Angle jib" are displayed according to which boom has reached the limit.
The outer booms of the crane and of the hydraulic jib can reach both the alfa1
(temporary block) and alfa2 (definitive block) limits, independently from the
position of the other booms.
But if one of these two booms reaches the second limit alfa2, this condition
evidently stops any other lifting.

Only if neither the crane outer boom nor the hydraulic jib reach the first angle limit
alfa1, the inner boom can attain its max limit alfa2, that is its mechanic stroke end.

Lift stop by the activation of crane angle sensor

Manoeuvres not allowed

- inner boom lift

- outer boom lift

Lift stop by the activation of hydraulic jib angle sensor

Manoeuvres not allowed

- inner boom lift

- outer boom lift
- hydraulic jib lift
- winch lift
16.4.4 Other functional characteristics CONTROLS TO OPERATE
THE CRANE 16.4.4
Crane block by the attainment of the mechanical stroke end of the lifting GR4_5 - EVOLUTION
ram.
The limiting device may intervene also during loadless crane operation fol-
lowing a pressure peak provoked by the attainment of the stroke end of the
lifting ram at high speed. In this condition, the permitted manoeuvres can be
activated, but to reset the block it is necessary to perform the opposite manoe-
uvre to the one that caused the block. Then the limiting device checks if the
pressure goes down and therefore decides whether to remove the block, or to
maintain it. Such type of reset works only one time.

Activation of the temporised exclusion device of the lifting moment limi-

ting device

Such device has been added in order to solve the problem of the lifting of
heavy and bulky loads with the extension boom sections almost completely re-
entered. Once above the horizontal line (with pressure reaching the activation
level of the lifting moment limiting device), during the load descent, due to the
dynamic overload caused by the descent, the lifting moment limiting device
is activated and therefore it becomes impossible to put down the load on the
ground.
The temporised exclusion device sets remedy to what described above as fol-
lows:
With the crane in block condition, maintain the command for the extensions
boom re-entry until stroke end until "LMI" is displayed at the top right corner
of the radio remote and contemporarily the icon (flag) is displayed at the right
end corner.
Release the lever commanding the extensions booms and then press the
exclusion device button of the lifting moment limiting device (if the procedure
has been correctly executed, "ELMI" will be displayed at the top right corner
of the radio remote controller). From this moment on you have at your disposal
five (5) seconds to carry out the descent of the outer boom in order to bring
the load under the horizontal line and therefore put it down on the ground. As
soon as the crane exits the block, "ELMI" is no more displayed.
After the execution of such manoeuvre (5 seconds) wait at least one (1) minu-
te in order to be allowed to carry out the manoeuvre once again.

(!) ATTENTION (!)

Activation of the exclusion device of the lifting moment limiting device.
Only the outer boom descent is allowed.

When the operator uses this device, it means that he wishes to override
the lifting moment lifting device in order to make some manoeuvres (which
would be impossible with the device active) that bring the moment to within
the maximum level, but involve an overload condition.
In such an emergency condition (where the lifting moment limiting devi-
ce has been disabled), the operator, who is the main responsible for the
machine safety, must:
- carefully consider the manoeuvres required to return to normal
working conditions: it is however compulsory to effect the re-entry
of the extension booms at first;
- calmly and carefully assess the type and scale of the hazards arising
from these manoeuvres and the possible reaction of the crane (tipping
over, frame overload, uncontrolled fall of the load due to a hydraulic
system overload etc.);
- make all movements as slowly as possible to reduce the dynamic
over load to the minimum.
Crane folded into the rest position CONTROLS TO OPERATE
THE CRANE 16.5
We introduced the handling of the crane in the rest condition. When you fold GR4_5 - EVOLUTION
the crane to its rest position, the angle sensor detects a value around 90°, thus
disabling the lifting manoeuvres. In order to obviate to this condition, when
turning on the crane, if it exceeds the limit values, the message "CRANE
FOLDED" will be displayed on the main unit. At this point the only manoeuvre
allowed is the folding of the outer ram (according to the manual for Use and
Maintenance, this is the first manoeuvre to be executed when unfolding the
crane). If during this manoeuvre the pressure in the outer ram goes down for
at least two seconds, then the crane is considered in rest condition, the mes-
sages "CRANE FOLDED" disappears and all the manoeuvres are allowed.

NOTE: the message "CRANE FOLDED" is displayed also when the crane is
turned off with the booms in "LIFTING BLOCK" condition and then the crane
is turned back on; descend the outer boom below the horizontal line in order to
remove the message.

16.4.5 Visual indicator yellow/red light

The crane is fitted with visual indicator of the following signals: yellow light
upon reaching 90% and red light upon activation of the lifting moment limiting
device. The visual indicator (fig. 4) is in full view on the structure of the crane or
of the vehicle.
NOTE: If the radio-remote control is off or however one cannot comunicate with
the crane (receiver) the yellow and red warning lights alternately flash.

16.5 Lifting moment limiting device for two working

sectors
fig. 4
In case of one sector of the working area with reduced stability of the vehicle
(e.g. sector in front of vehicle cab) the limiting device can be provided with a
special function which allows to operate with a reduction of the intervention
level. The reduction of the intervention level reduces the crane capacity values
and this reduction value is defined in the vehicle stability calculation.
Consequently the working area is divided in one sector (e.g. body side) where
the crane works according to the capacity plate values and another sector (e.g.
cab side) where it works with reduced capacity values. The device has 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 fol-
lowing conditions is reached:
- rotation of a load bigger than the one admitted in the reduced
sector defined in the vehicle stability calculation;
- rotation without load applied but with (at least) one of the inner,
outer rams of the crane or the jib (if fitted) extended and pressuri-
sed at the stroke end.
The following manoeuvres are allowed:
- the opposite rotation;
- the manoeuvres allowed by the limiting device.

If a reduction of capacity is necessary because of insufficient stability of the

complete unit, new capacity plates must be fixed giving the derated capacity in
accordance with the final stability test.

(!) ATTENTION (!)

Always check carefully that the vehicle is perfectly stable, paying special
attentino to the area immediately in front of the driver's cabin as this is
usually less stable.
16.6 "Rotation limiting device" CONTROLS TO OPERATE
THE CRANE 16.6
When a sector of the working area exists in which the stability is insufficient GR4_5 - EVOLUTION
(for example in the area in front of the cab) the permitted arc of rotation is limi-
ted by means of an adjustable electro-hydraulic device which only allows ope-
ration within the safe area.
When exceeding the "safe area" the rotation limiting device only allowing:
- the opposite rotation
- the manoeuvres allowed by the limiting device.

16.7 Setting menu

How to visualise the data
· Press the clock button to have the current date visualized on display

How to activate the timer:

<< Partial timer >>:

· Start from the main screen showing pressures in the lifting rams, and
select the "CLOCK" icon until "TIME"is displayed
· select the icon : "Partial Time" is displayed,
· select the icon "ENTER" to read the value on the timer.
· To reset the partial time, do as follows:
· keep the icon pressed until you read "TIME" on the display,
· select the icon to read "Partial Time" on the display,
· select again the icon : "Total Time" is displayed,
· select again the icon : "Work Time" s displayed,
· select again the icon : "Reset Partial" is displayed,
· select the icon to read "Enter to Confirm" on the display,
· select again : the timer is reset and it will start recording again.

<< Total Time (total activation time of the electric panel)>>:

· Start from the main screen and select the "CLOCK" : icon until
"TIME" is displayed,
· select the icon : "Partial Time" is displayed,
· select again the icon : "Total Time" is displayed,
· select the icon "ENTER" to visualize, for about 5 seconds, the
total time expressed in hours and minutes.

<< Work Time (total crane work time linked to the activation of the levers) >>:
· Start from the main screen and select the "CLOCK" icon until
"TIME" is displayed,
· select the icon : "Partial Time" is displayed,
· select again the icon : "Total Time" is displayed,
· select again the icon "Work Time" is displayed,
· select the icon "ENTER" to visualize, for about 5 seconds, the
total work time expressed in hours and minutes.
VERSION: how to control the software release. CONTROLS TO OPERATE
THE CRANE 16.7
· Select the icon "ENTER" (FX800 will be displayed), select, again, GR4_5 - EVOLUTION
press the icon repeatedly and then select icon.
· Select the menu "VERSION" by using the icon then select the icon
· The software release (i.e. 02.00 09/06/05) will be displayed; by selec
ting the icon you'll read the graphic version (GUI).

v n n . n n g g / m m / a a

HOW TO CONTROL THE LOAD HOOKED ON MANUAL EXTENSIONS.

When to use the procedure:

The procedure allows to calculate if a load can be moved when using manual
extensions on crane and/or hydraulic jibs.

This procedure give us back the following information:

- YES/NO response about lifting a load (YES if the load weight is smaller
or equal to the maximum applicable load; NO in the opposite case).
- Approximate calculation of the load weight

The procedure can be activated only if:

- The procedure for the use of the manual extensions has been activated
through password.
- The password has been typed in and accepted.

Procedure:

· Start from the main menu and press contemporarily the ENTER and %
buttons.

% 1 2 2 1 3 3

- At this point, if the crane can install manual extensions both on crane
and on hydraulic jibs, the following message will be displayed.
(Note: the bold characters represent non-flashing characters).

C R A N E ? J I B ?

- Select JIB if the manual extensions are mounted on hydraulic jib or CRANE
if they are mounted on crane, by using the "+"button. To confirm the selec-
tion press the ENTER key. The following screen will be displayed.

M 1 M 2 M 3
- Select the correct number of manual extensions installed by using the "+" CONTROLS TO OPERATE
button. If the crane version doesn't allow the installation of all the three THE CRANE 16.7
manual extensions, select only the manual extensions allowed though the GR4_5 - EVOLUTION
"+" button. The selection is valid both for extensions installed on crane
(CRANE) and on hydraulic jib (JIB). Press ENTER to confirm and pass
to the following screen.

F C P 2

- If no load is applied to the hook, bring the outer ram to its stroke end
while lifting. If the ram is already in this condition, perform anyway the
procedure of lifting the ram to be able to pass to the following screen.

E N T E R T O S T A R T

- If the manual extensions are mounted on the hydraulic jib, by pressing

the ENTER button you can get the following screen.

K 1 K 2 K 3 K 4

- Select the outer boom configuration, by using the "+" button:

K1 Outer booms of the crane totally re-entered
K2 Outer booms of the crane totally re-entered and jib extensions
totally extended
K3 Outer booms of the crane totally extended and jib extensions
totally re-entered
K4 Outer booms of the crane and jib extensions totally extended

- Press ENTER to confirm the selected configuration. The following

screen will be displayed.

F C P 3

- Bring the hydraulic jib to its stroke end. If it is already in this position, lift
the ram to be able to pass to the following screen.

E N T E R T O S T A R T
- Press ENTER to continue. The following screen will be displayed. CONTROLS TO OPERATE
THE CRANE 16.7
GR4_5 - EVOLUTION

U P P 1

- Activate the lifting of the inner ram to eliminate possible overpressures

(the manoeuvre does not determine the crane movement). When the
lever is in the neutral position, the system calculates the pressure in
the inner ram. Errors in the pressure will display the following message.

P R E S S U R E E R R O R

- In this case repeat the procedure (press ENTER to go back to the main
screen). If the system does not found errors in the pressure of the inner
ram, the procedure will continue with the request to lift the load.

S T A R T L O A D P 1

- Lift the load from the ground. If the load is accepted the following mes
sage is displayed.

L O A D O K

- By pressing the "%" button you can read an estimation of the load.

L O A D O K 6 0 8

- If the load exceeds the limit of the selected manual extension, the fol-
lowing message will be displayed.

N O S P E E D
- If during the load calculation the lifting has been too quick, the system CONTROLS TO OPERATE
will display the following error message. THE CRANE 16.8
GR4_5 - EVOLUTION

N O S P E E D

- Finally if the load exceeds the crane limit (i.e. inner ram overload), the
following message will be displayed.

N O L O A D C R A N E

- When one of the above mentioned messages is displayed, the proce

dure is over. Press ENTER to go back to the main menu (ram pressures).

16.8 Diagnostic: alarms and warnings

It is possible to install on the machine some operation improvements of the
limiting device. The crane software has a reference code that can be read on
the display when switching on or by following the VERSION procedure (see
par. 16.7). For further explanations refer to Fassi service network.

All eventual problems of the electronic system are detected and shown as
codes on the display of the push-button panel of the radio remote control (or
displayed on the operator panels) and determine the interruption of EV outputs
(towards the electrovalves) and the immediate halt of the machine.

The alarms can be divided in two groups:

Alarm:
non-resettable alarm; this means that the alarm can be reset by pressing on
the LMI button only if the problem has been solved. The alarm is signalled not
only on the display, but also by the fixed red light on the push-button panel, by
the red tower light and by the acoustic alarm.

Warning:
resettable alarm; this means that the alarm can be reset by pressing on the
LMI button which brings the display back to its main menu and restores the
crane operation, even if the problem has not been solved. The malfunctioning
is signalled not only on the display, but also by the red flashing light on the
push-button panel, the red tower light and by the intermittent audible alarm.

Notes:
. In case of crane block due to overload conditions, the resettable alarms
(warning) become non-resettable and determine the appearance of the
signal "Alarm".
. On the alphanumeric panel the red light corresponds to the last led on
the led band signalling the load percentage, while on the graphical
panel and the push-button panel of the remote control the warning con
dition is signalled by the flashing of the 100% icon.
16.8.1 Temporary override - Reactivation for the crane CONTROLS TO OPERATE
THE CRANE 16.8.1
functions GR4_170»215 - EVOLUTION

In the event of a black-out or failure of the electronic limiting device, it has been
installed an emergency exclusion tap lever (fig. 5) that, if activated, overrides
all crane emergency devices. Only in the event the crane cannot be manoeu-
vred otherwise, remove the original lead seal placed on the tap lever in order
to lower down the load on the ground, using the levers of the emergency distri-
butor mounted on the column.
When operating the tap lever, the working pressure of the crane is reduced.
For the access to the tap lever remove the carter (fig. 6) placed under the protection
guard of the distributor by unscrewing the fixing screws (13 mm hexagonal spanner).

(!) ATTENTION (!)

When the electric power is restablished, remember to put the lever in the
opened position.

fig. 5 fig. 6

(!) ATTENTION (!)

Activation of the emergency lever.

This activation prevents the operation of the lifting moment limiting device,
consequently, the operation under such conditions can involve an overload
condition. In such an emergency condition (where the lifting moment 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.

(!) ATTENTION (!)

Interferences with the valves or removal of the lead seal release the FASSI
GRU 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 (!) CONTROLS TO OPERATE
On the outer boom there is a mercury capsule (mercury level switch) duly THE CRANE 16.8.1
protected and provided with the following warning stickers. GR4_170»215 - EVOLUTION

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... DE1679

Do not use water to estinguish fire! DE1680

DE1679 DE1680
17 USE OF IMPLEMENTS USE OF IMPLEMENTS
GRU FASSI 17

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

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

(!) ATTENTION (!)

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.

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 requi-
rements.

(!) ATTENTION (!)

When the crane is fitted with implements or laid on the truck body it is neces-
sary to check they are locked to assure the impossibility of accidental move-
ments and that the led signalling maximum obstruction in height (if fitted) con-
firms the correct positioning of the crane.

(!) ATTENTION (!)

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

(!) ATTENTION (!)

In case of using the crane with lifting devices other than the hook,
the access to the working area at the persons must be prevented.

The dimensions and the capacity of the implements must be proportio-

ned with crane performances.

(!) ATTENTION (!)

Crushing (F) or push (F) manoeuvres are not permitted.
17.2 Hydraulic connections for implements - supple- USE OF IMPLEMENTS

mentary hoses. GRU FASSI 17.2

(!) ATTENTION (!)

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.

(!) ATTENTION (!)

The heat exchanger openings must be kept clear and clean. At no time
should it be covered.
18 MANUAL EXTENSIONS USE OF IMPLEMENTS
GR4_5 - EVOLUTION 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 opera-
tive, 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 unautho-
rized 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 fin-
gers; 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.

(!) ATTENTION (!)

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 (see Chapter 16.7)
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.
The instructions for the correct execution of the procedure of manual exten-
scions weight control are in the paragraph “Setting Menù”.
19 CONTROLS TO OPERATE THE HYDRAULIC USE OF IMPLEMENTS
IMPLEMENTS OF THE CRANE
GR4_5 - EVOLUTION 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

Jib Jib
Rotator Bucket outer extension Winch
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.
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. 1)

Pos. Description
1. Winch
2. Cable
3. Fixed pulley
4. Balance weight
5. Hook
6. Transmission pulley
fig. 1
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

(!) ATTENTION (!)

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.

(!) ATTENTION (!)

Under no circumstances interfere with the limiter device adjustment.
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. 2
- 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 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 proxi-
mity (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. 2 to the fig. 3).
(!) 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. 3
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
22 MAINTENANCE INSTRUCTIONS MAINTENANCE
INSTRUCTIONS 22
EVOLUTION
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.

(!) ATTENTION (!)

Before disconnecting any hydraulic hoses, ensure that there is no pres-
sure in the hydraulic circuit. After removing hoses always mark them and
their respective ports on the crane. Faulty replacement can cause dama-
ge 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.

Do not weld the fixing rods of the crane (see plate DE1574 fig. 1)
fig. 1

When repairs to, or checks of, the hydraulic circuit and

of the rams are carried out, it is very important not to TIRANTI: NON SALDARE!
use, or be in the proximity of, materials which can dama- FIXING ROD: DO NOT WELD!
ge the circuit or contaminate the hydraulic oil eg. metal TIRANTS: NE PAS SOUDER!
shavings, sand or dust.
ZUGSCHRAUBEN: NICHT SCHWEISSEN!
DE1574
Do not use the high pressure washing on the controls
(deviators, distributors, double controls, hand cable con-
trols...), 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.
22.2 After every 8 working hours or at the end of every MAINTENANCE
working day INSTRUCTIONS
EVOLUTION
22.2
- Check that all safety devices are efficient.
- Check the level of the hydraulic oil in the tank.
- Check all the components of the hydraulic circuit for possible leaks.
- Check that the control and the oil diverter levers can easily be positioned;
they must show no signs of forcing.
- Check the condition of shackles, hooks, wire ropes and any other lifting equipment.

22.3 After every 40 working hours or atfter every

working week fig. 2
Check the tightening torque of the fixing rods of the crane (fig. 2).

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. 3.
- 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 fig. 3
(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. 4.
- When the visual indicator becomes red, replace the cartridge.
- Unscrew with a suitable spanner the filter body (1) from the head (2).
- Remove the cartridge (3) and clean inside the holder (1). fig. 4
- Insert a new cartridge and re-assemble the filter body into the head checking
the seal (4).
MAX
Check the oil level in the tank with the crane in the folded position and with the MIN
outriggers (crane and supplementary) fully re-entered. The oil level must not
exceed the maximum or be lower than the minimum (fig. 5).
Top up using hydraulic oil with the same characteristics as those indicated in the
fig. 5
table at paragraph 23.

The following lubricators have been centralized and gathered in a case (fig. 6)
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.

(!) ATTENTION (!)

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.

(!) ATTENTION (!)

Centralized lubrication shall not be used when room temperature is below
-10°C / -20°C. fig. 6
All the lubricators mounted on the crane are protected by a plastic cap so to avoid
the oil contamination.
22.4 After every 100 working hours or more frequently in MAINTENANCE

case of more intensive utilisation

INSTRUCTIONS 22.4
EVOLUTION

WITH RACK WITH RACK

Periodically grease the points indicated on the crane
(fig.7-9)(and on the hydraulic jib, when fitted, fig.8-
10) paying particular attention to the points not easi-
ly detected. For the sliding sections of the outrigger fig. 8
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 sur-
faces of the extension booms are free from impuri-
ties 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 rota- fig. 7
tion and to ensure that it is stable by preventing water
(corrosion protection) and contami-
nants from entering the bearings. WITH SLEW RING
For a better internal distribution of
the grease it is advisable to rotate
the crane and grease it in such a
way as to see grease at the seals.
Top up using hydraulic oil with the
same characteristics as those indi-
cated in the table at paragraph
23. Grease the winch cable (if fit-
ted) after having first cleaned the
cable of any encrustation (grease
mixed with sand, dust, dirt etc.)
The lubricant used must guarantee
a good level of penetration in order
to lubricate both the inside and the
outside of the cable. Top up using fig. 10
hydraulic oil with the same cha-
racteristics as those indicated in fig. 9
the table at paragraph 23.

22.5 After every 500 working hours or atfte every 6

working months
CCheck 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
WITH SLEW RING MAINTENANCE
- of the slew gear screws (bolts M20 Class 12.9: Thightening torque = 620 Nm) INSTRUCTIONS
EVOLUTION
22.5
WITH RACK
- 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 1
30 1173 1723 2016
33 1594 2342 2740 2
36 2046 3006 3517
39 2658 3905 4570
WITH SLEW RING
Check the rotation control motoreducer oil level. Fig. 11 3
- Remove the bleed plug (1) using a 22 mm Allen wrench.
- Remove the plug (2) using an 8 mm Allen wrench and the O-ring.
- Top up, if necessary, with the same type of oil as indicated in the table at Paragraph 23
via the mouth (bleed plug).
- The correct level is reached when oil starts to escape from the threaded hole in plug (2).
- 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 fig. 11
Allen wrench.

Check the guide shoe wear as it affects the sliding section tolerances; if the clearances
are considerable, damage to the rams and the structure may occur.
Clean the air filter placed in the top of the oil tank filter cap.
Completely replace the hydraulic oil and the filter cartridges.

(!) ATTENTION (!)

The waste oil and the filter cartridges MUST be disposed of by authorized per-
sons.
(!) 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 CAP-
SULE CONTAINING MERCURY WITH MAXIMUM CARE, AND
IN ACCORDANCE WITH THE NATIONAL REGULATIONS IN
FORCE.
22.6 After every 1000 working hours or after every MAINTENANCE

working year
INSTRUCTIONS 22.6
EVOLUTION

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
 MAINTENANCE
Oil-pressure system Checking of the pressure, oil-leaks, INSTRUCTIONS 22.7
Hoses, hose protection devices inspection of hoses EVOLUTION

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

22.7 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.

22.8 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
different 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
components. Be careful not to let the oil drop on the ground, therefore collect it in
special containers, 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 com-
ponents of the electric circuits.
23 TABLE OF HYDRAULIC OIL AND LUBRICANTS TABLE OF HYDRAULIC

CHARACTERISTICS
OIL AND LUBRICANTS
CHARACTERISTICS
23
EVOLUTION

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...)

Use only GREASE NILEX EP1 of the firm NILS.

NOTE: Do not ABSOLUTELY mix different types of grease.

HYDRAULIC OIL FOR MOTOREDUCER

Classification ISO-L-CC

Gradation EP ISO-VG 150

LUBRICATING OIL (for winch cable)

The most suitable here is a general-purpose lubricating oil with about SAE 30°
viscosity. A lubricating oil containing non-stick additives is recommended if the
cables are expected to move quickly through the pulleys.

BRILUBE 50 (BRITISH ROPES - BRINDON)

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

(!) ATTENTION (!)

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 clea-
red 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
24.3 Operations to be carried out only by an authorized POSSIBLE FAULTS

service center
EVOLUTION 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
25 INSTRUCTION AND WARNING PLATES INSTRUCTION AND
WARNING PLATES 25
GR4 - EVOLUTION

DE 1771A
Instruction plate and safety norms

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

DE 6400
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
Functions of control levers for stabilization with horizontal distributor INSTRUCTION AND
WARNING PLATES
GR4 - EVOLUTION
25

Oil-diverter
control plates

DE 4496 DE 4489

Instruction plates to stabilize the vehicle

DE 6340

DE 6341

DE 6251

DE 6252
Functions of control levers for stabilization with vertical distributor INSTRUCTION AND
WARNING PLATES
GR4 - EVOLUTION
25
Instruction plates to stabilize the vehicle

DE 4485 DE 4497 Oil-diverter

control plate

DE 4488

DE 5263 DE 5264
 INSTRUCTION AND
WARNING PLATES 25
GR4 - EVOLUTION

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

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

DE 2100
Danger plate for crushing of lower limbs
 INSTRUCTION AND
WARNING PLATES
GR4 - EVOLUTION
25

DE 1679
Do not walk on...

DE 1680
Do not use water to estinguish fire

DE 6409A
Warning of shearing danger

DE 4945A
Warning of burn danger

TIRANTI: NON SALDARE!

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

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