Fantuzzi CS45 Reach Stacker — Technical Legacy Guide

Summary

The Fantuzzi CS45 is a 45-tonne reach stacker: a container handler with a telescopic arm and a rotating spreader, which its 2013 operator's manual presents as suited to heavy loads and to the combined transport of containers between railway wagons and road vehicles, as recorded by the HIT SRL technical desk. The manufacturer's manuals, in editions from 2002 to 2013, give five variants — CS 45 KM, KC, KS, KL and KE — first under the Fantuzzi Reggiane name and later under Terex. The present owner of the brand states that new Fantuzzi Reggiane machines are no longer sold and that it supports those still in operation. This guide sets out how the variants differ, the equipment they list, the planned-maintenance intervals and the main data; reports from the field are labelled as such.

Model identification

The specification tables of the 2002–2006 manuals, which recur unchanged across those editions, describe a common layout: diesel engine, four driven front wheels and two steered rear wheels on 18.00-25 pneumatic tyres inflated to 10 bar, a hydrodynamic transmission with torque converter and four forward and four reverse power-shift gears, a drive axle with epicyclic reduction gears and oil-bath front brakes, servo-assisted hydraulic steering, a 24 V electrical system with 200 Ah batteries and an SRP 45 telescopic spreader for 20' to 40' containers. The same tables give noise as 85 dB(A) outside and 74 dB(A) in the cab, and travel speed as 25 km/h empty and 23 km/h loaded.

HIT SRL service technicians report that the letters KM, KC, KS, KL and KE are commercial designations, which do not encode the engine or the transmission, and that the real differences between the variants are those shown in the tables.

The documentation tells the variants apart by the following data:

• CS 45 KC — empty weight 69,500 kg, hydraulic tank 950 l, fuel tank 460 l (2002–2006 tables). According to the LMS Edgevision manual, its load management display is the "LMS BOX", which adds LEDs for approaching overload and for overload or general faults, serial ports and a key to bypass overload protection.
• CS 45 KM — empty weight 72,000 kg, hydraulic tank 850 l, fuel tank 500 l (2002–2006 tables); 75,000 kg service weight and 6,000 mm wheelbase in the 2013 table; "LMS Standard" display.
• CS 45 KL and CS 45 KS — hydraulic tank 1,000 l and fuel tank 550 l in the 2002–2006 family tables (850 l and 500 l in the dedicated CS 45 KL table of 2002); in the 2013 table, 6,500 mm wheelbase and service weights of 77,500 kg (KL) and 81,000 kg (KS), with 18.00-33 tyres on the KS.
• CS 45 KE — its own 2004 table refers to the data plate for the empty weight and gives 850 l of hydraulic fluid and 500 l of fuel.

In the 2013 table the KM, KL and KS are all rated 45 t in the first row and stack five high; second-row capacity is 31, 33 and 35 t, third-row capacity 15, 17 and 19 t respectively. The tables also list CS 42 versions (CS 42 KC, CS 42 KM and CS 42 KE), the suffix "HD" appears on some CS 45 KM electrical diagrams without any documented technical difference, and an operation and maintenance handbook of Officine Meccaniche Fantuzzi describes the earlier CS 45 S.

Industrial history and parts supply

According to a local newspaper, Fantuzzi took over the former Officine Meccaniche Reggiane works in 1994, and one published source gives 1992; HIT SRL service technicians report 1994 as the correct year. The CS45 manuals of 2002–2006 carry the Fantuzzi Reggiane name.

According to published sources, Terex agreed to buy the port equipment business of Fantuzzi Industries in August 2008, terminated that agreement in December 2008, reached a new agreement at the end of the first quarter of 2009 and completed the acquisition, together with Noell Crane, in July 2009. The CS 45 KM manuals follow the change of owner: the 2012 edition names Reggiane Cranes and Plants S.p.A. – Terex Corporation as manufacturer, and the 2013 manuals carry Terex branding.

Published sources state that Konecranes agreed on 16 May 2016 to acquire Terex Material Handling & Port Solutions and completed the acquisition on 4 January 2017. Konecranes states that it has owned the Fantuzzi Reggiane brand since then, that new Fantuzzi Reggiane machines are no longer available and that it is the official provider of support and genuine spare parts for them.

Driveline as installed

Engines

The 2013 table lists the same engines for the KM, KL and KS: a Volvo TAD 1250VE as standard (247 kW at 1,900 rpm, 1,760 Nm at 1,400 rpm) and a Cummins QSM 11 as option (246 kW at 2,100 rpm); for the latest emission rules, a Volvo TAD 1360VE (256 kW) as standard and a Cummins QSX 11.9 (250 kW) as option. The earlier editions refer to a motor table of six-cylinder engines: Cummins M11-C (330 hp), Volvo TWD1031VE (320 hp), Volvo TWD1231VE (400 hp), Cummins N14 (400 hp) and Caterpillar 3306B in 245 hp and 300 hp ratings. A longer version of the same table, printed also in the CS 7.5 manuals, adds the Volvo TWD1240VE (348 hp), TAD720VE and TWD731VE. HIT SRL service technicians report that the Volvo TWD1240VE was the standard engine of the CS 45 KS in 2004, consistent with that longer table.

For the engine itself the maintenance manual refers to the engine manufacturer's manual; its planned-maintenance table still sets, among other jobs, oil and filter changes every 250 h, air filter replacement every 1,500 h and coolant replacement every 1,500 h or at least once a year.

Transmission

The transmissions named in the CS45 documentation are: Clark 36000 or Dana TE 27 on the KM and KL and Dana TE 32 on the KS (2013 table); Clark 36000 or a Caterpillar 960/970 unit on the KC and KM, with a Clark 40000 also listed for the KL and KS (2002 filling tables); ZF 4WG-261, Clark 36000 or Dana TE 27 on the KE. In these manuals the Clark 32000 is listed only for the CS 7.5 empty-container handler: in its filling table, bound into the same maintenance manual, and in its column of the 2013 table.

Oil quantities differ between editions: 48 l for the Clark 36000 and 59 l for the Caterpillar unit in the 2002 tables; 85 l of automatic transmission fluid to Dexron IID for the Clark 36000 in the 2013 filling table of the CS 45 KM. HIT SRL service technicians report that both capacities correspond to machines in service: check the plate or the manual of the specific machine. The level is checked daily at the FULL mark with the engine at low revs and the oil at 82–85 °C according to the maintenance manual (82–93 °C in the operator's manual); the filter is changed every 500 h and the oil every 1,500 h.

According to its manual, the Powertronic controller, described as typically installed on the CS 45 KM and KC, manages the electro-hydraulic transmission together with the engine and is linked to the load management system over CAN bus. The same manual has it put the transmission in neutral if a direction change is attempted above about 2 km/h, if the parking brake or the inching button is used with a gear engaged, or if the drive-shaft speed sensor signal is faulty. The 2013 manual describes the transmission control unit as factory preset, with reprogramming reserved to the manufacturer, and with an anti-reverse function in manual mode.

Drive axle and brakes

According to the 2013 maintenance manual, the drive axle combines a differential with epicyclic wheel hubs, and each hub houses oil-cooled multi-plate service brakes. The same manual places the parking brake on the axle, as a disc with an electro-hydraulic caliper, while the 2002–2006 specification tables describe a dry disc on the transmission with mechanical release.

Hubs and differential take 100 l of SAE 85W-90 gear oil to API GL-5 in the 2013 filling table (SAE 90 or SAE 85W-140, API GL-5, in the 2002 table). The planned-maintenance table checks the level every 100 h and changes the oil every 1,500 h, and greases the cardan-shaft joints and cleans their slide areas every 500 h.

Steering axle

According to the 2013 maintenance manual, steering is servo-assisted through a hydraulic cylinder on the steering axle that drives two connecting rods on the hubs; stabiliser cylinders and wheel-hub disc brakes are optional. The planned-maintenance table greases the axle every 250 h. Where the optional disc brakes are fitted, the steering axle section of the manual checks the discs every 200 h and states that they must not go below 20 mm thickness and may be re-machined by no more than 2 mm per side.

Hydraulic system as installed

The 2013 table gives a maximum hydraulic pressure of 250 bar and an 850 l oil tank for the KM, KL and KS, with a variable-displacement pump as standard; a gear-pump configuration is marked as available for the KM, the HIT SRL technical desk notes. The 2013 filling table assigns the same 850 l of oil to the hydraulic system and to the cooling circuit of the wet disc brakes: a multipurpose SAE 80W oil to API GL-4 with limited-slip properties, a viscosity of 50–60 mm²/s at 40 °C and a viscosity index of 150 or more. Earlier filling tables give 900 l of SAE 80W oil to API GL-4 for the KC and KM, 950 l for the KL and KS (plus 60 l for a separate brake-cooling circuit where fitted) and 600 l for the KE.

According to the 2013 maintenance manual, oil added to the tank must be pre-filtered to 10 microns, and the return filters carry an electrical blockage indicator shown on the monitor in the cab. In the 2013 table the boom lifts at 0.30 m/s with a container and 0.34 m/s with the spreader alone, and lowers at 0.28 m/s and 0.50 m/s respectively. The maintenance manual prescribes replacing all hydraulic hoses within 5,000 operating hours.

The accumulator gas precharge is a skilled-staff check every 3,000 h in the 2013 table and every 1,500 h in the 2002–2005 tables. According to the 2013 maintenance manual, it is done at a fairly constant ambient temperature with the system depressurised, and the accumulator shell must never be welded, brazed or drilled.

For pump noise the manual lists misalignment, low or unsuitable oil, air drawn in at the intake, drain or shaft seals, a tank that cannot breathe and blocked filters. For missing or low pressure the same manual lists an empty tank, a faulty gauge, an open discharge or maximum-pressure valve, leaks or a pressure limiter set too low. According to the same manual, a low oil level points to external leaks, although after major work the level may drop slowly while the system de-aerates.

Structure, boom and spreader

The 2002–2006 tables give Weldox 700 steel for the arm and Fe 510 D (Fe 52) for the chassis, with both used in the spreader. The maintenance manual has the main frame first inspected after one year of operation and then at intervals of no more than one year, with a yearly sample check of the bolt torque of high-strength joints using a calibrated wrench; if one bolt of a joint fails the check, all bolts of that joint are checked. According to the same manual, cracks or flaking paint near welds call for a penetrant test, and load-bearing structures damaged by impact or overload are not to be repaired without the manufacturer's opinion.

The fixed and moving arms run on sliding blocks that the planned-maintenance table greases every 100 h and checks every 500 h. The maintenance manual allows a maximum play of 2 mm per side between blocks and arm, and wear of up to 3 mm per side on the fixed-arm blocks before adjustment or replacement. The boom chapter gives a replacement interval of 1,500 h for the fixed-arm and moving-arm sliding blocks, while the planned-maintenance table of the same 2013 manual marks this job in its 250 h column. HIT SRL service technicians report that workshop practice applies the chapter value of 1,500 h.

The spreaders documented for the CS45 are the SRP 45 of the 2002–2006 tables (20' to 40', rotation −95°/+185°, side shift ±800 mm, lateral oscillation ±3°) and, in 2013, the SRP 45L, the SRP 45 LSS with pile-slope cylinders and the twinlift SRP2-45TL. According to the 2013 maintenance manual, the SRP 45L opens from 20' to 40' in 14 s and closes in 16 s, works at 170 bar on 24 V DC, weighs 9,500 kg and is rated 45,000 kg at 20' and 40,000 kg at 40'. According to the same manual, the SRP2-45TL weighs 12,200 kg and, with the twinlift lowered, handles two empty 20' containers. HIT SRL service technicians report that Fantuzzi SRP is the correct designation of these spreaders. The SRP 45L, SRP2-45TL and SRP2-55TL of the 2013 maintenance manual have their own sections in the Fantuzzi Reggiane attachments guide.

According to the 2013 manuals, on these spreaders a mechanical twistlock feeler blocks twistlock rotation unless the container is properly seated. The spreader section of the maintenance manual has the twistlocks replaced after 6,000 h, or earlier when dimension "a" falls below 27 mm or dimension "D" is reduced by more than 5%, and has them undergo non-destructive testing every year or every 3,000 h. For the spreader rotation reducer, the planned-maintenance table gives an oil change every 500 h, while the spreader chapter gives a first change after about 100 h of running-in and then every 2,000–2,500 h or at least once a year. HIT SRL service technicians report that workshop practice applies the chapter interval. To lift the spreader itself, the figure in the 2013 maintenance manual has all four lifting eyes used together, with slings at no more than 15°, and marks "Max load 10 T", as printed.

Electrical and control

The electrical system is 24 V with 200 Ah batteries (2002–2006 tables); battery fastening, charge, electrolyte and terminals are checked every 250 h. According to the LMS Edgevision manual, the load management system (LMS) of the KM and KC reads boom angle from an inclinometer, boom length from a cable-reel sensor, the lifting and lowering pressures and the twistlock status. The same manual has it lock all boom movements except retraction when the load exceeds the maximum allowed, lock boom lifting and retraction below the minimum distance and boom lifting above the angle limit, and record sensor faults, overloads, bypass use and the containers moved. In the same manual, its fault messages point to the sensor concerned — "angle fault" to the inclinometer, "length fault" to the cable-reel sensor, "pressure up/down fault" to the lifting or lowering pressure sensor — while "invalid calibration" calls for a restart and, if it persists, a reset and full recalibration.

According to the Powertronic manual, from the LMS stability signal the controller limits travel speed to 20 km/h in normal conditions, 13 km/h with a small load and the boom extended and 8 km/h in overload or with a large load and the boom extended. The same manual has it also shut the engine down after a delay on low fuel (10 min), low coolant level (2 min) and low oil pressure (3 s), and on high oil or coolant temperature first set the engine to idle. According to the same manual, its "CAN engine fault" and "LMS CAN fault" messages call for a check of the cables and of the 120-ohm line termination. Later manuals describe LMS Plus as a network of CAN-bus nodes with which the machine keeps working even without the display, and a Digicontrol version for the CS45KL as a full CAN-bus machine at 250 kbit/s; earlier manuals describe the Logicontrol system.

The 2013 operator's manual lists the safety bypass keys: in the cab, a safety-system key that disables all safety devices to recover boom functions after an anti-overtipping fault, and a twistlock key; in the electrical compartment, a lifting key for twistlock-sensor faults and a drop-stop key for faulty proximity sensors, to be used by two people with the approval of the person in charge. According to the same manual, if the "twistlock locked-on" sensor (green light on the spreader and in the cab) fails during handling, boom movement stops except retraction. Editions of different periods use opposite conventions for the twistlock lights; for HIT SRL service technicians the convention in service is green = twistlocks open, container free. Given its relevance to safety, always check the convention on the specific machine and spreader before operating. The 2013 operator's manual also states that the engine does not start unless the gear switch is in neutral, and that a capacitive "dead man" sensor in the joystick disables functions when the grip is released.

According to its 2011 user manual, an anti-tipping system for the CS 45 KM monitors rear-axle deformation and blocks movements that lead to instability. Its manual requires a functional test every two weeks and states that the system does not warn of tipping from sudden overload, travelling with a raised load, uneven ground or slopes.

Recurring failure points — field reports and HIT SRL experience

Published field reports specific to the CS45 are scarce, and most of those found are second-hand or concern other models.

Claims circulating online that HIT SRL's field experience does not confirm

Some web pages report the following statements about the CS45:

• recurring transmission problems and engine-compartment fires caused by oil leaks;
• the charge pump of the Clark transmission, the lift-cylinder seals and the joystick potentiometer as typical weak points;
• salt-spray corrosion of the original hydraulic cylinders;
• spreader twistlocks with a shank geometry different from the twistlocks of two third-party spreader manufacturers;
• CS45 machines fitted with a Clark 32000 transmission.

HIT SRL service technicians report that they do not encounter these conditions on the CS45 machines in service. For the transmissions, the manuals bear out the list given under Transmission above, where the Clark 32000 appears only for the CS 7.5.

Maintenance interval summary

Planned maintenance of the CS 45 KM from the 2013 maintenance manual. The same table appears in the 2002–2005 editions for the KC, KM, KL and KE, except for the accumulator check. The table gives intervals in operating hours; (1) = at least once a year; (2) = skilled staff.

Two jobs read differently in the chapters of the same manual: sliding-block replacement (1,500 h in the boom chapter) and spreader rotation-reducer oil (2,000–2,500 h in the spreader chapter); see Structure, boom and spreader above. In both cases HIT SRL service technicians report that workshop practice applies the chapter value: 1,500 h for the sliding blocks, 2,000–2,500 h or once a year for the reducer oil.

Key specification table

Spare parts

HIT SRL supplies genuine, OEM and aftermarket spare parts for Fantuzzi reach stackers, including the CS45 family, as an independent distributor that is not an official representative, affiliate or agent of the manufacturer. For availability, see the Fantuzzi spare parts page or send the machine model and serial number through the contact page.

Technical cards by system

HIT SRL technical cards, one fact per card, each with its source, HIT ref and fingerprint stated in the text:

• Identification (15 cards)
• Engine (9 cards)
• Transmission and driveline (15 cards)
• Hydraulics (9 cards)
• Structure, boom and spreader (13 cards)
• Electrical and control (8 cards)
• Maintenance intervals (23 cards)
• Safety and interlocks (18 cards)
• Troubleshooting (24 cards)