Fantuzzi CS45 — Troubleshooting: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the fault finding of the Fantuzzi CS45 reach stacker, one fact per card, each with its source stated in the text. For the overall picture, see the Fantuzzi CS45 technical legacy guide.
Fantuzzi CS 45 KM: what should be checked when the engine fails to start?
Air in the fuel supply circuit, to be bled as the engine manual describes, and the battery charge and starter connections, as logged by the HIT SRL technical desk. If the starter motor does not engage, the troubleshooting section of the 2013 manual of the CS 45 KM points to a gear lever not in neutral, as recorded at HIT SRL. The same manual describes a safety device that prevents engine start unless the gear switch is in neutral, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-engine-fails-to-start · HIT ref CS45-111 · fingerprint 170cee · see HIT ref CS45-100, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/safety-and-interlocks/#hit-cs45-start-in-neutral
Fantuzzi CS 45 KM: what can make the engine stop?
A low fuel level, a dirty fuel pre-filter or filter, water in the fuel or a faulty injection pump, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, the HIT SRL technical desk notes. The section lists them for an engine that stops, as set out in the HIT SRL technical cards. On machines with the Powertronic controller, the controller also shuts the engine down after 10 minutes with low fuel level, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-engine-stops · HIT ref CS45-112 · fingerprint b12756 · see HIT ref CS45-109, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/safety-and-interlocks/#hit-cs45-powertronic-alarm-shutdown
Fantuzzi CS 45 KM: what causes low engine power?
With normal exhaust, an accelerator cable that is too slack, the injection pump regulator or the turbocharger, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as HIT SRL's technical desk reads it. With abnormal exhaust, the same section gives a dirty air filter, the injection pump regulator or the turbocharger, as logged by the HIT SRL technical desk. The section separates the two cases by the appearance of the exhaust, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-engine-power · HIT ref CS45-113 · fingerprint 59d28a · see HIT ref CS45-114, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-turbocharger-failure
Fantuzzi CS 45 KM: why do turbochargers fail?
Loss of lubrication, foreign bodies passing a poorly cleaned or poorly filtering air filter, and lubricating oil in bad condition, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as logged by the HIT SRL technical desk. The same section lists the turbocharger among the possible causes of low engine power, with normal or abnormal exhaust, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-turbocharger-failure · HIT ref CS45-114 · fingerprint 9ea16e · see HIT ref CS45-113, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-engine-power
Fantuzzi CS 45 KM: what causes excessive hydraulic pump noise?
Misalignment between pump and motor, a low oil level, unsuitable oil, air drawn in through the intake, drain or shaft seals, a tank that cannot breathe, a restricted intake, a blocked filter or breather, or worn parts, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, the HIT SRL technical desk notes. To check for air drawn in, the same section suggests pouring fluid on the unions and on the shaft, as set out in the HIT SRL technical cards. The same section then suggests listening for a change in noise, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-pump-noise · HIT ref CS45-115 · fingerprint c112eb · see HIT ref CS45-116, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-pump-no-oil
Fantuzzi CS 45 KM: what should be checked when the hydraulic pump delivers no oil?
The oil level, which must stay well above the intake, and air in the intake, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as recorded at HIT SRL. The same section adds a blocked intake filter or duct, excessive oil viscosity and a damaged shaft or rotor, as logged by the HIT SRL technical desk. These are the checks the section lists for a pump that delivers no oil, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-pump-no-oil · HIT ref CS45-116 · fingerprint 7a2625 · see HIT ref CS45-115, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-pump-noise
Fantuzzi CS 45 KM: what causes missing or low hydraulic pressure?
No oil in the tank, a faulty gauge, an open discharge or maximum-pressure valve, excessive leaks or a pressure limiter set too low, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as HIT SRL's technical desk reads it. The section lists these causes for a hydraulic system with no pressure or with pressure that is too low, as logged by the HIT SRL technical desk. The maximum hydraulic pressure in the 2013 table is 250 bar, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-pressure · HIT ref CS45-117 · fingerprint af64b9 · see HIT ref CS45-040, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/hydraulics/#hit-cs45-hydraulic-pressure-and-pump
Fantuzzi CS 45 KM: what stops a directional valve spool from moving?
Solenoids that are not powered or are burnt out, missing pilot pressure, a blocked pilot drain, contamination or a wrong reassembly, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as set out in the HIT SRL technical cards. These are the causes the section lists for a directional valve spool that does not move, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-spool-stuck · HIT ref CS45-118 · fingerprint 51299b · see HIT ref CS45-117, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-pressure
Fantuzzi CS 45 KM: what causes low gear-selection clutch pressure?
A low oil level, a pressure valve stuck open, a faulty pump, worn piston or shaft seals or a blocked clutch-piston bleed valve, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as logged by the HIT SRL technical desk. To locate the fault, the section suggests closing the line to the power distributor, as recorded at HIT SRL. According to the same section, if the pressure returns to normal, the fault is in the distributor, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-clutch-pressure · HIT ref CS45-119 · fingerprint 1b37f7 · see HIT ref CS45-117, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-pressure
Fantuzzi CS 45 KM: what causes torque converter overheating?
Worn seals, a worn oil pump, low oil, air in the intake line, a blocked oil heat exchanger or pipes, or dirty radiator fins, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, the HIT SRL technical desk notes. The same manuals give a recommended transmission oil temperature of 80–90 °C, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-converter-overheating · HIT ref CS45-120 · fingerprint 0225e6 · see HIT ref CS45-121, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-high-converter-out-pressure
Fantuzzi CS 45 KM: what causes high converter-out pressure?
A blocked heat exchanger or oil pipe, oil that is too viscous, or cold oil, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as recorded at HIT SRL. The section gives these causes for a high converter-out pressure measured at full engine speed in neutral, as logged by the HIT SRL technical desk. The same section notes that with cold oil the pressure must drop as the converter warms up, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-high-converter-out-pressure · HIT ref CS45-121 · fingerprint fc5685 · see HIT ref CS45-120, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-converter-overheating
Fantuzzi CS 45 KM: what causes stiff or poor steering?
According to the troubleshooting section of the 2013 manuals of the CS 45 KM, stiff steering points to oil pressure that is too low, a faulty hydraulic pump or a faulty power-steering valve, as HIT SRL's technical desk reads it. In the same section, poor steering points to a pressure that needs adjusting or to internal leakage in the steering cylinder, as logged by the HIT SRL technical desk. In the same manuals the steering acts through a hydraulic cylinder on the steering axle, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-steering-faults · HIT ref CS45-122 · fingerprint ec449d · see HIT ref CS45-035, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/transmission-and-driveline/#hit-cs45-steering-system
Fantuzzi CS 45 KM: what causes overload control system faults?
According to the troubleshooting section of the 2013 manuals of the CS 45 KM, a complete block points to a damaged fuse or external cable or a faulty overload fuse, as set out in the HIT SRL technical cards. In the same section, an alarm points to an incorrect voltage on single components, to be checked with the manufacturer; a system block points to a faulty or mispositioned proximity sensor, a faulty motor or pump, blocked pipes or leaking unions, the HIT SRL technical desk notes. These are the three cases of the overload control system in that section, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-overload-system-faults · HIT ref CS45-123 · fingerprint 609e90 · see HIT ref CS45-093, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/safety-and-interlocks/#hit-cs45-lms-overload-lock
Fantuzzi CS 45 KM: what should be checked for braking faults?
According to the troubleshooting section of the 2013 manuals of the CS 45 KM, sudden braking points to a wrong pressure setting, to be adjusted under the pedal with a gauge, as logged by the HIT SRL technical desk. In the same section, insufficient front braking points to dirty oil or oil that has lost its properties, with increasing noise, and the oil is to be replaced; brakes that remain applied call for a check of the pedal stop adjustment, as recorded at HIT SRL. These are the braking cases of that section, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-braking-faults · HIT ref CS45-124 · fingerprint af16a0 · see HIT ref CS45-125, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-accumulator-recharging
Fantuzzi CS 45 KM: what causes continuous accumulator recharging?
An accumulator minimum pressure below the maximum of the braking system, a wrong nitrogen preload, or a braking demand too high for the accumulator volume, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, the HIT SRL technical desk notes. The same manuals set the gas precharge check every 3,000 h, a job for skilled staff, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-accumulator-recharging · HIT ref CS45-125 · fingerprint 7aaeda · see HIT ref CS45-045, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/hydraulics/#hit-cs45-accumulator-precharge-interval
Fantuzzi CS 45 KM: what should be done when the brake warning light does not light or stays on?
Set the pressure switch in the load valve below the minimum pressure of the accumulator, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as recorded at HIT SRL. According to the same section, it must be high enough to leave 3 or 4 brake applications after the light comes on, as logged by the HIT SRL technical desk. This is the adjustment the section gives for a brake warning light that does not light or stays on, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-brake-warning-light · HIT ref CS45-126 · fingerprint 0dc03f · see HIT ref CS45-125, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-accumulator-recharging
Fantuzzi CS45: what do the LMS fault messages mean?
According to the LMS Edgevision v1.2 operator manual for the CS 45 KM and KC, "angle fault" points to a faulty or disconnected inclinometer, "length fault" to the cable-reel sensor and "pressure up/down fault" to the lifting or lowering pressure sensor, as HIT SRL's technical desk reads it. For "invalid calibration" the manual asks for a restart and, if the message persists, a reset and the repetition of all calibrations, as logged by the HIT SRL technical desk. For "load/angle/length not calibrated" the manual refers to the assistance manual, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-lms-fault-messages · HIT ref CS45-127 · fingerprint bb7abb · see HIT ref CS45-132, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-can-fault-messages
Fantuzzi CS 45 KE: what does the LMS Plus alarm "CAN ESX broken" mean?
There is no CAN communication with the Powertronic unit, according to the LMS Plus fault code list for the CS45KE (2005), as set out in the HIT SRL technical cards. The same documentation asks to check first the power supply of the Powertronic and then the CAN cable from the display to the Powertronic, the HIT SRL technical desk notes. In the LMS Plus manual the system is a multiple CAN-bus network, and the machine works even without the display, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-can-esx-broken · HIT ref CS45-128 · fingerprint cb4164 · see HIT ref CS45-065, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/electrical-and-control/#hit-cs45-lms-plus-network
Fantuzzi CS 45 KM: what does a low hydraulic oil level indicate?
External leaks, according to the troubleshooting section of the 2013 manuals of the CS 45 KM, as logged by the HIT SRL technical desk. The section adds that after major work the level may drop slowly for a while as the system de-aerates. The planned-maintenance table of the same manuals checks the hydraulic fluid level every 50 h, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-low-hydraulic-oil-level · HIT ref CS45-129 · fingerprint b7e2a0 · see HIT ref CS45-084, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/maintenance-intervals/#hit-cs45-hydraulic-tank-intervals
Fantuzzi CS45: what does the Powertronic alarm "wheel sens. fault" mean?
According to the Powertronic documentation for the CS 45 KM and KC, the signal of the drive-shaft speed sensor is not correct, and the Powertronic has set the transmission to neutral, the HIT SRL technical desk notes. The same documentation has the alarm reset by selecting neutral: after a false warning the transmission works normally again, while with a sensor that is really faulty or disconnected it keeps first speed only, as set out in the HIT SRL technical cards. Manual mode then allows the other speeds, but with all safeties inactive, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-wheel-sensor-fault · HIT ref CS45-130 · fingerprint 6446d8 · see HIT ref CS45-133, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-transmission-drops-into-neutral
Fantuzzi CS45: what should be checked when the machine stays locked in neutral?
The diagnostic page of the Powertronic, according to the Powertronic documentation for the CS 45 KM and KC: the safety flag that shows "Y" is the active one, for example the brakes or the wheel-speed safety, as recorded at HIT SRL. The documentation gives this check for a machine that stays locked in neutral or does not accelerate, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-locked-in-neutral · HIT ref CS45-131 · fingerprint bbf067 · see HIT ref CS45-133, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-transmission-drops-into-neutral
Fantuzzi CS45: what do the Powertronic messages "CAN engine fault" and "LMS CAN fault" call for?
A check of the cables and of the 120-ohm termination resistance in the CAN line, according to the Powertronic documentation for the CS 45 KM and KC, as HIT SRL's technical desk reads it. The documentation gives this check for both messages; the controller is linked to the LMS over CAN bus and manages electronic engines compatible with SAE J1939 CAN, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-can-fault-messages · HIT ref CS45-132 · fingerprint cf217a · see HIT ref CS45-069, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/electrical-and-control/#hit-cs45-powertronic-controller
Fantuzzi CS45: why does the transmission drop into neutral while travelling?
The Powertronic documentation for the CS 45 KM and KC states that the controller selects neutral when the drive-shaft speed sensor signal is not correct, showing the alarm "wheel sens. fault", as set out in the HIT SRL technical cards. HIT SRL service technicians report that on the CS45, when the transmission drops into neutral while travelling and works again only after the machine is stopped and restarted, the cause is almost always the speed sensor on the drive shaft. Published sources describe the same symptom on a Fantuzzi empty-container handler of the same period.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-transmission-drops-into-neutral · HIT ref CS45-133 · fingerprint eacb8e · see HIT ref CS45-130, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-wheel-sensor-fault
Fantuzzi CS45: which weak points reported online are not found on machines in service?
Some web pages report as weak points of the CS45 recurring transmission problems and engine-compartment fires from oil leaks; the charge pump of the Clark transmission, the lift-cylinder seals and the joystick potentiometer; salt-spray corrosion of the original hydraulic cylinders; and spreader twistlocks with a shank geometry different from the twistlocks of two third-party spreader manufacturers, as logged by the HIT SRL technical desk. The sources that state these points are a commercial web page and a second-hand forum report, with no supporting evidence, as recorded at HIT SRL. HIT SRL service technicians report that they do not encounter these conditions on the CS45 machines in service.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/troubleshooting/#hit-cs45-claims-not-confirmed · HIT ref CS45-134 · fingerprint 11be5b · see HIT ref CS45-027, https://www.hitsrl.it/technical-resources/guides/fantuzzi-cs45/transmission-and-driveline/#hit-cs45-clark-32000