Fantuzzi CS 7.5 Empty Container Reach Stacker — Technical Legacy Guide

Summary

CS 7.5 is the designation of a Fantuzzi reach stacker built in S5, S6 and S7 versions, which the manual of its transmission controller calls an empty handler and a Fantuzzi Reggiane brochure presents in its Empty Container Reach stacker Range, as recorded by the HIT SRL technical desk. The operator's manuals of 2003 to 2006 give empty weights of 37,500 to 41,000 kg, 14.00-24 tyres, a hydrodynamic power-shift transmission and an SR10 telescopic spreader, and a Terex table of 2012 rates the CS 7.5 S6 at 10, 8 and 5 t in the first three rows. A load management system interlocks the boom, and its manual is written for the CS 7.5. Another Fantuzzi reach stacker, the CS 42 S, built by Officine Meccaniche Fantuzzi according to its handbook, is described in the Related models section. The present owner of the Fantuzzi Reggiane brand states that new Fantuzzi Reggiane machines are no longer sold and that it supports those still in operation.

Model identification

The general description of the CS 7.5 manuals, the same as in the larger CS and RS reach stackers, presents an arm truck for lifting heavy loads in the combined transport of containers from railway wagons to road vehicles and names ten main parts: rear steering wheels, electrical compartment, front driving wheels, lifting cylinder, operator's cab, fixed arm, moving arm, damping cylinder, spreader and twistlocks, the HIT SRL technical desk notes. The manual of the Powertronic transmission controller is written for the stackers CS45 KM/KC and CS7.5 and describes the CS 7.5 as an empty handler. A brochure of the Fantuzzi Liftrucks Division shows the CS 7.5 S and CS 7.5 S6 as its Empty Container Reach stacker Range and dates the launch of the model to 1992.

S5, S6 and S7 are the three versions of the specification tables. The brochure gives the S6 a stacking height of six 8 ft 6 in or five 9 ft 6 in containers, and the 2012 Terex table five 9 ft 6 in or six 8 ft 6 in containers in the first row and four or five in the second.

CS 7.5 S5, S6 and S7, 2003-2006 manuals

The CS 7.5 specification table of the 2003 to 2006 operator's manuals sits in a family section that also holds the tables of the CS 42-45 and of the RS 50 and RS 55, and the CS 45 KM manual of 2004 carries the same CS 7.5 tables. It gives empty weights of 37,500 kg for the S5, 39,000 kg for the S6 and 41,000 kg for the S7, noise levels of 85 dB(A) outside and 76 dB(A) in the cab and a travel speed of 25 km/h empty and 23 km/h loaded. The dimension drawing of the same editions gives a 5,000 mm wheelbase, a 1,200 mm rear overhang, a height of 4,100 mm and a turning radius of 6,900 mm; the overall length is 10,225 mm on the S5 and S7 and 11,225 mm on the S6. The data plate shown in the manuals records model, serial number, year of construction, unladen weight with equipment, maximum capacity and front and rear tyre pressures.

CS 7.5 S6, 2012 Terex table

The 2012 Terex manual puts the CS 7.5 S6 in one specification table and load chart with the CS 45 KM, KL and KS and the RS 55 and RS 60, the same table found in the CS 45 KM manual of 2013. It gives the CS 7.5 S6 a capacity of 10 t in the first row, 8 t in the second and 5 t in the third, no piggy-back option, a service weight of 40,500 kg, a 5,150 mm wheelbase, a turning radius of 10,200 mm with a 40 ft container and 7,850 mm with a 20 ft container, and a height of 4,300 mm. The same table gives a lifting speed of 0.44 m/s with a load and 0.50 m/s without, and a lowering speed of 0.38 and 0.57 m/s.

Load charts and brochure data

The load chart of the 2012 manual gives 10 t in the first row up to the fifth container and 7.6 t at the sixth, 8 t in the second row up to the fourth and 4.5 t at the fifth, 5 t in the third row up to the third and 4 t at the fourth, and 0.5 t in a fourth row two containers high. The brochure chart of the CS 7.5 S6 matches it in the first two rows except for 7.5 t at the sixth container, gives 4.5 t at the fourth container of the third row and shows no fourth row. The brochure drawing gives a 5,150 mm wheelbase and a height of 4,300 mm, like the 2012 table, with an overall length of 10,370 mm on the S5 and S7 and 11,370 mm on the S6.

Industrial history and parts supply

The CS 7.5 manuals of 2003 to 2006 are Fantuzzi-Reggiane S.p.A. publications, and the brochure carries the Fantuzzi Reggiane and Fantuzzi Liftrucks Division names. 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.

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 2012 manual carries the name of Reggiane Cranes and Plants S.p.A. and 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 2003 to 2006 tables refer the engine to a motor table shared with the larger CS models. In 2003 the table lists six-cylinder engines from 245 to 400 hp: Cummins M11-C, Volvo TWD1031VE and TWD1231VE, Cummins N14 and Caterpillar 3306B. The 2004 and 2006 editions add three Volvo engines at the top of the list: the TAD720VE, 174 kW at 2,000 rpm from 7,150 cm3, the TWD731VE, 238 hp at 2,400 rpm from 6,730 cm3, and the TWD1240VE, 348 hp. HIT SRL service technicians report that the first CS 7.5 machines had the Volvo TWD731VE as standard engine and later machines the Volvo TAD720VE.

In the 2012 Terex table the standard engine is a Volvo TAD 750VE, 181 kW at 2,300 rpm and 1,050 Nm at 1,500 rpm, and the option a Cummins QSC 8.3, 183 kW at 2,200 rpm; for the Tier 4 rules the table gives a Volvo TAD 762VE, 185 kW, or a Cummins QSB 6.7, 194 kW, both at 2,200 rpm. Engine oil is SAE 15W-40 to API CG-4/SG in the quantity set by the engine manual, the cooling system is filled with 40% antifreeze for protection down to -26 °C, and a turbocharged engine runs at about 1,000 rpm with reduced load for 2 or 3 minutes before it is stopped.

Transmission

The specification tables give a hydrodynamic transmission with torque converter and power-shift clutches, four forward and four reverse gears and a hydraulic cooling system. The CS 7.5 filling table names a Clark 32000 with 28.5 litres of oil, grade 30 for 0 to +60 °C or grade 10 for -25 to +60 °C; the 2006 and 2012 tables add the Dana TE17 with 48 litres of automatic transmission fluid to Dexron III or Mercon, and the 2012 specification table gives both units. According to its manual, the Powertronic controller, typically installed on the CS 7.5, manages the electro-hydraulic transmission together with the engine, sets shift points by load and stability and exchanges data with the load management system over a CAN bus. The same manual has it put the transmission in neutral when the direction is reversed above about 2 km/h, when the parking brake or the inching button is used with a gear engaged and when the drive-shaft speed sensor fails, and allow first gear from neutral only below a minimum engine speed, normally 900 rpm.

The automatic transmission unit is preset at the factory and reprogrammed only by Fantuzzi; the gear selector engages gears automatically up to the lever position, a key used with the machine stopped and the lever in neutral switches to manual shifting, and the engine starts only in neutral. The transmission oil is checked daily at FULL with the engine at low revs, at 82-93 °C according to the operator's manual and at 82-85 °C according to the maintenance section, which changes the filter every 500 hours and the oil every 1,500 hours. According to the operator's manual, the far-left brake pedal has a switch that brakes and selects neutral together.

Drive axle, brakes and steering

The specification tables give a drive axle with epicyclic reduction gears, oil-bath disc service brakes at the front, optional dry disc brakes at the rear and a mechanically released dry-disc parking brake on the transmission, while the drive axle section of the maintenance manual describes oil-cooled multi-plate brakes inside the hubs and a parking brake on the axle with an electro-hydraulic caliper. HIT SRL service technicians report that CS 7.5 machines have existed with both brake configurations. According to the filling table, differential and hubs take 45 litres of SAE 90 oil to API GL-5, or SAE 85W-140 above 0 °C; the maintenance table checks the level every 100 hours and changes the oil every 1,500 hours. According to the maintenance manual, cardan shafts carry the drive from the gearbox to the axle, with grease nipples on the joints and clean, unpainted sliding areas. The maintenance manual gives the steering axle a power-steering cylinder and two connecting rods to the hubs, with stabiliser cylinders and hub disc brakes as options, and the tables give four front and two rear 14.00-24 tyres inflated to 10 bar.

Hydraulic system as installed

The hydraulic system takes SAE 80W oil to API GL-4: 660 litres in the filling and specification tables of 2003 to 2006 and 520 litres in the 2012 tables. The 2012 table gives a variable displacement pump, with a gear pump configuration available, and a maximum hydraulic pressure of 230 bar, and the component list of a CS 7.5 S6 hydraulic schematic includes a double pump of 64 + 40 cc/rev and a triple pump of 64 + 40 + 17 cc/rev. According to the operator's and maintenance manuals, the reservoir is on the chassis to the right of the driver's seat and is checked with the engine off at the top notch; its return filters have an electrical blockage indicator shown in the cab, and topping-up fluid is pre-filtered at 10 microns.

The maintenance table checks the fluid level every 50 hours, changes the oil filter at 1,500 hours and analyses and changes the oil at 3,000 hours or at least once a year. Accumulator gas precharge is checked with the system not under pressure, at 1,500 hours in the 2003 to 2006 table and at 3,000 hours in the 2012 table, and all hydraulic hoses are replaced within 5,000 operating hours. For the precharge, HIT SRL service technicians report that both intervals are valid, depending on the type of accumulator fitted. After a component failure the maintenance manual has the filters and the sump checked for fragments, and a contaminated system cleaned before it runs again.

Structure, boom and spreader

Telescopic arm

According to the maintenance manual, the arm is made of a fixed arm, a moving arm and an extension cylinder; the moving arm slides on lubricated sliding blocks inside the fixed arm and carries the spreader couplings, and cables and hoses run in a protection chain outside the arm. The tables give Weldox 700 steel for the arm, Fe 510 D for the chassis and both steels for the spreader. The boom section greases the sliding blocks every 100 hours and checks them every 500 hours, with a play of no more than 2 mm per side, or 3 mm per side on the fixed-arm blocks, and the maintenance table marks their replacement in the 250-hour column, with the note at least once a year. The load management manual of the CS 7.5 notes that the boom cannot be extended completely at low angles even when empty, and its geometry example sets the boom angle from 0 to 66.6 degrees and the boom length from 9.00 to 15.80 m.

Spreader

The CS 7.5 tables give an SR10 telescopic spreader for 20 to 40 ft containers, with rotation from -95 to +185 degrees, side shift of plus or minus 800 mm and lateral oscillation of plus or minus 3 degrees. The spreader reduction unit takes 2.5 litres of grade 10 oil; the maintenance table checks its level every 50 hours, changes it every 500 hours and replaces the twistlocks at 6,000 hours, under a heading for the SRP45SS spreader. The equipment section of the maintenance manual describes the SRP2 spreaders of the larger CS models rather than the SR10, and the 2006 cab has an optional 30 ft lock button and a spreader opening and closing button. HIT SRL service technicians report that both the SR10 and SRP2-45 spreaders are found on CS 7.5 machines in service. The brochure shows a telescopic rotating spreader that carries a container rotated end-on through doorways or high racks. The SR10 of the CS 7.5 table has its own section in the Fantuzzi Reggiane attachments guide.

Frame

The maintenance manual has the main frame first inspected after one year of work, then at intervals never longer than one year, with a yearly sample check of bolt torques using a calibrated torque wrench. The torque table of the maintenance manual gives, for example, 229 and 336 Nm for M16 x 1.5 screws of class 8.8 and 10.9.

Electrical and control

The 2003 to 2006 tables give a 24 V, 150 Ah battery. The load management equipment changes between editions: the 2003 cab has an optional load management system and a spreader bypass key, the 2004 cab the LMS Edgevision with lights for the stabilisers, and the 2006 cab the Logicontrol Plus load limiting device with a safety system bypass key.

The LMS Edgevision manual written for the CS 7.5 shows the weight lifted and the weight allowed, the load centre distance, twistlock height, boom length and angle and twistlock status, and reads an inclinometer, a cable reel and two load cells. According to that manual, its safeties lock all boom movements except retraction in overload, boom lifting and retraction at minimum distance, boom lifting at high angle and stabiliser lifting when the machine would not be stable, with the overload alarm at 100% and a pre-alarm at 90% of the capacity. A 1998 Logicontrol manual gives type 1 load cells rated 9 t for CS 7.5 machines, against type 2 cells rated 40 t for the CS 42, CS 45 and CS 50. The LMS Edgevision manual gives an operative black box with the data of the last 6,500 containers and an alarms black box with about 4,500 messages, bypass use included.

According to the 2006 operator's manual, the dashboard has lights for neutral, preheating, low transmission oil level, parking brake, battery charge, blocked air filter, low engine oil pressure and blocked oil filter, and the joystick has a capacitive dead man's handle that inhibits functions when it is released. The 2006 operator's manual gives green for twistlocks latched; 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. According to its manual, the Powertronic limits travel speed by stability, to 20 km/h with the machine unloaded, 13 km/h with a small load and the boom extended and 8 km/h in overload, and shuts the engine down on low oil pressure after 3 seconds. According to its manual, the Logicontrol LMS Plus is built on a CAN bus network with a single display, optional operator badges and black boxes.

Recurring failure points — field reports

Published field reports specific to the CS 7.5 are scarce, as recorded at HIT SRL.

Maintenance interval summary

The planned-maintenance table of the CS 7.5 maintenance manual, unchanged between the 2003 and 2006 editions, uses intervals of 10, 50, 100, 250, 500, 1,500, 3,000 and 6,000 hours; (1) = at least once a year; (2) = skilled staff.

According to the operator's and maintenance manuals, every day the engine oil is checked 15 minutes after the engine stops and kept between L and H, and the transmission oil at FULL; wheels and tyres are serviced at least once a year, and the fire extinguisher, where fitted, is refilled every 36 months.

Key specification table

Related models

The CS 7.5 shares its manuals with the larger CS 42 and CS 45 reach stackers; the CS 42 KC, KM and KE columns of those family tables are covered by the Fantuzzi CS45 guide, as HIT SRL's technical desk reads it.

CS 42 S

The CS 42 S is an Officine Meccaniche Fantuzzi reach stacker, according to its operation and maintenance handbook. Its capacity table gives ratings under the twistlocks by radius and boom length, with booms of 8.75 to 15.15 m: 45,000 kg at the shortest radii, 32,000 kg at 3.85 m with booms of 10.75 to 13.75 m and 8,000 kg at 8.2 m with the longest boom, or 10,000 kg at 8.2 m with the stabilisers down. The handbook gives four engines: a FIAT 8210 of 13,798 cm3 rated 189 kW gross at 2,200 rpm, a Volvo TD 100 G of 9,600 cm3 rated 203 kW, a Mercedes OM 442 of 15,078 cm3 rated 213 kW at 1,850 rpm and a Volvo TD 121 G of 11,980 cm3 rated 256 kW.

According to the handbook, drive goes through a Clark 34000 or Clark 5000 power-shift transmission with four forward and four reverse gears and inching, selected electrically from the cab, to a Fantuzzi drive axle with oil-bath disc brakes on four front tyres 18.00-33 inflated to 9 bar. The handbook gives a sound level of 76 dB(A) at the operator's position and asks for a 40 ft container to be rotated only after lowering it to no more than 1 metre above the ground with the boom fully extended.

CS 42 SP and CS 50

A one-page chart of a CS 42 SP with spreader and piggy-back gives 42 t in the first row up to the fourth container and 27 t at the fifth, 24 t in the second row and 9 t in the third, the values of the CS 42 KM piggy-back chart. The 1998 Logicontrol manual also names CS 50 machines, which take the same type 2 load cells as the CS 42 and CS 45, and applies its CS 45 software type to the CS 45 and CS 50 with the Opera cab and its CS 42 type to the CS 45 KM and to CS 42 machines without it.

Spare parts

HIT SRL supplies genuine, OEM and aftermarket spare parts for Fantuzzi port equipment, including the CS 7.5 empty container reach stackers, 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 (22 cards)
• Engine (13 cards)
• Transmission and driveline (17 cards)
• Hydraulics (8 cards)
• Boom and spreader (12 cards)
• Electrical and control (13 cards)
• Maintenance intervals (19 cards)
• Safety and interlocks (24 cards)
• Troubleshooting (9 cards)
• Related models (6 cards)