Fantuzzi FDC — Safety and interlocks: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the safety devices and interlocks of the Fantuzzi FDC front lift trucks, one fact per card, each with its source stated in the text. For the overall picture, see the Fantuzzi FDC technical legacy guide.
Fantuzzi FDC 25 K7: what are the safety bypass keys for?
According to the FDC 25 K7 and FDC 500 G5 manuals, safety bypass keys operate switches in the cab and in the electrical compartment that interrupt safety signals, to finish handling a load or to latch onto damaged containers, as set out in the HIT SRL technical cards. The same manuals allow them only with the approval of the person in charge and after finding the cause, the HIT SRL technical desk notes. According to the same manuals, the keys in the electrical compartment need two people, one in the cab and one at the compartment, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-safety-bypass-keys · HIT ref FDC-102 · fingerprint 671c3d · see HIT ref FDC-104, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-g-series-lifting-bypass-key
Fantuzzi FDC 25 K7: when may the twistlock bypass key be used?
According to the FDC 25 K7 manual, the twistlock bypass key may be used to latch without the permission of the spreader position sensors, as HIT SRL's technical desk reads it. According to the same manual, it may be used on containers damaged near the corner fittings or when position sensors are faulty, once the spreader is correctly positioned, as logged by the HIT SRL technical desk. The same manual then asks for the damaged parts or sensors to be repaired as soon as possible, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-bypass-key · HIT ref FDC-103 · fingerprint 1993db · see HIT ref FDC-104, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-g-series-lifting-bypass-key
Fantuzzi FDC 500 G5: what does the lifting bypass key do?
According to the 2003 FDC 500 G5 manual, on the G series a lifting bypass key in the electrical compartment restores arm and twistlock lifting when the twistlock locked-on sensor fails during handling, as set out in the HIT SRL technical cards. Without it, the same manual has that failure stop arm movement except retraction; the sensor is the one shown by the green light on the spreader and in the cab, the HIT SRL technical desk notes. Afterwards, the manual asks for the fault to be found and the sensors reset, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-g-series-lifting-bypass-key · HIT ref FDC-104 · fingerprint 25b8f4 · see HIT ref FDC-103, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-bypass-key
Fantuzzi FDC: what do the twistlock lights mean?
The sources give opposite meanings for green, as logged by the HIT SRL technical desk. The FDC manuals give green for twistlocks or hooks latched, red for unlatched and amber for a container in position, with the twistlocks ready to be latched or unlatched. HIT SRL service technicians report that the convention in service is green = twistlocks open, container free. Verify the convention on your own machine and spreader before operating.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-lights · HIT ref FDC-105 · fingerprint 3ee849 · see HIT ref FDC-106, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-sensors
Fantuzzi FDC 25 K7: how do the twistlock position sensors work?
According to the FDC 25 K7 manual, position sensors on each twistlock confirm to the electronic control system that the twistlocks are seated in the container corner fittings, as recorded by the HIT SRL technical desk. The same manual has the yellow light allow latching and the green light confirm that all twistlocks are latched and lifting can begin; the container must rest on a stable surface before release, and the red light confirms release. In that manual, in case of a fault the system prevents raising the lifting unit, and the spreader lift control does not work if the twistlocks released or fastened light is off. HIT SRL service technicians report that the convention in service is green = twistlocks open, container free. Verify the convention on your own machine and spreader before operating.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-sensors · HIT ref FDC-106 · fingerprint 63db76 · see HIT ref FDC-105, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-twistlock-lights
Fantuzzi FDC 25 K7: what happens if reverse is engaged with the spreader seated?
According to the FDC 25 K7 manual, with the spreader in the seated position, shown by the yellow light, engaging reverse gear brings up a spreader seated message on the display and a warning sound, the HIT SRL technical desk notes. The LMS Plus fault code manual lists spreader seated among the warnings that are not stored in the black box, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-spreader-seated-warning · HIT ref FDC-107 · fingerprint 1a90eb · see HIT ref FDC-140, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-lms-plus-alarms
Fantuzzi FDC: what prevents the engine from starting in gear?
According to the FDC manuals, a safety device prevents the engine from starting unless the gear switch is in neutral, as recorded at HIT SRL. LMS Plus, Powertronic and Digicontrol also refuse to start the engine unless the speed selector is in neutral, according to the manuals of the three systems, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-start-in-neutral · HIT ref FDC-108 · fingerprint 999aff · see HIT ref FDC-040, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/transmission-and-driveline/#hit-fdc-second-gear-start
Fantuzzi FDC 25 K7: what does the switch on the left brake pedal do?
According to the FDC 25 K7 operator's manual, the switch on the left brake pedal engages neutral while braking, as HIT SRL's technical desk reads it. In that manual, pressing the pedal brakes; pressing the switch brakes and engages neutral; releasing the switch re-engages the selected direction, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-brake-pedal-switch · HIT ref FDC-109 · fingerprint 749562 · see HIT ref FDC-137, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-inching-faults
Fantuzzi FDC 25 K7: how are the emergency button and parking brake used?
According to the FDC 25 K7 manual, the emergency button stops the diesel engine and prevents all movement, as logged by the HIT SRL technical desk. The same manual has the parking brake applied by a button and always applied, with the engine off, before leaving the machine, and warns that driving with the parking brake on can cause brake failure, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-emergency-and-parking-brake · HIT ref FDC-110 · fingerprint 3143a3 · see HIT ref FDC-117, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-transmission-safeties
Fantuzzi FDC 25 K7: how should loads be carried and slopes driven?
According to the FDC 25 K7 manual, heavy loads must not be carried raised: the lifting unit and the load stay lowered while travelling, and the load is lifted only during stacking, the HIT SRL technical desk notes. On slopes the same manual has the machine move up and down slowly and never turn on or drive across the slope, as set out in the HIT SRL technical cards. On gradients over 10% it travels with the load facing uphill, according to the same manual, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-driving-with-loads-and-slopes · HIT ref FDC-111 · fingerprint d6e289 · see HIT ref FDC-110, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-emergency-and-parking-brake
Fantuzzi FDC: can safety devices be disabled?
No: the FDC manuals forbid disconnecting or disabling the electrical, mechanical and hydraulic safety devices, as recorded at HIT SRL. If one is faulty, the same manuals forbid operating the machine and ask for maintenance staff to be told at once. The rule appears in the FDC manuals, among them the 2008 manual of the FDC 25 K7, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-safety-devices · HIT ref FDC-112 · fingerprint f9a153 · see HIT ref FDC-102, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-safety-bypass-keys
Fantuzzi FDC: how does the LMS Plus badge system work?
According to the LMS Plus FDC V5.x operator manual, with the optional badge system the machine asks for an operator code at start-up, as HIT SRL's technical desk reads it. In the same manual, without a code the transmission stays in neutral and the boom is locked, as logged by the HIT SRL technical desk. In the same manual, manual code entry accepts only the maintenance code, and its use is recorded in the black box, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-lms-plus-badge · HIT ref FDC-113 · fingerprint 688c08 · see HIT ref FDC-072, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/electrical-and-control/#hit-fdc-lms-plus
Fantuzzi FDC: when does LMS Plus put the transmission in neutral?
According to the LMS Plus manual, LMS Plus puts the transmission in neutral when engine speed is above 1,000 rpm, when the direction is changed above 0.5 km/h, with the parking brake, with the declutch button pressed and a gear engaged, or when the drive-shaft speed sensor signal is wrong, as set out in the HIT SRL technical cards. According to the same manual, the thresholds are adjustable, the HIT SRL technical desk notes. The same manual states that these safeties can be removed only with a transmission or total bypass, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-lms-plus-transmission-safeties · HIT ref FDC-114 · fingerprint b00122 · see HIT ref FDC-117, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-transmission-safeties
Fantuzzi FDC: which boom and spreader safeties does LMS Plus apply?
According to the LMS Plus manual, LMS Plus locks mast lifting on overload, that is a load above maximum capacity or a broken weight sensor, and when the locked and unlocked sensors are both inactive, as logged by the HIT SRL technical desk. The same manual makes twistlock lock and unlock need the seated sensor active, as recorded at HIT SRL. It gives the 20-40 foot movement a 40-second timeout, according to the same manual, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-lms-plus-boom-safeties · HIT ref FDC-115 · fingerprint 3a3741 · see HIT ref FDC-114, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-lms-plus-transmission-safeties
Fantuzzi FDC: who may use the LMS Plus and Digicontrol bypass codes?
Bypass and access codes are not published in these pages and are given by the manufacturer's service network to authorised personnel, the HIT SRL technical desk notes. The LMS Plus and Digicontrol manuals make the operator alone responsible for using the safety bypasses of the machine, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-bypass-codes · HIT ref FDC-116 · fingerprint 280d3d · see HIT ref FDC-120, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-digicontrol-bypasses
Fantuzzi FDC: which transmission safeties does Powertronic apply?
According to the Powertronic V5.x manual, Powertronic refuses first gear from neutral above a minimum engine speed, normally 900 rpm, as recorded at HIT SRL. According to the same manual, it puts the transmission in neutral if a direction change is attempted above a minimum speed, normally 2 km/h, or if the parking brake or the brake-pedal button is used with a gear engaged, as logged by the HIT SRL technical desk. The same manual has it check the drive-shaft speed sensor as well, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-transmission-safeties · HIT ref FDC-117 · fingerprint 31832e · see HIT ref FDC-114, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-lms-plus-transmission-safeties
Fantuzzi FDC: how does the Powertronic overload control work?
According to the Powertronic manual, the optional overload control estimates the lifted weight to within 10% from a pressure sensor on the lifting cylinder, as HIT SRL's technical desk reads it. The same manual has it lock mast lifting and show a message on the display when the weight exceeds the maximum allowed, with any spreader or tool, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-overload · HIT ref FDC-118 · fingerprint 8d202e · see HIT ref FDC-119, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-spreader-safeties
Fantuzzi FDC: which spreader safeties does Powertronic apply?
According to the Powertronic manual, Powertronic allows twistlock locking only when the spreader is seated, as set out in the HIT SRL technical cards. The same manual allows unlocking always in the standard version, only without load with the weight system, and only with the machine standing still in the English standard, the HIT SRL technical desk notes. With gantry and forks-type spreaders, mast lifting needs the twistlocks locked or unlocked, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-spreader-safeties · HIT ref FDC-119 · fingerprint 08c63f · see HIT ref FDC-117, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-transmission-safeties
Fantuzzi FDC 550 G5: which bypasses does Digicontrol offer?
Digicontrol offers bypasses for mast lowering, engine alarms, buzzer, mast in, mast lifting, overload, gear safety, 20-40 manual and lock, total bypass, spreader CAN on and off and limited speed, the HIT SRL technical desk notes. On machines with stabilisers no gear is selected unless the stabilisers are lifted, according to the 2007 Digicontrol manual for the FDC 550 G5, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-digicontrol-bypasses · HIT ref FDC-120 · fingerprint d90afd · see HIT ref FDC-116, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-bypass-codes
Fantuzzi FDC 450 G4: what is the ELCOS protection device?
According to the 2002 manual of the G series, ELCOS is a protection device, fitted on some G-series machines, that inhibits machine functions and stops the engine when its red light comes on, as recorded at HIT SRL. The same manual has it act for low or overheated coolant, insufficient engine oil pressure or excessive transmission oil temperature, as logged by the HIT SRL technical desk. According to the same manual, with its green light on the machine works normally, and a bypass key restores operation, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-elcos-protection · HIT ref FDC-121 · fingerprint bc5a80 · see HIT ref FDC-104, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-g-series-lifting-bypass-key
Fantuzzi FDC 500 G5: how does the cab angle work?
According to the 2003 operator's manual of the FDC 500 G5, on the G series the cab angle follows the spreader height in automatic mode, as HIT SRL's technical desk reads it. A key selects manual mode, in which a button changes the cab angle, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-g-series-moving-cab · HIT ref FDC-122 · fingerprint f8905d · see HIT ref FDC-012, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/identification/#hit-fdc-g-series-specifications
Fantuzzi FDC: what safety rules apply to tyres and rims?
According to the FDC maintenance manuals, when inflating a tyre the operator stands to the side of the wheel at least 2 m from its centre, never in front of it, does not exceed the plate pressure, and inflates within a safety cage during tyre fitting, as set out in the HIT SRL technical cards. Rims and wheel centres must never be repaired by welding or patching, replacement parts must be identical in size, type and section, and rims are inspected at each tyre change, with a penetrant test in case of doubt, the HIT SRL technical desk notes. The same manuals also require a new O-ring at every reassembly, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-tyres-and-rims-safety · HIT ref FDC-123 · fingerprint 67a7c3 · see HIT ref FDC-089, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/maintenance-intervals/#hit-fdc-wheels-intervals
Fantuzzi FDC 25 J7: what wind limits does the manual give?
The FDC 25 J7 manual states wind-tested limits: in wind of 40-50 km/h the machine operates in all conditions, at 50-60 km/h up to the 7th stacking height, at 60-70 km/h up to the 6th and at 70-80 km/h up to the 5th, as recorded at HIT SRL. Braking deceleration must not exceed 1 m/s2, according to the same 2006 manual, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-wind-limits · HIT ref FDC-124 · fingerprint d0ab02 · see HIT ref FDC-111, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-driving-with-loads-and-slopes