Fantuzzi FDC — 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 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: what can stop the engine from starting?
The FDC troubleshooting table lists, for an engine that fails to start or stops, air in the fuel circuit, generator or starter faults and a gear lever not in neutral, as recorded at HIT SRL. The same table also lists low fuel, a dirty pre-filter and filter, water in the fuel or a faulty injection pump, as logged by the HIT SRL technical desk. The table is part of the FDC maintenance manuals, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-engine-fails-to-start · HIT ref FDC-125 · fingerprint 81af54 · see HIT ref FDC-108, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-start-in-neutral
Fantuzzi FDC: what causes low engine power?
With normal exhaust, the FDC troubleshooting table points to the accelerator cable, the injection pump regulator or the turbocharger, as set out in the HIT SRL technical cards. With abnormal exhaust, the same table points to a dirty air filter, the injection pump regulator or the turbocharger, the HIT SRL technical desk notes. For the turbocharger itself, the maintenance manuals list lubrication problems, foreign bodies passing the air filter and lubricating oil in poor condition as sources of faults, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-engine-power · HIT ref FDC-126 · fingerprint 08a877 · see HIT ref FDC-125, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-engine-fails-to-start
Fantuzzi FDC: what can make a hydraulic motor lose speed or torque?
For a hydraulic motor that does not turn or lacks speed or torque, the FDC troubleshooting table lists a misaligned or restricted drive and a stuck or low-set maximum-pressure valve, as HIT SRL's technical desk reads it. The same table adds a wrong angle on adjustable motors, and low pump pressure or flow, as logged by the HIT SRL technical desk. When there is no flow at all, it lists no oil, wrong rotation, a broken coupling, an open discharge valve, a blocked pressure duct or actuator faults, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-hydraulic-motors · HIT ref FDC-127 · fingerprint 809268 · see HIT ref FDC-128, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-hydraulic-pressure
Fantuzzi FDC: what can cause no or low hydraulic pressure?
The FDC troubleshooting table lists no oil in the tank, a faulty gauge, a discharge or maximum-pressure valve fully open, excessive leaks or a pressure limiter set too low, as set out in the HIT SRL technical cards. These are the checks of the FDC maintenance manuals when there is no hydraulic pressure or the pressure is too low, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-hydraulic-pressure · HIT ref FDC-128 · fingerprint 5adb76 · see HIT ref FDC-131, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-clutch-pressure
Fantuzzi FDC: what can make a hydraulic pump noisy or deliver no oil?
For a noisy pump, the FDC troubleshooting table lists misaligned pump and motor, low or unsuitable oil, air drawn in at the intake, drain or shaft seals, a tank that does not breathe, a restricted intake, worn seals or a blocked filter, as logged by the HIT SRL technical desk. For a pump that delivers no oil, the same table lists an oil level too low over the intake and air in the intake, as recorded at HIT SRL. It also lists a blocked intake filter, excessive viscosity or a damaged shaft or rotor, according to the same table, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-pump-noise · HIT ref FDC-129 · fingerprint 0071ad · see HIT ref FDC-053, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/hydraulics/#hit-fdc-pump-repair
Fantuzzi FDC: what can stop a directional valve spool from moving?
For a spool that does not move, the FDC troubleshooting table lists solenoids not powered or burnt out, no pilot pressure, a blocked pilot drain, contaminants or wrong reassembly, the HIT SRL technical desk notes. For an irregular response it lists residues, fine contaminants, oil too viscous at start-up or an incorrect solenoid supply, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-spool-stuck · HIT ref FDC-130 · fingerprint fa4af6 · see HIT ref FDC-137, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-inching-faults
Fantuzzi FDC: what causes low pressure at the gear-selection clutches?
The FDC troubleshooting table lists low oil, a pressure valve stuck open, a faulty pump, worn piston or shaft seals or a blocked clutch-piston bleed valve, as recorded at HIT SRL. Closing the line to the power distributor shows whether the fault is in the distributor, according to the maintenance manuals, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-clutch-pressure · HIT ref FDC-131 · fingerprint 4b23f7 · see HIT ref FDC-128, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-hydraulic-pressure
Fantuzzi FDC: what can make the torque converter overheat?
The FDC troubleshooting table lists worn seals or oil pump, low oil, air in the intake line, a blocked heat exchanger or pipes and dirty radiator fins, as HIT SRL's technical desk reads it. For a high converter-out pressure at full speed in neutral the same table lists a blocked exchanger or pipe and oil too viscous or cold, as logged by the HIT SRL technical desk. The same table gives the pressure dropping as the converter warms, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-converter-overheating · HIT ref FDC-132 · fingerprint 50cb61 · see HIT ref FDC-036, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/transmission-and-driveline/#hit-fdc-transmission-oil-type
Fantuzzi FDC: what causes stiff or poor steering?
For stiff steering, the FDC troubleshooting table lists oil pressure too low, a faulty pump or a faulty power-steering valve, as set out in the HIT SRL technical cards. For poor steering the same table lists a pressure that needs adjusting or an internal leak in the steering cylinder. These are the checks given in the FDC maintenance manuals, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-steering-faults · HIT ref FDC-133 · fingerprint 796cd2 · see HIT ref FDC-044, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/transmission-and-driveline/#hit-fdc-steering-system
Fantuzzi FDC: what do the overload control system faults point to?
According to the FDC troubleshooting table, a complete block of the overload control system points to a damaged fuse or external cable or a faulty overload fuse, as logged by the HIT SRL technical desk. In the same table, an alarm points to incorrect voltage at single components, to be checked with the manufacturer, as recorded at HIT SRL. A system block points to a faulty or mispositioned proximity sensor, a faulty motor or pump, blocked pipes or leaking unions, in the same table, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-overload-system-faults · HIT ref FDC-134 · fingerprint e75b1f · see HIT ref FDC-118, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/safety-and-interlocks/#hit-fdc-powertronic-overload
Fantuzzi FDC: what causes braking faults?
According to the FDC troubleshooting table, sudden braking points to a wrong pressure setting, adjusted under the pedal with a gauge, the HIT SRL technical desk notes. In the same table, weak front braking points to dirty oil or a faulty actuator cylinder, with the oil-bath discs to be replaced, as set out in the HIT SRL technical cards. Weak optional rear braking points to worn discs or pads or a faulty caliper, in the same table, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-braking-faults · HIT ref FDC-135 · fingerprint 3002c1 · see HIT ref FDC-136, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-accumulator-recharging
Fantuzzi FDC: what does continuous accumulator recharging point to?
According to the FDC troubleshooting table, continuous accumulator recharging points to an accumulator minimum pressure below the braking system maximum, a wrong nitrogen preload or a braking demand too high for the accumulator volume, as recorded at HIT SRL. If the brake warning light does not light or stays on, the same table calls for the load-valve pressure switch to be set below the accumulator minimum, as logged by the HIT SRL technical desk. The same table calls for it to be high enough for 3 or 4 brake applications after the light comes on, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-accumulator-recharging · HIT ref FDC-136 · fingerprint 58a144 · see HIT ref FDC-135, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-braking-faults
Fantuzzi FDC: what can stop the inching control from working?
With pressure too low, the FDC troubleshooting table lists dirty or blocked pipes, leaking unions, a low oil level, a faulty pump, air in the circuit or a pedal stroke that is too short for an inching control that does not work, as HIT SRL's technical desk reads it. These checks are in the FDC maintenance manuals, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-inching-faults · HIT ref FDC-137 · fingerprint f221b4 · see HIT ref FDC-128, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-low-hydraulic-pressure
Fantuzzi FDC: what do lifting chain defects indicate?
The hoist chapter of the FDC manuals links abnormal protrusion or turned pins to high loads and poor lubrication, with the chain to be replaced and lubrication improved, and worn outer links or pin heads to misalignment, as set out in the HIT SRL technical cards. In the same chapter of the manuals, a worn contour comes from normal sheave wear, with the chain replaced when 5% of the link height is worn, the HIT SRL technical desk notes. According to the same chapter, tight joints come from dirt or corrosion, and bent pins or missing parts call for replacement, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-chain-faults · HIT ref FDC-138 · fingerprint 7b898d · see HIT ref FDC-059, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/mast-and-spreader/#hit-fdc-chain-inspection
Fantuzzi FDC 25 K7: which dashboard lights stop the machine from being used?
According to the FDC 25 K7 operator's manual, the machine is not to be used with the blocked oil filter, blocked air filter, low engine oil pressure or low transmission oil level light on, as logged by the HIT SRL technical desk. In the same manual, the battery-charge light must go out after start, as recorded at HIT SRL. A parking brake light that stays on after release calls for assistance, in 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/troubleshooting/#hit-fdc-dashboard-indicators · HIT ref FDC-139 · fingerprint 2e7739 · see HIT ref FDC-101, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/maintenance-intervals/#hit-fdc-pre-operational-inspection
Fantuzzi FDC: which alarms does LMS Plus store in the black box?
According to the LMS Plus fault code manual, LMS Plus FDC stores alarms such as CAN PLC core broken, the bypasses used, high coolant or engine oil temperature, low oil pressure, low fuel and engine shutdown, the HIT SRL technical desk notes. The same manual adds low brake oil pressure, high gear oil temperature, wheel sensor fault, engine CAN fault, emergency stop, TCU faults and broken length, spreader 20 and 40 and pedal sensors, as set out in the HIT SRL technical cards. Warnings such as spreader seated, inversion not permitted and sensors not calibrated are not stored, in 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/troubleshooting/#hit-fdc-lms-plus-alarms · HIT ref FDC-140 · fingerprint dbcef6 · see HIT ref FDC-141, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-powertronic-messages
Fantuzzi FDC: which messages can the Powertronic display show?
According to the Powertronic V5.x manual, the display messages include high cooling temperature, high engine oil temperature, low engine oil pressure, low coolant level, engine shut off, low brake oil pressure and high transmission temperature, as recorded at HIT SRL. The same manual adds rpm engine safety, anti inversion, brake inserted, wheel sensor fault, CAN engine fault, CAN transmission fault, TCU unit fault, alarm overload, forks inserted, pedal fault and cylinder oil pressure fault, as logged by the HIT SRL technical desk. The list is in that manual, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-powertronic-messages · HIT ref FDC-141 · fingerprint f6a822 · see HIT ref FDC-140, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-lms-plus-alarms
Fantuzzi FDC: what happens when the drive-shaft speed sensor fails?
According to their manuals, LMS Plus, Powertronic and Digicontrol put the transmission in neutral when the drive-shaft speed sensor signal is wrong, as HIT SRL's technical desk reads it. According to the same manuals, the alarm is reset by selecting neutral, and a false alarm clears, as logged by the HIT SRL technical desk. With a really faulty or disconnected sensor only first gear is available, and manual mode allows the other gears with all safeties inactive, according to the same manuals, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-speed-sensor-fault · HIT ref FDC-142 · fingerprint 4103bd · see HIT ref FDC-144, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-transmission-drops-into-neutral
Fantuzzi FDC 550 G5: which alarms does Digicontrol software 6000 list?
According to the alarm list of software 6000 for the FDC 550 G5, the Digicontrol alarms include emergency CAN activated after more than 5 seconds without messages from the spreader PLC, as set out in the HIT SRL technical cards. The same list gives mast valve solenoid faults, engine and transmission controller fault codes, speed sensor fault, low brake oil pressure, low coolant level and low engine oil pressure, the HIT SRL technical desk notes. They also include high engine oil, coolant and transmission oil temperatures, emergency stop, overload and missing CAN signals from keyboard, transmission or engine, in the same list, as recorded by the HIT SRL technical desk.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-digicontrol-alarms · HIT ref FDC-143 · fingerprint 6a6b31 · see HIT ref FDC-141, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-powertronic-messages
Fantuzzi FDC 25: what can make the transmission drop into neutral while travelling?
The FDC manuals state that LMS Plus, Powertronic and Digicontrol put the transmission in neutral when the drive-shaft speed sensor signal is wrong, as logged by the HIT SRL technical desk. Operators report, on a Fantuzzi FDC25 empty container handler, the transmission dropping into neutral while travelling forward and working again only after the machine was switched off and restarted; a published reply points to the device that prevents direction reversal while moving and to the proximity sensor on the drive shaft or gearbox output. HIT SRL service technicians report that when the transmission drops into neutral while travelling, the cause is almost always the speed sensor on the drive shaft. In the manuals a false alarm clears on selecting neutral, while a faulty or disconnected sensor leaves only first gear.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-transmission-drops-into-neutral · HIT ref FDC-144 · fingerprint 1b91e3 · see HIT ref FDC-142, https://www.hitsrl.it/technical-resources/guides/fantuzzi-fdc/troubleshooting/#hit-fdc-speed-sensor-fault