Fantuzzi RS Rail Stackers — Technical Legacy Guide

Summary

RS is the designation of the Fantuzzi rail stackers, reach stackers with a telescopic arm that the RS 55 manual describes as used for the combined transport of containers from railway wagons to road vehicles, as recorded by the HIT SRL technical desk. In the Terex period the machine is named Terex Fantuzzi Rail Stacker RS 55, according to the Terex edition of its manual. Specification tables cover the RS 50 and RS 55 in the manuals of 2002 to 2006 and the RS 55 and RS 60 in a Terex table of 2013, and a 2005 manual describes an RS 50 fitted with a slab clamp for steel slabs. 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 RS 55 manual 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 suffix CONT that follows RS 50 and RS 55 in the manuals is not explained in the documentation and is treated here as a commercial designation.

RS 50 and RS 55, 2002-2006 tables

The same specification table appears in the reach stacker manuals of 2002 to 2006, the Mi-Jack MJ 55 manual among them: 85,000 kg unladen for the RS 50 and 86,000 kg for the RS 55, diesel power, four front and two rear 18.00-33 tyres at 10 bar with front drive, a travel speed of 25 km/h empty and 23 km/h loaded and noise levels of 85 dB(A) outside and 74 dB(A) in the cab. The Mi-Jack MJ 55 manual is an RS 55 manual: its load chart names an RS 55. The 2005 manual of the RS 50 CONT describes an arm truck for transferring steel slabs, with a slab clamp in place of the spreader.

RS 55 and RS 60, 2013 table

The Terex specification table of 2013, in the CS 45 KM manual, has columns for the RS 55 and RS 60, both marked as machines with stabilisers. It gives 84,000 kg for the RS 55 and 101,000 kg for the RS 60, wheelbases of 7,000 and 7,500 mm, turning radii of 10,750 and 11,100 mm with a 40 ft container and heights of 5,100 and 5,500 mm. The 2013 table gives capacities of 45, 42 and 31 t in the first, second and third row for the RS 55 and 45, 45 and 37 t for the RS 60, stacking five 9 ft 6 in containers high in the first row.

Load chart of the 2007 RS 55 manual

The load chart of the 2007 RS 55 manual, drawn for a third-party model 857 spreader, gives 45 t in the first row up to the fourth container and 40 t at the fifth, 36 t in the second row with stabilisers up and 41 t with stabilisers down, 20 and 27 t in the third row and 2 t at 8.7 m, with a lift height of 14.8 m.

Industrial history and parts supply

The 2007 RS 55 manual is a Fantuzzi-Reggiane S.p.A. publication, and the later Terex edition carries the name of Reggiane Cranes and Plants S.p.A. 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; its announcement included reach stackers in the Fantuzzi range.

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. According to a spare-parts list of the axle maker Kessler, the RS55 has a Kessler axle, with Terex Reggiane as the customer.

Driveline as installed

Engines

The 2002-2006 table refers the engine to the motor table, which lists six-cylinder engines: Cummins M11-C (330 hp at 2,100 rpm), Volvo TWD1031VE (320 hp), Volvo TWD1231VE (400 hp), Cummins N14 (400 hp) and Caterpillar 3306B in 245 hp and 300 hp versions at 2,200 rpm. In the 2013 Terex table the RS 55 and RS 60 have a Volvo TAD 1251VE as standard engine, 280 kW at 1,900 rpm and 1,950 Nm at 1,200 rpm, with a Cummins QSM 11 as option and, for Tier 4, the Volvo TAD 1361VE or the Cummins QSX 11.9.

Transmission

The 2002-2006 table gives a hydrodynamic transmission with torque converter and power-shift clutches, four forward and four reverse gears, a hydraulic cooling system and servo-assisted controls; the 2013 table gives a Dana TE 32. The filling table for the CS 45 KL, CS 45 KS, RS 50 and RS 55 lists four transmissions with their oil: 48 litres for the Clark 36000, 50 litres for the Clark 40000, 59 litres of TO-2 fluid for the Caterpillar 960/970 and 90 litres of ATF to Dexron III or Mercon for the Dana TE 32. According to the 2007 RS 55 manual, the gearbox shifts automatically through four gears, the lever setting the highest gear, and a key switches it to manual shifting with the machine stopped and the lever in neutral; the engine starts only with the lever in neutral. According to the 2007 operator's manual, the far-left brake pedal has a switch that brakes and selects neutral together. The transmission oil is checked daily at FULL, at 82-93 °C with the engine at low revs 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.

Axles, brakes and wheels

The drive axle of the RS 55 has the differential and epicyclic wheel hubs, with oil-cooled multi-plate service brakes inside each hub and a parking brake on the axle made of a disc and an electro-hydraulic caliper; the 2002-2006 table gives instead oil-bath disc service brakes at the front, optional dry rear brakes and a dry-disc parking brake on the transmission. HIT SRL service technicians report that both versions of the parking brake exist on RS machines. According to the filling table and the drive axle section, the differential and hubs take 100 litres of SAE 90 API GL-5 oil to MIL-L-2105D, or SAE 85W-140 above 0 degrees, checked every 100 hours and changed 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. According to the maintenance manual, the steering axle carries a power-steering cylinder and two connecting rods to the hubs, with stabiliser cylinders and hub disc brakes as options; no more than 2 mm is machined from each side of a brake disc.

Hydraulic system as installed

The filling table for the RS 50 and RS 55 gives 950 litres of SAE 80W API GL-4 hydraulic fluid, SAE 75W API GL-4 in cold climates, and the 2002-2006 specification table a 1,000 litre tank. HIT SRL service technicians report that different tank configurations have existed, with 1,000 litres of hydraulic oil and 550 litres of fuel or 950 and 580 litres. According to the filling table, a separate brake cooling circuit, where fitted, takes 60 litres of SAE 80W API GL-4 oil, and the spreader reduction unit 2.5 litres of grade 10 oil. According to the 2007 operator's manual, the reservoir of the RS 55 is on the chassis to the right of the driver's seat, with the level checked engine off at the top notch. The 2013 Terex table gives hydraulic pressures of 250 bar for the RS 55 and 200 bar for the RS 60, with 950 and 980 litres of hydraulic oil. According to the 2007 operator's manual, an optional auxiliary emergency pump, started with a key after a diesel engine or hydraulic fault, allows arm, stabiliser and moving cab movements, and is not left running longer than needed, to avoid flattening the batteries. The maintenance manual has all hydraulic hoses replaced within 5,000 operating hours.

Boom, spreader and stabilisers

Telescopic arm

According to the boom section of the maintenance manual, the telescopic arm is made of a fixed arm, a moving arm and an extension cylinder; the moving arm slides inside the fixed arm on greased sliding blocks and carries the spreader couplings, while cables and hoses run in a protection chain outside the arm. The 2002-2006 table gives 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 after each replacement, checks them every 500 hours and replaces them every 1,500 hours on both arms; the play allowed is 2 mm per side in the general check and 3 mm per side for the fixed-arm blocks.

Spreaders

The 2002-2006 table gives an SRP45 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 load chart of the 2007 RS 55 manual is drawn for a third-party model 857 spreader, and the operator's manual describes piggy-back controls that lower and lift two front and two rear legs and close or open them to fasten and release the load. The spreader manufacturer's manual for the model 857 covers the pendular twistlocks, extension cylinders, end beam adjustment and the fold, clamp and rotation blocks. The 2002 edition of the RS 55 maintenance manual also describes three Fantuzzi telescopic spreaders: the SRP2-45, for 45,000 kg at 20 ft and 40,000 kg at 40 ft, and the SRP2-45TL and SRP2-55TL with a twinlift unit, the SRP2-55TL rated 53,000 kg at 20 ft and 2 x 25,000 kg with the twinlift lowered; all work at 170 bar and 24 V DC. HIT SRL service technicians report that RS machines in service carry spreaders of different models. The SRP2-45, SRP2-45TL and SRP2-55TL of the RS 55 maintenance manual have their own sections in the Fantuzzi Reggiane attachments guide.

Stabilisers and cab

Before work the operator makes sure the stabilisers are fully extended on solid ground, and the 2007 load chart gives higher second and third row capacities with the stabilisers down. According to the 2007 operator's manual, the cab may be forward only while approaching and locking onto a container and must be in the rear position when driving loaded. When the movable cab stands between the two lifting cylinders and the doors cannot open, the operator's manuals give the rear sliding window as the emergency exit. HIT SRL service technicians report that both rules apply on RS machines in service. According to the RS 55 parts catalogue (2007 edition), the sliding cab hydraulic system of the RS 50 to RS 60 is shared with the CS 45.

Electrical and control

The 2002-2006 table gives a 24 V, 200 Ah battery. According to the 2007 operator's manual, the RS 55 cab has twistlock lights, a Backsense display, a rear camera monitor, the Digicontrol display and keyboard, the joystick, a twistlock bypass key, a gear-change mode key, an auxiliary emergency pump key, a grease pump button with a lubrication fault light, an emergency button and a parking brake button. The same manual gives the Digicontrol keyboard keys for damping movements, cab movements, hazard lights and the damping brake, and keys that set the spreader at 20, 30 or 40 ft. According to the same manual, from the joystick the operator raises, lowers, extends and retracts the arm, turns the twistlocks and shifts and rotates the spreader; a capacitive dead man's handle in the joystick inhibits functions when the grip is released.

According to the 2007 operator's manual, twistlock lights show yellow when the twistlocks are seated in the corner castings, green when all are locked and lifting can begin, and red when they are released; the pick-up and set-down procedures wait for each light before the next step. The manual's green means twistlocks locked; 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 the 2007 operator's manual, the dashboard has lights for blocked oil filter, blocked air filter, parking brake, low transmission oil level and neutral gear; the machine is not used with a blocked filter light on, and the engine starts only with the neutral light on. According to the same manual, the emergency button stops the diesel engine and prevents all movement.

Recurring failure points — field reports

Published field reports specific to the RS rail stackers are scarce, as recorded at HIT SRL.

Maintenance interval summary

The planned-maintenance table of the RS 55 maintenance manual 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; (3) = chain inspection every three months.

The boom section replaces the fixed-arm and moving-arm sliding blocks every 1,500 hours, the drive axle section changes the hub and differential oil every 1,500 hours and the transmission section the filter every 500 hours and the oil every 1,500 hours.

Key specification table

Spare parts

HIT SRL supplies genuine, OEM and aftermarket spare parts for Fantuzzi port equipment, including the RS rail 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 (11 cards)
• Driveline (13 cards)
• Hydraulics and controls (12 cards)
• Boom and spreader (13 cards)
• Maintenance and faults (11 cards)
• Safety and interlocks (10 cards)