Fantuzzi Reggiane MHC 200 Mobile Harbour Crane — Technical Legacy Guide
General guidance only — always follow the operation and maintenance manual for your specific machine.
Summary
The MHC 200 is a rubber-tyred mobile harbour crane of the Fantuzzi Reggiane MHC range, which its 2006 operator's manual intends for lifting materials and in particular for loading and unloading cargo from ships, as recorded by the HIT SRL technical desk. The manufacturer's documentation gives a 100 t version and a 120 t version, seven steering axles of which three driving, a diesel engine that changes between editions and hydrostatic travel. Two generations of control system appear in the manuals: the ALC system up to 2002 and ESX central units with a touch-screen display from 2003. The MHC 130, the MHC 250 and the MHC 5000 series are described in the Related models section, and the MHC 115 in its own guide.
Model identification
According to the 2006 operator's manual, the MHC 200 is defined up to the hook and is identified by the data stamped on a metal plate on the front of the chassis, the HIT SRL technical desk notes.
100 t and 120 t versions
The 2000-2002 editions and the 100 t data sheet give hook capacities of 100/65/50/35/17 t, the 2003-2006 editions and the 120 t data sheet 120/114/75/60/50/40/14 t. The 2006 data give a working radius from 11 to 50 m, a maximum moment of 2200 tm and a maximum boom length of 48 m, with the boom fulcrum at 17.60 m and the operator's view at 21.50 m. According to the weight list of the 2002 use and maintenance manual, the 100 t version weighs 405,000 kg in total, of which 141,000 kg of counterweight. According to the 2006 technical data, the crane is classified to FEM 1987 as A6 for grab use, A5 for general cargo up to 55 t, A4 over 55 t and A3 for heavy use.
Control system and lifting equipment
According to the 2002 control-system description, the MHC 200 always has a second master box in the lower cabin and uses four slave units, like the MHC 130 and the double-winch MHC 115, while the MHC 20, 40, 65 and single-winch MHC 115 use three. The manufacturer's training material of 2003 gives seven ESX units on the MHC 200: Cabin and Spreader in the upper cabin, Motor, Boom, Winch 1 and Winch 2 in the engine room and Truck on the chassis. The documentation lists as lifting equipment a hook block with powered rotation, an automatic telescopic spreader for 20, 30, 40 and 45 ft containers, an electro-hydraulic grab, a motorised beam and, as an option, log tongs.
Industrial history and parts supply
In the editions from 2001 to 2006 the MHC 200 manuals are issued under the Fantuzzi-Reggiane S.p.A. name, with Reggiane as a division of Fantuzzi Reggiane 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. 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, and Konecranes states that it has owned the Fantuzzi Reggiane brand since then. The 2006 manual asks that crane type and serial number, stamped on the data plate, be quoted in every communication with the manufacturer.
Power unit and driveline as installed
Engines
The diesel engine changes between editions: the 2000-2002 editions and the 2004 data sheets give a Perkins 3012 TAG 3A of 741 kW at 1500 rpm, the 2003 edition a Caterpillar 3412 DISTA GSE of 708 kW, the 2005 edition an MTU 16V 2000 G63 of 805 kW and the 2006 edition a Deutz TBD 616 V16-G1 of 765 kW prime power, 851 kW rated, at 1500 rpm. HIT SRL service technicians report that the engine of an MHC 200 is identified from its data plate and from the technical data of that crane. The 2002 use and maintenance manual lists an optional electric main motor of 630 kW at 1500 rpm, and the maintenance tables of later editions keep a separate hour counter for the electric engine.
According to the 2006 manual, the engine drives the variable-displacement pumps of the crane movements, the fixed-displacement pumps of the services and the electrical generator through cardan shafts and a gear-type pump driving unit, the pumps coupler. The lubricants chart of the 2006 edition gives 98 litres of SAE 15W-40 engine oil to API CF-4 and 210 litres of coolant. The fuel tank holds 7000 litres, for about 130 hours according to the 2000-2002 editions and about 150 hours according to the 2003-2006 editions.
Travel, axles and suspension
According to the 2002 use and maintenance manual, travel is hydrostatic: an axial-piston pump feeds axial-piston motors with two fixed displacements on the drive axles, and a slow and a fast range are selected from the cabin. The 2006 manual gives seven steering axles, three of them also driving, with a central bevel drive and epicyclic reduction units in the wheel hubs, and an axle spacing of 1670 mm between axles 1, 2 and 3 and between axles 4, 5, 6 and 7, 4450 mm between axles 3 and 4 and a wheel track of 4170 mm. According to the 2006 data, suspension is by oscillating rocker arms with a maximum wheel stroke of +/-150 mm; the 2002 use and maintenance manual gives a maximum rocker-arm excursion of +/-25 cm.
According to the 2002 use and maintenance manual, the crane runs on 28 tyres 14.00 x 24 in, twinned on all wheels, and the 2006 maintenance manual tightens the wheel nuts to 650 Nm and inflates the tyres to 10 atm. According to the same 2002 manual, the service brakes are hydraulic on all wheels, and the spring-applied multi-disc parking brake holds the crane on gradients up to 7.5%. The 2006 manual gives fully hydraulic steering with a circle mode and a crab mode and a steering angle of +/-35 degrees. Travel speed changes between editions: 2.0-4.5 km/h in the 2000 edition and the 2002 use and maintenance manual, 2.0-4.0 km/h in 2001 and in the 2004 data sheets, 2.0-5.0 km/h in 2003 and 1.6-3.3 km/h in 2005-2006, with a maximum gradient of 7.5%.
Hydraulic system as installed
According to the 2002 use and maintenance manual, hoisting, slewing and travel run on closed circuits with variable pumps, luffing on variable pumps feeding a double-acting cylinder with hose-burst safety valves, and steering and stabilisers on open circuits, with air-oil heat exchangers keeping the oil temperature constant. The same 2002 manual gives maximum pressures of 280 bar for hoisting, 350 bar for travel, 180 bar for luffing and 250 bar for slewing on the 100 t crane.
The hydraulic tank holds 3000 litres according to the technical data of the 2000-2006 editions and the 2006 lubricants chart, which gives ISO VG 46 oil, while the 2002 use and maintenance manual describes a 2500 litre tank above the pumps. HIT SRL service technicians report that the two capacities, 3000 and 2500 litres, correspond to different cranes. According to the 2006 maintenance manual, oil added to the tank is pre-filtered to 10 microns and of the same type, and an oil change is done to the maximum level with all cylinders retracted, the boom on the ground and the stabilisers raised and retracted. The same manual keeps the pumps coupler casing below 80 °C in operation, with a maximum oil temperature of 105 °C. The engine management of the 2006 manual stops the engine 3 s after a low pump suction pressure and 10 s after a low boost pressure of pumps 1, 2 and 3, with default thresholds of 1500 mbar and 20 bar.
Structure, tower, boom and hoist
Chassis, turret and slewing
According to the 2002 use and maintenance manual, the chassis is a sheet-steel box frame and the rotating turret a box structure with a central section and two lateral box beams carrying the mast housings and the anchorage of the luffing cylinder, as recorded at HIT SRL. The same 2002 manual gives two slewing drives at the front of the turret, each with a hydraulic motor, an epicyclic reduction gear and a spring-applied parking brake, on a roller slew ring of about 3850 mm outside diameter, with a rotary hydraulic coupling and an electrical slip ring between turret and chassis.
Hoist winch and ropes
The 2002 use and maintenance manual gives the 100 t crane a double-groove drum for two ropes, driven by six hydraulic motors through two three-stage epicyclic reduction units, with a maximum rope pull of 2 x 50 t and a drum pitch diameter of 1150 mm; the 2004 100 t sheet and the 2006 edition give 1300 mm. According to the 2006 data, the drum is double-race, with the two ropes wound in opposite directions for a level suspension of the load. The hoisting ropes are two galvanised 52 mm ropes: the 2002 use and maintenance manual gives a breaking load of 240 t and a length of 232 m, the 2006 data 2394 kN and 225 m and the 2004 100 t sheet 2246 kN and 225 m. According to the 2006 maintenance manual, a rope is discarded for a broken strand, a localised concentration of broken wires, core deterioration, loss of elasticity, internal corrosion, deformation, heat or arc damage, or an outside diameter reduced by 7% of the nominal even without visible broken wires. The same manual has a new rope work for a short period with about 10% of the rated load after installation.
Boom, mast and counterweight
According to the 2002 use and maintenance manual, the boom is a welded steel-tube lattice in two flange-bolted sections with a self-compensating hoisting tackle for level luffing, moved by a double-acting cylinder anchored to the turret. According to the same 2002 manual, the mast is an open structure of two welded beams supported by two front trunnions and by stay rods, raised by the luffing cylinder and lowered to the ground for maintenance or for travel under low obstacles. According to the 2002 use and maintenance manual, the counterweight is made of a fixed group of removable modular panels and a mobile boom counterweight running along the rear of the mast, which is removed before the mast is lowered. According to the 2006 manual, the boom cable reel carries the power cable of the hoisting equipment and has three electric motors, one keeping the cable taut and two starting with hoisting or boom-lowering commands.
Lifting equipment
The SMHC 35 spreader manual covers a telescopic automatic spreader for the MHC with its own hydraulic power pack, and the FRT motorised beam manual covers the FRT 63, FRT 100, FRT 110 and FRT 120 beams. The data and maintenance tables of these manuals are collected in the SMHC 35 and FRT 100, FRT 110 and FRT 120 sections of the Fantuzzi Reggiane attachments guide.
Electrical and control
According to the 2002 use and maintenance manual, the 24 V system has two 275 Ah batteries, and a generator driven by the diesel engine supplies 380 V and 220 V for fans, lubrication pump and boom cable reel, as HIT SRL's technical desk reads it. The manuals describe two generations of control: the ALC system, with a master unit in the cabin and slave units on a CAN network, in the editions up to 2002, and ESX central units on a CAN bus with a touch-screen display in the 2003-2006 editions. According to the 2006 control-system data, the ESX unit has a 16-bit microcontroller, two CAN interfaces and an IP65 aluminium housing, and the system includes a 12-inch TFT touch-screen display, CAN joysticks, the radio control, pressure sensors, the anemometer and encoders.
According to the same manual, three encoders read the slewing angle, the boom angle and the winch rope length, and one or two load cells with an amplifier card on the winch read the weight. In the 2002 control-system description the master card stores up to 2000 messages with date, time and duration in a black box, and the 2006 manual records there the overload stops at 105% of the permitted load. According to the 2006 manual, the cabin whose key is turned on first takes control, and the radio-control console has priority over both cabins and is disabled after a period of inactivity, 10 minutes by default. According to the 2002 use and maintenance manual, the upper cab sits at about 21.5 m with an internal noise of at most 72 dB(A) and a spherical spirit level for levelling, and the lower cab carries a PC for monitoring and diagnostics.
Safety systems
Wind
According to the MHC 200 technical data of 2000 to 2006, the crane works up to 72 km/h and travels up to 72 km/h with the hook block only and 50 km/h with block and grab; stationary on stabilisers, the boom may stay erected up to 151 km/h, rests on the ground from 151 to 200 km/h, and above 200 km/h boom and pylon are lowered. The 2002 use and maintenance manual gives different stationary values, with the boom on the ground above 200 km/h and the mast lowered as well above 270 km/h. According to the same 2002 manual, the anemometer gives an audible pre-alarm and, when the limit is exceeded for more than 5 minutes, blocks slewing, travel, boom lowering and hoisting. HIT SRL service technicians report that the limits applied on MHC 200 cranes are 72 km/h in service and 50 km/h when travelling with a load or a grab, that the block after 5 minutes also applies on cranes with ESX control units, and that above the limits the boom and then the column are lowered to the ground, also when the crane is parked. The wind table to follow is the one in the manual of the specific crane.
Load limiter
According to the 2006 manual, the anti-tilting system selects grab or hook tables automatically, lets the operator set the hook or spreader table at 66% or 75% where available, computes the load from the load cell and the boom angle, warns at 90% of the permitted load and stops hoisting and boom lowering at 105%, recording the event in the black box. The manufacturer's training material of 2003 gives the grab table as 50%, and in overload the system locks winch raising and boom raising and lowering, according to the 2006 manual. HIT SRL service technicians report that these values apply on MHC 200 cranes in service. Load tables and limiter settings are those of the manual of the specific crane.
Stabilisers
According to the 2006 manual, the crane lifts only on stabilisers, on flat and solid ground, with the beams fully extended, levelled within +/-0.5% and with the tyres fully off the ground, and the stabilisers are raised or retracted only with tower and boom in travel configuration and slewing locked. The 2006 data give a maximum opening of 16.00 x 12.00 m, a maximum load of 240 t on a stabiliser over 360 degrees and 3.92 kg/cm2 under the standard 1800 x 3400 mm pads, and the manual allows manual or automatic stabilisation, with a time limit for each phase of the automatic cycle. HIT SRL service technicians report that the stabilising procedure of the manual applies on MHC 200 cranes in service. Ground conditions and stabiliser data are those of the manual of the specific crane.
Emergency stops, travel and access
According to the manuals, the emergency push buttons stop all movements and the main engine with rapid braking; the 2002 use and maintenance manual places two in the machinery room, one in each cab, one on the chassis and one on the portable board, and a pressed button stays locked until turned clockwise. HIT SRL service technicians report that the emergency push buttons work on MHC 200 cranes in service as the manuals describe. Every manipulator has a dead-man push button that must be held for any movement, and the 2006 manual forbids taping over it. The 2006 manual enables travel only with the crane at 0 or 180 degrees, the slewing lock pin in place and all beams destabilised, and gives boom and tower positions for travel according to the load. The 2006 manual allows climbing on or off only with the turret stopped and locked, does not treat the chassis platform as a working position and keeps everyone out of the machinery and winch rooms during operation; access follows the manual of the specific crane. HIT SRL service technicians report that nobody must be in the machinery room or in the winch room while the crane is working. According to the same manual, the crane is connected to the quay earth network before work and when parked, and work during heavy storms is forbidden.
Recurring failure points — field reports
What the documentation says to check: according to the 2006 diagnostics chapter, most control-system faults are electrical or sensor problems, and a blocked movement is first checked for a missing logical condition, as set out in the HIT SRL technical cards. A unit that does not respond on the CAN bus is checked at its connector, its power supply and the line, which reads 120 ohm between high and low at both ends, and replaced only if all are correct, according to the same chapter. The manual has the weight calibration repeated from the Parameters menu when the system reports it as not calibrated, and points to the load cell or the amplifier card when a calibrated system reads the weight wrongly. According to the maintenance manual, winch and slewing gearboxes running above 80 °C or noisy and uneven wear of the slewing teeth call for the manufacturer's after-sales service, while a changing relief-valve whistle, creaking cylinders and pump noise rising with pressure are signs of hydraulic wear. Lack of grease can seriously damage the slewing bearing, the boom-to-tower hinge and the luffing cylinder, according to the 2006 manual.
Maintenance interval summary
According to the maintenance tables, from 2003 the MHC check list refers each job to the hour counter of its mechanism (general, diesel engine, electric engine, winch, boom, slewing, translation, stabilisers), with a first interval for a new crane, a repeat interval and, for some jobs, a calendar limit; note (1) marks jobs for highly experienced personnel.
| System | Job | Interval |
|---|---|---|
| Main structure | Welded and bolted joints, bolt tightness, structural integrity | 2,400 h of the general counter and at least yearly |
| Wheels (translation counter) | Visual check / tyre pressure / wheel fitting, steering levers, parallelism / steering relief valve | Daily / 10 h / 20 h / every 2 years |
| Axles (translation counter) | Oil level / oil change / parking brake (1) | 20 h / first 100 h, then 120 h and at least yearly / 20 h |
| Cardan shafts | Visual check / joint lubrication / sliding zone cleaning and greasing | 100 h / first 100 h, then 1,200 h / 600 h |
| Diesel engine | Oil level, air filter, fuel pre-filter / oil and filter, fuel cartridge, air filter, belt, turbocharger bolts / injection pump, injectors, valve clearances, turbocharger, alternator (1) | 10 h and daily / 600 h / 1,200 h |
| Radiator, exhaust and fuel | Leaks and coolant level / tank air filter / water draining / radiator cleaning, tank filter / coolant change, exhaust check, tank cleaning | 10 h and daily / 50 h / first 200 h, then 600 h / 600 h / 2,400 h or yearly |
| Hydraulic tank | Oil level / cartridge check, lines, tank air filter / cartridge change / oil analysis | 50 h and daily / 200 h / first 200 h, then 1,200 h / 2,400 h or yearly |
| Pumps coupler and pumps | Coupler oil level / oil temperature, exchanger cleaning / pumps visual and noise / coupler oil and exchanger filter, supercharging and pilot filters / system pressures | Daily / 100 h / 200 h / first 200 h, then 1,200 h / 2,400 h or yearly |
| Hydraulic motors and cylinders | Cylinders visual / motors visual and noise, stabiliser rod greasing / rod cleaning / boom cylinder relief valve | 50 h / 200 h / 400 h / at least every 5 years |
| Electrical items | Controls and sockets function / battery bolts / batteries, slip ring brushes, fixings / electrical boxes, cable reel brushes / alternator, contactors, cards | Daily / 100 h / 400 h / 1,200 h / 2,400 h or yearly |
| Lubrication | Turret grease level / turret distribution, filter, pipes / chassis greasing, stabiliser cylinder pins / filter elements | 10 h and daily / 200 h / 800 h / 2,400 h or yearly |
| Winch reduction gear (winch counter) | Oil level / noise and temperature / bolt tightness / oil change | 15 h / 200 h / first 60 h, then 700 h and yearly / first 100 h, then 2,000 h |
| Winch drum | Bearings, mounting and rope clamp bolts / drum race wear | 400 h / 400 h and yearly |
| Winch brakes coupler | Oil level / casing temperature, exchanger cleaning / exchanger filter / oil change | 15 h / 60 h / first 100 h, then 400 h / first 100 h, then 2,000 h and yearly |
| Slewing reduction gears (slewing counter) | Oil level / noise and temperature / bolts, pinion bearing lubrication / gear and brake oil change | 20 h / 200 h / 800 h and yearly / first 100 h, then 2,000 h |
| Slewing bearing | Lubrication check and lubrication / bolt tightness, teeth wear | 60 h / 800 h and yearly |
| Hoisting ropes | Visual check / end connections / wear check / cleaning and greasing | 50 h / 200 h / 1,200 h / 2,400 h or yearly |
| Pulleys | Stop plate bolts, functionality, race wear | 1,200 h |
| Safety devices | Emergency devices, communication system, radio control, brakes, lighting | 10 h and daily |
| Mobile counterweight and other items | Counterweight visual / its ropes and end connections / paint, pin stop plates and pins / rope greasing, wheel pins / machinery-room filter cells | 15 h / 60 h / 200 h / 800 h and yearly / 1,200 h |
The 2003 table gives the first filter change of the hydraulic tank at 100 h and other oil changes: winch reduction gear first at 60 h, then every 700 h and yearly, winch brakes coupler first at 60 h, then every 400 h and yearly, and slewing gears first at 70 h, then every 800 h and yearly. The 2001 table uses one hour counter for all jobs and gives other values, among them a first change at 200 h and then every 2,400 h for winch and slewing gear oil, every 1,200 h for the winch brakes coupler oil, 1,200 h for drum bolts and bearings and 2,400 h for drum race wear, slewing bearing lubrication every 200 h and safety-device checks every 24 h.
Key specification table
| Quantity | Value and edition |
|---|---|
| Hook capacity | 100/65/50/35/17 t (100 t version, 2000-2002 editions and sheet); 120/114/75/60/50/40/14 t (120 t version, 2003-2006 editions and sheet) |
| Working radius and moment | 11-50 m; 2,200 tm (2006) |
| Maximum boom length | 48 m (2006) |
| Hook speed | 14 m/min with 120 t, 85 m/min with 14 t (2006); 16 m/min with the maximum load, 87 m/min with 17 t (100 t version) |
| Slewing speed with load | 1.25 rpm intensive use, 0.65 rpm heavy use (2006) |
| Hoisting height with linear load | 38 m up to 42 m radius, 40 m as an option (2006) |
| Travel speed | 1.6-3.3 km/h (2005-2006); 2.0-5.0 km/h (2003); 2.0-4.0 km/h (2001, 2004 sheets); 2.0-4.5 km/h (2000, 2002 use and maintenance manual) |
| Axles | 7 steering, 3 also driving; wheel track 4,170 mm |
| Tyres | 28 x 14.00 x 24 in, twinned; 10 atm |
| Stabiliser opening | 16.00 x 12.00 m (2006) |
| Engine | Perkins 3012 TAG 3A, 741 kW (2000-2002, 2004 sheets); Caterpillar 3412 DISTA GSE, 708 kW (2003); MTU 16V 2000 G63, 805 kW (2005); Deutz TBD 616 V16-G1, 765 kW (2006) |
| Hydraulic tank | 3,000 l (2000-2006 editions); 2,500 l (2002 use and maintenance manual) |
| Fuel tank | 7,000 l |
| Winch drum pitch diameter | 1,150 mm (2002 use and maintenance manual, 100 t); 1,300 mm (2004 100 t sheet, 2006) |
| Hoisting ropes | 2 x 52 mm; 232 m (2002 use and maintenance manual), 225 m (2004 sheet, 2006) |
| Crane length / height with pylon erected | 18,705 mm / 33,700 mm (2006) |
| Noise in the upper cab | 57.7 dB(A) (2006) |
Related models
The 2006 MHC 200, 2007 MHC 130 and 2008 MHC 115 maintenance tables have the same items and intervals in 128 of 142 rows; the MHC 115 is covered by the Fantuzzi Reggiane MHC 115 guide, as logged by the HIT SRL technical desk.
MHC 130
The MHC 130 manuals give a hook capacity up to 100 t, a maximum radius of 44 m and a maximum moment of 1600 tm, with five steering axles of which two driving and a Caterpillar 3412 DISTA GSE engine of 708 kW in the 2001 edition and 778 kW prime power in the 2007 edition. The MHC 130 manual (2007 edition) gives a stabiliser opening of 13.00 x 11.50 m with a 190 t maximum load and an in-service wind limit of 90 km/h, against the 72 km/h of the MHC 200 editions up to 2006.
MHC 250
According to the MHC 250 manual (2004 edition), the MHC 250 has a hook capacity of 150/110/65/50/30/17 t, a maximum radius of 52 m, a maximum moment of 2900 tm, a 53 m boom and a Caterpillar 3508 B engine of 968 kW, with stabilisers opening 15.40 x 13.00 m and a travel speed of 1.7-3.5 km/h.
MHC 5000 series and MHC 150
The 2011 technical data of the MHC 5150, whose general assembly drawing is titled MHC5000, give 150 t at the hook with a single winch and two ropes, a 51 m maximum radius, 2530 tm and seven steering axles of which three driving, with an MTU 16V 2000 G65 engine of 890 kW. The same data give an in-service wind limit of 90 km/h, a 6400 l fuel tank and a 3100 l hydraulic tank. According to the 2002 control-system description of the MHC 200, the MHC 150 is another model of the same range.
Spare parts
HIT SRL supplies genuine, OEM and aftermarket spare parts for Fantuzzi Reggiane port equipment, including the MHC 200 mobile harbour cranes, as an independent distributor that is not an official representative, affiliate or agent of the manufacturer. HIT SRL has reconditioned spare parts available for the older black-and-white display electronics of these cranes. For availability, see the Fantuzzi Reggiane spare parts page or send the crane 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 (13 cards)
- Engine and power unit (8 cards)
- Chassis, travel and stabilisers (14 cards)
- Hydraulics (9 cards)
- Structure, boom and hoist (20 cards)
- Electrical and control (10 cards)
- Maintenance intervals (25 cards)
- Safety and interlocks (27 cards)
- Troubleshooting (18 cards)
- Related models (8 cards)