Haulotte Group HTL 3210, Operator'S Manual

Page 1: ...Operator s manual T ELESCOPIC HANDLERS 2420344510 E 11 11 AUS Operator s manual TELESCOPIC HANDLERS HTL 4010 HTL 3510 HTL 3210 2420344510 E 11 11 AUS...

Page 2: ...2 2420344510 E 11 11 AUS Telescopic handlers...

Page 3: ...VENOR S RESPONSIBILITY 1 Owner s or hirer s responsibility 23 2 Employer s responsibility 23 3 Trainer s responsibility 23 4 Operator s responsibility 23 5 Inspection and maintenance 24 C PRE OPERATIO...

Page 4: ...CHMENTS 1 Approved attachments 75 2 Unapproved attachments 75 3 Telehandler Attachment Fork capacities 76 4 Using the capacity chart with forks 77 5 Attachment installation 82 5 1 Mechanicalattachment...

Page 5: ...ly jib control 117 5 9 3 Attachment installation procedure 117 5 9 4 Using the load capacity chart 118 5 9 5 Operation instructions 120 5 9 6 Precautions to avoid damaging the equipment 121 5 9 7 Oper...

Page 6: ...tion of leaks on hydraulic cylinders 193 7 3 Electric 194 7 3 1 Replacing damaged cables 194 8 Every day or every 10 h of operation 195 8 1 Generalchecks 195 8 2 Loadmomentindicator 195 8 3 Dieselcirc...

Page 7: ...lade Option 214 15 Every 1000 h hours of operation or once a year 215 15 1 Chainwear 215 15 2 Primaryairfilter 215 15 3 Internalcombustionengine 215 15 4 Hydrauliccircuit 216 15 4 1 Equipment hydrauli...

Page 8: ...228 21 2 Operatingincidentontheside shiftforkcarriage Option 228 21 3 Operatingincidents Flyjib2 5m 8ft2in 1 2t 2646lb withhydraulicwinch Option Flyjib4m 13ft1in 0 6t 1323lb withhydraulicwinch Option...

Page 9: ...HAULOTTE product When contacting our After Sales Service ensure that you provide the machine model and serial number When ordering any consumables or spare parts please use this manual and the Haulott...

Page 10: ...manual Certain options can modify the machine s operating characteristics and its associated safety If your machine was originally delivered with options fitted replacing a safety component associate...

Page 11: ...11 2420344510 E 11 11 AUS Telescopic handlers 4 HAULOTTE Services contact details HAULOTTE Services contact details...

Page 12: ...12 2420344510 E 11 11 AUS Telescopic handlers...

Page 13: ...tion of the products covered by the manual This manual must be kept on the machine or in the cab in its storage case The manual must be available to all operators and must be kept in good condition Ad...

Page 14: ...damage and or minor injury Other Additional technical information Green Maintenance operation or information It is preferable to operate the machine on flat consolidated ground tarmac concrete etc Ne...

Page 15: ...d the HAULOTTE accessory load capacity chart installed on the telehandler Do not exceed the rated lifting capacity Check that the ground can support the machine Do not drive at high speed with the boo...

Page 16: ...as part of the load weight Start travel turn and stop slowly to prevent the load from tipping over Beware of the wind The wind can cause a suspended load to tip over and generate destabilising side f...

Page 17: ...oint of impact Trying to escape from a tipping machine could result in death or serious injury The machine is not electrically insulated and does not offer any protection in the event of proximity to...

Page 18: ...0 300 V Avoid contact 300 V 50 kV 3 10 50 200 kV 5 15 200 350 kV 6 20 350 500 kV 8 25 500 750 kV 11 35 750 1000 kV 14 45 The turning radii change according to the steering mode selected 2 or 4 steer w...

Page 19: ...and spaced apart as far as possible Before moving the machine ensure that the path is clear and sound the horn When driving retract the boom and keep the boom and the attachment as low as possible Mai...

Page 20: ...NCHING or shift to NEUTRAL when travelling downhill Always ensure that the fork carriage or the attachment is correctly positioned on the boom and is secured by a lock pin and a retainer pin Incorrect...

Page 21: ...on the handler Do not approach moving parts while the engine is running Keep clear of the tires and the chassis or other steering parts when manoeuvring the telehandler Keep clear of the boom Keep ar...

Page 22: ...ry Do not run the engine in a place where there is a risk of build up of toxic gases Do not operate the machine in an enclosed area without proper ventilation Sparks produced by the electrical system...

Page 23: ...le local regulations The training must be given in an obstacle free area until the trainee is considered competent as defined by the training program undertaken 4 Operator s responsibility The operato...

Page 24: ...ied HAULOTTE Services technician Operator s manual Pre operation inspection Before operation or when the operator changes Operator Operator Operator s manual Section C Pre operation and controls Perio...

Page 25: ...r state of cleanliness and visibility Visual state of the machine Absence of leaks battery acid hydraulic oil etc Absence of foreign objects on all surfaces Call the staff in charge of the maintenance...

Page 26: ...of the control No damage Back to neutral for all joysticks selectors etc Present and legible control labels Movement safety limit switches No damage No missing or loose bolts Absence of foreign objec...

Page 27: ...riodical inspections Depending on the condition of certain critical components after 5000 hours the maintenance staff may have to reduce the interval between periodical inspections and maintenance If...

Page 28: ...ght anticlockwise when viewed from above checking each part in sequence N B For each component ensure that there are no loose or missing parts that the components are securely fastened and that there...

Page 29: ...bing is cut the buc kles are damaged or the mounting hardware is loose or damaged Check that the applicable load and capacity charts are installed in the cab 10 Hydraulic oil tank Recommended fluid le...

Page 30: ...HTL3510 only 22 Right hand stabiliser and contactor Pins secure hydraulic hoses in good condition no leaks on HTL4010 and HTL3210 only 23 Attachment Correctly installed Section E Attachments Check th...

Page 31: ...stickers Ensure that all stickers and appropriate capacity charts are legible and in place Clean or replace if necessary 3 1 RED LABELS Common labels CE standard Specific labels HTL4010 CE standard Sp...

Page 32: ...escopic handlers C Pre operation and controls Specific labels HTL3510 CE standard 3 2 YELLOW LABELS Common labels Specific labels HTL4010 HTL 3510 HTL 3210 The yellow labels indicate a risk of materia...

Page 33: ...33 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Specific labels optional 3 3 OTHER LABELS Common labels The other labels provide additional technical information...

Page 34: ...34 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Specific labels HTL4010 Specific labels HTL3510...

Page 35: ...35 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Specific labels HTL3210 Specific labels optional...

Page 36: ...36 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls 3 4 IDENTIFICATION Localization isometric view HTL4010 HTL3210...

Page 37: ...37 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization isometric view HTL3510 Localization left view HTL4010 HTL3210...

Page 38: ...38 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization left view HTL3510 Localization right view HTL4010 HTL3210...

Page 39: ...39 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization right view HTL3510...

Page 40: ...40 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization cab view...

Page 41: ...41 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization view from above HTL4010 HTL3210...

Page 42: ...42 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization view from above HTL3510...

Page 43: ...43 2420344510 E 11 11 AUS Telescopic handlers C Pre operation and controls Localization rear view...

Page 44: ...40 Battery Battery isolation switch 1 307P220930 Other A41 Indicator 1 307P221070 Other A43 Wear the seat belt 1 307P220780 Other A44 25 km h 1 307P216110 Other A45 Angle sensor 1 307P220900 Other A46...

Page 45: ...Drift side offset On stabilizers 1 307P229820 307P229720 Other Load capacity chart Bucket On wheels 1 307P229950 307P229140 Other Load capacity chart Bucket On stabilizers 1 307P229960 307P229150 Oth...

Page 46: ...150 Other Load capacity chart Forks on stabilisers 1 307P230070 307P230160 Other Load capacity chart Drift side offset On wheels 1 307P230080 307P2230170 Other Load capacity chart Drift side offset On...

Page 47: ...Other Load capacity chart Forks 1 307P231970 Other Load capacity chart Drift side offset 1 307P231980 Other Load capacity chart Bucket 1 307P232270 Other Load capacity chart Jib crane 1 307P232280 Oth...

Page 48: ...Controls General view HTL4010 HTL3510 Never use the machine unless the overhead guards and the cab structure are in good condition Any modifications to this machine must be approved in writting by HAU...

Page 49: ...pedal to increase the engine speed and the hydraulic fluid flow C124 Steering column adjuster Section C 2 5 3 Steering column C125 Transmission control lever Section C 2 5 3 Steering column C126 Headl...

Page 50: ...C131 Load moment indicator display Section C 2 5 10 Load moment indicator display C132 Heating and air conditioning control C133 Adjustable air vents Individual controllable C134 Air louvers Individu...

Page 51: ...ed Selector in position II Travel direction selection Forward drive Pull the lever backwards and then push it upwards Neutral Reverse drive Pull the lever backwards and then pull it downwards A sudden...

Page 52: ...clockwise ACW P169 Full beam headlights On Push forward Off Pull backward Flashing the lights Pull backward in short bursts Bring the Telehandler to a complete stop and shutdown the engine before adj...

Page 53: ...forward backward Use the handle P170 to move the seat forward and backward Height Use knob P171 to adjust the seat height Suspension Use the know P172 to adjust the suspension to the appropriate weig...

Page 54: ...ch P203 on the side instrument panel Adjust the heating temperature using the knob under the driver s seat Adjust the air flow using the air locks and round vents Heating and ventilation HTL4010 HTL35...

Page 55: ...ocated on the lateral control console Adjust the fan speed Adjust the air flow using the air locks and round vents 3 5 7 Instrument control panel General view The heating must be off when the air cond...

Page 56: ...clogged P190 HL690 Service brake fault LED On Insufficient pressure in the service brake circuit P191 HL143 ECU defect LED On ECU fault3 P192 HL683 Rear axle alignment LED On Rear wheels aligned P193...

Page 57: ...utral position Center Radio control position Rotate to left P224 Drive speed 1 indicator On Speed 1 engaged P225 Drive speed 2 indicator5 On Speed 2 engaged Flashing Do not shift gear The stabilisers...

Page 58: ...els mode Rotate steering wheel slowly to bring the rear wheels to the right position The Rear wheels aligned indicator P192 must remain switched on Continue to rotate steering wheel slowly until you s...

Page 59: ...ards Tool control direction B Push the right rocker switch downwards Button Float option Hydraulic attachmet locking option Marking Description Function P211 Joystick To raise the telescopic arm Pull...

Page 60: ...low button and push the joystick forwards Lifting the left stabiliser Press the low button and push the joystick towards the left and then backwards Lifting the right stabiliser Press the low button a...

Page 61: ...top of switch downwards Off Press bottom of switch downwards P213 Fog lights switch On Press top of switch downwards Off Press bottom of switch downwards P214 Parking brake switch On Activated To rel...

Page 62: ...enabled at high and low speeds 3 5 10 Load moment indicator LMI General view Controls and indicators A display set into the right hand windscreen strut shows the percentage remaining load triggers a p...

Page 63: ...ment System which monitors and manages the load on the Telehandler in all position For details refer to the supplementary manual supplied with the Telehandler Movement Fork mode Winch mode Booms raisi...

Page 64: ...he rear view mirrors as required for optimal visibility before and during use The window must be locked in open or closed position during use Open the cab door window and lock it with the locking mech...

Page 65: ...ht P188 goes off before starting the engine The following LEDs should light upon start up and then go off again Engine oil pressure light P181 Parking brake LED P182 possible if deactivated for a prol...

Page 66: ...y Perform all additional checks Section H Lubrication and maintenance 1 3 STARTING THE ENGINE WITH A BOOSTER BATTERY If the engine has to be started with a booster battery jumper cable proceed as foll...

Page 67: ...or traffic lanes Actuate the parking brake switch P214 Shift the speed selector to neutral Lower the forks or the attachment to the ground Operate the engine at idling speed for 1 mn Stop the engine T...

Page 68: ...ngage into the pallet or under the load at maximum width and remain centred on the fork carriage Face the load and approach it slowly with the fork tips straight and horizontal 2 2 2 For operation wit...

Page 69: ...guide persons must remain in constant communication verbal or hand and be in visual contact with the operator at all times Never place the guide persons between the suspended load and the telehandler...

Page 70: ...of the load Ensure that the unloading point is level both lengthways and sideways Use the capacity chart to determine the permitted boom extension range Lower the forks to the level at which the load...

Page 71: ...om The front edge of the attachment should be approximately 0 30 m 1 ft0 in to 0 40 m 1 ft4 in above the ground Tilt the attachment back completely Place a protective cover over the front edge of the...

Page 72: ...Switch all controls to neutral stop the engine and remove the ignition key To secure the machine to the deck pass chains through the designated tie down points as illustrated in the figure Do not tie...

Page 73: ...vers is authorized and empowered to use lifting equipment Before loading the machine to be transported check that the deck the ramps and the machine wheels are free of mud snow and ice Otherwise the m...

Page 74: ...74 2420344510 E 11 11 AUS Telescopic handlers D Operation...

Page 75: ...attachment may not be approved for the machine model being used Additional information can be obtained from HAULOTTE Services The user must enlist the services of a competent person to familiarise th...

Page 76: ...espond to the attachment number which appears on the load chart To determine the maximum capacity of the telehandler and the attachment use the smallest of the capacities as determined by the capacity...

Page 77: ...distance the load must be placed forward of the front tires of the Telehandler An alphabetical key A B C D E F indicates the boom extension and a pendulum indicates the boom angle Section E Boom angle...

Page 78: ...78 2420344510 E 11 11 AUS Telescopic handlers E Attachments Boom extension indicators Example of a load capacity chart HTL4010...

Page 79: ...the loads indicated on the load capacity chart are based on the machine being on firm ground with the chassis level the forks being positioned symmetrically on the fork carriage the load being centre...

Page 80: ...80 2420344510 E 11 11 AUS Telescopic handlers E Attachments HTL4010 load capacity chart...

Page 81: ...81 2420344510 E 11 11 AUS Telescopic handlers E Attachments HTL3210 load capacity chart HTL3510 load capacity chart...

Page 82: ...cab insert the locking pins and secure them with the retaining locks If the attachment requires hydraulic control connect auxiliary hydraulic hoses A and B Marking Description C143 Attachment C144 At...

Page 83: ...must not show any boom angle fault 5 flashes that the boom is below 15 The hydraulic adaptation kit connection is carried out with the machine stopped Connect the hoses from the hydraulic adaptation k...

Page 84: ...he fork carriage forwards until the fork heel is no longer in contact with the fork carriage Stand next to the fork carriage to slide the fork push it or pull it near its pin If the forks must be chan...

Page 85: ...mation provided on the attachment identification plate Use the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the...

Page 86: ...4 Use the capacity table load chart booklet corresponding to this attachment located in the cab Left hand dashboard The machine must not be used without the capacity chart booklet All the loads indic...

Page 87: ...ered stabilisers Values given for information only Do not fill the bucket while telescoping the boom It is forbidden to have an unevenly spread load in the bucket Do not raise the boom unless the chas...

Page 88: ...cident resulting in death or serious injury Do not raise the boom unless the chassis is level 0 Do not use the bucket to pull a load Do not fill the bucket while telescoping the boom It is forbidden t...

Page 89: ...bucket smoothly and with the boom completely retracted Tip the bucket upwards enough to stabilise the load and reverse Travel as specified Section A Safety precautions Tilt the bucket downwards to ti...

Page 90: ...S Telescopic handlers E Attachments 5 4 8 Attachment life expectancy Section H Refer to this section of the user manual to check bucket blade wear and or change the blade Check the bucket blade and co...

Page 91: ...tion provided on the attachment identification plate Use the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the m...

Page 92: ...4 Use the capacity table load chart booklet corresponding to this attachment located in the cab Left hand dashboard The machine must not be used without the capacity chart booklet All the loads indic...

Page 93: ...ered stabilisers Values given for information only Do not fill the bucket while telescoping the boom It is forbidden to have an unevenly spread load in the bucket Do not raise the boom unless the chas...

Page 94: ...cident resulting in death or serious injury Do not raise the boom unless the chassis is level 0 Do not use the bucket to pull a load Do not fill the bucket while telescoping the boom It is forbidden t...

Page 95: ...ket with the boom extended may damage the boom or the telescope cylinder Distribute the material evenly in the dump The bucket capacity charts only apply to evenly distributed loads Any other use is f...

Page 96: ...smoothly and with the boom completely retracted Tip the bucket upwards enough to stabilise the load and reverse Travel as specified Section A Safety precautions Tilt the bucket downwards to tip out th...

Page 97: ...ovided on the attachment identification plate Use the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the manual h...

Page 98: ...lt in the attachment or load disengaging causing death or serious injury Make yourself familiar with the information Section E 3 Section E 4 Use the capacity table load chart booklet corresponding to...

Page 99: ...ments HTL 3510 NA load capacity chart stabilisers raised Values given for information only To be used when lifting a load with the stabilisers lowered Do not raise the boom unless the chassis is level...

Page 100: ...e load capacity chart supplied by HAULOTTE on the handler Load chart located on the left hand dashboard in the handler Failure to install the relevant HAULOTTE supplied capacity chart could cause an a...

Page 101: ...e of the equipment can be written and given to the driver by the company director The user must be trained in handling loads at height by an authorised organisation The user must therefore strictly ad...

Page 102: ...se the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the manual holder situated behind the cab seat with the tel...

Page 103: ...th of machine 1 6 m 5 ft25 in Tare weight 390 kg 860 lb User pressure 180 bar 2610 67 psi Maximum permissible pressure 220 bar 3190 83 psi Minimum flow 50 l min Standard FEM3A Dimensions of pallet for...

Page 104: ...e loads indicated on the nominal capacity chart load chart booklet assume that the machine is on firm ground with the chassis level the load evenly distributed on the attachments tyres of the correct...

Page 105: ...ting the attachments which appear on the table To be used when lifting a load with the stabilisers raised HTL 4010 HTL 3210 NA load capacity chart stabilisers raised Values given for information only...

Page 106: ...r use an attachment without first having made yourself familiar with the load capacity chart supplied by HAULOTTE on the handler Load chart located on the left hand dashboard in the handler Failure to...

Page 107: ...r must be trained in handling loads at height by an authorised organisation The user must therefore strictly adhere to the slinging rules Do not use the fork carriage as a lever Excessive leverage cou...

Page 108: ...th the pallet forks or the fork carriage while the load is being handled To ensure that the pallet does not move on the forks you are advised to tilt the fork carriage by 10 Do not exceed 10 The palle...

Page 109: ...vement Lateral movement Discharging Discharging Before starting to move the fork carriage laterally ensure that there is no obstacle in the way Before tilting the fork carriage forwards to unload it e...

Page 110: ...ad the fork carriage ensure that the fork carriage is in unloading position with the pallet forks parallel to the ground and 0 05 m 0 ft2 in above it Check the following regularly Bolts and connection...

Page 111: ...vided on the attachment identification plate Use the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the manual ho...

Page 112: ...iliar with the information Section E 3 Section E 4 Use the capacity table load chart booklet corresponding to this attachment located in the cab Left hand dashboard The machine must not be used withou...

Page 113: ...US Telescopic handlers E Attachments HTL 3510 NA load capacity chart stabilisers raised Values given for information only Do not raise the boom unless the chassis is level 0 Do not move a load without...

Page 114: ...o not raise the boom unless the chassis is level 0 Do not move a load without having secured it first Never use an attachment without first having made yourself familiar with the load capacity chart s...

Page 115: ...st be moved the load must be kept in the low position Speed of movement must not exceed 5 km h 3 11 mph and the load must be secured to the telescopic handler fork carriage The weight of all riggings...

Page 116: ...attachment immediately Change it If the winch frame is hit stop using the attachment immediately The attachment must be inspected by an authorised organisation to validate its capacity Contact HAULOT...

Page 117: ...vided on the attachment identification plate Use the capacity table load chart booklet corresponding to this attachment located in the cab Keep the specific instructions for the forks in the manual ho...

Page 118: ...iliar with the information Section E 3 Section E 4 Use the capacity table load chart booklet corresponding to this attachment located in the cab Left hand dashboard The machine must not be used withou...

Page 119: ...US Telescopic handlers E Attachments HTL 3510 NA load capacity chart stabilisers raised Values given for information only Do not raise the boom unless the chassis is level 0 Do not move a load without...

Page 120: ...instructions Do not raise the boom unless the chassis is level 0 Do not move a load without having secured it first Never use an attachment without first having made yourself familiar with the load ca...

Page 121: ...ad must be kept in the low position Speed of movement must not exceed 5 km h 3 11 mph and the load must be secured to the telescopic handler fork carriage The weight of all riggings slings etc must be...

Page 122: ...attachment immediately Change it If the winch frame is hit stop using the attachment immediately The attachment must be inspected by an authorised organisation to validate its capacity Contact HAULOT...

Page 123: ...attachment located in the cab Keep the specific instructions for the forks in the manual holder situated behind the cab seat with the telehandler operator manual Description Capacity Maximum flow rate...

Page 124: ...ins 1 Connect the hydraulic hoses 2 Before using the winch for the first time operate the fly jib winch while empty and check that the cable goes up and down correctly Make yourself familiar with the...

Page 125: ...ting the attachments which appear on the table To be used when lifting a load with the stabilisers raised HTL 4010 HTL 3210 NA load capacity chart stabilisers raised Values given for information only...

Page 126: ...having secured it first Do not raise the boom unless the chassis is level 0 Do not move a load without having secured it first Never use an attachment without first having made yourself familiar with...

Page 127: ...e a suspended load to tip over and generate destabilising side forces even with tag lines Comply with current Highway Code regulations The maximum authorised speed is 25 km h 15 53 mph and maximum too...

Page 128: ...the highway with the cable unwound The lower stop is adjusted on the winch by positioning the cable gland in the required place 1 This adjustment can be carried out in the factory for 3 rotations of t...

Page 129: ...draulic circuit by pressing on the end of travel valve 1 If it must be moved the load must be kept in the low position Speed of movement must not exceed 5 km h 3 11 mph and the load must be secured to...

Page 130: ...slinging rules For any operation on the winch you must Place the attachment on the ground Stop the carrier vehicle Release the hydraulic pressure Disconnect the hydraulic hoses Do not walk under the...

Page 131: ...machine in a suitable place sheltered from bad weather Clean the machine regularly Grease the whole fly jib Section H Lubrication and maintenance Put a layer of oil over the whole machine to ensure t...

Page 132: ...ttachment located in the cab Keep the specific instructions for the forks in the manual holder situated behind the cab seat with the telehandler operator manual Description Capacity Maximum flow rate...

Page 133: ...ins 1 Connect the hydraulic hoses 2 Before using the winch for the first time operate the fly jib winch while empty and check that the cable goes up and down correctly Make yourself familiar with the...

Page 134: ...ting the attachments which appear on the table To be used when lifting a load with the stabilisers raised HTL 4010 HTL 3210 NA load capacity chart stabilisers raised Values given for information only...

Page 135: ...having secured it first Do not raise the boom unless the chassis is level 0 Do not move a load without having secured it first Never use an attachment without first having made yourself familiar with...

Page 136: ...e a suspended load to tip over and generate destabilising side forces even with tag lines Comply with current Highway Code regulations The maximum authorised speed is 25 km h 15 53 mph and maximum too...

Page 137: ...the highway with the cable unwound The lower stop is adjusted on the winch by positioning the cable gland in the required place 1 This adjustment can be carried out in the factory for 3 rotations of t...

Page 138: ...ydraulic circuit by pressing on the end of travel valve 1 If it must be moved the load must be kept in the low position Speed of movement must not exceed 5 km h 3 mph and the load must be secured to t...

Page 139: ...rules For any operation on the winch you must Place the attachment on the ground Stop the carrier vehicle Release the hydraulic pressure Disconnect the hydraulic hoses Do not walk under the winch whe...

Page 140: ...lace sheltered from bad weather Clean the machine regularly Grease the whole fly jib Section H Lubrication and maintenance Put a layer of oil over the whole machine to ensure total protection Attachme...

Page 141: ...g The maximum travel speed permitted for towing is 6 km h 4 mph The towing distance should not exceed Turn on ignition key and start up engine Deactivate the parking brake When the parking brake is re...

Page 142: ...1 2 3 see figure below you must loosen the 6 cap screws 3 on each side positioned around the flanges on the rigid front axle See photo opposite Block the four wheels with chocks to prevent any machine...

Page 143: ...torque suddenly decreases Loosen screws 1 2 3 alternatively anticlockwise until the screw heads brush against the top of the special screws Tighten nuts 1 2 3 clockwise by a quarter of turn The parkin...

Page 144: ...as a last resort the cylinder chock Completely unscrew the stop screw from the counter balance valve block flanged on the boom lift cylinder Note the number of turns with the spanner Remove the locknu...

Page 145: ...hat the counter balance valve functions properly after the intervention by raising lowering the boom with a load 3 Emergency exit from cab In an emergency exit from the cab can be achieved via the rea...

Page 146: ...146 2420344510 E 11 11 AUS Telescopic handlers F Emergency procedure...

Page 147: ...ed out by a certified agency competent person Ensure that any additional labels that relate to the option installed are affixed to the machine in the appropriate location s HAULOTTE has a continuous i...

Page 148: ...brake controlled by the brake pedal Parking brake Electrically controlled multi disc oil bath brake Cab Interior width 940 mm Tyres HTL4010 HTL3510 HTL3210 Type 405 70 24 HAULOTTE code 2326014870 Pre...

Page 149: ...tomatic speed deceleration at the limits of the capacity chart Side tilt corrector 9 9 HTL3510 Pre wirring for radio and loudspeakers Horn Adjustable seat height and armrest with safety belt Adjustabl...

Page 150: ...n D 2 78 9 ft 1 in 2 78 9 ft 1 in E 0 40 1 ft 4 in 0 40 1 ft 4 in F 1 85 6 ft 1 in 1 85 6 ft 1 in G 0 94 3 ft 1 in 0 94 3 ft 1 in H 2 23 11 ft 2 23 11 ft I 2 71 7 ft 4 in 2 71 7 ft 4 in J 1 66 5 ft 5...

Page 151: ...ic handlers G Technical characteristics 3 Working area 3 1 MACHINE HTL4010 Working area 3 2 MACHINE HTL3510 Working area K 39 L 23 M 103 N 2 55 8 ft 4 in O 4 80 15 ft 9 in Total weight 8200 kg 18 081...

Page 152: ...ncrease in noise emission all panels and other sound absorbing materials must be replaced in their original position after maintenance and repair work The sound power values indicated in the technical...

Page 153: ...ion are measured in accordance with method and conditions described in standard ISO5349 1 and ISO2631 1 The hand and feet vibration values indicated in the technical characteristics tables are obtaine...

Page 154: ...11 11 AUS Telescopic handlers G Technical characteristics 6 Declaration of conformity Declaration of conformity Carriages CE Declarations of Conformity only apply to machines that are certified for th...

Page 155: ...he grease points After lubricating the machine actuate all functions several times to distribute the lubricants Perform all these maintenance procedures without any accessories fitted Check the state...

Page 156: ...t any risk of sparks that could cause an explosion use the battery cables in accordance with the instructions provided in this manual Hydraulic oil leaks or fluid under pressure can cause serious inju...

Page 157: ...afety systems or elements concerns mechanics hydraulics and electrics Any modifications not approved by HAULOTTE are not permitted The manufacturer s product liability will be void if the work specifi...

Page 158: ...158 2420344510 E 11 11 AUS Telescopic handlers H Lubrication and maintenance 4 Lubrication and maintenance schedule...

Page 159: ...159 2420344510 E 11 11 AUS Telescopic handlers H Lubrication and maintenance...

Page 160: ...copic handlers H Lubrication and maintenance For machines fitted with Engine PERKINS 1104D44T Description of the components Symbol Marking Description Check the level Filter Oil change 1 Lubrication 2...

Page 161: ...2420344510 E 11 11 AUS Telescopic handlers H Lubrication and maintenance 4 Air filter system 5 Internal combustion engine 6 Travel axles 7 Hydraulic circuit 8 Operating battery Symbol Marking Descript...

Page 162: ...e periods below are recommended for fuel powered machines in normal use 1 Increase in periodical inspections 2 For countries where machines are not subject to controlled periodic maintenance Symbol Me...

Page 163: ...r fuel leaks Appearance of the mechanical parts hydraulic hoses and wiring Attachment device nuts and bolts and hydraulic fitting Operation of the work lighting controls the light indicators display l...

Page 164: ...Remove the dust Primary air filter Secondary air filter Internal combustion engine See manufacturer s guide Oil Oil filter cartridge Engine mounting Glow plugs Belt tension Travel axles See manufactur...

Page 165: ...horisation Check Test See user manual or machine maintenance book 1 Visual inspection with dismantling and exchange or replacement if necessary Operation requiring HAULOTTE Services authorisation Incr...

Page 166: ...t Diesel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s...

Page 167: ...tate of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air f...

Page 168: ...it Diesel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer...

Page 169: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter Oil f...

Page 170: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 171: ...f anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter...

Page 172: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 173: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Remove the dust Internal combustion engine See manufacturer s guide Primary air filter Oil Secon...

Page 174: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 175: ...f anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter...

Page 176: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 177: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Remove the dust Internal combustion engine See manufacturer s guide Primary air filter Oil Secon...

Page 178: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 179: ...f anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter...

Page 180: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 181: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Remove the dust Internal combustion engine See manufacturer s guide Primary air filter Oil Secon...

Page 182: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 183: ...f anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter...

Page 184: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 185: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Remove the dust Internal combustion engine See manufacturer s guide Primary air filter Oil Secon...

Page 186: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 187: ...f anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guide Remove the dust Oil Primary air filter...

Page 188: ...sel engine operation Condensation State of anti slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Internal combustion engine See manufacturer s guid...

Page 189: ...i slip parts Pre filter State of tires and inflation pressure Filter Wheel nut torque Air filter system Remove the dust Internal combustion engine See manufacturer s guide Primary air filter Oil Secon...

Page 190: ...mities during the daily visual inspections Poor or no maintenance Replace slew ring in the following cases Deformations fatigue failure of the bearings and or the pins Presence of excessive clearance...

Page 191: ...oisture and salinity in the air Checking procedure After disassembling the affected pivot protect the bearing from external pollutants and potential damage Clean the bearing with a suitable solvent Re...

Page 192: ...Slowly undo the hose end fitting to allow the residual hydraulic pressure to dissipate To protect personal safety observe the following conditions when disassembling or reassembling components Stow an...

Page 193: ...ference between two measurements does not exceed 4 cm the test validates correct operation If the difference between two measurements exceeds 4 cm contact HAULOTTE Services or carry out the additional...

Page 194: ...eassembly Respect the order configuration of origin during the reassembly Type of cylinders Maximum drift authorised due to an internal leak of the cylinder Lift cylinder arm or boom Machine with work...

Page 195: ...n Check the wheel lug nut torque 300Nm after the first 10 hours and then after every 100 of operation 8 2 LOAD MOMENT INDICATOR The load moment indicator s function is to constantly monitoring the sta...

Page 196: ...sor situated on the filter body Visually inspect the state of the sensor If red marking is visible Clean or replace the filter element even if the cleaning frequency indicated above has not been reach...

Page 197: ...ge Clean the filter cartridge replace it at the latest after every 1000 h of operation or once a year Blow with dry compressed air with a maximum pressure of 5 bar 72 5 psi from the inside of the filt...

Page 198: ...WITH HYDRAULIC WINCH OPTION Regularly check that the bolts and connections are correctly tightened Tightening torques 3 5 daN m 25 8 lbf ft Regularly check the condition of the hydraulic hoses Regular...

Page 199: ...properly lubricate the plates 1 holding the clamps for the fixed section every 24 h working Never carry out lubrication maintenance and adjustment operations while the machine is switched on Escaping...

Page 200: ...owing zones every 24 h of operation Lubricate generously until a ring of grease appears at the ends of each hinge Never carry out lubrication maintenance and adjustment operations while the machine is...

Page 201: ...f operation Lubricate generously until a ring of grease appears at the ends of each hinge Never carry out lubrication maintenance and adjustment operations while the machine is switched on Escaping li...

Page 202: ...th grease points Lubricate the extension boom shaft Lubricate the sliding area friction pads Check the boom telescope synchronisation fully retract the boom and fully extend it The various elements mu...

Page 203: ...he wheel lug nut torque 300 Nm N B Perform the first torque check after the first 10 h of operation 11 2 DIESEL CIRCUIT Engine Perkins 1104D44T Perform the first diesel pre filter change after the fir...

Page 204: ...elescopic handlers H Lubrication and maintenance 11 4 LUBRICATING THE FRONT AXLE Remove the 4 protective caps from the grease point Connect the grease gun HTL4010 HTL3210 HTL3510 Remove the protective...

Page 205: ...handlers H Lubrication and maintenance 11 5 LUBRICATING THE REAR AXLES Remove the 6 protective caps from the grease point Connect the grease gun HTL4010 HTL3210 HTL3510 Replace the protective caps on...

Page 206: ...NDITIONING OPTION Check cleanliness of the condenser Clean where applicable N B Remove the protective covers in order to gain access to clean the condenser unit Check the cleanliness of the cab air fi...

Page 207: ...ct the battery Check that the terminals are not corroded Replace the battery if its case is cracked distorted or damaged Close and secure the battery access cover under the cab 12 4 AIR CONDITIONING O...

Page 208: ...91 mm To change the teeth Knock out the flexible block key using a punch Install a new tooth using a new key which must be inserted from above Under normal conditions of use the bucket teeth must be r...

Page 209: ...the diesel filter Loosen the filter cartridge Replace the used cartridge with a new one Close the engine canopy again 14 2 2 Changing the diesel pre filter To access the diesel pre filter open the en...

Page 210: ...few minutes Stop the engine and check the level Top up the oil if necessary Change the oil filter cartridge Loosen and remove the filter cartridge Oil the seal on the new cartridge insert it into plac...

Page 211: ...ghtened using a torque value recomended by the manufacturer 14 4 1 Checking the oil level of the front axle Capacity Transfer case 0 5 l 0 13 gal US Differential 8 l 2 11 gal US Before performing the...

Page 212: ...plugs 2 to eliminate any pressure from inside the housing Loosen the control plug 1 The lubricant level in the axle must be at the level of the control plug 1 otherwise top up to the correct level via...

Page 213: ...to repeat this operation for each of the machine wheels Capacity 4 x 1 3 l 4 x 0 34 gal US When it is in the high position loosen the plug 3 by a few turns to release any internal pressure from the ho...

Page 214: ...ging the blade When the corners of the bucket blade reach 50 of their initial value and are displaying signs of precipitated wear the blade must be changed N B Blade on the toothed bucket If teeth are...

Page 215: ...engine supports and the vibratory mount supports are in good condition Never clean the cartridge by hitting it against a hard surface or by using hot flammable liquid Remove the cover Pull the trigger...

Page 216: ...the engine compartment by removing the lower protective covers Loosen the casing from the transmission hydraulic filter Change the filter cartridge Switch on the engine and perform travel movements Ch...

Page 217: ...ed using a torque value recomended by the manufacturer Perform the first drainage after the first 250 hours of operation 16 1 1 Draining the front axle Capacity Transfer case 0 5 l 0 13 gal US Differe...

Page 218: ...ining the epicycloidal reducers N B To replace the reducer oil you must move the machine to position the closure plug in the required positions Due to the presence of a differential on each of the axl...

Page 219: ...adiator GRADUALLY until the coolant has reached the correct level Close the expansion bottle cap again Switch the acceleration control lever to IDLING Start the engine Let the engine run AT IDLING SPE...

Page 220: ...oils that that possess the technical characteristics that correspond to HAULOTTE recommendations Check the cleanliness of the oil filter cartridge no metal shavings rubber plastic If necessary drain a...

Page 221: ...nd repair work on the air conditioning must be carried out by a qualified and authorised person Any top up on the circuit must be carried out by a qualified and authorised person Never open the circui...

Page 222: ...d requires changing when The drum brake no longer holds the cable And or the drum no longer turns normally worn bearings Changing the winch The cable must be removed to change the winch Section H 16 7...

Page 223: ...Section H 16 6Accumulator For the following operations park the machine on a horizontal surface and turn off the engine Never undertake maintenance on the accumulators with the engine running Only beg...

Page 224: ...SO MOBIL AGIP SHELL Greases Pins and hinges 6743 0 cat gorie X EPEXELF 2 Upper boom Grade 2 ou 3 Multimove 2 Driver seat rails Multi Purpose Grease Moly Oils Front axle and differential 10 l 2 64 gal...

Page 225: ...225 2420344510 E 11 11 AUS Telescopic handlers H Lubrication and maintenance Axle oil viscosity according to the ambient temperature Engine oil viscosity according to the ambient temperature...

Page 226: ...for rear foglights FU140 Sensor relay power supply fuse FU161 Fuse for the engine preheat management system FU180 Fure for the cab heating FU181 Air conditioning fuse FU182 Fuse for accessory power i...

Page 227: ...Check faulty solenoid valve connection Change the faulty solenoid valve 2 flashes Joystick operation defect Check the SJ120 joystick connection Change the SJ120 joystick Handle failure Check the SJ120...

Page 228: ...age does not travel Poor hydraulic connections Check the hydraulic connections The fork carriage touches an obstacle Move the fork carriage back slightly from the obstacle Incorrect flow limiter setti...

Page 229: ...nd change the parts which cannot be repaired The cable is not rewound properly The cable is frayed Have the cable changed immediately by an authorised person Contact HAULOTTE Services The cable is kin...

Page 230: ...the parts which cannot be repaired The cable is not rewound properly The cable is frayed Have the cable changed immediately by an authorised person Contact HAULOTTE Services The cable is kinked Have...

Page 231: ...register keeps a record of maintenance and repair work carried out inside or outside the maintenance programme N B In the case of a HAULOTTE Services intervention the qualified technician must indicat...

Page 232: ...232 2420344510 E 11 11 AUS Telescopic handlers H Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 233: ...233 2420344510 E 11 11 AUS Telescopic handlers H Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 234: ...234 2420344510 E 11 11 AUS Telescopic handlers H Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 235: ...235 2420344510 E 11 11 AUS Telescopic handlers H Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 236: ...236 2420344510 E 11 11 AUS Telescopic handlers H Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number...

Page 237: ...3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A B C D E F G H I J K L M S T A R T U P A L T E R N A T O R P R E H E A T I N G R E S I S T O R F U E L P U M P POWER CONTACTOR S T O P E N G I N E 27 16...

Page 238: ...T O R A I R C O N D I T I O N I N G S A U E R S U P P L Y D C U S U P P L Y V A L V E S S U P P L Y S W I T C H A N D S E N S O R S S U P P L Y R A D I O C O M M A N D E Radio control option L M I S...

Page 239: ...L I G H T S F R O N T R I G H T C O M P R E S S O R A I R C O N D I T I O N I N G A I R C O N D I T I O N I N G S E E I N G O N S W I T C H V E N T I L A T O R S A I R C O N D I T I O N I N G SWITCH...

Page 240: ...E I L I N G L I G H T F R O N T W I N D S C R E E N W I P E R W I N D S C R E E N W A S H E R R E A R W I N D S C R E E N W I P E R FLASHER UNIT 100A 210 101 90 90 184 51 0 0 0 0 0 0 106 100 63 110 1...

Page 241: ...N T I L A T O N S E E I N G O N S W I T C H E L E C T R I C A L P L U G S E E I N G S T E E R I N G I N D I C A T O R TOW CONNECTOR RA S T E E R I N G I N D I C A T O R L E F T S T E E R I N G I N D...

Page 242: ...xiliary A 104 13 E TOR 106 10 E ANA 106 11 E ANA 106 12 E ANA 106 13 E ANA E TOR 104 15 105 3 E TOR E TOR 104 12 E TOR 105 17 E TOR 105 12 DPLUS startup Contactor safety ALIM 5V 106 22 E ANA 106 15 Sy...

Page 243: ...OR 104 35 S TOR 104 29 S TOR 104 36 S TOR 104 33 S TOR 104 32 S TOR 104 31 S TOR 104 26 S TOR Validation 1st speed translation Validation 2nd speed translation Float Preheating system Boom angle Conta...

Page 244: ...1K 0 25W 5 C6 5 C6 6 Sensor Sensor signal C1 4 C1 3 C2 1 C2 2 C2 3 CAN HIGH CAN LOW CAN SHD C_SAUER C6 8 C1 5 signal Sensor Sensor 7 2 3 RED GREEN YELLOW High speed direction motor C6 4 Sens Parking...

Page 245: ...ein parking Temp rature huile hydraulique Filtre huile colmat Indicateur de niveau de carburant Niveau de carburant P160 P189 COMPTE TOURS HORAMETRE P161 D W indicateur de temp rature moteur 114 0 0 6...

Page 246: ...I SUPPLY Battery RECEIVER RADIO CONTROL EMERGENCY STARTUP HORN Raising signal Telescoping signal A B Up Down E ANA 106 7 0 20mA E ANA 106 4 0 20mA E ANA 106 5 0 20mA E ANA 106 6 0 20mA E TOR 104 6 rad...

Page 247: ...x1 5 M18x1 5 1 7 8 12 T 1 5 16 12 L2 M4 M2 78CM3 M1 M5 28b 480b B S 480b E A 17CM3 2 13b 1L C2 C1 TELESCOPING CYLINDER 110 63 90 56 S2800 REAR STEERING CYLINDER STEER SELECT VALVE 3 8 HYDRAULIC MOTOR...

Page 248: ...1 5 M22x1 5 3 8 3 8 1 2 1 2 1 2 1 2 1 5 16 1 5 16 1 7 8 12 T 1 5 16 12 L2 M4 M2 68CM3 M1 M5 28b 450b B S 450b E A 17CM3 2 13b 1L TELESCOPIC CYLINDER 110 63 90 56 S2800 REAR STEERING CYLINDER STEER SEL...