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C

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H

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55

4000328140 E01.15 

AUS

Telescopic handlers

C

- Pre-operation and controls

1

 : Do not exceed  3100 tr/min (3100 rpm). Do not run the engine speed into the red zone. 

2

 : Service the machine as set out in this manual (

Section H  - Lubrication and

maintenance). 

3

 : The  (P191) indicator flashes to indicate an internal malfunction. 

When the machine switches downgraded mode, certain movements can be limited or
prohibited to safeguard the operator's well being (

Section H 21 - Troubleshooting). 

4

 : Condition for prohibiting action : Extended boom or active float option or service brake

pressure fault. 

5

 : The level of clogging of the particulate filter requires regeneration. Disabled mode must be

deactivated rapidly, as soon as the environment allows it (outside areas with explosive
atmosphere). 

6

 : High level of particulate filter clogging. 

7

 : The particulate filter is clogged. 

8

 : Description of fault codes : 

Section H 21 - Troubleshooting. 

P227

Particulate filter regeneration disabled 
indicator (For machines fitted with 
engine  PERKINS 854E-34TA only)

On : Automatic particulate filter regeneration disabled

P228

High exhaust gas temperature indicator 
(HEST) (For machines fitted with 
engine  PERKINS 854E-34TA only)

On : Particulate filter regeneration in progress

P229

Engine warning

On : Drive motor faulty OR machine maintenance to be 
performed

5 flashes when switched on : machine maintenance to be 

performed in 20 h maximum

P230

Engine shutdown

On : Serious engine fault

P231

Fault codes

 8

One or more faults detected and/or active

 3

Machine counters (hour or service)

Total machine running hours
Number of hours to next service

P232

Navigation button

In case of machine fault, each press on the button scrolls 
through the fault codes
In the absence of machine fault, each press on the button 
navigates between the hour counter and the service counter

Marking

Description

Function

Summary of Contents for HTL 3010

Page 1: ...Operator s manual T ELESCOPIC HANDLERS 4000328140 E01 15 AUS Operator s manual TELESCOPIC HANDLERS HTL 4010 HTL 3510 HTL 7732 HTL 3010 24203 21 0 E01 15 EN ...

Page 2: ...2 4000328140 E01 15 AUS Telescopic handlers ...

Page 3: ...4 B INTERVENOR S RESPONSIBILITY 1 Owner s or hirer s responsibility 25 2 Employer s responsibility 25 3 Trainer s responsibility 25 4 Operator s responsibility 25 5 Inspection and maintenance 26 C PRE OPERATION AND CONTROLS 1 Checks before use 27 1 1 Generalmechanicalfunctions 27 2 Pre operation checks and inspection 29 3 Safety stickers 33 3 1 Redlabels 33 3 2 Yellowlabels 35 3 3 Otherlabels 37 3...

Page 4: ...eload 75 2 3 1 For operation with non suspended load 75 2 3 2 For operation with suspended load 75 2 4 Dumpingprocedure 75 2 5 Stabiliseroperationprocedure HTL4010 76 2 6 Placingtheload 76 2 7 Disengagingtheload 76 3 Road operation 77 4 Loading and securing for transport 78 E ATTACHMENTS 1 Approved attachments 81 2 Unapproved attachments 81 3 Telehandler Attachment Fork capacities 82 4 Using the c...

Page 5: ...pment 105 1 3 Optionalequipment 106 1 3 1 Slings attached 3T 6 615 lb 106 1 3 1 1 Main components 106 1 3 1 2 Characteristics 106 1 3 1 3 Control 106 1 3 1 4 Operation 107 1 3 1 5 Lubrication and maintenance 107 2 Overall dimensions 108 3 Working area 110 3 1 Machine HTL4010 110 3 2 Machine HTL3510 110 3 3 Machine HTL3010 111 3 4 Machine HTL7732 111 4 Noise emission level 112 5 Telehandler vibrati...

Page 6: ...73 10 6 Hydrauliccircuit 174 10 7 Air conditioning Option 174 11 Every 250 h hours of operation 175 11 1 Coolingsystem 175 11 2 Travelaxles 175 11 3 Battery 175 11 4 Air conditioning Option 175 12 Every 500 h hours of operation 176 12 1 Lubricatingthesuspensionandthedriverseatrails 176 12 2 Airfilter system Formachinesfittedwithengine PERKINS854E 34TA or KOHLERKDI3404TCRonly 176 12 3 Dieselcircuit...

Page 7: ...oning Option Option 189 16 Every 3000 h hours of operation or every 3 years 190 16 1 Internalcombustionengine EnginePERKINS854E 34TA 190 16 2 Dieselparticulatefilter EnginePERKINS854E 34TA 190 16 3 Coolingsystem Formachinesfittedwithengine PERKINS854E 34TA or KOHLERKDI3404TCRonly 191 17 Every 5000 h hours of operation or every 5 years 192 17 1 Internalcombustionengine EngineKOHLERKDI3404TCR 192 18...

Page 8: ...8 Operator s manual ...

Page 9: ...ng 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 Haulotte Essential catalogue to receive your genuine HAULOTTE spare parts your only guarantee of parts interchangeability and correct machine operation If there is an equipment malfunction involving a HAULOTTE product then contact HAULOT...

Page 10: ...er technical specifications and to make improvements or modifications to the machine without modifying this 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 associated with a particular options not require any particular precautions other than those associate...

Page 11: ...otline 65 6546 6150 FAX 65 6536 3969 E mail haulotteasia haulotte com www haulotte sg HAULOTTE MIDDLE EAST FZE PO BOX 293881 Dubaï Airport Free Zone DUBAÏ United Arab Emirates TEL 971 0 4 299 77 35 FAX 971 0 4 299 60 28 E mail haulottemiddle east haulotte com www haulotte international com HAULOTTE SCANDINAVIA AB Taljegårdsgatan 12 431 53 Mölndal SWEDEN TEL 46 31 744 32 90 FAX 46 31 744 32 99 E ma...

Page 12: ...12 4000328140 E01 15 AUS Telescopic handlers ...

Page 13: ...ient operation 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 Additional copies can be ordered from HAULOTTE Services Symbol Meaning Danger Risk of injury or death work safety Caution Risk of material damage work quality Prohibition relating to work safe...

Page 14: ...n Customs Union and the Ukraine only The labels must be kept in good condition Additional labels can be ordered from HAULOTTE Services Labels Color Meaning Red Potentially fatal danger Orange Risk of serious injury Yellow Risk of material damage and or minor injury Other Additional technical information Green Maintenance operation or information Labels Color Meaning Red Prohibitions Danger Yellow ...

Page 15: ...able the safety devices Do not make contact with a fixed or mobile obstacle The contact can cause premature deterioration of the structure and lead to the corruption of certain safety elements Do not climb onto the covers Never use the machine with only an operator in the platform It must be operated by a pair of operators Never leave the hydraulic cylinders fully extended or retracted before swit...

Page 16: ...rts displayed in the cab The weight of all riggings slings etc must be included 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 forces even with tag lines Do not try to use the telehandler s dumping function to return the load to horizontal position ...

Page 17: ...ot ballast the tires Always wear the seat belt Do not hang your head your arms your hands your legs or any other parts of your body out of the cab If the telehandler starts to tip over Stay in the machine cabin Keep your seat belt fastened Hold on tightly Lean away from the point of impact Trying to escape from a tipping machine could result in death or serious injury ...

Page 18: ...t with electrical current Never operate the handler in an area where overhead power lines overhead or underground cables or other power sources may exist without ensuring that the appropriate utility company has de energized the lines Maintain a minimum safe distance with regard to power lines and electrical devices Respect the local rules and the minimum safety distance from power lines Electric ...

Page 19: ...A B C D E F G H I 19 4000328140 E01 15 AUS Telescopic handlers A Safety precautions Minimum safety distance For AS standard only ...

Page 20: ...er in 4 steer wheels mode Look out for and avoid other personnel machinery and vehicles in the area Always obtain assistance from a guide on the ground when manoeuvring Before moving the machine ensure that there is adequate visibility 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 21: ...deways chassis swaying and lengthways accessory tilt Ensure that there is no one under the accessory Do not lift or transport anyone in the bucket or on the forks Never suspend loads from the forks or from any other parts of the fork carriage Do not drill holes in the fork s Do not heat or weld the forks Do not use the machine to lift one or more people Always ensure that the fork carriage or the ...

Page 22: ... maintain sufficient traction and braking capabilities travel on slopes as follows When the machine is unloaded the rear of the machine is the heavy end Drive with the forks pointed downhill When it is loaded the front of the machine is the heavy end Drive with the forks pointed uphill To avoid the machine racing on slopes downshift to a lower gear and use the service brake as necessary to maintai...

Page 23: ...ing parts 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 arms and hands clear of the attachment tilt cylinder Keep hands and fingers clear of the fork carriage and the forks Keep others away during operation ...

Page 24: ...ic gases Do not operate the machine in an enclosed area without proper ventilation Sparks produced by the electrical system or the engine exhaust can cause an explosion Do not fill the fuel tank or service the fuel system near a naked flame sparks or smoking material Engine fuel is flammable and can cause a fire and or an explosion Do not attempt to repair or tighten any hydraulic hoses or fitting...

Page 25: ...th applicable 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 operator must read and understand the contents of this manual and the labels affixed on the machine The operator must inform the owner or hirer if the manual or any labels are missing or in poor c...

Page 26: ...fied 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 Periodical preventive maintenance At the specified intervals 250 hours or 1 year Owner or hirer On site technician or qualified HAULOTTE Services technician Operator s manual Section H Lubrication and mai...

Page 27: ...eir 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 if necessary No missing or loose parts bolts nuts connectors cables etc Absence of cracks broken parts damaged paint No deformations or other anomalies on the structure s parts Example State of the...

Page 28: ...ge Back to neutral for all joysticks selectors etc Presence and readablility of the control box labels Movement safety limit switches No damage No missing or loose bolts Absence of foreign objects on all surfaces The state and connection of the electric wires and cables No damage wear marks or other faults No contact between connectors State of the tanks No leaks No missing or loose parts bolts nu...

Page 29: ...or loose bolts Absence of foreign objects on all surfaces Grease the extension system if necessary A walk around inspection must be performed at the beginning of each work shift or at each change of operator Ensure that all safety labels are legible and in place Clean or replace if necessary Section C 2 Labels Before removing the filler plugs wipe all dirt or grease away from the ports Dirt enteri...

Page 30: ... 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 are no visible leaks or excessive wear in addition to any other criteria mentioned Inspect all structural elements including the attachment for cracks excessive corrosion and other damage 7 1 2 22 15 15 16 17 18 19 20 21 3 9 10 1...

Page 31: ... General appearance no visible damage capacity charts and Operator Safety manual loca ted in the manual holder Window glass in good condition and clean Gauges switches joystick parking brake pedals and horn all operational Check the seat belt for damage replace it if it is frayed or the webbing is cut the buckles are damaged or the mounting hardware is loose or damaged Check for the presence of th...

Page 32: ... that the engine calculator has not been damaged impact deterioration etc 2 19 Mirrors Clean in good condition and working properly 20 Wheel Tyre assembly No loose or missing wheel nuts inflated correctly Check the state of the tyres and their level of wear 21 Tilt correction cylinder Pins secure hydraulic hoses in good condition no leaks on HTL3510 and HTL3010 only 22 Right hand stabiliser and co...

Page 33: ... in place Clean or replace if necessary 3 1 RED LABELS Common labels AS standard The red labels indicate a potentially fatal danger R27 R13 R28 R29 R42 It is prohibited to use attachments without appropriate load charts Interdiction d utiliser les accessoires sans leurs abaques de charges correspondants Prohibido utilizar accesorios sin el abaco de carga correspondiente 307P223840B ...

Page 34: ... controls Specific labels HTL 4010 AS standard Specific labels HTL 3510 AS standard Specific labels HTL 3010 AS standard 307P228350 a 6100 daN 4 2 daN cm R9 R10 307P228360 a 6400 daN 7 5 daN cm 307P228710 a 6200 daN 4 6 daN cm R9 307P228710 a 6200 daN 4 6 daN cm R9 ...

Page 35: ...ESEL LOW SULFUR OR ULTRA LOW SULFUR DIESEL À FAIBLE OUTRÈS FAIBLETENEUR EN SOUFRE GASÓLEO BAJO EN AZUFRE O ULTRA BAJO EN AZUFRE DIESEL A BASSOTENORE DI ZOLFO O A BASSISSIMOTENORE DI ZOLFO DIESELKRATSTOFF MIT NIEDRIGEM ODER EXTREM NIEDRIGEM SCHWEFELGEHALT EU EN590 US ASTMD975 91class2D CAUTION 307P232480 b J32 4 0 0 0 0 1 9 7 0 0 a A PI CJ 4 A EC A E 9 SAE 10W 40 15W 40 J45 4 0 0 0 3 1 8 6 8 0 a A ...

Page 36: ...36 4000328140 E01 15 AUS Telescopic handlers C Pre operation and controls Specific labels HTL4010 HTL 3510 HTL 3010 AS standard Specific labels optional AS standard J18 J29 J30 ...

Page 37: ... 7814 870 LWA dB 104 A42 A73 307P228370 a 4010 EN 1459 annexe B 4T réf 194P287760 réf 194P273050 réf 194P306620 réf 194P306610 307P228860a rp H T L 4 0 1 0 0m 0m 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 7 2 A B C D E F 0 10 20 30 40 50 60 68 1200Kg 1500Kg 1800Kg 2000Kg 2500Kg 3000Kg 3500Kg 4000Kg 0 5 m 0m 1 1 7 1 9 2 2 3 7 4 2 6 1 7 2 3 5 0m 1 2 3 4 5 6 7 8 9 10 A B C D E F 0 2 10 20 30 40 50 60 2500Kg ...

Page 38: ...r of manufacture Serial No Gross Vehicle Mass Unladden Mass Gross combined weight rating Maximum load on front axle kg Maximum load on rear axle kg kg Maximum Capacity kg kg kg Design Standard Compliance AS1418 19 A73 A42 A4 Standard used AS1418 19 fork load centre 600mm D RUNV 3 1 3 3 3 0D LPXP FDS NJ 10 9 8 7 6 5 4 3 2 1 0 m 1 0 m 7 2 4 8 4 2 3 5 2 5 2 1 2 5 8 0 6 m 0 2 10 20 30 40 50 60 65 A B ...

Page 39: ...and controls 3 4 IDENTIFICATION Locations HTL 4010 HTL 3510 HTL 3010 Standards CE and AS J21 R29 A16 J21 A4 A41 A46 A45 A47 A48 A49 A50 A51 J21 R13 R10 J4 J20 A30 A95 J21 A98 A96 A10 A5 J21 J21 J3 J21 A43 A6 R27 A95 A30 A7 A42 A39 A76 A75 J31 R10 R13 J3 J19 R29 A16 A4 R28 A44 A95 ...

Page 40: ... 4000328140 E01 15 AUS Telescopic handlers C Pre operation and controls VUE COTE CABINE CAB VIEW COMPARTIMENT CABINE CAB COMPARTMENT VUE COTE MOTEUR ENGINE VIEW COMPARTIMENT MOTEUR ENGINE COMPARTMENT A94 ...

Page 41: ...ng key C 1 307P222630 Other A49 Telescoping key D 1 307P222640 Other A50 Telescoping key E 1 307P222650 Other A51 Telescoping key F 1 307P222660 Other A73 Capacity chart booklet 1 107P345780 107P347640 4000059330 Other A75 Safe Use 1 AS standard only 307P232430 Other A76 Electrocution 1 AS standard only 307P226440 Other A90 Anchor points on the machine 4 307P216800 Other A96 Read the operation man...

Page 42: ...d R13 Risk of crushed feet 2 307P220890 Red R27 Danger of electrocution 1 307P220770 Red R28 Cylinder locking 1 307P220860 Red R29 Do not mount on the forks during elevation 2 307P221950 Red R42 Label book 1 307P223840 Color Marking Description Quantity HTL4010 HTL3510 HTL3010 ...

Page 43: ...city chart Boom 2 5 m On wheels 1 307P232050 Other Load capacity chart Boom 2 5 m On stabilisers 1 307P232060 Other Load capacity chart Boom 4 m On wheels 1 307P232070 Other Load capacity chart Boom 4 m On stabilisers 1 307P232080 Other Load capacity chart Winch 1 2 T On wheels 1 307P232110 Other Load capacity chart Winch 1 2 T On stabilisers 1 307P232120 Other Load capacity chart Winch 2 4 T On w...

Page 44: ... 1 4000059340 Other Load capacity chart Drift side offset 1 4000059350 Other Load capacity chart Bucket 1 4000059360 Other Load capacity chart Jib crane 1 m 3 T 1 Other Load capacity chart Jib crane 1 m 2 9 T 1 4000062220 Other Load capacity chart Hook 1 m 2 9 T 1 4000062200 Other Load capacity chart Jib crane 2 m 2 T 1 4000059420 Other Load capacity chart Boom 2 5 m 1 4000059370 Other Load capaci...

Page 45: ...achine unless the overhead guards and the cab structure are in good condition Any modifications to this machine must be approved in writting by HAULOTTE to ensure complience with FOPS ROPS certification for this cab machine configuration The cab cannot be repaired if it is damaged It must be replaced C122 C123 C124 C127 C130 C135 C102 C126 C125 C142 C129 C128 C150 C120 C121 C141 C153 C134 C133 C13...

Page 46: ... 5 3 Steering column C125 Transmission control lever Section C 2 5 3 Steering column C126 Headlight indicator and buzzer control C127 Indicator and control box Controls and indicates certain machine functions Displays engine speed Section C 2 5 7 Instrument control panel C128 Fuel gauge Indicates fuel level in tank C129 Engine temperature gauge C130 Joystick Section C 2 5 8 Joystick C131 Load mome...

Page 47: ...01 15 AUS Telescopic handlers C Pre operation and controls 3 5 2 Pedals General view Pedals Marking Description Function P163 Accelerator Pedal for increasing the engine speed P164 Brake Machine braking Inching Slow approach P164 P163 ...

Page 48: ...elector 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 change of direction could destabilise the machine and or cause the load to tip over or fall When reverse drive is activated a audible sound warns that the machine is in reversing mode and warns of potent...

Page 49: ...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 adjusting the steering column A sudden change of direction could destabilise the machine and or cause the load to tip over or fall Failure to comply with these instructions could result in death or seriou...

Page 50: ...e 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 weight In the green zone Suspension is adapted to the operator s weight In the red zone The suspension is not adapted to the operator s weight Backrest Use the button P174 to adjust the backrest angle Seat belt Always fasten the seat b...

Page 51: ...nd ventilation 3 5 6 Air conditioning Optional To activate the air conditioning operate the switch P207 located on the lateral control console Adjust the fan speed Adjust the air flow using the air locks and round vents Do not operate the Telehandler for an extended period without ventilating the cab via the ventilation system Always ensure proper ventilation A lack of proper ventilation in the ca...

Page 52: ...52 4000328140 E01 15 AUS Telescopic handlers C Pre operation and controls 3 5 7 Instrument control panel P222 P199 P198 P221 P200 P201 P214 P213 P215 P204 P203 P207 P208 P209 P205 P223 ...

Page 53: ...to right and hold Emergency pump in platform mode Option Operation of the emergency pump Rotate to right and hold P199 3 position ignition key Position 0 Machine shutdown Position 1 Ignition Position 2 Starter P221 Fork Winch Platform Selector Option Fork position Center Winch position Rotate to left Aerial lift position Turn right P222 Radio control selector Cab selector Option Radio control posi...

Page 54: ...gine pre heating LED On Engine pre heating P189 Hydraulic oil filter LED On Hydraulic oil filter clogged P190 Service brake fault LED On Service brake fault or parking brake engaged P191 Machine fault indicator Flashing One or more faults detected and or active OR machine maintenance to be performed 3 P192 Rear axle alignment LED On Rear wheels aligned P193 LED floating Option On Activated Flashin...

Page 55: ...g 7 The particulate filter is clogged 8 Description of fault codes Section H 21 Troubleshooting P227 Particulate filter regeneration disabled indicator For machines fitted with engine PERKINS 854E 34TA only On Automatic particulate filter regeneration disabled P228 High exhaust gas temperature indicator HEST For machines fitted with engine PERKINS 854E 34TA only On Particulate filter regeneration ...

Page 56: ...56 4000328140 E01 15 AUS Telescopic handlers C Pre operation and controls Right hand control panel General view P213 P205 P215 P214 P209 P208 P207 P201 P200 P203 P204 ...

Page 57: ...left stabiliser Press top of switch downwards P209 Right stabiliser switch Right stabiliser lowering Press bottom of switch downwards Right stabiliser lifting Press top of switch downwards P213 Beacon switch On Press top of switch downwards Off Press bottom of switch downwards P214 Parking brake switch 2 Activated Press top of switch downwards Deactivated Press bottom of switch downwards P215 Road...

Page 58: ...he stabilizer LED P208 and P209 also flash Once the conditions are met indicator P215 comes on and driving is enabled at high and low speeds 1 For high speed driving and any driving on public roads Only use the Front steer wheels mode Check the alignment of the rear wheels The Rear wheels aligned indicator P192 must be switched on Axles must be realigned At the start of each day At least once a da...

Page 59: ...ick to the right Keeping pressed the back trigger in the joystick Crowding Push the joystick to the left Keeping pressed the back trigger in the joystick To telescope out Push the left rocker switch upwards Keeping pressed the back trigger in the joystick To telescope in Push the left rocker switch downwards Keeping pressed the back trigger in the joystick Auxiliary direction A Push the right rock...

Page 60: ...on 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 and push the joystick towards the right and then backwards Lifting of the 2 stabilisers Press the low button and pull the joystick backwards Marking Description Function P211 Joystick Button High Float option ...

Page 61: ...s minimum Particulate filter regeneration disabled mode compulsory in areas with explosive atmosphere The P227 indicator lights up Press upwards a second time and hold for 2 seconds minimum Reactivation of particulate filter regeneration mode compulsory in areas with explosive atmosphere The P227 indicator goes off Press downwards Start of forced particualate filter regeneration Press downwards an...

Page 62: ...ion can exceptionally be interrupted in the following ways Pressing the accelerator pedal Parking brake deactivation P214 Translation activated in forward or reverse Engine switched off using the ignition key DANGER OF BURNS During regeneration the temperature of the exhaust gases is high and may reach 650 C 1202 F Always start the engine and run it in a well ventilated area If the engine is in an...

Page 63: ...ance In all cases the load capacity chart supplied in the cab is the only reference which may be used to define load capacity and ensure that the machine operates correctly Even a lit green LED does not authorise the machine to be used without the load chart or the load capacity to be moved Marking Description Function P216 Green LED s Loading percent P217 Yellow LED Pre alarm intermittent buzzer ...

Page 64: ... the Telehandler in all position For details refer to the supplementary manual supplied with the Telehandler Movement Fork mode Winch mode Booms raising Authorized Prohibited Boom lowering Deactivated if the alarm sounds but can be activated with the exclusion key Prohibited Crowding Deactivated if the alarm sounds but can be activated with the exclusion key Prohibited Discharging Deactivated if t...

Page 65: ... Rear view mirrors and windows Cab door window Rear window The window must be blocked in open or closed position during use Open the cab door window and block it with the locking mechanism Press the unlocking button in the cab to unlock the window Pull the lever and push to open the rear window 1 2 ...

Page 66: ...copic handlers C Pre operation and controls Rear view mirror adjustment The machine is fitted with 5 mirrors Locations Visibility zone Description of the components Mirrors Visibility in zone 1 A 2 B 3 C 4 D 5 E 1 2 3 4 5 C A B D E ...

Page 67: ...or on the axle on which it is fitted Adjust the rear view mirrors as required for optimal visibility before and during use Ensure that rear view mirrors are clean and clear at all times Before each use of the machine ensure that the mirrors are not damaged Any modifications to this machine can affect the visibility in driving position ...

Page 68: ...onfirm the movement 1 Move to the left Clockwise rotation Press the joystick to activate and confirm the movement 1 Move to the right Counter clockwise CCW rotation P235 Power switch Position 0 De energizes control system Position 1 Energizes control system P236 Buzzer push button Remote control validation 2 Buzzer Remote control validation P237 Weighing indicator Anti tipping system Permanently o...

Page 69: ...then operate the joystick without having to hold it down Movement validation is cancelled if the joystick returns to neutral position for longer than 5 s 2 The 2 joysticks P145 and P234 must be in neutral position in order to validate switching on of the remote control P242 Electrical connector Electrical connection of the remote control Marking Description Function ...

Page 70: ...ments can be limited or forbidden to preserve the operator s safety Overload If the load on the accessory is greater than the maximum authorised load no movement is possible using the remote control Movements which could worsen the situation are prevented Arm lowering unless the telescope is retracted To telescope out The weiging indicator P237 flashes and an intermittent audible signal warns the ...

Page 71: ...til the pre heating light P188 goes off before starting the engine The following LEDs should light upon start up and then go off again Parking brake LED P182 possible if deactivated for a prolonged period Battery LED P180 Service brake fault LED P190 possible if deactivated for a prolonged period When the machine is switched on ignition key in position 1 the warning light P220 comes on for one sec...

Page 72: ... 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 follows Never allow the vehicles to come into contact with each other Connect the terminal of the discharged battery to the terminal of the booster battery Connect the terminal of the back up battery to the termin...

Page 73: ... for 30 s Stop the engine Turn the ignition key to the left to position 0 Remove the ignition key Exit the machine correctly Block the wheels if necessary Switch off the battery disconnector located under the cab on the left of the steps 1 6 PARKING BRAKE OPERATION At speeds under 5 km h 3 1 mph pressing the switch P214 automatically activates the parking brake When the parking brake is activated ...

Page 74: ... 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 with suspended load Only use approved lifting devices rated for the lifting of the load Section E Attachments Identify the proper lifting points of the load taking into consideration the center of gravity and load...

Page 75: ... the operator at all times Only transport the load at walking speed 0 4 m s or less 2 4 DUMPING PROCEDURE Position the machine in the best location for lifting or placing the load Disable drive mode and drive at a speed lower than 5 km h 3 1 mph Place the boom attachment at less 30 Check the level gauge to determine if the machine must be levelling and to do it with the switch P200 For HTL3010 351...

Page 76: ...ght 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 must be placed and then extend the boom slowly until the load is just above the area where it must be placed Lower the boom until the load rests in position and the forks can be retracted 2 7 DISE...

Page 77: ...e 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 bucket remove the carriage forks Raise the stabilisers If the rear wheels are not in line with the chassis move them back slowly to a neutral position Actuate the road switch P215 Empty the bucket If equip...

Page 78: ...ral stop the engine and remove the ignition key To secure the machine to the deck pass chains through the designated tie downpoints as illustrated in the figure Do not tie down the front of the boom N B The user is fully responsible for choosing the proper method of transportation and the tie down devices Ensure that the equipment used is able to support the weight of the vehicle to be transported...

Page 79: ... the maneuvers 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 machine may slide which could result in serious injury or death A 2 lifting straps length 3200 50 mm B 2 lifting straps length 4000 Keep different length between A and B Caution to lifting ma...

Page 80: ...80 4000328140 E01 15 AUS Telescopic handlers D Operation ...

Page 81: ...t The machine may not be equipped with the relevant capacity chart or the 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 themselves with the test procedures for the specific attachments they have for the Telehandler The user is responsible for carryi...

Page 82: ...ssory load capacity chart installed on the telehandler Failure to install the relevant HAULOTTE supplied capacity chart could cause an accident resulting in death or serious injury Serial number L Volume SAE Capacity Wind speed max Kg lbs lbs Weight K m s g Manufacture date Accessory type HAULOTTE GROUP La Péronière BP9 42152 L HORME FRANCE 307P222900 c Part number Part number Serial number Manufa...

Page 83: ...ced The 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 indicator On the capacity chart for a given load find the area corresponding to the key and follow it to the permitted reach The number that appears in the load capacity range must be equal t...

Page 84: ...84 4000328140 E01 15 AUS Telescopic handlers E Attachments Boom extension indicators 400 400 400 400 400 400 400 ...

Page 85: ...used when lifting a load with the stabilisers lowered All of 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 centred on the forks appropriately sized tires being inflated correctly and the telehandler being in good working condition Failure to comply with...

Page 86: ... 4409 lb 4 5 m 14 ft9 in 8 m 26 ft24 in Yes 2 3200 kg 7056 lb 5 m 16 ft40 in 7 m 22 ft96 in No 3 3000 kg 6615 lb 3 m 9 ft84 in 5 m 16 ft40 in Yes Example The weight of the load to be lifted Distance Height Lifting authorised 4 1200 kg 2646 lb 3 m 9 ft84 in 9 m 29 ft52 in Yes 5 1000 kg 2204 lb 6 m 19 ft68 in 6 m 19 ft68 in No 6 800 kg 1764 lb 5 5 m 18 ft1 in 4 m 13 ft12 in No Standard used AS1418 1...

Page 87: ...2 3 4 5 6 7 8 9 10 A B C D E F 2000Kg 1500Kg 1000Kg 800Kg 500Kg 200Kg 4 0 0 0 K g 3 0 0 0 K g 0 6 m 0m 0m 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 7 2 A B C D E F 0 10 20 30 40 50 60 68 1000Kg 1500Kg 2000Kg 2500Kg 3000Kg 4000Kg 0 6 m Standard used AS1418 19 fork load centre 600mm 3 D RUNV 3 1 3 3 3 0D LPXP FDS NJ 10 9 8 7 6 5 4 3 2 1 0 m 1 0 m 7 2 4 8 4 2 3 5 2 5 2 1 2 5 8 0 6 m 0 2 10 20 30 40 50 60 65 A B...

Page 88: ...s Length Width Weight 1200 mm 125 mm 80 kg 1200 mm 100 mm 65 kg Standard used AS1418 19 fork load centre 600mm D RUNV 3 1 3 3 3 0D LPXP FDS NJ 10 9 8 7 6 5 4 3 2 1 0 m 1 0 m 7 2 4 8 4 2 3 5 2 5 2 1 2 5 8 0 6 m 0 2 10 20 30 40 50 60 65 A B C D E F 500 kg 800 kg 1000 kg 1500 kg 2000 kg 2500 kg 2990 kg HTL 3010 ...

Page 89: ...b 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 Attachment pin recess C145 Attachment pin C146 Lock pin C147 Retainer pin Always ensure that the fork carriage or the accessory is correctly positioned on the boom secured by 2 locking pins and held in pla...

Page 90: ...the boom is below 15 The hydraulic adaptation kit connection is carried out with the machine stopped Connect the hoses from the hydraulic adaptation kit to the push pull sockets on the tool holder carriage To unlock the tool holder carriage press the locking button for at least 2 s and hold down Releasing the button locks the attachment Do not press on the locking button for longer than 2 s when t...

Page 91: ...10 tilt the 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 changed out Place the forks on the ground Remove the fork pin Change out the forks and place them in position Change out the fork pins and their retaining mechanisms Using forks The machine s cap...

Page 92: ...ituated behind the cab seat with the telehandler operator manual Floating forks carriage Attachment reference 194P287760 194P306620 Mass 290 kg 639 lb Dimensions of pallet forks Section Standard 0 125 m 41 in X 0 050 m 2 in Section Option 0 100 m 40 in X 0 050 m 2 in Length 1 2 m 4 ft0 in Nominal capacity 4000 kg 8819 49 lb If the capacity of the machine is less than 4000 kg 8819 49 lb respect the...

Page 93: ...940 Width 1 25 m 4 ft10 in Mass 390 kg 860 lb Dimensions of pallet forks Section 0 125 m 41 in X 0 045 m 1 7 in Length 1 2 m 4 ft0 in Lateral movement 100 mm in relation to the central position Nominal capacity 3000 kg 6614 lb User pressure 180 bar 2610 67 psi Maximum admissible pressure 220 bar 3190 83 psi Minimum flow 50 l min Standard FEM3A ...

Page 94: ...apacity 1140 l 301 gal Width 2 4 m 7 ft10 in Mass 465 kg 1025 lb Toothed bucket Attachment reference 2820302820 Nominal capacity 1140 l 301 gal Width 2 4 m 7 ft10 in Mass 595 kg 1312 lb 4 in 1 bucket Hydraulic kit Attachment reference 2820302830 Nominal capacity 850 l 225 gal Width 2 4 m 7 ft10 in Mass 636 kg 1402 lb ...

Page 95: ...achment reference 4000023260 Nominal capacity 4000 kg 8820 lb Mass 72 kg 159 lb 3 T 6615 lb 1 m 3 ft3 in jib crane Attachment reference 2820305490 Nominal capacity 3000 kg 6615 lb Mass 141 kg 311 lb 2 T 4410 lb 2 m 6 ft7 in jib crane Attachment reference 4000016740 Nominal capacity 2000 kg 4410 lb Mass 205 kg 452 lb ...

Page 96: ...ft1 in 0 6 T 1323 lb on telescopic arm Attachment reference 2820304090 2820304090 Nominal capacity 600 kg 1323 lb Mass 276 kg 609 lb Fly jib 2 5 m 8 ft2 in 1 2 T 2646 lb with hydraulic winch Attachment reference 2820304120 Nominal capacity 1200 kg 2646 lb Mass 310 kg 684 lb Fly jib 4 m 13 ft1 in 0 6 T 1323 lb with hydraulic winch Attachment reference 2820304130 Nominal capacity 600 kg 1323 lb Mass...

Page 97: ...ndlers E Attachments Winch 1 2 T 2646 lb Hydraulic kit Attachment reference 2820304100 Nominal capacity 1200 kg 2646 lb Mass 190 kg 419 lb Winch 2 4 T 5292 lb Hydraulic winch Attachment reference 2820304110 Nominal capacity 2400 kg 5292 lb Mass 190 kg 419 lb ...

Page 98: ... precautions Incorrect installation could result 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 this accessory The machine must not be used without the capacity chart booklet All the loads indicated on the nominal capacity chart load chart booklet as...

Page 99: ...AULOTTE Services 1 Unscrew each pressure relief valve by 3 turns before towing The maximum travel speed permitted for towing is 6 km h 4 mph The towing distance should not exceed 300 m 984 ft4 in Turn on ignition key and start up engine Deactivate the parking brake When the parking brake is released the machine can be towed Towing must only be performed when the machine has broken down and once th...

Page 100: ...the Telehandler Block the four wheels again The machine can be towed Section F 1 1 Towing a broken down vehicle 1 2 2 Parking brake reactivation Tools required Spanner 19 When the four wheels are properly blocked Loosen the 4 screws from 18 mm to 21 mm Tighten the lock nuts The parking brake can then be reactivated and the front wheels blocked Remove the chocks from the four wheels Check that the ...

Page 101: ...ible with telehandler stability Block the boom in position with another machine a crane or 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 locknut and rescrew the stop screw fully into its socket 1 Take off the cover located under the counterweight at th...

Page 102: ...lace the counternut and rescrew the assembly fully into its socket Check that 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 rear window Secure the boom into position before any interventions on the counter balance valve Release the stop 1 upwards Push t...

Page 103: ... a continuous improvement policy in place for its product range Given this policy The Company reserves the right to modify their product technical characteristics without notice Engine Model Perkins 1104D44T Perkins 854E 34TA Wall Flow DPF Kohler KDI 3404 TCR Type Four stroke water cooled Cubic capacity 4400 cm3 268 50 cu in 3400 cm3 207 48 cu in 3359 cm3 204 97 cu in Intake Turbo Power 70 kW 94 H...

Page 104: ...ing system Inner turning radius on tyre 2550 mm Outer turning radius on tyre 4800 mm Electric circuit Model Perkins 1104D44T Perkins 854E 34TA Wall Flow DPF Kohler KDI 3404 TCR Operating voltage 12 V 12 V 12 V Battery 110 Ah 110 Ah 110 Ah Alternator 100 A 100 A 90 A Starter 3 2 kW 4 3 Hp 3 2 kW 4 3 Hp 3 2 kW 4 3 Hp Filling capacity Fuel tank 120 l 32 gal US Hydraulic oil tank 103 l 27 gal US Front...

Page 105: ...ut off and sound signal with automatic 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 Adjustable steering column Power steering Metal protection above cab Sun visor Left and right exterior rearview mirrors Hour meter Boom angle indicator Mudguards Stabilisers in t...

Page 106: ...under dynamic and static load in horizontal position 1 3 1 3 Control The joystick P211 controls movements of the boom and the option tilt Section C 2 5 8 Joystick Operator s manual Slings attached Option number 4000072600 Nominal capacity 3T 6 615 lb Marking Description 1 Tool holder carriage 2 Shackle 3 Hook 4 Overload limitation label The safety coefficient used is in compliance with the legisla...

Page 107: ...n and maintenance Do not use slings attached For pulling loads laterally Under conditions of repeated cyclic fatigue i e fast running on a bumpy surface This option is designed for load lifting necessarily in horizontal position When using the jib it is forbidden to use the carriage tilt down or up while there is a load on the jib It is strictly forbidden to move the load drive the telescopic hand...

Page 108: ... Feet inch A 5 14 16 ft 10 in 5 14 16 ft 10 in B 2 25 7 ft 5 in 2 25 7 ft 5 in C 2 42 7 ft 11 in 2 42 7 ft 11 in 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 in 1 66 5 ft 5 in K 39 39 L 23 23 M 103 103 N 2 55 8 ft 4 in 2 55 8 ft 4 in O 4 80 15 ft ...

Page 109: ...Imperial Metric Imperial Vehicule mass without accessory 8440 kg 19 492 lb 8300 kg 18 302 lb Vehicule mass with bucket 9040 kg 19 933 lb 8910 kg 19 647 lb Vehicule mass with fork 8740 kg 19 272 lb 8610 kg 24 321 lb Total weight allowed on road 9750 kg 28 665 lb 9450 kg 18 985 lb Total weight allowed in load Gross vehicle weight rating 12730 kg 28 07 lb 12300 kg 27 122 lb HTL3010 Metric Imperial Ve...

Page 110: ...2 3 5 0m 1 2 3 4 5 6 7 8 9 10 A B C D E F 2000Kg 1500Kg 1000Kg 800Kg 500Kg 200Kg 4 0 0 0 K g 3 0 0 0 K g 0 6 m 0m 0m 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 7 2 A B C D E F 0 10 20 30 40 50 60 68 1000Kg 1500Kg 2000Kg 2500Kg 3000Kg 4000Kg 0 6 m Standard used AS1418 19 fork load centre 600mm 3 D RUNV 3 1 3 3 3 0D LPXP FDS NJ 10 9 8 7 6 5 4 3 2 1 0 m 1 0 m 7 2 4 8 4 2 3 5 2 5 2 1 2 5 8 0 6 m 0 2 10 20 30 40 5...

Page 111: ...UNV 3 1 3 3 3 0D LPXP FDS NJ 10 9 8 7 6 5 4 3 2 1 0 m 1 0 m 7 2 4 8 4 2 3 5 2 5 2 1 2 5 8 0 6 m 0 2 10 20 30 40 50 60 65 A B C D E F 500 kg 800 kg 1000 kg 1500 kg 2000 kg 2500 kg 2990 kg HTL 3010 ANSI ITSDF B56 6 2005 PART III D RUNV 3 1 3 3 3 0D LPXP FDS OEV 2 ft 2 10 30 40 50 60 65 A B C D E F 1100 lbs 1760 lbs 2200 lbs 3300 lbs 4400 lbs 5500 lbs 7700 lbs HTL 7732 IW IW IW IW IW IW IW IW IW IW I...

Page 112: ...34TA only Technical characteristics For machines fitted with engine KOHLER KDI 3404 TCR only The sound power values indicated in the technical characteristics tables are obtained in the following conditions For machines equipped with internal combustion engines the guaranteed accoustic level LWA displayed on the product and is measured in accordance with the method and the conditions described in ...

Page 113: ...nd conditions described in standard ISO5349 1 and ISO2631 1 Technical characteristics The hand and feet vibration values indicated in the technical characteristics tables are obtained in the following conditions The maximum quadratic mean value weighted as an acceleration frequency and the total value of the vibrations to which the hand arm system is exposed have been measured on the products by s...

Page 114: ...114 4000328140 E01 15 AUS Telescopic handlers G Technical characteristics ...

Page 115: ...aps and the 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 of the filling plug seals do not forget to replace them if they are damaged or worn Maintain the Telehandler and associated equipment especially the brakes and the steering in good condition ...

Page 116: ...ressure The pressure is regulated by the radiator cap Before operate maintenance operation on hydraulic component or component localized under the boom use safety prop as follow Place the boom to 24 25 without load and machine on wheels Put the safety prop in the boom in the same way that it is shown in the picture it is prohibited to lift up or lift down the boom with the safety prop placed Proce...

Page 117: ... system is under high pressure For any operations or adjustments please contact a qualified technician or your dealer Failure to comply with these guidelines can result in serious injury Protective equipment must be worn when performing any service repair on the machine Do not use your hands to check for oil leaks Search for leaks with a piece of cardboard or paper Do not intervene on the air cond...

Page 118: ...ing a very low sulphur content If the ASTM D5453 ASTM D2622 or ISO 20846 ISO 20884 test methods are used the level of sulphur in the low sulphur content diesel fuel must be less than 15 ppm mg kg or 0 0015 by weight Using diesel fuel containing more than 15 ppm of sulphur in these engines may damage the anti pollution control systems sometimes irreversibly or reduce the service frequency Engines F...

Page 119: ...nt Please refer to the table of permitted engine oils Not using the appropriate specification of engine oil may reduce the service life of the engine and post treatment system Engines Engine oil specification PERKINS 854E 34TA Wall Flow DPF API CJ 4 ACEA E9 ECF 3 KOHLER KDI 3404 TCR API CJ 4 ACEA E9 ACEA E7 ACEA E6 CC CD CD 2 CF 4 CG 4 CH 4 CI 4 engine oils not approved must not be used 4 0 0 0 0 ...

Page 120: ...the temperatures are high Glycol in the coolant helps to provide protection against the following conditions Boiling Freezing Cavitation of the water pump Coolant service life 1 Use the interval that occurs first The cooling system must also be flushed out at this time Coolant type Service life 1 Commercial heavy duty antifreeze that meets ASTM D6210 Every 3000 hours of operation or every 2 years ...

Page 121: ...repairs or adjustments on the safety 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 specified above is not performed by HAULOTTE approved staff or if the spare parts are not original spare parts ...

Page 122: ...122 4000328140 E01 15 AUS Telescopic handlers H Lubrication and maintenance 4 Lubrication and maintenance schedule 50h 10h 500h ...

Page 123: ... I 123 4000328140 E01 15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine PERKINS 1104D44T 1500h 2000h 1000h 500h 200h 100h 10h 1500h 2000h 1000h 500h 100h 10h 5 5 50h 50h 2 250h 4 ...

Page 124: ...140 E01 15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine PERKINS 1104D44T 1500h 2000h 1000h 500h 100h 10h 1500h 2000h 1000h 500h 100h 10h 1 2 2 6 6 7 7 50h 50h 250h 8 3 250h ...

Page 125: ...s H Lubrication and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change 1 Lubrication 2 Diesel circuit 3 Cooling system 4 Air filter system 5 Internal combustion engine 6 Travel axles 7 Hydraulic circuit 8 Battery ...

Page 126: ...0328140 E01 15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine PERKINS 854E 34TA 1500h 2000h 1000h 500h 200h 100h 10h 1500h 2000h 1000h 500h 100h 10h 5 5 50h 50h 2 250h 4 ...

Page 127: ...28140 E01 15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine PERKINS 854E 34TA 1500h 2000h 1000h 500h 100h 10h 1500h 2000h 1000h 500h 100h 10h 1 2 2 6 6 7 7 50h 50h 250h 8 3 250h 3000h 3000h ...

Page 128: ...cation and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change 1 Lubrication 2 Diesel circuit 3 Cooling system 4 Air filter system 5 Internal combustion engine 6 Travel axles 7 Hydraulic circuit 8 Battery ...

Page 129: ... 129 4000328140 E01 15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine KOHLER KDI 3404 TCR 1500h 2000h 1000h 500h 200h 100h 10h 1500h 2000h 1000h 500h 100h 10h 5 5 50h 50h 2 250h 4 ...

Page 130: ...15 AUS Telescopic handlers H Lubrication and maintenance For machines fitted with Engine KOHLER KDI 3404 TCR 1500h 2000h 1000h 500h 100h 10h 1500h 2000h 1000h 500h 100h 10h 1 2 2 6 6 7 7 50h 50h 250h 8 3 250h 3000h 3000h ...

Page 131: ...s H Lubrication and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change 1 Lubrication 2 Diesel circuit 3 Cooling system 4 Air filter system 5 Internal combustion engine 6 Travel axles 7 Hydraulic circuit 8 Battery ...

Page 132: ...me 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 Meaning Symbol Meaning Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation Check Test See user manual or machine maintenance book 1 Visual inspection with dism...

Page 133: ...he platform control box sliding bar Cylinders No leaks Refer to the Maintenance book No rust and abrasions on the cylinder rod Absence of foreign objects on all surfaces Steering system Wheels Axles Brake and Tyres No cracks distortions damaged paint or other faults No missing or loose bolts Condition of the tyres cuts excessive wear etc Condition of the pulley system No excessive clearance Refer ...

Page 134: ...ic fitting Operation of the work lighting controls the light indicators display load moment indicator Diesel engine operation State of anti slip parts State of tires and inflation pressure Wheel nut torque Lubrication Cylinder pins Boom bottom shaft Telescopic boom pads Suspension driver seat rails Diesel circuit Condensation Diesel pre filter 1 2 Filter Cooling system Coolant 1 2 3 State of the h...

Page 135: ...ines fitted with Engine KOHLER KDI 3404 TCR Diesel particulate filter 2 Engine crankcase breather 2 Engine mounting Glow plugs Belt tension 1 2 3 Travel axles See manufacturer s guide Front axle Reducer differential transfer case on front axle pivots Rear axle Reducer differential pivots Epicyclic gears Hydraulic circuit Hydraulic oil Attachment hydraulic oil Transmission hydraulic filter Pressure...

Page 136: ...ck Test See user manual or machine maintenance book 1 Visual inspection with dismantling and exchange or replacement if necessary Operation requiring HAULOTTE Services authorisation Increase in periodical inspections Check level Tightening bolt etc Lubrication Lubrication Tolerance clearance lubrication Oil change 2 Static and dynamic tests For countries where machines are not subject to controlle...

Page 137: ...the light indicators display load moment indicator Diesel circuit Diesel engine operation Condensation State of anti slip parts Pre filter 1 2 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 filter cartridge Secondary air filter Belt tension Cooling system Travel axles See...

Page 138: ...ion 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufacturer s guide Radiator slats Front axle Re...

Page 139: ...ent indicator Diesel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine crankcase breather 1 Coolant Travel axles See manu...

Page 140: ...rcuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension 1 2 Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufa...

Page 141: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 142: ...ion driver seat rails State of anti slip parts Diesel circuit State of tires and inflation pressure Condensation Wheel nut torque Pre filter Internal combustion engine See manufacturer s guide Filter Oil Air filter system Oil filter cartridge Remove the dust Diesel particulate filter 1 Primary air filter Alternator belt 1 Secondary air filter Engine crankcase breather 1 Cooling system Belt tension...

Page 143: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 144: ...rcuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension 1 2 Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufa...

Page 145: ...dicator Diesel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine crankcase breather 1 Coolant Travel axles See manufactur...

Page 146: ... 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension 1 Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufacturer s guide Radiat...

Page 147: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 148: ...river seat rails State of anti slip parts Diesel circuit State of tires and inflation pressure Condensation Wheel nut torque Pre filter Internal combustion engine See manufacturer s guide Filter Oil Air filter system Oil filter cartridge Remove the dust Diesel particulate filter 1 Primary air filter Alternator belt 1 Secondary air filter Engine crankcase breather 1 Cooling system Belt tension 2 Co...

Page 149: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 150: ...ate 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 filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufacturer s guide Radiator slats Front axle Reducer ...

Page 151: ...dicator Diesel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine crankcase breather 1 Coolant Travel axles See manufactur...

Page 152: ...rcuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension 1 2 Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufa...

Page 153: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 154: ...ion driver seat rails State of anti slip parts Diesel circuit State of tires and inflation pressure Condensation Wheel nut torque Pre filter Internal combustion engine See manufacturer s guide Filter Oil Air filter system Oil filter cartridge Remove the dust Diesel particulate filter 1 Primary air filter Alternator belt 1 Secondary air filter Engine crankcase breather 1 Cooling system Belt tension...

Page 155: ...el circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer differenti...

Page 156: ...moment indicator Diesel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension 1 3 2 Cooling system Engine mounting Coolant Glow plugs Hoses and col...

Page 157: ...ndicator Diesel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine crankcase breather 1 Coolant Travel axles See manufactu...

Page 158: ...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 filter Oil filter cartridge Secondary air filter Belt tension Cooling system Engine mounting Coolant Glow plugs Hoses and collars Travel axles See manufacturer s guide Radiator slats Front axle Reducer...

Page 159: ...sel circuit 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 guide Remove the dust Oil Primary air filter Oil filter cartridge Secondary air filter Belt tension Cooling system Travel axles See manufacturer s guide Coolant Front axle Reducer different...

Page 160: ...river seat rails State of anti slip parts Diesel circuit State of tires and inflation pressure Condensation Wheel nut torque Pre filter Internal combustion engine See manufacturer s guide Filter Oil Air filter system Oil filter cartridge Remove the dust Diesel particulate filter 1 Primary air filter Alternator belt 1 Secondary air filter Engine crankcase breather 1 Cooling system Belt tension 2 Co...

Page 161: ...remities 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 between the pin and housing at 0 5 mm Presence of deformations cracks or breakage of the bearings and or the pins Presence of scoring on the surface of the bearing If there is excessive friction Whe...

Page 162: ... and salinity of 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 Replace the bearing in the following cases Presence of abrasions in the bearing housing and or inside the bearing itself Presence of abrasion wear oxidation deformations of the balls or rollers and the ring ro...

Page 163: ...low the residual hydraulic pressure to dissipate To protect personal safety observe the following conditions when disassembling or reassembling components Stow and park the machine on level cleared ground The machine should not be tilted The boom at horizontal position Stow the machine completely Place barriers around the perimeter of the work area risk area maximum height of the machine Locate th...

Page 164: ... reference point on the attachment and the ground Leave the machine in this condition for 15 mn minutes Check the distance between the reference point on the accessory and the ground again If the difference 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 165: ...he creep of the cylinder rod is higher than the values indicated in the table below replace the cylinder 7 3 ELECTRIC 7 3 1 Replacing damaged cables Locate the faulty wire s and its their points of connection to ensure continuity of machine operation after the wire is replaced Note the cable path to facilitate reassembly Respect the order configuration of origin during the reassembly Type of cylin...

Page 166: ...m indicators Check diesel engine operation Check the colour of the exhaust fumes and locate any abnormal noises Check and clean the radiator s protection grill Check the state of the anti slip parts cab access steps and replace them if necessary Check that the tires are not damaged after the first 10 hours and then after every 100 h of operation Check the wheel lug nut torque 300Nm after the first...

Page 167: ...he system is working properly 8 2 2 Checking procedure Lift a known load with the accessory Telescope until load cut off Check that the results are consistant check that the alphabetical reference A B C D E F for the boom extension and the area corresponding to the reference on the load capacity table match Do not raise the boom during this test Press the TEST button on the anti tipping system dis...

Page 168: ...oom to the maximum height Check the temperature of the axle the temperature of the axle must be between 20 C 4 F and 60 C 140 F The procedure must be carried out without any accessories or load If these conditions are not satisfied the resetting procedure may be distored and cause the weighing system to be offset If a malfunction occurs contact HAULOTTE Services Drain any condensate and clean the ...

Page 169: ... the sensor If red marking is visible Clean or replace the filter element even if the cleaning frequency indicated above has not been reached Clean the inside of the box Do not remove the filling cap when the engine is hot DANGER OF BURNS Loosen the plug to the first notch and let it depressurize then unscrew the cap completely Never run the engine without an air cleaner element installed or with ...

Page 170: ...e inside of the filter outwards or Unclog by tapping Only in the event of an emergency In this case do not damage the cartridge or Wash it in accordance with the manufacturer s guidelines Check that neither the cartridge filter paper translucent paper nor the seal are damaged Replace it them if necessary Replace the filter cartridge Refit the cover checking that the dust evacuation valve is direct...

Page 171: ...e before you turn on the compressor this the heat produced by the engine to turn the liquid coolant accumulated in the lower part of the compressor circuit to turn into gas Liquid coolant could damage the compressor 9 Every 50 h hours of operation Lubricate the cylinder pins equipped with grease points Lubricate the boom bottom shaft Lubricate the sliding area friction pads Check the telescope syn...

Page 172: ...rque 300 Nm N B Perform the first torque check after the first 10 h of operation 10 2 DIESEL CIRCUIT Perform the first diesel pre filter change after the first 500 hours of operation and then after every 500 h or once a year Section H 12 3 Diesel circuit For machines fitted with engine PERKINS 854E 34TA or PERKINS 1104D44T only 10 3 INTERNAL COMBUSTION ENGINE Perform the first engine oil drainage ...

Page 173: ...HE FRONT AXLE Remove the 4 protective caps from each grease point Connect the grease gun 10 5 LUBRICATING THE REAR AXLES Remove the 6 protective caps from each grease point Connect the grease gun Remove the 1 protective caps from each grease point Replace the protective caps once you have lubricated the rear axle ...

Page 174: ...NING OPTION Check cleanliness of the condenser Clean where applicable N B Disassemble the protective covers in order to gain access to clean the condenser unit Check the cleanliness of the cab air filter Clean where applicable The system becomes less efficient when the circuit is being discharged If the air conditioning unit does not work properly have a qualified and properly equipped person exam...

Page 175: ...he 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 11 4 AIR CONDITIONING OPTION Do not remove the filling cap when the engine is hot DANGER OF BURNS Loosen the plug to the first notch and let it depressurize then unscrew the cap completely Only clean with water when the engine ...

Page 176: ...gine canopy to access the diesel filter Loosen the filter cartridge Replace the used cartridge with a new one Close the engine canopy again 12 3 2 Changing the diesel pre filter To access the diesel pre filter open the engine cover Loosen the transparent lower cover Replace the filter Carefully clean the cover Retighten it manually 1 4 turn after contact with the seal Refit the cover N B Perform t...

Page 177: ... the oil if necessary N B Perform the first drainage and the first oil filter cartridge change after the first 500 hours of operation For the following operations park the machine onto a horizontal surface and turn off the engine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Drainage is performed when hot L...

Page 178: ... case 1 25 l 0 33 gal US Front axle 8 l 2 11 gal US Before performing the oil replacement operations firstly remove the drain 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 the same hole Refit the control plugs 1 and the drain plugs 2 Section H 1...

Page 179: ...clean the control plugs 1 and the drain plugs 2 12 6 3 Checking the level of the epicycloidal reducers N B To check the reducer oil level you must move the machine to position the closure plug in the required positions Due to the presence of the differential on each of the axles you will have to repeat this operation individually for each of the machine wheels Capacity 4 x 1 3 l 4 x 0 34 gal US Wh...

Page 180: ...gine 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 situated on the cover 1 Locate the angular position of the cover which should be identical upon reassembly Turn the cover to the right 2 Pull the cover to remove it Turn and pull the outer cartridge Fo...

Page 181: ...engine Open 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 Check the oil level and top up if necessary Close the casing again N B Perform the first filter change after the first 500 hours of operation 13 5 ACCUMULATORS You are advised to check the p...

Page 182: ...e recomended by the manufacturer Perform the first drainage after the first 250 hours of operation 14 1 1 Draining the front axle Capacity Transfer case 1 25 l 0 33 gal US Front axle 8 l 2 11 gal US Before performing the oil replacement operations firstly remove the drain plugs 2 to eliminate any pressure from inside the housing Loosen the drainage plug 4 and let the oil drain out Refit and tighte...

Page 183: ...14 1 3 Draining 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 the differential on each of the axles you will have to repeat this operation individually 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...

Page 184: ... is installed is very important The filter element protects the engine from excessive quantities of oil from entering the induction system The filter element also protects the engine aftertreatment system N B Excessive quantities of oil that enter the induction system of the engine can rapidly increase the engine speed without control 14 1 4 1 Remove the breather element Before performing any inte...

Page 185: ...efore installation Diameter A is visibly larger than diameter B Ensure that all the components are clean and free from damage Install diameter A of the breather element 3 onto the shaft 2 When correctly installed the part number of the breather element will be visible Install circlip 4 and cover 6 Install nuts 7 and tighten to 25 Nm 18 lb ft If necessary install breather pipes to cover Install the...

Page 186: ...ystem thoroughly with water or if necessary with a cleaning product In this case retighten the plug and let the engine run at mid throttle for 10 mn stop the engine and drain the system again Refit the drainage plug Filling the cooling system Remove the filter cap from the expansion bottle filter cap Fill the radiator GRADUALLY until the coolant has reached the correct level Close the expansion bo...

Page 187: ...t to the bottom of the socket provided in the case Place the new primary cartridge above the secondary cartridge insert it in place with a rotation movement near the stop Refit the cover checking that the dust evacuation valve is directed downwards N B Perform the secondary cartridge change every 2 years or after every 5 maintenance operations 15 3 INTERNAL COMBUSTION ENGINE ENGINE PERKINS 1104D44...

Page 188: ... the tank is empty Fill the tank with the recommended oil until the gauge indicates the max level Refit the filling cap 2 Start the engine Actuate the equipment controls in both directions for approx five minutes without placing the cylinders at the stops 2 Place the machine in road position Refer to the Lubricants and equivalents table for the type of oil used Do not mix two oils with different c...

Page 189: ... 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 circuit as this would cause a loss of coolant The cooling circuit contains a gas which under given circumstances may present some risks This gas i e the R 134a coolant is colourless and odourless and heavier than air It is a stable product at n...

Page 190: ...E FILTER ENGINE PERKINS 854E 34TA Have the particulate filter cleaned For all engine maintenance operations Consult the guide provided by the engine manufacturer or HAULOTTE Services All repairs must be carried out by a qualified and authorised person For all engine maintenance operations Consult the guide provided by the engine manufacturer or HAULOTTE Services All repairs must be carried out by ...

Page 191: ... 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 SPEED for approx 2 mn Stop the engine Open the expansion bottle and top up if necessary Before performing any interventions let the engine cool down Remove the filter cap from the expansion bottle filter cap Loosen the drainage plug and let the coola...

Page 192: ...r For all engine maintenance operations Consult the guide provided by the engine manufacturer or HAULOTTE Services All repairs must be carried out by a qualified and authorised person For the following operations park the machine onto a horizontal surface and turn off the engine Never undertake maintenance on the accumulators with the engine running Only begin working on the accumulator 24 h minim...

Page 193: ...Driver seat rails Multi Purpose Grease Moly Oils Front axle and differential 8 l 2 11 gal US SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 Rear axle and differential 8 5 l 2 24 gal US SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 Wheel reducer 1 3 l 0 34 gal US SAE 80W90 MIL L2105 API GL5 ENERGEA R 90 80W90 TRANSELF TYPE 80W90 ESSO GEAR GX SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 ...

Page 194: ...00328140 E01 15 AUS Telescopic handlers H Lubrication and maintenance Axle oil viscosity according to the ambient temperature Engine oil viscosity according to the ambient temperature GREASE GRAISSE OIL HUILE ...

Page 195: ...U117 Fuse 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 in the cab FU183 Fuse for windscreen wiper Fuse for front windscreen washer FU184 Fuse for rear windscreen wiper FU187 Fuse for radio control FU189 Fuse for air conditioning fan FU191 Fuse for...

Page 196: ...alve ON OFF 3 sections HTL4010 8 Valve ON OFF 2 sections HTL3510 9 Brake unit 10 Parking brake accumulator 11 Service brake valve 12 Steering selector valve 13 Pressure switch 90 b 14 Pressure switch 5 b 15 Hydraulic drive engine 16 Hydraulic oil cooler fan motor Hydraulic motor 17 Crowding valve 18 Telescoping valve 19 Outrigger valve HTL4010 20 Lifting valve 21 Boom lift cylinder 22 Boom telesco...

Page 197: ...ectional valve 8 Valve ON OFF 2 sections 9 Brake unit 10 Parking brake accumulator 11 Service brake valve 12 Steering selector valve 13 Pressure switch 90 b 14 Pressure switch 5 b 15 Hydraulic drive engine 16 Hydraulic oil cooler fan motor Hydraulic motor 17 Crowding valve 18 Telescoping valve 20 Lifting valve 21 Boom lift cylinder 22 Boom telescopic cylinder 23 Level compensation cylinder 24 Leve...

Page 198: ...F02 05 D Pre post heating relay fault Check KM160 F03 Relay F03 08 D Start up relay fault Check KA160 F03 09 D Engine power supply relay fault Ignition key Check KA161 F03 12 D PWM supply relay fault Check KA122 F04 Solenoid valves F04 02 D Fork carriage compensation PWM solenoid valve fault Check YV400 or YV420 F04 05 D Boom lifting PWM solenoid valve fault Check YV300 or YV320 F04 06 D Boom tele...

Page 199: ... Check D F07 32 D LMI fault For LMI529 only Check sensor LMI159 F08 Electric circuit F08 04 D ECU power supply fault Check the power supply F08 05 D Voltage 5 V Check the 5 V power supply F09 Engine F09 01 D Engine overheating F09 02 D Low engine oil pressure F09 03 D Presence of water in diesel fuel F09 04 D 1 Clogged air filter F09 07 D 1 Drive motor faulty Check Engine F09 08 D 1 Engine shutdow...

Page 200: ... F13 10 A Neutral position of one of the cab selectors not detected since start up Check the switches in the cab F13 11 A Neutral position of one of the remote control selectors not detected since start up Check the remote control switches F13 12 A 1 Problem with control FAP Check SA161 F14 Driving pump F14 01 D H1 pump fault Check the drive pump F14 02 D Fault on the H1 pump inputs Check the driv...

Page 201: ...vention 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 indicate the HAULOTTE Services intervention number Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 202: ...202 4000328140 E01 15 AUS Telescopic handlers Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 203: ...A B C D E F G H I 203 4000328140 E01 15 AUS Telescopic handlers Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 204: ...204 4000328140 E01 15 AUS Telescopic handlers Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 205: ...A B C D E F G H I 205 4000328140 E01 15 AUS Telescopic handlers Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 206: ...206 4000328140 E01 15 AUS Telescopic handlers Intervention register Date Type of intervention Number of hours Intervenor HAULOTTE Services intervention number ...

Page 207: ...mp Gavage moteur DEUTZ ONLY PERKINS ONLY Coupe circuit booster pump surcal dem froid cold start 120 ohm 1 4W Option kit raffinerie Option refinery kit if T4 final if T4 interim 27A 0 161 160 03 27 28 26 5 5 100C 2002 1A 27 27 27 B106 2001 160 1 160 B106 120 B106 161 1B 1A GB100 250A FU122 M120 KM120 10 9 3 TI 05 19 10 9 KM160 02 9 R160 80A FU160 KM160 2 TI 31 MA M160 KA160 12 14 YA160 13 16 TI YA1...

Page 208: ...2 57A CN01 Starter Battery Alternator Emerg pump Option Nacelle Basket B key swich Coupe batterie ENGINE ECU GCU engine side components Battery switch K45 2001 5 K68 5 1A 1B 27 K23 B106 27 K21 32 1 79 73 76 1 27 75 120 31 gnd 0 K41 2002 28 B106 161 0 K52 GB100 M120 KM120 250A FU122 3 TI 10 9 05 19 M160 KA160 12 14 YA160 13 16 TI KA161 12 18 1 MA 6 TI QS100 02 18 3A FU22 to_BT sensor KM3 20A FU18 5...

Page 209: ... 1 3 4 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 1 3 5 1 3 1 1 3 4 1 3 1 3 1 3 4 1 3 4 1 3 4 1 3 1 3 1 3 4 EGR 1 2 3 4 5 6 Valve 6 0 B400 412 2002 1A B106 27 411 B106 404 1 419 0 1 413 422 415 5 415 414 417 B400 27 415 405 4002 0 0 421 1 406 0 418 419 401 4001 4001 2001 414 161 420 416 1 5 404 0 4002 GB100 250A F1 M1 KA1 3 TI 18 MA 10 9 05 19 M160 YA160 KM7 50A FU407 R160 04 15 KM7 04 7 QS100 KM5 02 18 KA160 ...

Page 210: ...amp flash lamp L R A C fan heating A C 12V plug cigar lighter dome light car radio front ws w rear ws w ws washer rotating light horn Radio horn Warnings car adio supply Start up 12V After keyon Main relay Key switch ES basket ES radio Weight supply Radio supply SUPPLY LAMPS A C ACCESSOIRIES BEFORE KEY ON PRISE DIAG Diag plug 47 ohm 2W REV E Bat Bat C1 C2 C3 D1 D2 Option Anti Demarrage Modcod ou M...

Page 211: ...Fréon Rétro ecl 12V PLUG REAR W WIPPER FRONT W WIPPER W WASHER DOME LIGHT CIGAR LIGHTER CAR RADIO A C HEATING heating switch Heating A C fan Compressor P Freon backlighting P 181 210 0 49 181 48 184 54 188 51 182 183 180 43 41 110 0 43 43 195 100 183 D 186 182 182 G D 282 51 196 210 42 183 G 183 0 50 XP195 M M183 2 1 3 6 XP183 M189 1 2 3 45 46 SA180 M180 M181 05 19 05 19 05 19 05 19 05 19 SA195 M1...

Page 212: ... HAZARD WARNING SIDE MARKER LIGHT ROTATING LIGHT REVERSE HORN RIGHT SIDE LEFT SIDE Buzzer Lamp Rotating light FT RR FT RR 0 111 105 105 110 90 106 101 110 100A 112 185 103 0 185 103 622 90 112 62 100B 100B 0 92 0 111 100A 100A 92 0 110 63 62 90 623 622 63 0 0 112 111 31 R 49 KA104 06 20 05 19 05 19 05 19 KA620 12 15 HA620 EL116 HL185 SA185 HA185 SB105 HA105 14 1 SA101 101 7 5A FU112 103 08 3 7 5A ...

Page 213: ...t Left Lamps Left Right Right comodo STOP LAMP TURN SIGNAL LAMP Right Left Right Left TRAILER Turn light L and R Stop lamp L and R Side marker light L and R P Mano contact Display Afficheur Display Afficheur Display 0 62 191 59 64A 197 193 0 66 0 118 117 61 100A 100A 191 63 60 0 62 100A 192 64 59A 112 0 111 63 63 109 61 110 110 61 62 0 07 20 07 20 07 11 07 9 05 19 SP114 EL113 SA103 KA107 EL114 EL1...

Page 214: ... 5 2 4 PARK BREAK STEERING E V HYDROLIC ENGINE SPEED HYDROLIC PUMP SPEED INCHING PEDAL Park break FWD REV Drive direction 2nd speed REV E REV E 2002 4 2001 102 2001 2001 685 102 124 123 122 165 604 605 7 601 606 2002 121 2001 2002 0 0 6 603 620 B605 600 602 683 B605 0S ALIM 12V S_PWM S_PWM S_PWM S_PWM S_PWM S_PWM S_TOR S_TOR ALIM OV CAN_High CAN CAN_Low CAN CAN_Gnd CAN 05 19 HL685 YV682 YV600 sign...

Page 215: ...t HTL36 14 HTL36 17 HTL4014 HTL4017 amort déblocage essieu amort unlock axle S_TOR 3 4 1 2 2 1 4 3 SP100 Arret d urgence cabine Cab emergency stop E_TOR SPU can gateway E_TOR E_TOR L T4 final T4 interim T3 1002 0 100A 113 B106 0 B180 B108 11 100A 11 0 B651 684 0 140 400 B106 0 113 113 0 B112 0 0 0 2002 167 B653 680 B181 681 168 B109 0 B106 2002 2001 2 0 2001 B513 0 0 104 B110 380 0 2001 2002 0 B10...

Page 216: ...nie oil pressure fule level Engine temp Engine overheat Turn lamp left Turn lamp right High beam Side marker lamp Masse moteur Engine ground 166 189 164B 62 0 162 2001 125 100A 691 00C 0 100B 126 2002 113 60 00C 00C 63 164 113 189A _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 10 7 10 4 10 4 can L 7 can H 7 12V APC 7 16 13 PD 4 7 08 10 cligno GD 14 PD 5 7 08 7 PD 6 7 feux Rte 14 08 7 feux Pos ...

Page 217: ...ay EV Off neutral Y lifting X Forks tilting roller telesco Dead man BUTTON LIGHTS RELAYS CMD Crab Synchro up Down Up Down Left Right 0 5V 0 5V 0 5V 0 5V 0 5V 2001 0 0 B132 3000 0 101 0 B782B 160 0 B505 0 B507 B781B 0 1001 3002 B400 1002 1001 1002 0 B509 B501 102 102 B505 B780B 0 B400 101 0 B502 B781A 102 B780A B144 B782A 3001 B124 B120 B303 0 0 B302 B301 B300 B118 113 0 113 B400 113 B131 B508 B400...

Page 218: ...ILTING Up Down Out In Up Down aux validation seat present Service break fault Front axle in line Rear axle in line teslesco in stab left up stab right up half way telesco stab right down satb left down stab D baissé stab G baissé capteur pression pressure sensor satb left down stab right down FRAME LEVELLING 0 5V 0 5V HTL3614 3617 4014 4017 HTL 3617 4017 Angle flèche Boom angle Sealed air filter F...

Page 219: ... Radio receiver Radio transmitter basket weighting sensors basket lock sensors Horn 0 20mA 0 20mA 0 20mA 0 20mA 0 5V 0 5V pompe de secours safety pump Tilt Devers B310 0 B312 0 B313 0 B103 0 B111 B140 0 B104 B311 0 490 B100 494 495 187B B402 187A 492 187B B400 B102 B401 493 194 0 B129 B511 B512 B510 0 B512 B511 103 B510 113 105 491 B105 0 E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_ANA E_ANA E_ANA...

Page 220: ... 11 12 13 14 15 16 17 18 19 20 A B C D E F G H I J K L M MOTEUR TIER3 MOTEUR TIER4 CN TI RES CAN DS FAISCEAU MOTEUR RES INTERNE CALCULO MOTEUR AFFICHEUR CAN 2 0 POMPE H1 res term J1939 SPU NOEUD B CN DIAG CAB CAN HG CN DIAG MOTEUR DISPLAY LMI GAUGE 5m CAN 2 0 ...

Page 221: ...0 pin fem Mat n lock 9 voies 1 480706 0 sockets male Mat n lock 6 voies 1 480704 0 sockets male WINCH BASKET SELECTOR OPTION RADIO SELECTOR OPTION BATERY MAINTIEN IGNITION ENERGIZE BATERY 1 2 3 4 5 HOLD APPEL BATTERIE BATTERIE Option kit raffinerie Option refinery kit 04 100C 0 100A 03 02 0 II I SA187 3 1 2 4 1 1 5 2 2 6 3 3 7 4 4 8 5 5 9 6 6 1 SA188 4 2 3 6 5 11 5 40A FU23 02 14 YA3 05 8 02 15 ...

Page 222: ... LECTRICAL IAGRAM 4ELESCOPIC ANDLERS ...

Page 223: ... YDRAULIC IAGRAM 4ELESCOPIC ANDLERS 4 4 4 107P315160 D ...

Page 224: ... YDRAULIC IAGRAM 4ELESCOPIC ANDLERS ...

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