Haulotte HTL4014 Operator'S Manual Download Page 109

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103

2420331560

E 04 07

TELESCOPIC HANDLERS

- LUBRIFICATION AND MAINTENANCE

Internal combustion engine (see manufacturer’s
guide)

Oil

Oil filter cartridge

Belt tension

Travel axles (see manufacturer’s guide)

Front axles: differ
transfer case on front axle +
pivots

Rearaxles: differ pivots

Epicycloidal reducers

Hydraulic circuit

Hydraulic oil

Battery

Level

Date :
Number of hours :
Intervenor :
HAULOTTE Services® contract number :
Intervention sheet number :
Signature :

Comments

2500h service

Zone

Type of

intervention

Zone

Type of

intervention

Summary of Contents for HTL4014

Page 1: ...1 Operator manual OPERATOR MANUAL TELESCOPIC HANDLERS HTL4014 HTL4017 2420331560 E 04 07 GB TELESCOPIC HANDLERS ...

Page 2: ......

Page 3: ...ERAL SAFETY B THE RESPONSIBILITIES OF THE PARTIES INVOL VED C PRE OPERATION AND CONTROLS D OPERATION E ATTACHMENTS F EMERGENCY PROCEDURE G TECHNICAL SPECIFICATIONS H LUBRIFICATION AND MAINTENANCE I INTERVENTION LOG SUMMARY ...

Page 4: ...Operator manual ...

Page 5: ...autions machine operation environment Use within the equipment performance limits 2 After Sales Service Our HAULOTTE Services after sales service is at your disposal both during and beyond the warranty period to provide you with the service you require Contact our After Sales service indicating the exact machine type and its serial number When ordering any consumables or spare parts please use thi...

Page 6: ...nes comply with the provisions of thedirectives currently applicable to this type of machine HAULOTTE cannot be held liable for the technical specifications contained in this manual HAULOTTE reserves the right to make improvements or modifications to the machine without modifying this manual ...

Page 7: ... machines efficiently and safely The operator manual must be kept in the cab in its storage case This manual must be made available to each operator and kept in good condition Additional copies can be ordered from HAULOTTE Services S y m b o l m e a n i n g s Symbol Meaning Risk of injury or death work safety Risk of material damage work quality Prohibition relating to work safety and quality No i...

Page 8: ...tes The labels must be kept in good condition Additional labels can be obtained from HAULOTTE Services Familiarize yourself with the labels and their respective color codes L a b e l c o l o r c o d e Label Color Meaning Red Potentially fatal danger Orange Risk of serious injury Yellow Risk of material damage and or minor injury Others Additional technical information ...

Page 9: ... the rated lifting capacity Check that the ground can support the machine Never use an accessory without having checked the HAULOTTE accessory load capacity chart installed on the telehandler Do not drive at high speed with the boom raised When driving at high speed use only front wheel steering if the steering mode can be selected ...

Page 10: ...4 2420331560 E 04 07 GB TELESCOPIC HANDLERS Do not raise the boom unless the chassis is level 0 degrees Do not level the machine with the boom or the accessory above 30 ...

Page 11: ...t 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 withtag lines Do not try to use the telehandler s dumping function to return the load to horizontal position Keep the heaviest part of the load closest to the attachment Never drag the load Lift it vertically Mainta...

Page 12: ...hine 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 This machine is not insulated and does not offer any protection in the event of proximity to or contact with electrical current Never operate the handler in an area where overhead power lines overhead or underground cables or other pow...

Page 13: ... and avoid other personnel machinery and vehicles in the area Use a spotter in the event of bad 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 Maintain visibility of the mirrors and optimal visibility of the path of travel Always look in the direction of travel Always check ...

Page 14: ...ndler both sideways 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 solder the forks Never tilt the platform forward rearward or sway the machine when the platform ...

Page 15: ...ill To 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 m...

Page 16: ...ndler Stay clear of moving parts when 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 17: ...e the machine until the complete shutdown procedure has been performed Do not carry any passengers Falling from the machine may cause death or serious injury Do not operate the machine in an enclosed area without proper ventilation Do not operate the machine in hazardous environments unless specifically approved by Haulotte or the site owner Sparks produced by the electrical system or the engine e...

Page 18: ...ny hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure Do not use your hand to check for leaks the pressurized hydraulic fluid can penetrate the skin Use a piece of cardboard or paper instead Wear gloves and goggles to protect yourself from fluid splashes ...

Page 19: ...TTE Services The owner or hirer is responsible for applying the local regulations regarding operation 2 The employer s responsibility The employer has the obligation to issue the operator with a driving permit The employer has the obligation to inform the operator of the local regulations 3 The trainer s responsibility The trainer must be qualified to provide training to operators in an obstacle f...

Page 20: ...st be familiar with the emergency controls and how to operate the machine in an emergency It must be operated by pairs of operators so that one of the operators can intervene rapidly if necessary Take over the controls in the event of an accident or failure Monitor and regulate the movement of machines or personnel in the work area Guide the driver if necessary The operator has the obligation to s...

Page 21: ...ach delivery of sold hired or resold equipment Owner or hirer Qualified HAULOTTE Services techni cian Operator manual Pre operation inspection Before operation or when the operator changes Operator Operator Operator manual Section C Periodical preventive maintenance At the specified intervals 250 hrs or 1 year Owner or hirer On site technician or qualified HAULOTTE Servi ces technician Operator ma...

Page 22: ...16 2420331560 E 04 07 GB TELESCOPIC HANDLERS ...

Page 23: ... of operator Ensure that all safety labels are legible and in place Clean or replace as required See Labels section Before removing the filler plugs wipe all dirt or grease away from the ports If dirt enters these ports this can severely reduce component life When adding fluids refer to Section H to determine the correct type and frequency Use extreme caution when checking parts that are difficult...

Page 24: ...18 2420331560 E 04 07 GB TELESCOPIC HANDLERS 1 2 3 4 5 7 6 8 9 10 12 12 14 15 16 17 18 19 20 11 13 ...

Page 25: ...lic hoses in good condition no leaks 5 Wheel Tire assembly No loose or missing wheel nuts inflated correctly Check the state of the tires and their level of wear 6 Hydraulic reservoir Recommended fluid level on the level gauge the lubricant must be cold filler breather cap securely in place and in working order 7 Cab and Electrical system General appearance no visible damage proper capacity charts...

Page 26: ...that the radiator is clean Drive belts check their condition and replace as required Air filter blockage indicator check if it is clogged Replace the part as required Battery cables well secured no visible damage or corrosion Engine cover properly secured and locked 16 Mirrors Clean in good condition and working properly 17 Wheel Tire assembly No loose or missing wheel nuts inflated correctly 18 D...

Page 27: ... HANDLERS C PRE OPERATION AND CONTROLS 2 Safety Stickers Ensure that all stickers and appropriate capacity charts are legible and in place Clean or replace as required 2 1 RED LABELS C o m m o n l a b e l s The red labels indicate a potentially fatal danger R27 R13 R28 R29 ...

Page 28: ...22 2420331560 E 04 07 GB TELESCOPIC HANDLERS S p e c i f i c l a b e l s R9 R10 ...

Page 29: ...23 2420331560 E 04 07 GB TELESCOPIC HANDLERS C PRE OPERATION AND CONTROLS 2 2 YELLOW LABELS C o m m o n l a b e l s S p e c i f i c l a b e l s The yellow labels indicate a risk of material damage and or minor injury J4 J3 J21 J20 J19 J18 ...

Page 30: ...0331560 E 04 07 GB TELESCOPIC HANDLERS 2 3 OTHER LABELS C o m m o n l a b e l s S p e c i f i c l a b e l s The other labels provide additional technical information A5 A46 A47 A48 A49 A50 A51 A45 A44 A3 A42 ...

Page 31: ... D E F G H I A B C D E F G H I 25 2420331560 E 04 07 GB TELESCOPIC HANDLERS C PRE OPERATION AND CONTROLS 2 4 IDENTIFICATION L o c a l i z a t i o n i s o m e t r i c v i e w A6 J21 J3 A46 A47 A48 A49 A50 A51 ...

Page 32: ...26 2420331560 E 04 07 GB TELESCOPIC HANDLERS L o c a l i z a t i o n f r o n t v i e w R28 R10 R10 R13 R13 J21 J21 ...

Page 33: ... C D E F G H I A B C D E F G H I 27 2420331560 E 04 07 GB TELESCOPIC HANDLERS C PRE OPERATION AND CONTROLS L o c a l i z a t i o n l e f t v i e w J4 A45 A30 A10 J19 A40 J20 J21 A30 J21 J21 A27 A4 A16 A41 ...

Page 34: ...28 2420331560 E 04 07 GB TELESCOPIC HANDLERS L o c a l i z a t i o n r i g h t v i e w A5 J21 R29 A16 ...

Page 35: ...A B C D E F G H I A B C D E F G H I 29 2420331560 E 04 07 GB TELESCOPIC HANDLERS C PRE OPERATION AND CONTROLS L o c a l i z a t i o n c a b v i e w A42 R27 A7 A37 A39 A38 A3 ...

Page 36: ...30 2420331560 E 04 07 GB TELESCOPIC HANDLERS L o c a l i z a t i o n v i e w f r o m a b o v e J21 J21 J21 R9 R9 J18 J18 J18 J18 J21 J21 ...

Page 37: ...A B C D E F G H I A B C D E F G H I 31 2420331560 E 04 07 GB TELESCOPIC HANDLERS C PRE OPERATION AND CONTROLS L o c a l i z a t i o n r e a r v i e w A52 A52 A44 A58 ...

Page 38: ... 307P220870 J21 7 Lubrication point 307P220840 307P220840 A4 1 Machine name graphic 307P221030 307P222600 A10 1 Sound power 307P220790 307P220790 A16 1 Yellow Black adhesive tape 2421808660 2421808660 A27 1 Safe weight load 307P220910 307P220910 A30 3 Machine anchorage points 307P220830 307P220830 A40 1 Battery disconector 307P220930 307P220930 A41 1 A B auxiliary hydraulic outputs 307P221070 307P...

Page 39: ...ate ITALY 307P220810 307P222040 307P222050 307P222670 307P222030 307P220810 307P222040 307P222050 307P222670 307P222030 A7 1 Read the operator manual 307P220740 307P220740 A38 1 Fuse amperage 307P221130 307P221130 A39 1 Joystick movements 307P220800 307P220800 A42 1 Load diagram 307P222850 307P223310 A43 1 Wear the seat belt 307P220780 307P220780 Markings Quantity Description HTL4017 HTL4014 R9 2 ...

Page 40: ...ss the overhead guards and the cab structure are in good condition Any modifications to this machine must be approved by HAULOTTE to ensure compliance 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 C113 C121 C120 C132 C134 C133 C131 C141 C46 ...

Page 41: ...gine speed and the hydraulic fluid flow C124 Steering column adjuster See 1 23 for more details C125 Transmission control lever See 1 23 for more details C126 Controls for wiper lights turn signals and horn C127 Instrument panel Controls and indicates certain machine functions Displays the machine out put See page or 1 25 for more details C128 Fuel gauge Orientation diesel fuel tank gauge C129 Eng...

Page 42: ...GB TELESCOPIC HANDLERS 2 5 2 Pedals General view P e d a l s Marking Description Function P163 Accelerator Pedal for increasing the engine speed P164 Brake Machine braking Inching Slow approach at accelerated speed P164 P163 ...

Page 43: ...ed Selector position I Fast speed Selector position II Travel direction selection Forward drive Pull the lever upwards and then push it forwards Neutral Reverse drive Pull the lever upwards and then pull it backwards A sudden change in direction could destabilize the machine and or cause the load to tip over or fall When reverse drive is activated a sound signal indicates the presence of a danger ...

Page 44: ...166 Turn signals Direction indicators Left Raise the lever Right Lower the lever P167 Sidelights On Turn clockwise Off Turn anticlockwise P168 Headlights On Turn clockwise Off Turn anticlockwise P169 Full beam headlights On Pull forward Off Push backwards Flashing headlamp Pull backwards by pulse action P166 P167 P168 P169 ...

Page 45: ... the steering wheel Move the steering wheel to the most appropriate position Block the steering wheel by pulling the lever up Bring the handler to a complete stop and shutdown the engine before adjusting the steering column A sudden change in direction could destabilize the machine and or cause the load to tip over or fall Failure to comply with these instructions could result in death or serious ...

Page 46: ...ortable position Moving forward back Use the handle P170 to move the seat forward or back Height Use the knob P171 to adjust the seat height Suspension Use the knob P172 to adjust the suspension to the appropriate weight adjustment P173 Backrest Use the button P174 to adjust the backrest angle Seatbelt Always fasten the seatbelt P175 during operation P171 P170 P172 P174 P175 ...

Page 47: ...n To activate the fan actuate the heating ventilation switch P203 situated on the side instrument panel Adjust the heating temperature by actuating the handle situated under the driver s seat Adjust the air flow via the air louvers and the round air vents Do not operate the machine for a long period without aeration or with the cab completely closed without activating ventilation Ensure good aerat...

Page 48: ...SCOPIC HANDLERS 2 5 6 Cab instrument panel General view P176 P177 P178 P179 P180 P181 P182 P183 P184 P185 P186 P187 P188 P189 P190 P191 P192 P193 P194 P195 P196 P197 P198 P199 P200 P201 P202 P203 P204 P205 P206 P207 P208 P209 P210 ...

Page 49: ...ssure in the service brake P191 ECU defect LED On Engine computer defect 3 P192 Pinned rear axle LED On Rear wheels pinned P193 Floating LED option Flashing Floating option activated P194 Sidelight LED On Sidelights on P195 Seat presence LED On Operator on seat P196 Aerial lift Winch selector option Aerial lift position Turn right Winch position Turn left P197 Remote control selector option Remote...

Page 50: ...e limited or prohibited to safeguard the operator s safety For more details see Section H Operating Incidents P210 Rear fog lamps On Press downwards Off Press upwards The stabilizers only increase stability and load capability if they are used correctly Using stabilizers on soft surfaces can cause the machine to tip over and result in serious injury Always ensure that the surface can support the w...

Page 51: ...Push the joystick To lower the telescopic arm Pull the joystick Dumping Move towards the right Crowding Move towards the left Telescope out Pull the left rocker switch upwards Telescope in Pull the left rocker switch downwards Auxiliary direction A Pull the right rocker switch upwards Tool control direction B Pull the right rocker switch downwards Rapid jerky operation of the controls causes rapid...

Page 52: ...ion of the steering selector with the rear axle automatically returning to position Overriding the steering with the exclusion key is deactivated L e f t k e y p a d e Marking Description Function P212 Signal warning light switch On Press downwards Off Press upwards P213 Beacon light switch option On Press downwards Off Press upwards P214 Parking brake switch On Activated Unlock manually Press dow...

Page 53: ...hese conditions are not respected and the road mode is selected traveling is deactivated The road mode LED P215 flashes to indicate failure to comply with the conditions If the stabilizers are not raised the stabilizer LED P208 and P209 also flashes Once the conditions are met the road mode is validated the indicator light P215 is constantly lit and traveling is authorized at slow and fast speeds ...

Page 54: ...es the remaining load percentage triggers a pre alarm signal and blocks aggravating movements at the safe weight load limit Test the anti tip system at the beginning of each work shift See Section H C o n t r o l s a n d i n d i c a t o r s Marking Description Function P216 Green LEDs Loading degrees P217 Yellow LED Pre alarm P218 Red LED Alarm P219 Test The indicator can be tested at any time Thi...

Page 55: ...d if the alarm sounds but can be activa ted with the exclusion key Forbidden Deactivated if the alarm sounds but can be activa ted with the exclusion key Crowding Deactivated if the alarm sounds but can be activa ted with the exclusion key Forbidden Deactivated if the alarm sounds but can be activa ted with the exclusion key Dumping Deactivated if the alarm sounds but can be activa ted with the ex...

Page 56: ...osed Open the cab door window and secure it in the latch mechanism Press the release button located inside the cab to unlatch the window Rear window Pull the lever and push to open the rear window Adjusting the mirrors Adjust the mirrors as required for optimal visibility before and during operation Always keep the mirrors clean and unobstructed 1 2 ...

Page 57: ...wing LEDs should light upon start up and then go off again Engine oil pressure LED P181 Parking brake LED P182 possible if deactivated for a prolonged period Battery LED P180 Service brake system LED P190 possible if deactivated for a prolonged period Warm up the engine at approximately 1 2 throttle N B The engine will not start if the gear control lever is not in neutral Do not actuate the starte...

Page 58: ...d and reverse drive Each gear Steer in both directions with the engine at idling speed Check each steering mode forward and reverse The horn and the back up alarm They must be audible from inside the operator s cab with the engine running All of the boom and attachment functions should operate smoothly and correctly Perform all additional checks See Section H Engine explosion Do not spray ether in...

Page 59: ...ual noises and vibrations If a fault occurs park the machine in a safe position and perform the shut down procedure See Section D 1 1 6 Report the fault to HAULOTTE AFTER SALES Avoid prolonged idling Turn the engine off when not in use 1 5 ENGINE SHUT DOWN PROCEDURE Park the machine in a safe location on a flat surface and away from any other equipment or traffic lanes Actuate the parking brake sw...

Page 60: ... load Adjust the fork spacing so that they engage 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 Never attempt to lift a load with just one fork The cab seat is equipped with an operator presence detection system The LED P195 lights If the operator leaves the seat when the ma...

Page 61: ...evel indicator to determine whether the machine must be leveled and level the machine with the switch P200 The machine is designed to allow movement of the main chassis 10 forward and backwards 2 5 PLACING THE LOAD Before placing a load Ensure that the unloading point can safely support the weight of the load Ensure that the unloading point is level both lengthways and sideways Use the capacity ch...

Page 62: ...hts and the mirrors and adjust them if necessary Follow the recommendations in force in each country of use registration plate jacket warning triangle first aid kit chocks Lower the boom The front edge of the attachment should be approximately 30 40cm above the ground Tilt the attachment back completely Place a protective cover over the front edge of the bucket remove the carriage forks or reposit...

Page 63: ... chains through the designated tie downpoints as illustra ted 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 and that all manufacturer s instructions and warnings regulations and safety rules a...

Page 64: ...58 2420331560 E 04 07 GB TELESCOPIC HANDLERS ...

Page 65: ...es equipped with auxiliary hy draulics 2 Unapproved attachments If any of the above conditions is not met do not use the attachment 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 Do not use unapproved attachments for the following reasons HAULOTTE c...

Page 66: ...y chart to determine the maximum capacity for the various machine configurations Lifting and placing a load may require the use of more than one capacity chart depending on the machine configuration The forks must be used in matched pairs 4 Using the capacity chart with forks To use the capacity chart properly the operator must first determine and or obtain the following A HAULOTTE approved attach...

Page 67: ...responding to the key and follow it to the permitted reach The number that appears in the load capacity range must be equal to or greater than the weight of the load to be lifted Determine the load capacity range limits with the capacity chart and keep within those limits Boom angle indicator Boom extension indicators horizontal boom ...

Page 68: ...62 2420331560 E 04 07 GB TELESCOPIC HANDLERS HTL 4017 Load capacity chart HTL 4014 Load capacity chart ...

Page 69: ...hen 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 these...

Page 70: ...ent 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 place by 2 retaining locks Incorrect installation could cause fork carriage attachment load disengagement resulting in serious injury or death C143 C144 C145 C146 C147 ...

Page 71: ...GHT COATING OF AN APPROPRIATE LUBRICANT TO FACILITATE FORK OR FORK BAR SLI DING To slide the forks Ensure that the fork carriage is correctly installed see Section E Lift the boom by approx 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 nearits pin If the forks must be replac...

Page 72: ...l from the pile Load the bucket by driving gently with the boom fully retracted Tilt the bucket upwards sufficiently to retain the load and move away from the pile Travel as specified in Section A Tilt the bucket downwards to dump the load Familiarize yourself with the information provided on the bucket identification plate Use this accessory s capacity chart situated in the cab Keep the specific ...

Page 73: ...ing ve hicle If the vehicle cannot be raised sufficiently to avoid interferences contact HAULOTTE Services Towing can only be performed when the machine has broken down and once the operator has ensured that there is no risk of additional deterioration Check that the steering can be used Release the front axle after the operation To tow the machine fix a towing bar to the towing clevis situated at...

Page 74: ...ing the brake before towing 1 2 RELEASING THE AXLE BRAKE FOR TOWING The following procedure is used to deactivate the parking brake acting on the front axle in the event of a heat engine breakdown or when the accumulator is empty 1 2 1 Parking brake deactivation Tools required 8mm Allen wrench Reversible 3 8 ratchet and 3 extension To access brake release screws 1 2 3 you must loosen the six caps ...

Page 75: ...s 1 2 3 clockwise by a turn The parking brake can then be reactivated and the front wheels blocked Remove the chocks from the four wheels Check that the hand brake control functions properly The 8mm Allen wrench will be used to disengage the parking brake correctly Draw a mark so that you can count the number of revolutions made by each nut in order to make the correct adjustment upon reassembly L...

Page 76: ... position with another machine an axle or as a last resort the cylinder chock Unscrew completely the stop screw from the balance valve block flanged on the boom lift cylinder Remove the locknut and rescrew the stop screw fully into its socket 1 Take off the cover located under the counterweight at the back of the machine to access the valve block Unscrew slowly the cap situated on the boom lift pl...

Page 77: ...raise the boom to its high position and secure it into place using the hold cylinder Unscrew the stop screw from the balance valve block replace the counternut and rescrew the as sembly fully into its socket Check that the balance valve functions properly after the intervention by raising lowering the boom with a load Secure the boom into position before any interventions on the balance valve 2 ...

Page 78: ...HE LOCAL AND GOVERNMENTAL REGULATIONS IN FOR CE A HAMMER SECURED TO THE INSIDE OF THE CAB CAN BE USED TO BREAK THE WINDOW OR WINDOWS TO ALLOW THE OPERATION TO LEAVE THE CAB In an emergency the rear window can be used to exit the machine Release the stop upwards 1 Push the window outwards with your hand 2 1 2 ...

Page 79: ...taneous movements Control Electro hydraulic control with 4 function joystick Accessory soc ket flow 62 L min Tank capacity 110 L T r a n s m i s s i o n Type Hydrostatic type with pump and variable cylinder capacity engine with 4 permanent drive wheels Control Electro hydraulic control with front rear 2 2 and neutral position selector Speed in work mode 0 8 km h Speed in road mode 0 30 km h 25 km ...

Page 80: ... in the cab cut off and sound signal with auto matic speed deceleration at the limit of the capacity chart Automatic hydraulic locking of the rear axle for safety Tilt correction 10 Pre wiring for radio and loudspeakers Horn Hydraulic oil pressure indicator Light indicating clearance of front wheels aligned with rear wheels T i r e s Type 18 22 5 profil TM R4 Turning inner radius on tire 2400 mm T...

Page 81: ...illar Power steering Metal protection above the cab Tinted windows and sun visor Left and right outside rear view mirrors Timer Boom angle indicator Mud flap Long stabilisers with ground contact presence contactor Forks Manual fork carriage attachment with 2 pins Front and rear bracket Road machine configuration button Beacon Front and rear full beam headlamps ...

Page 82: ...76 2420331560 E 04 07 GB TELESCOPIC HANDLERS 2 Overall dimensions General diagram I F B G H E A C J K L M D ...

Page 83: ...A B C D E F G H I 77 2420331560 E 04 07 GB TELESCOPIC HANDLERS G TECHNICAL SPECIFICATIONS N O ...

Page 84: ... in 2 60 8 ft 6 in D 2 89 9 ft 6 in 2 89 9 ft 6 in E 0 50 1 ft 8 in 0 50 1 ft 8 in F 1 93 6 ft 4 in 1 93 6 ft 4 in G 0 94 3 ft 1 in 0 94 3 ft 1 in H 3 34 11 ft 0 in 3 34 11 ft 0 in I 2 71 8 ft 11 in 2 71 8 ft 11 in J 1 82 6 ft 0 in 1 82 6 ft 0 in K 28 28 L 18 18 M 104 104 N 2 40 7 ft 10 in 2 40 7 ft 10 in O 4 20 13 ft 9 in 4 20 13 ft 9 in Weight 12220 kg 26945 lb 12040 kg 26548 lb ...

Page 85: ...A B C D E F G H I 79 2420331560 E 04 07 GB TELESCOPIC HANDLERS G TECHNICAL SPECIFICATIONS 3 Work area 3 1 MACHINE HTL 4017 3 2 MACHINE HTL 4014 ...

Page 86: ... on the machine To avoid any increase in noise emission all panels and other sound absorbing materials must be replaced in their original position after maintenance and repair work 5 Telehandler vibration The load and acceleration values for vibrations transmitted to the body are below the levels required by the various regulations The measurements have been performed according to the currently ap...

Page 87: ...he filling holes the plugs and the grease points After lubricating the machine actuate all functions several times to distribute the lubricants Perform this maintenance procedure without any accessories Check the state of the filling plug seals do not forget to replace them Maintain the machine and the equipment especially the brakes and the steering in good condition to ensure your safety and to ...

Page 88: ...tections and plates that have been dismantled before starting the ma chine Paintwork shall be performed in well ventilated premises and with approved protective equipment The engine cooling system operates under pressure The pressure is regulated by the radiator plug To prevent any risks of fire or explosion keep any flames away from the battery To prevent any risk of sparks that could cause an ex...

Page 89: ...nts on the safety systems or elements concerns mechanics hydraulics and electricity They must be performed by HAULOTTE Services staff or staff working on behalf of HAULOTTE who will only use original spare parts Any modifications outwith HAULOTTE s control are not permitted The manufacturer s liability is excluded if the work specified above is not performed by HAULOTTE approved staff or if the sp...

Page 90: ...84 2420331560 E 04 07 GB TELESCOPIC HANDLERS 4 Lubrication and maintenance schedule 50h 10h 500h ...

Page 91: ...A B C D E F G H I 85 2420331560 E 04 07 GB TELESCOPIC HANDLERS H LUBRIFICATION AND MAINTENANCE 1500h 2000h 1000h 500h 200h 100h 10h 1500h 2000h 1000h 500h 100h 10h 4 5 5 50h 50h 4 250h ...

Page 92: ...86 2420331560 E 04 07 GB TELESCOPIC HANDLERS 1500h 2000h 1000h 500h 200h 100h 10h 1500h 2000h 1000h 500h 100h 10h 1 2 2 6 6 3 7 7 50h 50h 250h 8 ...

Page 93: ... 04 07 GB TELESCOPIC HANDLERS H LUBRIFICATION AND MAINTENANCE D e s c r i p t i o n o f t h e c o m p o n e n t s Symbol Marking Description Check the level Filter Oil change 1 Lubrication 2 Diesel circuit 3 Cooling system 4 Air system ...

Page 94: ...88 2420331560 E 04 07 GB TELESCOPIC HANDLERS 5 Internal combustion engine 6 Travel axles 7 Hydraulic circuit 8 Battery D e s c r i p t i o n o f t h e c o m p o n e n t s Symbol Marking Description ...

Page 95: ...In cases of intensive use reduce the intervals between servicing Symbol Signification Symbol Signification Visual inspections Systematic replacement Operation requiring HAULOTTE Services authorisation Check Test See user manual or machine maintenance book Visual inspection followed by dismantling or replacement if necessary Operation requiring HAULOTTE Services authorisation Check level Tightening...

Page 96: ... Chain wear Appearance of the mechanical parts and flexibles Attachment device nuts and bolts and hydraulic fitting Operation of the work lighting controls and the light indicators Diesel engine operation State of anti skid parts Etat et Pressure pneumatiques Wheel lug nut torque Lubrication Cylinder pins Boom bottom shaft Telescope pads Suspension driver seat rails Diesel circuit Condensate Diese...

Page 97: ...ir filter Secondary air filter Internal combustion engine See manuacturer s guide Oil Oil filter cartbridge Motor supports Preheating resistor Belt tension Travel axles See manuacturer s guide Front axles Differential Transfer case on front axle Pivots Rear axles Differential Pivots Réducteur épicycloïdaux Zone Intervals Daily Every 50 h Every 100 h Every 250 h Every 500 h Every 1000 h Every 2000 ...

Page 98: ...7 GB TELESCOPIC HANDLERS Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Zone Intervals Daily Every 50 h Every 100 h Every 250 h Every 500 h Every 1000 h Every 2000 h ...

Page 99: ...spections Systematic replacement Operation requiring HAULOTTE Services auth orisation Check Test See user manual or machine maintenance book Visual inspection followed by dismantling or replacement if necessary Operation requiring HAULOTTE Services authorisation Check level Tightening bolt etc Lubrification Tightening oil clearance Oil change Static and dynamic tests ...

Page 100: ...echanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Teles...

Page 101: ...n Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 500h or 6 months service Zone Type of intervention Zone Type of intervention ...

Page 102: ...the mechanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bo...

Page 103: ...les see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 1000 h or 12 months service Zone Type of interve...

Page 104: ...mechanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Tele...

Page 105: ... Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 1500h or 18 months service Zone Type of intervention Zone Type of intervention ...

Page 106: ...es Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom shaft Radiator slats Telesc...

Page 107: ...uide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 2000h service Zone Type of intervention Zone Type of intervent...

Page 108: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 109: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 2500h service Zone Type of intervention Zone Type of intervention ...

Page 110: ...es Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom shaft Radiator slats Telesc...

Page 111: ...r s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 3000h service Zone Type of intervention Zone Type of intervention ...

Page 112: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 113: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 3500h service Zone Type of intervention Zone Type of intervention ...

Page 114: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 115: ...les see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor Numéro de contrat HAULOTTE Services Numéro de fiche intervention Signature Comments 4000h service Zone Type of interv...

Page 116: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 117: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 4500h service Zone Type of intervention Zone Type of intervention ...

Page 118: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 119: ...avel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 5000h service Zone Type of intervention Z...

Page 120: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 121: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 5500h service Zone Type of intervention Zone Type of intervention ...

Page 122: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 123: ...axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 6000h service Zone Type of intervent...

Page 124: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 125: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 6500h service Zone Type of intervention Zone Type of intervention ...

Page 126: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 127: ...avel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 7000h service Zone Type of intervention Z...

Page 128: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 129: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 7500h service Zone Type of intervention Zone Type of intervention ...

Page 130: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 131: ...axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 8000h service Zone Type of intervent...

Page 132: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 133: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 8500h service Zone Type of intervention Zone Type of intervention ...

Page 134: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 135: ...avel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 9000h service Zone Type of intervention Z...

Page 136: ...ical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope ...

Page 137: ...tension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 9500h service Zone Type of intervention Zone Type of intervention ...

Page 138: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 139: ...axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 10000h service Zone Type of interven...

Page 140: ...nical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope...

Page 141: ...ension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 10500h service Zone Type of intervention Zone Type of intervention ...

Page 142: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 143: ...avel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 11000h service Zone Type of intervention ...

Page 144: ...nical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Lubrication Cooling system Cylinder pin Coolant Boom bottom shaft Hoses and collars Telescope...

Page 145: ...ension Travel axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 11500h service Zone Type of intervention Zone Type of intervention ...

Page 146: ...chanical parts and flexibles Air filter Nuts ans bolts and hydraulic fittings Remove the dust Operation of the work lighting controls and the light indicators Primary air filter Diesel engine operation Secondary air filter State of the anti skid parts State of tires and inflation presure Wheel lug nut torque Chain wear Cooling system Lubrication Coolant Cylinder pin Hoses and collars Boom bottom s...

Page 147: ...axles see manufacturer s guide Front axles differential transfer case on front axle pivots Rearaxles differential pivots Epicycloidal reducers Hydraulic circuit Hydraulic oil Equipment hydraulic oil Transmission hydraulic filter Pressures Battery Level Date Number of hours Intervenor HAULOTTE Services contract number Intervention sheet number Signature Comments 12000h service Zone Type of interven...

Page 148: ... access steps and replace them if necessary Check that the tires are not damaged after the first 10 hours and then after every 100h of opera tion Check the wheel lug nut torque 500Nm after the first 10 hours and then after every 100h of ope ration 7 2 ANTI TIP DEVICE The anti tip device is intended for constantly monitoring the stability of the front of the machine To check this function proceed a...

Page 149: ...clogging check It is performed constantly by a sensor 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 reached Clean the inside of the box If the test gives another result the system is not working properly and the machine must be taken out of service and re...

Page 150: ...he latest after every 1000 hours of operation or once a year Blow with dry compressed air with a maximum pressure of 5 bars from the inside of the filter outwards or Unclog it by tapping only in the event of an emer gency In this case do not damage the cartridge or Wash it in accordance with the manufacturer s gui delines Check that neither the cartridge filter paper translu cent paper nor the sea...

Page 151: ...Place the machine on a horizontal surface Fold the machine with the stabilisers raised as far as possible the fork carriage lowered as far as possible the boom telescoped and retracted and the cylinders retracted The level must be situated between the two marks as indicated in the photo opposite Complete if necessa ry via the filling hole ...

Page 152: ...s by turning one of the nuts and then the other by successive turns Then retighten the lower extended telescoping chains only on the 17m arm by applying a 60Nm torque to each of the locking nuts on the threaded rods situated at the end of each of the chain yokes Ensure that you distribute the tension between the chains by turning one of the nuts and then the other by successive turns Finish retrac...

Page 153: ...e points Lubricate the boom bottom shaft Lubricate the sliding area friction pads For lubrication operations refer to the Lubricants and equivalents table in Section H 14 5 for the type of grease used Outside tube Mid plans Inside tube Intermediate tube 2 70 N m torque Intermediate tube 2 60 N m torque Upper extension chains Lower extension chains only 17 m arm Chain yokes ...

Page 154: ...on and then after every 1000 hours or once a year See Section H 12 2 10 3 INTERNAL COMBUSTION ENGINE Perform the first engine oil drainage and change the filter cartridge after the first 100 hours of ope ration and then every 500 hours See Section H 11 2 Check the tire inflation pressure at least 4 5 bars During a pressure check or an inflation operation always face the thread and never the side o...

Page 155: ...04 07 GB TELESCOPIC HANDLERS H LUBRIFICATION AND MAINTENANCE 10 4 LUBRICATING THE FRONT AXLES Remove the 4 protective caps from each grease point Connect the grease pump Replace the protective caps once you have lubricated the rear axles ...

Page 156: ...e caps from each grease point Connect the grease pump 10 6 HYDRAULIC CIRCUIT Perform the first filter cartridge change after the first 100 hours of operation and then after every 1000 hours or once a year See Section H 12 5 and 12 6 Replace the protective caps once you have lubricated the front axles ...

Page 157: ...al reducers after the first 250 hours of operation and then every 1500 hours See Section H 13 1 Level check every 500 hours See Section H 11 3 11 4 BATTERY Battery check Perform the machine shut down procedure Open the battery access cover under the cab Wear safety goggles and visually inspect the battery Check that the terminals are not corroded Replace the battery if its case is cracked melted o...

Page 158: ...nage plug and let the oil flow completely Open the oil filling hole Clean the drainage plug and replace it taking care to change the seal Fill until the oil reaches the MAX gauge mark Replace the filling plug and let the engine run at idling speed for a few minutes Stop the engine and check the level Complete if necessary For lubrication operations refer to the Lubricants and equivalents table in ...

Page 159: ...e and check the oil level Complete if necessary Perform the first drainage and the first oil filter cartridge change after the first 100 hours of operation 12 3 TRAVEL AXLES The level check operations must be performed periodically respecting the maintenance schedule provided It is recommended that you intervene immediately in the event of leaks or other faults resulting in a drop in oil levels to...

Page 160: ...rain plugs 2 to eliminate any pressure from inside them Loosen the control plug 1 The lubricant level in the axle must arrive at the control plug 1 otherwise refill to the correct level via the same hole Reassemble the control plugs 1 and the drain plugs 2 Refer to the Lubricants and equivalents table in Section H 14 5 for the type of oil used Take advantage of this operation to clean the drain pl...

Page 161: ...ion to clean the control plugs 1 and the drain plugs 2 12 3 3 Checking the level of the epicycloidal reducers 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 litres Loosen the...

Page 162: ...ridge Replace the used cartridge with a new one Close the motor cover again 13 2 2 Changing the diesel pre filter To access the diesel pre filter situated next to the filling plug remove the plate fixed by 3 HM10 screws Loosen the transparent lower cover Replace the filter Carefully clean the cover Retighten it manually 1 4 turn after contact with the seal Reassemble the plate Reinitiate the diese...

Page 163: ...and pull the outer cartridge See Section H 6 5 3 Change the outer filter cartridge Reassemble the cover checking that the dust evacuation valve is directed downwards 13 4 INTERNAL COMBUSTION ENGINE Check that the motor supports and the elastic mount attachments are in good condition Never clean the cartridge by hitting it against a hard surface or with a hot or inflammable liquid For the following...

Page 164: ...lock Perform boom lifting movements Check the oil level and complete if necessary Close the filling plug again Perform the first filter change after the first 100 hours of operation 13 5 2 Transmission hydraulic circuit Change the hydraulic filter cartridge Place the machine in work position and stop the engine Open the engine compartment Loosen the tank from the transmission hydraulic filter Chan...

Page 165: ...enance schedule provided It is recommended that you intervene immediately in the event of leaks or other faults resulting in a drop in oil levels to avoid any possible damage to the mechanical components Once you have removed the filling and drainage plugs they should be closed again by tightening using a torque wrench with the torque intended by the manufacturer Perform the first drainage after t...

Page 166: ... pressure from inside them Loosen the drainage plug 4 and let the oil flow Reassemble the drainage plug 4 Loosen the level 1 control plug Fill the axle the lubricant level in the axle must arrive at the control plug 1 Reassemble the control plugs 1 and the drain plugs 2 Refer to the Lubricants and equivalents table in Section H 14 5 for the type of oil used Take advantage of this operation to clea...

Page 167: ...rst remove the drain plug 2 to eliminate any pressure from inside it Loosen the drainage plug 4 and let the oil flow Reassemble the drainage plug 4 Loosen the level 1 control plug Fill the axle the lubricant level in the axle must arrive at the control plug 1 Reassemble the control plugs 1 and the drain plugs 2 Refer to the Lubricants and equivalents table in Section H 14 5 for the type of oil use...

Page 168: ...zontal position Fill the reducer the oil level must arrive at the plug Reassemble the plug 3 Refer to the Lubricants and equivalents table in Section H 14 5 for the type of oil used 15 Every 2000 hours of operation or every 2 years 15 1 COOLING SYSTEM Change the coolant Capacity approx 18L OPEN THE HEATING VALVE SITUATED IN THE CAB WHEN DRAINING THE COOLING SYSTEM AND THE TWO VALVES SITUATED IN TH...

Page 169: ... which should be identical upon reassembly Turn the cover to the right See Section H 6 5 2 Pull the cover to remove it Turn and pull the primary outer cartridge Then pull the secondary inner cartridge See Section H 6 5 3 Insert a new secondary cartridge by pushing it to the bottom of the socket provided in the case Place the new primary cartridge above the secondary cartridge insert it in place wi...

Page 170: ...es technician Change the oil Tank capacity 110 litres For all engine maintenance operations consult the guide provided by the engine manufacturer or HAULOTTE Services Drainage must be performed when the oil is hot Place the machine in its folded position Stop the engine Go underneath the machine Remove the filling plug 2 on the photo opposite Remove the drainage plug 1 on the photo opposi te Let t...

Page 171: ...the drainage plug Fill the tank with the recommended oil until the gau ge indicates the max level Reassemble the filling plug 2 on the photo oppo site Switch on the engine Actuate the equipment controls in both directions for approx five minutes without placing the cylinders at the stops Place the machine in road position The level must be as indicated in the photo opposi te Complete if necessary ...

Page 172: ...u 3 Multi move 2 Driver seat rails Multi Purpose Grease Moly OILS Front axle and diffe rential 10 litres SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 Rear axle and diffe rential 8 litres SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 Wheel reducer 1 3 litre SAE 80W90 MIL L2105 API GL5 ENER GEAR 90 80W90 TRAN SELF TYPE 80W90 ESSO GEAR GX SAE 80W90 ROTRA MULTI THC C 80W90 SPIRAX LS 80W90 Tra...

Page 173: ...I 167 2420331560 E 04 07 GB TELESCOPIC HANDLERS H LUBRIFICATION AND MAINTENANCE Axle oil viscosity according to the ambient temperature Engine oil viscosity according to the ambient temperature GREASE GRAISSE OIL HUILE ...

Page 174: ...ly FU113 7 5A Fuse for sensor supply controls FU114 30A Fuse for electrovalve supply FU620 10A Fuse for reverse warning signal FU183 20A Fuse for front windscreen wiper windscreen washer FU195 30A Fuse for 12V socket FU191 20A Fuse for work headlight FU184 10A Fuse for rear windscreen wiper FU183 10A Fuse for front windscreen wiper windscreen washer FU182 20A Fuse for cab accessories FU180 30A Fus...

Page 175: ...r Parking brake defect LED P182 Not enough pressure in the parking brake system Motor oil pressure LED P181 Not enough pressure Service brake defect LED P182 Not enough pressure Battery LED P180 Wiring problem ECU LED P191 The machine is equipped with an internal defect detection system The number of times the ECU LED flashes indicates the type of fault to the operator The machine switches to down...

Page 176: ... defect in descent with Vmax Check connection between S1x and noeud B 4 flashes Left chocking failure Right chocking failure Check the left chocking sensor connections Change the left chocking sensors Check the right chocking sensor connections Change the right chocking sensors 5 flashes Arm length failure Boom angle failure Check the arm length sensor connections Change the arm length sensors Che...

Page 177: ...TENANCE 18 1 PROCEDURE Record the number of flashes emitted by the ECU LED Note any other LEDs that may be lit and the situation of the machine when the defect appears Fold the machine Stop the machine Service it as required It is prohibited to use the machine until the defect is repaired ...

Page 178: ...172 2420331560 E 04 07 GB TELESCOPIC HANDLERS Probable cause ...

Page 179: ...A B C D E F G H I 173 2420331560 E 04 07 GB TELESCOPIC HANDLERS I INTERVENTION LOG Date Type of intervention Number of hours Intervening Number of intervention HAULOTTE Services ...

Page 180: ...174 2420331560 E 04 07 GB TELESCOPIC HANDLERS Date Type of intervention Number of hours Intervening Number of intervention HAULOTTE Services ...

Page 181: ...A B C D E F G H I 175 2420331560 E 04 07 GB TELESCOPIC HANDLERS I INTERVENTION LOG Date Type of intervention Number of hours Intervening Number of intervention HAULOTTE Services ...

Page 182: ...176 2420331560 E 04 07 GB TELESCOPIC HANDLERS Date Type of intervention Number of hours Intervening Number of intervention HAULOTTE Services ...

Page 183: ...N A T O R P R E H E A T I N G S Y S T E M S E NS OR TE MPE R ATUR E E NGINE POWE R CONTACTOR P R E H E A T I N G R E S I S T O R E N G I N E S T O P 161 0 28 160 161 161 163 26 27 1A 12 B106 161 B 106 1A 0 0 5 161 161 0A 0 0A 2 5 5 B106 161 02 7 01 11 01 6 02 1 M160 02 11 R 160 QS 100 GB100 02 1 65 09 7 07 4 YA160 YA161 02 14 KA160 S T161 KT160 KM160 YV160 HL160 HL161 07 10 194P264340 d 1 10 ...

Page 184: ... CONDITIONING SAUER SUPPLY DCU SUPPLY VALVES SUPPLY SW ITCH AND SENSORS SUPPLY IGNITION KE Y 113 182 183 106 180 103 184 181 0 107 100 102 108 161 109 101 100 191 160 195 622 1A 100A 114 11 187 11 100 2 2 186 100A 10A 10A 30A 5A 10A 10A 04 1 03 1 03 1 03 15 03 17 06 1 05 11 01 20 01 16 01 18 08 1 10A 05 5 02 12 04 1 20A 20A 10A 15A 200A 10A 15A 15A 04 9 30A 01 20 06 1 7 5A 03 1 01 5 FU161 10A 05 9...

Page 185: ...E CTOR SEEING ON SW ITCH AIR CONDITIONING AIR CONDITIONING COM PRESSOR AIR CONDITIONING VENTILATORS AIR CONDITIONING 622 181 43 48 0 100A 185 105 42 41 49 180 0 111 103 100B 0 111 110 0 103 105 112 45 45 46 46 43 43 186 186 50 623 622 02 8 05 1 GYRO M181 02 7 04 1 04 1 SA180 03 14 4A 4A 4A 02 14 02 14 KA181 02 14 FU110 FU111 E L100 S A101 E L101 EL102 E L103 E L104 FU112 S B105 HA105 S A185 HA185 ...

Page 186: ...UNIT ELECTRICAL CONNECTOR 12V CIGAR LIGHTER CAR RADIO CEILING LIGHT 90 184 0 101 183 183 0 0 106 0 51 210 111 183 92 92 191 182 63 100 62 G D G D 196 54 192 193 0 90 197 188 195 0 110 111 31 R 49 05 1 M 03 20 XP195 05 13 02 9 M183 02 15 M186 02 9 02 16 M184 E L191 02 3 SA191 05 14 05 17 E L192 E L193 E L194 SA184 XP183 S A104 03 12 02 19 M M S A106 SA182 E L182 02 17 SA195 03 8 05 3 03 8 KA110 02 ...

Page 187: ...SEEING STEERING INDICATOR TOW CONNECTOR R A STEERING INDICATOR LEFT STEERING INDICATOR RIGHT SIDE LIGHT LEFT SIDE LIGHT RIGHT BRAKE LIGHT RIGHT BRAKE LIGHT LEFT SIDE LIGHTS SEEING 0 60 0 66 107 61 0 100B 59 111 61 108 64 63 0 0 0 62 109 62 62 63 63 63 70 110 0 05 13 1 D5 2 1 2 D6 05 13 03 13 P 04 20 3 4 D106 D107 5 04 20 KA103 05 3 1 2 S A103 04 15 05 16 04 15 05 7 05 9 05 9 05 19 E L115 HL111 KA1...

Page 188: ... 5V 106 13 0 5V 104 15 U100 synchro S TOR 3 5A 105 34 B A S ynchro E TOR E TOR 105 14 105 15 P arking brake S hunt limits load S election winch nacelle S election direction axle AR High speed translation F orward gear translation R everse gear translation Neutral position C rab S eeing neurtal position raising signal excavation signal Telescoping signal auxiliary signal S eeing brake parking C rab...

Page 189: ...F R ONT R IG HT G ONE UP B OOM LOW B OOM AT 45 T E LE S C OP E R E T UR NE D T E LE S C OP E MIDDLE R ANG E S T AB F R ONT LE F T DR OP P E D S T AB F R ONT R IG HT DR OP P E D R adio control S lope WE IGHING S YS TE M WE IGHING OK sensor of constraint S YS TE M ANTI S WING Alarm limit load pre alarm DE AD MAN S IT S C P U F AILUR E V alidation corrector of plate ANT I S T AR T UP C ONT AC T OR F ...

Page 190: ...E T OUR P P U INP UT 1 NC NC R S 232 T xD R S 232 R xD HIG H C UR R E NT 4 HIG H C UR R E NT 5 NC NC NC NC NC NC INP UT C R E E P MODE NC NC NC NC NC NC NC B AT T E R Y ANALOG INP UT 1 ANALOG INP UT 0 B AT T E R Y B AT T E R Y 1 4 3 2 D_S AUE R AV AR R OUGE JAUNE VE R T 28 29 15 S V685 U600 10K 0 25W 5 F orward gear translation R everse gear translation Low speed translation S E NS OR S PE E D THE...

Page 191: ...down R E V COUNTE R HOR AME TR E Oil pressure engine F ront axle centered S afety brake service S afety brake parking Temperature oils hydraulic F ilter oil clogged R ear axle centered Level of fuel Level fuel indicator 0 760 740 0 691 B 117 0 720 700 163 162 113 126 0 B106 164 189 189A B 115 B 116 721 114 690 701 164B 695 682 125 07 19 06 12 01 9 06 20 08 17 YV740 BN S A782 YV760 YV700 S A780 YV7...

Page 192: ...plug valve S UPPLY Oil pressure engine Temperature of hydraulic oil R ADIO CONTR OL E ME R GE NCY S TAR TUP HOR N R aising signal Telescoping signal Basket rotation Basket compensation Left R ight Up Down 187 0 380 190 0 B 401 0 194 B 402 B 102 198 B 103 B 104 B 105 B400 B 400 103 105 162 B 106 125 187A 187 114 09 8 YV380 09 8 09 10 YV190 S A190 02 4 KA187 KA188 06 20 03 4 03 1 09 16 S A188 KA380 ...

Page 193: ...187 2420331560 E 04 07 GB HYDRAULIC DIAGRAM Telescopics handlers 1 HTL 4017 4014 1 1 FOLIO 1 1 194P261380 a ...

Page 194: ...188 2420331560 E 04 07 GB HYDRAULIC DIAGRAM Telescopics handlers ...

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Haulotte HTL4014, Operator'S Manual

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