Haulotte HTL 4010 Operator's Manual
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Haulotte HTL 4010 Operator's Manual

Telescopic handlers
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Operator's manual
Operator's manual
TELESCOPIC HANDLERS
HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010
24203 21 0
E01.15
EN
4000328140
E01.15
AUS

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Summary of Contents for Haulotte HTL 4010

  • Page 1 Operator's manual Operator's manual TELESCOPIC HANDLERS HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010 24203 21 0 E01.15 4000328140 E01.15...
  • Page 2 Telescopic handlers 4000328140 E01.15...

  • Page 3: Table Of Contents

    3 - Compliance ........4 - HAULOTTE Services® contact details....
  • Page 4 2.4 - Dumping procedure ......... . . 2.5 - Stabiliser operation procedure (HTL 4010) ..... . .
  • Page 5 Operator's manual EMERGENCY PROCEDURE 1 - Towing a broken-down vehicle ....1.1 - General precautions......... . . 1.2 - Releasing the axle brake for towing .
  • Page 6 Operator's manual 7 - General points....... . . 7.1 - Mechanical ..........7.1.1 - Bolts and Tightening torques .
  • Page 7 Operator's manual 14 - Every 1500 h hours of operation ....14.1 - Travel axles ..........14.1.1 - Draining the front axle.
  • Page 8 Operator's manual...

  • Page 9: Operator's Manual

    Services® immediately even if the malfunction does not involve material and/or bodily damage.. • HAULOTTE® must be informed in the event of an incident that either involves one of these products or has caused bodily injury or significant deterioration of property (personal property or the product);...

  • Page 10: Compliance

    Telescopic handlers 3 - Compliance We would like to remind you that HAULOTTE® complies with the provisions of any applicable directives applicable to this type of machine. HAULOTTE advises you that NO modifications carried out without the written permission of HAULOTTE® can affect the visibility in driving position and will void the HAULOTTE warranty.

  • Page 11: Haulotte Services® Contact Details

    E.mail : haulotte@de.haulotte.com E.mail : info@haulottevostok.ru E.mail : haulotte@haulotte.com.br www.haulotte.de www.haulotte-international.com www.haulotte.com.br HAULOTTE MÉXICO, Sa de Cv HAULOTTE IBERICA HAULOTTE POLSKA Sp. Z.o.o. Calle 9 Este, Lote 18, Civac, Jiutepec, C/ARGENTINA N° 13 - P.I. LA GARENA UL. GRANICZNA 22...
  • Page 12 Telescopic handlers 4000328140 E01.15...

  • Page 13: Safety Precautions

    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®.

  • Page 14: Label Colors

    The potential dangers and any specific regulations are indicated around the product by labels and identification plates. The labels must be kept in good condition. Additional labels can be ordered from HAULOTTE Services®. Familiarize yourself with the labels and their respective color codes.

  • Page 15: Operation Instructions

    POTENTIAL RISKS 2.2.1 - Tip-over hazards Never use an accessory without having checked the HAULOTTE® accessory load capacity chart installed on the telehandler. • Do not exceed the rated lifting capacity. • Check that the ground can support the machine.
  • Page 16 Telescopic handlers - Safety precautions Do not raise the boom unless the chassis is level (0 °). Do not level the machine with the boom or the accessory above 30 ° • Transport the load as low as possible. Attach the suspended loads to restrict movement.
  • Page 17 Telescopic handlers - Safety precautions • Maintain proper tire pressure at all times. Otherwise, the machine could tip over. Do not 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 : •...

  • Page 18: Electrical Hazards

    Telescopic handlers - Safety precautions 2.2.2 - Electrical hazards • The machine is not electrically 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 power sources may exist without ensuring that the appropriate utility company has de-energized the lines.
  • Page 19 Telescopic handlers - Safety precautions Minimum safety distance - For AS standard only 4000328140 E01.15...

  • Page 20: Travel Hazards

    Telescopic handlers - Safety precautions 2.2.3 - Travel hazards • The turning radii change according to the steering mode selected ( 2 or 4 steer wheels). • Ensure that adequate clearance is provided for pivoting the rear tail and the front fork. The rear offset is larger in 4 steer wheels mode.

  • Page 21: Load Falling Hazards

    Telescopic handlers - Safety precautions 2.2.4 - Load falling hazards 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. The forks must be centred under the load and on the fork carriage and spaced apart as far as possible.

  • Page 22: Driving Hazards On Slopes

    Telescopic handlers - Safety precautions 2.2.6 - Driving hazards on slopes 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. •...

  • Page 23: Pinching And Crushing Hazards

    Telescopic handlers - Safety precautions 2.2.7 - Pinching and crushing hazards Stay clear of pinch points and rotating 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.

  • Page 24: Risk Of Falling

    Telescopic handlers - Safety precautions 2.2.8 - Risk of falling Enter the cab using the proper hand rails and the steps provided. Always maintain 3 points of contact when entering or leaving the machine. Never grab the control levers or the steering wheel when mounting or dismounting the machine.

  • Page 25: Intervenor's Responsibility

    The owner (or hirer) has the obligation to renew all manuals or labels that are either missing or in bad condition. Additional copies can be ordered from HAULOTTE Services®. The owner (or hirer) is responsible for applying the local regulations regarding operation of the machine.

  • Page 26: Inspection And Maintenance

    Inspections and maintenance Type of Reference Frequency Person-in-charge Intervenor intervention document Before each delivery Pre-delivery Qualified HAULOTTE of sold, hired or Owner (or hirer) Operator's manual inspection Services® technician resold equipment Operator's manual Before operation or Pre-operation when the operator...

  • Page 27: Pre-Operation And Controls

    Telescopic handlers - Pre-operation and controls Pre-operation and controls 1 - Checks before use Each day and before the beginning of a new work period and on each change of operator, the machine must be subjected to a visual inspection and a complete functional test. Any repairs required must be performed before the machine is used, its correct operation depends on it.
  • Page 28 Telescopic handlers - Pre-operation and controls • Steering system's state : axles, wheels and tyres : • No cracks, distortions, damaged paint or other faults • No missing or loose bolts. • Condition of the tyres (cuts, excessive wear, etc.). •...

  • Page 29: Pre-Operation Checks And Inspection

    Telescopic handlers - Pre-operation and controls 2 - Pre-operation checks and inspection N.B.-:-Perform all required maintenance work before operating the unit. Use extreme caution when checking parts that are difficult to reach. Use an approved ladder. "Failure" to comply with these instructions could result in death or serious injury. Increase in periodical inspections : Depending on the condition of certain critical components after 5000 hours, the maintenance staff may have to reduce the interval between periodical inspections and maintenance.
  • Page 30 Telescopic handlers - Pre-operation and controls Major Component Location Diagram Begin the walk-around inspection at item 1, as indicated below. Continue to the right (anticlockwise, when viewed from above) checking each part in sequence. N.B.-:-For each component, ensure that there are no loose or missing parts, that the components are securely fastened and that there are no visible leaks or excessive wear in addition to any other criteria mentioned.
  • Page 31 Telescopic handlers - Pre-operation and controls Jib cylinders, lifting, telescoping, compensation output and input, cases : • Pins secure, hydraulic hoses in good condition, no leaks. • Check the state of the extension booms wear pads. Left-hand stabiliser and detector : Pins secure, hydraulic hoses in good condition, no leaks (For HTL4010 only).
  • Page 32 Telescopic handlers - Pre-operation and controls Engine compartment : • Engine crankcase and radiator : Check the levels and top up as required. Check that the ra- diator is clean. • Drive belt : check their condition, adjust and/or replace as required. •...

  • Page 33: Safety Stickers

    Telescopic handlers - Pre-operation and controls 3 - Safety stickers Ensure that all stickers and appropriate capacity charts are legible and in place. Clean or replace if necessary. 3.1 - RED LABELS The red labels indicate a potentially fatal danger. Common labels - AS standard It is prohibited to use attachments without appropriate load charts.
  • Page 34 Telescopic handlers - Pre-operation and controls Specific labels HTL 4010 - AS standard 6400 daN daN/cm² 6100 daN 4.2 daN/cm² 307P228350 a 307P228360 a Specific labels HTL 3510 - AS standard 6200 daN 4.6 daN/cm² 307P228710 a Specific labels HTL 3010 - AS standard 6200 daN 4.6 daN/cm²...

  • Page 35: Yellow Labels

    Telescopic handlers - Pre-operation and controls 3.2 - YELLOW LABELS The yellow labels indicate a risk of material damage and/or minor injury. Common labels - AS standard CAUTION DIESEL LOW SULFUR OR ULTRA-LOW SULFUR / 10W-40 10W-40 DIESEL À FAIBLE OU TRÈS FAIBLE TENEUR EN SOUFRE / GASÓLEO BAJO EN AZUFRE O ULTRA-BAJO EN AZUFRE / 15W-40 5W-40...
  • Page 36 Telescopic handlers - Pre-operation and controls Specific labels HTL4010 - HTL 3510 - HTL 3010 - AS standard Specific labels, optional - AS standard 4000328140 E01.15...

  • Page 37: Other Labels

    FU189 / 30A 307P223480 a 307P216800 a 307P220800 b Specific labels HTL 4010 - AS standard 4010 HAULOTTE GROUP, La Péronnière, BP9, 42152, L'Horme - France 4010 Maximum Capacity Serial No Unladden Mass Maximum load on front axle Maximum load on rear axle...
  • Page 38 Telescopic handlers - Pre-operation and controls Specific labels HTL 3510 - AS standard 3510 HAULOTTE GROUP, La Péronnière, BP9, 42152, L'Horme - France 3510 Maximum Capacity Serial No Unladden Mass Maximum load on front axle Maximum load on rear axle...

  • Page 39: Identification

    Telescopic handlers - Pre-operation and controls 3.4 - IDENTIFICATION Locations - HTL 4010 - HTL 3510 - HTL 3010 - Standards CE and AS 4000328140 E01.15...
  • Page 40 Telescopic handlers - Pre-operation and controls 4000328140 E01.15...
  • Page 41 HTL4010 HTL3510 HTL3010 Other Identification plate AS standard : 307P230120 Other Machine name logo 4000096280 4000085110 400010080 Other Label HAULOTTE® 307P224740 Other Label HAULOTTE® 307P228770 Other Read the operation manual 307P220740 Other Noise emission level 307P223480 Other Yellow and black adhesive tape...
  • Page 42 Telescopic handlers - Pre-operation and controls Color Marking Description Quantity HTL4010 HTL3510 HTL3010 Risk of crushed feet 307P220890 Danger of electrocution 307P220770 Cylinder locking 307P220860 Do not mount on the forks during 307P221950 elevation Label book 307P223840 4000328140 E01.15...
  • Page 43 Telescopic handlers - Pre-operation and controls Load capacity chart - HTL4010 - AS standard Color Marking Description Quantity HTL 4010 Other Load capacity chart 307P232400 Other Load capacity chart - Book 107P345780 Other Load capacity chart - Cover book 307P232130...
  • Page 44 Telescopic handlers - Pre-operation and controls Load capacity chart - HTL3010 - AS standard Color Marking Description Quantity HTL 3010 Other Load capacity chart 4000059310 Other Load capacity chart - Book 4000059330 Other Load capacity chart - Cover book 4000059410 Other Load capacity chart - Forks 4000059340...

  • Page 45: Operator's Cab

    Never use the machine unless the overhead guards and the cab structure are in good condition. Any modifications to this machine must be approved in writting by 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.
  • Page 46 Telescopic handlers - Pre-operation and controls Description of the components Marking Description C120 Warning lights C121 Parking brake C122 Brake pedal /Inching : The further the pedal is pressed, the slower the travel speed C123 Accelerator pedal : Press on the pedal to increase the engine speed and the hydraulic fluid flow C124 Steering column adjuster : Section C 2.5.3 - Steering column...

  • Page 47: Pedals

    Telescopic handlers - Pre-operation and controls 3.5.2 - Pedals General view P163 P164 Pedals Marking Description Function P163 Accelerator Pedal for increasing the engine speed Machine braking P164 Brake Inching : Slow approach 4000328140 E01.15...

  • Page 48: Steering Column

    Telescopic handlers - Pre-operation and controls 3.5.3 - Steering column General view P165 Left-hand control lever Marking Description Function Speed selection : • Neutral • Slow speed : Selector in position I • Fast speed : Selector in position II Travel direction selection : P165 Gear and movement direction control...

  • Page 49: Steering Column Adjustment

    Telescopic handlers - Pre-operation and controls General view P167 P168 P166 P169 Right-hand control lever Marking Description Function Left-hand steering : Raise the lever P166 Turn signals/Direction indicators Right-hand steering : Lower the lever On : Turn clockwise P167 Sidelights Off : Turn anti - clockwise (ACW) On : Turn clockwise P168...

  • Page 50: Operator's Seat

    Telescopic handlers - Pre-operation and controls 3.5.4 - Operator's seat General view P175 P171 P170 P174 P172 Before starting the engine, adjust the seat as follows to place the seat in an appropriate and comfortable position : • Move forward/backward : Use the handle ( P170 ) to move the seat forward and backward. •...

  • Page 51: Heating And Ventilation

    Telescopic handlers - Pre-operation and controls 3.5.5 - Heating and ventilation The cab is equipped with a heater that is also used for de misting the windscreen. The air is circulated via a two-speed fan. To activate the fan, press the heating fan switch ( P203 ) on the side instrument panel.

  • Page 52: Instrument/Control Panel

    Telescopic handlers - Pre-operation and controls 3.5.7 - Instrument/control panel P198 P223 P221 P222 P199 P214 P213 P215 P207 P204 P203 P205 P208 P209 4000328140 E01.15...
  • Page 53 Telescopic handlers - Pre-operation and controls Instrument/control panel Marking Description Function Exclusion key in fork/winch mode Folds the machine in case of anti-tipping alarm : Rotate to (Option) right and hold 'Enable Switch' selector in platform Control of the platform from the cab : Rotate to right and P198 mode (Option) hold...
  • Page 54 Telescopic handlers - Pre-operation and controls Display General view Display Marking Description Function Service counter (when power is Number of hours to next service switched on) Engine revs indicator graduated from 0 to 3100 tr/min (3100 P176 Engine tachometer with hour meter RPM) Vehicle speed (Km/h) P178...
  • Page 55 Telescopic handlers - Pre-operation and controls Marking Description Function Particulate filter regeneration disabled P227 indicator (For machines fitted with On : Automatic particulate filter regeneration disabled engine PERKINS 854E-34TA only) High exhaust gas temperature indicator P228 (HEST) (For machines fitted with On : Particulate filter regeneration in progress engine PERKINS 854E-34TA only) On : Drive motor faulty OR machine maintenance to be...
  • Page 56 Telescopic handlers - Pre-operation and controls Right-hand control panel General view P214 P215 P213 P200 P204 P207 P203 P201 P208 P209 P205 4000328140 E01.15...
  • Page 57 Telescopic handlers - Pre-operation and controls Right-hand control panel Marking Description Function Load levelling system (on HTL 3010 and HTL 3510 (HTL P200 Chassis leveling switch 7732) only) Synchronised axle Rear axle selection P201 Front steer wheels Steering mode Crab mode axle P203 Heating/Ventilation switch Ventilation - 2 speeds...
  • Page 58 Telescopic handlers - Pre-operation and controls 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 Axles must be realigned : •...

  • Page 59: Joystick

    Telescopic handlers - Pre-operation and controls 3.5.8 - Joystick General view - AS standard P211 4000064510 a Joystick - AS standard Marking Description Function To raise the telescopic arm : Pull the joystick. Keeping pressed the back trigger in the joystick. To lower the telescopic arm : Push the joystick.
  • Page 60 Telescopic handlers - Pre-operation and controls Additional controls - Joystick - HTL 4010 Marking Description Function Button (High) : Float option Button (Low) : Load levelling system Lowering left stabiliser : Press the low button and push the joystick towards the left and then forwards...

  • Page 61: Left-Hand Control Panel

    Telescopic handlers - Pre-operation and controls 3.5.9 - Left-hand control panel General view P210 P202 P212 P233 General view Marking Description Function P202 12 V socket switch (Option) On : Press top of switch downwards P210 Rear fog lights switch Off : Press bottom of switch downwards On : Press top of switch downwards P212...
  • Page 62 Telescopic handlers - Pre-operation and controls While a forced regeneration is running, it is essential to be aware of the following points : • The machine is immobilised for 15 20 minutes (until the ( P228 ) indicator goes out). •...

  • Page 63: Load Moment Indicator (Lmi)

    Telescopic handlers - Pre-operation and controls 3.5.10 - Load moment indicator (LMI) General view P218 P217 P216 P219 Controls and indicators Marking Description Function P216 Green LED's Loading percent P217 Yellow LED Pre-alarm (intermittent buzzer) P218 Red LED Alarm (continuous buzzer) P219 Test The indicator can be tested at any time...
  • Page 64 Telescopic handlers - Pre-operation and controls If a load moment indicator system alarm is triggered, the following movements are disabled : Movements-Modes 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...

  • Page 65: Rear-View Mirrors And Windows

    Telescopic handlers - Pre-operation and controls 3.5.11 - Rear-view mirrors and windows Cab door 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.
  • Page 66 Telescopic handlers - 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 4000328140 E01.15...
  • Page 67 Telescopic handlers - Pre-operation and controls Rear-view mirror adjustment : Rotate the mirror 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.

  • Page 68: Radio-Control Emitter

    Telescopic handlers - Pre-operation and controls 3.6 - RADIO-CONTROL EMITTER General view 307P224480 a 307P224490 a 307P224500 a 307P224510 a Radio-control emitter Marking Description Function Move upwards : Accessory lifting Accessory compensation control Move downwards : Accessory lowering Engine start-up selector Starting the engine Press the joystick to activate and confirm the movement Move forward : Boom in...
  • Page 69 Telescopic handlers - Pre-operation and controls Marking Description Function P242 Electrical connector Electrical connection of the remote control : Press the joystick to activate and confirm the movement. The operator can 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.

  • Page 70: Safety Devices

    Telescopic handlers - Pre-operation and controls 3.6.1 - Safety devices To protect the user and the machine, safety systems prevent the operation of the machine beyond its capacities. These security systems if activated, immobilize the machine and neutralize the movements. Poor knowledge of the characteristics and operation of the machine can lead the operator to think that a normal safety operation is a malfunction.

  • Page 71: Operation

    To establish the type of fuel suitable for the engine fitted on your HAULOTTE® machine, please refer to the engine manufacturer's manual. The engine may not be covered by the warranty in case of damage caused by using unsuitable fuel.

  • Page 72: Operational Checks

    Telescopic handlers - Operation 1.2 - OPERATIONAL CHECKS 1.2.1 - During the warm-up period Check at the beginning of each work shift or at each change of operator : • The heating, the defrost system and the windscreen wiper. • check all lighting systems for proper operation. Keep the engine cover closed while the engine is running.

  • Page 73: Normal Engine Operation

    Pay attention to unusual noises and vibrations. If a fault occurs, park the machine in a safe position and perform the shut-down procedure ( Section D 1.5 -Engine shut-down procedure). Report the fault to HAULOTTE Services®. Avoid prolonged idling. Turn the engine off when not in use. 1.5 -...

  • Page 74: Operation With A Load

    Telescopic handlers - Operation 2 - Operation with a load 2.1 - LOAD LIFTING SAFETY • Know the weight and the centre of gravity of each load to be lifted. • Use the load capacity chart associated with each attachment. Exceeding the machine's lifting capacity may damage the equipment and/or cause tipping over, resulting in death or serious injury.

  • Page 75: Transporting The Load

    Telescopic handlers - Operation 2.3 - TRANSPORTING THE LOAD 2.3.1 - For operation with non-suspended load Once the load is engaged on the forks and leaning against the fork carriage, tilt the load backwards to place it in the travel position. Travel as specified Section A - Safety precautions, Section E - Attachments.

  • Page 76: Stabiliser Operation Procedure (Htl 4010)

    Telescopic handlers - Operation 2.5 - STABILISER OPERATION PROCEDURE (HTL 4010) The stabilizers increase lifting capacity and make it possible to level the machine. • Position the machine in the best location for lifting or placing the load (Gradeability 3 °).

  • Page 77: Road Operation

    Telescopic handlers - Operation 3 - Road operation • Preparation : • Remove any large amounts of dirt from the machine. • Check the lights and the mirrors, and adjust them if necessary. • Follow the recommendation in force in the country of use (Registration plate, jacket, warning triangle, first-aid kit, chocks…).

  • Page 78: Loading And Securing For Transport

    Telescopic handlers - Operation 4 - Loading and securing for transport HTL 4010 307P216800 a 307P216800 a HTL 3510 - HTL 3010 307P216800 a 307P216800 a • Level the machine before loading. • Obtain assistance from an operator for manœuvres and loading the machine, with the boom as low as possible.
  • Page 79 Telescopic handlers - Operation 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. Lifting the machine Ensure that : •...
  • Page 80 Telescopic handlers - Operation 4000328140 E01.15...

  • Page 81: Attachments

    The user must ensure that the accessory can be used in the country in which the machine is be used. 2 - Unapproved attachments Do not use attachments that have not been approved in writing by Haulotte for the following reasons : • HAULOTTE® cannot establish the capacity range limits for DIY, home-made, altered or other unapproved attachments.

  • Page 82: Telehandler/Attachment/Fork Capacities

    The forks must be used in matched pairs. Never use an accessory without having checked the HAULOTTE® accessory 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.

  • Page 83: Using The Capacity Chart With Forks

    4 - Using the capacity chart with forks To use the capacity chart properly, the operator must first determine and/or obtain the following : • Approved attachments HAULOTTE®. • A load chart corresponding to the attachment. • The weight of the load to be lifted.
  • Page 84 Telescopic handlers - Attachments Boom extension indicators 4000328140 E01.15...
  • Page 85 Telescopic handlers - Attachments Example of a load capacity chart : HTL 4010 68° 60° 50° 40° 30° 20° 10° 0.6 m 0.6 m 0° fork load centre 600mm fork load centre 600mm Standard used AS1418.19 Marking Description HTL4010 : The load capacity chart must only be used for this machine...
  • Page 86 Telescopic handlers - Attachments Examples of how to read the load capacity chart for the HTL4010 fitted with the fork carriage The following examples illustrate situations where the load may or may not be lifted. Use the capacity chart corresponding to the machine. The attachment number located on the manufacturer's plate must correspond to the attachment number which appears on the load chart.
  • Page 87 Telescopic handlers - Attachments HTL4010 load capacity chart 68° 60° 50° 40° 30° 20° 10° 0.6 m 0.6 m 0° fork load centre 600mm fork load centre 600mm Standard used AS1418.19 HTL3510 load capacity chart HTL 3510 65° 60° 50° 40°...
  • Page 88 Telescopic handlers - Attachments HTL3010 load capacity chart HTL 3010 65° 60° 50° 40° 30° 20° 10° 0.6 m 0° -2° fork load centre 600mm Standard used AS1418.19 Forks characteristics Length Width Weight 1200 mm 125 mm 80 kg 1200 mm 100 mm 65 kg 4000328140...

  • Page 89: Attachment Installation

    Telescopic handlers - Attachments 5 - Attachment installation C143 C144 C145 C146 C147 Description of the components 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 place by 2 retaining locks.

  • Page 90: Hydraulic Accessory Locking Device (Option)

    Telescopic handlers - Attachments 5.2 - HYDRAULIC ACCESSORY LOCKING DEVICE (OPTION) 5.2.1 - Specific instructions Before installing the hydraulic adaptation kit, ensure : • that the boom is below 15 °. The hydraulic adaptation kit connection is carried out with the machine stopped. 5.2.2 - Operation •...

  • Page 91: Adjusting/Moving Forks

    Telescopic handlers - Attachments 5.3 - ADJUSTING/MOVING FORKS Fork carriages may have different locations for positioning forks. N.B.-:-Apply a light coating of an appropriate lubricant to facilitate fork or fork bar sliding. To slide the forks : • Ensure that the fork carriage is correctly installed : Section E - Attachments.

  • Page 92: Attachments

    Telescopic handlers - Attachments 6 - Attachments Familiarize yourself with the information provided on the attachment identification plate. Use the capacity table (load chart booklet) corresponding to this accessory. Keep the specific instructions for the forks in the manual holder situated behind the cab seat, with the telehandler operator manual.
  • Page 93 Telescopic handlers - Attachments Side-shift fork carriage Hydraulic kit Attachment reference 2820303940 Width 1,25 m(4 ft10 in) Mass 390 kg(860 lb) 0,125 m (41 in) X Section 0,045 m (1,7 in) Dimensions of pallet forks Length 1,2 m(4 ft0 in) 100 mm in relation to the central Lateral movement position...
  • Page 94 Telescopic handlers - Attachments Toothless bucket Attachment reference 2820302810 Nominal capacity 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...
  • Page 95 Telescopic handlers - Attachments 4 T (8820 lb) 0 m(0 ft0 in) jib crane Attachment 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)
  • Page 96 Telescopic handlers - Attachments Fly jib 2,5 m(8 ft2 in), 1,2 T (2646 lb) on telescopic arm Attachment reference 2820304080 Nominal capacity 1200 kg(2646 lb) Mass 206 kg(454 lb) Fly jib 4 m(13 ft1 in), 0,6 T (1323 lb) on telescopic arm Attachment reference 2820304090 2820304090...
  • Page 97 Telescopic handlers - 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) 4000328140 E01.15...

  • Page 98: Operation

    Telescopic handlers - Attachments 6.2 - OPERATION 6.2.1 - Accessory control joystick ( P211 ) controls movements boom attachment tilt Section C 2.5.8 - Joystick). 6.2.2 - Attachment installation procedure Section E 5 - Attachment installation. Incorrect installation could result in the attachment or load disengaging, causing death or serious injury. 6.2.3 - Using the load capacity chart Make yourself familiar with the information Section E 3,...

  • Page 99: Emergency Procedure

    • Ensure that the Telehandler boom is sufficiently raised to avoid interferences with the ground or the towing vehicle. • If the Telehandler boom cannot be raised sufficiently to avoid interferences, contact HAULOTTE Services®. Before towing the Telehandler, you should loosen the two pressure limiters on the travel pump by three turns (1)Unscrew each pressure relief valve by 3 turns before towing.

  • Page 100: Releasing The Axle Brake For Towing

    Telescopic handlers - Emergency procedure If the parking brake is still engaged and the engine has broken down, de-activate the brake before towing ( Section F 1.2 - Releasing the axle brake for towing. ) 1.2 - RELEASING THE AXLE BRAKE FOR TOWING The following procedure is used to release the front axle parking brake in the event of a engine breakdown or when the accumulator is empty.

  • Page 101: Emergency Boom Lowering

    Telescopic handlers - Emergency procedure 2 - Emergency boom lowering 2.1 - MANUAL BOOM LOWERING (EMERGENCY MODE) This operation should only be performed as a last resort as it presents a danger for the operator (machine and load stability). Before any manual lowering operation : •...

  • Page 102: Emergency Exit From Cab

    Telescopic handlers - Emergency procedure • Slowly unscrew the cap situated on the boom lift plate (first plate from the back) until you can see the boom lowering, then unscrew once the boom in low position (2). • Once the boom is lowered and the machine has been repaired, raise the boom to its high position and secure it into place using the cylinder prop.

  • Page 103: Technical Characteristics

    • Have stability tests carried out by a certified agency/competent person. • Ensure label compliance. HAULOTTE® has 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.
  • Page 104 The cab complies with the ROPS (ISO 3471) / FOPS (ISO 3449) European safety standard. Door with two separate sections, opening rear window with wiper, heating, ventilation and joystick with 4 proportional functions. Tyres 405/70 - 24(HAULOTTE® code : 2326014870) Type Pre-charge pressure : 4,5 bar(65,2 psi) Steering system...

  • Page 105: Standard Equipment

    Telescopic handlers - Technical characteristics 1.2 - STANDARD EQUIPMENT • Dual-element air filter • Fuel filter with water separator • Transmission oil filter • 4 Drive and steer wheels • Safety valves on hydraulic cylinders • Auxiliary hydraulic circuit to the boom head •...

  • Page 106: Optional Equipment

    Telescopic handlers - Technical characteristics 1.3 - OPTIONAL EQUIPMENT 1.3.1 - Slings attached 3T (6,615 lb) Slings attached Option number 4000072600 Nominal capacity 3T (6,615 lb) 1.3.1.1 - Main components Marking Description Tool holder carriage Shackle Hook Overload limitation label 1.3.1.2 - Characteristics Lifting hook mounted on tool holder carriage, designed to operate under dynamic and static load, in horizontal position.

  • Page 107: Operation

    Telescopic handlers - Technical characteristics 1.3.1.4 - Operation Operation instructions The swivel in the hook is only to be used to align with the load and support it in a fixed position, it is not designed for rotation under load. The swivel head permits the hook to rotate and avoid the chains twisting.

  • Page 108: Overall Dimensions

    Telescopic handlers - Technical characteristics 2 - Overall dimensions General diagram HTL 4010 - HTL 3510 - HTL 3010 Overall dimension specifications Marking HTL 4010 HTL 3510 Mètre Feet inch Mètre Feet inch 5,14 16 ft 10 in 5,14 16 ft 10 in...
  • Page 109 5 ft 5 in 39 ° 23 ° 103 ° 2,55 8 ft 4 in 4,80 15 ft 9 in Technical characteristics HTL 4010 HTL 3510 Metric Imperial Metric Imperial Vehicule mass without accessory 8440 kg 19,492 lb 8300 kg...

  • Page 110: Working Area

    Telescopic handlers - Technical characteristics 3 - Working area 3.1 - MACHINE HTL4010 Working area 68° 60° 50° 40° 30° 20° 10° 0.6 m 0.6 m 0° fork load centre 600mm fork load centre 600mm Standard used AS1418.19 3.2 - MACHINE HTL3510 Working area HTL 3510...

  • Page 111: Machine Htl3010

    Telescopic handlers - Technical characteristics 3.3 - MACHINE HTL3010 Working area HTL 3010 65° 60° 50° 40° 30° 20° 10° 0.6 m 0° -2° fork load centre 600mm Standard used AS1418.19 3.4 - MACHINE HTL7732 Working area HTL 7732 65° 60°...

  • Page 112: Noise Emission Level

    Do not modify the machine in a way that may increase noise emissions. Technical characteristics (For machines fitted with engine PERKINS 1104D44T only) HTL 4010 - HTL 3510 (HTL 7732) Noise emission level at driving station 75 dBA...

  • Page 113: Telehandler Vibration

    Hand and body vibration are measured in accordance with method and conditions described in standard ISO5349-1 and ISO2631-1. Technical characteristics HTL 4010 - HTL 3510 - HTL 3010 Hand - feet vibration < 2,5 m/s2 Body vibration < 0,5 m/s2 4000328140 E01.15...
  • Page 114 Telescopic handlers - Technical characteristics 4000328140 E01.15...

  • Page 115: Lubrication And Maintenance

    Telescopic handlers - Lubrication and maintenance Lubrication and maintenance 1 - Maintenance guidelines The Telehandler was given an arbitrary Design Life of 10 years at the design stage of the product. There are a number of factors which can affect the design life including but not limited to, severity of operating conditions/routine maintenance which should be carried out in accordance with this manual.

  • Page 116: Maintenance Instructions

    Telescopic handlers - Lubrication and maintenance 2 - Maintenance instructions 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). •...
  • Page 117 N.B.-:-Check that all connections are tight before restarting the machine or pressurizing the system. Do not intervene on the air-conditioning system. A refrigerant fluid leak can cause serious injury. Contact HAULOTTE Services®. • The diesel in the injection system is under high pressure. For any operations or adjustments, please contact a qualified technician or your dealer.
  • Page 118 To establish the type of fuel suitable for the engine fitted on your HAULOTTE® machine, please refer to the engine manufacturer's manual. The engine may not be covered by the warranty in case of damage caused by using unsuitable fuel.
  • Page 119 Telescopic handlers - Lubrication and maintenance Engine oil Only use API CJ-4 oil or equivalent. Please refer to the table of permitted engine oils. 10W-40 15W-40 10W-40 5W-40 Not using the appropriate specification of engine oil may reduce the service life of the engine and post- treatment system.
  • Page 120 Telescopic handlers - Lubrication and maintenance Coolant N.B.-:-The engine fitted in your HAULOTTE® machine must operate with a 1:1 solution of water and glycol. This concentration allows the NOx reduction system to operate correctly in environments where the temperatures are high.

  • Page 121: Repairs And Adjustments

    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. 4000328140 E01.15...

  • Page 122: Lubrication And Maintenance Schedule

    Telescopic handlers - Lubrication and maintenance 4 - Lubrication and maintenance schedule 500h 4000328140 E01.15...
  • Page 123 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine PERKINS 1104D44T 2000h 1500h 1000h 500h 250h 100h 100h 200h 500h 1000h 1500h 2000h 4000328140 E01.15...
  • Page 124 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine PERKINS 1104D44T 2000h 1500h 1000h 500h 250h 100h 100h 250h 500h 1000h 1500h 2000h 4000328140 E01.15...
  • Page 125 Telescopic handlers - Lubrication and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change Lubrication Diesel circuit Cooling system Air filter (system) Internal combustion engine Travel axles Hydraulic circuit Battery 4000328140 E01.15...
  • Page 126 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine PERKINS 854E-34TA 2000h 1500h 1000h 500h 250h 100h 100h 200h 500h 1000h 1500h 2000h 4000328140 E01.15...
  • Page 127 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine PERKINS 854E-34TA 3000h 2000h 1500h 1000h 500h 250h 100h 100h 250h 500h 1000h 1500h 2000h 3000h 4000328140 E01.15...
  • Page 128 Telescopic handlers - Lubrication and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change Lubrication Diesel circuit Cooling system Air filter (system) Internal combustion engine Travel axles Hydraulic circuit Battery 4000328140 E01.15...
  • Page 129 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine KOHLER KDI 3404 TCR 2000h 1500h 1000h 500h 250h 100h 100h 200h 500h 1000h 1500h 2000h 4000328140 E01.15...
  • Page 130 Telescopic handlers - Lubrication and maintenance For machines fitted with : Engine KOHLER KDI 3404 TCR 3000h 2000h 1500h 1000h 500h 250h 100h 100h 250h 500h 1000h 1500h 2000h 3000h 4000328140 E01.15...
  • Page 131 Telescopic handlers - Lubrication and maintenance Description of the components Symbol Marking Description Check the level Filter Oil change Lubrication Diesel circuit Cooling system Air filter (system) Internal combustion engine Travel axles Hydraulic circuit Battery 4000328140 E01.15...

  • Page 132: General Program / Recommendations

    It must be noted that should the product be subject to ongoing use in harsh environments, then the effective service life will be reduced. Contact Haulotte Services for further advice. The time periods below are recommended for fuel-powered machines in normal use.
  • Page 133 Telescopic handlers - Lubrication and maintenance Increase in periodical inspections : Depending on the condition of certain critical components after 5000 hours, the maintenance staff may have to reduce the interval between periodical inspections and maintenance. If the decision is made not to replace a part, the part concerned must be recorded in the inspection schedule.
  • Page 134 Telescopic handlers - Lubrication and maintenance Intervals Every Every Every Every Every Every Every Every Every Area Daily 1000 1500 2000 3000 5000 hours hours hours hours hours hours hours hours hours General checks Structure parts Windscreen washer fluid Oil, water, fuel leaks Appearance of the mechanical parts, hydraulic hoses and wiring...
  • Page 135 Telescopic handlers - Lubrication and maintenance Diesel particulate filter Engine crankcase breather Engine mounting Glow plugs Belt tension 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...

  • Page 136: Detailed Program

    The time periods below are recommended for fuel-powered machines in normal use. Symbol Meaning Symbol Meaning Systematic replacement Visual inspections Operation requiring HAULOTTE Services® authorisation Visual inspection with dismantling and exchange or Check-Test See user manual or replacement if necessary machine maintenance book Operation requiring HAULOTTE Services®...
  • Page 137 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 1104D44T. (2) : For machines fitted with : Engine PERKINS 854E-34TA.
  • Page 138 Rear axle : Reducer + Hydraulic circuit differential + pivots Epicyclic gears Hydraulic oil Battery Attachment hydraulic oil Level Transmission hydraulic filter Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 139 Epicyclic gears Battery Hydraulic circuit Level Hydraulic oil Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. 4000328140 E01.15...
  • Page 140 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 1104D44T. (2) : For machines fitted with : Engine PERKINS 854E-34TA.
  • Page 141 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 142 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. (2) : For machines fitted with : Engine PERKINS 1104D44T.
  • Page 143 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 144 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 1104D44T. (2) : For machines fitted with : Engine PERKINS 854E-34TA.
  • Page 145 Epicyclic gears Battery Hydraulic circuit Level Hydraulic oil Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. 4000328140 E01.15...
  • Page 146 Attachment hydraulic oil Level Transmission hydraulic filter Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine KOHLER KDI 3404 TCR. 4000328140 E01.15...
  • Page 147 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 148 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. (2) : For machines fitted with : Engine PERKINS 1104D44T.
  • Page 149 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 150 Rear axle : Reducer + Hydraulic circuit differential + pivots Epicyclic gears Hydraulic oil Battery Attachment hydraulic oil Level Transmission hydraulic filter Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 151 Epicyclic gears Battery Hydraulic circuit Level Hydraulic oil Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. 4000328140 E01.15...
  • Page 152 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 1104D44T. (2) : For machines fitted with : Engine PERKINS 854E-34TA.
  • Page 153 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 154 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. (2) : For machines fitted with : Engine PERKINS 1104D44T.
  • Page 155 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 156 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 1104D44T. (2) : For machines fitted with : Engine PERKINS 854E-34TA.
  • Page 157 Epicyclic gears Battery Hydraulic circuit Level Hydraulic oil Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. 4000328140 E01.15...
  • Page 158 Rear axle : Reducer + Hydraulic circuit differential + pivots Epicyclic gears Hydraulic oil Battery Attachment hydraulic oil Level Transmission hydraulic filter Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 159 Radiator slats differential + pivots Cleanliness of the radiator's Epicyclic gears protection grill Hydraulic circuit Battery Hydraulic oil Level Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : 4000328140 E01.15...
  • Page 160 Date : Number of hours : Intervenor : Comments HAULOTTE Services® contract number : Intervention sheet number : Signature : (1) : For machines fitted with : Engine PERKINS 854E-34TA. (2) : For machines fitted with : Engine PERKINS 1104D44T.

  • Page 161: General Points

    Telescopic handlers - Lubrication and maintenance 7 - General points 7.1 - MECHANICAL 7.1.1 - Bolts and Tightening torques • Bolts that become damaged and need to be replaced, must be replaced with bolts of identical specification : Type, Length, Diameter, Class . •...

  • Page 162: Bearings

    Telescopic handlers - Lubrication and maintenance Recommended Values Marking Description At least 0,5 times the nominal diameter Make a chamfer Nominal diameter of the bearing - 0,2 / - 0,3 mm Bearing drift Diameter of the bearing guide - 0,20 / - 0,25 mm Bearing Housing •...

  • Page 163: Hydraulics

    Telescopic handlers - Lubrication and maintenance • Reassembly of the bearing/pivot : • Clean the bearing housing or pin in order to remove all the foreign objects/abrasions. • Lightly lubricate the bearing housing and/or pin. • Lightly lubricate the outer ring of the bearing. •...

  • Page 164: Evaluation Of Leaks On Hydraulic Cylinders

    • 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 tests described below.

  • Page 165: Electric

    Telescopic handlers - Lubrication and maintenance Control cylinder by cylinder : • Position a load equal to the rated capacity on the attachment. • Perform the movement of the concern cylinder to half of its stroke. • Fix the cylinder with a comparator : •...

  • Page 166: Every Day Or Every 10 H Of Operation

    • 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 tire inflation pressure : 4,5 bar(65,2 psi) minimum (For HAULOTTE® tyres, code : 2326014870 or 232601508).

  • Page 167: Load Moment Indicator

    Telescopic handlers - Lubrication and maintenance 8.2 - LOAD MOMENT INDICATOR 8.2.1 - Test procedure The load moment indicator's function is to constantly monitoring the stability of the front of the machine. To check that it is functioning correctly, proceed as follows : •...

  • Page 168: Resetting Procedure

    • Press on the TEST (P219) button for 6 s until you hear the beep to start the resetting procedure. • The procedure is executed. If a malfunction occurs, contact HAULOTTE Services®. 8.3 - DIESEL CIRCUIT •...

  • Page 169: Cooling System

    Telescopic handlers - Lubrication and maintenance 8.4 - COOLING SYSTEM • Check the coolant level : • When the engine is cool, the liquid level must be situated between the min. and max. marks on the expansion bottle. • Open the radiator and top up with fluid as necessary. •...
  • Page 170 Telescopic handlers - Lubrication and maintenance • Clean the primary air filter's filter cartridge : • Remove the cover : • Pull the trigger situated on the cover ( 1 ). • Locate the angular position of the cover which should be identical upon reassembly.

  • Page 171: Internal Combustion Engine

    Telescopic handlers - Lubrication and maintenance 8.6 - INTERNAL COMBUSTION ENGINE For the following operations, park the machine onto a horizontal surface and turn off the engine. • Check the oil level : • Open the motor canopy, remove the oil dip stick; the level must be situated between the two min. and max.

  • Page 172: Every 100 H Hours Of Operation

    • Check that the tires are not damaged. • Remove the valve rod cap. Check the tire inflation pressure : 4,5 bar(65 psi) minimum (For HAULOTTE® tyres, code : 2326014870 or 232601508). During a pressure check or an inflation operation, always face the end of the tyre; never face the side of the tyre •...

  • Page 173: Lubricating The Front Axle

    Telescopic handlers - Lubrication and maintenance 10.4 - LUBRICATING THE FRONT AXLE • Remove the 4 protective caps from each grease point. • Connect the grease gun. Remove the *1 protective caps from each grease point. 10.5 - LUBRICATING THE REAR AXLES •...

  • Page 174: Hydraulic Circuit

    Telescopic handlers - Lubrication and maintenance 10.6 - HYDRAULIC CIRCUIT Perform the first filter cartridge change after the first 500 hours of operation and then after every 1000 h or once a year ( Section H 13.4 - Hydraulic circuit). 10.7 - AIR-CONDITIONING (OPTION) •...

  • Page 175: Every 250 H Hours Of Operation

    Telescopic handlers - Lubrication and maintenance 11 - Every 250 h hours of operation 11.1 - COOLING SYSTEM • Clean the radiator slats. 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.

  • Page 176: Every 500 H Hours Of Operation

    Perform a cleaning of the primary air cleaner elements by pressurized air or vacuum cleaning. For all engine maintenance operations : Consult the guide provided by the engine manufacturer or HAULOTTE Services®. N.B.-:-Operating in dirty conditions may require more frequent service of the air cleaner element.

  • Page 177: Internal Combustion Engine

    Telescopic handlers - Lubrication and maintenance 12.4 - INTERNAL COMBUSTION ENGINE 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.

  • Page 178: Engine Oil Service Reset

    After changing the engine oil and the filter, a reset must be performed to avoid engine derating. 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.

  • Page 179: Checking The Level Of The Rear Axle

    Telescopic handlers - Lubrication and maintenance 12.6.2 - Checking the level of the rear axle Capacity : • Rear axle : 8,5 l(2,24 gal US). • Before performing the oil replacement operations, firstly remove the drain plugs ( 2 ) to eliminate any pressure from inside the housing.

  • Page 180: Every 1000 H Hours Of Operation (Or Once A Year)

    13 - Every 1000 h hours of operation (or once a year) 13.1 - CHAIN WEAR Have the chain wear checked by a HAULOTTE Services® technician. 13.2 - PRIMARY AIR FILTER Never clean the cartridge by hitting it against a hard surface or by using hot flammable liquid.

  • Page 181: Hydraulic Circuit

    • Accumulator 1 l(0,26 gal US) : Pre-charge pressure : 13 bar(188 psi) (Parking brake circuit). • Accumulator 0,75 l(0,20 gal US) : Pre-charge pressure : 30 bar(435 psi) (Service brake circuit). This operation requires specific tools (Consult HAULOTTE Services®) and a bottle of nitrogen to recharge the accumulator (if the pre-charge pressure drops).

  • Page 182: Every 1500 H Hours Of Operation

    Telescopic handlers - Lubrication and maintenance 14 - Every 1500 h hours of operation 14.1 - TRAVEL AXLES The oil replacement 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 may result in a drop in oil levels to avoid any possible damage to the mechanical components.

  • Page 183: Draining The Rear Axle

    Telescopic handlers - Lubrication and maintenance 14.1.2 - Draining the rear axle Capacity : • Rear axle : 8,5 l(2,24 gal US). • Before performing the oil replacement operations, firstly remove the drain plugs ( 2 ) to eliminate any pressure from inside the housing.

  • Page 184: Engine Crankcase Breather (Engine Perkins 854E-34Ta)

    Telescopic handlers - Lubrication and maintenance 14.1.4 - Engine crankcase breather (Engine PERKINS 854E-34TA) Before performing any interventions, let the engine cool down. DANGER OF BURNS! Hot oil and hot components can cause personal injury. Avoid any contact with the skin.

  • Page 185: Install The Breather Element

    Telescopic handlers - Lubrication and maintenance 14.1.4.2 - Install the breather element Ensure that all the components are clean and free from damage. • Install a new O ring seal ( 5 ) onto the cover ( 6 ). N.B.-:-The breather element must have the correct orientation before installation. Diameter ( A ) is visibly larger than diameter ( B ).

  • Page 186: Every 2000 H Hours Of Operation (Or Every 2 Years)

    Telescopic handlers - Lubrication and maintenance 15 - Every 2000 h hours of operation (or every 2 years) 15.1 - COOLING SYSTEM (ENGINE PERKINS 1104D44T) Before performing any interventions, let the engine cool down. • Change the coolant : Capacity : approx. 18 l(4,75 gal US). N.B.-:-Open the heating valve situated in the cab when draining the cooling system.

  • Page 187: Air Filter (System)

    N.B.-:-Perform the secondary cartridge change every 2 years or after every 5 maintenance operations. 15.3 - INTERNAL COMBUSTION ENGINE (ENGINE PERKINS 1104D44T) • Change the engine belts. For all engine maintenance operations : Consult the guide provided by the engine manufacturer or HAULOTTE Services®. 4000328140 E01.15...

  • Page 188: Hydraulic Circuit

    Tank capacity : 103 l(27 gal US) Replace oil after each major intervention, and each time an anomaly has been detected. • Only use oils that that match the technical characteristics that correspond to HAULOTTE® recommendations. Do not mix two oils with different characteristics : If necessary, drain and clean the whole system.

  • Page 189: Air-Conditioning (Option)Option

    Telescopic handlers - Lubrication and maintenance 15.5 - AIR-CONDITIONING (OPTION) Maintenance and repair work on the air conditioning must be carried out by a qualified and authorised person. • Cleaning of condenser and evaporator coils. • Cleaning of condenser water outlets. •...

  • Page 190: Every 3000 H Hours Of Operation (Or Every 3 Years)

    • Change the engine belts. 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. 16.2 - DIESEL PARTICULATE FILTER (ENGINE PERKINS 854E-34TA) •...

  • Page 191: Cooling System (For Machines Fitted With Engine Perkins 854E-34Ta Or Kohler Kdi 3404 Tcr Only)

    Telescopic handlers - Lubrication and maintenance 16.3 - COOLING SYSTEM (FOR MACHINES FITTED WITH ENGINE PERKINS 854E- 34TA OR KOHLER KDI 3404 TCR ONLY) Before performing any interventions, let the engine cool down. • Change the coolant : Capacity : approx. 18 l(4,75 gal US). N.B.-:-Open the heating valve situated in the cab when draining the cooling system.

  • Page 192: Every 5000 H Hours Of Operation (Or Every 5 Years)

    17.1 - INTERNAL COMBUSTION ENGINE (ENGINE KOHLER KDI 3404 TCR) • Change the engine belts. 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. 18 - Every 10 years 18.1 - REPLACEMENT OF THE BRAKE CIRCUIT ACCUMULATORS...

  • Page 193: Lubricants And Equivalents

    Telescopic handlers - Lubrication and maintenance 18.2 - LUBRICANTS AND EQUIVALENTS Standard references Manufacturer references Uses Capacities MIL API ESSO MOBIL AGIP SHELL Greases 6743/0 Pins and hinges EPEXELF 2 catégorie X Grade 2 ou Upper boom Multimove 2 Multi- Purpose Driver seat rails Grease...
  • Page 194 Telescopic handlers - Lubrication and maintenance Axle oil viscosity according to the ambient temperature GREASE HUILE GRAISSE Engine oil viscosity according to the ambient temperature 4000328140 E01.15...

  • Page 195: Electric Circuit

    Telescopic handlers - Lubrication and maintenance 19 - Electric circuit 19.1 - WIRING DIAGRAM-MAIN COMPONENTS N.B.-:- See end of manual. Nomenclature Marking Description FU100 General electrical equipement fuse FU101 Fuse for warning lights FU102 Fuse for calculator power supply FU103 Fuse for flashing beacon-Horn FU106 Fuse for indicator lights...

  • Page 196: Hydraulic Circuit

    Telescopic handlers - Lubrication and maintenance 20 - Hydraulic circuit 20.1 - HYDRAULIC DIAGRAM-MAIN COMPONENTS N.B.-:- See end of manual. Nomenclature - HTL4010 - HTL3510 Marking Description Attachment hydraulic oil Drive hydraulic pump Dual pump Charge pump Steering unit Hydraulic oil tank assembly Main proportional directional valve Valve ON/OFF ( 3 sections) (HTL4010) Valve ON/OFF ( 2 sections) (HTL3510)
  • Page 197 Telescopic handlers - Lubrication and maintenance Nomenclature - HTL3010 Marking Description Attachment hydraulic oil Drive hydraulic pump Dual pump Charge pump Steering unit Hydraulic oil tank assembly Main proportional directional valve Valve ON/OFF ( 2 sections) Brake unit Parking brake accumulator Service brake valve Steering selector valve Pressure switch 90 b...

  • Page 198: Troubleshooting

    - Lubrication and maintenance 21 - Troubleshooting Stop the machine and contact HAULOTTE Services® if the following LEDs flash or remain lit : • Parking brake defect LED P182 : Not enough pressure. • Engine oil pressure fault LED P181 : Not enough pressure.
  • Page 199 Telescopic handlers - Lubrication and maintenance Faults Description Solution Operating fault on the remote control F05.09 (D) Check B402 (Radio-control) joystick (Boom telescoping) Operating fault on the remote control F05.10 (D) Check B401 (Radio-control) joystick (Lifting) Neutral position of the cab joystick not F05.11 (A) Check SJ120 detected since start-up...

  • Page 200: Procedure

    Telescopic handlers - Lubrication and maintenance Faults Description Solution Inconsistency in the position of the drive F13.07 (D) Check SA600 or SA620 selector (Cab) Inconsistency in the position of the Left/ F13.08 (D) Check SA780 or SA781 Right stabiliser selector (Cab) Inconsistency in the position of the tilt F13.09 (D) Check SA782...

  • Page 201: Intervention Register

    1 - Intervention register The intervention 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. HAULOTTE...
  • Page 202 Telescopic handlers - Intervention register HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4000328140 E01.15...
  • Page 203 Telescopic handlers - Intervention register HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4000328140 E01.15...
  • Page 204 Telescopic handlers - Intervention register HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4000328140 E01.15...
  • Page 205 Telescopic handlers - Intervention register HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4000328140 E01.15...
  • Page 206 Telescopic handlers - Intervention register HAULOTTE Number of Date Type of intervention Intervenor Services® hours intervention number 4000328140 E01.15...
  • Page 209 04-12...
  • Page 213 11-5 11-6...
  • Page 214 12-1 12-1...
  • Page 216 07-13 08-7 08-7 08-10...
  • Page 217 02-18...
  • Page 219 14-11 14-10 14-12...
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