Operator's manual T TELESCOPIC HANDLERS

Operator's manual

TELE

SC

OP

IC H

AN

DLE

RS

Operator's manualTELESCOPIC HANDLERS

HTL 4010 - HTL 3510 - HTL 32102420344510

E 11.11

AUS

2420344510 E 11.11 AUS

Telescopic handlers

2 2420344510 E 11.11 AUS

CONT

ENTS

Operator's manual

CONTENTS

1 - Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 - HAULOTTE Services® contact details. . . . . . . . . . . . . . 11

ASAFETY PRECAUTIONS1 - Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 - Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 - Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.3 - Label colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 - Operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1 - Prohibitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.2 - Potential risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.1 - Tip-over hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.2 - Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.2.3 - Travel hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.2.4 - Load falling hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.2.5 - Mechanical attachment locking device . . . . . . . . . . . . . . . . . . . . 20 2.2.6 - Driving hazards on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.2.7 - Pinching and crushing hazards. . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.2.8 - Risk of falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.2.9 - Chemical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

BINTERVENOR'S RESPONSIBILITY1 - Owner's (or hirer's) responsibility. . . . . . . . . . . . . . . . . . 23

2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . 23

3 - Trainer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4 - Operator's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . 24

CPRE-OPERATION AND CONTROLS1 - Checks and inspection before use . . . . . . . . . . . . . . . . . 25

1.1 - General mechanical functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 - Pre-operation checks and inspection. . . . . . . . . . . . . . . 27

3 - Safety stickers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 - Red labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.2 - Yellow labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.3 - Other labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.4 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.5 - Operator's cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.5.1 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.5.2 - Pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.5.3 - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.5.3.1 - Steering column adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.5.4 - Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3.5.5 - Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3.5.6 - Air-conditioning(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3.5.7 - Instrument/control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3.5.8 - Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3.5.9 - Left-hand control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 3.5.10 - Load moment indicator (LMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3.5.11 - Rear-view mirrors and windows . . . . . . . . . . . . . . . . . . . . . . . . . 64

3

Operator's manual

DOPERATION1 - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

1.1 - Starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 1.2 - Operational checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.2.1 - During the warm-up period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.2.2 - When the engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.3 - Starting the engine with a booster battery . . . . . . . . . . . . . . . . . . . . . . . . 66 1.4 - Normal engine operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1.5 - Engine shut-down procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2 - Operation with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.1 - Load lifting safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2.2 - Before lifting a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2.2.1 - For operation with non-suspended load . . . . . . . . . . . . . . . . . . . 68 2.2.2 - For operation with suspended load . . . . . . . . . . . . . . . . . . . . . . 68 2.3 - Transporting the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 2.3.1 - For operation with non-suspended load . . . . . . . . . . . . . . . . . . . 69 2.3.2 - For operation with suspended load . . . . . . . . . . . . . . . . . . . . . . 69 2.4 - Dumping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 2.5 - Stabiliser operation procedure (HTL4010 - HTL3210). . . . . . . . . . . . . 70 2.6 - Placing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.7 - Disengaging the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3 - Road operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4 - Loading and securing for transport . . . . . . . . . . . . . . . . 72

EATTACHMENTS1 - Approved attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2 - Unapproved attachments. . . . . . . . . . . . . . . . . . . . . . . . . 75

3 - Telehandler/Attachment/Fork capacities . . . . . . . . . . . . 76

4 - Using the capacity chart with forks . . . . . . . . . . . . . . . . 77

5 - Attachment installation . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.1 - Mechanical attachment locking device. . . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.2 - Hydraulic accessory locking device (Option) . . . . . . . . . . . . . . . . . . . . . 83 5.2.1 - Specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.2.2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.3 - Adjusting/Moving forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 5.4 - Toothless bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 5.4.1 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 5.4.2 - Toothless bucket control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 5.4.3 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . . 85 5.4.4 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.4.5 - Operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 5.4.6 - Precautions to avoid damaging the equipment . . . . . . . . . . . . . 89 5.4.7 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 5.4.8 - Attachment life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 5.5 - Toothed bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 5.5.1 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 5.5.2 - Toothed bucket control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 5.5.3 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . . 91 5.5.4 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 5.5.5 - Operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 5.5.6 - Precautions to avoid damaging the equipment . . . . . . . . . . . . . 95 5.5.7 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 5.5.8 - Attachment life expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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CONT

ENTS

Operator's manual

5.6 - 3 t (6615 lb)1 m(3 ft3 in) jib crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.6.1 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.6.2 - Jib crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 5.6.3 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . . 98 5.6.4 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 5.6.5 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.6.6 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 101 5.6.7 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.6.8 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.7 - Side-shift fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 5.7.1 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 5.7.2 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 5.7.3 - Side-shift fork carriage control . . . . . . . . . . . . . . . . . . . . . . . . . 103 5.7.4 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . 103 5.7.5 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . 104 5.7.6 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.7.7 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 107 5.7.8 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 5.7.9 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.8 - Fly jib2,5 m(8 ft2 in), 1,2 t (2646 lb) on telescopic arm . . . . . . . . . . . 111 5.8.1 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.8.2 - Fly jib control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.8.3 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . 111 5.8.4 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . 112 5.8.5 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.8.6 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 115 5.8.7 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.8.8 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 5.9 - Fly jib4 m(13 ft1 in), 0,6 t (1323 lb) on telescopic arm. . . . . . . . . . . . 117 5.9.1 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 5.9.2 - Fly jib control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 5.9.3 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . 117 5.9.4 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5.9.5 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.9.6 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 121 5.9.7 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 5.9.8 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 5.10 - Winch support- 1,2 t (2646 lb) with hydraulic winch (Option) . . . . . . 123 5.10.1 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 5.10.2 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 5.10.3 - Winch support control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 5.10.4 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . 124 5.10.5 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . 124 5.10.6 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 5.10.7 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 130 5.10.8 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 5.10.9 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 5.11 - Winch support- 2,4 t (5292 lb) with hydraulic winch (Option) . . . . . . 132 5.11.1 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 5.11.2 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 5.11.3 - Winch support control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.11.4 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . 133 5.11.5 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.11.6 - Operation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 5.11.7 - Precautions to avoid damaging the equipment. . . . . . . . . . . . . 139 5.11.8 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 5.11.9 - Attachment life expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

FEMERGENCY PROCEDURE1 - Towing a broken-down vehicle . . . . . . . . . . . . . . . . . . . 141

1.1 - General precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 1.2 - Releasing the axle brake for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 1.2.1 - Parking brake deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 1.2.2 - Parking brake reactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2 - Emergency boom lowering . . . . . . . . . . . . . . . . . . . . . . 144

2.1 - Manual boom lowering (emergency mode). . . . . . . . . . . . . . . . . . . . . 144

3 - Emergency exit from cab . . . . . . . . . . . . . . . . . . . . . . . . 145

5

Operator's manual

GTECHNICAL CHARACTERISTICS1 - Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

2 - Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3 - Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.1 - Machine HTL4010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 3.2 - Machine HTL3510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 3.3 - Machine HTL3210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4 - Acoustic power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5 - Telehandler vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

6 - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . 154

HLUBRICATION AND MAINTENANCE1 - Maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 155

2 - Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . 156

3 - Repairs and adjustments . . . . . . . . . . . . . . . . . . . . . . . . 157

4 - Lubrication and maintenance schedule . . . . . . . . . . . . 158

5 - General program / Recommendations . . . . . . . . . . . . . 162

6 - Detailed program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

7 - General points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

7.1 - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 7.1.1 - Bolts and Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . 190 7.1.2 - Pins and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 7.1.3 - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 7.2 - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 7.2.1 - Replacing damaged of hoses. . . . . . . . . . . . . . . . . . . . . . . . . . 192 7.2.2 - Evaluation of leaks on hydraulic cylinders . . . . . . . . . . . . . . . . 193 7.3 - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 7.3.1 - Replacing damaged cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

8 - Every day or every 10 h of operation . . . . . . . . . . . . . . 195

8.1 - General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 8.2 - Load moment indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 8.3 - Diesel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 8.4 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 8.5 - Air filter (system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 8.6 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 8.7 - Hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 8.8 - Air-conditioning (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 8.9 - Fly jib2,5 m(8 ft2 in),1,2 with hydraulic winch (Option) -

Fly jib4 m(13 ft1 in),0,6 with hydraulic winch (Option) . . . . . . . . . . . 198 8.10 - Winch support-1,2 with hydraulic winch (Option) -

Winch support-2,4 with hydraulic winch (Option) . . . . . . . . . . . . . . . 198

9 - Every 24 h hours of operation . . . . . . . . . . . . . . . . . . . . 199

9.1 - Side-shift fork carriage grease point (Option) . . . . . . . . . . . . . . . . . . . . 199 9.2 - Lubrication point : Fly jib2,5 m(8 ft2 in), 1,2 t (2646 lb) with

hydraulic winch (Option) - Fly jib4 m(13 ft1 in), 0,6 t (1323 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

9.3 - Lubrication point : Winch support- 1,2 t (2646 lb) with hydraulic winch (Option) - Winch support- 2,4 t (5292 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

6

CONT

ENTS

Operator's manual

10 - Every 50 h hours of operation . . . . . . . . . . . . . . . . . . . 202

11 - Every 100 h hours of operation . . . . . . . . . . . . . . . . . . 203

11.1 - Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 11.2 - Diesel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 11.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 11.4 - Lubricating the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 11.5 - Lubricating the rear axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 11.6 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 11.7 - Air-conditioning (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206


12.1 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 12.2 - Travel axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 12.3 - Operating battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 12.4 - Air-conditioning (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207


13.1 - Bucket teeth (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208


14.1 - Lubricating the suspension and the driver seat rails . . . . . . . . . . . . . . 209 14.2 - Diesel circuit (Engine PERKINS 1104D44T). . . . . . . . . . . . . . . . . . . . 209 14.2.1 - Changing the diesel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 14.2.2 - Changing the diesel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 209 14.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 14.4 - Travel axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 14.4.1 - Checking the oil level of the front axle . . . . . . . . . . . . . . . . . . . 211 14.4.2 - Checking the oil level of the rear axle. . . . . . . . . . . . . . . . . . . . 212 14.4.3 - Checking the oil level of the epicycloidal reducers . . . . . . . . . . 213 14.5 - Bucket blade (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

15 - Every 1000 h hours of operation (or once a year) . . . 215

15.1 - Chain wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.2 - Primary air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.4 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 15.4.1 - Equipment hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 15.4.2 - Transmission hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 216 15.5 - Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

16 - Every 1500 h hours of operation . . . . . . . . . . . . . . . . . 217

16.1 - Travel axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 16.1.1 - Draining the front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 16.1.2 - Draining the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 16.1.3 - Draining the epicycloidal reducers . . . . . . . . . . . . . . . . . . . . . . 218

17 - Every 2000 h hours of operation (or every 2000 h years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

17.1 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 17.2 - Air filter (system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 17.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 17.4 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 17.5 - Air-conditioning (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 17.6 - Toothless bucket (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 17.7 - Toothed bucket (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 17.8 - Side-shift fork carriage (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 17.9 - Winch : Winch support- 1,2 t (2646 lb) with hydraulic winch

(Option) - Winch support- 2,4 t (5292 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

17.10 - Winch : Fly jib2,5 m(8 ft2 in), 1,2 t (2646 lb) with hydraulic winch (Option) - Fly jib4 m(13 ft1 in), 0,6 t (1323 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

18 - Every 10 years. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

18.1 - Replacement of the brake circuit accumulators. . . . . . . . . . . . . . . . . . 223 18.1.1 - Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 18.1.2 - Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 18.2 - Lubricants and equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

7

Operator's manual

19 - Electric circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

19.1 - Wiring diagram-Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

20 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

20.1 - Hydraulic diagram-Main components . . . . . . . . . . . . . . . . . . . . . . . . . . 227

21 - Operating incidents . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

21.1 - Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 21.2 - Operating incident on the side-shift fork carriage (Option) . . . . . . . . . 228 21.3 - Operating incidents : Fly jib2,5 m(8 ft2 in), 1,2 t (2646 lb)

with hydraulic winch (Option) - Fly jib4 m(13 ft1 in), 0,6 t (1323 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

21.4 - Operating incidents : Winch support- 1,2 t (2646 lb) with hydraulic winch (Option) - Winch support- 2,4 t (5292 lb) with hydraulic winch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

IINTERVENTION REGISTER1 - Intervention register . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

8

Telescopic handlers

You have just purchased a HAULOTTE® product

and we would like to thank you for your business.

1 - Operator's manual

As stated on the delivery slip, this manual is one of the documents in the on-board document holderprovided upon delivery of your HAULOTTE® machine.

The operator manual is a translation of the original instructions.

Safe operation of this product can only be assured if you follow the operating instructions contained inthis manual.

We would particularly like to draw your attention to 2 essential points :

• Compliance with safety instruction (machine, use, environment)

• Use of the equipment within the performance limits set down in this manual.

2 - After Sales Service

Our HAULOTTE Services® After Sales Service is at your disposal throughout your machine's servicelife to ensure optimal use of your HAULOTTE product..

• When contacting our After Sales Service, ensure that you provide the machine model and serialnumber.

• When ordering any consumables or spare parts, please use this manual and the Haulotte Essentialcatalogue to receive your genuine HAULOTTE spare parts, your only guarantee of partsinterchangeability and correct machine operation.

• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTEServices® immediately even if the malfunction does not involve material and/or bodily damage..

• In the event of malfunctions or incidents involving a HAULOTTE® machine, contact HAULOTTEServices® immediately even if no material or bodily damage is observed and we will intervene assoon as possible (See : HAULOTTE Services® contact details)

With regard to the designation of our equipment, we stress that this is purely for commercial purposes andnot to be confused with the technical characteristics. Only the tables of technical characteristics shouldbe used to study the suitability of the equipment for the intended use.

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3 - Compliance

We would like to remind you that HAULOTTE® complies with the provisions of any applicabledirectives applicable to this type of machine.

HAULOTTE advises you that NO modifications carried out without the written permissionof HAULOTTE® will void the HAULOTTE warranty..

HAULOTTE® cannot be held liable for any changes to the technical specifications contained in thismanual.

HAULOTTE® reserves the right to alter technical specifications and to make improvements ormodifications to the machine without modifying this manual.

Certain options can modify the machine's operating characteristics and its associated safety. If yourmachine was originally delivered with options fitted, replacing a safety component associated with aparticular options not require any particular precautions other than those associated with the installationitself (static test).

If you intend to add options to your product after original delivery, it is essential to follow themanufacturer's recommendations below :

• Installation by authorised HAULOTTE® personnel only.

• Update the manufacturer's identification plate.

• Have stability tests carried out by a certified agency/competent person.

• Ensure that any additional labels that relate to the option installed, are affixed to the machine in theappropriate location/s.

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4 - HAULOTTE Services® contact detailsHAULOTTE Services® contact details

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A- Safety precautions

Safety precautions1 - Recommendations

1.1 - OPERATOR'S MANUAL

This operators manual is specific to the HAULOTTE® products listed on the cover page of thismanual..

1.2 - SYMBOLS USED

Symbols are used to alert the operator to safety precautions or to highlight practicalinformation.

Legend

The operator manual does not replace the basic training required for all worksite equipment operators.

HAULOTTE® has compiled this manual to assist in safe and efficient operation of the products coveredby the manual.

This manual must be kept on the machine (or in the cab in its storage case. The manual must be availableto all operators and must be kept in good condition. Additional copies can be ordered from HAULOTTEServices®.

Symbol Meaning

Danger : Risk of injury or death (work safety)

Caution : Risk of material damage (work quality)

Prohibition relating to work safety and quality

Reminder : No identified risk, but a reminder of the need for common sense, good practice or pre-action prerequisites

Cross-reference to another part of the manual (see section or sheet)

Cross-reference to another manual (see manual)

Cross-reference to repairs (contact HAULOTTE Services®)

N.B. : Additional technical information

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1.3 - LABEL COLORS

The potential dangers and any specific regulations are indicated around the product by labelsand identification plates.

Familiarize yourself with the labels and their respective color codes.

Label color code

2 - Operation instructions

2.1 - PROHIBITIONS

• Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, orduring an extended stop period.

The labels must be kept in good condition. Additional labels can be obtained from HAULOTTE Services®.

Labels Color Meaning

Red Potentially fatal danger

Orange Risk of serious injury

Yellow Risk of material damage and/or minor injury

Other Additional technical information

Green Maintenance operation or information

It is preferable to operate the machine on flat, consolidated ground (tarmac, concrete, etc.).

• Never use a faulty machine (hydraulic leaks, worn tires, malfunction).

• Never operate the machine controls suddenly.

• Never place the machine against a structure to hold that structure in place.

• Never use the machine to tow other machines or to drag materials.

• Never expose the batteries or electrical components to water (pressure cleaner, rain).

• Never disable the safety devices.

• Do not make contact with a fixed or mobile obstacle. The contact can cause premature deterioration ofthe structure and lead to the corruption of certain safety elements.

• Do not climb onto the covers.

• Never use the machine with only an operator in the platform. It must be operated by a pair of operators.

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2.2 - 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.

Do not drive at high speed with the boom raised.

When driving at high speed, use only front-wheelsteering (if the steering mode can be selected).

Do not raise the boom unless the chassis is level (0 °).

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Do not level the machine with the boom or the accessory above 30 °

• Transport the load as low as possible. Attach thesuspended loads to restrict movement.

• Comply with the capacity charts displayed in the cab.

• The weight of all riggings (slings, etc…) must be includedas part of the load weight.

• Start, travel, turn and stop slowly to prevent the load fromtipping over.

• Beware of the wind. The wind can cause a suspended loadto 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 theattachment.

• Never drag the load. Lift it vertically.

• Maintain proper tire pressure at all times. Otherwise, themachine could tip over.

Do not ballast the tires.

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2.2.2 - Electrical hazards

• Always check for power lines before raising the boom.

• Always wear the seat belt.

Do not hang your head, your arms, your hands, your legs or any other parts of your body out of the cab.

If the telehandler starts to tip over :

• Stay in the machine cabin.

• Keep your seat belt fastened.

• Hold on tightly.

• Lean away from the point of impact.

Trying to escape from a tipping machine could result in death or serious injury.

• The machine is not electrically insulated and does not offerany protection in the event of proximity to or contact withelectrical current.

Never operate the handler in an area where overhead power lines, overhead or underground cables orother power sources may exist without ensuring that the appropriate utility company has de-energized thelines.

• Maintain a minimum safe distance with regard to powerlines and electrical devices.

• Respect the local rules and the minimum safety distancefrom power lines..

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Minimum safety distance

N.B.-:-This table is applicable, except when the local regulations are more strict.

Minimum safety distanceFor AS standard only

2.2.3 - Travel hazards

Electric voltage Minimum safety distance

Mètre Feet

0 - 300 V Avoid contact300 V - 50 kV 3 1050 - 200 kV 5 15

200 - 350 kV 6 20350 - 500 kV 8 25500 - 750 kV 11 35

750 - 1000 kV 14 45

• The turning radii change according to the steering modeselected ( 2 or 4 steer wheels).

• Ensure that adequate clearance is provided for pivoting therear tail and the front fork.

The rear offset is larger in 4 steer wheels mode.

Look out for and avoid other personnel, machinery and vehicles in the area. Always obtain assistance froma guide on the ground when manoeuvring.

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• Do not change the steering mode while travelling; only do that when the telescopic handling machinehas halted.

• Visually check that the wheels are properly aligned every time the steering mode has changed.

• When driving at high speed, use only front-wheel steering (if the steering mode can be selected).

2.2.4 - Load falling hazards

The forks must be centred under the load and on the fork carriage and spaced apart as far aspossible.

• Before moving the machine, ensure that the path is clearand sound the horn.

• When driving, retract the boom and keep the boom and theattachment as low as possible.

• Maintain visibility of the mirrors and optimal visibility of thepath of travel.

• Always look in the direction of travel.

• Always check boom clearances carefully before drivingunderneath overhead obstacles. Position the attachment orthe load so as to clear the obstacles.

Never suspend loads from the forks or from any other parts of the fork carriage.

Do not drill holes in the fork(s).

Do not heat or weld the forks.

• Do not use the machine to lift one or more people.

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2.2.5 - Mechanical attachment locking device

• Ensure that the machine is placed on a firm and level surface.

• Actuate the parking brake. Blocking the wheels is also recommended.

• Level the handler 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.

2.2.6 - Driving hazards on slopes

• Avoid excessively steep slopes or unstable surfaces. To avoid tipping over, do not drive acrossexcessively steep slopes under any circumstances.

• Avoid turning on a slope.

• Never engage INCHING or shift to NEUTRAL when travelling downhill.

Always ensure that the fork carriage or the attachment is correctly positioned on the boom and is securedby a lock pin and a retainer pin. Incorrect installation could result in the fork carriage/attachment/loaddisengaging, causing death or serious injury.

To maintain sufficient traction and braking capabilities,travel on slopes as follows :

• When the machine is unloaded, the rear of the machine isthe 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 lowergear and use the service brake as necessary to maintain aslow speed.

Do not shift to neutral to avoid coasting downhill.

Do not park on a slope without having blocked the machine wheels.

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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.

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.

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2.2.8 - Risk of falling

2.2.9 - Chemical hazards

Exhaust Fumes :

Flammable Fuel :

Hydraulic Fluid :

Enter the cab using the proper hand rails and the stepsprovided.

Always maintain 3 points of contact when entering orleaving the machine.

Never grab the control levers or the steering wheel when mounting or dismounting the machine.

Never leave 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 run the engine in a place where there is a risk of build up of toxic gases.

Do not operate the machine in an enclosed area without proper ventilation. Sparks produced by theelectrical system or the engine exhaust can cause an explosion.

Do not fill the fuel tank or service the fuel system near a naked flame, sparks or smoking material. Engine fuel is flammable and can cause a fire and/or an explosion.

Do not attempt to repair or tighten any hydraulic hoses or 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.

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B- Intervenor's responsibility

Intervenor's responsibility1 - Owner's (or hirer's) responsibility

The owner (or hirer) has the obligation to inform operators of the instructions contained in the OperatorManual.

The owner (or hirer) has the obligation to renew all manuals or labels that are either missing or in badcondition. Additional copies can be ordered from HAULOTTE Services®.

The owner (or hirer) is responsible for applying the local regulations regarding operation of themachine.

2 - Employer's responsibility

The employer has the obligation to issue a driving permit to the operator.

N.B.-:-In accordance with the regulation in the country where the machine is operating, the user mustbe authorized to drive by the doctor of Labour Ministry.

3 - Trainer's responsibility

The trainer must be qualified to provide training to operators in accordance with applicable localregulations. The training must be given in an obstacle-free area until the trainee is consideredcompetent as defined by the training program undertaken.

4 - Operator's responsibility

The operator must read and understand the contents of this manual and the labels affixed on themachine.

The operator must inform the owner (or hirer) if the manual or any labels are missing or in poorcondition, and of any malfunction of the machine.

The operator may only operate the machine for the purpose intended by the manufacturer.

All operators must become familiar with and fully understand the emergency controls and how tooperate the machine in an emergency as a component of their formal operator training.

The operator has the obligation to stop using the machine in the event of malfunction or safetyproblems on the machine or in the work area and report the problem to his/her supervisor.

Forbid anyone from operating the machine who is : • Under the influence of drugs, alcohol, etc..

• subject to fits, loss of motor skills, dizziness, etc..

Only authorized and qualified operators may operate HAULOTTE® machines.

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B- Intervenor's responsibility

5 - Inspection and maintenance

The inspection and maintenance table below, identifies the role and the responsibilities of each partyin periodical machine maintenance..

Inspections and maintenance

If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.

Type of intervention

Frequency Person-in-charge IntervenorReference document

Pre-delivery inspection

Before each delivery of sold, hired or resold equipment

Owner (or hirer)Qualified HAULOTTE Services® technician

Operator's manual

Pre-operation inspection

Before operation or when the operator changes

Operator OperatorOperator's manual

Section C - Pre-operation and controls

Periodical preventive maintenance

At the specified intervals (250 hours or 1 year)

Owner (or hirer)On-site technician or qualified HAULOTTE Services® technician

Operator's manual

Section H - Lubrication and maintenance

Periodical visit

2 times a year or at the latest 6 months after the last periodic visit, and according to the local regulations

Owner (or hirer)

Organization or technician approved by the employer or by the intermediary of HAULOTTE Services® in accordance with the HAULOTTE Services® contract

Operator's manual

Section H - Lubrication and maintenance

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C- Pre-operation and controls

Pre-operation and controls1 - Checks and inspection before use

Each day and before the beginning of a new work period and on each change of operator, the machinemust 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.

1.1 - GENERAL MECHANICAL FUNCTIONS

For all the following checks, ensure that the machine is switched off.

Check the following points :

• The presence of the identification plate, labels and operator manual :

• Their state of cleanliness and visibility.

• Visual state of the machine :

• Absence of leaks (battery acid, hydraulic oil, etc.). Absence of foreign objects on allsurfaces. Call the staff in charge of the maintenance if necessary.

• No missing or loose parts (bolts, nuts, connectors, cables, etc.).

• Absence of cracks, broken parts, damaged paint. No deformations or other anomalieson the structure’s parts.

Example

• State of the structure's parts : Chassis, boom, cab, tool holder, attachments :

• No cracks, damaged paint.

• No distortion in metal components or visible damage.

• No foreign objects at the ends of the booms, between arms and link parts.

• Presence of guardrails.

• Presence and check the original position of the driving station system.

• Cylinders’ state :

• No leaks.

• No rust and abrasions on the cylinder rod.

• Absence of foreign objects on all surfaces.

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• 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.).

• State of the rotation systems (Cage option, pulleys, ...)

• No excessive clearance.



• Greasing and lubrication according to the maintenance plan.

• State of the control :

• No damage.

• Back to neutral for all joysticks, selectors, etc..

• Present and legible control labels.

• Movement, safety limit switches :

• No damage.



• The state and connection of the electric wires and cables :

• No damage, wear marks or other faults.

• No contact between connectors.

• State of the tanks :

• No leaks.


• Hydraulic oil level : Top up the oil level, if necessary (Machine in transport position).

• Sufficient fuel level.

• State of the hydraulic pump :

• No leaks.


• Hydraulic oil filter.

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2 - Pre-operation checks and inspection

N.B.-:-Perform all required maintenance work before operating the unit.

• A walk-around inspection must be performed at the beginning of each work shift or at each changeof operator.

• Ensure that all safety labels are legible and in place. Clean or replace if necessary. ( Section C 2- Labels).

• Before removing the filler plugs, wipe all dirt or grease away from the ports. Dirt entering these portscan severely reduce component life.

• When adding fluids, determine the correct type and frequency( Section H - Lubrication andmaintenance).

Use extreme caution when checking parts that are difficult to reach. Use an approved ladder. "Failure" tocomply 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. If the decision is made notto replace a part, the part concerned must be recorded in the inspection schedule.

• The condition of structural parts: chassis, boom, cab, shield, attachments. • Absence of cracks, broken parts, damaged paint.

• No distortion in metal components or visible damage.

• Absence of foreign objects at the ends of boom/attachments.

• Cylinders :

• No leaks : Please refer to paragraph 7.2.2( Section H - Lubrication and maintenance).

• No rust and abrasions on the cylinder rod.


• Steering system : Wheels, Axles, Brake and Tyres : • No cracks, distortions, damaged paint or other faults.


• Condition of the tyres (cuts, excessive wear, etc.)

• Condition of the pulley system :



• Grease the extension system if necessary.

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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 aresecurely fastened and that there are no visible leaks or excessive wear in addition to any other criteriamentioned. Inspect all structural elements including the attachment for cracks, excessive corrosion andother damage.

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1. Jib cylinders: lifting and telescopic action cylinders, compensation output, compensation input(crowding) and cases :

• Pins secure, hydraulic hoses in good condition, no leaks. • Check the state of the extension booms wear pads.

2. Left-hand stabiliser and detector : Pins secure, hydraulic hoses in good condition, no leaks (onHTL4010 and HTL3210 only).

3. Front axle : Steering cylinders in good condition, no leaks; joint pins and flanges secured tightly,hydraulic hoses in good condition, no leaks.

4. Wheel/Tyre assembly : No loose or missing wheel nuts, inflated correctly. Check the state of thetyres and their level of wear.

5. Front headlights : Clean, in good condition and working properly.

6. Mirrors : Clean, in good condition and working properly.

7. Fuel tank : Check the fuel level, top up as required, the filler cap is securely fastened. Check forany leaks on the fuel tank..

8. Front work lights (optional) : Clean, in good condition and working properly.

9. Cab and electrical circuit :

• The cab is an approved protective cab in accordance with FOPS and ROPS standards:Check the FOPS/ROPS label in the cab.

• Check alarms: eg. engage the reverse drive and sound the horn. • General appearance, no visible damage, capacity charts and Operator & Safety ma-

nual located in the manual holder. • Window glass in good condition and clean. • Gauges, switches, joystick, parking brake pedals and horn all operational. • Check the seat belt for damage, replace it if it is frayed or the webbing is cut, the buc-

kles are damaged or the mounting hardware is loose or damaged. • Check that the applicable load and capacity charts are installed in the cab..

10. Hydraulic oil tank : Recommended fluid level on the level gauge (the oil must be cold) ; filler/brea-ther cap securely in place and in working order. Check for hydraulic leaks around the reservoir.

11. Rear work lights (optional) : Clean, in good condition and working properly.


13. Rear axle : Steering cylinders in good condition, no leaks, pivot pins secure, hydraulic hoses ingood condition, no leaks.

14. Left axle locking cylinder (Option) : Cylinders in good condition, no leaks and securely fastened.

15. Stop and reverse lights : Clean, in good condition and working properly.

16. Right axle locking cylinder(Option) : Cylinders in good condition, no leaks and securely fastened.


18. Engine compartment :

• Engine crankcase and radiator : Check the levels and top up as required. Check thatthe radiator is clean.

• Drive belt : check their condition, adjust and/or replace as required. • Air filter blockage indicator : Check if it is clogged. Replace the element as required. • Open the engine cover under the cab and check the battery cables : They are secure

and that there is no visible damage or corrosion. • Engine canopy properly secured and locked.

19. Mirrors : Clean, in good condition and working properly.


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21. Tilt correction cylinder : Pins secure, hydraulic hoses in good condition, no leaks (For HTL3510only).

22. Right-hand stabiliser and contactor : Pins secure, hydraulic hoses in good condition, no leaks (onHTL4010 and HTL3210 only).

23. Attachment : Correctly installed( Section E - Attachments).

Check the operation of : • All the Telehandler boom and chassis side tilt movement.

• All the functions related to the travel of the Telehandler.

• The Telehandler braking system.

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3 - Safety stickers

Ensure that all stickers and appropriate capacity charts are legible and in place. Clean or replace ifnecessary.

3.1 - RED LABELS

Common labels - CE standard

Specific labels HTL4010 - CE standard


The red labels indicate a potentially fatal danger.

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3.2 - YELLOW LABELS

Common labels

Specific labels HTL4010 - HTL 3510 - HTL 3210

The yellow labels indicate a risk of material damage and/or minor injury.

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Specific labels, optional

3.3 - OTHER LABELS

Common labels

The other labels provide additional technical information.

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Specific labels HTL4010


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Specific labels, optional

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3.4 - IDENTIFICATION

Localization: isometric view - HTL4010 - HTL3210

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Localization: isometric view - HTL3510

Localization: left view - HTL4010 - HTL3210

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Localization: left view - HTL3510

Localization: right view - HTL4010 - HTL3210

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Localization: right view - HTL3510

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Localization: cab view

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Localization: view from above - HTL4010 - HTL3210

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Localization: view from above - HTL3510

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Localization: rear view

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Common labels - Standards CE and AS

Color Marking Description Quantity

Other A3 Identification plate 1

In french ( CE standard) : 307P220810In german ( CE standard) : 307P222040In spanish( CE standard) : 307P222050In italian ( CE standard) : 307P226270In english ( CE standard) : 307P222670AS standard only : 307P230120

Other A4 Machine name logo 2

For HTL 3210 (NA) : 307P228750For HTL 3510 (NA) : 307P228760For HTL 4010 (NA) : 307P228370

Other A6 Label HAULOTTE® 1 307P217770Other A7 Read the operation manual 1 307P220740Other A7 Read the operation manual 1 307P220740Other A10 Acoustic power 1 307P223480Other A16 Yellow and black adhesive tape 1 242808660Other A30 slings attached 6 307P220830Other A38 Terminal fuses 1 307P228740

Other A39 Joystick 1CE standard : 307P220800AS standard : 307P230140

Other A40 Battery / Battery isolation switch 1 307P220930Other A41 Indicator 1 307P221070Other A43 Wear the seat belt 1 307P220780Other A44 25 km/h 1 307P216110Other A45 Angle sensor 1 307P220900Other A46 Telescoping key A 1 307P222610Other A47 Telescoping key B 1 307P222620Other A48 Telescoping key C 1 307P222630Other A49 Telescoping key D 1 307P222640Other A50 Telescoping key E 1 307P222650Other A51 Telescoping key F 1 307P222660Other A75 "Safe Use" 1 AS standard only : 307P232430Other A76 Minimum safety distance 1 AS standard only : 307P226440Other A86 ECU 1 307P229550Yellow J3 Do not place your foot on the cover 3 307P220820Yellow J4 Ground for welding 1 307P221090Yellow J12 Danger of Heat burns 1 307P223710

Yellow J18 Tyre pressure 4

For HTL 3210 (NA) : 307P224050For HTL 35 10 / HTL 4010 (NA) : 307P220880

Yellow J19 Fuel tank 1 307P220920Yellow J20 Hydraulic oil 1 307P220870Yellow J21 Lubrication 24 307P220840Yellow J31 Engine cover 1 307P223830

Red R9 Maximum effort on wheel 2

For HTL 3210 / HTL 4010 (NA) : 307P220950For HTL 35 10 (NA) : 307P228710

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Load capacity chart - CE standard

Red R10 Maximum effort on the stabilizers 2

For HTL 3210 (NA) : 307P220960For HTL 4010 (NA) : 307P228360

Red R13 Risk of crushed feet 2 307P220890Red R27 Danger of electrocution 1 307P220770Red R28 Cylinder locking 1 307P220860

Red R29Do not mount on the forks during elevation

1 307P221950

Red R42 Label book 1 307P223840

Color Marking DescriptionQuantity

HTL 3210 HTL 4010

Other Load capacity chart - Book 1 107P334440 107P334450Other Load capacity chart - Cover book 1 307P232400

OtherLoad capacity chart - Forks on wheels

1 307P229230 307P229120

OtherLoad capacity chart - Forks on stabilisers

1 307P229240 307P229130

OtherLoad capacity chart - Drift side offset - On wheels

1 307P229810 307P229710

OtherLoad capacity chart - Drift side offset - On stabilizers

1 307P229820 307P229720

OtherLoad capacity chart - Bucket - On wheels

1 307P229950 307P229140

OtherLoad capacity chart - Bucket - On stabilizers

1 307P229960 307P229150

OtherLoad capacity chart - Jib crane - On wheels

1 307P229830 307P229730

OtherLoad capacity chart - Jib crane - On stabilizers

1 307P229840 307P229740

OtherLoad capacity chart - Boom 2,5 m - On wheels

1 307P229850 307P229750

OtherLoad capacity chart - Boom 2,5 m - On stabilizers

1 307P229860 307P229760

OtherLoad capacity chart - Boom 4 m - On wheels

1 307P229870 307P229770

OtherLoad capacity chart - Boom 4 m - On stabilizers

1 307P229880 307P229780

OtherLoad capacity chart - Winch 2,4 t - On wheels

1 307P229890 307P229790

OtherLoad capacity chart - Winch 2,4 t - On stabilizers

1 307P229900 307P229800


1 307P229910 307P229930


1 307P229920 307P229940

Other Load capacity chart - Title page 1 307P229220 307P229160

Color Marking Description Quantity

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Load capacity chart - CE standard

Load capacity chart - AS standard


HTL 3510

Other Load capacity chart - Book 1 107P334460Other Load capacity chart - Cover book 1 107P341980Other Load capacity chart - Forks 1 307P229290

OtherLoad capacity chart - Drift side offset

1 307P229950

Other Load capacity chart - Bucket 1 307P229290Other Load capacity chart - Jib crane 1 307P229960Other Load capacity chart - Boom 2,5 m 1 307P229970Other Load capacity chart - Boom 4 m 1 307P229980Other Load capacity chart - Winch 2,4 t 1 307P229990Other Load capacity chart - Winch 1,2 t 1 307P230000Other Load capacity chart - Title page 1 307P229270


HTL 3210 HTL 4010

Other Load capacity chart - Book 1 107P343900 107P345780Other Load capacity chart - Cover book 1 307P232420 307P232400

OtherLoad capacity chart - Forks on wheels

1 307P230060 307P230150

OtherLoad capacity chart - Forks on stabilisers

1 307P230070 307P230160

OtherLoad capacity chart - Drift side offset - On wheels

1 307P230080 307P2230170

OtherLoad capacity chart - Drift side offset - On stabilizers

1 307P230090 307P230180

OtherLoad capacity chart - Bucket - On wheels

1 307P232140 307P232010

OtherLoad capacity chart - Bucket - On stabilizers

1 307P232150 307P232020

OtherLoad capacity chart - Jib crane - On wheels

1 307P232160 307P232030

OtherLoad capacity chart - Jib crane - On stabilizers

1 307P232170 307P232040

OtherLoad capacity chart - Boom 2,5 m - On wheels

1 307P232180 307P232050

OtherLoad capacity chart - Boom 2,5 m - On stabilizers

1 307P232190 307P232060

OtherLoad capacity chart - Boom 4 m - On wheels

1 307P232200 307P232070

OtherLoad capacity chart - Boom 4 m - On stabilizers

1 307P232210 307P232080


1 307P232220 307P232090


1 307P32230 307P232100


1 307P232240 307P232110


1 307P232250 307P232120

Other Load capacity chart - Title page 1 307P232130

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Load capacity chart - AS standard


HTL 3510

Other Load capacity chart - Book 1 107P347640Other Load capacity chart - Cover book 1 307P232440Other Load capacity chart - Forks 1 307P231970Other Load capacity chart - Drift side offset 1 307P231980Other Load capacity chart - Bucket 1 307P232270Other Load capacity chart - Jib crane 1 307P232280Other Load capacity chart - Boom 2,5 m 1 307P232290Other Load capacity chart - Boom 4 m 1 307P232300Other Load capacity chart - Winch 2,4 t 1 307P232310Other Load capacity chart - Winch 1,2 t 1 307P232320Other Load capacity chart - Title page 1 307P232330

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3.5 - OPERATOR'S CAB

The machine is equipped with an enclosed FOPS/ROPS cab.

3.5.1 - Controls

General view - HTL4010 - HTL3510

Never use the machine unless the overhead guards and the cab structure are in good condition. Anymodifications to this machine must be approved in writting by HAULOTTE® to ensure complience withFOPS/ROPS certification for this cab/machine configuration. The cab cannot be repaired if it is damaged,It must be replaced.

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General view - HTL3210

Description of the components

Marking Description

C120 Warning lightsC121 Parking brakeC122 Brake pedal /Inching : The further the pedal is pressed, the slower the travel speedC123 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

C125 Transmission control lever : Section C 2.5.3 - Steering columnC126 Headlight, indicator and buzzer control

C127Indicator and control box : Controls and indicates certain machine functions. Displays engine speed.

Section C 2.5.7 - Instrument/control panel

C128 - (P189)* Fuel gauge : Indicates fuel level in tank

C129 - (P160)* Engine temperature gauge

C130 - (S5120)* Joystick : Section C 2.5.8 - Joystick

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N.B.-:-The functions are described for the entire range. Refer to the machine model to identify thecontrols and functions indicators.

(*) : Identification of the components on the electrical diagrams

3.5.2 - Pedals

General view

Pedals

C131 Load moment indicator display : Section C 2.5.10 - Load moment indicator displayC132 Heating and air-conditioning controlC133 Adjustable air vents: Individual controllableC134 Air louvers: Individual adjustableC102 DumpingC135 Car radioC141 Road modeC142 Rear-axle steering

C149 - (SA100)* Ignition key

C150 Fog lightsC153 Windscreen washer

Marking Description Function

P163 Accelerator Pedal for increasing the engine speed

P164 BrakeMachine brakingInching : Slow approach

Marking Description

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3.5.3 - Steering column

General view

Left-hand control lever

Forward and reverse can be selected while in slow or fast speed.


P165 Gear and movement direction control

Speed selection : • Neutral• Slow speed : Selector in position I• Fast speed : Selector in position IITravel direction selection : • Forward drive : Pull the lever backwards and then push it upwards• Neutral• Reverse drive : Pull the lever backwards and then pull it downwards

A sudden change of direction could destabilise the machine and/or cause the load to tip over or fall.

When reverse drive is activated, a audible sound warns that the machine is in reversing mode and warnsof potential danger anyone present in the manoeuvring area.

Reverse mode of travel should only be selected whilst the machine is stationary.

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General view

Right-hand control lever

3.5.3.1 - Steering column adjustment


P166 Turn signals/Direction indicatorsLeft-hand steering : Raise the leverRight-hand steering : Lower the lever

P167 SidelightsOn : Turn clockwiseOff : Turn anti - clockwise (ACW)

P168 HeadlightsOn : Turn clockwiseOff : Turn anti - clockwise (ACW)

P169 Full beam headlightsOn : Push forwardOff : Pull backwardFlashing the lights : Pull backward in short bursts

Bring the Telehandler to a complete stop and shutdown the engine before adjusting the steering column.A sudden change of direction could destabilise the machine and/or cause the load to tip over or fall."Failure" to comply with these instructions could result in death or serious injury.

Adjust the steering column as follows :

• Push the lever down to release the steering column.

• Move the steering wheel to the required position.

• Lock the steering column by pulling the lever up.

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3.5.4 - Operator's seat

General view - HTL4010 - HTL3510

General view - HTL3210

Before starting the engine, adjust the seat as follows to place the seat in an appropriate andcomfortable position :

• Move forward/backward : Use the handle ( P170 ) to move the seat forward and backward.

• Height : Use knob ( P171 ) to adjust the seat height.

• Suspension : Use the know ( P172 ) to adjust the suspension to the appropriate weight :

• In the green zone : Suspension is adapted to the operator's weight.

• In the red zone : The suspension is not adapted to the operator's weight.

• Backrest : Use the button ( P174 ) to adjust the backrest angle.

• Seat belt : Always fasten the seat belt ( P175 ) when operating the machine.

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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 fanswitch ( P203 ) on the side instrument panel.

Adjust the heating temperature using the knob under the driver's seat.

Adjust the air flow using the air locks and round vents.

Heating and ventilation - HTL4010 - HTL3510

Heating and ventilation - HTL3210

Do not operate the Telehandler for an extended period without ventilating the cab via the ventilationsystem.

Always ensure proper ventilation.

A lack of proper ventilation in the cab during use can lead to driver tiredness (oxygen depravation).

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3.5.6 - Air-conditioning(Optional)

To activate the air conditioning, operate the switch ( P207 ) located on the lateral controlconsole.

Adjust the fan speed.

Adjust the air flow using the air locks and round vents.

3.5.7 - Instrument/control panel

General view

The heating must be off when the air conditioning is on.

This equipment should not be started before starting the thermal engine.

Do not start the Telehandler engine while the air conditioning is switched on.

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Instrument/control panel


P176 -

(P161)*Engine tachometer with hour meter

Engine revs indicator graduated from 0 to 3000 tr/min (3000

RPM)1

P178 -

(P160)*Engine temperature indicator Coolant temperature2

P179 -

(P189)*Fuel level gauge

Gauge with two colour areas(green: more than 1/4 fuel / red: less than 1/4 fuel)

P180 Battery LED On : Electrical problem

P181 -

(HL162)*Engine oil pressure light On : Oil pressure problem

P182 -

(HL691)*Parking brake defect LED On : Not enough pressure in the parking brake circuit

P183 Hydraulic oil temperature indicator On : Hydraulic oil temperature too highP185 Steering indicator Flashing : Left-hand or right-hand steering activatedP186 Headlight indicator On : Headlights on

P187 -

(HL684)*Neutral LED On : Drive in neutral position

P188 -

(HL160)*Engine pre-heating LED

Constantly on : Engine pre-heating

Flashing : Pre-heating fault

P189 Hydraulic oil filter LED On : Hydraulic oil filter clogged

P190 -

(HL690)*Service brake fault LED On : Insufficient pressure in the service brake circuit

P191 -

(HL143)* ECU defect LED On : ECU fault3

P192 -

(HL683)*Rear axle alignment LED On : Rear wheels aligned

P193 LED floating(Option) Flashing : Activated

P198 -

(SA140)* Shunt winch Exclusion key : Deactivates the Loan Moment System

P199 -

(SA100)* 3-position ignition keyPosition 0 : Machine shutdownPosition 1 : IgnitionPosition 2 : Starter

P200 Chassis leveling switch Load levelling system

P201 -

(SA681)*Rear axle selection

Steering mode4

Synchronised axle

Front steer wheels

Crab mode axle

P203 Heating/Ventilation switch Ventilation - 2 speeds

P204 Windscreen wiper switchActivated : Press top of switch downwardsDeactivated : Press bottom of switch downwardsWindscreen washer : Press bottom of switch downward fully

P207 Air-conditioning switchActivated : Press top of switch downwardsDeactivated : Press bottom of switch downwards

P208 Left stabiliser switchTo lower left stabiliser : Press top of switch downwardsTo raise the left stabiliser : Press bottom of switch downwards

P209 Right stabiliser switchRight stabiliser lowering : Press top of switch downwardsRight stabiliser lifting : Press bottom of switch downwards

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(*) : Identification of the components on the electrical diagrams1 : Do not exceed 3000 tr/min (3000 rpm). Do not run the engine speed into the red zone. 2 : Service the machine as set out in this manual ( Section H - Lubrication andmaintenance). 3 : The ECU (P191) indicator flashes to indicate an internal malfunction.

When the machine switches downgraded mode, certain movements can be limited orprohibited to safeguard the operator's well being ( Section H 23 - Operating incidents).

P213 Beacon switchOn : Press top of switch downwardsOff : Press bottom of switch downwards

P214 Parking brake switchActivated : Press top of switch downwardsDeactivated : Press bottom of switch downwards

P215 Road mode selection switchOn : Press top of switch downwardsOff : Press bottom of switch downwards

P220

(HL163)*Water in GO indicator On : Presence of water in diesel fuel

P221

(SA187)*Fork/Winch Selector (Option)

Fork position : Center

Winch position : Rotate to left

P222Emergency pump / Radio-control Selector (Option)

Back-up pump power supply : Rotate to right and holdDrive in neutral position : CenterRadio-control position : Rotate to left

P224 Drive speed 1 indicator On : Speed 1 engaged

P225 Drive speed 2 indicator5On : Speed 2 engagedFlashing : Do not shift gear

The stabilisers only increase stability and load capabilities if they are used correctly. Using stabilisers onsoft surfaces can cause the machine to tip over which can result in serious injury. Always make sure thatthe surface on which the machine operates, is capable of supporting the combined weight of the machineand the load.

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 switchedon.

Driving mode must be realigned : • At the start of each day.

• At least once a day.

• If a misalignment problem is observed between the front and rear axles.

Follow the instructions below to realign the driving system : 1. Select the "Front steer wheels" mode. Rotate steering wheel slowly to

bring the rear wheels to the right position. The "Rear wheels aligned" indicator (P192) must be switched on. Continue to rotate steering wheel slowly until you see the front wheels aligned.

2. Select the "Synchronised axle" mode again. Check the realignment by carefully driving the machine a short distance.


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Driving mode must be realigned :

• At the start of each day.

• At least once a day.

• If a misalignment problem is observed between the front and rear axles.

Follow the instructions below to realign the driving system : 1. Select the "Front steer wheels" mode. Rotate steering wheel slowly to bring the rear

wheels to the right position. The "Rear wheels aligned" indicator ( P192 ) must remain switched on. Continue to rotate steering wheel slowly until you see the front wheels aligned.

2. Select the "Synchronised axle" mode again. Check the realignment by carefully driving the machine a short distance.

5 : Condition for prohibiting action : Extended boom or active float option or service brakepressure fault.

3.5.8 - Joystick

General view - CE standard

General view - AS standard

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General view - ANSI standard

Joystick - CE standard

Joystick - AS standard


P211 Joystick

To raise the telescopic arm : Pull the joystickTo lower the telescopic arm : Push the joystickDischarging : Push the joystick to the rightCrowding : Push the joystick to the leftTo telescope out : Push the left rocker switch upwardsTo telescope in : Push the left rocker switch downwardsAuxiliary, direction A : Push the right rocker switch upwardsTool control, direction B : Push the right rocker switch downwardsButton : Float optionHydraulic attachmet locking option


P211 Joystick

To raise the telescopic arm : Pull the joystickTo lower the telescopic arm : Push the joystickDischarging : Push the joystick to the right. Keeping pressed the back button in the joystick. Crowding : Push the joystick to the left. Keeping pressed the back button in the joystick. To telescope out : Push the left rocker switch upwardsTo telescope in : Push the left rocker switch downwardsAuxiliary, direction A : Push the right rocker switch upwardsTool control, direction B : Push the right rocker switch downwardsButton : Float optionHydraulic attachmet locking option

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Joystick - HTL4010 - HTL3210

Joystick - HTL3510

The speed of the joystick functions depends on the amplitude of the joystick travel in thecorresponding direction. Increasing the engine speed also increases the function speed.


P211 Joystick

Button (High) : Float optionHydraulic attachmet locking optionTo raise the telescopic arm : Pull the joystickTo lower the telescopic arm : Push the joystickDischarging : Push the joystick to the rightCrowding : Push the joystick to the leftTo telescope out : Push the left rocker switch upwardsTo telescope in : Push the left rocker switch downwardsAuxiliary, direction A : Push the right rocker switch upwardsTool control, direction B : Push the right rocker switch downwardsButton (Low) : Load levelling systemLowering left stabiliser : Press the low button and push the joystick towards the left and then forwardsLowering right stabiliser : Press the low button and push the joystick towards the right and then forwardsLowering the 2 stabilisers : Press the low button and push the joystick forwardsLifting the left stabiliser : Press the low button and push the joystick towards the left and then backwardsLifting the right stabiliser : Press the low button and push the joystick towards the right and then backwardsLifting of the 2 stabilisers : Press the low button and pull the joystick backwards


P211 Joystick

Button (High) : Float optionHydraulic attachmet locking optionTo raise the telescopic arm : Pull the joystickTo lower the telescopic arm : Push the joystickDischarging : Push the joystick to the rightCrowding : Push the joystick to the leftTo telescope out : Push the left rocker switch upwardsTo telescope in : Push the left rocker switch downwardsAuxiliary, direction A : Push the right rocker switch upwardsTool control, direction B : Push the right rocker switch downwardsButton (Low) : Load levelling systemChassis tilt : Move to the left : Press the low button and tilt the joystick leftChassis tilt Move to the right : Press the low button and tilt the joystick right

Rapid, jerky operation of the controls causes rapid and jerky machine movements. Such movements cancause the load to drift or fall and the machine may tip over. "Failure" to comply with these instructionscould result in death or serious injury.

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3.5.9 - Left-hand control panel

General view

General view

N.B.-:-The parking brake is automatically applied when the engine is switched off.

In road mode :

• All boom movements are prohibited (joystick deactivated).

• Using the stabilizers and dumping is prohibited.


P212 Hazard warning lights switchOn : Press top of switch downwardsOff : Press bottom of switch downwards

P213 Fog lights switchOn : Press top of switch downwardsOff : Press bottom of switch downwards

P214 Parking brake switch

On : Activated : • To release the brake manually• Press top of switch downwardsOff : Deactivated : • To release the brake manually• Press top of switch downwards

P215 Windscreen wiper switchActivated : Press top of switch downwardsDeactivated : Press top of switch downwardsWindscreen washer : Press bottom of switch downward fully

Parking brake switch :

• Respect the activation mode: locking /unlocking.

• Do not force the activation mode.

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• Steering switches to "2 steering wheels" mode, whatever the position of the steering selector may be(with the rear axle automatically returning to road position).

• Overriding the steering function with the exclusion key is also deactivated.

To switch to road mode, you must :

• Have the stabilizers raised

• Have stowed the machine

If these conditions are not respected and the road mode is selected, travelling is deactivated.The road mode indicator ( P215 ) flashes to failure to comply with the conditions. If thestabilisers are not raised,the stabilizer LED ( P208 ) and ( P209 ) also flash. Once theconditions are met, indicator ( P215 ) comes on and driving is enabled at high and low speeds.

3.5.10 - Load moment indicator (LMI)

General view

Controls and indicators

A display set into the right-hand windscreen strut shows the percentage remaining load,triggers a pre-alarm, reduces movement speed and then disables boom lowering andextension movements.

Test the load moment indicator at the start of each work period ( Section H - Lubricationand maintenance)

In all cases, the load capacity chart supplied in the cab is the only reference which may beused to define load capacity and ensure that the machine operates correctly. Even a lit green


P216 Green LED's Loading percentP217 Yellow LED Pre-alarm (intermittent buzzer)P218 Red LED Alarm (continuous buzzer)P219 Test The indicator can be tested at any time

The machine is fitted with an impending forward stability limit indicator. Indication is only valid on flatground when machine is stationary.

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LED does not authorise the machine to be used without the load chart or the load capacity tobe moved.

If a load moment indicator system alarm is triggered, the following movements are disabled :

Movements-Modes

Temporary suspension of the Load Moment Indicator system :

An exclusion key ( P198 ) allows the operator to disregard this movement deactivation to avoidbeing blocked in certain configurations. In this case, the operator should knowingly takeresponsibility for the for the machine's stability. This function is automatically deactivatedafter 8 s of activation in the absence of movement. It must be released before in can bereactivated.

AS Telehandlers are optionally fitted with an EQSS Load Management System whichmonitors and manages the load on the Telehandler in all position. For details refer to thesupplementary manual supplied with the Telehandler.

Movement Fork mode Winch mode

Booms raising Authorized Prohibited

Boom loweringDeactivated if the alarm sounds but can be

activated with the exclusion keyProhibited

CrowdingDeactivated if the alarm sounds but can be


DischargingDeactivated if the alarm sounds but can be


To telescope in Authorized ProhibitedTo telescope out Prohibited ProhibitedAttachments Deactivated if the alarm sounds but can be activated with the exclusion keyDriving Authorized

When the Load Moment is deactivated, the machine stability is no longer guaranteed. Consequently, thereis a risk of the machine tipping over. The operator therefore assumes full responsibility for the machine'smovements and must be aware of the consequences of his actions.

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3.5.11 - Rear-view mirrors and windows

Cab door window :

Rear window

Rear-view mirror adjustment

Adjust the rear-view mirrors as required for optimal visibility before and during use.

The window must be locked in open or closed positionduring use.

Open the cab door window and lock it with the lockingmechanism.

Press the unlocking button in the cab to unlock thewindow.

Pull the lever and push to open the rear window.

Ensure that rear-view mirrors are clean and clear at all times.

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D- Operation

Operation1 - Engine

N.B.-:-The fuel to be used is regulated by national laws; refer to these requirements to define theappropriate fuel. Using unsuitable fuel may cause diminished performance, difficulties starting,excessive pollution and premature wear. To establish the type of fuel suitable for the engine fitted onyour HAULOTTE® machine, please refer to the engine manufacturer's manual. The engine may not becovered by the warranty in case of damage caused by using unsuitable fuel.

1.1 - STARTING THE ENGINE

This machine can be operated at temperatures of -20 °C(0 °F) to 40 °C(104 °F) .Consult HAULOTTE Services® for operation outside this temperature range.

• Turn on the battery isolator located under the cab to the left of the s.eps.png.

• Make sure that all of the controls are in neutral and that all of the electrical components (lighting,heating, defrost system, …) are turned off.

• Insert the ignition key.

• Turn the ignition key completely to position 1.

• Wait until the pre-heating light ( P188 ) goes off before starting the engine.

The following LEDs should light upon start-up and then go off again :

• Engine oil pressure light P181.

• Parking brake LED P182 (possible if deactivated for a prolonged period).

• Battery LED P180.

• Service brake fault LED P190 (possible if deactivated for a prolonged period).

• When the machine is switched on (ignition key in position 1), the warning light ( P220 ) comes on forone second to check that the system is working properly.

• 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 starter for more than 15 s at the time.

Wait 10 s seconds between 2 attempts to avoid excessive drain of the battery power.

Do not try to start the machine by towing or pushing it, this could cause serious damage to the hydrostatictransmission.

If a LED indicates a fault, stop the engine immediately and perform the necessary operations orcontact HAULOTTE Services®.

Unexpected movement hazard. Always ensure that the gear control lever is in neutral.

Engine explosion. Do not spray ether into the air intake when starting the engine in cold weather. "Failure"to comply with these instructions could result in death or serious injury.

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D- 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.

1.2.2 - When the engine is running

Check at the beginning of each work shift or at each change of operator :

• Boost pressure P177.

• Service brake and parking brake operation.

• Forward and reverse.

• Each gear.

• Steer in 2 directions with the engine at idling speed. Check each steering mode (Forward andreverse).

• The horn and the back-up alarm. They must be audible from inside the operator's cab with the enginerunning.

• All of the boom and attachment functions should operate smoothly and correctly.

• Perform all additional checks ( Section H - Lubrication and maintenance).

1.3 - STARTING THE ENGINE WITH A BOOSTER BATTERY

If the engine has to be started with a booster battery (jumper cable...) proceed as follows :

• Never allow the vehicles to come into contact with each other.

• Connect the (+) terminal of the discharged battery to the (+) terminal of the booster battery.

• Connect the terminal - of the back-up battery to the terminal - of the discharged battery.

• Follow the standard starting procedures.

• Remove the cables in reverse order once the machine has been started.

Keep the engine cover closed while the engine is running. "Failure" to comply with these instructionscould result in death or serious injury.

Never jump-start or charge a frozen battery as it could explode. Do not produce sparks or flames or smoke near the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses. "Failure" to comply with these instructions could result in death or serious injury.

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D- Operation

1.4 - NORMAL ENGINE OPERATION

Observe the gauges and the display screen frequently to ensure that all engine systems arefunctioning properly.

Pay attention to unusual noises and vibrations. If a fault occurs, park the machine in a safeposition and perform the shut-down procedure ( Section D 1.5 -Engine shut-downprocedure). Report the fault to HAULOTTE Services®.

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 ortraffic lanes.

• Actuate the parking brake switch P214.

• Shift the speed selector to neutral.

• Lower the forks or the attachment to the ground.

• Operate the engine at idling speed for 1 mn.

• Stop the engine : Turn the ignition key to the left to position ''0''.

• Remove the ignition key.

• Exit the machine correctly.

• Block the wheels if necessary.

• Switch off the battery disconnector located under the cab on the left of the s.eps.png.

Do not overrev the engine.

The cab seat is equipped with an operator presence detection system and the LED ( P195 ) lights. If theoperator leaves the seat when the machine engine is operating, after an 8 s time delay, the presencedetector deactivates travel and automatically actuates the parking brake.

Remain correctly seated during movement. Otherwise, the machine may brake suddenly.

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D- 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.

You should know the machine's rated load capacities to determine the operating range withinwhich you can safely lift, transport and place loads ( Section G - Technicalcharacteristics).

2.2 - BEFORE LIFTING A LOAD

• Check the ground conditions. Adapt the travel speed and reduce the load weight according to theground.

• Avoid lifting unbalanced loads.

• Make sure that there are no obstacles near the load.

2.2.1 - For operation with non-suspended load

• Adjust the fork spacing so that they engage into the pallet or under the load at maximum width andremain centred on the fork carriage.

• Face the load and approach it slowly with the fork tips straight and horizontal.

2.2.2 - For operation with suspended load

• Only use approved lifting devices rated for the lifting of the load.

• Identify the proper lifting points of the load, taking into consideration the center of gravity and loadstability.

• Always properly tether loads to restrict movement.

Exceeding the machine's lifting capacity may damage the equipment and/or cause tipping over, resultingin death or serious injury.

Wheels must be aligned to lift a load.

Never lift any loads if a correct and legible capacity chart corresponding to the accessory used is notdisplayed in the operator's cab.

Never operate the telehandler without a proper and legible capacity chart displayed in the operator's cabfor the telehandler/attachment combination in use.

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D- 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 loadbackwards to place it in the travel position. Travel as specified Section A - Safetyprecautions, Section E - Attachments.

2.3.2 - For operation with suspended load

Travel in accordance with safety rules specified Section A - Safety precautions,Section E - Attachments

• Ensure the boom is fully retracted.

• Never raise the load more than 300 mm (11.8 in) above the ground or the boom more than 30°.

• The combination of sideways movement and the load could cause the machine to tip over.

• The guide persons must remain in constant communication (verbal or hand) and be in visual contactwith the operator at all times.

• Never place the guide persons between the suspended load and the telehandler.

• Only transport the load at walking speed (0.4 m/s) or less.

2.4 - DUMPING PROCEDURE

• Position the machine in the best location for lifting or placing the load.

• Actuate the parking/service brake and shift the gear control lever to neutral.

• Place the boom/attachment at less than 30 °.

• Check the level gauge to determine if the machine must be levelling and to do it with theswitch ( P200 ) (For HTL3510 only).

The machine is designed to allow movement of the main chassis 9 ° forward and backwards(For HTL3510 only).

Never raise the boom/attachment more than 1.2 m(3 ft11 in) above the ground unless the machine islevelled. The combination of sideways movement and the load could cause the machine to tip over.

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D- Operation

2.5 - STABILISER OPERATION PROCEDURE (HTL4010 - HTL3210)

• Position the machine in the best location for lifting or placing the load (Gradeability 3 °).

• Actuate the parking (P214) brake and shift the gear control lever to neutral.

• Release the service brake.

• Engage the stabilizers with the switch ( P208 ) and P209.

• Check the level indicator to determine whether the machine must be levelled, if required, do so usingthe joystick.

2.6 - 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 chart to determine the permitted boom extension range.

• Lower the forks to the level at which the load must be placed, and then extend the boom slowly untilthe load is just above the area where it must be placed.

• Lower the boom until the load rests in position and the forks can be retracted.

2.7 - DISENGAGING THE LOAD

Once the load has been safely placed at the unloading point, proceed as follows :

• When the load weight is no longer resting on the forks, the boom can be retracted and/or move themachine back from under the load if the surface so allows without changing the machine level.

• Lower the fork carriage.

• Drive the machine away from the landing point to continue work.

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D- 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…).

• Lower the boom. The front edge of the attachment should be approximately 0,30 m(1 ft0 in) to 0,40m(1 ft4 in) above the ground.

• Tilt the attachment back completely.

• Place a protective cover over the front edge of the bucket ; remove the carriage forks.

• Raise the stabilisers.

• If the rear wheels are not in line with the chassis, move them back slowly to a neutral position.

• Actuate the road switch P215.

• Empty the bucket (If equipped).

• The machine is now ready for road operation.

N.B.-:-Ensure that you follow all local, regional and national traffic regulations.

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D- Operation

4 - Loading and securing for transportHTL4010 - HTL3210

HTL3510

• Level the machine before loading.

• Obtain assistance from an operator for manœuvring and loading the machine, with the boom as lowas possible.

• Once loaded, apply the parking brake and lower the boom until the boom or attachment touches thedeck. Switch all controls to neutral, stop the engine and remove the ignition key.

• To secure the machine to the deck, pass chains through the designated tie-down points as illustratedin the figure.

• Do not tie down the front of the boom.

N.B.-:-The user is responsible for choosing the proper method of transportation and the tie-downdevices : Ensure that the equipment used is able to support the weight of the vehicle to be transportedand that all manufacturer's instructions and warnings, regulations and safety rules and all national,regional and local laws are followed.

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D- Operation

Lifting the machine

Ensure that :

• The machine is completely folded

• The accessories are in good conditions and have sufficient capacity

• The staff performing the maneuvers is authorized and empowered to use lifting equipment

Before loading the machine to be transported, check that the deck, the ramps and the machine wheels arefree of mud, snow and ice. Otherwise, the machine may slide, which could result in serious injury or death.

A 2 lifting straps length 3200 +/- 50 mm

B 2 lifting straps length 4000

• Keep different length between A and B.

• Caution to lifting machine with air conditioned cab.

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D- Operation

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E- Attachments

Attachments1 - Approved attachments

To determine whether an attachment is approved for use on the machine in use, proceed as followsbefore installation of attachment :

• The attachment model/option number indicated on the attachment identification plate mustcorrespond to the attachment number indicated on a capacity chart located in the operator's cab.

• The model indicated on the capacity chart must correspond to the model of the machine being used.

• The center of gravity of the load on the fork (if applicable) must correspond to the center of gravity ofthe load indicated on the capacity chart.

• Hydraulically-powered attachments must only be used on machines equipped with auxiliaryhydraulics.

2 - Unapproved attachments

If any of the above conditions are not met, do not use the attachment. The machine may not be equippedwith the relevant capacity chart or the attachment may not be approved for the machine model being used.Additional information can be obtained from HAULOTTE Services®.

The user must enlist the services of a competent person to familiarise themselves with the test proceduresfor the specific attachments they have for the Telehandler. The user is responsible for carrying out anyrequired checks of the attachment..

The user must ensure that the accessory can be used in the country in which the machine is be used.

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 otherunapproved attachments.

• An overextended or overloaded machine may tip over with little or no warning, can result in serious injuryor death to the operator and/or those working nearby.

• HAULOTTE® cannot guarantee the ability of an unapproved attachment to perform its intended functionsafely.

Only use HAULOTTE approved attachments. Attachments that have not been approved by HAULOTTE foruse with this machine may cause material and/or bodily damage, or even death.

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E- Attachments

3 - Telehandler/Attachment/Fork capacities

Before installing the attachment, check that it is approved and that the telehandler is equipped with therelevant capacity chart.

Attachment manufacturer's plate

Load capacity chart

N.B.-:-The attachment number located on the manufacturer's plate must correspond to the attachmentnumber which appears on the load chart.

To determine the maximum capacity of the telehandler and the attachment, use the smallest of thecapacities as determined by the capacity stamped on the attachment or the lifting position on the loadchart..

The forks must be used in matched pairs.

Never use an accessory without having checked the HAULOTTE® accessory load capacity chart installedon the telehandler. Failure to install the relevant HAULOTTE® supplied capacity chart could cause anaccident resulting in death or serious injury.

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E- Attachments

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.

• The load placement data :

• The height at which the load must be placed.

• The distance the load must be placed forward of the front tires of the Telehandler.

• An alphabetical key ( A, B, C, D, E, F ) indicates the boom extension and a pendulum indicates theboom angle ( Section E - Boom angle indicator).

• On the capacity chart for a given load, find the area corresponding to the key and follow it to thepermitted reach.

• The number that appears in the load capacity range must be equal to or greater than the weight ofthe load to be lifted. Determine the load capacity range limits with the capacity chart and keep withinthose limits.

Boom angle indicator

1 : Horizontal boom

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E- Attachments

Boom extension indicators

Example of a load capacity chart : HTL4010

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E- Attachments

To identify the appropriate load capacity table, refer to the icons (representing the attachments) whichappear on the table :

Examples of how to read the load capacity chart for the HTL3210 fitted with the fork carriage

The following examples illustrate situations where the load may or may not be lifted.

Stabilisers lowered

Stabilisers raised

Marking Description

1 HTL4010 : The load capacity chart must only be used for this machine

2Attachment reference : The attachment reference must correspond to the number on the attachment manufacturer's plate

3 Boom extension indicators4 Load area : The load areas indicate the maximum weight which can be lifted5 Boom angle

• To be used when lifting a load with the stabilisers raised :

• To be used when lifting a load with the stabilisers lowered :

All of the loads indicated on the load capacity chart are based on the machine being on firm ground withthe chassis level, the forks being positioned symmetrically on the fork carriage, the load being centred onthe forks, appropriately sized tires being inflated correctly and the telehandler being in good workingcondition. "Failure" to comply with these instructions could result in death or serious injury.

Use the capacity chart corresponding to the machine.

The attachment number located on the manufacturer's plate must correspond to the attachment numberwhich appears on the load chart.

ExampleThe weight of the load to be lifted

Distance Height Lifting authorised

1 2000 kg(4409 lb) 4,5 m(14 ft9 in) 8 m(26 ft24 in) Yes2 3200 kg(7056 lb) 5 m(16 ft40 in) 7 m(22 ft96 in) No3 3000 kg(6615 lb) 3 m(9 ft84 in) 5 m(16 ft40 in) Yes

ExampleThe weight of the load to be lifted

Distance Height Lifting authorised

4 1200 kg(2646 lb) 3 m(9 ft84 in) 9 m(29 ft52 in) Yes5 1000 kg(2204 lb) 6 m(19 ft68 in) 6 m(19 ft68 in) No6 800 kg(1764 lb) 5 m(16 ft40 in) 4 m(13 ft12 in) No

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E- Attachments

HTL4010 load capacity chart

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E- Attachments



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E- Attachments

5 - Attachment installation


5.1 - MECHANICAL ATTACHMENT LOCKING DEVICE

• Pull the locks and disengage the locking pins from the accessory.

• Align the tool apron pin with the attachment recess by lifting and crowding ( P211 ).

• Actuate the parking brake P214. Leave the cab, insert the locking pins and secure them with theretaining locks.

• If the attachment requires hydraulic control, connect auxiliary hydraulic hoses A and B.

Marking Description

C143 AttachmentC144 Attachment pin recessC145 Attachment pinC146 Lock pinC147 Retainer pin

Always ensure that the fork carriage or the accessory is correctly positioned on the boom, secured by 2locking pins and held in place by 2 retaining locks. Incorrect installation could result in the fork carriage/attachment/load disengaging, causing death or serious injury.

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E- Attachments

5.2 - HYDRAULIC ACCESSORY LOCKING DEVICE (OPTION)

5.2.1 - Specific instructions

5.2.2 - Operation

• Start the engine.

• Align the tool apron pin with the attachment recess by lifting and crowding ( P211 ).

• Carry out the attachment installation operations while holding the locking button down.

• Release the button to lock.

Before installing the hydraulic adaptation kit, ensure :

• there is no internal malfunction. The ECU indicator must not show any boom angle fault (-5 flashes)

• that the boom is below 15 °.

The hydraulic adaptation kit connection is carried out with the machine stopped.

• Connect the hoses from the hydraulic adaptation kit to thepush/pull sockets on the tool holder carriage.

• To unlock the tool holder carriage, press the locking buttonfor at least 2 s and hold down.

Releasing the button locks the attachment.

Do not press on the locking button for longer than 2 s when the auxiliary line is connected to theattachment. Danger of unexpected movement.

If the attachment requires hydraulic control, connect auxiliary hydraulic hoses A and B.

Hold the button down for 5 s to unlock the carriage.

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E- 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.

• Lift the boom by approximately 10 °, tilt the fork carriage forwards until the fork heel is no longer incontact with the fork carriage.

• Stand next to the fork carriage to slide the fork, push it or pull it near its pin.

If the forks must be changed out :

• Place the forks on the ground.

• Remove the fork pin.

• Change out the forks and place them in position.

• Change out the fork pins and their retaining mechanisms.

Using forks :

• The machine's capacity and range limits change according to the forks used.

Keep the specific instructions for the forks in the manual holder situated behind the cab seat, with thetelehandler operator manual.

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E- Attachments

5.4 - TOOTHLESS BUCKET

5.4.1 - Characteristics

5.4.2 - Toothless bucket control

The joystick (P211) controls movements of the boom and attachment tilt ( Section C 2.5.8-Joystick).

5.4.3 - Attachment installation procedure

Section E 5 - Attachment installation.

Familiarize yourself with the information provided on the attachment identification plate.

Use the capacity table (load chart booklet) corresponding to this attachment located in the cab.


Toothless bucket

Marking Metric Imperial

A 0,796 m (2 ft7 in)B 0,804 m (2 ft8 in)C 0,904 m (3 ft0 in)D 1,088 m (3 ft7 in)E 2,4 m (7 ft10 in)F 2,45 m (8 ft0 in)

Incorrect installation could result in the attachment or load disengaging, causing death or serious injury.

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E- Attachments

5.4.4 - Using the load capacity chart

To identify the appropriate load capacity table, refer to the icons (representing theattachments) which appear on the table :

• To be used when lifting a load with the stabilisers raised

HTL4010 - HTL3210 load capacity chart stabilisers raised (Values given for information only)

Make yourself familiar with the information Section E 3, Section E 4.

Use the capacity table (load chart booklet) corresponding to this attachment located in the cab (Left handdashboard).

The machine must not be used without the capacity chart booklet.

All the loads indicated on the nominal capacity chart (load chart booklet) assume that the machine is onfirm ground with the chassis level, the load evenly distributed on the attachments, tyres of the correct size,sufficiently inflated and that the handler is in good working order. "Failure" to comply with theseinstructions could result in death or serious injury.


Do not use the bucket to pull a load.

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E- Attachments

• To be used when lifting a load with the stabilisers lowered.

HTL4010 - HTL3210 load capacity chart for lowered stabilisers (Values given for information only)

Do not fill the bucket while telescoping the boom.

It is forbidden to have an unevenly spread load in the bucket.





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Never use an attachment without first having made yourself familiar with the load capacity chart suppliedby HAULOTTE® on the handler (Load chart located on the left hand dashboard in the handler). Failure toinstall the relevant HAULOTTE® supplied capacity chart could cause an accident resulting in death orserious injury.






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5.4.5 - Operation instructions

The bucket is recommended for picking up loose products such as sand, gravel or soil, but itis under no circumstances designed for excavation work.

The attachment may be used for lifting construction materials and handling.

5.4.6 - Precautions to avoid damaging the equipment

• Loading the bucket must be performed smoothly and with the boom completely retracted. Loading thebucket with the boom extended may damage the boom or the telescope cylinder.

• Distribute the material evenly in the dump. The bucket capacity charts only apply to evenly distributedloads.

5.4.7 - Operation

• Raise or lower the boom to the appropriate height for loading the material.

• Load the bucket smoothly and with the boom completely retracted.

• Tip the bucket upwards enough to stabilise the load and reverse.

• Travel as specified Section A - Safety precautions.

• Tilt the bucket downwards to tip out the load.

Mounting teeth on this bucket is forbidden.

Any other use is forbidden.

It is strictly forbidden to use the equipment for :

• Stump extraction

• Rock excavation

• Putting in fence posts

Specific instructions concerning use of the equipment can be written and given to the driver by thecompany director.

Never walk under the bucket when the lifting arm is in the raised position.

Do not use the bucket as a lift platform (Transporting personnel is strictly forbidden).

Do not load the bucket on one side only.

Do not use the bucket as a lever. Excessive leverage could damage the buckets and the handler.

Do not use the bucket to pull a load. This could cause serious damage to the mechanical attachmentlocking system and the telescope cylinder.

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5.4.8 - Attachment life expectancy

Section H : Refer to this section of the user manual to check bucket blade wear and/orchange the blade.

Check the bucket blade and corners regularly for wear.

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5.5 - TOOTHED BUCKET


5.5.2 - Toothed bucket control







Toothed bucket


A 0,796 m (2 ft7 in)B 0,804 m (2 ft8 in)C 0,967 m (3 ft2 in)D 1,206 m (3 ft11 in)E 2,4 m (7 ft10 in)F 2,45 m (8 ft0 in)


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HTL4010 - HTL3210 load capacity chart stabilisers raised (Values given for information only)







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The bucket is recommended for picking up loose loads such as sand of gravel and forexcavation operations. It can be used on all types of low abrasion ground and is perfectlysuited to construction and excavation work.

The teeth are U profile (Universal). They are designed for loose, non-compact, slightlyabrasive ground (top soil, sand, gravel) or with pre-split stones and for general applications.

The flush tooth holder is mainly designed for picking up loose material requiring "standard"digging force and for cleaning work (Leaving the ground surface flat).


• Loading the bucket must be performed smoothly and with the boom completely retracted. Loading thebucket with the boom extended may damage the boom or the telescope cylinder.

• Distribute the material evenly in the dump. The bucket capacity charts only apply to evenly distributedloads.

Any other use is forbidden.

It is strictly forbidden to use the equipment for :

• Stump extraction

• Rock excavation

• Putting in fence posts

It is strictly forbidden to use the attachment on very hard ground.


Never walk under the bucket when the lifting arm is in the raised position.

Do not use the bucket as a lift platform (Transporting personnel is strictly forbidden).

It is forbidden to use the attachment on concrete slabs.

Do not load the bucket on one side only.

Do not use the bucket as a lever. Excessive leverage could damage the buckets and the handler.

Do not use the bucket to pull a load. This could cause serious damage to the mechanical attachmentlocking system and the telescope cylinder.

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5.5.7 - Operation


• Load the bucket smoothly and with the boom completely retracted.

• Tip the bucket upwards enough to stabilise the load and reverse.


• Tilt the bucket downwards to tip out the load.


Section H : See this section of the user manual for changing the teeth and bucket blade.

Check the bucket teeth regularly for wear.

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5.6 - 3 T (6615 LB) 1 M(3 FT3 IN) JIB CRANE


Jib crane fitted with a swivel hook, designed to operate under dynamic and static load.

5.6.2 - Jib crane control





The safety coefficient used is in compliance with the legislation on lifting apparatus or attachment tests.

3 t (6615 lb) 1 m(3 ft3 in) jib crane


A 1,176 m (3 ft10 in)B 1 m (3 ft3 in)C 0,881 m (2 ft11 in)D 0,790 m (2 ft7 in)

Weight 141 kg (311 lb)Maximum static load 3000 kg (6615 lb)

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HTL 4010 - HTL 3210 (NA) load capacity chart stabilisers raised (Values given for information only)






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HTL 3510 (NA) load capacity chart stabilisers raised (Values given for information only)



Do not move a load without having secured it first.

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HTL 4010 - HTL 3210 (NA) load capacity chart for lowered stabilisers (Values given for information only)





The jib crane must only be mounted on a suitable machine bracket.

Do not use the attachment :

• As a mobile jib crane.

• For pulling loads laterally.

• Under conditions of repeated cyclic fatigue : i.e. fast running on a bumpy surface.

It is strictly forbidden to move the load (drive the telescopic handler) with the jib in high position.

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5.6.7 - Operation

• Raise or lower the boom to the appropriate height for lifting the load.

• Lift the load smoothly and with the boom fully retracted.



The load must be lifted with the mast positioned as specified on the load charts.

If it must be moved, the load must be kept in the low position. Speed of movement must not exceed 5 km/h (3,1 mph) and the load must be secured to the telescopic handler fork carriage.

The weight of all riggings (slings, etc…) must be included as part of the load weight.

Beware of the wind. The wind can cause a suspended load to tip over and generate destabilising sideforces (even with tag lines).


The user must be trained in handling loads at height by an authorised organisation. The user musttherefore strictly adhere to the slinging rules.

Never walk under the jib crane when the lifting arm is in the raised position.

Do not use the jib as a lever. Excessive leverage could damage the fly jib and the handler.

Do not use the jib to drag loads. This could cause severe damage to the mechanical attachment lockingsystem and the retraction chains.

Lubricate the hinge pin every 16 h ( Section H - Lubrication and maintenance).

If the hook is damaged, stop using the attachment immediately. Change it.

If the jib frame is hit, stop using the attachment immediately.

The attachment must be inspected by an authorised organisation to validate its capacity.Contact HAULOTTE Services®.

If the load is exceeded, or the attachment is used abnormally (driving while loaded, shovelling up work,etc.) have the attachment checked by an authorised organisation or contact HAULOTTE Services®.

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5.7 - SIDE-SHIFT FORK CARRIAGE

5.7.1 - Main components




Marking Description

1 Double pilot-operated check valve + coupling2 Travel cylinder3 Pallet forks FEM3A4 Side-shift fork carriage (Moving part)5 Fork carriage chassis (Fixed part)

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5.7.2 - Technical characteristics

Side-shift fork carriage, designed to operate under dynamic and static load conditions.

Side-shift fork carriage

5.7.3 - Side-shift fork carriage control





Characteristics Metric Imperial

Overall width of machine 1,25 m (4 ft10 in)Height of fork carriage

alone0,839 m (2 ft75 in)

Overall height of machine 0,915 m (3 ft0 in)Length of fork carriage

alone0,356 m (1 ft17 in)

Overall length of machine 1,6 m (5 ft25 in)Tare weight 390 kg (860 lb)

User pressure 180 bar (2610,67 psi)Maximum permissible

pressure220 bar (3190,83 psi)

Minimum flow 50 l/minStandard : FEM3A

Dimensions of pallet forksSection 0,125 m x 0,045 m m( ft41 in) x m( ft15 in)Length 1,2 m (4 ft0 in)Height 0,645 m (2 ft11 in)

Fork capacity 4700 kg (10362 lb)Maximum static load 3000 kg (6614 lb)

Never fit pallet forks onto the fork carriage with dimensions exceeding 0,125 m(0 ft41 in) x 0,45 m(0 ft15 in)x 1,2 m(4 ft0 in) for a maximum permissible load capacity of 4700 kg(10362 lb) as the tool is designed forforks of standard FEM3A ( A or B).

Ensure that the hydraulic hoses are connected correctly.


Never start up the accessory when other people are nearby.

Before using the attachment for the first time, operate the fork carriage empty and check that it travelscorrectly.

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For safe usage, the information giving the maximum load on the pallet forks in relation to themaximum height of the machine fork carriage and its maximum reach must be strictly adheredto (For a load 0,5 m(1 ft8 in) from the side-shift fork carriage).





HTL 4010 (NA) HTL 3210 (NA)

Maximum load capacity 3000 kg(6,615 lb) 3000 kg(6,615 lb)

Maximum load capacity at maximum height without stabilisers

1000 kg(2,205 lb) 800 kg(1763,7 lb)

Maximum load capacity at maximum reach without stabilisers

200 kg(441 lb) 200 kg(441 lb)

Maximum load capacity at maximum height with stabilisers

2500 kg(5,513 lb) 2500 kg(5,513 lb)

Maximum load capacity at maximum reach with stabilisers

1000 kg(2,205 lb) 800 kg(1763,7 lb)

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Do not use the fork carriage to pull loads.


Do not use the fork carriage to pull loads.


The side-shift fork carriage must only be mounted on a suitable machine bracket.

This accessory is not designed to "shovel up" loads, i.e. pull a load laterally.

It is strictly forbidden to move the load (drive the telescopic handler) with the fork carriage in the highposition.

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5.7.8 - Operation

Loading :


• Before loading the fork carriage, ensure that the fork carriage is in loading position, with the palletforks parallel to the ground and approximately 0,05 m(0 ft2 in) above it. The whole length of the palletmust be resting on the pallet forks.

Loading

• Load smoothly and with the boom completely retracted.



Do not use the fork carriage as a lever. Excessive leverage could damage the fork carriage and the handler.

Do not use the fork carriage to pull loads. This could cause severe damage to the mechanical attachmentlocking system and the retraction chains.

Be careful that the fork carriage does not get in the way of the wheels.

Never walk under the fork carriage when the lifting arm is in the raised position.

Do not use the fork carriage as a lift platform (Transporting personnel is strictly forbidden).

Do not use the fork carriage with the hydraulic hoses disconnected or the fork carriage may move.

Place the lifting arm in low position and the fork carriage in central position when driving on the road.

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Crowding :

Crowding

Ensure that no one is in the work zone.

Check that nothing collides with the pallet forks or the fork carriage while the load is being handled.

To ensure that the pallet does not move on the forks, you are advised to tilt the fork carriage by 10 °.

Do not exceed 10 ° : The pallet and its load might tip over on the fork carriage.

Before tilting the fork carriage, ensure that there is no obstacle at the end of the pallet forks.

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Lateral movement :

Lateral movement

Discharging :

Discharging

Before starting to move the fork carriage laterally, ensure that there is no obstacle in the way.

Before tilting the fork carriage forwards to unload it, ensure that there are no obstacles under the palletforks and the pallet.

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Unloading :

Unloading



Section H : See this section of the user manual for lubricating the fork carriage.

Section H : See chapter of the user manual entitled "Operating incidents", to analysereasons why the attachment does not work.

Storing the attachment :

• Always store the assembly with the carriage lifted.

• Wedge the attachments so that they cannot fall.

Before beginning to load the fork carriage, ensure that the fork carriage is in unloading position, with thepallet forks parallel to the ground and 0,05 m(0 ft2 in) above it.

Check the following regularly :

• Bolts and connections are tightened to the correct torque.

• The condition of the hydraulic hoses.

• The condition of the pallet forks.

• The attachment fastenings.

If the pallet forks are damaged, stop using the attachment immediately. Change it.


Attachments which are not stored correctly can cause death or serious injury when reattached and used.

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5.8 - FLY JIB 2,5 M(8 FT2 IN), 1,2 T (2646 LB) ON TELESCOPIC ARM


Fly jib, fitted with swivel hook, mounted on telescopic jib designed to operate under dynamicand static load.

5.8.2 - Fly jib control








Fly jib 2,5 m(8 ft2 in), 1,2 t (2646 lb) on telescopic arm


A 2,705 m (8 ft11 in)B 0,880 m (2 ft11 in)C 0,770 m (2 ft6 in)

Weight 206 kg (454 lb)Maximum load, machine halted 1200 kg (2646 lb)


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5.8.7 - Operation




The fly jib must only be mounted on a suitable machine bracket.







If it must be moved, the load must be kept in the low position. Speed of movement must not exceed 5 km/h (3,11 mph) and the load must be secured to the telescopic handler fork carriage. The weight of allriggings (slings, etc…) must be included as part of the load weight.




Do not walk under the winch when the lifting arm is in raised position.

Do not use the fly jib as a lever. Excessive leverage could damage the fly jib and the handler.


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If the winch frame is hit, "stop using the attachment immediately".



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5.9 - FLY JIB 4 M(13 FT1 IN), 0,6 T (1323 LB) ON TELESCOPIC ARM


Fly jib, fitted with swivel hook, mounted on telescopic jib designed to operate under dynamicand static load.

5.9.2 - Fly jib control








Fly jib 4 m(13 ft1 in), 0,6 t (1323 lb) on telescopic arm


A 4,215 m (13 ft10 in)B 0,880 m (2 ft11 in)C 0,770 m (2 ft6 in)

Weight 276 kg (609 lb)Maximum load, machine halted 600 kg (1323 lb)


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5.9.7 - Operation




The fly jib must only be mounted on a suitable machine bracket.





Moving the load (driving the telescopic handler) is strictly forbidden with the fly jib raised.







Do not use the fly jib as a lever. Excessive leverage could damage the fly jib and the handler.


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5.10 - WINCH SUPPORT- 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION)






Description Capacity Maximum flow rateMaximum pressure

Comments

Winch 600 kg(1323 lb) 75 litres per minute 175 bar

Cable 3900 kg(8600 lb)Anti-

torsion,diameter 8Hook 3200 kg(7056 lb) Swivelling

Marking Description

1 Cable2 Hydraulic winch3 Hydraulic hoses4 Frame winch support5 Upper stop system - End of travel valve6 Handling hook7 Support foot8 Cable guide pulley

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5.10.3 - Winch support control




Coupling the winch support :



Turn the key selector ( P221 ) to winch position ( Section C 2.5.7 - Instrument/control panel).

• Connect the tool and lock it in place using the locking pins1.

• Connect the hydraulic hoses 2.

Before using the winch for the first time, operate the fly jib winch while empty and check that the cablegoes up and down correctly.





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First phase : Unwinding the cable

This attachment is designed for handling loads. Any other use is forbidden.



• with the hydraulic hoses disconnected with a risk of the cable unwinding.


Comply with current Highway Code regulations.

The maximum authorised speed is 25 km/h (15,53 mph) and maximum tool width is 2,55 m(8 ft2 in).

Ensure that the dimensions of the attachment are correctly indicated in compliance with currentlegislation when driving on the public highway ( 2,5 m(8 ft2 in) protruding in front of the handler).

Do not drive on the highway with the cable unwound.

Before starting up the machine ensure that the winch support is correctly attached.

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Second phase : Handling the load

The fly jib must not operate with an angle between the cable and the vertical greater than 3 °.


• The lower stop is adjusted on the winch by positioning thecable gland in the required place 1. This adjustment can becarried out in the factory for 3 rotations of the drum.

The load must be correctly attached to the handling hook according to current specifications.


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Third phase : Lifting the load

To lift the load, use the hydraulic winch function to wind up the cable onto the winch drum. Theupper stop is created by a weight which lifts the connecting rod at the end of the fly jib whichcuts the hydraulic circuit by pressing on the end of travel valve 1.



Do not lift the load if the angle between the winch support and the ground is greater than 5 °.

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5.10.8 - Operation





Section H : Consult this section of the user manual to change the fly jib cable and winch.




For any operation on the winch you must :

• Place the attachment on the ground.

• Stop the carrier vehicle.

• Release the hydraulic pressure.

• Disconnect the hydraulic hoses.



Grease the following zones every 24 h ( Section H - Lubrication and maintenance) :

• Greasing the roller.

• Greasing the end of course valve.

• The pulley greaser.

Check the attachment fastenings regularly.




If the load is exceeded, or the attachment is used abnormally (driving while loaded, etc.) have theattachment checked by an authorised organisation or contact HAULOTTE Services®.

Never do any work on the mounted attachment without switching off the engine.

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Prolonged periods of non-use and storage :

In case of prolonged periods of non-use, you are advised to :

• Store the machine in a suitable place, sheltered from bad weather.

• Clean the machine regularly.

• Grease the whole fly jib ( Section H - Lubrication and maintenance).

• Put a layer of oil over the whole machine to ensure total protection.


Wedge the attachment so that it cannot fall or roll.

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5.11 - WINCH SUPPORT- 2,4 T (5292 LB) WITH HYDRAULIC WINCH (OPTION)






Description Capacity Maximum flow rateMaximum pressure

Comments

Winch 1200 kg(2646 lb) 50 litres per minute 220 bar

Cable 3900 kg(8600 lb)Anti-

torsion,diameter 10Hook 3200 kg(7056 lb) Swivelling

Marking Description

1 Cable2 Hydraulic winch3 Hydraulic hoses4 Frame winch support5 Upper stop system - End of travel valve6 Handling hook7 Support foot8 Cable guide pulley

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5.11.3 - Winch support control




Coupling the winch support :



Turn the key selector ( P221 ) to winch position ( Section C 2.5.7 - Instrument/control panel).

• Connect the tool and lock it in place using the locking pins1.

• Connect the hydraulic hoses 2.

Before using the winch for the first time, operate the fly jib winch while empty and check that the cablegoes up and down correctly.





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First phase : Unwinding the cable

This attachment is designed for handling loads. Any other use is forbidden.



• with the hydraulic hoses disconnected with a risk of the cable unwinding.


Comply with current Highway Code regulations.

The maximum authorised speed is 25 km/h (15,53 mph) and maximum tool width is 2,55 m(8 ft2 in).

Ensure that the dimensions of the attachment are correctly indicated in compliance with currentlegislation when driving on the public highway ( 2,5 m(8 ft2 in) protruding in front of the handler).


Before starting up the machine ensure that the winch support is correctly attached.

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Second phase : Handling the load

The fly jib must not operate with an angle between the cable and the vertical greater than 3 °.


• The lower stop is adjusted on the winch by positioning thecable gland in the required place 1. This adjustment can becarried out in the factory for 3 rotations of the drum.

The load must be correctly attached to the handling hook according to current specifications.


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Third phase : Lifting the load

To lift the load, use the hydraulic winch function to wind up the cable onto the winch drum. Theupper stop is created by a weight which lifts the connecting rod at the end of the fly jib whichcuts the hydraulic circuit by pressing on the end of travel valve 1.

If it must be moved, the load must be kept in the low position. Speed of movement must not exceed 5 km/h (3 mph) and the load must be secured to the telescopic handler fork carriage. The weight of all riggings(slings, etc…) must be included as part of the load weight.


Do not lift the load if the angle between the winch support and the ground is greater than 5 °.

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5.11.8 - Operation





Section H : Consult this section of the user manual to change the fly jib cable and winch.




For any operation on the winch you must :

• Place the attachment on the ground.

• Stop the carrier vehicle.

• Release the hydraulic pressure.




Grease the following zones every 24 h ( Section H - Lubrication and maintenance) :

• Greasing the roller.

• Greasing the end of course valve.

• The pulley greaser.

Check the attachment fastenings regularly.





Never do any work on the mounted attachment without switching off the engine.

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Prolonged periods of non-use and storage :

In case of prolonged periods of non-use, you are advised to :

• Store the machine in a suitable place, sheltered from bad weather.

• Clean the machine regularly.

• Grease the whole fly jib ( Section H - Lubrication and maintenance).

• Put a layer of oil over the whole machine to ensure total protection.


Always store the assembly with the fly jib flat.

Wedge the attachment so that it cannot fall or roll.

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F- Emergency procedure

Emergency procedure1 - Towing a broken-down vehicle

1.1 - GENERAL PRECAUTIONS

The first option should be to complete repairs on-site.

If the machine is on a public highway, ensure that no part of the Telehandler encroaches ontothe road. If encroachment cannot be avoided, place warning signage on the road inaccordance with the currently applicable regulations (example: warning triangle (optional),safety vest for the operator (optional), etc.).

Before towing the Telehandler, complete the following: :

• Ensure that the Telehandler boom is sufficiently raised to avoid interferences with the ground or thetowing vehicle.

• If the Telehandler boom cannot be raised sufficiently to avoid interferences, contact HAULOTTEServices®.

(1)Unscrew each pressure relief valve by 3 turns before towing.

The maximum travel speed permitted for towing is 6 km/h (4 mph) . The towing distanceshould not exceed .

• Turn on ignition key and start up engine..

• Deactivate the parking brake.

• When the parking brake is released, the machine can be towed.

If the parking brake is still engaged and the engine has broken down, de-activate the brakebefore towing ( Section F 1.2 -Releasing the axle brake for towing. )

Towing must only be performed when the machine has broken down and once the operator has ensuredthat there is no risk of additional damage.

• Check that the steering can be used.

• Unbraked the front axle according to the procedure.

• To tow the Telehandler, attach a towing bar to the towingclevis situated at the front or rear of the Telehandler

If the Telehandler must be towed, the combined weight of the towing vehicle and machine must not exceedto 28,5 Tonne.

Towing is performed at the operator's risk and must be completed with extra care.

Before towing the Telehandler, you should loosen thetwo pressure limiters on the travel pump by three turns1.

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1.2 - RELEASING THE AXLE BRAKE FOR TOWING

on HTL4010 and HTL3210 only :

The following procedure is used to release the front axle parking brake in the event of a enginebreakdown or when the accumulator is empty.

1.2.1 - Parking brake deactivation


Tools required :

• Allen 8 mm wrench.

• Reversible 3/8'' ratchet and 3'' extension.

• Park the Telehandler.

• Block the four wheels again.

• The machine can be towed ( Section F 1.1 - Towing a broken-down vehicle).

To access brake release screws ( 1-2-3 ) (see figurebelow), you must loosen the 6 cap screws ( 3 on eachside) positioned around the flanges on the (rigid) frontaxle. (See photo opposite).

Block the four wheels with chocks to prevent any machine movement when the brake is disengaged.

• The Allen 8 mm key should be used to disengage theparking brake correctly.

• Draw a mark so that you can count the number ofrevolutions made by each nut in order to make the correctadjustment upon reassembly.

• Locate the six brake release bolts ( 3 on each side) underthe front axle.

• Tighten bolts ( 1-2-3 ) alternatively in half turns clockwiseuntil you feel resistance (approximately 5,5 turns).

• Note the number of turns made for each screw.

Come out from under the Telehandler and remove the chocks placed under the four wheels.

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For HTL3510 only :

Tools required :

• Spanner 19 mm.

1.2.2 - Parking brake reactivation


Tools required :

• BTR 8 mm wrench.

• Reversible 3/8'' ratchet and 3'' extension.

When the four wheels are properly blocked :

• Loosen nuts ( 1-2-3 ) under the axle successively anticlockwise in half turns.

• Continue loosening them in ½ turns until the torque suddenly decreases.

• Loosen screws ( 1-2-3 ) alternatively anticlockwise until the screw heads brush against the top of thespecial screws.

• Tighten nuts ( 1-2-3 ) clockwise by a quarter of 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.

For HTL3510 only :

Tools required :

• Spanner 19.

• Loosen the 4 screws from 18 mm to 21 mm.

• Tighten the lock nuts.

• Loosen the lock nuts.

• Fully tighten the 4 screws.

Block the four wheels with chocks to prevent any Telehandler movement when the brake is disengaged

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2 - Emergency boom lowering 2.1 - MANUAL BOOM LOWERING (EMERGENCY MODE)

Before any manual lowering operation :

• Retract the boom before lowering it.

• Activate the parking brake and chock the wheels.

If the boom cannot be retracted, check on the load capacity chart in the cab that lowering theboom in a horizontal position is compatible with telehandler stability.

• Block the boom in position with another machine, a crane or, as a last resort, the cylinder chock.

• Completely unscrew the stop screw from the counter-balance valve block flanged on the boom liftcylinder. Note the number of turns with the spanner. Remove the locknut and rescrew the stop screwfully into its socket ( 1 ).

• Remove the cover located under the counterweight at the rear of the machine to access the valveblock.

• Slowly unscrew the cap situated on the boom lift plate (first plate from the back) until you can see theboom lowering, then screw back in once the boom in low position (2).

This operation should only be performed as a last resort as it presents a danger for the operator (machineand load stability).

Marking Description1 Stop screw

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• Once the boom is lowered and the machine has been repaired, raise the boom to its high position andsecure it into place using the cylinder prop.

• Unscrew the stop screw from the counter-balance valve block, replace the counternut and turn thescrew in the assembly fully into its socket.

• Check that the counter-balance valve functions properly after the intervention (by raising/lowering theboom with a load).

3 - Emergency exit from cab

In an emergency, exit from the cab can be achieved via the rear window..

Secure the boom into position before any interventions on the counter-balance valve.

• Release the stop ( 1 ) upwards.

• Push the window ( 2 ) outwards with your hand.

In accordance with the local and governmental regulations in force in some countries, a "break glasshammer" is provided inside the cab to allow exist in an emergency by breaking the rear window glass.

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G- Technical characteristics

Technical characteristics1 - Main characteristics

Technical characteristics

Certain options can modify the machine's operating characteristics and its associated safety If yourTelehandler was originally delivered with options fitted, replacing a safety component associated with aparticular option does not require any particular precautions other than those associated with theinstallation itself (static test). Certain options can modify the Telehandler's operating characteristics andits associated safety

If you intend to add options to your product after original delivery, it is essential to follow themanufacturer's recommendations below :

• Any options added must be either HAULOTTE® original options, or must be approved in writingby HAULOTTE®.

• Installation by authorised HAULOTTE® personnel only.

• Update the manufacturer's identification plate.

• Have stability tests carried out by a certified agency/competent person.

• Ensure that any additional labels that relate to the option installed, are affixed to the machine in theappropriate location/s.

HAULOTTE® has a continuous improvement policy in place for its product range ; Given this policy, TheCompany reserves the right to modify their product technical characteristics without notice.

Engine

HTL4010 - HTL3510 HTL3210

Model Perkins 1104D44TType Four-stroke, water-cooled

Cubic capacity 4400 cm3 (268,50 cu in)Intake TurboPower 70 kW (94 Hp) at 2300 rpm (97/68EC) 62.5 kW (84 Hp) at 2300 rpm (97/68EC)Torque 392 Nm at 1400 rpm 353 Nm at 1400 rpm

Hydraulic circuit

Pump Gear pumpFlow 100 l/min

Pressure 260 bar(3771 psi)Regulation Load Sensing

Control Electro-hydraulic with 4-function joystickAccessory plug flow 62 l/min

Hydraulic oil tank capacity 103 l(27 gal US)

Transmission

HTL4010 - HTL3510 HTL3210

TypeHydrostatic with pump and variable cubic capacity engine, 4 permanent drive

wheelsControl Electro-hydraulic with 2/2 front, rear and neutral position selector

Speed in operating mode 0 - 8 km/h (5 mph) Speed in road mode 0 - 25 km/h (15,53 mph)

Slow approach Yes-Inching pedal

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The cab complies with the ROPS (ISO 3471) / FOPS (ISO 3449) European safety standard. Door withtwo separate sections, opening rear window with wiper, heating, ventilation and joystick with 4proportional functions.

Traction force 6500 daN(14612 lbf) 4900 daN(11011 lbf)Negotiable slope 45 %

Axles Epicyclic gears - Limited-slip differential blockingSwing axle Yes

Braking circuit

Engine brake HydrostaticService brake Multi-disc oil bath brake controlled by the brake pedalParking brake Electrically-controlled multi-disc oil bath brake

Cab

Interior width 940 mm

Tyres

HTL4010 - HTL3510 HTL3210

Type

405/70 - 24(HAULOTTE® code : 2326014870)

Pre-charge pressure : 4,5 bar(65,2 psi)

405/70 - 20(HAULOTTE® code : 232601508)

Pre-charge pressure : 4,5 bar(65,2 psi)

Steering system

Inner turning radius on tyre 2550 mmOuter turning radius on tyre 4800 mm

Electric circuit

Operating voltage 12 VOperating battery 110 Ah

Alternator 100 AStarter 4.2 kW (5.6 Hp)

Filling capacity

Fuel tank 120 l(32 gal US)Hydraulic oil tank 103 l(27 gal US)

Front axle 12,6 l(3 gal US)Rear axle 10,6 l(3 gal US)

Transfer case 0,5 l(0.14 gal US)Engine oil 7 l(2 gal US)

Transmission

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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

• Incremental approach movements possible via the Inching system

• Deactivation of aggravating movements in the event of overload

• Load moment indicating device with load status controller and 5 LED's in the cab: cut-off and soundsignal with automatic speed deceleration at the limits of the capacity chart

• Side tilt corrector : +9° / - 9° (HTL3510)

• Pre-wirring for radio and loudspeakers

• Horn

• Adjustable seat (height and armrest) with safety belt

• Adjustable steering column

• Power steering

• Metal protection above cab

• Sun visor

• Left and right exterior rearview mirrors

• Hour meter

• Boom angle indicator

• Mudguards

• Stabilisers in the machine gauge with weight-bearing presence contactor

• Forks

• Manual fork carriage with 2 pins

• Rear hitch

• Road Mode wheel configuration selector button

• Beacon light

• Front and rear full beam headlights

• Folding rear lights, working position and road driving position (Option)

• Diesel fuel prefilter with water separator

Cooling 18 l(5 gal US)

Filling capacity

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2 - Overall dimensionsGeneral diagram HTL4010 - HTL3510 - HTL3210

Overall dimension specifications

Overall dimension specifications

Marking HTL4010 HTL3510

Mètre Feet inch Mètre Feet inch

A 5,14 16 ft 10 in 5,14 16 ft 10 inB 2,25 7 ft 5 in 2,25 7 ft 5 inC 2,42 7 ft 11 in 2,42 7 ft 11 inD 2,78 9 ft 1 in 2,78 9 ft 1 inE 0,40 1 ft 4 in 0,40 1 ft 4 inF 1,85 6 ft 1 in 1,85 6 ft 1 inG 0,94 3 ft 1 in 0.94 3 ft 1 inH 2,23 11 ft 2,23 11 ftI 2,71 7 ft 4 in 2,71 7 ft 4 inJ 1,66 5 ft 5 in 1,66 5 ft 5 inK 39 ° 39 °L 23 ° 23 °M 103 ° 103 °N 2,55 8 ft 4 in 2,55 8 ft 4 inO 4,80 15 ft 9 in 4,80 15 ft 9 in

Total weight 8730 kg (19,25 lb) 8500 kg (18,743 lb)

Marking HTL3210

Mètre Feet inch

A 5,14 16 ft 10 inB 2,25 7 ft 5 inC 2,42 7 ft 11 inD 2,78 9 ft 1 inE 0,40 1 ft 4 inF 1,85 6 ft 1 inG 0,94 3 ft 1 inH 2,23 11 ftI 2,71 7 ft 4 inJ 1,66 5 ft 5 in

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3 - Working area 3.1 - MACHINE HTL4010

Working area

3.2 - MACHINE HTL3510

Working area

K 39 °L 23 °M 103 °N 2,55 8 ft 4 inO 4,80 15 ft 9 in

Total weight 8200 kg (18,081 lb)

Marking HTL3210

Mètre Feet inch

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3.3 - MACHINE HTL3210

Working area

4 - Acoustic power

The Telehandler's noise emission sound levels comply with :

• The European directives mentioned on the compliance certificate supplied with the machine.

• National road regulations.

• National work regulations.

The LWA noise emission level is shown on the machine.

To avoid any increase in noise emission, all panels and other sound-absorbing materials must bereplaced in their original position after maintenance and repair work.

The sound power values indicated in the technical characteristics tables are obtained in the followingconditions :

• For machines equipped with internal combustion engines, the guaranteed accoustic level LWA(displayed on the product) and is measured in accordance with the method and the conditionsdescribed in Appendix III, Part B, Point 36 of the 2000/14/CE European directive.

Do not modify the machine in a way that may increase noise emissions.

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5 - Telehandler vibration

The load and acceleration values for vibrations transmitted to the body are below the levels requiredby the various regulations. The measurements have been performed according to the currentlyapplicable standards.

Hand and body vibration are measured in accordance with method and conditions described instandard ISO5349-1 and ISO2631-1.

The hand and feet vibration values indicated in the technical characteristics tables are obtained in thefollowing conditions :

• The maximum quadratic mean value weighted as an acceleration frequency and the total value of thevibrations to which the hand-arm system is exposed have been measured on the products by simulatinga cycle representative of normal use. The values meet the requirements of the 2006/42/CE machinedirective.

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6 - Declaration of conformity

Declaration of conformity - Carriages

CE Declarations of Conformity only apply to machines that are certified for the European market.

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H- Lubrication and maintenance

Lubrication and maintenance1 - 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 ofoperating conditions/routine maintenance which should be carried out in accordance with this manual.Severity of operating conditions may require a reduction in time between maintenance periods. Thesefactors are amongst a number, which may extend or shorten the Design Life of the product. LocalRegulations may also require Enhanced Periodic Inspection/ 10 year inspection to be carried out onthe product to extend its service life beyond the Design life.

Perform the maintenance in accordance with the maintenance schedule set out on the following pages.

• Adapt the frequency of maintenance according to use to obtain maximum service life.

• Read all of the instructions in the guide before starting Telehandler maintenance.

• Follow the Telehandler shut-down procedure before performing any servicing or maintenance

• For all checks, park the Telehandler on flat ground, stop the engine, actuate the parking brake andlower the booms to the parked position.

• To obtain accurate fluid level readings ensure that the machine is on level ground.

• Before each check : top-up, refill or lubrication check, you must clean the filler inlets, the filler capsand the grease points.

• After lubricating the machine, actuate all functions several times to distribute the lubricants. Performall these maintenance procedures without any accessories fitted.

• Check the state of the filling plug seals; do not forget to replace them if they are damaged or worn.

• Maintain the Telehandler and associated equipment, especially the brakes and the steering, in goodcondition to protect your safety and to comply with the statutory requirements.

• Always check the pins, the bushes, the fastening pins, etc… daily

• Incorrect or poorly performed maintenance can damage the machine.

• Check that there are no tools or other objects left in the engine compartment after maintenance workhas been completed.

• Drain the engine after operation when the oil is hot.

N.B.-:-Mechanical vibrations may occur on the machine during the first 50 hours of operation. Thisphenomenon will disappear after the internal combustion engine's run-in period.

• Remove the keys from the ignition switch during maintenance work.

• Batteries, plastic objects or other components of a toxic nature that could be harmful to theenvironment must be disposed of in a way that does not harm. Ensure that they must be disposedof in a way that does not harm.

N.B.-:-Accumulators are pressurized vessels. It is the user's responsibility to refer to the nationalregulations in force in the country of use concerning their use and disposal.

Do not modify or alter the machine or its equipment without the manufacturer's permission.

Stop the engine before opening the canopy : Presence of moving parts that could cause bodily injuries.

Do not stand close to the front or rear of the machine while the engine is running.

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2 - Maintenance instructions

Safety prop

• Wear protective clothing and personal protection equipment supplied or required by the jobconditions.

• If the engine is started inside a building, there must be sufficient ventilation to remove the exhaustgases.

• Always refit the guards and plates that have been dismantled before starting the machine.

• Paintwork shall be performed in well-ventilated premises using approved protective equipment.

• The engine cooling system operates under pressure. The pressure is regulated by the radiator cap.

• To prevent any risks of fire or explosion, keep any naked flames away from the battery. To preventany risk of sparks that could cause an explosion, use the battery cables in accordance with theinstructions provided in this manual.

• Hydraulic oil leaks or fluid under pressure can cause serious injury.

Before operate maintenance operation on hydraulic component or component localized under the boom,use safety prop as follow :

• Place the boom to 24° - 25° (without load and machine on wheels).

• Put the safety prop in the boom in the same way that it is shown in the picture (it is prohibited to lift upor lift down the boom with the safety prop placed).

• Proceed to work under boom.

Do not wear loose fitting clothes or jewellery that could get caught on controls or moving parts.

Do not perform Telehandler servicing or maintenance with the engine running.

Never dismantle a component from the system while it is hot. Always loosen the radiator cap slowly andlet the pressure escape before removing it completely.

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N.B.-:-Stop the engine and depressurize the system before intervening on the hydraulic system.

N.B.-:-Check that all connections are tight before restarting the machine or pressurizing the system.

• The diesel in the injection system is under high pressure. For any operations or adjustments, pleasecontact a qualified technician or your dealer. Failure to comply with these guidelines can result inserious injury.

• Protective equipment must be worn when performing any service/repair on the machine.

3 - Repairs and adjustments

Significant repairs or adjustments on the safety systems or elements (concerns mechanics, hydraulicsand electrics).

Any modifications not approved by HAULOTTE® are not permitted.

The manufacturer's product liability will be void if the work specified above is not performedby HAULOTTE® approved staff or if the spare parts are not original spare parts.

Do not use your hands to check for oil leaks. Search for leaks with a piece of cardboard or paper.

Do not intervene on the air-conditioning system. A refrigerant fluid leak can cause serious injury.Contact HAULOTTE Services®.

Never let anyone stand or work under the boom when it is raised unless the safety prop is installed andthe cylinder is secured.

Hydraulics.

Never try to repair or tighten pressurized pipes or hoses.

Never perform lubrication or adjustment operations when the machine is in motion or when the engine isrunning.

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4 - Lubrication and maintenance schedule

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For machines fitted with : Engine PERKINS 1104D44T


Symbol Marking Description

Check the level

Filter

Oil change

1* Lubrication

2* Diesel circuit

3* Cooling system

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4* Air filter (system)

5* Internal combustion engine

6* Travel axles

7* Hydraulic circuit

8* Operating battery

Symbol Marking Description

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5 - General program / Recommendations

The design service life of the products covered by this manual is for a period of 10 years. This servicelife is based on the machine being maintained within the maintenance regime set down in theMaintenance Manual supplied with the product.

It must be noted that should the product be subject to ongoing use in harsh environments, then theeffective service life will be reduced. Contact Haulotte Services for further advice.

The time periods below are recommended for fuel-powered machines in normal use.

1 - Increase in periodical inspections

2 - For countries where machines are not subject to controlled periodic maintenance

Symbol Meaning Symbol Meaning

Visual inspectionsSystematic replacement Operation requiring HAULOTTE Services® authorisation

Check-Test See user manual or machine maintenance book (1)

Visual inspection with dismantling and exchange or replacement if necessary Operation requiring HAULOTTE Services® authorisation Increase in periodical inspections

Check level Tightening (bolt, etc.)

Lubrication-Lubrication Tolerance (clearance lubrication)

Oil change(2)

Static and dynamic tests For countries where machines are not subject to controlled periodic maintenance

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Area

Intervals

DailyEvery 50 hours

Every 100

hours

Every 250

hours

Every 500

hours

Every 1000

hours

Every 2000

hours

General checks

Structure parts

Windscreen washer fluid

Oil, water, fuel leaks

Appearance of the mechanical parts, hydraulic hoses and wiring

Attachment device : nuts and bolts and hydraulic fitting

Operation of the work lighting controls, the light indicators, display load moment indicator

Diesel engine operation

State of anti-slip parts

State of tires and inflation pressure

Wheel nut torque

Lubrication

Cylinder pins

Boom bottom shaft

Telescopic boom pads

Suspension, driver seat rails

Diesel circuit

Condensation

Diesel pre-filter

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Filter

Cooling system

Coolant

State of the hoses and collars

Radiator slats

Cleanliness of the radiator's protection grill

Air filter (system)

Remove the dust

Primary air filter

Secondary air filter

Internal combustion engine (See manufacturer's guide)

Oil

Oil filter cartridge

Engine mounting

Glow plugs

Belt tension

Travel axles (See manufacturer's guide)

Front axle : Reducer + differential + transfer case on front axle + pivots

Rear axle : Reducer + differential + pivots

Epicyclic gears

Hydraulic circuit

Hydraulic oil

Attachment hydraulic oil

Transmission hydraulic filter

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6 - Detailed program

The time periods below are recommended for fuel-powered machines in normal use.

1 - Increase in periodical inspections

2 - For countries where machines are not subject to controlled periodic maintenance

Pressures

Operating battery

Symbol Meaning Symbol Meaning

Visual inspectionsSystematic replacement Operation requiring HAULOTTE Services® authorisation

Check-Test See user manual or machine maintenance book (1)

Visual inspection with dismantling and exchange or replacement if necessary Operation requiring HAULOTTE Services® authorisation Increase in periodical inspections

Check level Tightening (bolt, etc.)

Lubrication-Lubrication Tolerance (clearance lubrication)

Oil change(2)

Static and dynamic tests For countries where machines are not subject to controlled periodic maintenance

During the periodic inspection of the 2000 h (visual inspection with dismantling and exchange orreplacement if necessary), a record must be made of all parts that have been dismantled but not replaced

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500 h or 6 month service

Area Type of intervention Area Type of intervention

General checks Lubrication

Windscreen washer fluid Cylinder pins

Oil, water, fuel leaks Boom bottom shaft






Diesel circuit

Diesel engine operation Condensation

State of anti-slip parts Pre-filter


Filter

Wheel nut torque Air filter (system)

Internal combustion engine (See manufacturer's guide) Remove the dust

Oil Primary air filter

Oil filter cartridge Secondary air filter

Belt tension Cooling system

Travel axles (See manufacturer's guide) Coolant


Hoses and collars


Radiator slats

Epicyclic gearsCleanliness of the radiator's protection grill

Hydraulic circuit Operating battery

Hydraulic oil Level

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

Comments

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1000 h or 12 month serviceArea Type of intervention Area Type of intervention









Diesel circuit




Filter






Engine mounting Coolant

Glow plugs Hoses and collars

Travel axles (See manufacturer's guide) Radiator slats




Hydraulic circuit

Epicyclic gears Hydraulic oil

Operating battery Attachment hydraulic oil

Level Transmission hydraulic filter


Comments

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1500 h or 18 month service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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2000 h serviceArea Type of intervention Area Type of intervention









Diesel circuit




Filter












Hydraulic circuit




Pressures


Comments

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2500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter












Hydraulic circuit





Comments

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3500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter


Remove the dust

Internal combustion engine (See manufacturer's guide) Primary air filter

Oil Secondary air filter

Oil filter cartridge Cooling system

Belt tension Coolant

Engine mounting Hoses and collars

Glow plugs Radiator slats

Travel axles (See manufacturer's guide)Cleanliness of the radiator's protection grill


Hydraulic circuit


Hydraulic oil

Epicyclic gears Attachment hydraulic oil

Operating battery Transmission hydraulic filter

Level Pressures


Comments

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4500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter












Hydraulic circuit





Comments

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5500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter


Remove the dust









Hydraulic circuit


Hydraulic oil



Level Pressures


Comments

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6500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter












Hydraulic circuit





Comments

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7500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter


Remove the dust









Hydraulic circuit


Hydraulic oil



Level Pressures


Comments

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8500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter












Hydraulic circuit





Comments

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9500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter


Remove the dust









Hydraulic circuit


Hydraulic oil



Level Pressures


Comments

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10500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter












Hydraulic circuit





Comments

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11500 h service










Diesel circuit




Filter








Hoses and collars


Radiator slats



Hydraulic oil Level


Comments

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Diesel circuit




Filter


Remove the dust









Hydraulic circuit


Hydraulic oil



Level Pressures


Comments

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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 identicalspecification : Type, Length, Diameter, Class .

• Tighten to the torque indicated when reassembling.

7.1.2 - Pins and bearings

Over and above the normal maintenance schedule, check pins and bearings in the followingcases :

• Abnormal noise during the movements of the structure.

• Observance of excessive amounts of foreign material around the bearing extremities during the dailyvisual inspections.

• Poor or no maintenance.

Replace slew ring in the following cases :

• Deformations, fatigue failure of the bearings and/or the pins.

• Presence of excessive clearance between the pin and housing(> at 0,5 mm).

• Presence of deformations, cracks or breakage of the bearings and/or the pins.

• Presence of scoring on the surface of the bearing.

• If there is excessive friction.

When reassembling bearings and pins ensure that :

• Lightly lubricate the housing into which the bearing is to be installed.

• Insert the bearing using a bearing drift, preferably made out of mild steel.

• The bearing, the bearing drift and the bearing housing must be correctly aligned during the assemblyprocess.

• The recommended values for the bearing drift are given on the diagram below :

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Recommended Values

• After inserting the bearing, lubricate and fit the pin.

7.1.3 - Bearings

Action on bearings needs to be taken outside the normal maintenance schedule if the followingoccurs :

• Abnormal noise during the movements of the structure.

• Machine not use for a period of 6 months or more.

• Environment of storage and specific uses(Strong moisture and salinity in the air).

Checking procedure :

• After disassembling the affected pivot, protect the bearing from external pollutants and potentialdamage.

• Clean the bearing with a suitable solvent.

• Replace the bearing in the following cases :

• Presence of abrasions in the bearing housing and/or inside the bearing itself.

• Presence of abrasion, wear, oxidation, deformations of the balls (or rollers) and the ring rollers.

Marking Description

A At least 0,5 times the nominal diameterB Make a chamferC Nominal diameter of the bearing - 0,2 / - 0,3 mmD Bearing driftE Diameter of the bearing guide - 0,20 / - 0,25 mmF BearingG Housing

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• 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.

• When fitting a bearing in a housing ensure that the outer bearing ring is properly supported duringinstallation.

• When fitting a bearing onto a shaft ensure that the inner bearing ring is properly supported duringinstallation.

7.2 - HYDRAULICS

7.2.1 - Replacing damaged of hoses

Replace hoses in the following circumstances :

• Tears in the outer casing.

• Cracks in the outer casing.

• Damage to wire shielding.

• Visible leak in the hose.

• Damage to the outer casing caused by chemical reaction from a foreign source.

N.B.-:-Slowly undo the hose end fitting to allow the residual hydraulic pressure to dissipate.

To protect personal safety, observe the following conditions when disassembling or reassemblingcomponents :

• Stow and park the machine on level cleared ground(The machine should not be tilted. The boom athorizontal position).

• Stow the machine completely.

• Place barriers around the perimeter of the work area (risk area = maximum height of the machine).

• Locate the faulty hose/s and their end connection points, to ensure proper machine operation afterintervention.

• Identify and memorise the hose path of the hose to be replaced.

Use an oil collection pan to avoid polluting the environment.

• After hose removal, plug the the hose ends and the ports from which the hose was removed, to avoidpolluting the hydraulic system.

• Check the cleanliness of the hoses and hydraulic components (no metal shavings, rubber, plastic, …).

• If necessary, drain and clean the whole system (tank included).

• Tighten to the torque indicated when reassembling.

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Tightening torque table

7.2.2 - Evaluation of leaks on hydraulic cylinders

These measures must be taken each time an anomaly has been detected in the hydrauliccylinder during daily inspection and periodic maintenance checks.

Generic Control :

• Position a load equal to the rated capacity on the cage (or platform).

• Raise the loaded attachment using the ground control box. To activate the cylinder to be tested,proceed as follows :

• Raise Arm hydraulic cylinder : Raise the arm to approximately half full height. The telescopic boomshould be fully extended and in the horizontal position..

• Boom lifting cylinder : Raise the boom approximately half way to its maximum angle.

• Telescopic cylinder : Raise the boom to its maximum angle and telescope approximately 50 cm.

• Measure the distance between a reference point on the attachment and the ground.

• Leave the machine in this condition for 15 mn (minutes).

• Measure the distance between the floor of the cage (or of the platform) and the ground.

• If the difference between two measurements does not exceed 4 cm : the test validates correctoperation.

• If the difference between two measurements exceeds 4 cm, contact HAULOTTE Services® or carryout the additional tests described below.

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.

• Attach a comparator to the cylinder concerned :

• Attach the body of the comparator to the cylinder rod.

• The needle of the comparator must be in contact with the end of the casing of the cylinder.

• The target is to measure the creep of the cylinder rod.

Description Torque (JIC) Torque (ORFS)

Hose 1/4" (diameter 6mm) 1,5 daN.m(11,08 lbf.ft) 2,6 daN.m(19,22 lbf.ft) Hose 3/8" (diameter 10mm) 3,5 daN.m(25,86 lbf.ft) 4,2 daN.m(31,04 lbf.ft) Hose 1/2" (diameter 12mm) 5 daN.m(36,95 lbf.ft) 5,7 daN.m(42,12 lbf.ft) Hose 5/8" (diameter 16mm) 8 daN.m(59,12 lbf.ft) 8,5 daN.m(62,82 lbf.ft)

Hose 3/4" (diameter 19) 10 daN.m(73,91 lbf.ft) 12,2 daN.m(90,17 lbf.ft)

• Place the machine in its operating configuration.

• To purge the hydraulic system, operate the function/s on the machine that correspond to the hose/s thathas/have been replaced, a few times.

• Check the oil level in the hydraulic oil tank.

• Check the pressure.

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• If the creep of the cylinder rod is higher than the values indicated in the table below, replace thecylinder.

7.3 - ELECTRIC

7.3.1 - Replacing damaged cables

• Locate the faulty wire/s and its/their points of connection to ensure continuity of machine operationafter the wire is replaced.

• Note the wire path to facilitate reassembly.

• Respect the order (configuration) of origin during the reassembly.

Type of cylinders Maximum drift authorised due to an internal leak of the cylinder

Lift cylinder arm or boom (Machine with working heights > 26 m(85 ft4 in))

After 10 mn, creep < 0,2 mm After 60 mn, creep < 1 mm

Outriggers cylinder, Oscillating axle locking, Lift cylinder arm or boom (Machine with range-limiting system)

After 10 mn, creep < 0,5 mm After 60 mn, creep < 2,5 mm

Lift cylinder arm or boom, Telescoping, Compensation, ...

After 10 mn, creep < 1 mm After 60 mn, creep < 6 mm

Steering cylinder After 10 mn, creep < 1,5 mm After 60 mn, creep < 9 mm

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8 - Every day or every 10 h of operation 8.1 - GENERAL CHECKS

• Perform a visual check for any leaks (Check the corresponding reservoir fluid level if leak is detected).

• Check that there are no signs of scratches, tears and warping on the hoses, accessories and worktools.

• Check the attachment devices and the hydraulic connections.

• Check the appearance of the mechanical parts.

• Check the operation of the controls, control indicator lights and other system indicators.

• Check diesel engine operation : Check the colour of the exhaust fumes and locate any abnormalnoises.

• Check and clean the radiator's protection grill.

• Check the state of the anti-slip parts (cab access steps) and replace them if necessary.

• Check that the tires are not damaged after the first 10 hours and then after every 100 h of operation.

• Check the wheel lug nut torque ( 300Nm) after the first 10 hours and then after every 100 ofoperation.

8.2 - LOAD MOMENT INDICATOR

The load moment indicator's function is to constantly monitoring the stability of the front of themachine. To check that it is functioning correctly, proceed as follows :

• Without any payload on the machine, retract the boom fully and level it.

• Level the chassis.

• Press the test button on the load moment indicator display.

• All of the LEDs should flash and a warning signal should sound. This indicates that the system isworking properly.

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

During a pressure check or an inflation operation, always face the end of the tyre; never face the side ofthe tyre.

Do not allow contact with abrasive materials.

Do not raise the boom during this test.

If the test gives a different result then it is indicating a fault in the system the machine must be removedfrom service and the fault identified and fixed before putting the machine back into service.

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8.3 - DIESEL CIRCUIT

• To prevent condensation from forming, top up the reservoir at the end of every working day (Capacity: 120 l(31,6 gal US)).

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 theexpansion bottle.

• Open the radiator and top up with fluid as necessary.

• Only refill with SHELL ANTIFREEZE -38 °C(-36,4 °F) coolant.

• Check the state of the hoses and that the collars are secured.

8.5 - AIR FILTER (SYSTEM)

• Empty the dust filter :

N.B.-:-Filter clogging check : Clogging is constantly being monitored via a sensor situated on the filterbody. Visually inspect the state of the sensor. If red marking is visible : Clean or replace the filter elementeven if the cleaning frequency indicated above has not been reached. Clean the inside of the box.

• Drain any condensate and clean the diesel pre-filter.

• To access the diesel pre-filter, open the engine cover. Thepre-filter is located under the diesel filter

• Drain water and dirt by removing the purge screw situatedunder the pre-filter.

• Refit and tighten the purge screw.

Do not remove the filling cap when the engine is hot. DANGER OF BURNS! Loosen the cap to the firstnotch and let it depressurize, then unscrew the cap completely.

• Empty the dust evacutation valve ( 1 ) by pressing on theevacuation slot in the direction of the arrow.

• Clean the evacuation slot.

• Clean away any remaining dust by pressing the upper partof the valve.

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• Clean the primary air filter's filter cartridge :

8.6 - INTERNAL COMBUSTION ENGINE

• Check the oil level :

• Open the motor canopy, remove the oil dip stick; the level must be situated between the two min. andmax. marks.

• Top up as necessary via the filler.

• Check the belt tension :

• Correct belt tension is essential to ensure that the alternator, the diesel pump and the water pumpwork properly and for the service life of the belts themselves.

• A belt in poor condition must be replaced immediately.

• Remove the cover :

• Pull the trigger situated on the cover ( 1 ).

• Locate and note the angular position of the cover whichshould be identical upon reassembly.

• Turn the cover to the right ( 2 ).

• Pull the cover to remove it.

• Turn and pull the outer cartridge.

• Clean the filter cartridge (replace it, at the latest, afterevery 1000 h of operation or once a year).

• Blow with dry compressed air (with a maximum pressureof 5 bar(72,5 psi)) from the inside of the filter, outwards or

• Unclog by tapping (Only in the event of an emergency). Inthis case, do not damage the cartridge, or

• Wash it in accordance with the manufacturer's guidelines.

• Check that neither the cartridge filter paper (translucentpaper) nor the seal are damaged. Replace it/them ifnecessary.

• Replace the filter cartridge.

• Refit the cover, checking that the dust evacuation valve isdirected downwards.

Check the state of the sealing ring before reassembling the cartridges. Check the state of the filter elementwith a light source placed inside the cartridge. Change the cartridge if a hole is detected (by a light ray).

Never clean the cartridge by hitting it against a hard surface or by using hot flammable liquid.

For the following operations, park the machine on a horizontal surface and turn off the engine.

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8.7 - HYDRAULIC CIRCUIT

8.8 - AIR-CONDITIONING (OPTION)

Cold weather use :

In order to guarantee the correct operation and for operational efficiency of the air conditioningsystem it is advisable to turn the compressor on once a week, even for a short period of time,so as to ensure that internal moving parts are lubricated.

Warm up the engine before you turn on the compressor, this the heat produced by the engineto turn the liquid coolant accumulated in the lower part of the compressor circuit to turn intogas. Liquid coolant could damage the compressor.

8.9 - FLY JIB 2,5 M(8 FT2 IN), 1,2 WITH HYDRAULIC WINCH (OPTION) - FLY JIB 4 M(13 FT1 IN), 0,6 WITH HYDRAULIC WINCH (OPTION)

• Regularly check that the bolts and connections are correctly tightened (Tightening torques : 3,5daN.m(25,8 lbf.ft) ).

• Regularly check the condition of the hydraulic hoses.

• Regulary check that the winch nuts are tightened correctly.

8.10 - WINCH SUPPORT- 1,2 WITH HYDRAULIC WINCH (OPTION) - WINCH SUPPORT-2,4 WITH HYDRAULIC WINCH (OPTION)

• Regularly check that the bolts and connections are correctly tightened (Tightening torques : 3,5daN.m(25,8 lbf.ft) ).

• Regularly check the condition of the hydraulic hoses.

• Regulary check that the winch nuts are tightened correctly.

• Check the oil level :

• Park the machine on a horizontal surface.

• Stow the machine : With the stabilisers raised as far aspossible, the fork carriage lowered as far as possible, theboom retracted, the cylinders retracted.

• The level must be situated between the two marks, asindicated in the photo/picture opposite. Top up asnecessary via the filler.

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9 - Every 24 h hours of operation 9.1 - SIDE-SHIFT FORK CARRIAGE GREASE POINT (OPTION)

Before carrying out any operations on the fork carriage, it is essential to :

• Disengage all the drives.

• Operate the controls until the pressure has dissipated.

• Set the fork carriage on the ground.

• Stop the engine (if necessary let the engine cool down).


To ensure the fork carriage works properly, lubricate the plates ( 1 ) holding the clamps for thefixed section every 24 h working.

Never carry out lubrication, maintenance and adjustment operations while the machine is switched on.

Escaping liquid can be under enough pressure to penetrate under the skin, causing serious injury. Toavoid any risk of accident, eliminate the pressure before disconnecting the hydraulic hoses. Beforerepressurising the system, ensure that all the connections are correctly tightened.

Hydraulic liquid can get very hot when operating, do not carry out any operations which may cause a burn.Wear gloves and goggles to protect yourself from fluid splashes.

Keep away from moving parts.

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9.2 - LUBRICATION POINT : FLY JIB 2,5 M(8 FT2 IN), 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - FLY JIB 4 M(13 FT1 IN), 0,6 T (1323 LB) WITH HYDRAULIC WINCH (OPTION)

Before carrying out any operations on the fly jib, it is essential to :



• Set the fly jib on the ground



In order for the fly jib to operate correctly, grease the following zones every 24 h of operation.

Lubricate generously until a ring of grease appears at the ends of each hinge.





Marking Description

1 Contact zone2 The pulley greaser3 Raceway

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9.3 - LUBRICATION POINT : WINCH SUPPORT- 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - WINCH SUPPORT- 2,4 T (5292 LB) WITH HYDRAULIC WINCH (OPTION)

Before carrying out any operations on the winch, it is essential to :



• Set the winch on the ground.



In order for the winch support to operate correctly, grease the following zones every 24 h ofoperation.

Lubricate generously until a ring of grease appears at the ends of each hinge.





Marking Description

1 Greasing the roller2 Greasing the end of course valve3 The pulley greaser

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10 - Every 50 h hours of operation• Lubricate the cylinder pins equipped with grease points.

• Lubricate the extension boom shaft.

• Lubricate the sliding area friction pads.

• Check the boom telescope synchronisation: fully retract the boom and fully extend it. The variouselements must come out simultaneously.

Section H 20.3 -For lubrication application, refer to the Lubricants and equivalents tablefor the type of grease to be used.

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11 - Every 100 h hours of operation 11.1 - TYRES

Criteria of replacement

Replace the hub and the tyres if any of the following conditions exist :

• Presence of cracks, damage, deformations or other faults on the hub.

• Damage on the tyre :

• A or hole > 3 cm (2 in) in the rubber side wall on the whole tyre thickness.

• Blister or pronounce lump on the external and lateral membrane.

• Damaged wheel stud.

• Damage or wear on the side wall to the extent that the reinforcing wire become visible.

• Check that the tyres are not damaged.

• Remove the valve cap.

• Add air if required.

• Replace the valve cap.

• Check the wheel lug nut torque (300 Nm).

N.B.-:-Perform the first torque check after the first 10 h of operation.

11.2 - DIESEL CIRCUIT

• Engine Perkins 1104D44T : Perform the first diesel pre-filter change after the first 500 hours ofoperation and then after every 500 h or once a year ( Section H 15.2 -Diesel circuit).


• Perform the first engine oil drainage and change the filter cartridge after the first 500 hours ofoperation and then every 500 h ( Section H 15.3 -Internal combustion engine).

For safety reasons, always use original HAULOTTE® spare parts that are specific to this machine. Referto the spare parts catalogue.

Check the tire inflation pressure : 4,5 bar(65 psi) minimum (For HAULOTTE® tyres, code : 2326014870 or232601508).

During a pressure check or an inflation operation, always face the end of the tyre; never face the side ofthe tyre

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11.4 - LUBRICATING THE FRONT AXLE

• Remove the 4 protective caps from the grease point.

• Connect the grease gun.

HTL4010 - HTL3210

HTL3510

Remove the protective caps from the grease point.

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11.5 - LUBRICATING THE REAR AXLES

• Remove the 6 protective caps from the grease point.

• Connect the grease gun.

HTL4010 - HTL3210

HTL3510

Replace the protective caps once you have lubricated the rear axle.

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• Perform the first filter cartridge change after the first 500 hours of operation and then after every 1000h or once a year ( Section H 16.5 -Hydraulic circuit).


• Check cleanliness of the condenser. Clean whereapplicable.

N.B.-:-Remove the protective covers in order to gain accessto clean the condenser unit.

• Check the cleanliness of the cab air filter. Clean whereapplicable.

The system becomes less efficient when the charge gas is lost. If the air conditioning unit does not workproperly, have a qualified and properly equipped person examine it.

All repairs must be carried out by a qualified and authorised person.

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12 - Every 250 h hours of operation 12.1 - COOLING SYSTEM

• Clean the radiator slats.

• Clean with a pressurized jet of water or air.

12.2 - TRAVEL AXLES

• Perform the first drainage operation on the front and rear axles and the epicycloidal reducers after thefirst 250 hours of operation and then every 1500 h ( Section H 17.1 -Travel axles).

N.B.-:-Level check every 500 h ( Section H 15.4 -Travel axles).

12.3 - OPERATING BATTERY

Battery check :

• Perform the machine shut-down procedure.

• Open the engine cover.

• Wear safety goggles and visually inspect the battery. Check that the terminals are not corroded.Replace the battery if its case is cracked, distorted or damaged.

• Close and secure the battery access cover (under the cab).


Do not remove the filling cap when the engine is hot. DANGER OF BURNS! Loosen the cap to the firstnotch and let it depressurize, then unscrew the cap completely.

Only clean with water when the engine has cooled down.

• Check the tension on the compressor driving belt : belttension 50 kg(110,23 lb).

• Replace the internal and external air filters as necessary.

The system becomes less efficient when the charge gas is lost. If the air conditioning unit does not workproperly, have a qualified and properly equipped person examine it.

All repairs must be carried out by a qualified and authorised person.

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13 - Every 400 h hours of operation 13.1 - BUCKET TEETH (OPTION)

The bucket teeth are considered to be worn and must be replaced when :

• the useful length has reached 50 % of its initial length. i.e. when the total length of the tooth has lost 28% (Total initial length = 127 mm ; Total remaining length = 91 mm).

To change the teeth :

• Knock out the flexible block key using a punch.

• Install a new tooth using a new key which must be inserted from above.

Under normal conditions of use, the bucket teeth must be replaced every 400 h.

Check the condition of the bucket teeth regularly : corner teeth and central teeth. The corner teeth areplaced to protect the sides of the bucket and wear more quickly than the central teeth.

It is forbidden to mount a tooth using an old key.

A broken tooth holder must be replaced rapidly so as not to cause premature wear on the remaining teeth.

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14 - Every 500 h hours of operation 14.1 - LUBRICATING THE SUSPENSION AND THE DRIVER SEAT RAILS

Dirt may affect correct seat operation. The seat must always be clean.

14.2 - DIESEL CIRCUIT (ENGINE PERKINS 1104D44T)

14.2.1 - Changing the diesel filter

• Open the engine canopy to access the diesel filter.

• Loosen the filter cartridge.

• Replace the used cartridge with a new one.

• Close the engine canopy again.

14.2.2 - Changing the diesel pre-filter

To access the diesel pre-filter, open the engine cover.

• Loosen the transparent lower cover.

• Replace the filter.

• Carefully clean the cover.

• Retighten it manually ( 1/4 turn after contact with the seal).

• Refit the cover.

N.B.-:-Perform the first pre-filter change after the first 500 h of operation.

For lubrication application, refer to the Lubricants andequivalents table for the type of grease to be used.

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• Drain the motor oil :

Capacity : 7 l(1,8 gal US) with filters.

• Drainage is performed when hot.

• Loosen the drain plug and let the oil drain completely. Remove the oil filling cap.

• Clean the drain plug and refit it, taking care to change the seal.

• Fill until the oil reaches the MAXI gauge mark.

• Replace the filling cap and let the engine run at idle speed for a few minutes.

• Stop the engine and check the level. Top up the oil if necessary.

• Change the oil filter cartridge :

• Loosen and remove the filter cartridge.

• Oil the seal on the new cartridge, insert it into place on the engine carrier. Screw on the cartridge untilthe seal contacts the sealing face.

• Tighten the cartridge by screwing it a further half-turn.

• Start the engine and check for sealing.

• Stop the engine and check the oil level. Top up the oil if necessary.

N.B.-:-Perform the first drainage and the first oil filter cartridge change after the first 500 hours ofoperation.


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14.4 - TRAVEL AXLES

N.B.-:-The level check operations must be performed periodically, respecting the maintenanceschedule provided. It is recommended that you intervene immediately in the event of leaks or otherfaults that may result in a drop in oil levels, to avoid any possible damage to the mechanicalcomponents. Once you have removed the filling and drainage plugs, they should be refitted again andtightened using a torque value recomended by the manufacturer.

14.4.1 - Checking the oil level of the front axle

Capacity :

• Transfer case : 0,5 l(0,13 gal US).

• Differential : 8 l(2,11 gal US).

• Before performing the oil replacement operations, firstly remove the drain plugs ( 2 ) to eliminate anypressure from inside the housing.

• Loosen the control plug ( 1 ).

• The lubricant level in the axle must be at the level of the control plug ( 1 ), otherwise top up to thecorrect level via the same hole.

• Refit the control plugs ( 1 ) and the drain plugs ( 2 ).

Section H 20.3 -Refer to the Lubricants and equivalents table for the type of oil used.

• Take advantage of this operation to clean the drain plugs ( 2 ).

HTL4010 - HTL3210

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HTL3510

14.4.2 - Checking the oil level of the rear axle

Capacity :

• Differential : 10 l(2,64 gal US).



• The lubricant level in the axle must be at the level of the control plug ( 1 ), otherwise top up to thecorrect level via the same hole.



• Take advantage of this operation to clean the control plugs ( 1 ) and the drain plugs ( 2 ).

HTL4010 - 3210

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HTL3510

14.4.3 - Checking the oil level of the epicycloidal reducers

N.B.-:-To check the reducer oil level, you must move the machine to position the closure plug in therequired positions. Due to the presence of a differential on each of the axles, you will have to repeat thisoperation for each of the machine wheels.

Capacity : 4 x 1,3 l(4 x 0,34 gal US)

• When it is in the high position, loosen the plug ( 3 ) by a few turns, to release any internal pressurefrom the housing and then close it again.

• Drive the machine slowly to bring the plug to horizontal position.

• Loosen the plug completely : the oil level must be at the level of the plug hole, otherwise top up to thecorrect level via the same hole.

• Refit the plug ( 3 ).


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14.5 - BUCKET BLADE (OPTION)

Description of the wear :

The blade is considered to be worn and requires changing when :

• The length has reached two thirds of the initial size, i.e 100 mm for 150 mm initially.

• And/or the average remaining thickness is only 50 % of the initial value, i.e. 10 mm.

Changing the blade :

When the corners of the bucket blade reach 50 % of their initial value and are displaying signsof precipitated wear, the blade must be changed.

N.B.-:-Blade on the toothed bucket : If teeth are regularly checked and replaced, the blade may bereplaced every 800 h, except if it is being used for working on the flat which causes rapid wear of thethickness (e.g. working on a concrete slab).

The blade must be replaced every 500 h.

Check the corners of the blade regularly.

The blade must be replaced by a qualified, authorised person.

Contact HAULOTTE Services®.

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15 - Every 1000 h hours of operation (or once a year) 15.1 - CHAIN WEAR

Have the chain wear checked by a HAULOTTE Services® technician.

15.2 - PRIMARY AIR FILTER

Change the filter cartridge :

• Change the outer filter cartridge.

• Refit the cover, checking that the dust evacuation valve is directed downwards.


• Check that the engine supports and the vibratory mount supports are in good condition.



• Pull the trigger situated on the cover ( 1 ).

• Locate and note the angular position of the cover whichshould be identical upon reassembly.

• Turn the cover to the right ( 2 ).


• Turn and pull the outer cartridge.


For all engine maintenance operations : Consult the guide provided by the engine manufactureror HAULOTTE Services®.

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15.4.1 - Equipment hydraulic circuit

• Change the hydraulic filter cartridge :

• Place the machine in the working position and stop the engine.

• Open the engine compartment by removing the lower protective covers.

• Loosen the casing from the transmission hydraulic filter.

• Change the filter cartridge.


• Perform driving movements.

• Check the oil level and top up if necessary.

• Close the casing again.

N.B.-:-Perform the first filter change after the first 500 hours of operation.

15.4.2 - Transmission hydraulic circuit

• Change the hydraulic filter cartridge :

• Place the machine in the working position and stop the engine.

• Open the engine compartment by removing the lower protective covers.

• Loosen the casing from the transmission hydraulic filter.

• Change the filter cartridge.

• Switch on the engine and perform travel movements.

• Check the oil level and top up if necessary.

• Close the casing again.

N.B.-:-Perform the first filter change after the first 500 hours of operation.

15.5 - ACCUMULATORS

You are advised to check the pre-charge pressures regularly via the M28x1,5 orifice used foradding gas.

• 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 rechargethe accumulator/s (if the pre-charge pressure drops).

The accumulator/s must be emptied before any maintenance operation : Section H 20.1 -Replacement of the brake circuit accumulators.

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16 - Every 1500 h hours of operation 16.1 - TRAVEL AXLES

The oil replacement operations must be performed periodically, respecting the maintenanceschedule provided.

It is recommended that you intervene immediately in the event of leaks or other faults that mayresult 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 refitted again andtightened using a torque value recomended by the manufacturer.

Perform the first drainage after the first 250 hours of operation.

16.1.1 - Draining the front axle

Capacity :

• Transfer case : 0,5 l(0,13 gal US)

• Differential : 8 l(2,11 gal US)


• Loosen the drain plug ( 4 ) and let the oil drain out.

• Refit and tighten the drain out ( 4 ).


• Fill the axle with oil to the level of the control plug ( 1 ).



• Take advantage of this operation to clean the drain plugs ( 2 ).

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16.1.2 - Draining the rear axle

Capacity :

• Differential : 10 l(2,64 gal US)



• Refit and tighten the drain out ( 4 ).


• Fill the axle with oil to the level of the control plug ( 1 ).



16.1.3 - Draining the epicycloidal reducers

N.B.-:-To replace the reducer oil, you must move the machine to position the closure plug in the requiredpositions. Due to the presence of a differential on each of the axles, you will have to repeat this operationfor each of the machine wheels.

Capacity : 4 x 1,3 l(4 x 0,34 gal US).

• When it is in the high position, loosen the plug ( 3 ) by a few turns, to release any internal pressurefrom the housing and then close it again.

• Drive the machine slowly to bring the plug to its low position.

• Loosen the plug completely and let the oil drain out.

• Drive the machine slowly to bring the plug to horizontal position.

• Fill the reducer; the oil level must be level with the plug.

• Refit the plug ( 3 ).


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17 - Every 2000 h hours of operation (or every 2000 h years) 17.1 - COOLING SYSTEM

• 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.

• Remove the filter cap from the expansion bottle filter cap.

• Loosen the drain plug and let the coolant drain out.

• Empty the expansion bottle.

• Clean the system thoroughly with water (or, if necessary, with a cleaning product). In this case,retighten the plug and let the engine run at mid throttle for 10 mn, stop the engine and drain the systemagain.

• Refit the drain plug.

• Filling the cooling system :

• Remove the filter cap from the expansion bottle filter cap.

• Fill the radiator GRADUALLY until the coolant has reached the correct level.

• Close the expansion bottle cap again.

• Switch the acceleration control lever to IDLING.


• Let the engine run AT IDLING SPEED for approx. 2 mn.

• Stop the engine.

• Open the expansion bottle and top up if necessary.

17.2 - AIR FILTER (SYSTEM)

Change the filter cartridge :


• Pull the trigger situated on the cover ( Section H 7.5 Marking1).

• Locate and note the angular position of the cover which should be identical upon reassembly.

• Turn the cover to the right ( Section H 7.5 Marking2).


• Turn and pull the (primary) outer cartridge. Then pull the (secondary) inner cartridge( Section H 7.5 Marking3).

• Insert a new secondary cartridge, by pushing it to the bottom of the socket provided in the case.

Before performing any interventions, let the engine cool down.


2192420344510 E 11.11 AUS

Telescopic handlers


• Place the new primary cartridge above the secondary cartridge, insert it in place with a rotationmovement near the stop.

• Refit the cover, checking that the dust evacuation valve is directed downwards.

N.B.-:-Perform the secondary cartridge change every 2 years or after every 5 maintenance operations.


• Change the engine belts.


• Checking the hydraulic pressures.

This operation must be performed by a HAULOTTE Services® technician.

• Change the oil :

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 possess the technical characteristics that correspond to HAULOTTE®recommendations.

• Check the cleanliness of the oil filter cartridge (no metal shavings, rubber, plastic, …) : If necessary,drain and clean the whole system.

When the tank is empty :

• Fill the tank with the recommended oil until the gauge indicates the max. level.

• Refit the filling cap ( 2 ).


Never clean the secondary filter.

Check the state of the sealing ring before reassembling the cartridges.

For all engine maintenance operations : Consult the guide provided by the engine manufactureror HAULOTTE Services®.

Do not mix two oils with different characteristics : If necessary, drain and clean the whole system.

Drainage must be performed when the oil is hot.

• Place the machine in its stowed position.

• Stop the engine.

• Move underneath the machine.

• Remove the filling cap ( 2 ).


220 2420344510 E 11.11 AUS

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• Actuate the equipment controls in both directions for approx. five minutes (without reaching thecylinder at stops 2).

• Place the machine in road position. Refer to the Lubricants and equivalents table for the type of

oil used.


• Cleaning of condenser and evaporator coils.

• Cleaning of condenser water outlets.

• Recovery of coolant in order to replace the filter-drier.

• Top up with coolant and check of thermostatic regulation and pressure switches.

17.6 - TOOTHLESS BUCKET (OPTION)

17.7 - TOOTHED BUCKET (OPTION)

• The level must be as indicated in the photo/pictureopposite. Top up as necessary via the filler.

Maintenance and repair work on the air conditioning must be carried out by a qualified and authorisedperson.

Any top up on the circuit must be carried out by a qualified and authorised person.

Never open the circuit as this would cause a loss of coolant. The cooling circuit contains a gas which,under given circumstances, may present some risks. This gas, i.e. the R-134a coolant, is colourless andodourless and heavier than air. It is a stable product at normal temperature.. The compressor is fitted witha gauge to check the oil level : Never unscrew this lid, as this would discharge the system. The oil level isonly checked when the oil is changed.

The bucket must be replaced every 2000 h or every 3.

The bucket must be replaced by a qualified, authorised person. Contact HAULOTTE Services®.

The bucket must be replaced every 2000 h or every 3.

The bucket must be replaced by a qualified, authorised person. Contact HAULOTTE Services®.

2212420344510 E 11.11 AUS

Telescopic handlers


17.8 - SIDE-SHIFT FORK CARRIAGE (OPTION)

17.9 - WINCH : WINCH SUPPORT- 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - WINCH SUPPORT- 2,4 T (5292 LB) WITH HYDRAULIC WINCH (OPTION)


The winch is deemed to be worn and requires changing when :

• The drum brake no longer holds the cable.

• And/or the drum no longer turns normally (worn bearings).

Changing the winch :

• The cable must be removed to change the winch ( Section H 16.7 ).

• When you have removed the cable, unscrew the 4 screws M12 on the winch.

17.10 - WINCH : FLY JIB 2,5 M(8 FT2 IN), 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - FLY JIB 4 M(13 FT1 IN), 0,6 T (1323 LB) WITH HYDRAULIC WINCH (OPTION)


The winch is deemed to be worn and requires changing when :

• The drum brake no longer holds the cable.

• And/or the drum no longer turns normally (worn bearings).

Changing the winch :

• The cable must be removed to change the winch ( Section H 16.7 ).

• When you have removed the cable, unscrew the 4 screws M12 on the winch.

The side-shift fork carriage must be replaced every 2000 h or every 3.

The fork carriage must be replaced by a qualified, authorised person. Contact HAULOTTE Services®.

Under normal conditions of usage, the winch must be replaced every 2000 h.

It is essential to change the self-locking nuts when reassembling the winch. Install new self-locking nuts.

Check the tightness of the winch nuts after installation and every 10 h of operation.

Under normal conditions of usage, the winch must be replaced every 2000 h.

It is essential to change the self-locking nuts when reassembling the winch. Install new self-locking nuts.

Check the tightness of the winch nuts after installation and every 10 h of operation.

222 2420344510 E 11.11 AUS

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18 - Every 10 years 18.1 - REPLACEMENT OF THE BRAKE CIRCUIT ACCUMULATORS

Replacement involves :

• Accumulator 1 l(0,26 gal US) : Parking brake circuit.

• Accumulator 0,75 l(0,20 gal US) : Service brake circuit.

18.1.1 - Parking brake

18.1.2 - Service brake

Press the brake pedal 40 times in a row with the engine switched off in order to empty theaccumulator to allow the accumulator to be changed over without danger.

N.B. - : -Accumu la to r in f la t ion p ressu re mus t be checked regu la r l y once a year( Section H 16.6Accumulator).


Never undertake maintenance on the accumulators with the engine running.

Only begin working on the accumulator 24 h minimum after the previous time the engine was started. Thisis the time necessary for the accumulator to fully discharge to allow it to be removed and replaced safely.

Maintenance operations on accumulators are dangerous (pressurised oil) ; the procedure must be strictlyadhered to and extreme caution must be exercised when removing this part.

Maintenance operations on accumulators are dangerous (pressurised oil) ; the procedure must be strictlyadhered to and extreme caution must be exercised when removing this part.

2232420344510 E 11.11 AUS

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18.2 - LUBRICANTS AND EQUIVALENTS

* : Uses an additive for axles fitted with a limited slip differential.

** : The axle manufacturer recommends using SHELL or AGIP products.

N.B.-:-The oils indicated above are valid for use at ambient temperatures of between -15 °C(5 °F)and 40 °C(104 °F) . If the equipment operates outside this temperature range, refer to the oil viscositytables below.

*** : Below an ambient temperature of -15 °C(5 °F) , use TELLUS ARTIC OIL 32 (SHELL).Above an ambient temperature of 45 °C(113 °F) , use TELLUS OIL T68 (SHELL). If abiodegradable oil is required, use TELLUS naturel HSE 46 (SHELL), at interval of oil changeevery 1000 h.

Standard references

Manufacturer references

Uses Capacities ISO MIL API BP ELF ESSO MOBIL AGIP SHELL

Greases

Pins and hinges

6743/0 catégorie

X

EPEXELF 2

Upper boomGrade 2

ou 3Multimove

2

Driver seat rails

Multi-Purpose Grease (Moly)

Oils

Front axle and differential**

10 l(2,64 gal US)

SAE 80W90*

ROTRA MULTI THC/C 80W90

SPIRAX LS 80W90

Rear axle and differential**

8 l(2,11 gal US)

SAE 80W90*


SPIRAX LS 80W90

Wheel reducer**

1,3 l(0,34 gal US)

SAE 80W90*

MIL-L2105 API

GL5

ENERGEAR 90 80W90

TRANSELF TYPE 80W90

ESSO GEAR GX

SAE 80W90


SPIRAX LS 80W90

Transfer case**

0,5 l(0,13 gal US)

SAE 80W90*

MIL-L2105 API

GL5

ENERGEAR 90 80W90

TRANSELF TYPE 80W90

ESSO GEAR GX

SAE 80W90


SPIRAX LS 80W90

Hydraulic circuit***

175 l(46,2 gal US)

HV 46ENERGOL SHF-HV

46

HYDRELF DS46

INVAROL EP46

DTE 15M SERIE

HYDRAULIC PW 46

Internal combustion

engine

10 l(2,64 gal US)

SAE 15W40

MIL-2140E

VANELLUS C5

DIESEL53 15W40

ELF PERFORMANCE

SUPER D 15W40

ESSO TUBE XT301 SAE

15W40

DELVAC M 15W40

RIMULAX 15W40

224 2420344510 E 11.11 AUS

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Axle oil viscosity according to the ambient temperature

Engine oil viscosity according to the ambient temperature

2252420344510 E 11.11 AUS

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19 - Electric circuit 19.1 - WIRING DIAGRAM-MAIN COMPONENTS

N.B.-:- See end of manual.

Nomenclature

Marking Description

FU100 General electrical equipement fuseFU101 Fuse for warning lightsFU102 Fuse for calculator power supplyFU103 Fuse for flashing beacon-HornFU106 Fuse for indicator lightsFU107 Fuse for high beam headlightsFU108 Fuse for low beam headlightsFU109 Fuse for stop lightFU110 Fuse for front left hand sidelightFU111 Fuse for front right hand sidelightFU112 Fuse for rear side lights-Registration plateFU113 Fuse for sensor power supply-ControlsFU114 Fuse for power supply to solenoid valvesFU117 Fuse for rear foglightsFU140 Sensor relay power supply fuseFU161 Fuse for the engine preheat management systemFU180 Fure for the cab heatingFU181 Air-conditioning fuseFU182 Fuse for accessory power in the cabFU183 Fuse for windscreen wiper-Fuse for front windscreen washerFU184 Fuse for rear windscreen wiperFU187 Fuse for radio controlFU189 Fuse for air conditioning fanFU191 Fuse for work lightFU195 Fuse for 12 V socketFU490 Weighing sensor power supply fuseFU620 Fuse for reversing alarmKA104 Relay for flasher indicatorKA110 Relay for sidelight validationKA160 Relay for auxiliary starter controlKA181 Relay for air conditioningKA187 Relay for radio controlKA189 Relay for air conditioning heat sink ventilationKA380 Relay for floating controlKA620 Relay for reversing alertKA680 Crab steering control relayKA681 Synchro mode steering control relayKM101 Power supply switch

226 2420344510 E 11.11 AUS

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20 - Hydraulic circuit 20.1 - HYDRAULIC DIAGRAM-MAIN COMPONENTS

N.B.-:- See end of manual.

21 - Operating incidents

Stop the machine and contact HAULOTTE Services® if the following LEDs flash or remain lit :

• Engine pre-heating LED P188 : Pre-heating defect indicator.

• Parking brake defect LED P182 : Not enough pressure.

• Engine oil pressure fault LED P181 : Not enough pressure.

• Service brake fault LED P190 : Not enough pressure.

• Battery LED P180 : Wiring problem.

• LED ECU P191.

The machine is equipped with an internal fault detection system.

The number of times the ECU LED flashes indicates the type of fault to the operator.

The machine switches to downgraded mode, depending on the type of fault : Certain movements canbe limited or forbidden to preserve the operator's safety.

Diagnosis

Incident Probable cause Solution

1 flash Electrovalve defectCheck faulty solenoid valve connectionChange the faulty solenoid valve

-2 flashes

Joystick operation defectCheck the ( SJ120 ) joystick connectionChange the ( SJ120 ) joystick

Handle failureCheck the ( SJ120 ) handle connectionChange the ( SJ120 ) handle

Radio-control failureCheck the radio-control connectionChange the radio-control

-3 flashes

Inconsistent ( SA187 ) selectorCheck the ( SA187 ) selector connectionChange the ( SA187 ) selector

Inconsistent ( SA681 ) selectorCheck the ( SA681 ) selector connectionChange the ( SA681 ) selector

Neutral position not detected

Check the ( SJ120 ) joystick connectionCheck the joystick buttons (SJ120)Change the joystick (SJ120)Check the connection and position of the selector ( P198 )Change the ( P198 ) selector

-4 flashes Angle sensor ( SR381 ) failureCheck connection of sensor ( SR381 )Recalibrate the sensor ( SR381 )Change the sensor (SR381)

-5 flashesBattery voltage

Check the alternator or batteryChange the alternator or battery

Voltage 5 VCheck for short circuit on the 5 V power supplyChange the calculator (U100)

-6 flashes ECU EEPROM faultRecalibrate the calculatorChange the calculator

2272420344510 E 11.11 AUS

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21.1 - PROCEDURE

• Record the number of flashes emitted by the ECU LED.

• Note any other LED's that may be lit and the situation of the machine when the defect appears.

• Stow the Telehandler.

• Stop the Telehandler.

• Service the machine as set out in this manual.

21.2 - OPERATING INCIDENT ON THE SIDE-SHIFT FORK CARRIAGE (OPTION)

Diagnosis

-7 flashes Inconsistent load controlCheck the ( U140 ) connectionChange the ( U140 ) load control system

-8 flashes ECU faultCheck the connection (U600)Recalibrate the calculator (U600)Change the calculator (U600)

Do not use the machine until the fault has been repaired.


The fork carriage does

not travel

Poor hydraulic connections Check the hydraulic connectionsThe fork carriage touches an obstacle Move the fork carriage back slightly from the obstacleIncorrect flow limiter setting (if the bucket is fitted with one)

Check that the thumb wheel is not fully tightened up

Hydraulic leaksCheck the hydraulic circuit and change the parts if necessary

Hydraulic rupturesCheck the hydraulic circuit and change the parts which cannot be repaired

Fork carriage travels too fast

Incorrect flow limiter setting (if the circuit is fitted with one)

Tighten the flow limiter thumb screw unit until the fork carriage travels slower

Fork carriage travels too

slowly

Incorrect flow limiter setting (if the fork carriage is fitted with one)

Unscrew the flow limiter thumb screw until the fork carriage travels faster



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21.3 - OPERATING INCIDENTS : FLY JIB 2,5 M(8 FT2 IN), 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - FLY JIB 4 M(13 FT1 IN), 0,6 T (1323 LB) WITH HYDRAULIC WINCH (OPTION)

Diagnosis


The fly jib cannot lift the load

Poor hydraulic connections Check the hydraulic connections

The load is too heavyBreak down the load into smaller loads weighing less than 1,2 t. If the load has been partially lifted, change the cable and hook

Incorrect flow limiter setting (if the bucket is fitted with one)




The cable is not rewound properly

The cable is frayedHave the cable changed immediately by an authorised person. Contact HAULOTTE Services®

The cable is kinkedHave the cable changed immediately by an authorised person. Contact HAULOTTE Services®

The cable winds crookedly on the drum Unwind the cable completely and wind it up without a loadInsufficient pressure in the handler pressure circuit

Have your supplier's calibration checked out and modified if necessary. Contact HAULOTTE Services®

The cable is wound with a vertical difference greater than 3 °

Lift the load without exceeding an angle of 3 ° maximum


The cable descends without hydraulic action

The winch brake is damagedHave the winch brake repaired by an authorised person. Change it if necessary. Contact HAULOTTE Services®


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21.4 - OPERATING INCIDENTS : WINCH SUPPORT- 1,2 T (2646 LB) WITH HYDRAULIC WINCH (OPTION) - WINCH SUPPORT- 2,4 T (5292 LB) WITH HYDRAULIC WINCH (OPTION)

Diagnosis


The winch does not lift the load

Poor hydraulic connections Check the hydraulic connections

The load is too heavyBreak down the load into smaller loads weighing less than 1,2 t. If the load has been partially lifted, change the cable and hook

Incorrect flow limiter setting (if the bucket is fitted with one)




The cable is not rewound properly

The cable is frayedHave the cable changed immediately by an authorised personContact HAULOTTE Services®

The cable is kinkedHave the cable changed immediately by an authorised personContact HAULOTTE Services®

The cable winds crookedly on the drum Unwind the cable completely and wind it up without a load

Insufficient pressure in the handler pressure circuit

Have your supplier's calibration checked out and modified if necessaryContact HAULOTTE Services®

The cable is wound with a vertical difference greater than 3 °

Lift the load without exceeding an angle of 3 ° maximum


The cable descends without hydraulic action

The winch brake is damagedHave the winch brake repaired by an authorised person. Change it if necessaryContact HAULOTTE Services®


230 2420344510 E 11.11 AUS

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H- Intervention register

Intervention register1 - Intervention register

The intervention register keeps a record of maintenance and repair work carried out inside or outsidethe maintenance programme.

N.B.-:-In the case of a HAULOTTE Services® intervention, the qualified technician must indicatethe HAULOTTE Services® intervention number.

Date Type of interventionNumber of

hoursIntervenor

HAULOTTE Services®

intervention number

2312420344510 E 11.11 AUS

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hoursIntervenor

HAULOTTE Services®

intervention number

232 2420344510 E 11.11 AUS

Telescopic handlers



hoursIntervenor

HAULOTTE Services®

intervention number

2332420344510 E 11.11 AUS

Telescopic handlers



hoursIntervenor

HAULOTTE Services®

intervention number

234 2420344510 E 11.11 AUS

Telescopic handlers



hoursIntervenor

HAULOTTE Services®

intervention number

2352420344510 E 11.11 AUS

Telescopic handlers



hoursIntervenor

HAULOTTE Services®

intervention number

236 2420344510 E 11.11 AUS

1

Electrical DiagramTelescopics Handlers

1 - HTL4010 - HTL3510 - HTL3210

1.1 - ENGINE

VISAMODIFICATIONIND DATEDATE DE CREATIONDESSINE PAR NBRE TOTAL DE FOLIOSMODIF INDICE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

STARTUP

ALTERNATOR

PREHEATING RESISTOR

FUEL PUMP

POWERCONTACTOR

STOP ENGINE

27

163

B106

27

27

0

1

1

1 1A

161

161

161

161

161

161

1

00

1

1

1

28

5

G

GB100

M160

YA160

KA160

G160

06-17

09-14

YA162 YV160R160

200AFU160

KM160

QS100

HL160

02-1

02-7

02-7

07-19


1.2 - FUSES

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

0 1 2

SA100

WARNING

ENGINE SUPPLYGYRO + HORN

FRONT WINDSCREEN W

IPER +

WINDSCREEN W

ASHER

REAR WINDSCREEN W

IPER

STEERING INDICATOR

BRAKE LIGHTS

REVERSING LIGHTS

HEATINGAIR-C

ONDITIONING

CIGAR-LI

GHTER CAR RADIO CEILI

NG LIGHT

ELECTRICAL CONNECTOR 12

V

VENTILATOR AIR-CONDITIO

NING

SAUER SUPPLYDCU SUPPLY

VALVES SUPPLY

SWITCH AND SENSORS SUPPLY

RADIOCOMMANDE

Radio control option

LMI S

UPPLY

100A

100A

103

182

161

181

183

109

180

106

622

0

184

101

1A

2

10

187A

2

11187

100

100 100

10

3

100

100

1A

195

186

114

113

140

102

102

10010

010

0D

187B

01 2

01-20

08-1

06-1

10AFU102

KM101

10-2

15AFU187

04-1

6

15AFU101

03-1

KA18710-7

20AFU161

01-2

0

01-20

10AFU103

03-1

20AFU100

KM100

04-1

10AFU183

04-8

10AFU184

03-1

10AFU106

04-1

6

1AFU490

06-19

06-18

10004-16

10AFU109

05-1

1

03-1

10AFU620

03-1

4

30AFU180

5AFU181

03-1

6

20AFU182

04-1

1

04-8

30AFU195

03-1

7

30AFU189

7.5AFU113

06-1

10AFU140

07-1

7

30AFU114

06-1

KM10002-8

1A1A

3


1.3 - SIGNALLING

VISAMODIFICATIONIND DATEMODIF

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

R180

123

COM

ODO

COM

ODO

M189

SEEING ON SWITCH

HORNREVERSING LI

GHTREVERSING BUZZER

PLATE NUMBER

SIDE-LIGHTS FRONT LE

FT

SIDE-LIGHTS REAR LE

FT

SIDE-LIGHTS REAR RIG

HT

SIDE-LIGHTS FRONT RIG

HT

COMPRESSOR

AIR-CONDITIO

NING

AIR-CONDITIO

NING

SEEING ON SWITCH

VENTILATORS AIR-C

ONDITIONING

SWITCH HEATING

AIR-CONDITIONING

TO TOWCONNECTOR

HEATING

181

48

180

4243

43

43

49

45

4546

46

186

186

103 103

111

111

110

110

41

185

0 0

0

0

100B

112

100A 100A

50623

622

622

103

105

02-6

02-8

02-9

02-12

10-11

GYRO

HA185

SA185

HL185

SB105

HA105

EL116

10-9

KA620

HA620

7.5AFU110

EL104

SA101

KA110

04-1

04-11

EL100 EL102

7.5AFU111

05-9

EL101

7.5AFU112

EL103

KA189

02-13

HL181

SP181

KA181

SA181

SA180

02-14

M181

02-16

KA18903-13

04-1


1.4 - CAB ATTACHMENTS - TURN SIGNALS1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

U182

+

+-

-

G

D

COM

ODO

D E

SA183

KA104

2 1

36

WORK HEADLIGHT

ECTRICAL CONNECTOR 12V

CIGAR-LI

GHTER

CAR RADIO

CEILING LI

GHT

FRONT WINDSCREEN W

IPER

WINDSCREEN WASHER

REAR WINDSCREEN W

IPER

FLASHER UNIT

100A

210

101

90

90

184

51

0

0

0

0

0

0

106

100

63

110

183

183

183

188

62

182

92

92

197 G+

D+

G-

D-

118

54

192

191

117193 196

195

31

R +

49

03-8

02-8

03-19

EL191

20A

FU191

KA11003-8

SA191

EL192

05-1

EL193EL194

M

M183

7.5A

FU117

SA117

EL117 HA117

M

M186

02-15

02-9

SA195

XP195

M

M184

03-8

02-14

XP183

05-1405-17

SA104

02-5

02-10

02-11

SA106

EL182

05-1

05-3

5


1.5 - SIGNALLING

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

COM

ODO

COM

ODO

MAIN-BEAM HEADLAMP

SEEING MAIN-BEAM HEADLA

MPS

BRAKE LIGHT

STEERING INDICATOR LE

FT

STEERING INDICATOR RIG

HT

LIGHTING DASHBOARDSEEING O

N SWITCH

WINDSCREEN WIPER

SEEING ON SWITCH

VENTILATON

SEEING ON SWITCH

ELECTRICAL P

LUG

SEEING

STEERING INDICATOR TOW CONNECTOR RA

STEERING INDICATOR LE

FT

STEERING INDICATOR RIG

HTSIDE-LI

GHT LEFT

SIDE-LIGHT RIG

HT

BRAKE LIGHT RIG

HT

BRAKE LIGHT LE

FT

109

100A

61

62

70

0 00

63

62

62

63

100A

100A

64

0

66

59

0

60

110

111

61

04-4

04-19

SA103

04-19

EL111

15AFU107

EL112

HL100

HL111

EL115 HL186 HL180

SA102

HL191

EL109

15AFU108

EL110

05-16

05-19

05-13

03-11

1

2

D106 1

2

D107

HL106

02-12

EL113

PSP114

EL114

05-9

EL105

04-14

34

EL107

51

2

05-9

EL106

04-14

EL108

06-1

05-9


1.6 - CONTROLS ANS ACTUATORS1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

COM

ODO

ALIM +12V107.2

107.1ALIM 0V

E-TOR E-TOR E-TOR

S-TOR3.5A PWM

S-ANAPWM

S-ANA3.5A

S-TOR3.5A

S-TORPWM

S-ANAPWM

S-ANAPWM

S-ANAPWM

S-ANAPWM

S-ANAPWM

S-ANA

SJ120

float

Raising Boom Telescopingboom

excavation Auxiliary/ excavation

Stab

L u

pco

rrect

or o

f pla

te L

3.5AS-TOR

3.5AS-TOR

E-TOR E-TOR

Win

ch

105.19 105.20 105.21 105.22 105.23 105.24 105.25 105.26105.27 105.29 105.30 105.31 105.32

104.2 104.3 104.7 104.8 104.9

U100

S-TOR3.5A

105.34

Park

ing

brak

e

Shun

t lim

its lo

ad

Sele

ctio

n wi

nch/

nace

lle

Sele

ctio

n di

rect

ion

axle

AR

High

spe

ed tr

ansla

tion

Forw

ard

gear

tran

slatio

n

Reve

rse

gear

tran

slatio

n

Crab

raising signal

excavation signal auxiliary signal

Up Down

Out In

Up Down Au

xilia

ry v

alid

atio

n

Valid

atio

n st

ab +

cor

rect

of p

late

Stab

R u

p

Road

mod

e

105.283.5A

S-TOR

telescoping signal

Auxil

iary

A

104.13E-TOR

106.10E-ANA

106.11E-ANA

106.12E-ANA

106.13E-ANA E-TOR

104.15 105.3E-TOR E-TOR

104.12E-TOR105.17

E-TOR105.12

DPLU

S

star

tup

Cont

acto

r saf

ety

ALIM 5V106.22

E-ANA106.15

Sync

ro

E-TOR E-TOR105.14 105.15

E-TOR104.14

E-TOR105.35

treui

l

E-TOR E-TOR104.4 104.5

Safe

ty b

rake

ser

vice

Stab

L d

own

corre

ctor

of p

late

R

Stab

R d

own

Auxil

iary

B

Auxiliary

Option blockingrear axle

Option stabilisers / corrector of plate

FreeStab

left

Stab

righ

t

Slop

e co

rreto

r

E-TOR E-TOR104.1 104.17

E-TOR E-TOR104.19 104.20

E-TOR E-TOR105.1 105.6

Up Down

Up Down Up Down

Float

S-TOR3.5A

105.33

B608

B609

B610

B611

B612

B614

B613

B615

B602

B603

B607

114

112

B600

B601

B606

B604

690

B106

B106

11

102 102

102

B131

B107

113

B108

B109

B110

B143

B144

380

B400

0

B112

B113

B114

684

0

B400

B400

B118

B300

B301

B302

B303

B120

B124

B780

A

B780

B

B781

A

B781

B

B782

B

B782

A

02-17

02-3

05-19

02-19

07-13

07-1

SA692 SB685 SA140

YV720 YV721

SA187

YV700

SA681

YV701

SA780

YV380

SA781 SA782

YV300

SA68

0

YV320

SA60

0

SA62

0

YV340

SA68

4

HL684

YV360 YV400

10-2

YV420 YV121 YV122

13

14

YV123

13

14

YV124

01-7

HL161

02-1

1

YV780

02-1

1

09-9

YV781

07-1

09-14

07-1

09-1

7


1.7 - SENSORS AND SIGNALLING


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

E-TOR

S-TOR

SP140

E-TOR

Calibration

S-TOR S-TOR

105.2 105.5

104.27104.24 104.25104.28S-TOR

U100

U140

102.1TX

102.2RX

102.4GND

3 2 4D_ACTIA

ALIM

E-TOR105.13

E-TOR105.16105.18

E-TOR

1

Rear axle centeredFront axle centered

TELE

SCO

PE R

ETUR

NED

sensor of constraint

SYSTEM ANTI SWING

Alarmlimitload pre-alarm

Cra

b

CPU

FAIL

URE

STAR

TUP

CO

NTAC

TOR

Cal

ibra

tion

Valid

atio

n R

oad

mod

e

LMI

Batte

ry

failu

re lig

ht

sync

hro

E-ANA

106.260-5V

E-ANA

106.270-5V

104.30S-TOR

SR381

104.21S-TOR

104.23S-TOR

104.34S-TOR

104.35S-TOR

104.29S-TOR

104.36S-TOR

104.33S-TOR

104.32S-TOR

104.31S-TOR

104.26S-TOR

Valid

atio

n 1s

t spe

ed tr

ansla

tion

Valid

atio

n 2n

d sp

eed

trans

latio

n

Floa

t

Preh

eatin

g sy

stem

Boom angle

Con

tact

or s

uppl

y ca

lcula

tor

104.16E-TOR

101.1CAN -

101.2CAN +

101.4GND

Seat

sen

sor

104.22S-TOR

101.3R120

REVE

RSE

LIG

HT R

ELAY

104.10E-TOR

104.11E-TOR

STAB R downcast STAB L downcast

Stab

+ c

orre

ctor

of p

late

0

B130

B142

B403

B404

113 113

113

682

113

695

695

B515

B503

0 00

B513

B514

0

B506

B506

140

0

0

0

0

0

102

0

B508

B508

11

B121

B510

B511

B512 27B504

B505

0

0

B127

0

1004

1005

113

011

3

B116

0

113

0

0

113

113

B115

B509

0010

01

1002

1000

0 00

1006B5

07

00B5

01

0 0 0

B132

06-20

06-2

06-20

1

2

D101

KM101

SQ141

KA680 KA681

SQ721

KA160 KA620

SQ720

HL780

HL781 HL782

SQ682

HL686 HL692

SQ683

HL143

HL683

HL380 HL687

06-2

08-5 08-5

SQ360

120R

08-5

02-18

01-20

10-1710-15

10-13

09-5

08-1


1.8 - DRIVING1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

AV AR

U600

1K 0.25W 5%

SENSOR SPEEDHYDRAULIC PUMP

SENSOR SPEEDHYDRAULIC MOTOR

INCHING PEDAL

C1.2

C1.1

ALIM

ALIM

C4.1 C4.2C4.6

C6.3

C6.7C4.5Sensor +signal Sensor-

C5.1C5.3C5.2

1K 0.25W 5%

C6.5 C6.6Sensor + Sensor-signal

C1.4 C1.3C2.1 C2.2 C2.3CANHIGH

CANLOW

CANSHD

C_SAUER

C6.8

C1.5signal Sensor- Sensor +

7 2 3

RED

GREEN YELLOW

High

spe

ed

dire

ctio

n m

otor

C6.4Sens

Park

ing

brak

e

C6.9C6.10

C1=CC1C2=CANC3=PPCC4=PSCC5=PPUC6=CC2

120R 0.25W 5%

HTL PRO

0

600

601

620

602

122

0

683

605

4

165

685

604

6037

606

606

0

B605

102

102

6

0

1004

1005

1006

1004

1005

1006

123

121 0S

124

02-3

07-20

HL685

YV600

YV682 YV683

YV620

07-16

07-15

07-15

YV684

R100

SV162SV685

09-1

R681RP680

R682

9


1.9 - OPTIONS - DASHBOARD


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

Crab

e

Sync

hro

Floa

t

Pres

sion

d'hu

ile m

oteu

r

prés

ence

eau

dan

s G

O

Sécu

rité

frein

ser

vice

Sécu

rité

frein

par

king

Tem

péra

ture

hui

le h

ydra

uliq

ue

Filtr

e hu

ile c

olm

até

Indicateur de niveaude carburant

Nive

au d

e ca

rbur

ant

P160P189

COMPTE TOURSHORAMETRE

P161

D+

W

indicateur detempérature moteur

114

0 068

1

0 0

163

B106

164

164B189 18

9A

0 0

0

690

126

691

113

166

125

125

114

680

114

114

162

08-17

06-20

YV680

KA68007-4

YV681

KA68107-5

KA380

07-19

SP162

HL162

BN

BUSQ163

HL163 HL690

SP690

06-19

SP691

HL691

ST125

HL125

R125 SQ126

HL126

01-7

06-20

SQ189ST160

10-2

ST160/C


1.10 - OPTIONS1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A

B

C

D

E

F

G

H

I

J

K

L

M

U100

E-ANA

106.240-5V

E-ANA

106.250-5V

E-TOR105.8

E-TOR105.9

E-TOR105.10

E-TOR105.11

LMI

SUPPLY

Battery

RECEIVER RADIO-CONTROL

EMERGENCY STARTUP HORNRaisingsignal

Telescopingsignal

A B Up

Down

E-ANA

106.70-20mA

E-ANA

106.40-20mA

E-ANA

106.50-20mA

E-ANA

106.60-20mA

E-TOR104.6

radio OK

weight alarm

E-TOR105.4

excavationAuxiliary 4x 4-20mA

B401

187A

187A

194

0

B512

B402

B102

B103

B104

B105

103

B511

B510

B310

B312

B313

B311

B111

105

B400

B400

B129

09-19

02-4

06-13

KA187

03-5

03-1

07-19 07-19 07-19

0

1

HYDRAULIC DIAGRAMTelescopic handlers

1 - HTL4010 - HTL3510

1.1 - FOLIO 1/1

5b switch

YV123 YV124 YV721

P

LS

T

L

R

YV701

+-

L2

18b switch

T G1/2

A1 G1/2

YV720 YV700

YV680

YV681

A B

P T

44CM3

M3 M4

M1

M2

M5

P T

A B

P T

A B

YV600 YV620

YV682

YV683

T

P

P1

inching

39l/mn

175l/mn

100l/mn

M3

T'1

R1

115L

R

5

23

L4

160b

12

3/8" 3/8"

3/8"

V

M18

x1.5

M18

x1.5

M10x1.5

M10x1.5

M10x1.5

M10x1.5

T

N

T1

G1/2

G1/2

7G1/2

G1/2

G1/4

1"5/16-12

G1/47/8"-14

7/8-14"

7/8-14"

M22x1.5

M22x1.5

7/8" 7/8"

210b

15

250b

16b

16l/mn

350b 350b

3000 1"1/2

1"1/167/16"1"1/16

107P315160

XA

XB

16

1"1/16-12

300b

P

T

A

B

PERKINS1104D 44T

70 KW2300T/MN

MINI 900T/MNMAXI 2400T/MN

LIFT CYLINDER140/80 S1280

6

L1

0,75L

17

8

F

90b switcjh

24

19

M14x1.5

M14x1.5

M10x1

M14x1.5

200b

BOOM LIFTING BOOM TELESCOPFORKS TILTING

P

nU

10CM3

A1 B1 A2 B2 4B4A3B3A

1"1/16-123/4"-16

1"5/16

L1

1"5/

16

3b

M22x1.5

M22x1.5

M22x1.5

M22x1.5

3/8" 3/8"1/2"

1/2"

1/2"1/2"

1"5/16

1"5/16

M18x1.5

M18x1.5

1"7/8-12

T1"5/16-12

L2 M4

M2

78CM3

M1

M5

28b

480bB

S

480b

E

A

17CM3

2

13b

1L

C2

C1

TELESCOPING CYLINDER110/63 - 90/56 - S2800

REAR STEERING CYLINDER STEER SELECT

VALVE

3/8"

HYDRAULIC MOTOR2 POSITIONS 42/160cc

FRONT STEERING CYLINDER A 1"

6000 psi

B 1"6000 psi

OIL COOLER

AUXILIAIRY +OUTRIGGERS

11CM3

7/8"

GEAR BOX

In 7/8"

Out 7/8"

Dr9/16"

SERVICE BRAKE VALVE

TILT CYLINDER140/80 S420

MASTER CYLINDER63/36 S1280

STEERING UNIT 200/100

EF1"1/16

LS7/16"

CF7/8"

25/mn

1

3/4"-16

3/4"-16

V1V2

C1C2

OUTRIGGER CYLINDERS120/60 S180

G3/4

G3/4

PARKING BRAKE VALVEACCUMULATOR LOADING VALVE

30b

Serv G3/8

11

P2G1/2

P1G3/8

V G1/2A2 G1/2

Br G3/8

9

(HTL3510 only)FRAME SWAY CYLINDER

100/60 S180

7/8"-14 7/8"-14 7/8"-14

1"1/16-12

4

18

175b

V11/2"

V21/2"

M14x1.5

24b

170b

145b120b

22

21

17

2620

25

23

200b

1"1/16-12

P

VG1/4

240b

10b

9/16-18

9/16-18

9/16-18

9/16-18

T

A

B

9/16-18

OSC

ILLA

TIN

G A

XLE

1b

27

LOCKOUT OPTION

PT

Reg

9/16-18

9/16-18

9/16-18

LOCKOUT OPTION

29

4b

YV780

YV781

28

1"5/16-12

1"7/8-12 1"5/16-12

7/8"-141"1/16-12

V21/2"

V11/2"

3

7/8-14

L37/8-14

RIGHT LEFT

(HTL4010 only)

8 bis

Connected to the YV720/700 valve

2

HYDRAULIC DIAGRAMTelescopic handlers

2 - HTL3210

2.1 - FOLIO 1/1

5b switch

YV123 YV124 YV721

P

LS

T

L

R

YV701

+-

L2

18b switch

T G1/2

A1 G1/2

YV720 YV700

YV680

YV681

A B

P T

44CM3

M3 M4

M1

M2

M5

P T

A B

P T

A B

YV600 YV620

YV682

YV683

T

P

P1

inching

39l/mn

175l/mn

100l/mn

M3

T'1

R1

115L

R

5

23

L4

160b

12

3/8" 3/8"

3/8"

V

M18

x1.5

M18

x1.5

M10x1.5

M10x1.5

M10x1.5

M10x1.5

T

N

T1

G1/2

G1/2

7G1/2

G1/2

G1/4

1"5/16-12

G1/47/8"-14

7/8-14"

7/8-14"

M22x1.5

M22x1.5

7/8" 7/8"

190b

15

250b

16b

15l/mn

350b 350b

3000 1"1/2

1"1/167/16"1"1/16

107P324190

9

1"1/16-12

300b

P

T

A

B

PERKINS1104D 44T

62,5 KW2300T/MN

MINI 900T/MNMAXI 2400T/MN

LIFT CYLINDER140/80 S1280

6

M14

0,75L

17

8

F

90b switcjh

24

M14x1.5

M14x1.5

M10x1

M14x1.5

200b

BOOM LIFTING BOOM TELESCOPFORKS TILTING

P

nU

10CM3

A1 B1 A2 B2 4B4A3B3A

1"1/16-123/4"-16

60l/mn

1"5/16

L1

1"5/

16

3b

M22x1.5

M22x1.5

M22x1.5

M22x1.5

3/8" 3/8"1/2"

1/2"

1/2"1/2"

1"5/16

1"5/16

1"7/8-12

T1"5/16-12

L2 M4

M2

68CM3

M1

M5

28b

450bB

S

450b

E

A

17CM3

2

13b

1L

TELESCOPIC CYLINDER110/63 - 90/56 - S2800

REAR STEERING CYLINDER STEER SELECT

VALVE

3/8"

HYDRAULIC MOTOR2 POSITIONS 32/110cc

FRONT STEERING CYLINDER A 1"

6000 psi

B 1"6000 psi

OIL COOLER

AUXILIAIRY +OUTRIGGERS

11CM3

7/8"

GEAR BOX

In 7/8"

Out 7/8"

Dr9/16"

SERVICE BRAKE VALVE

TILT CYLINDER140/80 S420

MASTER CYLINDER63/36 S1280

STEERING UNIT 200/100

EF1"1/16

LS7/16"

CF7/8"

25/mn

1

3/4"-16

3/4"-16

OUTRIGGER CYLINDERS120/60 S180

G3/4

G3/4

PARKING BRAKE VALVEACCUMULATOR LOADING VALVE

30b

Serv G3/8

11

P2G1/2

P1G3/8

V G1/2A2 G1/2

Br G3/8

9

7/8"-14 7/8"-14 7/8"-14

1"1/16-12

4

18

175b

V11/2"

V21/2"

M14x1.5

24b

170b

145b120b

22

21

17

25

23

200b

1"1/16-12

P

VG1/4

240b

10b

9/16-18

9/16-18

9/16-18

9/16-18

T

A

B

9/16-18

OSC

ILLA

TIN

G A

XLE

1b

27

LOCKOUT OPTION

PT

Reg

9/16-18

9/16-18

9/16-18

LOCKOUT OPTION

29

4b

YV780

YV781

28

1"5/16-12

1"7/8-12 1"5/16-12

7/8"-141"1/16-12

YV684

C2

C1

V21/2"

V11/2"

V11/2"

V21/2"

C2 C1

C2

C1

19

3

LEFT RIGHT

Documents

Operator's manual T TELESCOPIC HANDLERS