Haulotte Group HTL 4010 User manual

Operator's manual
T
ELESCOPIC
HANDLERS
2420344510 E 11.11 AUS
Operator's manual
TELESCOPIC HANDLERS
HTL 4010 - HTL 3510 - HTL 3210
2420344510
E 11.11
AUS

2 2420344510 E 11.11 AUS
Telescopic handlers

3
CONTENTS
Operator's manual
CONTENTS
1 - Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 - After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 - Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 - HAULOTTE Services® contact details. . . . . . . . . . . . . . 11
A
SAFETY PRECAUTIONS
1 - 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
B
INTERVENOR'S RESPONSIBILITY
1 - Owner's (or hirer's) responsibility. . . . . . . . . . . . . . . . . . 23
2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . 23
3 - Trainer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 - Operator's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . 24
C
PRE-OPERATION AND CONTROLS
1 - 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

4
Operator's manual
D
OPERATION
1 - 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
E
ATTACHMENTS
1 - Approved attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 - Unapproved attachments. . . . . . . . . . . . . . . . . . . . . . . . . 75
3 - Telehandler/Attachment/Fork capacities . . . . . . . . . . . . 76
4 - Using the capacity chart with forks . . . . . . . . . . . . . . . . 77
5 - Attachment installation . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 - 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

5
CONTENTS
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 jib 2,5 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 jib 4 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
F
EMERGENCY PROCEDURE
1 - 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

6
Operator's manual
G
TECHNICAL CHARACTERISTICS
1 - 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
H
LUBRICATION AND MAINTENANCE
1 - 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 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) . . . . . . . . . . . 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 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

7
CONTENTS
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 - Every 250 h hours of operation . . . . . . . . . . . . . . . . . . 207
12.1 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12.2 - Travel axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12.3 - Operating battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12.4 - Air-conditioning (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
13 - Every 400 h hours of operation . . . . . . . . . . . . . . . . . . 208
13.1 - Bucket teeth (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14 - Every 500 h hours of operation . . . . . . . . . . . . . . . . . . 209
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 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

8
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 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
I
INTERVENTION REGISTER
1 - Intervention register. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

9
2420344510 E 11.11 AUS
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 holder
provided 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 in
this 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 service
life to ensure optimal use of your HAULOTTE product..
• When contacting our After Sales Service, ensure that you provide the machine model and serial
number.
• When ordering any consumables or spare parts, please use this manual and the Haulotte Essential
catalogue to receive your genuine HAULOTTE spare parts, your only guarantee of parts
interchangeability and correct machine operation.
• If there is an equipment malfunction involving a HAULOTTE® product, then contact HAULOTTE
Services® 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 HAULOTTE
Services® immediately even if no material or bodily damage is observed and we will intervene as
soon as possible (See : HAULOTTE Services® contact details)
With regard to the designation of our equipment, we stress that this is purely for commercial purposes and
not to be confused with the technical characteristics. Only the tables of technical characteristics should
be used to study the suitability of the equipment for the intended use.

10 2420344510 E 11.11 AUS
Telescopic handlers
3 - Compliance
We would like to remind you that HAULOTTE® complies with the provisions of any applicable
directives applicable to this type of machine.
HAULOTTE advises you that NO modifications carried out without the written permission
of HAULOTTE® will void the HAULOTTE warranty..
HAULOTTE® cannot be held liable for any changes to the technical specifications contained in this
manual.
HAULOTTE® reserves the right to alter technical specifications and to make improvements or
modifications to the machine without modifying this manual.
Certain options can modify the machine's operating characteristics and its associated safety. If your
machine was originally delivered with options fitted, replacing a safety component associated with a
particular options not require any particular precautions other than those associated with the installation
itself (static test).
If you intend to add options to your product after original delivery, it is essential to follow the
manufacturer'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 the
appropriate location/s.

11
2420344510 E 11.11 AUS
Telescopic handlers
4 - HAULOTTE Services® contact details
HAULOTTE Services® contact details

12 2420344510 E 11.11 AUS
Telescopic handlers

13
2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
Safety precautions
1 - Recommendations
1.1 - OPERATOR'S MANUAL
This operators manual is specific to the HAULOTTE® products listed on the cover page of this
manual..
1.2 - SYMBOLS USED
Symbols are used to alert the operator to safety precautions or to highlight practical
information.
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 covered
by the manual.
This manual must be kept on the machine (or in the cab in its storage case. The manual must be available
to all operators and must be kept in good condition. Additional copies can be ordered from HAULOTTE
Services®.
Symbol Meaning
Danger : Risk of injury or death (work safety)
Caution : Risk of material damage (work quality)
Prohibition relating to work 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

14 2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
1.3 - LABEL COLORS
The potential dangers and any specific regulations are indicated around the product by labels
and 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, or
during 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 of
the structure and lead to the corruption of certain safety elements.
• Do not climb onto the covers.
• Never use the machine with only an operator in the platform. It must be operated by a pair of operators.

15
2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
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-wheel
steering (if the steering mode can be selected).
Do not raise the boom unless the chassis is level (0 °).

16 2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
Do not level the machine with the boom or the accessory
above 30 °
• Transport the load as low as possible. Attach the
suspended loads to restrict movement.
• Comply with the capacity charts displayed in the cab.
• The weight of all riggings (slings, etc…) must be included
as part of the load weight.
• Start, travel, turn and stop slowly to prevent the load from
tipping over.
• Beware of the wind. The wind can cause a suspended load
to tip over and generate destabilising side forces (even with
tag lines).
Do not try to use the telehandler's dumping function to return the load to horizontal position.
• Keep the heaviest part of the load closest to the
attachment.
• Never drag the load. Lift it vertically.
• Maintain proper tire pressure at all times. Otherwise, the
machine could tip over.
Do not ballast the tires.

17
2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
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 offer
any protection in the event of proximity to or contact with
electrical current.
Never operate the handler in an area where overhead power lines, overhead or underground cables or
other power sources may exist without ensuring that the appropriate utility company has de-energized the
lines.
• Maintain a minimum safe distance with regard to power
lines and electrical devices.
• Respect the local rules and the minimum safety distance
from power lines..

18 2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
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 contact
300 V - 50 kV 310
50 - 200 kV 515
200 - 350 kV 620
350 - 500 kV 825
500 - 750 kV 11 35
750 - 1000 kV 14 45
• The turning radii change according to the steering mode
selected ( 2 or 4 steer wheels).
• Ensure that adequate clearance is provided for pivoting the
rear tail and the front fork.
The rear offset is larger in 4 steer wheels mode.
Look out for and avoid other personnel, machinery and vehicles in the area. Always obtain assistance from
a guide on the ground when manoeuvring.

19
2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
• Do not change the steering mode while travelling; only do that when the telescopic handling machine
has 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 as
possible.
• Before moving the machine, ensure that the path is clear
and sound the horn.
• When driving, retract the boom and keep the boom and the
attachment as low as possible.
• Maintain visibility of the mirrors and optimal visibility of the
path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving
underneath overhead obstacles. Position the attachment or
the 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.

20 2420344510 E 11.11 AUS
Telescopic handlers
A - Safety precautions
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 across
excessively 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 secured
by a lock pin and a retainer pin. Incorrect installation could result in the fork carriage/attachment/load
disengaging, 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 is
the heavy end. Drive with the forks pointed downhill.
• When it is loaded, the front of the machine is the heavy end.
Drive with the forks pointed uphill.
• To avoid the machine racing on slopes, downshift to a lower
gear and use the service brake as necessary to maintain a
slow speed.
Do not shift to neutral to avoid coasting downhill.
Do not park on a slope without having blocked the machine wheels.