Haulotte HTL 4010 User manual

Operator's manual
T
ELESCOPIC
HANDLERS
4000328140 E01.15 AUS
Operator's manual
TELESCOPIC HANDLERS
HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010
24203210
E01.15
EN

2 4000328140 E01.15 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 - Prohibitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 - Potential risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.1 - Tip-over hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.2 - Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.3 - Travel hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.4 - Load falling hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.5 - Mechanical attachment locking device . . . . . . . . . . . . . . . . . . . . 21
2.2.6 - Driving hazards on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.7 - Pinching and crushing hazards. . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.8 - Risk of falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.9 - Chemical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
B
INTERVENOR'S RESPONSIBILITY
1 - Owner's (or hirer's) responsibility. . . . . . . . . . . . . . . . . . 25
2 - Employer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . 25
3 - Trainer's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 - Operator's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . 26
C
PRE-OPERATION AND CONTROLS
1 - Checks before use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 - General mechanical functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 - Pre-operation checks and inspection. . . . . . . . . . . . . . . 29
3 - Safety stickers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 - Red labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 - Yellow labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 - Other labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5 - Operator's cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.1 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5.2 - Pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.3 - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.3.1 - Steering column adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5.4 - Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.5.5 - Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5.6 - Air-conditioning(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5.7 - Instrument/control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5.8 - Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.5.9 - Left-hand control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5.10 - Load moment indicator (LMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.5.11 - Rear-view mirrors and windows . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Operator's manual
3.6 - Radio-control emitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.1 - Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.1.1 - Activation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.1.2 - Detection of internal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.1.3 - Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
D
OPERATION
1 - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 - Starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 - Operational checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2.1 - During the warm-up period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2.2 - When the engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 - Starting the engine with a booster battery . . . . . . . . . . . . . . . . . . . . . . . . 72
1.4 - Normal engine operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 - Engine shut-down procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.6 - Parking brake operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2 - Operation with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 - Load lifting safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 - Before lifting a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2.1 - For operation with non-suspended load . . . . . . . . . . . . . . . . . . . 74
2.2.2 - For operation with suspended load . . . . . . . . . . . . . . . . . . . . . . 74
2.3 - Transporting the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3.1 - For operation with non-suspended load . . . . . . . . . . . . . . . . . . . 75
2.3.2 - For operation with suspended load . . . . . . . . . . . . . . . . . . . . . . 75
2.4 - Dumping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.5 - Stabiliser operation procedure (HTL 4010) . . . . . . . . . . . . . . . . . . . . . . . 76
2.6 - Placing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.7 - Disengaging the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3 - Road operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 - Loading and securing for transport . . . . . . . . . . . . . . . . 78
E
ATTACHMENTS
1 - Approved attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 - Unapproved attachments. . . . . . . . . . . . . . . . . . . . . . . . . 81
3 - Telehandler/Attachment/Fork capacities . . . . . . . . . . . . 82
4 - Using the capacity chart with forks . . . . . . . . . . . . . . . . 83
5 - Attachment installation . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 - Mechanical attachment locking device. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2 - Hydraulic accessory locking device (Option). . . . . . . . . . . . . . . . . . . . . . 90
5.2.1 - Specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2.2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.3 - Adjusting/Moving forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6 - Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1 - Technical characteristics of the accessories . . . . . . . . . . . . . . . . . . . . . . 92
6.2 - Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.2.1 - Accessory control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.2.2 - Attachment installation procedure . . . . . . . . . . . . . . . . . . . . . . . 98
6.2.3 - Using the load capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.2.4 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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CONTENTS
Operator's manual
F
EMERGENCY PROCEDURE
1 - Towing a broken-down vehicle . . . . . . . . . . . . . . . . . . . . 99
1.1 - General precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 - Releasing the axle brake for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2.1 - Parking brake deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2.2 - Parking brake reactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 - Emergency boom lowering . . . . . . . . . . . . . . . . . . . . . . 101
2.1 - Manual boom lowering (emergency mode). . . . . . . . . . . . . . . . . . . . . 101
3 - Emergency exit from cab . . . . . . . . . . . . . . . . . . . . . . . . 102
G
TECHNICAL CHARACTERISTICS
1 - Main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1 - Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.2 - Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.3 - Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3.1 - Slings attached 3T (6,615 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3.1.1 - Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3.1.2 - Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3.1.3 - Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.3.1.4 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3.1.5 - Lubrication and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2 - Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3 - Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.1 - Machine HTL4010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.2 - Machine HTL3510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3 - Machine HTL3010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.4 - Machine HTL7732. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 - Noise emission level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5 - Telehandler vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
H
LUBRICATION AND MAINTENANCE
1 - Maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 115
2 - Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . 116
3 - Repairs and adjustments . . . . . . . . . . . . . . . . . . . . . . . . 121
4 - Lubrication and maintenance schedule . . . . . . . . . . . . 122
5 - General program / Recommendations . . . . . . . . . . . . . 132
6 - Detailed program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6
Operator's manual
7 - General points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1 - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1.1 - Bolts and Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1.2 - Pins and bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1.3 - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.2 - Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2.1 - Replacing damaged of hoses. . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2.2 - Evaluation of leaks on hydraulic cylinders . . . . . . . . . . . . . . . . 164
7.3 - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.3.1 - Replacing damaged cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8 - Every day or every 10 h of operation . . . . . . . . . . . . . . 166
8.1 - General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.2 - Load moment indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2.1 - Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2.2 - Checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2.3 - Resetting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.3 - Diesel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.4 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.5 - Air filter (system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.6 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.7 - Hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.8 - Air-conditioning (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
9 - Every 50 h hours of operation . . . . . . . . . . . . . . . . . . . . 171
10 - Every 100 h hours of operation . . . . . . . . . . . . . . . . . . 172
10.1 - Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.2 - Diesel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.4 - Lubricating the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.5 - Lubricating the rear axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.6 - Hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.7 - Air-conditioning (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
11 - Every 250 h hours of operation . . . . . . . . . . . . . . . . . . 175
11.1 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.2 - Travel axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.3 - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.4 - Air-conditioning (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
12 - Every 500 h hours of operation . . . . . . . . . . . . . . . . . . 176
12.1 - Lubricating the suspension and the driver seat rails . . . . . . . . . . . . . . 176
12.2 - Air filter (system) (For machines fitted with engine PERKINS 854E-34TA
or KOHLER KDI 3404 TCR only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
12.3 - Diesel circuit (For machines fitted with engine PERKINS 854E-34TA
or PERKINS 1104D44T only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
12.3.1 - Changing the diesel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
12.3.2 - Changing the diesel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 176
12.4 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
12.5 - Engine oil service reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
12.6 - Travel axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
12.6.1 - Checking the level of the front axle . . . . . . . . . . . . . . . . . . . . . 178
12.6.2 - Checking the level of the rear axle . . . . . . . . . . . . . . . . . . . . . . 179
12.6.3 - Checking the level of the epicycloidal reducers . . . . . . . . . . . . 179
13 - Every 1000 h hours of operation (or once a year) . . . 180
13.1 - Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
13.2 - Primary air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
13.3 - Internal combustion engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
13.4 - Hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.4.1 - Equipment hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.4.2 - Transmission hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.5 - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

7
CONTENTS
Operator's manual
14 - Every 1500 h hours of operation . . . . . . . . . . . . . . . . . 182
14.1 - Travel axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.1.1 - Draining the front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.1.2 - Draining the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
14.1.3 - Draining the epicycloidal reducers . . . . . . . . . . . . . . . . . . . . . . 183
14.1.4 - Engine crankcase breather (Engine PERKINS 854E-34TA) . . 184
14.1.4.1 - Remove the breather element . . . . . . . . . . . . . . . . . . . . . . . . . 184
14.1.4.2 - Install the breather element . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
15 - Every 2000 h hours of operation (or every 2 years) . 186
15.1 - Cooling system (Engine PERKINS 1104D44T). . . . . . . . . . . . . . . . . 186
15.2 - Air filter (system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
15.3 - Internal combustion engine (Engine PERKINS 1104D44T) . . . . . . 187
15.4 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
15.5 - Air-conditioning (Option)Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
16 - Every 3000 h hours of operation (or every 3 years) . 190
16.1 - Internal combustion engine (Engine PERKINS 854E-34TA). . . . . . 190
16.2 - Diesel particulate filter (Engine PERKINS 854E-34TA). . . . . . . . . . . 190
16.3 - Cooling system (For machines fitted with engine PERKINS 854E-34TA
or KOHLER KDI 3404 TCR only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
17 - Every 5000 h hours of operation (or every 5 years) . 192
17.1 - Internal combustion engine (Engine KOHLER KDI 3404 TCR) . . . 192
18 - Every 10 years. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
18.1 - Replacement of the brake circuit accumulators. . . . . . . . . . . . . . . . . . 192
18.1.1 - Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
18.1.2 - Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
18.2 - Lubricants and equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
19 - Electric circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19.1 - Wiring diagram-Main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
20 - Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
20.1 - Hydraulic diagram-Main components . . . . . . . . . . . . . . . . . . . . . . . . . . 196
21 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
21.1 - Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
I
INTERVENTION REGISTER
1 - Intervention register . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

8
Operator's manual

9
4000328140 E01.15 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.
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..
• HAULOTTE® must be informed in the event of an incident that either involves one of these products
or has caused bodily injury or significant deterioration of property (personal property or the product);
contact HAULOTTE Services® immediately (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 4000328140 E01.15 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® can affect the visibility in driving position and 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).
Otherwise, 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 label compliance.

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4000328140 E01.15 AUS
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4 - HAULOTTE Services® contact details
HAULOTTE Services® contact details
HAULOTTE FRANCE
PARC DES LUMIERES
601 RUE NICEPHORE NIEPCE
69800 SAINT-PRIEST
TECHNICAL Department:
[phone]
SPARE PARTS : [phone]
FAX : [phone]
E-mail : [email protected]
www.haulotte.fr
HAULOTTE ITALIA
VIA LOMBARDIA 15
20098 SAN GIULIANO MILANESE
(MI)
TEL: [phone]
FAX: [phone]
E-mail : [e-mail]
www.haulotte.it
HAULOTTE HUBARBEITSBÜHNEN GmbH
AN DER MÖHLINHALLE 1
D-79189 BAD KROZINGEN-HAUSEN
TEL : [phone]
FAX : [phone]
E.mail : [email protected]
www.haulotte.de
HAULOTTE VOSTOK
35, SVOBODY STREET
Bldg. 19
125362 MOSCOW
RUSSIA
TEL/FAX : [phone] / 03
E.mail : [e-mail]
www.haulotte-international.com
HAULOTTE DO BRASIL
AV. Tucunaré, 790
CEP: 06460-020 – TAMBORE
BARUERI – SAO PAULO – BRASIL
TEL : [phone]
FAX : [phone]
E.mail : [email protected]
www.haulotte.com.br
HAULOTTE IBERICA
C/ARGENTINA N° 13 - P.I. LA GARENA
28806 ALCALA DE HENARES
MADRID
TEL : [phone]
TEL SAT : [phone]
FAX : [phone]
E.mail : [email protected]
www.haulotte.es
HAULOTTE POLSKA Sp. Z.o.o.
UL. GRANICZNA 22
05-090 RASZYN - JANKI-
TEL : [phone]
FAX : [phone]
E-mail :
[e-mail]
www.haulotte.pl
HAULOTTE MÉXICO, Sa de Cv
Calle 9 Este, Lote 18, Civac, Jiutepec,
Morelos
CP 62500 Cuernavaca
México
TEL : [phone]
FAX : [phone]
E-mail : [email protected]
www.haulotte-international.com
HAULOTTE PORTUGAL
ESTRADA NACIONAL NUM. 10
KM. 140 - LETRA K
2695 - 066 BOBADELA LRS
TEL : + 351 21 995 98 10
FAX : + 351 21 995 98 19
E.mail : [email protected]
www.haulotte.es
HAULOTTE SINGAPORE Pte Ltd.
No.26 CHANGI NORTH WAY,
SINGAPORE 498812
Parts and service Hotline:
[phone]
FAX : [phone]
E-mail: [e-mail]
www.haulotte.sg
HAULOTTE MIDDLE EAST FZE
PO BOX 293881
Dubaï Airport Free Zone
DUBAÏ
United Arab Emirates
TEL : [phone]
FAX : [phone]
E-mail : haulottemiddle-
[email protected]
www.haulotte-international.com
HAULOTTE SCANDINAVIA AB
Taljegårdsgatan 12
431 53 Mölndal
SWEDEN
TEL : [phone]
FAX : [phone]
E-mail : [email protected]tte.com
[email protected]om
www.haulotte.se
HAULOTTE TRADING (SHANGHAI)
Co. Ltd.
#7 WORKSHOP
No 191 HUA JIN ROAD
MIN HANG DISTRICT
SHANGHAI 201108 CHINA
TEL : [phone]
FAX : [phone]
E-mail :
[email protected]
www.haulotte.cn
HAULOTTE ARGENTINA
Ruta Panamericana Km. 34,300
(Ramal A Escobar)
1615 Gran Bourg
(Provincia de Buenos Aires)
Argentina
TEL.: [phone]
FAX. [phone]
E-mail : [email protected]om
www.haulotte-international.com
HAULOTTE UK Ltd
STAFFORD PARK 6
TELFORD - SHROPSHIRE TF3 3AT
TEL : [phone]
FAX : + 44 (0)1952 292758
E.mail : [email protected]m
www.haulotte.co.uk
HAULOTTE GROUP / BILJAX
125 TAYLOR PARKWAY
ARCHBOLD, OH 43502 – USA
TEL : [phone]
FAX :[phone]
Toll free : [phone]
E.mail : [email protected].com
www.haulotte-usa.com
HAULOTTE GROUP
1301 E PATRICK STREET
FREDERICK, MD 21701 – USA
TEL : [phone]
FAX :[phone]
Toll free : [phone]
E.mail : [email protected]
www.haulotte
HAULOTTE CHILE
El Arroyo 840
Lampa (9380000)
Santiago (RM)
TEL : + 562 2 3727630
E.mail : [email protected]
www.haulotte-chile.com
-usa.com
HAULOTTE NETHERLANDS BV
Koopvaardijweg 26
4906 CV OOSTERHOUT - Nederland
TEL : [phone]
FAX : [phone]
E.mail :
[email protected]
HAULOTTE AUSTRALIA PTY Ltd
46 GREENS ROAD
DANDENONG – VIC – 3175
TEL : [phone]
FAX : [phone]
E.mail :
l
[email protected]u
hl
HAULOTTE INDIA
Unit No. 1205, 12th foor,Bhumiraj Costarica,
Plot No. 1&2, Sector 18,
Palm Beach Road,
Sanpada, Navi Mumbai- 400 705
Maharashtra, INDIA
Tel. : [phone] to 35
E-mail : [email protected]
www.haulotte.in

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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

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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
Label color code-For the Eurasian Customs Union and the Ukraine only
The labels must be kept in good condition. Additional labels can be ordered from HAULOTTE Services®.
Labels Color Meaning
Red Potentially fatal danger
Orange Risk of serious injury
Yellow Risk of material damage and/or minor injury
Other Additional technical information
Green Maintenance operation or information
Labels Color Meaning
Red Prohibitions - Danger
Yellow Warning : Risk of material damage and/or minor injury
Blue Precaution
Blue Information
Other Additional technical information

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4000328140 E01.15 AUS
Telescopic handlers
A - Safety precautions
2 - Operation instructions
2.1 - PROHIBITIONS
2.2 - POTENTIAL RISKS
2.2.1 - Tip-over hazards
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.
• Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or
during an extended stop period.
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).

16 4000328140 E01.15 AUS
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A - Safety precautions
Do not raise the boom unless the chassis is level (0 °).
Do not level the machine with the boom or the accessory
above 30 °
• Transport the load as low as possible. Attach the
suspended loads to restrict movement.
• 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.

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4000328140 E01.15 AUS
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A - Safety precautions
• Maintain proper tire pressure at all times. Otherwise, the
machine could tip over.
Do not ballast the tires.
• Always wear the seat belt.
Do not hang your head, your arms, your hands, your legs or any other parts of your body out of the cab.
If the telehandler starts to tip over :
• 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.

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A - Safety precautions
2.2.2 - Electrical hazards
• Always check for power lines before raising the boom.
Minimum safety distance
N.B.-:-This table is applicable, except when the local regulations are more strict.
• 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..
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

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4000328140 E01.15 AUS
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A - Safety precautions
Minimum safety distance - For AS standard only

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A - Safety precautions
2.2.3 - Travel hazards
• 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).
• 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.
• Before moving the machine, ensure that there is adequate
visibility.
• Before moving the machine, ensure that the path is clear
and sound the horn.
• When driving, retract the boom and keep the boom and the
attachment as low as possible.
• 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.
Look out for obstacles with a height less than 0,75 m(2 ft6 in) which may be located near the wheels or
behind the boom.