Humbaur HTK Series User manual

Operating manual
en
Serie 10000 humbaur.com
HTK three-way tipper (5 t - 7.5 t)
Multifunction construction transporter

1
This operating manual must be read,
understood and complied with in all
points by all persons responsible for
the vehicle manufactured by
Humbaur GmbH and its subassemblies.
Humbaur GmbH accepts no liability for
damage and malfunctions resulting from
failure to comply with these instructions!
For this reason, read this oper-
ating manual before using the
vehicle for the first time and
heed all instructions, warnings
and notes contained therein!
Note that the illustrations are intended to
serve as examples and that the design /
equipment shown may vary from that of
your specific vehicle.
Also read and observe the oper-
ating manuals for components
such as axles, landing gear, etc!
The technical documentation is part of
the product and should be kept in the
driver's cab of the towing vehicle at all
times for reference.
This operating manual draws attention to
particularly important details with regard
to the operation and use of the trailer and
to the required care and maintenance
work. Only with this information is it
possible to avoid errors and ensure fault-
free operation.
The manufacturer reserves the right to
correct errors and make technical
changes to the design, equipment and
accessories referred to in the informa-
tion, illustrations and descriptions of the
operating manual.
Humbaur GmbH
Mercedesring 1
89368 Gersthofen (Germany)
No claims whatsoever may consequently
be derived from the information, illustra-
tions and descriptions contained herein.
Obligations of the operating company
Only operate the trailer when it is in
perfect condition.
Ensure that the operating manual is
included when the trailer is sold on,
for example.
Use only trained and instructed
personnel.
Ensure compliance with the
operating manual throughout
the life of the trailer and that
the correct personal protective
equipment (See "Personal
protective equipment / rules and
prohibited activities" on page 21)
is used.
Provide the required operating and auxil-
iary materials.

2
Contents of this operating manual
Identification
Dimensions, weights and performance
data can be found in the trailer's registra-
tion documents.
Enter a cross next to the relevant trailer on delivery.
Vehicle type Version 
Three-way tipper, tandem (total mass 5 t) HTK 504020
Three-way tipper, tandem (total mass 6.5 t) HTK 654020
Three-way tipper, tandem (total mass 7.5 t) HTK 754020


3
Contents of this operating manual
Index
Use the Index starting on page 5to
search for specific topics.
1 Safety
The chapter "Safety," starting on page 9,
contains safety-relevant information on
correct handling of the trailer.
Read this chapter before driving with
the trailer for the first time.
2 General Information
The chapter entitled "General informa-
tion," starting on page 23, provides infor-
mation on vehicle identification.
3 Operation
The chapter "Operation," starting on
page 33, provides information on loading
and unloading, correct distribution of
loads and hitching / unhitching and
coupling / uncoupling the trailer.
4 Operating the chassis
In the chapter "Operating the chassis,"
starting on page 55, you will find all you
need to know about the chassis oper-
ating elements, for example the raising/
lowering system and landing gear, as
well as information on safe loading and
unloading.
5 Body
The chapter "Body," starting on page 97,
explains how to operate the body
correctly, for example how to fold down
the drive-up ramps and which equipment
you can use to secure loads.
6 Electrical system
In the chapter "Electrical system,"
starting on page 135, you will find infor-
mation on the lights, connectors and
connector assignments.
7 Inspection, care and mainte-
nance
The chapter "Inspection, care and main-
tenance," starting on page 153,
describes the activities required for main-
taining the operational safety and value
of your vehicle.
8 Troubleshooting
The chapter entitled "Troubleshooting,"
starting on page 203, tells you what to do
in the event of problems or malfunctions
and provides contact details for the
service team.

Contents of this operating manual
4

5
Index
Towing eye connection 235
A
ABS . . . . . . . . . . . . . . . . . . . . 57
Access aids . . . . . . . . . . . . . . 132
Address
Manufacturer . . . . . . . . . . . . . . 1
Replacement parts . . . . . . . . 205
Service . . . . . . . . . . . . . . . 205
Aluminium surfaces . . . . . . . . . 198
Approved operating materials . . 199
B
Batteries
Battery charging point. . . . . . . . 74
Charging . . . . . . . . . . . . . . 172
Disposal. . . . . . . . . . . . . . . 200
Body . . . . . . . . . . . . . . . . . . . 97
Brake matching . . . . . . . . . . . . 12
Brake name plate . . . . . . . . . . 180
C
Cable clips . . . . . . . . . . . . . . 179
Care. . . . . . . . . . . . . . . . . . . 153
Central lubrication . . . . . . . . . . 160
Chapter
Electrical system. . . . . . . . . . 135
General Information . . . . . . . . . 23
Inspection, care and maintenance 153
Operating the chassis . . . . . . . . 55
Operation. . . . . . . . . . . . . . . 33
body 97
Safety . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . 203
Chassis
Operation. . . . . . . . . . . . . . . 55
Check before driving off . . . . . . . 53
Check when parking . . . . . . . . . 53
Cleaning
Alloy disc wheels . . . . . . . . . . 195
Cleaning the coupling heads. . . . 184
Cleaning the Duo-Matic coupling . 183
Cleaning the line filter . . . . . . . . 182
Coefficient of friction matching. . . 126
Compressed air tank . . . . . . . . . 66
Connection element . . . . . . . . . 43
Connector
13-pin (ISO 11446-12V) . . . . . . 144
15-pin (ISO 12098-24V) . . . . . . 142
7-pin (ISO 1185-24V) . . . . . . . . 146
7-pin (ISO 1724-12V) . . . . . . . . 143
7-pin (ISO 3731-24V) . . . . 146, 147
7-pin (ISO 7638 - EBS). . . . . . . 145
ABS/EBS . . . . . . . . . . . . . . . 57
Connector pin assignment
13-pin (ISO 11446-12V) . . . . . . 144
15-pin (ISO 12098-24V) . . . . . . 142
7-pin (ISO 1185-24V) . . . . . . . . 146
7-pin (ISO 1724-12V) . . . . . . . . 143
7-pin (ISO 3731-24V) . . . . 146, 147
7-pin (ISO 7638 - EBS). . . . . . . 145
Contact
Humbaur Service Partners . . . . 205
Parts logistics . . . . . . . . . . . . 205
Technical Customer Service . . . 205
Coupling . . . . . . . . . . . . . . . . . 48
Hydraulic line . . . . . . . . . . . . . 70
Coupling heads
Red (supply line) . . . . . . . . . . . 59
Yellow (brake). . . . . . . . . . . . . 59
D
Danger of toppling . . . . . . . . . . . 35
Defective wheel . . . . . . . . . . . . 178
Diagnostics connection for EBS / ABS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Disposal
Batteries . . . . . . . . . . . . . . . 200
Tyres . . . . . . . . . . . . . . . . . 200
Used oil/lubricants . . . . . . . . . 200
Disposing of operating materials . 200
Disposing of tyres. . . . . . . . . . . 200
Disposing of used oil/lubricants . . 200
Documentation
Axle/wheel maintenance . . . . . . 155
Certificate of general inspection/safety
assessment . . . . . . . . . . . . . 155
Support equipment maintenance . 155
Draining the compressed air tank . 67
Driving off. . . . . . . . . . . . . . . . . 17

Index
6
E
EBS . . . . . . . . . . . . . . . . . . . . 57
EBS connector
7-pin (ISO 7638) . . . . . . . . . . 145
EC Declaration of Conformity . . . 31
Electrical system. . . . . . . . . . . 135
Servicing . . . . . . . . . . . . . . 185
Troubleshooting . . . . . . . . . . 207
Electro-hydraulic unit . . . . . . . . 171
General . . . . . . . . . . . . . . . . 71
Switching off the power supply . . 74
Environmental pollution
Toxic substances . . . . . . . . . 200
Environmental protection regulations
194
F
Fixings . . . . . . . . . . . . . . . . . 179
Fixings, cable clips . . . . . . . . . 179
Folding support . . . . . . . . . . . . 79
Form-fit load securing . . . . . . . 131
Friction-lock load securing . . . . 129
Front wall . . . . . . . . . . . . . . . 102
G
Galvanised steel surfaces. . . . . 197
General Information. . . . . . . . . . 23
Getting the spare wheel ready . . 178
H
High-pressure cleaners . . . . . . . 195
Hydraulic connections . . . . . . . . 168
Hydraulic cylinder . . . . . . . . . . . 169
Hydraulic supply
Switchover . . . . . . . . . . . . . . 73
I
Identification . . . . . . . . . . . . . . . 2
Index . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . 153
Intended use . . . . . . . . . . . . . . 10
L
Lashing points . . . . . . . . . . . . . 130
Lateral drop-sides. . . . . . . . . . . 103
LED rear light . . . . . . . . . . . . . 149
Lettering . . . . . . . . . . . . . . . . . 192
Lettering work . . . . . . . . . . . . . 192
Licence plate light. . . . . . . . . . . 151
Light system . . . . . . . . . . . . . . 136
Lighting
Lamps . . . . . . . . . . . . . . . . 186
Limit light . . . . . . . . . . . . . . . 186
Maintenance . . . . . . . . . . . . . 185
Marking light . . . . . . . . . . . . . 186
Peripheral light. . . . . . . . . . . . 186
Terminal diagram . . . . . . . . . . 185
Lighting terminal diagram. . . . . . 185
Lights . . . . . . . . . . . . . . . . . . 186
Limit light . . . . . . . . . . . . . . . . 186
Limit lights . . . . . . . . . . . . 150, 191
Load centre . . . . . . . . . . . . . . . 42
Load definition. . . . . . . . . . . . . . 42
Load distribution . . . . . . . . . . . . 42
Loading . . . . . . . . . . . . . . . . . . 37
Loading notes . . . . . . . . . . . . . . 37
Lubricating . . . . . . . . . . . . . . . 160
Lubricating grease . . . . . . . . . . 160
Lubrication
Alloy disc wheels . . . . . . . . . . 179
Central interlock. . . . . . . . . . . 166
Draw bar height adjustment . . . . 161
Drop-side locks . . . . . . . . . . . 165
Folding legs . . . . . . . . . . . . . 161
Spindle parking brake . . . . . . . 162
Spindle support . . . . . . . . . . . 161
Support wheel . . . . . . . . . . . . 164
Telescopic cylinder . . . . . . . . . 169
Tipping bearings . . . . . . . . . . 167
Towing eye . . . . . . . . . . . . . 163
M
Maintenance . . . . . . . . . . . . . . 153
Cleaning the coupling heads . . . 184
Cleaning the line filter . . . . . . . 182
Compressed air system . . . . . . 181
Compressed air tank . . . . . . . . 181

7
Index
Draw bar height adjustment . . . 161
Electrical system. . . . . . . . . . 185
Licence plate light "LED" . . . . . 190
Licence plate light "standard" . . 190
Lighting . . . . . . . . . . . . . . . 185
Limit lights . . . . . . . . . . . . . 191
Mechanical components . . . . . 173
Peripheral light standard 24 V . . 188
Rear light "24 V - standard" . . . 187
Rear light "LED" . . . . . . . . . . 189
Service brake system . . . . . . . 180
Side marking lights . . . . . . . . 191
Wheel brake . . . . . . . . . . . . 181
Maintenance intervals
One-time maintenance work . . . 156
Regular maintenance work . . . . 157
Maintenance regulations . . . . . 156
Maintenance support . . . . . . . . 169
Manufacturer . . . . . . . . . . . . . . . 1
Marking lights. . . . . . . . . . . . . 150
Max. weights . . . . . . . . . . . . . . 42
N
Notes
Conventions in the operating manual .
19
Operating manual . . . . . . . . . . . 1
O
Operating add-on drop sides. . . . 110
Operating drop-sides. . . . . . . . . 101
Operating manual instructions. . . . 1
Operating materials
Disposal . . . . . . . . . . . . . . . 200
Lubricating grease . . . . . . . . . 160
Operating the steel grid extensions .
115
Operating the support frame . . . . 113
Operation . . . . . . . . . . . . . . . . 33
Body . . . . . . . . . . . . . . . . . 97
Chassis . . . . . . . . . . . . . . . . 55
P
Painted or powder-coated steel surfac-
es . . . . . . . . . . . . . . . . . . . . . 197
Painting . . . . . . . . . . . . . . . . . 192
Parking warning signs . . . . . . . . 95
Peripheral light. . . . . . . . . 186, 188
Personal protective equipment . . 21
Personnel qualifications . . . . . . . 16
Physical fundamentals
Friction force . . . . . . . . . . . . . 126
Pin couplings. . . . . . . . . . . . . . 47
Plug connections . . . . . . . . . . . 137
Plug connections (optional). 138, 139
Pre-assembling the charging plug 172
Pressure level . . . . . . . . . . . . . . 66
Prohibitory signs . . . . . . . . . . . . 22
Putting lifting device into position. 177
Q
Quick-release coupling
Duo-Matic . . . . . . . . . . . . . . . 64
R
Ramps
Driving over . . . . . . . . . . . . . 122
Operating . . . . . . . . . . . . . . 118
positioning . . . . . . . . . . . . . . 121
Stowing . . . . . . . . . . . . . . . 123
Rear platform gate . . . . . . . . . . 106
Fold-down operation . . . . . . . . 107
Swing mode . . . . . . . . . . . . . 108
Replacement parts address . . . . 205
Replacing lights . . . . . . . . . . . . 187
Rollover resistance. . . . . . . . . . . 35
Rubber/seals. . . . . . . . . . . . . . 198
S
Safety . . . . . . . . . . . . . . . . . . . 9
Safety instructions . . . . . . . . . . . 19
Securing the load . . . . . . . . . . . 125
Fundamentals . . . . . . . . . . . . 125
Types. . . . . . . . . . . . . . . . . 128
Securing the loading platform

Index
8
Tipping bearings . . . . . . . . . . . 75
Service address . . . . . . . . . . . 205
Service brake
Activating . . . . . . . . . . . . . . . 61
Deactivating . . . . . . . . . . . . . 61
operating . . . . . . . . . . . . . . . 60
Service brake system . . . . . . . . 57
Servicing . . . . . . . . . . . . . . 180
Servicing the compressed air system
181
Servicing the hydraulic system. . 168
Servicing the mechanical components
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Servicing the wheel brake. . . . . 181
Side guard. . . . . . . . . . . . . . . . 87
Signal words . . . . . . . . . . . . . . 19
Sources of danger. . . . . . . . . . . 16
Spare wheel holder . . . . . . . . . . 89
Spare wheel storage . . . . . . . . . 89
Maintaining . . . . . . . . . . . . . 178
Spare wheel transport . . . . . . . . 90
Spindle parking brake . . . . . . . . 62
Spindle support identification. . . . 30
Stability. . . . . . . . . . . . . . . . . . 35
Standard rear light . . . . . . . . . 148
Steam cleaners . . . . . . . . . . . 195
Support equipment
Spindle support, optional . . . . . . 85
Support wheel . . . . . . . . . . . . 82
Swing mode. . . . . . . . . . . . . . 108
Switch-off / securing mechanisms
Stroke limiter. . . . . . . . . . . . . 173
T
Tightening torques
for screw connections . . . . . . . 158
for wheel nuts . . . . . . . . . . . . 159
Toolbox . . . . . . . . . . . . . . . . . 93
Towing eye versions . . . . . . . . . 44
Track width . . . . . . . . . . . . . . . 37
Trailer
Disposal . . . . . . . . . . . . . . . 201
Securing . . . . . . . . . . . . . . . 177
Taking out of operation . . . . . . . 201
Trailer materials . . . . . . . . . . . . 196
Troubleshooting . . . . . . . . . . . . 203
Axles . . . . . . . . . . . . . . . . . 209
Brake system . . . . . . . . . . . . 207
Electrical system . . . . . . 207, 208
Hydraulic / electro-hydraulic system .
211
Loading / driving performance . . . 206
Towing eye / draw bar . . . . . . . 210
Tyre pressure / tread . . . . . . . . . 175
Tyre types. . . . . . . . . . . . . . . . 174
U
Uncoupling
Duo-Matic . . . . . . . . . . . . . . 65
Uncoupling the lines
Manual . . . . . . . . . . . . . . . . . 59
Underrun guard . . . . . . . . . . . . . 88
Unloading. . . . . . . . . . . . . . . . . 37
Use
Foreseeable misuse . . . . . . . . . 11
Intended . . . . . . . . . . . . . . . . 10
V
Vehicle Identification Number . . . . 29
VIN . . . . . . . . . . . . . . . . . . . . . 29
W
Warning signs . . . . . . . . . . . . . . 20
Warranty . . . . . . . . . . . . . . . . . 14
What to do
In the event of fire . . . . . . . . . 204
in the event of malfunctions . . . . 204
What to do in the event of fire . . . 204
Wheel bolts. . . . . . . . . . . . . . . 175
Wheel changing. . . . . . . . . . . . 176
Wheel chocks . . . . . . . . . . . . . . 92
Wheel nuts 175