Humbaur HTK Series User manual

Operating Instructions
en
10000 Series humbaur.com
HTK three-way tipper (10 t - 18 t)
Construction transporter

2

1
This operating manual is intended to be
read carefully and understood and all its
instructions followed by all persons with
responsibility for the Humbaur GmbH
vehicle and its modules.
Humbaur GmbH accepts no liability for
any damage, injuries or malfunctions
resulting from a failure to do this.
It is therefore imperative that you
read and follow all the
instructions, warnings and notes
in this manual before driving for
the first time.
Please note that the figures are to be
considered sample figures and may
deviate from the actual appearance /
equipment.
Also read and observe the
operating 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 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
information, illustrations and descriptions
of the operating manual
Humbaur GmbH
Mercedesring 1
89368 Gersthofen (Germany)
No claims whatever may consequently
be derived from the information,
illustrations 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, for
example.
Use only trained and instructed
personnel.
Ensure compliance with the
operating manual throughout the
life of the trailer and that the
correct protective clothing (See
"Personal protective equipment/
rules and prohibited activities"
on page 21) is worn.
Provide the required consumables and
working and other materials.

2
Contents of this operating manual
Identification
Dimensions, weights and performance
data can be found in the trailer's registra-
tion documents.
The relevant trailer should be indicated on delivery by means of a cross.
Vehicle type Version 
Three-way tipper, tandem (total weight 10.5 t) HTK 104522
Three-way tipper, tandem (total weight 10.5 t) HTK 105024
Three-way tipper, tandem (total weight 10.5 t) HTK 105524
Three-way tipper, tandem (total weight 11.9 t) HTK 104522
Three-way tipper, tandem (total weight 11.9 t) HTK 105024
Three-way tipper, tandem (total weight 11.9 t) HTK 105524
Three-way tipper, tandem (total weight 13.6 t) HTK 135024
Three-way tipper, tandem (total weight 13.6 t) HTK 135524
Three-way tipper, tandem (total weight 18.0 t) HTK 185024
Three-way tipper, tandem (total weight 18.0 t) HTK 185524


3
Contents of this operating manual
Keyword index
Use the keyword index, starting on
page 5, to search for specific topics.
1 Safety
The chapter entitled "Safety", starting on
page 9, contains safety-related
information on handling the trailer
properly.
Read this chapter before driving for the
first time.
2 General Information
The chapter entitled "General
information", starting on page 23,
provides information on vehicle
identification.
3 Operation
The chapter "Operation", starting on
page 41, provides information on loading
and unloading, correct load distribution,
and coupling and uncoupling the trailer.
4 Operation of the chassis
The chapter entitled "Operation of the
chassis", starting on page 77, provides
everything you need to know about the
controls of the chassis such as the
raising/lowering system, landing gear as
well as information on safe loading and
unloading.
5 Body
In the chapter "Body", starting on
page 125, you can see how you operate
the vehicle body properly, for example,
folding down platform gates, securing
ramp planks or which devices you can
use for securing the load.
6 Electrical system
In the chapter "Electrical system",
starting on page 237, you will find
information on the "Connectors and
assignments" lamps.
7 Inspection, care and
maintenance
In the chapter "Inspection, care and
maintenance", starting on page 257, you
will be informed of the activities required
for maintaining operational safety and
the value of your vehicle.
8 Troubleshooting
The chapter entitled "Troubleshooting"
starting on page 317, tells you what to do
in the event of problems or malfunctions
and provides contact details for service
team.

Contents of this operating manual
4

5
Index
A
ABS 79
Access aids 229
Address
Manufacturer 1
Replacement parts 319
Service 319
Aluminium surfaces 311
Approved consumables 314
B
Batteries
Disposal 315
Brake nameplate 289
C
Cable clips 288
Care 257
Central lubrication 264
Chapter
Electrical system 237
General Information 23
Inspection, care and maintenance 257
Operation 41
Operation body 125
Operation of the chassis 77
Safety 9
Troubleshooting 317
Check when parking 73
Clean Duo-Matic coupling 293
Cleaning
Cleaning alloy wheels 308
Cleaning coupling heads 291
Cleaning line filter 292
Coefficient of friction matching 219
Compressed air tank 90
Connecting electrical system 241
Connection element 55
Connector
13-pin (ISO 11446-12V) 247
15-pin (ISO 12098-24V) 245
7-pin (ISO 1185-24V) 249
7-pin (ISO 1724-12V) 246
7-pin (ISO 3731-24V) 249, 250
7-pin (ISO 7638 - EBS) 248
ABS/EBS 79
Consumables
Disposal 315
Lubricating grease 264
Contact
Humbaur Service Partners 319
Parts logistics 319
Technical customer service 319
Coupling 66
Hydraulic line 100
Coupling heads
Red (supply line) 81
Yellow (brake) 81
D
Danger of toppling 43
Defective tyre 287
Departure check 72
Diagnosis connection for EBS/ABS 289
Disposal
Batteries 315
Tyres 315
Used oil/lubricants 315
Disposing of consumables 315
Disposing of tyres 315
Disposing of used oil/lubricants 315
Documentation

6
Axle/wheel maintenance 259
Certificate of general inspection/safety
assessment 259
Support equipment maintenance 259
Draining the compressed air tank 91
Driving off 17
Driving on ramp planks
214
E
EBS 79
EBS connector
7-pin (ISO 7638) 248
EC Declaration of Conformity 40
Electrical system 237
Maintaining 297
Troubleshooting 321
Emergency trigger device
Brake 294
deactivation 295
Parking brake 295
Environmental pollution
Poison 315
Environmental protection regulations
307
F
Fixings 288
Fixings, cable clips 288
Folding support 105
Form-fit load securing 226
Friction-lock load securing 222
Front platform gate 131, 132
G
Galvanised steel surfaces 310
General Information 23
H
Handling plugs 241
High-pressure cleaners 308
Hydraulic connections 276
Hydraulic cylinder 277
I
Identification 2
Index 5
Intended use 10
L
Lashing points 224
Lettering 305
Lettering work 305
Licence plate light 254
Lighting
Filament lamps 298
Limit light 298
Maintenance 297
Marking light 298
Peripheral light 298
Terminal diagram 297
Lighting system 238
Lighting terminal diagram 297
Lights 298
Limit light 298
Limit lights 253, 303
Load centre 51
Load definition 51
Loading 46
Loading notes 46
Lubricating 264
Lubricating grease 264
Lubrication
Cleaning alloy wheels 288

7
Draw pipe height adjustment system 265
Front platform gate locks 272
Front side central locking system 274
Pivot hinge 272
Rear side central locking system 273,
274
Rotatable towing eye 271
Spindle parking brake 268
Spindle support 267
Telescope cylinder 277
Tilt feet 266
Tilting bearing 275
Towing eye 269
M
Maintaining compressed air system 290
Maintaining hydraulic system 276
Maintaining mechanics 280
Maintaining wheel brake 290
Maintenance 257
"24 V - standard" rear light 299
"LED" licence plate light 302
Cleaning coupling heads 291
Cleaning line filter 292
Compressed air system 290
Compressed air tank 290
Draw pipe height adjustment system 265
Electrical system 297
Licence plate light "standard" 302
Lighting 297
Limit lights 303
Mechanical components 280
Peripheral light standard 24 V 300
Replacing "LED" rear light 301
Service brake system 289
Side marking lights 303
Wheel brake 290
Maintenance intervals
One-time maintenance work 260
Regular maintenance work 261
Maintenance regulations 260
Manufacturer 1
Marking lights 253
Multi-voltage version 12 V - 24 V 243
N
Notes
Conventions in the operating manual 19
Operating manual 1
O
Operating manual instructions 1
Operating platform gate attachments 169
Operating platform gates 129
Operating ramp planks
203
Operating service brake
82
Operation 41
P
Painted or powder-coated steel surfaces
310
Painting 305
Parking brake, spring-loaded 86
Parking plug 242
Parking warning panels 122
Pendulum mode 144, 147
Peripheral light 298, 300
Permissible weights 51
Personal protective equipment 21
Personnel qualifications 16
Physical fundamentals
Friction force 219

8
Pin couplings 64
Plug connections (standard) 239
Plug connections 2x7-pin (optional) 240
Pressure level 90
Prohibition signs 22
Putting lifting device into position 286
Q
Quick-release coupling
Duo-Matic 88
R
Ramp planks
Positioning 208
Setting track width 213
Rear platform gate 141
Folding mode 142
Pendulum mode 144, 147
Replacement parts address 319
Replacing lights 299
Rollover resistance 43
Rubber/seals 311
S
Safety 9
Safety instructions 19
Screw parking brake 84
Securing loading platform
Tilting bearing 101
Securing the load 218
Covering net 233
Fundamentals 218
Types 221
Service address 319
Service brake
Activating 83, 86
deactivation 83
Service brake system 79
Maintaining 289
Service support 277
Side platform gates 133
Signal words 19
Sockets
Standard 239
Sources of danger 16, 17
Spare wheel holder 114
Spare wheel storage 114
Maintaining 287
Spare wheel transport 115, 116
Spindle support identification 39
Spring-loaded parking brake 86
Emergency release 294
Stability 43
Stanchions (load securing) 233
Steam cleaners 308
Stowing ramp planks
215
Supplying spare wheel 287
Support equipment
Spindle support optional 109
Switch-off/safeguard mechanism
Lift limitation 280
T
Tail light
LED with peripheral light 252
Replacing "LED" 301
Standard with peripheral light 24 V 251
Testing 257
Tightening torques 263
For screw connections 262

9
Toolbox 120
Track width 46
Traction test 12
Trailer
Disposal 316
Securing 286
Taking out of operation 316
Trailer materials 309
Troubleshooting 317
Axles 323
Brake system 321
Electrical system 321, 322
Hydraulics/electro-hydraulic unit 325
Loading/driving performance 320
Towing eye/tongue 324
Tyre pressure/tread 284
Tyre types 282
U
Uncoupling
Duo-Matic 89
Uncoupling lines
Manual 81
Underrun guard 113
Unloading 46
Use
Proper 10
Reasonably foreseeable misuse 11
Using steel grate attachments 198
Using support frame 196
V
Vehicle identification numbers 38
versions of towing eye 56
VIN 38
W
Warning signs 20
warranty 14
What to do
In the event of faults 318
In the event of fire 318
What to do in the event of fire 318
Wheel bolts 284
Wheel changing 285
Wheel chocks 118
Wheel nuts 284
Working light 255
Changing 304
Changing 304

10

9
MACHT’S MÖGLICH
1
2
3
4
5
6
7
8
Safety

10 Safety
Use
1
Intended use
HUMBAUR vehicles and bodies are
constructed in accordance with the
technological regulations and the
recognised safety regulations. Despite
this, however, if used for other than their
intended purpose, they can pose a
hazard to life and limb for both users and
third parties, or cause damage either to
the HUMBAUR vehicle itself or to other
property.
HUMBAUR vehicles and bodies are
manufactured exclusively for transport
operations in accordance with all
relevant regulations and provisions.
Proper use entails adherence to
regulations, descriptions and instructions
provided in this manual and the
suppliers' operating and maintenance
manuals.
Should you be planning subsequent
modifications to your HUMBAUR vehicle
or vehicle body, enquire in good time at a
Humbaur GmbH factory or at an
approved HUMBAUR workshop.
Always check with HUMBAUR GmbH or
an approved HUMBAUR workshop
before having accessories fitted to your
HUMBAUR vehicle or body.
The following is permitted:
– Transport of goods
– Operation only in the range of the
total permitted payload
– Operation only with suitable towing
vehicle
– Operation only in when in technically
perfect condition
– Operation with uniform weight
distribution of the load
– Driving only with properly secured
load
– Driving only when in compliance with
maximum legal speed and speed
adjusted to poor road and weather
conditions
– Loading and unloading only in secure
areas or with additional safeguards in
public streets
– Only stop/park the trailer with
safeguards to prevent rolling away
Periodically subjecting the trailer to the
general inspection and safety inspection
by specialists as well as the certification
of this is a prerequisite to participating in
road transport.
The operator/user of the trailer is
obligated to regularly care for/clean the
trailer as well as perform maintenance.
HUMBAUR vehicles/bodies
carry a vehicle identification
number (VIN)- see page 38.
Always quote this number
without fail when making
enquiries or ordering parts.

Safety 11
Use 1
2
3
4
5
6
7
8
Improper use that can reasonably be foreseen
Any use that goes beyond use for
transport in accordance with the relevant
regulations is considered to be improper.
That includes, in particular:
– Transport of people/animals
– Transport of goods subject to special
regulations and/or for which special
vehicle versions are necessary
(e.g. chemical substances)
– Loading with exceeded payload
– Exceeding the maximum permissible
axle/bearing/trailing load
– Transport of hot/liquid materials
(e.g. tar)
– Driving only with poorly or unsecured
load
– Driving with tilted loading platform
– Driving with poor load distribution
(one-sided, selective loading)
– Unauthorised constructional changes
to the trailer or those not approved by
the manufacturer
– Use of non-authorised replacement
parts or accessories
– Driving with defective lighting system
or with faulty electrical system
– Driving with trailer dirty so that the
licence plate, lighting, markings are
not visible or not clearly visible
– Driving with open structures (e.g.
platform gates, support frame, steel
grate attachment, platform gate
attachment, toolbox, side guards,
ramp planks, landing gear, etc.)
– Unauthorised maintenance/repair of
safety-relevant components which
must only be maintained or repaired
by specialists
– Driving with excessive/inappropriate
speed in poor weather conditions
and/or on bad roads
– Parking trailer without taking
sufficient safety precautions to
prevent the trailer from rolling away
– Operating the trailer in a damaged
condition and visible part wear or with
broken safety-relevant components
– Operating a trailer without valid brake
matching with the towing vehicle
– Operating the ramp planks when a
person is in the danger area
– Transport of vehicles/loading goods
which protrude over the total width of
the trailer
– Standing under raised and unsecured
loading bridges
Any liability for damage resulting from
non-compliance is rejected by the
manufacturer:
Humbaur GmbH
Mercedesring 1
86368 Gersthofen (Germany)
The user shall bear sole responsibility for
any such risk.

Use
12 Safety
1
Traction test
A traction test must be completed to
ensure correct usage.
Unlike a drum brake, a disc brake does
not produce any detectable reduction in
the braking effect to the driver when
overloaded.
This overload can mean that the brakes
of the towing vehicle or trailer overheat.
Reduced braking force, greater brake
lining and/or brake disk wear as well as
wheel bearing or axle damage can occur
as a consequence of overloaded brakes.
For optimal distribution of the decelera-
tion of the entire vehicle combination, a
traction test must be conducted on the
loaded vehicle's brake system by an
independent brake service in compliance
with 71/320 EC or ECE R13 after a short
run-in time of 2,000 to 5,000 km or within
14 days following vehicle handover and
each time the towing vehicle is changed.
Fig. 1 Warning panel on the trailer
In the event of non-compliance
with any of the above or failure to provide
the results of a traction test, any warranty
claims made against Humbaur GmbH
will be invalidated.
WARNUNG
WARNING
nach
Überlastung der Bremsen!
Verminderte Bremswirkung durch über-
hitzte Bremsen / starker Bremsenverschleiß.
XBremskraft-Zugabstimmung
2000 - 5000 km und nach jedem
Zugmaschinenwechsel durchführen.
after 2000 - 5000 km and
Overloading of the brakes!
Reduced braking effect caused by over-
heated brakes / strong brake wear.
X
Perform Tractor / Trailer synchro-
nisation
after each exchange of tractor.
620.00127

Safety 13
Use 1
2
3
4
5
6
7
8
Disclaimer
Any liability of the manufacturer is invali-
dated if:
– Changes have been made to the
trailers or its components
independently.
– The original parts or the conversion
parts/accessories approved by
Humbaur GmbH being replaced by
other components.
– Subsequent alterations have been
made to the trailer (e.g. new holes
made in the frame or existing bore
holes enlarged). Any such
intervention is classified by
Humbaur GmbH as a structural
change, and accordingly invalidates
the operating permit.
– non-approved accessories such as
spares or components of other
makes which are not original
HUMBAUR parts being mounted or
integrated. The operating approval
for the vehicle is invalidated and
possibly the insurance cover as well.
– the maintenance intervals prescribed
by the manufacturer not being
adhered to.
All resulting risks and liability waivers
shall continue to apply in the event that:
– acceptances have been carried out
by testers/experts from the technical
testing authorities or officially
recognised organisations,
– approvals have been granted by
public authorities.

14 Safety
Service and warranty claims
1
The warranty covers
Defects occurring in the course of correct and
proper use of the trailer which are caused by the
design or can be traced back to material defects.
Repairs carried out during the warranty period do
not extend this period.
The dealer as the contracting party is respon-
sible for the warranty.
Prerequisites
Original replacement parts must be used during
repairs.
Repairs must be carried out by an approved
workshop.
The manufacturer's maintenance directions and
instructions set out in this operating manual must
have been followed
Defects may not be traced back to
Non-compliance with the technical and legal
regulations set out in this operating manual.
Improper use of the trailer or lack of user experi-
ence.
Unauthorised modifications to the trailer or built-
on accessories not approved by Humbaur GmbH
will invalidate the warranty. Non-observance of
the relevant legal regulations.
The following are not defects
Every trailer is a product manufactured by
craftsmen. Although every care has been taken,
minor, superficial scratches can occur that have
no effect on the intended use.
Production-related stress cracks in the surface
(hairline cracks) cannot be avoided. These hair-
line cracks have no effect on the stability or use
of the trailer.
Gaps between platform gate and loading ramp.
Furthermore, polyester components are not
100% colour-fast. UV and weather influences
can give rise to bleaching here as well.
It must also be noted that rubber parts generally
age due to UV influences, and the surface may
be subject to cracking and bleaching.
Parts coated by electro dip painting (edp) are not
colour-fast. They may bleach as a result of UV
radiation.
Galvanised parts are normally not glossy, but
lose their lustre after a short period of time. This
is not a defect, but instead a desired quality since
full protection against metal corrosion is only
guaranteed by oxidation. Wood is a natural
material. For this reason, in spite of the most
varied types of machining and coating, it is
subject to natural, weather-dependent stretching
or shrinkage, which can lead to distortions.
Natural wood blemishes and unevenness are
normal for this natural material and can show on
the surface. Bleaching caused by UV radiation
and weather influences is possible. A manufac-
turing tolerance regarding thickness is defined
for the wood components used. Claims cannot
be made for deviations within the tolerance
band.
Because trailers are generally not insulated,
condensation may form under curtain and poly-
ester covers in the event of temperature fluctua-
tions. In this event, ensure adequate ventilation
to prevent mould from forming. Trailers are also
not 100% watertight. Water may get in through
doors, flaps and windows even when rubber
seals are used and applied with the utmost care.