Humbaur 10000 Series User manual

HTK
OPERATING INSTRUCTIONS
10000 SERIES EN
MACHT’S MÖGLICH
Three way tipper (195024) xx
humbaur.com

Your trailer:
Model __________________________________________________
Type (abbreviation) _______________________________________________
Registration number ______________________________________________
VIN number
Trailer components
Axle(s)
(Type / manufacturer) ____________________________________________
Brake system
(Type / manufacturer) ____________________________________________
Support device ___________________________________________________
(Type / manufacturer)
Electronic system __________________________________________________
(installed components)
►►WHD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Humbaur GmbH
Mercedesring 1
86368 Gersthofen
Germany
Tel. + 49 821 24929-0 l [e-mail]
Fax + 49 821 249-100 l www.humbaur.com
Keep this instruction manual readily available in the towing vehicle!
Pass on the complete documentation to the new owner if you sell the trailer.
Trailer data:
Date of first registration ______________________
Gross weight ________________________________
Load capacity ________________________________

1
This operating instruction manual must
be carefully read, understood and
complied with in full by anyone who is
responsible for the Humbaur GmbH
vehicle and its modules.
Humbaur GmbH accepts no liability for
damage or failures which arise through
disregard of this manual!
Read and observe the operating
instruction manual with all the
instructions, warnings and notes
before driving for the first time!
Please note that all illustrations are
representative and may differ from the
actual appearance / equipment.
Also read and observe the
instruction manuals for
components such as axles,
support devices, etc.!
Thecompletetechnicaldocumentationis
part of the product and should be kept in
the driver's cab of the traction unit for
reference at all times.
Key details for the handling, operation
and the requisite care and maintenance
work of the trailer are referred to in this
operating instruction manual, and errors
can only be avoided and trouble-free
operation guaranteed if you are familiar
with them.
Errors excepted. The manufacturer:
Humbaur GmbH
Mercedesring 1
89368 Gersthofen (Germany)
reserves the right make technical
changes to the design, equipment and
accessories with respect to the
information and illustrations in the
operating instruction manual.
As a result, no claims whatsoever can be
derivedfrom theinformation, illustrations
and descriptions.
Obligations of the operator
The trailer may only be operated in
perfect condition.
Ensure that the operating instruction
manualis included withthe trailere.g. if it
is sold.
Only utilise trained or instructed
personnel.
Ensure that the operating
instruction manual is complied
with in all life cycle phases of the
trailer and that the prescribed
personal protective equipment
(see “Personal protective
equipment / rules prohibitions”
on page 24) is worn.
Provide the requisite operating and
auxiliary materials.

2
Contents
Identification
Dimensions, weights and performance
data can be found in the approval docu-
ments of the respective trailer.
The applicable trailer should be marked with a cross upon delivery.
Vehicle type: Model 
Three-way tipper, tandem (gross weight 19 t) HTK 195024


Contents
3
Keyword index
Use the keyword index from page 5to
search for specific topics.
1 Safety
You will find safety information for the
correct handling of the trailer in the
"Safety" chapter from page 9.
Read this chapter before driving for the
first time.
2 General information
You will find details on vehicle
identificationinthe "Generalinformation"
chapter from page 27.
3 Operation
You will find information on loading and
unloading, correct load distribution and
coupling and uncoupling the trailer in the
chapter on "Operation" from page 37.
4 Operating the chassis
You will find valuable information on the
operating elements of the chassis, such
as the lifting / lowering system, support
devices and information on the safe
loading and unloading, in the chapter on
"Operating the chassis" from page 59.
5 Body
You will find information on how to
operate the body correctly, e.g. folding
down the drop sides, securing loading
ramps, and also on the equipment you
can use to secure the load in the chapter
on the "Body" from page 101.
6 Electrical system
You will find information on the lights,
plug connections and connector
assignments in the chapter on the
"Electrical system" from page 143.
7 Testing, care and maintenance
You will find out more about the work
required to maintain operational safety
and the value of your vehicle in the
chapter on "Testing, care and
maintenance" from page 157.
8 Troubleshooting
You will find information on
troubleshooting and important service
addresses in the "Troubleshooting
guide" from page 217.

Contents
4

5
Keywords
A
Accumulator parking brake . . . . . 66
Action
in the event of faults. . . . . . . . 218
in the event of fire . . . . . . . . . 218
Address
Manufacturer. . . . . . . . . . . . . . 1
Adjusting the central locking mecha-
nism. . . . . . . . . . . . . . . . . . . 182
Adjusting the tubular drawbar . . 180
Aluminium surfaces. . . . . . . . . 212
Automatic lowering system . . . . . 72
Inductive sensor . . . . . . . . . . 153
Axle lifting system . . . . . . . . . . . 96
B
Body . . . . . . . . . . . . . . . . . . 101
Brake name plate . . . . . . . . . . 191
C
Care. . . . . . . . . . . . . . . . . . . 157
CE conformity statement . . . . . . 36
Centre of gravity . . . . . . . . . . . . 46
Changing the wheels. . . . . . . . 187
Chapter
Electrical system. . . . . . . . . . 143
General information . . . . . . . . . 27
Operating the body . . . . . . . . 101
Operating the chassis . . . . . . . 59
Operation. . . . . . . . . . . . . . . 37
Safety. . . . . . . . . . . . . . . . . . 9
Testing, care and maintenance . . 157
Troubleshooting guide . . . . . . . 217
Chassis
Operating. . . . . . . . . . . . . . . 59
Check when parking . . . . . . . . . 57
Cleaning
Aluminium disc wheels . . . . . . . 209
Cleaning the Duo-Matic coupling . 196
Climbing aids. . . . . . . . . . . . . . 126
Climbing the tipping box. . . . . . . 129
Compressed air container . . . . . 67
Connecting element . . . . . . . . . 48
Connecting the electric system . . 146
Coupling. . . . . . . . . . . . . . . . . 51
Hydraulic line . . . . . . . . . . . . 75
Coupling / uncoupling of the supply
lines. . . . . . . . . . . . . . . . . . . . 63
D
Danger area . . . . . . . . . . . . . . 40
Departure check. . . . . . . . . . . . 57
Disposal
Batteries . . . . . . . . . . . . . . . 215
Tyres . . . . . . . . . . . . . . . . . 215
Waste oil / lubricants . . . . . . . . 215
Disposing of operating materials . 215
Documentation
Maintenance of axles / wheels . . 159
Maintenance of support device . . 159
Proof of the HU/SP . . . . . . . . . 159
Draining the compressed air container
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E
EBS plug connection
7-pin (ISO 7638) . . . . . . . . . . 148
Electrical system . . . . . . . . . . . 143
maintenance. . . . . . . . . . . . . 199
Emergency release device
Brake. . . . . . . . . . . . . . . . . 197
Environmental pollution
Poisonous substances . . . . . . . 215
Environmental protection measures . .
208
Exchanging lights. . . . . . . . . . . 201
F
Fasteners, cable clamps . . . . . . 190
Fastening torque values
for screw connections . . . . . . . 163
for wheel nuts . . . . . . . . . . . . 163
Faulty wheel . . . . . . . . . . . . . . 189
Friction coefficients for material pairs .
123

Keywords
6
G
Galvanised steel surfaces. . . . . 211
General information. . . . . . . . . . 27
H
High-pressure cleaner . . . . . . . 209
Hydraulic connections . . . . . . . 175
Hydraulic pump
- switch off . . . . . . . . . . . . . 119
- switch on . . . . . . . . . . . . . 118
I
Identification . . . . . . . . . . . . . . . 2
Intelligent trailer access point (iTAP) .
155
L
Lettering work . . . . . . . . . . . . 206
Lifting axle. . . . . . . . . . . . . . . . 96
Lighting system . . . . . . . . . . . 144
Lights
Allocation plan . . . . . . . . . . . 199
Light bulbs . . . . . . . . . . . . . 200
Marker light. . . . . . . . . . . . . 200
Position lamp. . . . . . . . . . . . 200
Power / type . . . . . . . . . . . . 200
Side light . . . . . . . . . . . . . . 200
Load securing . . . . . . . . . . . . 122
Basic principles . . . . . . . . . . . 122
Tie-down points . . . . . . . . . . . 125
Loading . . . . . . . . . . . . . . . . . 42
Lubrication
Aluminium disc wheels . . . . . . . 190
Central locking for drop sides . . . 170
Central locking mechanism, front . 182
Drop side mounting . . . . . . . . . 168
Implementation instructions . . . . 164
Spindle support . . . . . . . . . . . 167
Tailgate mounting . . . . . . . . . . 171
Telescopic cylinder . . . . . . . . . 176
Tilting bearing . . . . . . . . . . . . 173
Towing ring. . . . . . . . . . . . . . 165
Underride protection lock. . . . . . 174
M
Maintenance . . . . . . . . . . . . . . 157
Adjusting / maintaining the brake linings
. . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Brake lining exchange . . . . . . . 193
Cleaning the compressed air filter 193
Cleaning the coupling heads . . . 195
Compressed air system . . . . . . 194
Drop side lifting spring . . . . . . . 181
Electric systems. . . . . . . . . . . 199
Greases . . . . . . . . . . . . . . . 164
Hydraulic system . . . . . . . . . . 175
Licence plate light "LED". . . . . . 204
Licence plate light "Standard . . . 204
Operating brake system . . . . . . 191
Position / marker lights. . . . . . . 205
Side light standard 24 V . . . . . . 202
Side marker lights. . . . . . . . . . 205
Tail light "24 V - standard". . . . . 201
Tail light "LED" . . . . . . . . . . . 203
Tailgate locking / unlocking mechanics
184
Tailgate tension spring. . . . . . . 183
Underride protection lock . . . . . 174
Maintenance brace. . . . . . . . . . 176
Maintenance intervals
Once-off maintenance work . . . . 160
Regular maintenance work . . . . 161
Marker lights . . . . . . . . . . . . . . 151
N
Number plate light . . . . . . . . . . 152
O
Operating
Body . . . . . . . . . . . . . . . . . 101
Chassis . . . . . . . . . . . . . . . . 59
Operating brake
use . . . . . . . . . . . . . . . . . . . 65
Operation . . . . . . . . . . . . . . . . . 37
P
Painted and powder-coated steel sur-
faces . . . . . . . . . . . . . . . . . . . 211
Parking warning signs. . . . . . . . 100

Keywords
7
Permitted weights / load distribution .
46
Personal protective equipment. . . 24
Physical foundations
Friction force . . . . . . . . . . . . 123
Plug connection
15-pin (ISO 12098-24V) . . . . . 147
7-pin (ISO 7638 - EBS) . . . . . . 148
ABS/EBS . . . . . . . . . . . . . . . 61
Plug connections (standard) . . . 145
Plug socket terminals
15-pin (ISO 12098-24V) . . . . . 147
7-pin (ISO 7638 - EBS) . . . . . . 148
Position lamps . . . . . . . . . . . . 151
Positioning the lifting device . . . 188
Product description
Three-way tipper HTK 19 t . . . . . 28
Versions / accessories . . . . . . . 31
Prohibitory signs / symbols . . . . . 25
Q
Quick coupling
Duo-Matic. . . . . . . . . . . . . . . 64
R
Rear drop side
- lock . . . . . . . . . . . . . . . . 120
unlocked . . . . . . . . . . . . . . 117
Reversing / operating lights. . . . 152
Roll-up tarpaulin . . . . . . . . . . . 131
CRAMARO. . . . . . . . . . . . . . 138
Horizontal version. . . . . . . . . . 132
Rubber hoses . . . . . . . . . . . . . 212
S
Safety . . . . . . . . . . . . . . . . . . . 9
Safety during tipping . . . . . . . . . 39
Safety instructions . . . . . . . . . . 22
Securing the cargo bed
Tilting bearings . . . . . . . . . . . 78
Securing the trailer . . . . . . . . . . 66
Service addresses . . . . . . . . . . 219
Side light . . . . . . . . . . . . . . . . 202
Signal words . . . . . . . . . . . . . . 22
Sources of danger . . . . . . . . 16, 17
Spare wheel . . . . . . . . . . . . . . 189
Specifications for HTK 19 t - three-way
tipper . . . . . . . . . . . . . . . . . . . 30
Spindle support identification . . . 35
Staff qualification . . . . . . . . . . . 16
Start of the journey . . . . . . . . . . 17
Steam jet . . . . . . . . . . . . . . . . 209
Steps
Pedestal with banister and folding lad-
der. . . . . . . . . . . . . . . . . . . 128
Pedestal with climbing steps. . . . 127
Stichwörter . . . . . . . . . . . . . . . . 5
Switch-off / securing mechanisms
Lift limitation . . . . . . . . . . . . . 179
T
Tail light
LED with side light . . . . . . . . . 150
Standard with side light 24 V . . . 149
Testing . . . . . . . . . . . . . . . . . 157
Tilting positional stability . . . . . . . 39
Toolbox . . . . . . . . . . . . . . . . . . 99
Traffic signs regarding height . . . . 25
Trailer
decommissioning . . . . . . . . . . 216
disposal . . . . . . . . . . . . . . . 216
securing . . . . . . . . . . . . . . . 188
Trailer information module (TIM) . 154
Trailer materials. . . . . . . . . . . . 210
Troubleshooting. . . . . . . . . . . . 217
Axles . . . . . . . . . . . . . . . . . 225
Braking system . . . . . . . . . . . 222
Electrical system . . . . . . . . . . 224
Loading / road handling . . . . . . 220
Rear drop side / side drop sides . 227
Troubleshooting guide. . . . . . . . 217
Tyre pressure / wheel profile. . . . 186
Tyre types . . . . . . . . . . . . . . . 185
U
Uncoupling . . . . . . . . . . . . . . . . 55
Unloading. . . . . . . . . . . . . . . . . 42
Use
Foreseeable misuse . . . . . . . . . 11

Keywords
8
Intended use . . . . . . . . . . . . . 10
V
Vehicle combination brake balancing
12
Vehicle identification number. . . . 34
VIN . . . . . . . . . . . . . . . . . . . . 34
W
Warning signs . . . . . . . . . . . . . 23
Warranty. . . . . . . . . . . . . . . . . 14
Waste plate (A-plate). . . . . . . . . 98
Wheel chocks
in front. . . . . . . . . . . . . . . . . 93
Retaining pin . . . . . . . . . . . . . 94
Use . . . . . . . . . . . . . . . . . . 92
Wheel nuts . . . . . . . . . . . . . . 186
Zugösen-Verbindung 235