Operator's Manual: HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010

Operator's manual
TELESCOPIC HANDLERS
Operator's manual
TELESCOPIC HANDLERS
HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010
24203 21 0
E01.15
EN
4000328140 E01.15 AUS
Downloaded from www.Manualslib.com manuals search engine

Telescopic handlers
2 4000328140 E01.15 AUS

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
CONTENTS
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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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
CONTENTS
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
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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
10.4 - Lubricating the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.5 - Lubricating the rear axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
11.1 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.2 - Travel axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.3 - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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
12.5 - 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
13.4.1 - Equipment hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.4.2 - Transmission hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.5 - Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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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
16.1 - 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
17.1 - 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
CONTENTS
I
INTERVENTION REGISTER
1 - Intervention register . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7
Operator's manual
8
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.
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.
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)
4000328140 E01.15 AUS 9

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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.
10 4000328140 E01.15 AUS

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4- HAULOTTE Services® contact details

HAULOTTE Services® contact details
HAULOTTE FRANCE
PARC DES LUMIERES HAULOTTE INDIA
HAULOTTE ITALIA
601 RUE NICEPHORE NIEPCE Unit No. 1205, 12th foor,Bhumiraj Costarica,
VIA LOMBARDIA 15
69800 SAINT-PRIEST Plot No. 1&2, Sector 18,
20098 SAN GIULIANO MILANESE
TECHNICAL Department: Palm Beach Road,
(MI)
+33 (0)820 200 089 Sanpada, Navi Mumbai- 400 705
TEL: +39 02 98 97 01
SPARE PARTS : +33 (0)820 205 344 Maharashtra, INDIA
FAX: +39 02 9897 01 25
FAX : +33 (0)4 72 88 01 43 Tel. : +91 22 66739531 to 35
E-mail : haulotteitalia@haulotte.com
E-mail : haulottefrance@haulotte.com E-mail : sray@haulotte.com
www.haulotte.it
www.haulotte.fr www.haulotte.in
HAULOTTE HUBARBEITSBÜHNEN GmbH HAULOTTE VOSTOK HAULOTTE DO BRASIL

AN DER MÖHLINHALLE 1 35, SVOBODY STREET AV. Tucunaré, 790
D-79189 BAD KROZINGEN-HAUSEN Bldg. 19 CEP: 06460-020 – TAMBORE
TEL : +49 (0) 7633 806 92-0 125362 MOSCOW BARUERI – SAO PAULO – BRASIL
FAX : +49 (0) 7633 806 92-18 RUSSIA TEL : +55 11 4196 4300
E.mail : haulotte@de.haulotte.com TEL/FAX : +7 495 221 53 02 / 03 FAX : +55 11 4196 4316
www.haulotte.de E.mail : info@haulottevostok.ru E.mail : haulotte@haulotte.com.br
www.haulotte-international.com www.haulotte.com.br
HAULOTTE IBERICA HAULOTTE MÉXICO, Sa de Cv

C/ARGENTINA N° 13 - P.I. LA GARENA HAULOTTE POLSKA Sp. Z.o.o. Calle 9 Este, Lote 18, Civac, Jiutepec,
28806 ALCALA DE HENARES UL. GRANICZNA 22 Morelos
MADRID 05-090
- RASZYN - JANKI CP 62500 Cuernavaca
TEL : +34 902 886 455 TEL : +48 22 720 08 80 México
TEL SAT : +34 902 886 444 FAX : +48 22 720 35 06 TEL : +52 77 7321 7923
FAX : +34 911 341 844 E-mail : FAX : +52 77 7516 8234
E.mail : iberica@haulotte.com haulottepolska@haulotte.com E-mail : haulotte.mexico@haulotte.com
www.haulotte.es www.haulotte.pl www.haulotte-international.com
HAULOTTE MIDDLE EAST FZE

HAULOTTE PORTUGAL HAULOTTE SINGAPORE Pte Ltd. PO BOX 293881
ESTRADA NACIONAL NUM. 10 No.26 CHANGI NORTH WAY, Dubaï Airport Free Zone
KM. 140 - LETRA K SINGAPORE 498812 DUBAÏ
2695 - 066 BOBADELA LRS Parts and service Hotline: United Arab Emirates
TEL : + 351 21 995 98 10 +65 6546 6150 TEL : +971 (0)4 299 77 35
FAX : + 351 21 995 98 19 FAX : +65 6536 3969 FAX : +971 (0) 4 299 60 28
E.mail : haulotteportugal@haulotte.com E-mail: haulotteasia@haulotte.com E-mail : haulottemiddle-
www.haulotte.es www.haulotte.sg east@haulotte.com
www.haulotte-international.com
HAULOTTE TRADING (SHANGHAI)
Co. Ltd. HAULOTTE ARGENTINA
HAULOTTE SCANDINAVIA AB #7 WORKSHOP Ruta Panamericana Km. 34,300
Taljegårdsgatan 12 No 191 HUA JIN ROAD (Ramal A Escobar)
431 53 Mölndal MIN HANG DISTRICT 1615 Gran Bourg
SWEDEN SHANGHAI 201108 CHINA (Provincia de Buenos Aires)
TEL : +46 31 744 32 90
Argentina
FAX : +46 31 744 32 99 TEL : +86 21 6442 6610 TEL.: +54 33 27 445991
E-mail : info@se.haulotte.com FAX : +86 21 6442 6619 FAX. +54 33 27 452191
spares@se.haulotte.com E-mail : E-mail : haulotteargentina@haulotte.com
www.haulotte.se haulotteshanghai@haulotte.com www.haulotte-international.com
www.haulotte.cn
HAULOTTE GROUP / BILJAX HAULOTTE GROUP
HAULOTTE UK Ltd 125 TAYLOR PARKWAY 1301 E PATRICK STREET
STAFFORD PARK 6 ARCHBOLD, OH 43502 – USA FREDERICK, MD 21701 – USA
TELFORD - SHROPSHIRE TF3 3AT TEL : +1 419 445 8915 TEL : +1 301 663 0852
TEL : +44 (0)1952 292753 FAX :+1 419 445 0367 FAX :+1 301 663 0572
FAX : + 44 (0)1952 292758 Toll free : +1 800 537 0540 Toll free : +1 800 537 0540
E.mail : salesuk@haulotte.com E.mail : sales@us.haulotte.com E.mail : sales@us.haulotte.com
www.haulotte.co.uk www.haulotte-usa.com www.haulotte-usa.com
HAULOTTE NETHERLANDS BV HAULOTTE AUSTRALIA PTY Ltd HAULOTTE CHILE

Koopvaardijweg 26 46 GREENS ROAD El Arroyo 840
4906 CV OOSTERHOUT - Nederland DANDENONG – VIC – 3175 Lampa (9380000)
TEL : +31 (0) 162 670 707 TEL : 1 300 207 683 Santiago (RM)
FAX : +31 (0) 162 670 710 FAX : +61 (0)3 9792 1011 TEL : + 562 2 3727630
E.mail :info@haulotte.nl E.mail : sales@haulotte.com.au E.mail : haulotte-chile@haulotte.com
l h l www.haulotte-chile.com
4000328140 E01.15 AUS 11

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12 4000328140 E01.15 AUS

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A - Safety precautions
Safety precautions A
1 - Recommendations
1.1 - OPERATOR'S MANUAL
This operators manual is specific to the HAULOTTE® products listed on the cover page of this
manual.. B
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®.
C
1.2 - SYMBOLS USED
Symbols are used to alert the operator to safety precautions or to highlight practical
Legend
information.
D
Symbol Meaning
Danger : Risk of injury or death (work safety)
Caution : Risk of material damage (work quality) E

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)

F
Cross-reference to another manual (see manual)
Cross-reference to repairs (contact HAULOTTE Services®)

G
N.B. : Additional technical information
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1.3 - LABEL COLORS
The potential dangers and any specific regulations are indicated around the product by labels
and identification plates.
The labels must be kept in good condition. Additional labels can be ordered from HAULOTTE Services®.
Familiarize yourself with the labels and their respective color codes.
Label color code
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
Label color code-For the Eurasian Customs Union and the Ukraine only
Labels Color Meaning
Red Prohibitions - Danger
Yellow Warning : Risk of material damage and/or minor injury
Blue Precaution
Blue Information
Other Additional technical information
14 4000328140 E01.15 AUS

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2 - Operation instructions A
It is preferable to operate the machine on flat, consolidated ground (tarmac, concrete, etc.).
2.1 - PROHIBITIONS B
• 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).
C
• 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.
D
• Never leave the hydraulic cylinders fully extended or retracted before switching off the machine, or
during an extended stop period.
2.2 - POTENTIAL RISKS
2.2.1 - Tip-over hazards

E
Never use an accessory without having checked
the HAULOTTE® accessory load capacity chart installed
on the telehandler.
F
• Do not exceed the rated lifting capacity.
• Check that the ground can support the machine. G
Do not drive at high speed with the boom raised.
When driving at high speed, use only front-wheel

H
steering (if the steering mode can be selected).
4000328140 E01.15 AUS 15

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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.
16 4000328140 E01.15 AUS

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• Maintain proper tire pressure at all times. Otherwise, the

machine could tip over.
A
B
Do not ballast the tires.
• Always wear the seat belt. C
D
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.
E
• Keep your seat belt fastened.
• Hold on tightly.
• Lean away from the point of impact.
F
Trying to escape from a tipping machine could result in death or serious injury.
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2.2.2 - Electrical hazards
• 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.
• Always check for power lines before raising the boom.
• 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..
Minimum safety distance

Electric voltage Minimum safety distance
Mètre Feet
0 - 300 V Avoid contact
300 V - 50 kV 3 10
50 - 200 kV 5 15
200 - 350 kV 6 20
350 - 500 kV 8 25
500 - 750 kV 11 35
750 - 1000 kV 14 45
N.B.-:-This table is applicable, except when the local regulations are more strict.
18 4000328140 E01.15 AUS

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Minimum safety distance - For AS standard only A
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2.2.3 - Travel hazards
• 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.
• 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).
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.
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2.2.4 - Load falling hazards A

Never suspend loads from the forks or from any other parts of the fork carriage.
Do not drill holes in the fork(s).

B
Do not heat or weld the forks.
The forks must be centred under the load and on the fork carriage and spaced apart as far as
possible.
• Do not use the machine to lift one or more people.
C
2.2.5 - Mechanical attachment locking device
• Ensure that the machine is placed on a firm and level surface.

E
• 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.

F
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.
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2.2.6 - Driving hazards on slopes
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.
• 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 put the machine in NEUTRAL while driving down a slope.
Do not park on a slope without having blocked the machine wheels.
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2.2.7 - Pinching and crushing hazards A

Stay clear of pinch points and rotating parts on the
handler.
Do not approach moving parts while the engine is

running.
C
Keep clear of the tires and the chassis or other steering
parts when manoeuvring the telehandler.
D
Keep clear of the boom.
E
Keep arms and hands clear of the attachment tilt
cylinder.
Keep hands and fingers clear of the fork carriage and the
forks.
F
Keep others away during operation.
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2.2.8 - Risk of falling
Enter the cab using the proper hand rails and the steps
provided.
Always maintain 3 points of contact when entering or
leaving the machine.
Never grab the control levers or the steering wheel when

mounting or dismounting the machine.
Never leave the machine until the complete shutdown

procedure has been performed.
Do not carry any passengers. Falling from the machine

may cause death or serious injury.
2.2.9 - Chemical hazards
Exhaust Fumes :
Do not run the engine in a place where there is a risk of build up of toxic gases.
Do not operate the machine in an enclosed area without proper ventilation. Sparks produced by the
electrical system or the engine exhaust can cause an explosion.
Flammable Fuel :
Do not fill the fuel tank or service the fuel system near a
naked flame, sparks or smoking material. Engine fuel is
flammable and can cause a fire and/or an explosion.
Hydraulic Fluid :
Do not attempt to repair or tighten any hydraulic hoses

or fittings while the engine is running or when the
hydraulic system is under pressure.
Do not use your hand to check for leaks, the pressurized

hydraulic fluid can penetrate the skin. Use a piece of
cardboard or paper instead. Wear gloves and goggles to
protect yourself from fluid splashes.
Areas with explosive atmospheres :
Before entering an explosive atmosphere (e.g. silo, etc.) and to avoid any risk of explosion, particulate
filter regeneration must be manually disabled ( Section C 3.5.9 - Left-hand control panel).
24 4000328140 E01.15 AUS

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B - Intervenor's responsibility
Intervenor's responsibility A
1 - Owner's (or hirer's) responsibility
The owner (or hirer) has the obligation to inform operators of the instructions contained in the Operator
Manual.
The owner (or hirer) has the obligation to renew all manuals or labels that are either missing or in bad
B
condition. Additional copies can be ordered from HAULOTTE Services®.
The owner (or hirer) is responsible for applying the local regulations regarding operation of the
machine.
2 - Employer's responsibility C
The employer has the obligation to issue a driving permit to the operator.
N.B.-:-In accordance with the regulation in the country where the machine is operating, the user must
be authorized to drive by the doctor of Labour Ministry.
Forbid anyone from operating the machine who is :

D
• Under the influence of drugs, alcohol, etc..
• subject to fits, loss of motor skills, dizziness, etc..
3 - Trainer's responsibility
E
The trainer must be qualified to provide training to operators in accordance with applicable local
regulations. The training must be given in an obstacle-free area until the trainee is considered
competent as defined by the training program undertaken.
4 - Operator's responsibility F
The operator must read and understand the contents of this manual and the labels affixed on the
machine.
The operator must inform the owner (or hirer) if the manual or any labels are missing or in poor
condition, and of any malfunction of the machine.
The operator may only operate the machine for the purpose intended by the manufacturer.
G
Only authorized and qualified operators may operate HAULOTTE® machines.
All operators must become familiar with and fully understand the emergency controls and how to
operate the machine in an emergency as a component of their formal operator training.
H
The operator has the obligation stop using the machine in the event of malfunction or safety problems
on the machine or in the work area and report the problem to his/her supervisor.
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B - Intervenor's responsibility
5 - Inspection and maintenance

The inspection and maintenance table below, identifies the role and the responsibilities of each party
in periodical machine maintenance..
If the machine is operated in a hostile environment or intensively, increase the frequency of maintenance.
Inspections and maintenance

Type of Reference
Frequency Person-in-charge Intervenor
intervention document
Before each delivery
Pre-delivery Qualified HAULOTTE
of sold, hired or Owner (or hirer) Operator's manual
inspection Services® technician
resold equipment
Before operation or Operator's manual
Pre-operation
when the operator Operator Operator Section C - Pre-
inspection
changes operation and controls
Operator's manual
Periodical At the specified On-site technician or
preventive intervals (250 hours Owner (or hirer) qualified HAULOTTE Section H -
maintenance or 1 year) Services® technician Lubrication and
maintenance
Organization or
2 times a year or at technician approved by
the latest 6 months the employer or by the Operator's manual
after the last intermediary of Section H -
Periodical visit Owner (or hirer)
periodic visit, and HAULOTTE Services® Lubrication and
according to the in accordance with the maintenance
local regulations HAULOTTE Services®
contract
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C - Pre-operation and controls
Pre-operation and controls A

1 - Checks before use
Each day and before the beginning of a new work period and on each change of operator, the machine
must be subjected to a visual inspection and a complete functional test.
Any repairs required must be performed before the machine is used, its correct operation depends on it.
B
1.1 - GENERAL MECHANICAL FUNCTIONS
For all the following checks, ensure that the machine is switched off.
Check the following points :
• The presence of the identification plate, labels and operator manual :
C
• Their state of cleanliness and visibility.
• Visual state of the machine :

• Absence of leaks (battery acid, hydraulic oil, etc.). Absence of foreign objects on all surfaces. Call the staff in
charge of the maintenance if necessary. D
• No missing or loose parts (bolts, nuts, connectors, cables, etc.).
• Absence of cracks, broken parts, damaged paint. No deformations or other anomalies on the structure’s parts.
Example
• State of the structure's parts : Chassis, boom, cab, tool holder, attachments : G
• No cracks, damaged paint.
• No distortion in metal components or visible damage.
• No foreign objects at the ends of the booms, between arms and link parts.
• Presence of guardrails. H
• Presence and check the original position of the driving station system.
• Cylinders’ state :
• No leaks.
• No rust and abrasions on the cylinder rod. I
• Absence of foreign objects on all surfaces.
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• Steering system's state : axles, wheels and tyres :

• No cracks, distortions, damaged paint or other faults
• No missing or loose bolts.

• Condition of the tyres (cuts, excessive wear, etc.).
• State of the rotation systems (Cage option, pulleys, ...)

• No excessive clearance.
• Greasing and lubrication according to the maintenance plan.
• State of the control boxes :

• No damage.
• Back to neutral for all joysticks, selectors, etc..
• Presence and readablility of the control box labels.
• Movement, safety limit switches :

• No damage.
• The state and connection of the electric wires and cables :

• No damage, wear marks or other faults.
• No contact between connectors.
• State of the tanks :

• No leaks.

• Hydraulic oil level : Top up the oil level, if necessary (Machine in transport position).
• Sufficient fuel level.
• Sufficient engine oil.
• Coolant level.
• State of the hydraulic pump :

• No leaks.
• Hydraulic oil filter.
28 4000328140 E01.15 AUS

Telescopic handlers
2 - Pre-operation checks and inspection A

N.B.-:-Perform all required maintenance work before operating the unit.
Use extreme caution when checking parts that are difficult to reach. Use an approved ladder. "Failure" to
comply with these instructions could result in death or serious injury.
B
Increase in periodical inspections : Depending on the condition of certain critical components after 5000
hours, the maintenance staff may have to reduce the interval between periodical inspections and
maintenance. If the decision is made not to replace a part, the part concerned must be recorded in the
inspection schedule.
Inspect the following items : C

• The condition of structural parts: chassis, boom, cab, shield, attachments.
• Absence of cracks, broken parts, damaged paint.
• No distortion in metal components or visible damage.
• Cylinders :
• Absence of foreign objects at the ends of boom/attachments.
D
• No leaks : Please refer to paragraph 7.2.2 ( Section H - Lubrication and maintenance).
• No rust and abrasions on the cylinder rod.

• Steering system : Wheels, Axles, Brake and Tyres :

E
• No cracks, distortions, damaged paint or other faults.
• Condition of the tyres (cuts, excessive wear, etc.)

• Condition of the pulley system : F
• Grease the extension system if necessary.
• A walk-around inspection must be performed at the beginning of each work shift or at each change
of operator.
G
• Ensure that all safety labels are legible and in place. Clean or replace if necessary. ( Section C 2
- Labels).
• Before removing the filler plugs, wipe all dirt or grease away from the ports. Dirt entering these ports
can severely reduce component life.
• When adding fluids, determine the correct type and frequency ( Section H - Lubrication and
H
maintenance).
4000328140 E01.15 AUS 29

Telescopic handlers
Major Component Location Diagram
1
2 22
3
21
4
5 20
6
7 19
9 18
10
11
12 17
13
14 16
15 15
Begin the walk-around inspection at item 1, as indicated below.
Continue to the right (anticlockwise, when viewed from above) checking each part in sequence.
N.B.-:-For each component, ensure that there are no loose or missing parts, that the components are
securely fastened and that there are no visible leaks or excessive wear in addition to any other criteria
mentioned. Inspect all structural elements including the attachment for cracks, excessive corrosion and
other damage.
30 4000328140 E01.15 AUS

Telescopic handlers
1. Jib cylinders, lifting, telescoping, compensation output and input, cases :

• Pins secure, hydraulic hoses in good condition, no leaks.
A
• Check the state of the extension booms wear pads.
2. Left-hand stabiliser and detector : Pins secure, hydraulic hoses in good condition, no leaks (For
HTL4010 only).
3. Front axle : Steering cylinders in good condition, no leaks; joint pins and flanges secured tightly,
hydraulic hoses in good condition, no leaks.
B
4. Wheel/Tyre assembly : No loose or missing wheel nuts, inflated correctly. Check the state of the
tyres and their level of wear.
5. Front headlights : Clean, in good condition and working properly.
6.
7.
Mirrors : Clean, in good condition and working properly.
Fuel tank : Check the fuel level, top up as required, the filler cap is securely fastened. C
8. Front work lights (optional) : Clean, in good condition and working properly.
9. Cab and electrical circuit :
• The cab is an approved protective cab in accordance with FOPS and ROPS standards: Check
the FOPS/ROPS label in the cab.
• Check alarms: eg. engage the reverse drive and sound the horn.
• General appearance, no visible damage, capacity charts and Operator & Safety manual loca-
D
ted in the manual holder.
• Window glass in good condition and clean.
• Gauges, switches, joystick, parking brake pedals and horn all operational.
• Check the seat belt for damage, replace it if it is frayed or the webbing is cut, the buckles are
damaged or the mounting hardware is loose or damaged.
• Check for the presence of the load and capacity charts.
E
10. Hydraulic oil tank : Recommended fluid level on the level gauge (the oil must be cold) ; filler/
breather cap securely in place and in working order. Check for hydraulic leaks around the reser-
voir.
11. Rear work lights (optional) : Clean, in good condition and working properly.
F
13. Rear axle : Steering cylinders in good condition, no leaks, pivot pins secure, hydraulic hoses in
good condition, no leaks.
14. Left axle locking cylinder (Option) : Cylinders in good condition, no leaks and securely fastened.
15.
16.
Stop and reverse lights : Clean, in good condition and working properly.
Right axle locking cylinder(Option) : Cylinders in good condition, no leaks and securely fastened.
G
4000328140 E01.15 AUS 31

Telescopic handlers
18. Engine compartment :

• Engine crankcase and radiator : Check the levels and top up as required. Check that the ra-
diator is clean.
• Drive belt : check their condition, adjust and/or replace as required.
• Air filter blockage indicator : Check if it is clogged. Replace the element as required.
• Engine canopy properly secured and locked.
• Diesel particulate filter : Check the connection of all the probes. Ensure that the particulate filter
has not been damaged (impact, deterioration, etc.). (1)
• Engine calculator : Check the connection of the electrical connectors. Ensure that the engine
calculator has not been damaged (impact,deterioration, etc.). (2)
19. Mirrors : Clean, in good condition and working properly.
21. Tilt correction cylinder : Pins secure, hydraulic hoses in good condition, no leaks (on HTL3510
and HTL3010 only).
22. Right-hand stabiliser and contactor : Pins secure, hydraulic hoses in good condition, no leaks
(For HTL4010 only).
23. Attachment : Correctly installed( Section E - Attachments).
Check the operation of :

• All the Telehandler boom and chassis side tilt movement.
• All the functions related to the travel of the Telehandler.
• The Telehandler braking system.
(1.) For machines fitted with engine PERKINS 854E-34TA only

(2.) For machines fitted with engine PERKINS 854E-34TA only
32 4000328140 E01.15 AUS

Telescopic handlers
3 - Safety stickers A
Ensure that all stickers and appropriate capacity charts are legible and in place. Clean or replace if
necessary.
3.1 - RED LABELS
B
The red labels indicate a potentially fatal danger.
Common labels - AS standard
R27 R28 R13 C
D
R29 R42
It is prohibited to use attachments

without appropriate load charts.
E
Interdiction d’utiliser les accessoires sans
leurs abaques de charges correspondants.
Prohibido utilizar accesorios

sin el abaco de carga correspondiente.
307P223840B
4000328140 E01.15 AUS 33

Telescopic handlers
Specific labels HTL 4010 - AS standard
R9 R10
6400 daN
7.5 daN/cm²
6100 daN
4.2 daN/cm²
307P228350 a 307P228360 a
R9
6200 daN
4.6 daN/cm²
307P228710 a
R9
6200 daN
4.6 daN/cm²
307P228710 a
34 4000328140 E01.15 AUS

Telescopic handlers
3.2 - YELLOW LABELS A

The yellow labels indicate a risk of material damage and/or minor injury.
J3 J19 J21 J12

B
C
J4 J20 J31
J32 J45 J45

E
CAUTION C
PISAE J C
PISAE J
-4
A
-4
A
DIESEL LOW SULFUR OR ULTRA-LOW SULFUR /

DIESEL À FAIBLE OU TRÈS FAIBLE TENEUR EN SOUFRE / 10W-40 10W-40
GASÓLEO BAJO EN AZUFRE O ULTRA-BAJO EN AZUFRE /
DIESEL A BASSO TENORE DI ZOLFO O A BASSISSIMO TENORE DI ZOLFO /
15W-40 5W-40
F
A
EC
A
DIESELKRATSTOFF MIT NIEDRIGEM ODER EXTREM NIEDRIGEM SCHWEFELGEHALT

EC
9
A E
9
EU (EN 590) A E
307P232480 b
US (ASTM D975-91 class 2D)

4000019700 a
4000318680 a
4000328140 E01.15 AUS 35

Telescopic handlers
Specific labels HTL4010 - HTL 3510 - HTL 3010 - AS standard
J18
Specific labels, optional - AS standard
J29 J30
36 4000328140 E01.15 AUS

Telescopic handlers
3.3 - OTHER LABELS A

The other labels provide additional technical information.
A43 A46 A49

B
FU110 / 7,5A FU102 / 10A
FU101 / 15A
KM101
D 107
FU111 / 7,5A FU103 / 10A
KA104
FU112 / 7,5A FU106 / 10A
KA160
FU117 / 7,5A FU109 / 10A
FU107 / 15A
D 106
KA680 FU191 / 20A FU113 / 7,5A
KA181
C
FU187 / 15A FU114 / 30A
KA681
A95 A47 A50
FU108 / 15A
FU140 / 10A FU180 / 30A
KA110
FU100 / 20A
KA189 FU181 / 5A
FU161 / 20A FU182 / 20A

7814 870 KA620
D 101
FU620 / 10A FU183 / 10A
LWA KA187
20
KA380 FU195 / 30A FU184 / 10A
104
FU490 / 1A FU189 / 30A
dB
0 b
633
P22
307
A44 A48 A51 A39 A90

D
307P228770 a
307P223480 a
LWA
A45 105 dB
307P216800 a
307P220800 b
E
A4 A3 A73
4010 HAULOTTE GROUP, La Péronnière, BP9, 42152, L'Horme - France
F
307P228370 a
Type
Serial No
Year of manufacture
Maximum Capacity
Unladden Mass
kg
kg HTL 4010
Maximum load on front axle kg
Maximum load on rear axle kg

Gross combined weight rating kg
Gross Vehicle Mass kg
Equipment
Power source kW
Gradeability %
Wind speed max m/s
Slope operation max degree
G
Country of manufacture
Design Standard Compliance - AS1418.19 307P230120 c
A42
réf. 194P287760
réf. 194P273050
réf. 194P306620
réf. 194P306610 = 4T 307P229160A 107P334450
68° F
F 10
H
10 60°
60° E
E 9
9 50° D
T
50° D 8
C
8
C
40°
L
7 B
7 40° B
H
6 A
6 A 30°
Kg
30° 5
00
30
Kg
4
00
Kg
4
35
00
20°
40
4
20°
0
3
1200Kg
1500Kg
2000Kg
2500Kg
300Kg
500Kg
850Kg
3
2 10°
1200Kg
1500Kg
1800Kg
2000Kg
2500Kg
3000Kg
3500Kg
4000Kg
1
2 10° 0.5 m
0.5 m 1
0
1
0m
0°
0m 0° -2° 5 3 1 0m
0m 7.2 6.1 4.2 3.7 2.2 1.7

5 4 3 2 1 EN-1459 annexe B
7.2 6.1 1.9 307P228860a rp
4000328140 E01.15 AUS 37

Telescopic handlers
A4 A3 A73
307P228760 a
Type
Serial No
Year of manufacture
Maximum Capacity
Unladden Mass
kg
kg HTL 3510

Equipment
Power source kW
Gradeability %
Wind speed max m/s
A42 307P229270A 107P334460
HTL 3510
réf. 194P287760
réf. 194P273050
réf. 194P306620
réf. 194P306610 = 3,5T
EN-1459 annexe B
65° F
10 60°
E
9
50° D
8 C
7 40° B
6 A
30°
5
4
20°
3
2 10°
2500 kg
3500 kg
2000 kg
1500 kg
1200 kg
850 kg
500 kg
600 kg
0.5 m
1
0 m 0°
-2° 2 1 0m
6.8 4.8 3.5 2.1
7.2 5.8 4.2 2.5 307P228870a
A4 A3 A73
4000060780 a
Type
Serial No
Year of manufacture
Maximum Capacity
Unladden Mass
kg
kg HTL 3010

Equipment
Power source kW
Gradeability %
Wind speed max m/s
A42 $
)RUNV31
HTL 3010 3

3
3
0D[LPXPFDSNJ
65° F
10 60°
E
9
50° D
8 C
7 40° B
6 A
30°
5
4
20°
3
2 10°
2500 kg
2990 kg
2000 kg
1500 kg
1000 kg
800 kg
500 kg
0.6 m
1
0 m 0°
-2° 2 1 0m
4.8 3.5 2.1 fork load centre 600mm
7.2 5.8 4.2 2.5
Standard used AS1418.19 D
Specific labels, optional - AS standard
A8
38 4000328140 E01.15 AUS

Telescopic handlers
3.4 - IDENTIFICATION A
Locations - HTL 4010 - HTL 3510 - HTL 3010 - Standards CE and AS
R28
B
A44
A95
R29
A16
C
A4
R13
R10
D
R27
A43
A76
A42
A39
A75
A7
J31
A6
E
A30
A95
J21
F
J3
J3
J19
J21
J21
J21
J20
A30
A95
G
A98
A96
A45
A10
A5
H
J4
J21
A47
J21
A48
A50
A51
A49
A46
R10
A41
R13
A4
I
J21
R29
A16
4000328140 E01.15 AUS 39

40
C
Telescopic handlers
4000328140
VUE COTE CABINE /
CAB VIEW
- Pre-operation and controls
E01.15
A94
VUE COTE MOTEUR /

ENGINE VIEW
COMPARTIMENT MOTEUR / COMPARTIMENT CABINE /

ENGINE COMPARTMENT CAB COMPARTMENT
AUS
Telescopic handlers
Common labels - HTL4010 - HTL3510 - HTL3010 - AS standard A

Color Marking Description Quantity HTL4010 HTL3510 HTL3010
Other A3 Identification plate 1 AS standard : 307P230120
Other A4 Machine name logo 2 4000096280 4000085110 400010080
Other A5 Label HAULOTTE® 1 307P224740
Other
Other
Other
A6
A7
A10
Label HAULOTTE®
Read the operation manual
Noise emission level
1
1
1
307P228770
307P220740
307P223480
B
Other A16 Yellow and black adhesive tape 1 2421808660
Other A30 Slings attached 4 307P220830
Other A38 Terminal fuses 1 4000023340
Other
Other
Other
A39
A40
A41
Joystick
Battery / Battery isolation switch
Indicator
1
1
1
AS standard : 4000064510
307P220930
307P221070
C
Other A42 Load capacity chart 1 307P232400 307P232440 4000059310
Other A43 Wear the seat belt 1 307P220780
Other A44 25 km/h 1 307P216110
Other A45 Angle sensor 1 307P220900
Other
Other
A46
A47
Telescoping key A
Telescoping key B
1
1
307P222610
307P222620 D
Other A48 Telescoping key C 1 307P222630
Other A49 Telescoping key D 1 307P222640
Other A50 Telescoping key E 1 307P222650
Other A51 Telescoping key F 1 307P222660
Other
Other
Other
A73
A75
A76
Capacity chart booklet
"Safe Use"
Electrocution
1
1
1
107P345780 107P347640 4000059330
AS standard only : 307P232430
AS standard only : 307P226440
E
Other A90 Anchor points on the machine 4 307P216800
Other A96 Read the operation manual 1 3078143680
Do not place your foot on the
Yellow J3 2 307P220820
cover
Yellow
Yellow
Yellow
J4
J12
J18
Ground for welding
Danger of Heat burns
Tyre pressure
1
1
4
307P221090
307P223710
307P220880
F
Yellow J19 Fuel tank 1 307P220920
Yellow J20 Hydraulic oil 1 307P220870
For HTL
Yellow J21 Lubrication

4010 and
HTL 3010 :
14
307P220840 G
For HTL
3510 : 12
Yellow J31 Engine cover 1 307P223830
Indication - Explanation - LOW
Yellow J32
SULFUR
(For machines fitted with engine
PERKINS 854E-34TA or
1 307P232480 H
KOHLER KDI 3404 TCR only)
Oil CJ-4
Yellow J45 (For machines fitted with engine 1 4000019700
PERKINS 854E-34TA only)
Yellow J45
Oil CJ-4
(For machines fitted with engine
KOHLER KDI 3404 TCR only)
1 4000318680 I
Red R9 Maximum effort on wheel 4 307P228350 307P228710 307P228710
Maximum effort on the
Red R10 2 307P228360
stabilizers
4000328140 E01.15 AUS 41

Telescopic handlers
Color Marking Description Quantity HTL4010 HTL3510 HTL3010

Red R13 Risk of crushed feet 2 307P220890
Red R27 Danger of electrocution 1 307P220770
Red R28 Cylinder locking 1 307P220860
Do not mount on the forks during
Red R29 2 307P221950
elevation
Red R42 Label book 1 307P223840
42 4000328140 E01.15 AUS

Telescopic handlers
Load capacity chart - HTL4010 - AS standard A

Color Marking Description Quantity HTL 4010
Other A42 Load capacity chart 1 307P232400
Other A73 Load capacity chart - Book 1 107P345780
Other Load capacity chart - Cover book 1 307P232130
Other
Other
Other
Load capacity chart - Forks on wheels
Load capacity chart - Forks on stabilisers
Load capacity chart - Drift side offset - On wheels
1
1
1
307P230150
307P230160
307P230170
B
Other Load capacity chart - Drift side offset - On stabilisers 1 307P230180
Other Load capacity chart - Bucket - On wheels 1 307P232010
Other Load capacity chart - Bucket - On stabilisers 1 307P232020
Other
Other
Other
Load capacity chart - Jib crane 1 m, 3 T - On wheels
Load capacity chart - Jib crane 1 m, 3 T - On stabilisers
Load capacity chart - Jib crane 2 m, 2 T - On wheels
1
1
1
307P232030
307P232040
4000027670
C
Other Load capacity chart - Jib crane 2 m, 3 T - On stabilisers 1 4000027680
Other Load capacity chart - Boom 2,5 m - On wheels 1 307P232050
Other Load capacity chart - Boom 2,5 m - On stabilisers 1 307P232060
Other Load capacity chart - Boom 4 m - On wheels 1 307P232070
Other
Other
Load capacity chart - Boom 4 m - On stabilisers
Load capacity chart - Winch 1,2 T - On wheels
1
1
307P232080
307P232110 D
Other Load capacity chart - Winch 1,2 T - On stabilisers 1 307P232120
Other Load capacity chart - Winch 2,4 T - On wheels 1 307P232090
Other Load capacity chart - Winch 2,4 T - On stabilisers 1 307P232100
Load capacity chart - HTL3510 - AS standard

Color Marking Description Quantity HTL 3510 E
Other A42 Load capacity chart 1 307P232440
Other A73 Load capacity chart - Book 1 107P347640
Other Load capacity chart - Cover book 1 307P232330
Other Load capacity chart - Forks 1 307P231970
Other
Other
Other
Load capacity chart - Drift side offset
Load capacity chart - Bucket
Load capacity chart - Jib crane 1 m, 3 T
1
1
1
307P231980
307P232270
307P232280
F
Other Load capacity chart - Jib crane 1 m, 2,9 T 1
Other Load capacity chart - Hook 1 m, 2,9 T 1
Other Load capacity chart - Jib crane 2 m, 2 T 1 4000023820
Other Load capacity chart - Boom 2,5 m 1 307P232290
Other
Other
Load capacity chart - Boom 4 m
Load capacity chart - Winch 1,2 T
1
1
307P232300
307P232320
G
Other Load capacity chart - Winch 2,4 T 1 307P232310
4000328140 E01.15 AUS 43

Telescopic handlers
Load capacity chart - HTL3010 - AS standard

Color Marking Description Quantity HTL 3010
Other A42 Load capacity chart 1 4000059310
Other A73 Load capacity chart - Book 1 4000059330
Other Load capacity chart - Cover book 1 4000059410
Other Load capacity chart - Forks 1 4000059340
Other Load capacity chart - Drift side offset 1 4000059350
Other Load capacity chart - Bucket 1 4000059360
Other Load capacity chart - Jib crane 1 m, 3 T 1
Other Load capacity chart - Jib crane 1 m, 2,9 T 1 4000062220
Other Load capacity chart - Hook 1 m, 2,9 T 1 4000062200
Other Load capacity chart - Jib crane 2 m, 2 T 1 4000059420
Other Load capacity chart - Boom 2,5 m 1 4000059370
Other Load capacity chart - Boom 4 m 1 4000059380
Other Load capacity chart - Winch 1,2 T 1 4000059400
Other Load capacity chart - Winch 2,4 T 1 4000059390
44 4000328140 E01.15 AUS

Telescopic handlers
3.5 - OPERATOR'S CAB A

The machine is equipped with an enclosed FOPS/ROPS cab.
Never use the machine unless the overhead guards and the cab structure are in good condition. Any
modifications to this machine must be approved in writting by HAULOTTE® to ensure complience with
FOPS/ROPS certification for this cab/machine configuration. The cab cannot be repaired if it is damaged,
It must be replaced. B
3.5.1 - Controls
General view
C133 C124 C128

C131 C
C134 C129 D
C150 C127
C120 C149
C122
C121
C141
C132
E
C125 C153
C142
C123
C126
F
C130
C102
C135
H
4000328140 E01.15 AUS 45

Telescopic handlers
Description of the components

Marking Description
C120 Warning lights
C121 Parking brake
C122 Brake pedal /Inching : The further the pedal is pressed, the slower the travel speed
C123 Accelerator pedal : Press on the pedal to increase the engine speed and the hydraulic fluid flow
C124 Steering column adjuster : Section C 2.5.3 - Steering column
C125 Transmission control lever : Section C 2.5.3 - Steering column
C126 Headlight, indicator and buzzer control
Indicator and control box : Controls and indicates certain machine functions. Displays engine
C127
speed. Section C 2.5.7 - Instrument/control panel
C128 Fuel gauge : Indicates fuel level in tank
C129 Engine temperature gauge
C130 Joystick : Section C 2.5.8 - Joystick
C131 Load moment indicator display : Section C 2.5.10 - Load moment indicator display
C132 Heating and air-conditioning control
C133 Adjustable air vents: Individual controllable
C134 Air louvers: Individual adjustable
C102 Dumping
C135 Car radio
C141 Road mode
C142 Rear-axle steering
C149 Ignition key
C150 Fog lights
C153 Windscreen washer
N.B.-:-The functions are described for the entire range. Refer to the machine model to identify the
controls and functions indicators.
46 4000328140 E01.15 AUS

Telescopic handlers
3.5.2 - Pedals A
General view
P163
B
P164
D
Pedals
Marking Description Function
P163
P164
Accelerator
Brake
Pedal for increasing the engine speed
Machine braking
E
Inching : Slow approach
4000328140 E01.15 AUS 47

Telescopic handlers
3.5.3 - Steering column
General view
I
II
P165
Left-hand control lever

Speed selection :
• Neutral
• Slow speed : Selector in position I
• Fast speed : Selector in position II
Travel direction selection :
P165 Gear and movement direction control
• Forward drive : Pull the lever backwards and then push it
upwards
• Neutral
• Reverse drive : Pull the lever backwards and then pull it
downwards
Forward and reverse can be selected while in slow or fast speed.

A sudden change of direction could destabilise the machine and/or cause the load to tip over or fall.
When reverse drive is activated, a audible sound warns that the machine is in reversing mode and warns
of potential danger anyone present in the manoeuvring area.
Reverse mode of travel should only be selected whilst the machine is stationary.
48 4000328140 E01.15 AUS

Telescopic handlers
General view A
P167
P168
P166
B
P169
D
Right-hand control lever
Left-hand steering : Raise the lever
P166
P167
Turn signals/Direction indicators
Sidelights
Right-hand steering : Lower the lever
On : Turn clockwise
E
Off : Turn anti - clockwise (ACW)
On : Turn clockwise
P168 Headlights
Off : Turn anti - clockwise (ACW)
On : Push forward
P169 Full beam headlights Off : Pull backward
Flashing the lights : Pull backward in short bursts F
3.5.3.1 - Steering column adjustment
Bring the Telehandler to a complete stop and shutdown the engine before adjusting the steering column.
A sudden change of direction could destabilise the machine and/or cause the load to tip over or fall.
"Failure" to comply with these instructions could result in death or serious injury.
G
Adjust the steering column as follows :
• Push the lever down to release the steering column.
• Move the steering wheel to the required position.
• Lock the steering column by pulling the lever up. H
4000328140 E01.15 AUS 49

Telescopic handlers
3.5.4 - Operator's seat
General view
P175
P171
P170 P174
P172
Before starting the engine, adjust the seat as follows to place the seat in an appropriate and
comfortable position :
• Move forward/backward : Use the handle ( P170 ) to move the seat forward and backward.
• Height : Use knob ( P171 ) to adjust the seat height.
• Suspension : Use the know ( P172 ) to adjust the suspension to the appropriate weight :
• In the green zone : Suspension is adapted to the operator's weight.
• In the red zone : The suspension is not adapted to the operator's weight.
• Backrest : Use the button ( P174 ) to adjust the backrest angle.
• Seat belt : Always fasten the seat belt ( P175 ) when operating the machine.
50 4000328140 E01.15 AUS

Telescopic handlers
3.5.5 - Heating and ventilation A

The cab is equipped with a heater that is also used for de misting the windscreen.
The air is circulated via a two-speed fan. To activate the fan, press the heating fan
switch ( P203 ) on the side instrument panel.
Adjust the heating temperature using the knob under the driver's seat.
Adjust the air flow using the air locks and round vents.
B
Heating and ventilation
E
Do not operate the Telehandler for an extended period without ventilating the cab via the ventilation
system.
Always ensure proper ventilation. F

A lack of proper ventilation in the cab during use can lead to driver tiredness (oxygen depravation).
3.5.6 - Air-conditioning(Optional)
To activate the air conditioning, operate the switch ( P207 ) located on the lateral control
console. G
The heating must be off when the air conditioning is on.
This equipment should not be started before starting the thermal engine.
H
Do not start the Telehandler engine while the air conditioning is switched on.
Adjust the fan speed.

Adjust the air flow using the air locks and round vents.
I
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Telescopic handlers
3.5.7 - Instrument/control panel
P198
P221 P223
P222
P199
P214
P215 P213
P200
P207
P204 P203
P205
P201 P208 P209
52 4000328140 E01.15 AUS

Telescopic handlers
Instrument/control panel A
Exclusion key in fork/winch mode Folds the machine in case of anti-tipping alarm : Rotate to
(Option) right and hold
'Enable Switch' selector in platform Control of the platform from the cab : Rotate to right and
P198
mode (Option)
Emergency pump in platform mode
(Option)
hold
Operation of the emergency pump : Rotate to right and hold
B
Position 0 : Machine shutdown
P199 3-position ignition key Position 1 : Ignition
Position 2 : Starter
Fork position : Center
P221 Fork/Winch/Platform Selector (Option) Winch position : Rotate to left
Aerial lift position : Turn right
C
Radio-control selector / Cab selector Radio-control position : Rotate to left
P222
(Option) Cab position : Turn right
Pulled out (activated) : Contact closed ON
P223 Emergency stop button (Option)
Pushed down (deactivated) : Contact open OFF
4000328140 E01.15 AUS 53

Telescopic handlers
Display
General view
Display
Service counter (when power is
Number of hours to next service
switched on)
P176 Engine revs indicator graduated from 0 to 3100 tr/min (3100
Engine tachometer with hour meter RPM) 1
Vehicle speed (Km/h)
P178 Engine temperature indicator Flashing : Coolant temperature 2
P179 Fuel level gauge Flashing : Low fuel level
P180 Battery LED On : Battery charge problem
P182 Parking brake defect LED On : Parking brake fault
P183 Hydraulic oil temperature indicator On : Hydraulic oil temperature too high
P185 Steering indicator Flashing : Left-hand or right-hand steering activated
P186 Headlight indicator On : Headlights on
P187 Neutral LED On : Drive in neutral position
P188 Engine pre-heating LED On : Engine pre-heating
P189 Hydraulic oil filter LED On : Hydraulic oil filter clogged
P190 Service brake fault LED On : Service brake fault or parking brake engaged
Flashing : One or more faults detected and/or active OR
P191 Machine fault indicator
machine maintenance to be performed 3
P192 Rear axle alignment LED On : Rear wheels aligned
On : Activated
P193 LED floating(Option)
Flashing : Floating lift selected but not validated
P194 Side clearance light LED On : Side lights on
P195 Seat occupied LED On : Seat presence not detected
On : Speed 2 engaged
P225 Drive speed 2 indicator 4
Flashing : High speed requested but not validated
On : Automatic or manual (forced) regeneration of the
particulate filter is required 5
Diesel particulate filter regeneration On + P229 Flashing : Manual (forced) regeneration of the
P226 indicator (For machines fitted with
engine PERKINS 854E-34TA only) particulate filter is required 6
On + P229 Flashing + 230 On : Necesary change of diesel
particulate filter 7
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Telescopic handlers
Marking Description Function A

Particulate filter regeneration disabled
P227 indicator (For machines fitted with On : Automatic particulate filter regeneration disabled
engine PERKINS 854E-34TA only)
High exhaust gas temperature indicator
P228 (HEST) (For machines fitted with On : Particulate filter regeneration in progress
engine PERKINS 854E-34TA only)
On : Drive motor faulty OR machine maintenance to be
B
performed
P229 Engine warning
5 flashes when switched on : machine maintenance to be
performed in 20 h maximum
P230 Engine shutdown On : Serious engine fault
P231
Fault codes 8
Machine counters (hour or service)
One or more faults detected and/or active 3
Total machine running hours
Number of hours to next service
C
In case of machine fault, each press on the button scrolls
through the fault codes
P232 Navigation button
In the absence of machine fault, each press on the button
navigates between the hour counter and the service counter
1
D
: Do not exceed 3100 tr/min (3100 rpm). Do not run the engine speed into the red zone.
2
: Service the machine as set out in this manual ( Section H - Lubrication and
maintenance).
3
: The (P191) indicator flashes to indicate an internal malfunction.
When the machine switches downgraded mode, certain movements can be limited or
E
prohibited to safeguard the operator's well being ( Section H 21 - Troubleshooting).
4
: Condition for prohibiting action : Extended boom or active float option or service brake
pressure fault.
5 : The level of clogging of the particulate filter requires regeneration. Disabled mode must be
deactivated rapidly, as soon as the environment allows it (outside areas with explosive
F
atmosphere).
6 : High level of particulate filter clogging.
7
: The particulate filter is clogged.
8
: Description of fault codes : Section H 21 - Troubleshooting.
G
4000328140 E01.15 AUS 55

Telescopic handlers
Right-hand control panel

General view
P215 P213 P214

P200
P204 P203 P207
P201 P208 P209 P205
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Telescopic handlers
Right-hand control panel A

Load levelling system (on HTL 3010 and HTL 3510 (HTL
P200 Chassis leveling switch
7732) only)
P201
Rear axle selection
Synchronised axle
B
Front steer wheels
Steering mode 1
Crab mode axle

P203 Heating/Ventilation switch Ventilation - 2 speeds
P204 Windscreen wiper switch

Activated : Press top of switch downwards
Deactivated : Press bottom of switch downwards
C
Windscreen washer : Press bottom of switch downward fully
On : Press top of switch downwards
P205 Work light switch (Option)
Off : Press bottom of switch downwards
P207 Air-conditioning switch (Option)
P208 Left stabiliser switch

To lower left stabiliser : Press bottom of switch downwards
To raise the left stabiliser : Press top of switch downwards
D
Right stabiliser lowering : Press bottom of switch
P209 Right stabiliser switch downwards
Right stabiliser lifting : Press top of switch downwards
P213
P214
Beacon switch
Parking brake switch 2

E
P215 Road mode selection switch
The stabilisers only increase stability and load capabilities if they are used correctly. Using stabilisers on
soft surfaces can cause the machine to tip over which cab result in serious injury. Always make sure that
F
the surface on which the machine operates, is capable of supporting the combined weight of the machine
and the load.
Stabiliser switches ( P208 ) and ( P209 ) are equipped with a warning light. A stabiliser can only be moved
if this indicator is lighted. If this indicator is off, retract and lower the telescopic arm until the indicator
lights up in order to move the stabiliser.
G
4000328140 E01.15 AUS 57

Telescopic handlers
1 :
For high-speed driving and any driving on public roads :

• Only use the "Front steer wheels" mode.
• Check the alignment of the rear wheels : The "Rear wheels aligned" indicator (P192) must be switched
on.
Axles must be realigned :

• At the start of each day.
• At least once a day.
• If a misalignment problem is observed between the front and rear axles.
Follow the instructions below to realign the driving system :

1. Select the "Front steer wheels" mode. Rotate steering wheel slowly to
bring the rear wheels to the right position. The "Rear wheels aligned"
indicator (P192) must be switched on. Continue to rotate steering wheel
slowly until you see the front wheels aligned.
2. Select the "Synchronised axle" mode again. Check the realignment by
carefully driving the machine a short distance.
2
:
N.B.-:-The parking brake is automatically applied when the engine is switched off.
Parking brake switch :

• Respect the activation mode: locking /unlocking.
• Do not force the activation mode.
In road mode :
• All boom movements are prohibited (joystick deactivated).
• Using the stabilizers and dumping is prohibited.
• Steering switches to "2 steering wheels" mode, whatever the position of the steering selector may be
(with the rear axle automatically returning to road position).
• Overriding the steering function with the exclusion key is also deactivated.
To switch to road mode, you must :
• Have the stabilizers raised
• Have stowed the machine

If these conditions are not respected and the road mode is selected, travelling is deactivated.
The road mode indicator ( P215 ) flashes to failure to comply with the conditions. If the
stabilisers are not raised,the stabilizer LED ( P208 ) and ( P209 ) also flash. Once the
conditions are met, indicator ( P215 ) comes on and driving is enabled at high and low speeds.
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3.5.8 - Joystick A
General view - AS standard
P211
+
+ +
B
+ +
+ +
C
+
4000064510 a
D
Joystick - AS standard
To raise the telescopic arm : Pull the joystick. Keeping
pressed the back trigger in the joystick.
To lower the telescopic arm : Push the joystick. Keeping
E
Discharging : Push the joystick to the right. . Keeping
Crowding : Push the joystick to the left. Keeping pressed the
P211 Joystick
back trigger in the joystick.
To telescope out : Push the left rocker switch upwards.
Keeping pressed the back trigger in the joystick.
F
To telescope in : Push the left rocker switch downwards.
Auxiliary, direction A : Push the right rocker switch upwards.
Auxiliary, direction B : Push the right rocker switch
downwards. Keeping pressed the back trigger in the G
joystick.
Button :
Float option
4000328140 E01.15 AUS 59

Telescopic handlers
Additional controls - Joystick - HTL 4010

Button (High) : Float option
Button (Low) : Load levelling system
Lowering left stabiliser : Press the low button and push the
joystick towards the left and then forwards
Lowering right stabiliser : Press the low button and push the
joystick towards the right and then forwards
Lowering the 2 stabilisers : Press the low button and push
P211 Joystick
the joystick forwards
Lifting the left stabiliser : Press the low button and push the
joystick towards the left and then backwards
Lifting the right stabiliser : Press the low button and push
the joystick towards the right and then backwards
Lifting of the 2 stabilisers : Press the low button and pull the
joystick backwards
Additional controls - Joystick - HTL 3510 - HTL 3010

Button (High) : Float option
Auxiliary, direction B : Push the right rocker switch
downwards
Button (Low) : Load levelling system
P211 Joystick
Chassis tilt : Move to the left : Press the low button and tilt
the joystick left
Chassis tilt Move to the right : Press the low button and tilt
the joystick right
The speed of the joystick functions depends on the amplitude of the joystick travel in the
corresponding direction. Increasing the engine speed also increases the function speed.
Rapid, jerky operation of the controls causes rapid and jerky machine movements. Such movements can
cause the load to drift or fall and the machine may tip over. "Failure" to comply with these instructions
could result in death or serious injury.
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Telescopic handlers
3.5.9 - Left-hand control panel A

General view
P210 P202
B
P212 P233 C
General view
E
P202 12 V socket switch (Option)
P210 Rear fog lights switch
P212 Hazard warning lights switch
Drive in neutral position : Automatic regeneration mode
F
Push upwards :
• Push upwards once and hold for 2 seconds minimum :
Particulate filter regeneration disabled (mode compulsory in
areas with explosive atmosphere). The ( P227 ) indicator
lights up.
• Press upwards a second time and hold for 2 seconds
minimum : Reactivation of particulate filter regeneration
G
(mode compulsory in areas with explosive atmosphere).
Particulate filter regeneration switch The ( P227 ) indicator goes off.
P233 (For machines fitted with engine Press downwards : Start of forced particualate filter
PERKINS 854E-34TA only) regeneration
• Press downwards and hold for 2 seconds minimum : Start
of manual (forced) regeneration outside areas with
explosive atmosphere. The ( P228 ) indicator lights up if the
H
following conditions for performance are satisfied :
• The ( P226 ) indicator is lit.
• Engine running for over 10 seconds and idling.
• Engine temperature greater than 65 °C(149 °F)
(engine temperature indicator ( P178 )).
• Parking brake activated.
• Translation in neutral position.
I
4000328140 E01.15 AUS 61

Telescopic handlers
While a forced regeneration is running, it is essential to be aware of the following points :

• The machine is immobilised for 15 20 minutes (until the ( P228 ) indicator goes out).
• The engine speed increases to 2000 tr/min.
If a significant problem arises, regeneration can exceptionally be interrupted in the following ways :
• Pressing the accelerator pedal.
• Parking brake deactivation (P214).
• Translation activated in forward or reverse.
• Engine switched off using the ignition key.
DANGER OF BURNS! During regeneration, the temperature of the exhaust gases is high and may
reach 650 °C(1202 °F) .
Always start the engine and run it in a well-ventilated area. If the engine is in an enclosed space, vent the
exhaust gases outside.
Do not run the engine in a place where there is a risk of build up of toxic gases.
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Telescopic handlers
3.5.10 - Load moment indicator (LMI) A

General view
P218 B
P217
P216
C
P219
D
Controls and indicators
P216
P217
Green LED's
Yellow LED
Loading percent
Pre-alarm (intermittent buzzer)
E
P218 Red LED Alarm (continuous buzzer)
P219 Test The indicator can be tested at any time
The machine is fitted with an impending forward stability limit indicator. indication is only valid on flat
ground when machine is stationary. F
A display set into the right-hand windscreen strut shows the percentage remaining load,
triggers a pre-alarm, reduces movement speed and then disables boom lowering and
extension movements.
Test the load moment indicator at the start of each work period (
and maintenance)
Section H - Lubrication
G
In all cases, the load capacity chart supplied in the cab is the only reference which may be
used to define load capacity and ensure that the machine operates correctly. Even a lit green
LED does not authorise the machine to be used without the load chart or the load capacity to
be moved.
4000328140 E01.15 AUS 63

Telescopic handlers
If a load moment indicator system alarm is triggered, the following movements are disabled :
Movements-Modes
Movement Fork mode Winch mode
Booms raising Authorized Prohibited
Boom lowering Deactivated if the alarm sounds but can be activated with the exclusion key Prohibited
Crowding Deactivated if the alarm sounds but can be activated with the exclusion key Prohibited
Discharging Deactivated if the alarm sounds but can be activated with the exclusion key Prohibited
To telescope in Authorized Prohibited
To telescope out Prohibited Prohibited
Attachments Deactivated if the alarm sounds but can be activated with the exclusion key
Driving Authorized
Temporary suspension of the Load Moment Indicator system :

An exclusion key ( P198 ) allows the operator to disregard this movement deactivation to avoid
being blocked in certain configurations. In this case, the operator should knowingly takes
responsibility for the for the machine's stability. This function is automatically deactivated
after 8 s of activation in the absence of movement. It must be released before in can be
reactivated.
When the Load Moment is deactivated, the machine stability is no longer guaranteed. Consequently, there
is a risk of the machine tipping over. The operator therefore assumes full responsibility for the machine's
movements and must be aware of the consequences of his actions.
AS Telehandlers are optionally fitted with an EQSS Load Management System which
monitors and manages the load on the Telehandler in all position. For details refer to the
supplementary manual supplied with the Telehandler.
64 4000328140 E01.15 AUS

Telescopic handlers
3.5.11 - Rear-view mirrors and windows A

Cab door window :
The window must be blocked in open or closed position
during use.
Open the cab door window and block it with the locking
mechanism.
B
Press the unlocking button in the cab to unlock the
window.
C
Rear window
Pull the lever and push to open the rear window.
2 1
E
4000328140 E01.15 AUS 65

Telescopic handlers
Rear-view mirror adjustment

The machine is fitted with 5 mirrors :
Locations
3 4 5
1
Visibility zone
A
C

Mirrors Visibility in zone
1 A
2 B
3 C
4 D
5 E
66 4000328140 E01.15 AUS

Telescopic handlers
Rear-view mirror adjustment : A

Rotate the mirror on the axle on which it is fitted.
Adjust the rear-view mirrors as required for optimal visibility before and during use.
Ensure that rear-view mirrors are clean and clear at all times. B
Before each use of the machine, ensure that the mirrors are not damaged.
Any modifications to this machine can affect the visibility in driving position. C
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Telescopic handlers
3.6 - RADIO-CONTROL EMITTER
General view
0 42 40
235
240 239
234 145
146 238 237

307P224490 a 307P224480 a
307P224500 a
236 I /
241
307P224510 a
242
Radio-control emitter
Move upwards : Accessory lifting
P40 Accessory compensation control
Move downwards : Accessory lowering
P42 Engine start-up selector Starting the engine
Press the joystick to activate and confirm the movement (1) :
Move forward : Boom in
P145 Telescoping joystick
Move backward : Boom extend
P146 Fault indicator Machine operating fault
Press the joystick to activate and confirm the movement(1) :
Move upwards : Boom raising
Boom lift joystick
Move downwards : Boom descent
P234
Move to the left : Clockwise rotation
Accessory orientation joystick
Move to the right : Counter clockwise (CCW) rotation
Position 0 : De-energizes control system
P235 Power switch
Position 1 : Energizes control system
Buzzer push button / Remote control
P236 Buzzer / Remote control validation
validation (2)
P237 Weighing indicator / Anti-tipping system Permanently on in case of overload
Constantly on : Engine off or problem with the battery
P238 Battery charge indicator
charging systemFlashing : If the back-up pump is in use
Pulled out (activated) : Remote control power supply
P239 Emergency stop button Pushed down (deactivated) : Power cut to the platform
controls and engine stopped
P240 Remote control on indicator On : Remote control switched on
Pressed down (activated) : Back-up unit activated
P241 Back-up pump unit push button
Release (deactivated) : Back-up unit deactivated
68 4000328140 E01.15 AUS

Telescopic handlers
Marking Description Function A

P242 Electrical connector Electrical connection of the remote control
(1)
: Press the joystick to activate and confirm the movement. The operator can then operate
the joystick without having to hold it down. Movement validation is cancelled if the joystick
returns to neutral position for longer than 5 s.
(2)
: The 2 joysticks (( P145 ) and ( P234 )) must be in neutral position in order to validate
B
switching on of the remote control.
4000328140 E01.15 AUS 69

Telescopic handlers
3.6.1 - Safety devices
To protect the user and the machine, safety systems prevent the operation of the machine
beyond its capacities.
These security systems if activated, immobilize the machine and neutralize the movements.
Poor knowledge of the characteristics and operation of the machine can lead the operator to think that a
normal safety operation is a malfunction.
3.6.1.1 - Activation of controls
The controls must be validated by a 'Enable Switch' system to activate the different
movements : Press on the joystick to activate and confirm the movement and then operate the
joystick ( P145, P234 ).
Detection of internal fault
The defect indicator flashs to indicate an internal malfunction.
The machine switches to downgraded mode.
Certain movements can be limited or forbidden to preserve the operator's
safety.
Overload
If the load on the accessory is greater than the maximum authorised load, no
movement is possible using the remote control.
Movements which could worsen the situation are prevented :
• Arm lowering (unless the telescope is retracted).
• To telescope out.
The weiging indicator ( P237 ) flashes and an intermittent audible signal warns the user.
There are 2 options that will allow restoration of normal operation :
• Remove some weight to return within the authorised load.
• Use the console located in the cab to lower the platform.
N.B.-:-All movements from the console located in the cab are slowed down and movements which could
worsen the situation are prevented.
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Telescopic handlers
D - Operation
Operation A
1 - Engine
N.B.-:-The fuel to be used is regulated by national laws; refer to these requirements to define the
appropriate fuel. Using unsuitable fuel may cause diminished performance, difficulties starting,
excessive pollution and premature wear. To establish the type of fuel suitable for the engine fitted on
your HAULOTTE® machine, please refer to the engine manufacturer's manual. The engine may not be
covered by the warranty in case of damage caused by using unsuitable fuel.
B
1.1 - STARTING THE ENGINE
This machine can be operated at temperatures of -20 °C(0 °F) to 40 °C(104 °F) .
Consult HAULOTTE Services® for operation outside this temperature range.
• Turn on the battery isolator located under the cab to the left of the steps.
C
• Make sure that all of the controls are in neutral and that all of the electrical components (lighting,
heating, defrost system, …) are turned off.
• Insert the ignition key.
• Turn the ignition key completely to position 1.

D
• Wait until the pre-heating light ( P188 ) goes off before starting the engine.
The following LEDs should light upon start-up and then go off again :
• Parking brake LED P182 (possible if deactivated for a prolonged period).
• Battery LED P180. E

• Service brake fault LED P190 (possible if deactivated for a prolonged period).
• When the machine is switched on (ignition key in position 1), the warning light ( P220 ) comes on for
one second to check that the system is working properly.
Do not actuate the starter for more than 15 s at the time.

F
Wait 10 s seconds between 2 attempts to avoid excessive drain of the battery power.
Do not try to start the machine by towing or pushing it, this could cause serious damage to the hydrostatic
transmission.
If a LED indicates a fault, stop the engine immediately and perform the necessary operations or
G
contact HAULOTTE Services®.
• Warm up the engine at approximately 1/2 throttle.
N.B.-:-The engine will not start if the gear control lever is not in neutral.
Unexpected movement hazard. Always ensure that the gear control lever is in neutral.
H
Engine explosion. Do not spray ether into the air intake when starting the engine in cold weather. "Failure"
to comply with these instructions could result in death or serious injury.
4000328140 E01.15 AUS 71

Telescopic handlers
D - Operation
1.2 - OPERATIONAL CHECKS
1.2.1 - During the warm-up period
Check at the beginning of each work shift or at each change of operator :

• The heating, the defrost system and the windscreen wiper.
• check all lighting systems for proper operation.
Keep the engine cover closed while the engine is running. "Failure" to comply with these instructions
could result in death or serious injury.
1.2.2 - When the engine is running
Check at the beginning of each work shift or at each change of operator :

• Service brake and parking brake operation.
• Forward and reverse.
• Each gear.
• Steer in 2 directions with the engine at idling speed. Check each steering mode (Forward and
reverse).
• The horn and the back-up alarm. They must be audible from inside the operator's cab with the engine
running.
• All of the boom and attachment functions should operate smoothly and correctly.
• Perform all additional checks ( Section H - Lubrication and maintenance).
1.3 - STARTING THE ENGINE WITH A BOOSTER BATTERY
If the engine has to be started with a booster battery (jumper cable...) proceed as follows :
• Never allow the vehicles to come into contact with each other.
• Connect the (+) terminal of the discharged battery to the (+) terminal of the booster battery.
• Connect the terminal - of the back-up battery to the terminal - of the discharged battery.
• Follow the standard starting procedures.
• Remove the cables in reverse order once the machine has been started.
Never jump-start or charge a frozen battery as it could

explode. Do not produce sparks or flames or smoke near
the battery. Lead acid batteries generate explosive
gases when charging. Wear safety glasses. "Failure" to
comply with these instructions could result in death or
serious injury.
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Telescopic handlers
D - Operation
1.4 - NORMAL ENGINE OPERATION A

Observe the gauges and the display screen frequently to ensure that all engine systems are
functioning properly.
Pay attention to unusual noises and vibrations. If a fault occurs, park the machine in a safe
position and perform the shut-down procedure (
procedure). Report the fault to HAULOTTE Services®.
Section D 1.5 -Engine shut-down
B
Avoid prolonged idling. Turn the engine off when not in use.
1.5 - ENGINE SHUT-DOWN PROCEDURE
Park the machine in a safe location on a flat surface and away from any other equipment or
traffic lanes.
• Actuate the parking brake switch P214.
C
• Shift the speed selector to neutral.
• Lower the forks or the attachment to the ground.
• Operate the engine at idling speed for 30 s. D

Do not overrev the engine.
• Stop the engine : Turn the ignition key to the left to position ''0''.
• Remove the ignition key.
• Exit the machine correctly.

E
• Block the wheels if necessary.
• Switch off the battery disconnector located under the cab on the left of the steps.
The cab seat is fitted with a device preventing the machine from moving if the operator is not sitting on the
seat correctly.
F
1.6 - PARKING BRAKE OPERATION
At speeds under 5 km/h (3,1 mph) , pressing the switch ( P214 ) automatically activates the
parking brake.
When the parking brake is activated, the indicator lights ( P190 ) and ( P214 ) stay lit.
G
At speeds over 5 km/h (3,1 mph) , pressing the ( P214 ) switch for more than 2 s automatically
activates an audible signal and makes the ( P182 ) indicator light flash.
After 2 s, the parking brake is activated automatically.
In this configuration, stopping the machine is detrimental. H

N.B.-:-Even if the machine's speed goes below 5 km/h (3,1 mph) during these 2 s, the parking brake
is activated automatically.
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Telescopic handlers
D - Operation
2 - Operation with a load

2.1 - LOAD LIFTING SAFETY
• Know the weight and the centre of gravity of each load to be lifted.
• Use the load capacity chart associated with each attachment.
Exceeding the machine's lifting capacity may damage the equipment and/or cause tipping over, resulting
in death or serious injury.
You should know the machine's rated load capacities to determine the operating range within
which you can safely lift, transport and place loads ( Section G - Technical
characteristics).
2.2 - BEFORE LIFTING A LOAD
• Check the ground conditions. Adapt the travel speed and reduce the load weight according to the
ground.
• Avoid lifting unbalanced loads.
• Make sure that there are no obstacles near the load.
2.2.1 - For operation with non-suspended load
• Adjust the fork spacing so that they engage into the pallet or under the load at maximum width and
remain centred on the fork carriage.
• Face the load and approach it slowly with the fork tips straight and horizontal.
2.2.2 - For operation with suspended load
• Only use approved lifting devices rated for the lifting of the load ( Section E - Attachments).
• Identify the proper lifting points of the load, taking into consideration the center of gravity and load
stability.
• Always properly tether loads to restrict movement.
Wheels must be aligned to lift a load.
Never lift any loads if a correct and legible capacity chart corresponding to the accessory usedis not
displayed in the operator's cab.
Never operate the telehandler without a proper and legible capacity chart displayed in the operator's cab
for the telehandler/attachment combination in use..
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Telescopic handlers
D - Operation
2.3 - TRANSPORTING THE LOAD A

2.3.1 - For operation with non-suspended load
Once the load is engaged on the forks and leaning against the fork carriage, tilt the load
backwards to place it in the travel position. Travel as specified Section A - Safety
precautions, Section E - Attachments. B
2.3.2 - For operation with suspended load
Travel in accordance with safety rules specified Section A - Safety precautions,

Section E - Attachments.
C
• Ensure the boom is fully retracted.
Never raise the load more than 300 mm (11.8 in) above the ground or the boom more than 30°.
E
Never operate the machine controls suddenly.
• The combination of sideways movement and the load could cause the machine to tip over. F
• The guide persons must remain in constant communication (verbal or hand) and be in visual contact
with the operator at all times.
Never place the guide persons between the suspended load and the telehandler.
• Only transport the load at walking speed (0.4 m/s) or less.

G
2.4 - DUMPING PROCEDURE
• Position the machine in the best location for lifting or placing the load.
• Disable drive mode and drive at a speed lower than 5 km/h (3,1 mph) . H
• Place the boom/attachment at less 30 °.
• Check the level gauge to determine if the machine must be levelling and to do it with the
switch ( P200 ) (For HTL3010/3510 only).
Never raise the boom/attachment more than 1.2 m(3 ft11 in) above the ground unless the machine is
leveled. The combination of sideways movement and the load could cause the machine to tip over.
I
The machine is designed to allow movement of the main chassis 9 ° forward and backwards
(For HTL3010/3510 only).
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D - Operation
2.5 - STABILISER OPERATION PROCEDURE (HTL 4010)
The stabilizers increase lifting capacity and make it possible to level the machine.
• Position the machine in the best location for lifting or placing the load (Gradeability 3 °).
• Actuate the parking (P214) brake and shift the gear control lever to neutral.
• Release the service brake.
• Install the stabilizers with the switch ( P208 ) and ( 209 ).
• Check the level indicator to determine whether the machine must be levelled and do so using the
joystick.
Risk of sideways overturning if only one stabilizer is actuated.
2.6 - PLACING THE LOAD
Before placing a load :

• Ensure that the unloading point can safely support the weight of the load.
• Ensure that the unloading point is level, both lengthways and sideways.
• Use the capacity chart to determine the permitted boom extension range.
• Lower the forks to the level at which the load must be placed, and then extend the boom slowly until
the load is just above the area where it must be placed.
• Lower the boom until the load rests in position and the forks can be retracted.
2.7 - DISENGAGING THE LOAD
Once the load has been safely placed at the unloading point, proceed as follows :
• When the load weight is no longer resting on the forks, the boom can be retracted and/or move the
machine back from under the load if the surface so allows without changing the machine level.
• Lower the fork carriage.
• Drive the machine away from the landing point to continue work.
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D - Operation
3 - Road operation A
• Preparation :
• Remove any large amounts of dirt from the machine.
• Check the lights and the mirrors, and adjust them if necessary.
• Follow the recommendation in force in the country of use (Registration plate, jacket, warning triangle,
first-aid kit, chocks…).
B
• Lower the boom. The front edge of the attachment should be approximately 0,30 m(1 ft0 in) to 0,40
m(1 ft4 in) above the ground.
• Tilt the attachment back completely.
• Place a protective cover over the front edge of the bucket ; remove the carriage forks. C
• Raise the stabilisers.
• If the rear wheels are not in line with the chassis, move them back slowly to a neutral position.
• Actuate the road switch P215.
• Empty the bucket (If equipped).
D
Never carry loads on the road.
• The machine is now ready for road operation.

N.B.-:-Ensure that you follow all local, regional and national traffic regulations.
E
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D - Operation
4 - Loading and securing for transport

HTL 4010
307P216800 a
307P216800 a
HTL 3510 - HTL 3010
307P216800 a 307P216800 a
• Level the machine before loading.

• Obtain assistance from an operator for manœuvres and loading the machine, with the boom as low
as possible.
• Once loaded, apply the parking brake and lower the boom until the boom or attachment touches the
deck. Switch all controls to neutral, stop the engine and remove the ignition key.
• To secure the machine to the deck, pass chains through the designated tie-downpoints as illustrated
in the figure.
• Do not tie down the front of the boom.
N.B.-:-The user is fully responsible for choosing the proper method of transportation and the tie-down
devices : Ensure that the equipment used is able to support the weight of the vehicle to be transported
and that all manufacturer's instructions and warnings, regulations and safety rules and all national,
regional and local laws are followed.
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D - Operation
Before loading the machine to be transported, check that the deck, the ramps and the machine wheels are
free of mud, snow and ice. Otherwise, the machine may slide, which could result in serious injury or death.
A
Lifting the machine
Ensure that :
• The machine is completely folded
B
• The accessories are in good conditions and have sufficient capacity
• The staff performing the maneuvers is authorized and empowered to use lifting equipment
B
2 lifting straps length 3200 +/- 50 mm
2 lifting straps length 4000

H
• Keep different length between A and B.
• Caution to lifting machine with air conditioned cab. I
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D - Operation
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E - Attachments
Attachments A
1 - Approved attachments
To determine whether an attachment is approved for use on the machine in use, proceed as follows
before installation of attachment :
• The attachment model/option number indicated on the attachment identification plate must
correspond to the attachment number indicated on a capacity chart located in the operator's cab (For
B
the forks, buckets and side-shift fork carriage). For other attachments, refer to the load chart booklet
of the attachment.
• The model indicated on the capacity chart must correspond to the model of the machine being used.
• The center of gravity of the load on the fork (if applicable) must correspond to the center of gravity of
the load indicated on the capacity chart. C
• Hydraulically-powered attachments must only be used on machines equipped with auxiliary
hydraulics.
If any of the above conditions are not met, do not use the attachment. The machine may not be equipped
with the relevant capacity chart or the attachment may not be approved for the machine model being used.
Additional information can be obtained from HAULOTTE Services®. D
The user must enlist the services of a competent person to familiarise themselves with the test procedures
for the specific attachments they have for the Telehandler. The user is responsible for carrying out any
required checks of the attachment..
The user must ensure that the accessory can be used in the country in which the machine is be used.
E
2 - Unapproved attachments
Do not use attachments that have not been approved in writing by Haulotte for the following reasons :
• HAULOTTE® cannot establish the capacity range limits for DIY, home-made, altered or other
unapproved attachments.
F
• An overextended or overloaded machine may tip over with little or no warning, can cause serious injury
or death to the operator and/or those working nearby.
• HAULOTTE® cannot guarantee the ability of an unapproved attachment to perform its intended function
safely.
G
Only use HAULOTTE approved attachments. Attachments that have not been approved by HAULOTTE for
use with this machine may cause material and/or bodily damage, or even death.
4000328140 E01.15 AUS 81

Telescopic handlers
E - Attachments
3 - Telehandler/Attachment/Fork capacities
Before installing the attachment, check that it is approved and that you are in possession of the relevant
capacity chart.
Attachment manufacturer's plate
Part number Part number

Accessory type Accessory type
HAULOTTE GROUP HAULOTTE GROUP
Serial number La Péronnière BP9
Serial number La Péronière BP9
42152 L'HORME 42152 L'HORME
Manufacture date FRANCE Manufacture date FRANCE
Authorized equipement OU / OR Weight Kg lbs
Volume (SAE) L
Weight Kg lbs Capacity Kg lbs
Maximum Capacity Kg lbs Wind speed max m/s
307P229340 a 307P222900 c
Load capacity chart
)RUNV31
3
3
3
68° F 0D[LPXPFDSNJ
H
10 F
60° 10
E E
9 9
D D
T
50°
8 8
C C
40° B B
L
7 7
6 A 6 A
30°
Kg
5 5
00
4 30
Kg
4
00
4
20°
40
3
1000Kg
1500Kg
2000Kg
0
3
200Kg
500Kg
800Kg
1000Kg
1500Kg
2000Kg
2500Kg
3000Kg
4000Kg
2
2 10°
0.6 m
0.6 m
1
1
1
0m
0m 0°
0
5 3 1 0m
5 4 3 2 1 0m
7.2 7.2
fork load centre 600mm fork load centre 600mm
Standard used AS1418.19 3D
N.B.-:-The attachment number located on the manufacturer's plate must correspond to the attachment
number which appears on the load chart.
To determine the maximum capacity of the telehandler and the attachment, use the smallest of the
capacities as determined by the capacity stamped on the attachment or the lifting position on the load
chart..
The forks must be used in matched pairs.
Never use an accessory without having checked the HAULOTTE® accessory load capacity chart installed
on the telehandler. Failure to install the relevant HAULOTTE® supplied capacity chart could cause an
accident resulting in death or serious injury.
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E - Attachments
4 - Using the capacity chart with forks A

To use the capacity chart properly, the operator must first determine and/or obtain the following :
• Approved attachments HAULOTTE®.
• A load chart corresponding to the attachment.
• The weight of the load to be lifted.
B
• The load placement data :
• The height at which the load must be placed.
• The distance the load must be placed forward of the front tires of the Telehandler.
• An alphabetical key ( A, B, C, D, E, F ) indicates the boom extension and a pendulum indicates the
boom angle ( Section E - Boom angle indicator).
C
• On the capacity chart for a given load, find the area corresponding to the key and follow it to the
permitted reach.
• The number that appears in the load capacity range must be equal to or greater than the weight of
the load to be lifted. Determine the load capacity range limits with the capacity chart and keep within
those limits. D
Boom angle indicator
G
1 : Horizontal boom
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E - Attachments
Boom extension indicators
400 400 400 400 400 400 400
84 4000328140 E01.15 AUS

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E - Attachments
Example of a load capacity chart : HTL 4010 A

2
5 1
B
)RUNV31
3
3
3
3
68° F 0D[LPXPFDSNJ
H
10 F
60° 10
E E
9
40°
50° D
B
T
9
8
D
C
B
C
L
7 7
6 A 6 A
30°
Kg
5 5
00
4
30
Kg
4
00
4
20°
40
3
D
1000Kg
1500Kg
2000Kg
0
3
200Kg
500Kg
800Kg
1000Kg
1500Kg
2000Kg
2500Kg
3000Kg
4000Kg
2
2 10°
0.6 m
0.6 m
1
1
1
0m
0m 0°
0
5 3 1 0m
5 4 3 2 1 0m
7.2 7.2
E
4
Marking Description
1
2
HTL4010 : The load capacity chart must only be used for this machine
Attachment reference : The attachment reference must correspond to the number on the
attachment manufacturer's plate
F
3 Boom extension indicators
4 Load area : The load areas indicate the maximum weight which can be lifted
5 Boom angle
To identify the appropriate load capacity table, refer to the icons (representing the attachments) which
appear on the table :
G
• To be used when lifting a load with the stabilisers raised :
• To be used when lifting a load with the stabilisers lowered :

H
All of the loads indicated on the load capacity chart are based on the machine being on firm ground with
the chassis level, the forks being positioned symmetrically on the fork carriage, the load being centred on
the forks, appropriately sized tires being inflated correctly and the telehandler being in good working
condition. "Failure" to comply with these instructions could result in death or serious injury.
I
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Telescopic handlers
E - Attachments
Examples of how to read the load capacity chart for the HTL4010 fitted with the fork carriage
The following examples illustrate situations where the load may or may not be lifted.
Use the capacity chart corresponding to the machine.
The attachment number located on the manufacturer's plate must correspond to the attachment number
which appears on the load chart.
Stabilisers lowered
The weight of the
Example Distance Height Lifting authorised
load to be lifted
1 2000 kg(4409 lb) 4,5 m(14 ft9 in) 8 m(26 ft24 in) Yes
2 3200 kg(7056 lb) 5 m(16 ft40 in) 7 m(22 ft96 in) No
3 3000 kg(6615 lb) 3 m(9 ft84 in) 5 m(16 ft40 in) Yes
Stabilisers raised
The weight of the
Example Distance Height Lifting authorised
load to be lifted
4 1200 kg(2646 lb) 3 m(9 ft84 in) 9 m(29 ft52 in) Yes
5 1000 kg(2204 lb) 6 m(19 ft68 in) 6 m(19 ft68 in) No
6 800 kg(1764 lb) 5,5 m(18 ft1 in) 4 m(13 ft12 in) No
)RUNV31
3
3
3
68° F 0D[LPXPFDSNJ
4
H
10 F
60° 10
E E
9
1 D
9
D 5
T
50°
8 8
C C
2 40° B B
L
7 7
A 6 A
6
3 6
30°
Kg
5 5
00
4
30
Kg
4
00
4
20°
40
3
1000Kg
1500Kg
2000Kg
0
3
200Kg
500Kg
800Kg
1000Kg
1500Kg
2000Kg
2500Kg
3000Kg
4000Kg
2
2 10°
0.6 m
0.6 m
1
1
1
0m
0m 0°
0
5 3 1 0m
5 4 3 2 1 0m
7.2 7.2
86 4000328140 E01.15 AUS

Telescopic handlers
E - Attachments
HTL4010 load capacity chart A

)RUNV31
3
3
3
68° F 0D[LPXPFDSNJ
H
10 F
60° 10
E
B
E
9 9
D D
T
50°
8 8
C C
40° B B
L
7 7
6 A 6 A
30°
Kg
5 5
00
4
30
Kg
4
00
4
20°
40
3
1000Kg
1500Kg
2000Kg
0
3
200Kg
500Kg
800Kg
1000Kg
1500Kg
2000Kg
2500Kg
3000Kg
4000Kg
2
2 10°
0.6 m
0.6 m
1
1
1
0m
0m 0°
0
5 3 1 0m
5 4 3 2 1 0m
7.2 7.2
HTL3510 load capacity chart

D
)RUNV31
HTL 3510 3

3
3
0D[LPXPFDSNJ
65° F
10
9
50°
60°
E
D
E
8 C
7 40° B
6 A
30°
5
3
20°
F
2 10°
2500 kg
3500 kg
2000 kg
1500 kg
1000 kg
800 kg
500 kg
0.6 m
1
0 m 0°
-2° 2 1 0m
G
7.2 5.8 4.2 2.5
4000328140 E01.15 AUS 87

Telescopic handlers
E - Attachments
HTL3010 load capacity chart
)RUNV31
HTL 3010 3

3
3
0D[LPXPFDSNJ
65° F
10 60°
E
9
50° D
8 C
7 40° B
6 A
30°
5
4
20°
3
2 10°
2500 kg
2990 kg
2000 kg
1500 kg
1000 kg
800 kg
500 kg
0.6 m
1
0 m 0°
-2° 2 1 0m
7.2 5.8 4.2 2.5
Forks characteristics
Length Width Weight
1200 mm 125 mm 80 kg
1200 mm 100 mm 65 kg
88 4000328140 E01.15 AUS

Telescopic handlers
E - Attachments
5 - Attachment installation A
C143 C144
B
C
C145

C146 C147
E
Marking Description
C143 Attachment
C144 Attachment pin recess
C145
C146
Attachment pin
Lock pin F
C147 Retainer pin
Always ensure that the fork carriage or the accessory is correctly positioned on the boom, secured by 2
locking pins and held in place by 2 retaining locks. Incorrect installation could result in the fork carriage/
5.1 -
attachment/load disengaging, causing death or serious injury.
MECHANICAL ATTACHMENT LOCKING DEVICE

G
• Pull the locks and disengage the locking pins from the accessory.
• Align the tool apron pin with the attachment recess by lifting and crowding ( P211 ).
• Actuate the parking brake P214. Leave the cab, insert the locking pins and secure them with the
retaining locks.
H
• If the attachment requires hydraulic control, connect auxiliary hydraulic hoses A and B.
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Telescopic handlers
E - Attachments
5.2 - HYDRAULIC ACCESSORY LOCKING DEVICE (OPTION)
5.2.1 - Specific instructions
Before installing the hydraulic adaptation kit, ensure :

• that the boom is below 15 °.
The hydraulic adaptation kit connection is carried out with the machine stopped.
5.2.2 - Operation
• Connect the hoses from the hydraulic adaptation kit to the

push/pull sockets on the tool holder carriage.
• Start the engine.
• Align the tool apron pin with the attachment recess by lifting and crowding ( P211 ).
• To unlock the tool holder carriage, press the locking button

for at least 2 s and hold down. P211
• Carry out the attachment installation operations while holding the locking button down.
• Release the button to lock.
Releasing the button locks the attachment.
Do not press on the locking button for longer than 2 s when the auxiliary line is connected to the
attachment. Danger of unexpected movement.
If the attachment requires hydraulic control, connect auxiliary hydraulic hoses A and B.
Hold the button down for 5 s to unlock the carriage.
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Telescopic handlers
E - Attachments
5.3 - ADJUSTING/MOVING FORKS A

Fork carriages may have different locations for positioning forks.
N.B.-:-Apply a light coating of an appropriate lubricant to facilitate fork or fork bar sliding.
To slide the forks :

• Ensure that the fork carriage is correctly installed : Section E - Attachments.
B
• Lift the boom by approximately 10 °, tilt the fork carriage forwards until the fork heel is no longer in
contact with the fork carriage.
• Stand next to the fork carriage to slide the fork, push it or pull it near its pin.
If the forks must be changed out : C
• Place the forks on the ground.
• Remove the fork pin.
• Change out the forks and place them in position.
• Change out the fork pins and their retaining mechanisms. D

Using forks :
• The machine's capacity and range limits change according to the forks used.
Keep the specific instructions for the forks in the manual holder situated behind the cab seat, with the
telehandler operator manual.
E
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Telescopic handlers
E - Attachments
6 - Attachments
Familiarize yourself with the information provided on the attachment identification plate.
Use the capacity table (load chart booklet) corresponding to this accessory.
Keep the specific instructions for the forks in the manual holder situated behind the cab seat, with the
telehandler operator manual.
6.1 - TECHNICAL CHARACTERISTICS OF THE ACCESSORIES
Floating forks carriage
194P287760
Attachment reference
194P306620
Mass 290 kg(639 lb)
0,125 m (41 in) X

Section (Standard)
0,050 m (2 in)
Dimensions of pallet forks 0,100 m (40 in) X

Section (Option)
0,050 m (2 in)
Length 1,2 m(4 ft0 in)
4000 kg(8819,49 lb)
Nominal capacity If the capacity of the machine is less

than 4000 kg(8819,49 lb), respect the nominal
capacity of the machine
Carriage extension (Option)
Attachment reference 194P306780
Height 0,473 m(1 ft7 in)
Mass 20 kg(44 lb)
92 4000328140 E01.15 AUS

Telescopic handlers
E - Attachments
A
Side-shift fork carriage
Hydraulic kit
Attachment reference 2820303940
Width 1,25 m(4 ft10 in) B

Mass 390 kg(860 lb)
0,125 m (41 in) X

Section
Dimensions of pallet forks 0,045 m (1,7 in)
100 mm in relation to the central

C
Lateral movement
position
Nominal capacity 3000 kg(6614 lb)
User pressure
Maximum admissible pressure

180 bar
220 bar
(2610,67 psi)
(3190,83 psi)
D
Minimum flow 50 l/min
Standard : FEM3A
4000328140 E01.15 AUS 93

Telescopic handlers
E - Attachments
Toothless bucket
Nominal capacity 1140 l (301 gal)
Width 2,4 m(7 ft10 in)
Mass 465 kg(1025 lb)
Toothed bucket
4-in- 1 bucket
Hydraulic kit
94 4000328140 E01.15 AUS

Telescopic handlers
E - Attachments
A
4 T (8820 lb) 0 m(0 ft0 in) jib crane

B
Mass 72 kg(159 lb)
C
Mass 141 kg(311 lb) D

Attachment reference 4000016740 E

Mass 205 kg(452 lb)
4000328140 E01.15 AUS 95

Telescopic handlers
E - Attachments
Fly jib 2,5 m(8 ft2 in), 1,2 T (2646 lb) on telescopic arm
Mass 206 kg(454 lb)
Fly jib 4 m(13 ft1 in), 0,6 T (1323 lb) on telescopic arm
Attachment reference 2820304090 2820304090
Mass 276 kg(609 lb)
Fly jib 2,5 m(8 ft2 in), 1,2 T (2646 lb) with hydraulic winch
Mass 310 kg(684 lb)
Fly jib 4 m(13 ft1 in), 0,6 T (1323 lb) with hydraulic winch
Mass 375 kg(827 lb)
96 4000328140 E01.15 AUS

Telescopic handlers
E - Attachments
A
Winch 1,2 T (2646 lb)
Hydraulic kit
Nominal capacity 1200 kg(2646 lb) B

Mass 190 kg(419 lb)
Winch 2,4 T (5292 lb)

Hydraulic winch
C
Mass 190 kg(419 lb) D
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Telescopic handlers
E - Attachments
6.2 - OPERATION
6.2.1 - Accessory control
The joystick ( P211 ) controls movements of the boom and attachment tilt
( Section C 2.5.8 - Joystick).
6.2.2 - Attachment installation procedure
Section E 5 - Attachment installation.
Incorrect installation could result in the attachment or load disengaging, causing death or serious injury.
6.2.3 - Using the load capacity chart
Make yourself familiar with the information Section E 3, Section E 4.
Use the capacity table (load chart booklet) corresponding to this accessory.
The machine must not be used without the capacity chart booklet.
All the loads indicated on the nominal capacity chart (load chart booklet) assume that the machine is on
firm ground with the chassis level, the load evenly distributed on the attachments, tyres of the correct size,
sufficiently inflated and that the handler is in good working order. "Failure" to comply with these
instructions could result in death or serious injury.
6.2.4 - Operation
• Raise or lower the boom to the appropriate height for lifting the load.
• Lift the load smoothly and with the boom fully retracted.
• Travel as specified Section A - Safety precautions.
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F - Emergency procedure
Emergency procedure A
1 - Towing a broken-down vehicle
1.1 - GENERAL PRECAUTIONS
Towing must only be performed when the machine has broken down and once the operator has ensured
that there is no risk of additional damage.
B
The first option should be to complete repairs on-site.
If the machine is on a public highway, ensure that no part of the Telehandler encroaches onto
the road. If encroachment cannot be avoided, place warning signage on the road in
accordance with the currently applicable regulations (example: warning triangle (optional),
safety vest for the operator (optional), etc.). C
Before towing the Telehandler, complete the following: :
• Check that the steering can be used.
• Unbraked the front axle according to the procedure.
• To tow the Telehandler, attach a towing bar to the towing
clevis situated at the front or rear of the Telehandler
D
If the Telehandler must be towed, the combined weight of the towing vehicle and machine must not exceed
E
to 28,5 Tonne.
Towing is performed at the operator's risk and must be completed with extra care.
• Ensure that the Telehandler boom is sufficiently raised to avoid interferences with the ground or the
towing vehicle.
F
• If the Telehandler boom cannot be raised sufficiently to avoid interferences, contact HAULOTTE
Services®.
Before towing the Telehandler, you should loosen the

two pressure limiters on the travel pump by three turns
1.
G
1
H
(1)Unscrew each pressure relief valve by 3 turns before towing.
The maximum travel speed permitted for towing is 6 km/h (4 mph) . The towing distance
should not exceed 300 m(984 ft4 in).
• Turn on ignition key and start up engine.. I
• Deactivate the parking brake.
• When the parking brake is released, the machine can be towed.
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Telescopic handlers
If the parking brake is still engaged and the engine has broken down, de-activate the brake
before towing ( Section F 1.2 - Releasing the axle brake for towing. )
1.2 - RELEASING THE AXLE BRAKE FOR TOWING
The following procedure is used to release the front axle parking brake in the event of a engine
breakdown or when the accumulator is empty.
1.2.1 - Parking brake deactivation
Tools required :
• Spanner 19 mm.
• Loosen the lock nuts.

• Fully tighten the 4 screws.
Come out from under the Telehandler and remove the chocks placed under the four wheels.
• Park the Telehandler.
• Block the four wheels again.
• The machine can be towed ( Section F 1.1 - Towing a broken-down vehicle).
1.2.2 - Parking brake reactivation
Tools required :
• Spanner 19.
Block the four wheels with chocks to prevent any Telehandler movement when the brake is disengaged.
When the four wheels are properly blocked :

• Loosen the 4 screws from 18 mm to 21 mm.
• Tighten the lock nuts.

The parking brake can then be reactivated and the front wheels blocked.
• Remove the chocks from the four wheels.
• Check that the hand brake control functions properly.
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Telescopic handlers
2 - Emergency boom lowering A

2.1 - MANUAL BOOM LOWERING (EMERGENCY MODE)
This operation should only be performed as a last resort as it presents a danger for the operator (machine
and load stability).
Before any manual lowering operation :

B
• Retract the boom before lowering it.
• Activate the parking brake and chock the wheels.

If the boom cannot be retracted, check on the load capacity chart in the cab that lowering the
boom in a horizontal position is compatible with telehandler stability. C
• Block the boom in position with another machine, a crane or, as a last resort, the cylinder chock.
• Completely unscrew the stop screw from the counter-balance valve block flanged on the boom lift
cylinder. Note the number of turns with the spanner. Remove the locknut and rescrew the stop screw
fully into its socket ( 1 ).
D
E
1
G
Marking Description
1 Stop screw
• Take off the cover located under the counterweight at the rear of the machine to access the valve
block. H
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Telescopic handlers
• Slowly unscrew the cap situated on the boom lift plate (first plate from the back) until you can see the
boom lowering, then unscrew once the boom in low position (2).
• Once the boom is lowered and the machine has been repaired, raise the boom to its high position and
secure it into place using the cylinder prop.
• Unscrew the stop screw from the counter-balance valve block, replace the counternut and rescrew
the assembly fully into its socket.
• Check that the counter-balance valve functions properly after the intervention (by raising/lowering the
boom with a load).
Secure the boom into position before any interventions on the counter-balance valve.
3 - Emergency exit from cab

In an emergency, exit from the cab can be achieved via the rear window..
• Release the stop ( 1 ) upwards.
• Push the window ( 2 ) outwards with your hand.
2 1
In accordance with the local and governmental regulations in force in some countries, a "break glass
hammer" is provided inside the cab to allow exist in an emergency by breaking the rear window glass.
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Telescopic handlers
G - Technical characteristics
Technical characteristics A
1 - Main characteristics
Certain options can modify the machine's operating characteristics and its associated safety If your
Telehandler was originally delivered with options fitted, replacing a safety component associated with a
particular option does not require any particular precautions other than those associated with the
installation itself (static test). Certain options can modify the Telehandler's operating characteristics and
B
its associated safety
Otherwise, it is essential to follow the manufacturer's recommendations below :

• Any options added must be either HAULOTTE® original options, or must be approved in writing
by HAULOTTE®.
• Installation by authorised HAULOTTE® personnel only. C
• Update the manufacturer's identification plate.
• Have stability tests carried out by a certified agency/competent person.
• Ensure label compliance.
HAULOTTE® has a continuous improvement policy in place for its product range ; Given this policy, The
Company reserves the right to modify their product technical characteristics without notice.
D
1.1 - TECHNICAL CHARACTERISTICS
Engine
Perkins 854E-34TA
Model
Type
Perkins 1104D44T
(Wall Flow DPF)
Four-stroke, water-cooled
Kohler KDI 3404 TCR
E
Cubic capacity 4400 cm3 (268,50 cu in) 3400 cm3 (207,48 cu in) 3359 cm3 (204,97 cu in)
Intake Turbo
70 kW (94 Hp) 83 kW (111,3 Hp) 56 kW (75,06 Hp)
Power
at 2300 rpm (97/68EC) at 2200 rpm (97/68EC) at 2200 rpm (97/68EC)
Torque 392 Nm at 1400 rpm 450 Nm at 1400 rpm 372,4 Nm at 1400 rpm
F
Hydraulic circuit
Pump Gear pump
Flow 100 l/min
Pressure 260 bar(3771 psi)
Regulation
Control
Load Sensing
Electro-hydraulic with 4-function joystick
G
Accessory plug flow 62 l/min
Hydraulic oil tank capacity 103 l(27 gal US)
Type
Control
Transmission
Hydrostatic with pump and variable cubic capacity engine, 4 permanent drive wheels
Electro-hydraulic with 2/2 front, rear and neutral position selector
H
Speed in operating mode 0 - 8 km/h (5 mph)
Speed in road mode 0 - 25 km/h (15,53 mph)
Slow approach Yes-Inching pedal
Traction force 6500 daN(14612 lbf)
Negotiable slope
Axles
45 %
Epicyclic gears - Limited-slip differential blocking
I
Swing axle Yes
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Braking circuit
Engine brake Hydrostatic
Service brake Multi-disc oil bath brake controlled by the brake pedal
Parking brake Electrically-controlled multi-disc oil bath brake
Cab
Interior width 940 mm
The cab complies with the ROPS (ISO 3471) / FOPS (ISO 3449) European safety standard.
Door with two separate sections, opening rear window with wiper, heating, ventilation and
joystick with 4 proportional functions.
Tyres
405/70 - 24(HAULOTTE® code : 2326014870)
Type
Pre-charge pressure : 4,5 bar(65,2 psi)
Steering system
Inner turning radius on tyre 2550 mm
Outer turning radius on tyre 4800 mm
Electric circuit
Perkins 854E-34TA
Model Perkins 1104D44T Kohler KDI 3404 TCR
(Wall Flow DPF)
Operating voltage 12 V 12 V 12 V
Battery 110 Ah 110 Ah 110 Ah
Alternator 100 A 100 A 90 A
Starter 3.2 kW (4.3 Hp) 3.2 kW (4.3 Hp) 3.2 kW (4.3 Hp)
Filling capacity
Fuel tank 120 l(32 gal US)
Hydraulic oil tank 103 l(27 gal US)
Front axle 8 l(2 gal US)
Rear axle 8,5 l(2 gal US)
Transfer case 0,5 l(0.14 gal US)
Engine oil (For machines fitted with engine PERKINS 1104D44T only) 8,4 l(2 gal US)
Engine oil (For machines fitted with engine PERKINS 854E-34TA only) 9,5 l(3 gal US)
15,6 l(4 gal US) - Maximum
Engine oil (For machines fitted with engine KOHLER KDI 3404 TCR only)
9,2 l(2 gal US) - Min.
Cooling 18 l(5 gal US)
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1.2 - STANDARD EQUIPMENT A

• Dual-element air filter
• Fuel filter with water separator
• Transmission oil filter
• 4 Drive and steer wheels

B
• Safety valves on hydraulic cylinders
• Auxiliary hydraulic circuit to the boom head
• Incremental approach movements possible via the Inching system C

• Deactivation of aggravating movements in the event of overload
• Load moment indicating device with load status controller and 5 LED's in the cab: cut-off and sound
signal with automatic speed deceleration at the limits of the capacity chart
• Side tilt corrector : +9° / - 9° (HTL3510)
• Pre-wirring for radio and loudspeakers

D
• Horn
• Adjustable seat (height and armrest) with safety belt
• Adjustable steering column
• Power steering
E
• Metal protection above cab
• Sun visor
• Left and right exterior rearview mirrors F

• Hour meter
• Boom angle indicator
• Mudguards
• Stabilisers in the machine gauge with weight-bearing presence contactor G

• Forks
• Manual fork carriage with 2 pins
• Rear hitch
• Road Mode wheel configuration selector button H

• Beacon light
• Front and rear full beam headlights
• Folding rear lights, working position and road driving position (Option)
• Diesel fuel prefilter with water separator

I
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1.3 - OPTIONAL EQUIPMENT
1.3.1 - Slings attached 3T (6,615 lb)
Slings attached
Option number 4000072600
Nominal capacity 3T (6,615 lb)
1.3.1.1 - Main components
Marking Description
1 Tool holder carriage
2 Shackle
3 Hook
4 Overload limitation label
1.3.1.2 - Characteristics
Lifting hook mounted on tool holder carriage, designed to operate under dynamic and static
load, in horizontal position.
The safety coefficient used is in compliance with the legislation on lifting apparatus or attachment tests.
1.3.1.3 - Control
The joystick ( P211 ) controls movements of the boom and the option tilt ( Section C 2.5.8
- Joystick - Operator's manual).
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1.3.1.4 - Operation A
Operation instructions
The swivel in the hook is only to be used to align with the load and support it in a fixed position,
it is not designed for rotation under load. The swivel head permits the hook to rotate and avoid
the chains twisting.
Do not use slings attached : B
• For pulling loads laterally.
• Under conditions of repeated cyclic fatigue : i.e. fast running on a bumpy surface.
This option is designed for load lifting necessarily in horizontal position.

C
When using the jib, it is forbidden to use the carriage tilt (down or up) while there is a load on the jib.
It is strictly forbidden to move the load (drive the telescopic handler) with the jib in high position.
D
The load must be lifted with the mast positioned as specified on the load charts.
If it must be moved, the load must be kept in the low position. Speed of movement must not exceed 5 km/
h (3,1 mph) and the load must be secured to the telescopic handler fork carriage.
Working conditions E
Raise or lower the boom to the appropriate height for lifting the load.
Lift the load smoothly and with the boom fully retracted.
Travel as specified Section A - Safety precautions.
1.3.1.5 - Lubrication and maintenance
F
If the hook is damaged, stop using the attachment immediately. Change it.
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2 - Overall dimensions
General diagram HTL 4010 - HTL 3510 - HTL 3010
Overall dimension specifications

Marking HTL 4010 HTL 3510
Mètre Feet inch Mètre Feet inch
A 5,14 16 ft 10 in 5,14 16 ft 10 in
B 2,25 7 ft 5 in 2,25 7 ft 5 in
C 2,42 7 ft 11 in 2,42 7 ft 11 in
D 2,78 9 ft 1 in 2,78 9 ft 1 in
E 0,40 1 ft 4 in 0,40 1 ft 4 in
F 1,85 6 ft 1 in 1,85 6 ft 1 in
G 0,94 3 ft 1 in 0.94 3 ft 1 in
H 2,23 11 ft 2,23 11 ft
I 2,71 7 ft 4 in 2,71 7 ft 4 in
J 1,66 5 ft 5 in 1,66 5 ft 5 in
K 39 ° 39 °
L 23 ° 23 °
M 103 ° 103 °
N 2,55 8 ft 4 in 2,55 8 ft 4 in
O 4,80 15 ft 9 in 4,80 15 ft 9 in
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Overall dimension specifications A

Marking HTL 3010
Mètre Feet inch
A 5,14 16 ft 10 in
B
C
D
2,25
2,42
2,78
7 ft 5 in
7 ft 11 in
9 ft 1 in
B
E 0,40 1 ft 4 in
F 1,85 6 ft 1 in
G 0.94 3 ft 1 in
H 2,23 11 ft
I
J
2,71
1,66
7 ft 4 in
5 ft 5 in
C
K 39 °
L 23 °
M 103 °
N 2,55 8 ft 4 in
O
Technical characteristics
4,80 15 ft 9 in
D
HTL 4010 HTL 3510
Metric Imperial Metric Imperial
Vehicule mass without accessory 8440 kg 19,492 lb 8300 kg 18,302 lb
Vehicule mass with bucket
Vehicule mass with fork
Total weight allowed on road
9040 kg
8740 kg
9750 kg
19,933 lb
19,272 lb
28,665 lb
8910 kg
8610 kg
9450 kg
19,647 lb
24,321 lb
18,985 lb
E
Total weight allowed in load :
12730 kg 28,07 lb 12300 kg 27,122 lb
Gross vehicle weight rating
Metric
HTL3010
Imperial
F
Vehicule mass without accessory 8300 kg 18,302 lb
Vehicule mass with bucket 8910 kg 19,647 lb
Vehicule mass with fork 8610 kg 24,321 lb
Total weight allowed on road
Total weight allowed in load :
Gross vehicle weight rating
9450 kg
12300 kg
18,985 lb
27,122 lb
G
4000328140 E01.15 AUS 109

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3 - Working area
3.1 - MACHINE HTL4010
Working area
)RUNV31
3
3
3
68° F 0D[LPXPFDSNJ
H
10 F
60° 10
E E
9 9
D D
T
50°
8 8
C C
40° B B
L
7 7
6 A 6 A
30°
Kg
5 5
00
4
30
Kg
4
00
4
20°
40
3
1000Kg
1500Kg
2000Kg
0
3
200Kg
500Kg
800Kg
1000Kg
1500Kg
2000Kg
2500Kg
3000Kg
4000Kg
2
2 10°
0.6 m
0.6 m
1
1
1
0m
0m 0°
0
5 3 1 0m
5 4 3 2 1 0m
7.2 7.2
Working area
)RUNV31
HTL 3510 3

3
3
0D[LPXPFDSNJ
65° F
10 60°
E
9
50° D
8 C
7 40° B
6 A
30°
5
4
20°
3
2 10°
2500 kg
3500 kg
2000 kg
1500 kg
1000 kg
800 kg
500 kg
0.6 m
1
0 m 0°
-2° 2 1 0m
7.2 5.8 4.2 2.5
110 4000328140 E01.15 AUS

Telescopic handlers
3.3 - MACHINE HTL3010 A

Working area
)RUNV31
HTL 3010 3
B
3
3
0D[LPXPFDSNJ
65° F
10 60°
E
9
50° D
8 C
7 40° B
A
C
6
30°
5
4
20°
3
2 10°
2500 kg
2990 kg
2000 kg
1500 kg
1000 kg
800 kg
500 kg
0.6 m
1
D
0 m 0°
-2° 2 1 0m
7.2 5.8 4.2 2.5
Working area
HTL 7732
)RUNV31
3
3
E
3
0D[LPXPFDSOEV
65° F
60°
E
IW
50° D
IW C
IW
IW
30°
40° B
A F
IW
IW
10°
1760 lbs
5500 lbs
7700 lbs
4400 lbs
1100 lbs
3300 lbs
2200 lbs
IW
G
2 ft
IW
-2°
IW IW IW IW IW IW
ANSI/ITSDF B56.6-2005 PART III D
4000328140 E01.15 AUS 111

Telescopic handlers
4 - Noise emission level

The sound power values indicated in the technical characteristics tables are obtained in the following
conditions :
• For machines equipped with internal combustion engines, the guaranteed accoustic level LWA
(displayed on the product) and is measured in accordance with the method and the conditions
described in Appendix III, Part B, Point 36 of the 2000/14/CE European directive.
The Telehandler's noise emission sound levels comply with :

• The European directives mentioned on the compliance certificate supplied with the machine.
• National road regulations.
• National work regulations.
The LWA noise emission level is shown on the machine.
To avoid any increase in noise emission, all panels and other sound-absorbing materials must be
replaced in their original position after maintenance and repair work.
Do not modify the machine in a way that may increase noise emissions.
Technical characteristics (For machines fitted with engine PERKINS 1104D44T only)
HTL 4010 - HTL 3510 (HTL 7732)
Noise emission level at driving station 75 dBA
Maximum noise emission level 105 dBA
Technical characteristics (For machines fitted with engine PERKINS 854E-34TA only)
HTL 4010 - HTL 3510 (HTL 7732)
Technical characteristics (For machines fitted with engine KOHLER KDI 3404 TCR only)
HTL 4010 - HTL 3510 (HTL 7732)
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5 - Telehandler vibration A
The hand and feet vibration values indicated in the technical characteristics tables are obtained in the
following conditions :
• The maximum quadratic mean value weighted as an acceleration frequency and the total value of the
vibrations to which the hand-arm system is exposed have been measured on the products by simulating
a cycle representative of normal use. The values meet the requirements of the 2006/42/CE machine
B
directive.
The load and acceleration values for vibrations transmitted to the body are below the levels required
by the various regulations. The measurements have been performed according to the currently
applicable standards.
C
Hand and body vibration are measured in accordance with method and conditions described in
standard ISO5349-1 and ISO2631-1.
Hand - feet vibration

HTL 4010 - HTL 3510 - HTL 3010
< 2,5 m/s2
D
Body vibration < 0,5 m/s2
4000328140 E01.15 AUS 113

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114 4000328140 E01.15 AUS

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H - Lubrication and maintenance
Lubrication and maintenance A

1 - Maintenance guidelines
The Telehandler was given an arbitrary Design Life of 10 years at the design stage of the product.
There are a number of factors which can affect the design life including but not limited to, severity of
operating conditions/routine maintenance which should be carried out in accordance with this manual.
Severity of operating conditions may require a reduction in time between maintenance periods. These
B
factors are amongst a number, which may extend or shorten the Design Life of the product. Local
Regulations may also require Enhanced Periodic Inspection/ 10 year inspection to be carried out on
the product to extend its service life beyond the Design life.
Perform the maintenance in accordance with the maintenance schedule set out on the following pages.
• Adapt the frequency of maintenance according to use to obtain maximum service life.
C
• Read all of the instructions in the guide before starting Telehandler maintenance.
• Follow the Telehandler shut-down procedure before performing any servicing or maintenance
• For all checks, park the Telehandler on flat ground, stop the engine, actuate the parking brake and
lower the booms to the parked position.
• To obtain accurate fluid level readings ensure that the machine is on level ground.
D
• Before each check : top-up, refill or lubrication check, you must clean the filler inlets, the filler caps
and the grease points.
• After lubricating the machine, actuate all functions several times to distribute the lubricants. Perform
all these maintenance procedures without any accessories fitted.
• Check the state of the filling plug seals; do not forget to replace them if they are damaged or worn. E
• Maintain the Telehandler and associated equipment, especially the brakes and the steering, in good
condition to protect your safety and to comply with the statutory requirements.
Do not modify or alter the machine or its equipment without the manufacturer's permission.
• Always check the pins, the bushes, the fastening pins, etc… daily
F
• Incorrect or poorly performed maintenance can damage the machine.
Stop the engine before opening the canopy : Presence of moving parts that could cause bodily injuries.
• Check that there are no tools or other objects left in the engine compartment after maintenance work
G
has been completed.
• Drain the engine after operation when the oil is hot.
N.B.-:-Mechanical vibrations may occur on the machine during the first 50 hours of operation. This
phenomenon will disappear after the internal combustion engine's break-in period.
• Remove the keys from the ignition switch during maintenance work.
H
Do not stand close to the front or rear of the machine while the engine is running.
• Batteries, plastic objects or other components of a toxic nature that could be harmful to the
environment must be disposed of in a way that does not harm. Ensure that they must be disposed I
of in a way that does not harm.
N.B.-:-Accumulators are pressurized vessels. It is the user's responsibility to refer to the national
regulations in force in the country of use concerning their use and disposal.
4000328140 E01.15 AUS 115

Telescopic handlers
2 - Maintenance instructions
Before operate maintenance operation on hydraulic component or component localized under the boom,
use safety prop as follow :
• Place the boom to 24° - 25° (without load and machine on wheels).
• Put the safety prop in the boom in the same way that it is shown in the picture (it is prohibited to lift up
or lift down the boom with the safety prop placed).
• Proceed to work under boom.
Safety prop
• Wear protective clothing and personal protection equipment supplied or required by the job
conditions.
Do not wear loose fitting clothes or jewellery that could get caught on controls or moving parts.
Do not perform Telehandler servicing or maintenance with the engine running.
• If the engine is started inside a building, there must be sufficient ventilation to remove the exhaust
gases.
• Always refit the guards and plates that have been dismantled before starting the machine.
• Paintwork shall be performed in well-ventilated premises using approved protective equipment.
• The engine cooling system operates under pressure. The pressure is regulated by the radiator cap.
Never dismantle a component from the system while it is hot. Always loosen the radiator cap slowly and
let the pressure escape before removing it completely.
116 4000328140 E01.15 AUS

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• To prevent any risks of fire or explosion, keep any naked flames away from the battery. To prevent
any risk of sparks that could cause an explosion, use the battery cables in accordance with the
A
instructions provided in this manual.
• Hydraulic oil leaks or fluid under pressure can cause serious injury.
Do not use your hands to check for oil leaks. Search for leaks with a piece of cardboard or paper. B
N.B.-:-Stop the engine and depressurize in the system before intervening on the hydraulic system.
N.B.-:-Check that all connections are tight before restarting the machine or pressurizing the system.
Do not intervene on the air-conditioning system. A refrigerant fluid leak can cause serious injury.
Contact HAULOTTE Services®. C
• The diesel in the injection system is under high pressure. For any operations or adjustments, please
contact a qualified technician or your dealer. Failure to comply with these guidelines can result in
serious injury.
Never let anyone stand or work under the boom when it is raised unless the safety prop is installed and
the cylinder is secured. D
Section H 7.2 - Hydraulics.
Never try to repair or tighten pressurized pipes or hoses.
Never perform lubrication or adjustment operations when the machine is in motion or when the engine is
E
running.
• Protective equipment must be worn when performing any service/repair on the machine.
4000328140 E01.15 AUS 117

Telescopic handlers
Consumables (Fuels - Engine oil - Coolant level ...) - For machines fitted with engine PERKINS 854E-
34TA or KOHLER KDI 3404 TCR only
Fuels
N.B.-:-The fuel to be used is regulated by national laws; refer to these requirements to define the
appropriate fuel. Using unsuitable fuel may cause diminished performance, difficulties starting,
excessive pollution and premature wear. To establish the type of fuel suitable for the engine fitted on
your HAULOTTE® machine, please refer to the engine manufacturer's manual. The engine may not be
covered by the warranty in case of damage caused by using unsuitable fuel.
The engine fitted in your HAULOTTE® machine is CAUTION

designed to run only with diesel fuel containing a very
low sulphur content. If the ASTM D5453, ASTM D2622 or DIESEL LOW SULFUR OR ULTRA-LOW SULFUR /
ISO 20846 ISO 20884 test methods are used, the level of DIESEL À FAIBLE OU TRÈS FAIBLE TENEUR EN SOUFRE /
GASÓLEO BAJO EN AZUFRE O ULTRA-BAJO EN AZUFRE /
sulphur in the low sulphur content diesel fuel must be DIESEL A BASSO TENORE DI ZOLFO O A BASSISSIMO TENORE DI ZOLFO /
less than 15 ppm (mg/kg) or 0,0015 % by weight. DIESELKRATSTOFF MIT NIEDRIGEM ODER EXTREM NIEDRIGEM SCHWEFELGEHALT
EU (EN 590)
307P232480 b
US (ASTM D975-91 class 2D)
Using diesel fuel containing more than 15 ppm of sulphur in these engines may damage the anti-pollution
control systems (sometimes irreversibly) or reduce the service frequency.
Table of technically permitted fuels

Engines Fuels
American gas oil
according to
European fuel oil
ASTM D975
European gas oil according to Japanese gas oil
Grade 1D S15
according to BS2869 2010 according to JIS
American gas oil
EN590 class A2 or UE K2204
according to
equivalent
ASTM D975
Grade 2D S15
PERKINS 854E-34TA
(Wall Flow DPF)
KOHLER KDI 3404 TCR
Compliant
Not compliant
118 4000328140 E01.15 AUS

Telescopic handlers
Engine oil A
Only use API CJ-4 oil or equivalent. Please refer to the
C
table of permitted engine oils.
PISAE J
-4
A
10W-40
15W-40
B
A
EC
9
A E
4000019700 a
C
PISAE J
C
-4
A
10W-40
5W-40
A
EC
9
A E
4000318680 a
Not using the appropriate specification of engine oil may reduce the service life of the engine and post-
treatment system. D
API CJ-4 and ACEA E9 oil categories have the following chemical limits :
• 0,1 % maximum sulfated ash
• 0,12 % maximum phosphorous
• 0,4 % maximum sulfur
Table of permitted engine oils
E
Engines Engine oil specification
API CJ-4
PERKINS 854E-34TA (Wall Flow DPF) ACEA E9
ECF-3
API CJ-4
F
ACEA E9
KOHLER KDI 3404 TCR
ACEA E7
ACEA E6
CC, CD, CD-2, CF-4, CG-4, CH-4, CI-4 engine oils, not approved, must not be used.
G
4000328140 E01.15 AUS 119

Telescopic handlers
Coolant
N.B.-:-The engine fitted in your HAULOTTE® machine must operate with a 1:1 solution of water and
glycol. This concentration allows the NOx reduction system to operate correctly in environments where
the temperatures are high.
Glycol in the coolant helps to provide protection against the following conditions :
• Boiling
• Freezing
• Cavitation of the water pump
Coolant service life
Coolant type Service life 1
Commercial heavy-duty antifreeze that meets ASTM D6210 Every 3000 hours of operation (or every 2 years)
Water and commercial SCA inhibitor Every 3000 hours of operation (or once a year)
1
:
Use the interval that occurs first. The cooling system must also be flushed out at this time.
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3 - Repairs and adjustments A

Significant repairs or adjustments on the safety systems or elements (concerns mechanics, hydraulics
and electrics).
Any modifications not approved by HAULOTTE® are not permitted.
The manufacturer's product liability will be void if the work specified above is not performed
B
by HAULOTTE® approved staff or if the spare parts are not original spare parts.
4000328140 E01.15 AUS 121

Telescopic handlers
4 - Lubrication and maintenance schedule
500h
50h
10h
122 4000328140 E01.15 AUS

Telescopic handlers
For machines fitted with : Engine PERKINS 1104D44T A

4*
2000h
1500h
1000h
500h
250h
100h
B
50h
10h
C
2*
D
5*
5*
10h
50h
F
100h
200h
500h
1000h
1500h
2000h
G
4000328140 E01.15 AUS 123

Telescopic handlers
For machines fitted with : Engine PERKINS 1104D44T

2000h
1500h
1000h
500h
250h
100h
50h
10h
1*
2*
2*
7* 3*
7*
10h
50h
100h
250h
500h
1000h
1500h
2000h
6* 8* 6*
124 4000328140 E01.15 AUS

Telescopic handlers
Description of the components A

Symbol Marking Description
Check the level

Filter
1*
Oil change
Lubrication
B
2* Diesel circuit
3* Cooling system
C
4* Air filter (system)
D
5* Internal combustion engine
E
6* Travel axles
F
7* Hydraulic circuit
8* Battery
4000328140 E01.15 AUS 125

Telescopic handlers
For machines fitted with : Engine PERKINS 854E-34TA

4*
2000h
1500h
1000h
500h
250h
100h
50h
10h
2*
5*
5*
10h
50h
100h
200h
500h
1000h
1500h
2000h
126 4000328140 E01.15 AUS

Telescopic handlers
For machines fitted with : Engine PERKINS 854E-34TA A

3000h
2000h
1500h
1000h
500h
250h
B
100h
50h
10h
C
1*
D
2*
2*
7* 3*
E
7*
10h
50h
F
100h
250h
500h
1000h
1500h
2000h
3000h
G
6* 8* 6*
4000328140 E01.15 AUS 127

Telescopic handlers

Check the level

Filter
Oil change
1* Lubrication
2* Diesel circuit
3* Cooling system
6* Travel axles
8* Battery
128 4000328140 E01.15 AUS

Telescopic handlers
For machines fitted with : Engine KOHLER KDI 3404 TCR A

4*
2000h
1500h
1000h
500h
250h
100h
B
50h
10h
C
2*
5* D
5*
10h
50h
F
100h
200h
500h
1000h
1500h
2000h
G
4000328140 E01.15 AUS 129

Telescopic handlers
For machines fitted with : Engine KOHLER KDI 3404 TCR
3000h
2000h
1500h
1000h
500h
250h
100h
50h
10h
1*
2*
2*
7* 3*
7*
10h
50h
100h
250h
500h
1000h
1500h
2000h
3000h
6* 8* 6*
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Description of the components A

Check the level

Filter
1*
Oil change
Lubrication
B
2* Diesel circuit
3* Cooling system
C
D
E
6* Travel axles
F
8* Battery
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Telescopic handlers
5 - General program / Recommendations

The design service life of the products covered by this manual is for a period of 10 years. This service
life is based on the machine being maintained within the maintenance regime set down in the
Maintenance Manual supplied with the product.
It must be noted that should the product be subject to ongoing use in harsh environments, then the
effective service life will be reduced. Contact Haulotte Services for further advice.
The time periods below are recommended for fuel-powered machines in normal use.
Symbol Meaning Symbol Meaning
Systematic replacement
Visual inspections Operation requiring HAULOTTE
Services® authorisation
Visual inspection with
dismantling and exchange or
Check-Test See user manual or replacement if necessary
machine maintenance book (1) Operation requiring HAULOTTE
Services® authorisation Increase
in periodical inspections
Check level Tightening (bolt, etc.)
Lubrication-Lubrication Tolerance (clearance lubrication)
Static and dynamic tests For

countries where machines are
Oil change
(2) not subject to controlled periodic
maintenance
1 - Increase in periodical inspections
2 - For countries where machines are not subject to controlled periodic maintenance
132 4000328140 E01.15 AUS

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A
Increase in periodical inspections : Depending on the condition of certain critical components after 5000
hours, the maintenance staff may have to reduce the interval between periodical inspections and
maintenance. If the decision is made not to replace a part, the part concerned must be recorded in the
inspection schedule.
Each day and before the beginning of a new work period and on each change of operator, the machine
B
must be subjected to a visual inspection and a complete functional test. Any repairs required must be
performed before the machine is used, its correct operation depends on it. Inspect the following items :
• State of the structure's parts : Chassis, Boom, jib, platform.
• Absence of cracks, broken parts, damaged paint.
• No distortion in metal components or visible damage. C
• Absence of foreign objects at the ends of boom/attachments.
• Presence and check the original position of the platform control box sliding bar.
• Cylinders :
• No leaks : Refer to the Maintenance book. D
• No rust and abrasions on the cylinder rod.
• Steering system : Wheels, Axles, Brake and Tyres :

• No cracks, distortions, damaged paint or other faults.
E
• Condition of the tyres (cuts, excessive wear, etc.)
• Condition of the pulley system :
• No excessive clearance : Refer to the Maintenance book.
• No missing or loose bolts. F

• Grease the extension system if necessary.
4000328140 E01.15 AUS 133

Telescopic handlers
Intervals
Every Every Every Every Every Every Every Every Every
Area
Daily 50 100 250 500 1000 1500 2000 3000 5000
hours hours hours hours hours hours hours hours hours
General checks
Structure parts
Windscreen washer fluid
Oil, water, fuel leaks

Appearance of the mechanical
parts, hydraulic hoses and
wiring
Attachment device : nuts and
bolts and hydraulic fitting
Operation of the work lighting
controls, the light indicators,
display load moment indicator
Diesel engine operation
State of anti-slip parts

State of tires and inflation
pressure
Wheel nut torque
Lubrication
Cylinder pins
Boom bottom shaft
Telescopic boom pads
Suspension, driver seat rails

Diesel circuit
Condensation
Diesel pre-filter
(1)(2)
Filter
Cooling system
Coolant
(1) (2)(3)
State of the hoses and collars
Radiator slats
Cleanliness of the radiator's
protection grill
Air filter (system)
Remove the dust
Primary air filter
Secondary air filter

Internal combustion engine (See manufacturer's guide)
Oil
Oil filter cartridge
134 4000328140 E01.15 AUS

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Diesel particulate filter

A
(2)
Engine crankcase breather

(2)
Engine mounting
Glow plugs B
Belt tension
(1) (2) (3)
Travel axles (See manufacturer's guide)
Front axle : Reducer +
differential + transfer case on
front axle + pivots
Rear axle : Reducer +
C
differential + pivots
Epicyclic gears
Hydraulic circuit
Hydraulic oil
Attachment hydraulic oil

D
Transmission hydraulic filter
Pressures
Battery
(1) : For machines fitted with : Engine PERKINS 1104D44T.
(2) : For machines fitted with : Engine PERKINS 854E-34TA.
E
(3) : For machines fitted with : Engine KOHLER KDI 3404 TCR.
4000328140 E01.15 AUS 135

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6 - Detailed program
The time periods below are recommended for fuel-powered machines in normal use.
Symbol Meaning Symbol Meaning
Systematic replacement
Visual inspections Operation requiring HAULOTTE
Services® authorisation
Visual inspection with
dismantling and exchange or
Check-Test See user manual or replacement if necessary
machine maintenance book (1) Operation requiring HAULOTTE
Services® authorisation Increase
in periodical inspections
Check level Tightening (bolt, etc.)
Lubrication-Lubrication Tolerance (clearance lubrication)
Static and dynamic tests For

countries where machines are
Oil change
(2) not subject to controlled periodic
maintenance
1 - Increase in periodical inspections
2 - For countries where machines are not subject to controlled periodic maintenance
During the periodic inspection of the 2000 h (visual inspection with dismantling and exchange or
replacement if necessary), a record must be made of all parts that have been dismantled but not replaced
136 4000328140 E01.15 AUS

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Area
500 h or 6 month service
Type of intervention Area Type of intervention
A
General checks Lubrication
Windscreen washer fluid Cylinder pins

Appearance of the
mechanical parts, hydraulic
Boom bottom shaft

B
hoses and wiring
Attachment device : nuts
and bolts and hydraulic Suspension, driver seat rails
fitting
Operation of the work
lighting controls, the light
indicators, display load
Diesel circuit C
moment indicator
Diesel engine operation Condensation
State of anti-slip parts Pre-filter

pressure
Filter
(1)(2)
D
Wheel nut torque Air filter (system)
Internal combustion engine (See manufacturer's guide) Remove the dust
Oil Primary air filter
Oil filter cartridge Secondary air filter E

Belt tension Cooling system
Travel axles (See manufacturer's guide) Coolant

differential + transfer case
on front axle + pivots
Hoses and collars
Radiator slats
F
Epicyclic gears
protection grill
Hydraulic circuit Battery
Date :
Hydraulic oil Level
G
Number of hours :
Intervenor :
Comments
HAULOTTE Services® contract number :
Intervention sheet number :
Signature :
H
4000328140 E01.15 AUS 137

Telescopic handlers

Area Type of intervention Area Type of intervention
Oil, water, fuel leaks Boom bottom shaft

Appearance of the
mechanical parts, hydraulic Telescopic boom pads
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure
Oil filter cartridge Secondary air filter
Engine mounting Coolant
Glow plugs Hoses and collars
Travel axles (See manufacturer's guide) Radiator slats

protection grill
Hydraulic circuit
Epicyclic gears Hydraulic oil
Battery Attachment hydraulic oil
Level Transmission hydraulic filter

Date :
Number of hours :
Intervenor :
Comments
Signature :
138 4000328140 E01.15 AUS

Telescopic handlers
Area
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Engine crankcase breather Coolant
(1)
Travel axles (See manufacturer's guide) Hoses and collars
differential + transfer case Radiator slats
F
Rear axle : Reducer + Cleanliness of the radiator's
differential + pivots protection grill
Epicyclic gears Battery
Hydraulic circuit
Hydraulic oil
Level
G
Date :
Number of hours :
Intervenor :
Comments
Signature :
H
4000328140 E01.15 AUS 139

Telescopic handlers
2000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

(1) (2)

protection grill
Hydraulic circuit
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
140 4000328140 E01.15 AUS

Telescopic handlers
Area
2500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
differential + transfer case Hoses and collars
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 141

Telescopic handlers
3000 h service
General checks Battery
Windscreen washer fluid Level
Oil, water, fuel leaks Lubrication

Appearance of the
mechanical parts, hydraulic Cylinder pins
hoses and wiring
and bolts and hydraulic Boom bottom shaft
fitting
moment indicator
Diesel engine operation Suspension, driver seat rails
State of anti-slip parts Diesel circuit

Condensation
pressure
Wheel nut torque Pre-filter
Internal combustion engine (See manufacturer's guide) Filter
Oil Air filter (system)
Oil filter cartridge Remove the dust
Diesel particulate filter Primary air filter

(1)
Alternator belt Secondary air filter

(1)
Engine crankcase breather Cooling system

(1)
Belt tension Coolant

(2) (1) (2)(3)
Engine mounting Hoses and collars
Glow plugs Radiator slats

protection grill
differential + transfer case Hydraulic circuit
Hydraulic oil
Epicyclic gears Attachment hydraulic oil

Date :
Number of hours :
Intervenor :
Comments
Signature :
142 4000328140 E01.15 AUS

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Area
3500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 143

Telescopic handlers
4000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

(1) (2)

protection grill
Hydraulic circuit
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
144 4000328140 E01.15 AUS

Telescopic handlers
Area
4500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
(1)
F
Hydraulic circuit
Hydraulic oil
Level
G
Date :
Number of hours :
Intervenor :
Comments
Signature :
H
4000328140 E01.15 AUS 145

Telescopic handlers
5000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

(1)

protection grill
Hydraulic circuit

Date :
Number of hours :
Intervenor :
Comments
Signature :
146 4000328140 E01.15 AUS

Telescopic handlers
Area
5500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 147

Telescopic handlers
6000 h service

Appearance of the
hoses and wiring
Boom bottom shaft
controls, the light indicators, Telescopic boom pads

Condensation
pressure

(1)

(1)

(1)

(2) (1) (2)(3)

protection grill
differential + transfer case on Hydraulic circuit
front axle + pivots
Hydraulic oil
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
148 4000328140 E01.15 AUS

Telescopic handlers
Area
6500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 149

Telescopic handlers
7000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

protection grill
Hydraulic circuit

Date :
Number of hours :
Intervenor :
Comments
Signature :
150 4000328140 E01.15 AUS

Telescopic handlers
Area
7500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
(1)
F
Hydraulic circuit Level G

Hydraulic oil
Date :
Number of hours :
Intervenor :
Comments
Signature :
H
4000328140 E01.15 AUS 151

Telescopic handlers
8000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

(1) (2)

protection grill
Hydraulic circuit
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
152 4000328140 E01.15 AUS

Telescopic handlers
Area
8500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 153

Telescopic handlers
9000 h service

Appearance of the
hoses and wiring
and bolts and hydraulic Boom bottom shaft
fitting
moment indicator

Condensation
pressure

(1)

(1)

(1)

(2) (1) (2)(3)

protection grill
differential + transfer case Hydraulic circuit
Hydraulic oil

Date :
Number of hours :
Intervenor :
Comments
Signature :
154 4000328140 E01.15 AUS

Telescopic handlers
Area
9500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 155

Telescopic handlers
10000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

(1)(3) (2)

protection grill
Hydraulic circuit
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
156 4000328140 E01.15 AUS

Telescopic handlers
Area
10500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
(1)
F
Hydraulic circuit
Hydraulic oil
Level
G
Date :
Number of hours :
Intervenor :
Comments
Signature :
H
4000328140 E01.15 AUS 157

Telescopic handlers
11000 h service

Appearance of the
hoses and wiring
fitting
Diesel circuit
moment indicator

Filter
pressure

protection grill
Hydraulic circuit

Date :
Number of hours :
Intervenor :
Comments
Signature :
158 4000328140 E01.15 AUS

Telescopic handlers
Area
11500 h service
A

Appearance of the
Boom bottom shaft

B
hoses and wiring
fitting
Diesel circuit C
moment indicator

pressure
Filter D
Belt tension
Cooling system
E
Radiator slats F
Epicyclic gears
protection grill
Hydraulic oil Level
Date :
Number of hours :
G
Intervenor :
Comments
Signature :
4000328140 E01.15 AUS 159

Telescopic handlers
12000 h service

Appearance of the
hoses and wiring
Boom bottom shaft
controls, the light indicators, Telescopic boom pads

Condensation
pressure

(1)

(1)

(1)

(2) (1) (2)(3)

protection grill
differential + transfer case on Hydraulic circuit
front axle + pivots
Hydraulic oil
Pressures
Date :
Number of hours :
Intervenor :
Comments
Signature :
160 4000328140 E01.15 AUS

Telescopic handlers
7 - General points A
7.1 - MECHANICAL
7.1.1 - Bolts and Tightening torques
• Bolts that become damaged and need to be replaced, must be replaced with bolts of identical
specification : Type, Length, Diameter, Class .
B
• Tighten to the torque indicated when reassembling.
7.1.2 - Pins and bearings
Except maintenance schedule, check pins and bearings in the following cases : C
• Abnormal noise during the movements of the structure.
• Observance of excessive amounts of foreign material around the bearing extremities during the daily
visual inspections.
• Poor or no maintenance. D
Replace slew ring in the following cases :
• Deformations, fatigue failure of the bearings and/or the pins.
• Presence of excessive clearance between the pin and housing(> at 0,5 mm).
• Presence of deformations, cracks or breakage of the bearings and/or the pins.

E
• Presence of scoring on the surface of the bearing.
• If there is excessive friction.
When reassembling bearings and pins ensure that : F

• Lightly lubricate the housing into which the bearing is to be installed.
• Insert the bearing using a bearing drift, preferably out of mild steel.
• The bearing, the bearing drift and the bearing housing must be correctly aligned during the assembly
process. G
• The recommended values for the bearing drift are given on the diagram below :
4000328140 E01.15 AUS 161

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Recommended Values
A D
Marking Description
A At least 0,5 times the nominal diameter
B Make a chamfer
C Nominal diameter of the bearing - 0,2 / - 0,3 mm
D Bearing drift
E Diameter of the bearing guide - 0,20 / - 0,25 mm
F Bearing
G Housing
• After inserting the bearing, lubricate and fit the pin.
7.1.3 - Bearings
Action on bearings needs to be taken outside the normal maintenance schedule if the following
occurs :
• Abnormal noise during the movements of the structure.
• Machine not use for a period of 6 months or more.
• Environment of storage and specific uses(Strong moisture and salinity of the air).
Checking procedure :
• After disassembling the affected pivot, protect the bearing from external pollutants and potential
damage.
• Clean the bearing with a suitable solvent.
• Replace the bearing in the following cases :
• Presence of abrasions in the bearing housing and/or inside the bearing itself.
• Presence of abrasion, wear, oxidation, deformations of the balls (or rollers) and the ring rollers.
162 4000328140 E01.15 AUS

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• Reassembly of the bearing/pivot : A

• Clean the bearing housing or pin in order to remove all the foreign objects/abrasions.
• Lightly lubricate the bearing housing and/or pin.
• Lightly lubricate the outer ring of the bearing.
• Fit a bearing in a boring, take support on the external ring of the bearing. B
• Fit a bearing on a pin, take support on the interior ring of the bearing.
7.2 - HYDRAULICS
7.2.1 - Replacing damaged of hoses

C
Replace hoses in the following circumstances :
• Tears in the outer casing.
• Cracks in the outer casing.
• Apparent shielding. D
• Visible leak in the hose.
• Damage to the outer casing caused by chemical reaction from a foreign source.
To protect personal safety, observe the following conditions when disassembling or reassembling
components :
• Stow and park the machine on level cleared ground(The machine should not be tilted. The boom at
E
horizontal position).
• Stow the machine completely.
• Place barriers around the perimeter of the work area (risk area = maximum height of the machine).
• Locate the faulty hose/s and their end connection points, to ensure proper machine operation after
intervention. F
• Identify and memorise the hose path of the hose to be replaced.
Use an oil collection pan to avoid polluting the environment.
N.B.-:-Slowly undo the hose end fitting to allow the residual hydraulic pressure to dissipate.
G
• After hose removal, plug the the hose ends and components the ports from which the hose was removed,
to avoid polluting the hydraulic system.
• Check the cleanliness of the hoses and hydraulic components (no metal cutting, rubber, plastic, …).
• If necessary, drain and clean the whole system (tank included).
H
• Tighten to the torque indicated when reassembling.
4000328140 E01.15 AUS 163

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Tightening torque table

Description Torque (JIC) Torque (ORFS)
Hose 1/4" (diameter 6mm) 1,5 daN.m(11,08 lbf.ft) 2,6 daN.m(19,22 lbf.ft)
Hose 3/8" (diameter 10mm) 3,5 daN.m(25,86 lbf.ft) 4,2 daN.m(31,04 lbf.ft)
Hose 1/2" (diameter 12mm) 5 daN.m(36,95 lbf.ft) 5,7 daN.m(42,12 lbf.ft)
Hose 5/8" (diameter 16mm) 8 daN.m(59,12 lbf.ft) 8,5 daN.m(62,82 lbf.ft)
Hose 3/4" (diameter 19) 10 daN.m(73,91 lbf.ft) 12,2 daN.m(90,17 lbf.ft)
• Place the machine in its operating configuration.

• To purge the hydraulic system, operate the function/s on the machine that correspond to the hose/s that
has/have been replaced, a few times.
• Check the oil level in the hydraulic oil tank.
• Check the pressure.
7.2.2 - Evaluation of leaks on hydraulic cylinders
These measures must be taken each time an anomaly has been detected in the hydraulic
cylinder during daily inspection and periodic maintenance checks.
Generic Control :
• Position a load equal to the rated capacity on the cage (or platform).
• Raise the loaded attachment using the ground control box. To activate the cylinder to be tested,
proceed as follows :
• Boom lift cylinder : Raise the boom approximately half way to its maximum angle.
• Telescoping cylinder : Lift the boom to its maximum angle and telescope approximately 50 cm.
• Crowding/Discharging cylinder : Place a load on the forks and put them in a horizontal position. The drift of the
forks must be less than 2 ° after 15 mn.
• Measure the distance between a reference point on the attachment and the ground.
• Leave the machine in this condition for 15 mn (minutes).
• Check the distance between the reference point on the accessory and the ground again.
• If the difference between two measurements does not exceed 4 cm : the test validates correct operation.
• If the difference between two measurements exceeds 4 cm, contact HAULOTTE Services® or carry out the
additional tests described below.
164 4000328140 E01.15 AUS

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Control cylinder by cylinder : A

• Position a load equal to the rated capacity on the attachment.
• Perform the movement of the concern cylinder to half of its stroke.
• Fix the cylinder with a comparator :

• Attach the body of the comparator on the cylinder rod. B
• The needle of the comparator must be in contact with the end of the casing of the cylinder.
• The target is to measure the creep of the cylinder rod.
• If the creep of the cylinder rod is higher than the values indicated in the table below, replace the
cylinder.
C
Maximum drift authorised due to an internal
Type of cylinders
leak of the cylinder
After 10 mn, creep After 60 mn, creep

Loads levelling cylinders and axle locking cylinders
Boom lifting cylinder, telescoping cylinder,

< 0,5 mm
After 10 mn, creep
< 2,5 mm
After 60 mn, creep
D
compensation cylinder (crowding) < 1 mm < 6 mm
7.3 - ELECTRIC
7.3.1 - Replacing damaged cables

E
• Locate the faulty wire/s and its/their points of connection to ensure continuity of machine operation
after the wire is replaced.
• Note the cable path to facilitate reassembly.
• Respect the order (configuration) of origin during the reassembly.

F
4000328140 E01.15 AUS 165

Telescopic handlers
8 - Every day or every 10 h of operation

8.1 - GENERAL CHECKS
• Perform a visual check for any leaks (Check the corresponding reservoir level if leak is detected).
• Check that there are no signs of scratches, tears and warping on the hoses, accessories and work
tolls.
• Check the attachment devices and the hydraulic connections.
• Check the appearance of the mechanical parts.
• Check the operation of the controls, control indicator lights and other system indicators.
• Check diesel engine operation : Check the colour of the exhaust fumes and locate any abnormal
noises.
• Check and clean the radiator's protection grill.
• Check the state of the anti-slip parts (cab access steps) and replace them if necessary.
• Check that the tires are not damaged after the first 10 hours and then after every 100 h of operation.
Check the tire inflation pressure : 4,5 bar(65,2 psi) minimum (For HAULOTTE® tyres, code : 2326014870
or 232601508).
During a pressure check or an inflation operation, always face the end of the tyre; never face the side of
the tyre.
• Check the wheel lug nut torque ( 300Nm) after the first 10 hours and then after every 100 of
operation.
Do not allow contact with abrasive materials.
166 4000328140 E01.15 AUS

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8.2 - LOAD MOMENT INDICATOR A

8.2.1 - Test procedure
The load moment indicator's function is to constantly monitoring the stability of the front of the
machine. To check that it is functioning correctly, proceed as follows :
• Without any payload on the machine, retract the boom fully and level it. B
Do not raise the boom during this test.
• Level the chassis.
• Press the TEST button on the anti-tipping system

display ( P219 ) for 1 s ( Section C 3.5.10 - Load
C
moment indicator). P218
P217
P216
D
P219
• All of the LEDs should flash and a warning signal should sound. This indicates that the system is
working properly.
E
8.2.2 - Checking procedure
Perform this operation on flat ground, with the chassis level, the wheels aligned and the stabilisers lifted.
F
• Lift a known load with the accessory.
• Telescope until load cut-off.
• Check that the results are consistant: check that the alphabetical reference (A, B, C, D, E, F) for the
boom extension and the area corresponding to the reference on the load capacity table match.
G
If the test gives another result, the system will not operate correctly. Reset the anti-tipping system.
4000328140 E01.15 AUS 167

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8.2.3 - Resetting procedure
To perform this operation :

• Raise the stabilisers.
• Place the machine on flat ground.
• Level the machine.
• Align the wheels.
• Retract the telescope section fully.
• Lift the boom to the maximum height.
• Check the temperature of the axle: the temperature of the axle must be between -20 °C(-4 °F) and 60
°C(140 °F) .
The procedure must be carried out without any accessories or load.
If these conditions are not satisfied, the resetting procedure may be distored and cause the weighing
system to be offset.
• Press on the TEST (P219) button for 6 s until you hear the beep to start the resetting procedure.
• The procedure is executed.
If a malfunction occurs, contact HAULOTTE Services®.
8.3 - DIESEL CIRCUIT
• To prevent condensation from forming, fill the reservoir every day after work (Capacity : 120 l(31,6 gal
US)).
• Drain any condensate and clean the diesel pre-filter.

• To access the diesel pre-filter, open the engine cover. The
pre-filter is located under the diesel filter
• Drain the water and dirt by removing the screw situated
under the pre-filter (For machines fitted with engine
PERKINS 854E-34TA or PERKINS 1104D44T only).
• Refit and tighten the purge screw.
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8.4 - COOLING SYSTEM A

• Check the coolant level :
• When the engine is cool, the liquid level must be situated between the min. and max. marks on the
expansion bottle.
• Open the radiator and top up with fluid as necessary. B
• Only refill with SHELL ANTIFREEZE -38 °C(-36,4 °F) coolant.
Do not remove the filling cap when the engine is hot. DANGER OF BURNS! Loosen the plug to the first
notch and let it depressurize, then unscrew the cap completely.
• Check the state of the hoses and that the collars are taut. C
8.5 - AIR FILTER (SYSTEM)
Never run the engine without an air cleaner element installed or with a damaged air cleaner element.
Do not use air cleaner elements with damaged pleats, gaskets or seals.
D
Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements
help to prevent airborne debris from entering the air inlet.
Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. E
• Empty the dust filter :
• Empty the dust evacutation valve ( 1 ) by pressing on the

evacuation slot in the direction of the arrow.
• Clean the evacuation slot.
F
• Clean away any remaining dust by pressing the upper part
of the valve. 1
G
N.B.-:-If the air cleaner element becomes plugged, the air can split the material of the air cleaner
element. Unfiltered air will drastically accelerate internal engine wear.
N.B.-:-Filter clogging check : Clogging is constantly being monitored via a sensor situated on the filter
body. Visually inspect the state of the sensor. If red marking is visible : Clean or replace the filter element
H
even if the cleaning frequency indicated above has not been reached. Clean the inside of the box.
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• Clean the primary air filter's filter cartridge :
• Remove the cover :

• Pull the trigger situated on the cover ( 1 ).
• Locate the angular position of the cover which should be
identical upon reassembly.
1
• Turn the cover to the right ( 2 ).
• Pull the cover to remove it.
• Turn and pull the outer cartridge.
2
• Clean the filter cartridge (replace it, at the latest, after
every 1000 h of operation or once a year).
• Blow with dry compressed air (with a maximum pressure
of 5 bar(72,5 psi)) from the inside of the filter, outwards or
• Unclog by tapping (Only in the event of an emergency). In
3
this case, do not damage the cartridge, or
• Wash it in accordance with the manufacturer's guidelines.
A
• Check that neither the cartridge filter paper (translucent B

paper) nor the seal are damaged. Replace it/them if
necessary.
A
• Replace the filter cartridge.

• Refit the cover, checking that the dust evacuation valve is
directed downwards.
Check the state of the sealing ring before reassembling the cartridges. Check the state of the filter element
with a light source placed inside the cartridge. Change the cartridge if a hole is detected (by a light ray).
Never clean the cartridge by hitting it against a hard surface or by using hot flammable liquid.
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8.6 - INTERNAL COMBUSTION ENGINE A

For the following operations, park the machine onto a horizontal surface and turn off the engine.
• Check the oil level :
• Open the motor canopy, remove the oil dip stick; the level must be situated between the two min. and B
max. marks.
• Top up as necessary via the filler.
• Check the belt tension :
• Correct belt tension is essential to ensure that the alternator, the diesel pump and the water pump
work properly and for the service life of the belts themselves.
C
• A belt in poor condition must be replaced immediately.
8.7 - HYDRAULIC CIRCUIT
• Check the oil level : D

• Park the machine on a horizontal surface.
• Stow the machine : With the stabilisers raised as far as
possible, the fork carriage lowered as far as possible, the
boom retracted, the cylinders retracted.
• The level must be situated between the two marks, as
indicated in the photo/picture opposite. Top up as
E
necessary via the filler.
8.8 - AIR-CONDITIONING (OPTION)
Cold weather use :

In order to guarantee the correct operation and for operational efficiency of the air conditioning
F
system it is advisable to turn the compressor on once a week, even for a short period of time,
so as to ensure that internal moving parts are lubricated.
Warm up the engine before you turn on the compressor, this the heat produced by the engine
to turn the liquid coolant accumulated in the lower part of the compressor circuit to turn into
gas. Liquid coolant could damage the compressor.
G
9 - Every 50 h hours of operation
• Lubricate the cylinder pins equipped with grease points.
• Lubricate the boom bottom shaft.
• Lubricate the sliding area friction pads. H
• Check the telescope synchronisation: fully retract the boom and fully extend it. The various elements
must come out simultaneously.
Section H 18.2 - For lubrication operations, refer to the Lubricants and equivalents table
for the type of grease to be used.
I
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10.1 - TYRES
Criteria of replacement
Replace the wheels and the tyres if any of the following conditions exist :
• Presence of cracks, damage, deformations or other faults on the hub.
• Damage on the tire :
• Cut or hole >at 3 cm (2 in) in the rubber side wall on the whole tire thickness.
• Blister or pronounce lump on the external and lateral membrane.
• Damaged wheel stud.
• Damage or wear on the side wall to the extent that the reinforcing wire become visible.
For safety reasons, always use original HAULOTTE® spare parts that are specific to this machine. Refer
to the spare parts catalogue.
• Check that the tires are not damaged.
• Remove the valve rod cap.
Check the tire inflation pressure : 4,5 bar(65 psi) minimum (For HAULOTTE® tyres, code : 2326014870 or
232601508).
During a pressure check or an inflation operation, always face the end of the tyre; never face the side of
the tyre
• Add air if required.
• Replace the valve cap.
• Check the wheel lug nut torque (300 Nm).
N.B.-:-Perform the first torque check after the first 10 h of operation.
10.2 - DIESEL CIRCUIT
Perform the first diesel pre-filter change after the first 500 hours of operation and then after
'every 500 h or once a year ( Section H 12.3 - Diesel circuit) (For machines fitted with
engine PERKINS 854E-34TA or PERKINS 1104D44T only).
10.3 - INTERNAL COMBUSTION ENGINE
Perform the first engine oil drainage and change the filter cartridge after the first 500 hours of
operation and then every 500 h ( Section H 12.4 - Internal combustion engine).
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10.4 - LUBRICATING THE FRONT AXLE A

• Remove the 4 protective caps from each grease point.
• Connect the grease gun.
Remove the *1 protective caps from each grease point.

E
10.5 - LUBRICATING THE REAR AXLES
• Remove the 6 protective caps from each grease point.
• Connect the grease gun. F
I
Replace the protective caps once you have lubricated the rear axle.
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Perform the first filter cartridge change after the first 500 hours of operation and then after
every 1000 h or once a year ( Section H 13.4 - Hydraulic circuit).
10.7 - AIR-CONDITIONING (OPTION)
• Check cleanliness of the condenser. Clean where

applicable.
N.B.-:-Disassemble the protective covers in order to gain

access to clean the condenser unit.
• Check the cleanliness of the cab air filter. Clean where

applicable.
The system becomes less efficient when the circuit is being discharged. If the air conditioning unit does
not work properly, have a qualified and properly equipped person examine it.
All repairs must be carried out by a qualified and authorised person.
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11 - Every 250 h hours of operation A

11.1 - COOLING SYSTEM
• Clean the radiator slats.
Do not remove the filling cap when the engine is hot. DANGER OF BURNS! Loosen the plug to the first
notch and let it depressurize, then unscrew the cap completely.
B
• Clean with a pressurized jet of water or air.
Only clean with water when the engine has cooled down.
11.2 - TRAVEL AXLES

C
Perform the first drainage operation on the front and rear axles and the epicycloidal reducers
after the first 250 hours of operation and then every 1500 h ( Section H 14.1 - Travel
axles).
N.B.-:-Level check every 500 h ( Section H 12.6 - Travel axles). D

11.3 - BATTERY
Battery check :
• Perform the machine shut-down procedure.
• Open the engine cover.

E
• Wear safety goggles and visually inspect the battery. Check that the terminals are not corroded.
Replace the battery if its case is cracked, distorted or damaged.
• Close and secure the battery access cover (under the cab).
11.4 - AIR-CONDITIONING (OPTION) F

• Check the tension of the compressor driving belt : driving
belt tension 50 kg(110,23 lb).
• Replace the internal and external air filters as necessary.
G
The system becomes less efficient when the circuit is being discharged. If the air conditioning unit does
not work properly, have a qualified and properly equipped person examine it.
H
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12.1 - LUBRICATING THE SUSPENSION AND THE DRIVER SEAT RAILS
For lubrication operations, refer to the Lubricants and

equivalents table for the type of grease to be used.
Dirt may affect correct seat operation. The seat must always be clean.
12.2 - AIR FILTER (SYSTEM) (FOR MACHINES FITTED WITH ENGINE PERKINS 854E-
34TA OR KOHLER KDI 3404 TCR ONLY)
Perform a cleaning of the primary air cleaner elements by pressurized air or vacuum cleaning.
For all engine maintenance operations : Consult the guide provided by the engine manufacturer
or HAULOTTE Services®.
N.B.-:-Operating in dirty conditions may require more frequent service of the air cleaner element.
12.3 - DIESEL CIRCUIT (FOR MACHINES FITTED WITH ENGINE PERKINS 854E-34TA
OR PERKINS 1104D44T ONLY)
12.3.1 - Changing the diesel filter
• Open the engine canopy to access the diesel filter.
• Loosen the filter cartridge.
• Replace the used cartridge with a new one.
• Close the engine canopy again.
12.3.2 - Changing the diesel pre-filter
To access the diesel pre-filter, open the engine cover.

• Loosen the transparent lower cover.
• Replace the filter.
• Carefully clean the cover.
• Retighten it manually ( 1/4 turn after contact with the seal).
• Refit the cover.
N.B.-:-Perform the first pre-filter change after the first 500 h of operation.
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12.4 - INTERNAL COMBUSTION ENGINE A

Be prepared to collect the fluid with suitable containers before opening any compartment or
disassembling any component containing fluids. B
• Drain the motor oil :
Capacity :
Engine PERKINS 1104D44T : 8,4 l(2,2 gal US) with filters.
Engine PERKINS 854E-34TA : 9,5 l(2,5 gal US) with filters.
• Drainage is performed when hot.
C
• Loosen the drainage plug and let the oil flow completely (1).
Remove the oil filling cap.
D
• Change the oil filter cartridge :
• Loosen and remove the filter cartridge. E
• Oil the seal on the new cartridge, insert it into place on the
engine carrier. Screw the cartridge manually until the seal
is in place.
• Tighten the cartridge by screwing it by an additional half-
turn.
F
• Clean the drainage plug and replace it, taking care to change the seal.
• Fill until the oil reaches the MAXI gauge mark.
• Replace the filling cap and let the engine run at idling speed for a few minutes.
G
• Check the seal on the oil filter cartridge.
• Stop the engine and check the oil level. Top up the oil if necessary.
N.B.-:-Perform the first drainage and the first oil filter cartridge change after the first 500 hours of
operation.
H
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12.5 - ENGINE OIL SERVICE RESET
After changing the engine oil and the filter, a reset must be performed to avoid engine derating.
12.6 - TRAVEL AXLES
N.B.-:-The level check operations must be performed periodically, respecting the maintenance
schedule provided. It is recommended that you intervene immediately in the event of leaks or other
faults may result in a drop in oil levels to avoid any possible damage to the mechanical components.
Once you have removed the filling and drainage plugs, they should be refitted again and tightened using
a torque walue recomended by the manufacturer.
12.6.1 - Checking the level of the front axle
Capacity :
• Transfer case : 1,25 l(0,33 gal US).
• Front axle : 8 l(2,11 gal US).
• Before performing the oil replacement operations, firstly remove the drain plugs ( 2 ) to eliminate any
pressure from inside the housing.
• Loosen the control plug ( 1 ).
• The lubricant level in the axle must be at the level of the control plug ( 1 ), otherwise top up to the
correct level via the same hole.
• Refit the control plugs ( 1 ) and the drain plugs ( 2 ).

Section H 18.2 - Refer to the Lubricants and equivalents table for the type of oil used.
• Take advantage of this operation to clean the drain plugs ( 2 ).
3 3
2 2
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12.6.2 - Checking the level of the rear axle A

Capacity :
• Rear axle : 8,5 l(2,24 gal US).
pressure from inside the housing. B
• The lubricant level in the axle must be at the level of the control plug ( 1 ), otherwise top up to the
correct level via the same hole.

C
• Take advantage of this operation to clean the control plugs ( 1 ) and the drain plugs ( 2 ).
3
1 2
3
E
F
12.6.3 - Checking the level of the epicycloidal reducers
N.B.-:-To check the reducer oil level, you must move the machine to position the closure plug in the
required positions. Due to the presence of the differential on each of the axles, you will have to repeat
this operation individually for each of the machine wheels.
G
Capacity : 4 x 1,3 l(4 x 0,34 gal US)
• When it is in the high position, loosen the plug ( 3 ) by a few turns, to release any internal pressure
from the housing and then close it again.
• Drive the machine slowly to bring the plug to horizontal position.

H
• Loosen the plug completely : the oil level must arrive at the plug, otherwise top up to the correct level
via the same hole.
• Refit the plug ( 3 ).

Section H 18.2 - Refer to the Lubricants and equivalents table for the type of oil used. I
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13 - Every 1000 h hours of operation (or once a year)

13.1 - CHAIN WEAR
Have the chain wear checked by a HAULOTTE Services® technician.

13.2 - PRIMARY AIR FILTER
Change the filter cartridge :

• Remove the cover :
1
• Pull the trigger situated on the cover ( 1 ).
• Locate the angular position of the cover which should be
identical upon reassembly.
• Turn the cover to the right ( 2 ).
2
• Turn and pull the outer cartridge.
• Change the outer filter cartridge.
• Refit the cover, checking that the dust evacuation valve is directed downwards.
13.3 - INTERNAL COMBUSTION ENGINE
• Check that the engine supports and the vibratory mount supports are in good condition.
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13.4 - HYDRAULIC CIRCUIT A

13.4.1 - Equipment hydraulic circuit
• Change the hydraulic filter cartridge :
• Place the machine in the working position and stop the engine.
• Open the engine compartment by removing the lower protective covers.

B
• Loosen the casing from the transmission hydraulic filter.
• Change the filter cartridge.
• Start the engine. C

• Perform driving movements.
• Check the oil level and top up if necessary.
• Close the casing again.
N.B.-:-Perform the first filter change after the first 500 hours of operation. D
13.4.2 - Transmission hydraulic circuit
• Change the hydraulic filter cartridge :
• Place the machine in the working position and stop the engine.
• Open the engine compartment by removing the lower protective covers.

E
• Loosen the casing from the transmission hydraulic filter.
• Change the filter cartridge.
• Switch on the engine and perform travel movements.
• Check the oil level and top up if necessary.

F
• Close the casing again.
N.B.-:-Perform the first filter change after the first 500 hours of operation.
13.5 - ACCUMULATORS G
You are advised to check the pre-charge pressure regularly via the M28x1,5 orifice used for
adding gas.
• Accumulator 1 l(0,26 gal US) : Pre-charge pressure : 13 bar(188 psi) (Parking brake circuit).
• Accumulator 0,75 l(0,20 gal US) : Pre-charge pressure : 30 bar(435 psi) (Service brake circuit). H
This operation requires specific tools (Consult HAULOTTE Services®) and a bottle of nitrogen to recharge
the accumulator (if the pre-charge pressure drops).
The accumulators must be emptied before any maintenance operation : Section H 18.1 -
Replacement of the brake circuit accumulators.
I
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14.1 - TRAVEL AXLES
The oil replacement operations must be performed periodically, respecting the maintenance
schedule provided.
It is recommended that you intervene immediately in the event of leaks or other faults may
result in a drop in oil levels to avoid any possible damage to the mechanical components.
Once you have removed the filling and drainage plugs, they should be refitted again and
tightened using a torque walue recomended by the manufacturer.
Perform the first drainage after the first 250 hours of operation.
14.1.1 - Draining the front axle
Capacity :
• Transfer case : 1,25 l(0,33 gal US).
• Front axle : 8 l(2,11 gal US).
pressure from inside the housing.
• Loosen the drainage plug ( 4 ) and let the oil drain out.
• Refit and tighten the drain out ( 4 ).
• Fill the axle, the lubricant level in the axle must be level with the control plug ( 1 ).

• Take advantage of this operation to clean the drain plugs ( 2 ).
4
3 3
2 2
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14.1.2 - Draining the rear axle A

Capacity :
• Rear axle : 8,5 l(2,24 gal US).
pressure from inside the housing. B
• Refit and tighten the drain out ( 4 ).
• Fill the axle, the lubricant level in the axle must be level with the control plug ( 1 ). C
D
4
3 1 3
2
E
F
14.1.3 - Draining the epicycloidal reducers
N.B.-:-To replace the reducer oil, you must move the machine to position the closure plug in the required
positions. Due to the presence of the differential on each of the axles, you will have to repeat this
operation individually for each of the machine wheels.
Capacity : 4 x 1,3 l(4 x 0,34 gal US).

G
• When it is in the high position, loosen the plug ( 3 ) by a few turns, to release any internal pressure
from the housing and then close it again.
• Drive the machine slowly to bring the plug to its low position.
• Loosen the plug completely and let the oil drain out.
H
• Drive the machine slowly to bring the plug to horizontal position.
• Fill the reducer; the oil level must be level with the plug.
• Refit the plug ( 3 ).

I
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14.1.4 - Engine crankcase breather (Engine PERKINS 854E-34TA)
Before performing any interventions, let the engine cool down.
DANGER OF BURNS! Hot oil and hot components can cause personal injury. Avoid any contact with the
skin.
The crankcase breather is a very important component in order to keep your engine emissions
compliant.
• The filter element of the housing breather must be serviced according to the stated
frequencies( Section H 6 -Detailed program).
• The correct filter element must be installed before the engine is operated.
• The installation of the filter element is very important.
• The quality of the filter element that is installed is very important.
• The filter element protects the engine from excessive quantities of oil from entering the induction
system. The filter element also protects the engine aftertreatment system.
N.B.-:-Excessive quantities of oil that enter the induction system of the engine can rapidly increase the
engine speed without control.
14.1.4.1 - Remove the breather element
• Remove the guard that covers the engine breather.

• If necessary, remove breather pipes on cover ( 6 ).
• Remove circlip ( 4 ) and remove the breather element ( 3 )
and discard.
• Remove the O ring seal ( 5 ) from the cover.
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14.1.4.2 - Install the breather element A

Ensure that all the components are clean and free from damage.
• Install a new O ring seal ( 5 ) onto the cover ( 6 ).
N.B.-:-The breather element must have the correct orientation before installation. Diameter ( A ) is
visibly larger than diameter ( B ).
B
• Install diameter ( A ) of the breather element ( 3 ) onto the
shaft ( 2 ). When correctly installed the part number of the
breather element will be visible.
• Install circlip ( 4 ) and cover ( 6 ). Install nuts ( 7 ) and
tighten to 25 Nm (18 lb ft). If necessary, install breather
C
pipes to cover.
• Install the guard that covers the engine breather.
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15 - Every 2000 h hours of operation (or every 2 years)

15.1 - COOLING SYSTEM (ENGINE PERKINS 1104D44T)
• Change the coolant :

Capacity : approx. 18 l(4,75 gal US).
N.B.-:-Open the heating valve situated in the cab when draining the cooling system.
• Remove the filter cap from the expansion bottle filter cap.
• Loosen the drainage plug and let the coolant drain out.
• Empty the expansion bottle.
• Clean the system thoroughly with water (or, if necessary, with a cleaning product). In this case,
retighten the plug and let the engine run at mid throttle for 10 mn, stop the engine and drain the system
again.
• Refit the drainage plug.
• Filling the cooling system :
• Fill the radiator GRADUALLY until the coolant has reached the correct level.
• Close the expansion bottle cap again.
• Switch the acceleration control lever to IDLING.
• Let the engine run AT IDLING SPEED for approx. 2 mn.
• Stop the engine.
• Open the expansion bottle and top up if necessary.
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15.2 - AIR FILTER (SYSTEM) A

Change the filter cartridge :

• Remove the cover : B
• Pull the trigger situated on the cover ( Section H 8.5 Marking1).
• Locate the angular position of the cover which should be identical upon reassembly.
• Turn the cover to the right (

Section H 8.5 Marking2).
C
• Turn and pull the (primary) outer cartridge. Then pull the (secondary) inner cartridge
( Section H 8.5 Marking3).
• Insert a new secondary cartridge, by pushing it to the bottom of the socket provided in the case.
• Place the new primary cartridge above the secondary cartridge, insert it in place with a rotation
movement near the stop.
D
• Refit the cover, checking that the dust evacuation valve is directed downwards.
Never clean the secondary filter.

E
Check the state of the sealing ring before reassembling the cartridges.
N.B.-:-Perform the secondary cartridge change every 2 years or after every 5 maintenance operations.
15.3 - INTERNAL COMBUSTION ENGINE (ENGINE PERKINS 1104D44T)

F
• Change the engine belts.
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• Checking the hydraulic pressures.

This operation must be performed by a HAULOTTE Services® technician.
• Change the oil :
Tank capacity : 103 l(27 gal US)
Replace oil after each major intervention, and each time an anomaly has been detected.
• Only use oils that that match the technical characteristics that correspond to HAULOTTE®
recommendations.
Do not mix two oils with different characteristics : If necessary, drain and clean the whole system.
• Check the cleanliness of the oil filter cartridge (no metal shavings, rubber, plastic, …) : If necessary,
drain and clean the whole system.
When the tank is empty :
Drainage must be performed when the oil is hot.
• Place the machine in its folded position. 2

• Go underneath the machine.
• Remove the filling cap ( 2 ).
• Fill the tank with the recommended oil until the gauge indicates the max. level.
• Refit the filling cap ( 2 ).
• Actuate the equipment controls in both directions for approx. five minutes (without placing the
cylinders at the stops 2).
• Place the machine in road position.
• The level must be as indicated in the photo/picture

opposite. Top up as necessary via the filler.
Refer to the Lubricants and equivalents table for the type of oil used.
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15.5 - AIR-CONDITIONING (OPTION) A

Maintenance and repair work on the air conditioning must be carried out by a qualified and authorised
person.
• Cleaning of condenser and evaporator coils.
• Cleaning of condenser water outlets. B

• Recovery of coolant in order to replace the filter-drier.
• Top up with coolant and check of thermostatic regulation and pressure switches.
Any top up on the circuit must be carried out by a qualified and authorised person. C
Never open the circuit as this would cause a loss of coolant. The cooling circuit contains a gas which,
under given circumstances, may present some risks. This gas, i.e. the R-134a coolant, is colourless and
odourless and heavier than air. It is a stable product at normal temperature.. The compressor is fitted with
a gauge to check the oil level : Never unscrew this lid, as this would discharge the system. The oil level is
only checked when the oil is changed.
D
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16.1 - INTERNAL COMBUSTION ENGINE (ENGINE PERKINS 854E-34TA)
16.2 - DIESEL PARTICULATE FILTER (ENGINE PERKINS 854E-34TA)
• Have the particulate filter cleaned.
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16.3 - COOLING SYSTEM (FOR MACHINES FITTED WITH ENGINE PERKINS 854E-
34TA OR KOHLER KDI 3404 TCR ONLY)
A
• Change the coolant :

Capacity : approx. 18 l(4,75 gal US).
B
N.B.-:-Open the heating valve situated in the cab when draining the cooling system.
• Loosen the drainage plug and let the coolant drain out (1).
• Empty the expansion bottle.
C
• Clean the system thoroughly with water (or, if necessary,
with a cleaning product). In this case, retighten the plug and
let the engine run at mid throttle for 10 mn, stop the engine
and drain the system again.
• Refit the drainage plug.
D
• Filling the cooling system :
• Fill the radiator GRADUALLY until the coolant has reached the correct level.
• Close the expansion bottle cap again.

E
• Switch the acceleration control lever to IDLING.
• Let the engine run AT IDLING SPEED for approx. 2 mn.

F
• Open the expansion bottle and top up if necessary.
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17.1 - INTERNAL COMBUSTION ENGINE (ENGINE KOHLER KDI 3404 TCR)
18 - Every 10 years
18.1 - REPLACEMENT OF THE BRAKE CIRCUIT ACCUMULATORS
Replacement involves :
• Accumulator 1 l(0,26 gal US) : Parking brake circuit.
• Accumulator 0,75 l(0,20 gal US) : Service brake circuit.
Never undertake maintenance on the accumulators with the engine running.
18.1.1 - Parking brake
Only begin working on the accumulator 24 h minimum after the previous time the engine was started. This
is the time necessary for the accumulator to fully discharge to allow it to be removed and replaced safely.
Maintenance operations on accumulators are dangerous (pressurised oil) ; the procedure must be strictly
adhered to and extreme caution must be exercised when removing this part.
18.1.2 - Service brake
Press the brake pedal 40 times in a row with the engine switched off in order to empty the
accumulator to allow the accumulator to be changed over without danger.
Maintenance operations on accumulators are dangerous (pressurised oil) ; the procedure must be strictly
adhered to and extreme caution must be exercised when removing this part.
N.B.-:-Accumulator inflation pressure must be checked regularly once a year ( Section H 14.5 -
Accumulator).
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18.2 - LUBRICANTS AND EQUIVALENTS A

Standard references Manufacturer references
Uses Capacities ISO MIL API BP ELF ESSO MOBIL AGIP SHELL
Greases
Pins and hinges
6743/0
catégorie X
Grade 2 ou
EPEXELF 2 B
Upper boom Multimove 2
3
Multi-
Purpose
Driver seat rails
Grease
Oils
(Moly)
ROTRA
C
Front axle and SAE SPIRAX LS
8 l(2,11 gal US) MULTI THC/
differential** 80W90* 80W90
C 80W90
ROTRA
Rear axle and 8,5 l SAE SPIRAX LS
MULTI THC/
differential** (2,24 gal US) 80W90* 80W90
Wheel reducer**
1,3 l
(0,34 gal US)
SAE
80W90*
MIL-L2105
API GL5
ENERGEA TRANSELF ESSO
R 90 TYPE GEAR GX
C 80W90
ROTRA
MULTI THC/
SPIRAX LS
80W90
D
80W90 80W90 SAE 80W90 C 80W90
ENERGEA TRANSELF ESSO ROTRA
1,25 l SAE MIL-L2105 SPIRAX LS
Transfer case** R 90 TYPE GEAR GX MULTI THC/
(0,33 gal US) 80W90* API GL5 80W90
80W90 80W90 SAE 80W90 C 80W90
Hydraulic 175 l ENERGOL HYDRELF INVAROL DTE 15M HYDRAULI
HV 46
circuit***
Internal
combustion
(46,2 gal US) SHF-HV 46
VANELLUS
DS46
ELF
PERFORM
EP46
ESSO
SERIE C PW 46
E
C5 TUBE DELVAC M RIMULAX
engine 8,4 l(2,2 gal US)SAE 15W40 MIL-2140E ANCE
DIESEL53 XT301 SAE 15W40 15W40
(PERKINS SUPER D
15W40 15W40
1104D44T) 15W40
Internal
combustion
engine
(PERKINS
9,5 l(2,5 gal US)SAE 15W40 MIL-2140E
RIMULA R5
LE 10W-40 F
854E-34TA)
Internal
9,2 l(2 gal US) -
combustion
Min. RIMULA R5
engine SAE 10W40
15,6 l(4 gal US) LE 10W-40
(KOHLER KDI
3404 TCR)
- Maximum
G
* : Uses an additive for axles fitted with a limited slip differential.
** : The axle manufacturer recommends using SHELL or AGIP products.
N.B.-:-The oils indicated above are valid for use at ambient temperatures of between -15 °C(5 °F)
and 40 °C(104 °F) . If the equipment operates outside this temperature range, refer to the oil viscosity
tables below. H
*** : Below an ambient temperature of -15 °C(5 °F) , use TELLUS ARTIC OIL 32 (SHELL).
Above an ambient temperature of 45 °C(113 °F) , use TELLUS OIL T68 (SHELL). If a
biodegradable oil is required, use TELLUS naturel HSE 46 (SHELL), at interval of oil change
every 1000 h.
I
4000328140 E01.15 AUS 193

Telescopic handlers
Axle oil viscosity according to the ambient temperature
OIL GREASE
HUILE GRAISSE
Engine oil viscosity according to the ambient temperature
194 4000328140 E01.15 AUS

Telescopic handlers
19 - Electric circuit A
19.1 - WIRING DIAGRAM-MAIN COMPONENTS
N.B.-:- See end of manual.
B
Nomenclature
Marking Description
FU100 General electrical equipement fuse
FU101 Fuse for warning lights
FU102
FU103
Fuse for calculator power supply
Fuse for flashing beacon-Horn
C
FU106 Fuse for indicator lights
FU107 Fuse for high beam headlights
FU108 Fuse for low beam headlights
FU109 Fuse for stop light
FU110
FU111
FU112
Fuse for front left hand sidelight
Fuse for front right hand sidelight
Fuse for rear side lights-Registration plate
D
FU113 Fuse for sensor power supply-Controls
FU114 Fuse for power supply to solenoid valves
FU117 Fuse for rear foglights
FU140 Sensor relay power supply fuse
FU161
FU180
Fuse for the engine preheat management system
Fure for the cab heating
E
FU181 Air-conditioning fuse
FU182 Fuse for accessory power in the cab
FU183 Fuse for windscreen wiper-Fuse for front windscreen washer
FU184 Fuse for rear windscreen wiper
FU187
FU189
FU191
Fuse for radio control
Fuse for air conditioning fan
Fuse for work light
F
FU195 Fuse for 12 V socket
FU490 Weighing sensor power supply fuse
FU620 Fuse for reversing alarm
KA104
KA110
KA160
Relay for flasher indicator
Relay for sidelight validation
Relay for auxiliary styarter control
G
KA181 Relay for air conditioning
KA187 Relay for radio control
KA189 Relay for air conditioning heat sink ventilation
KA380 Relay for floating control
KA620
KA680
Relay for reversing alert
Crab steering control relay
H
KA681 Synchro mode steering control relay
KM101 Power supply switch
4000328140 E01.15 AUS 195

Telescopic handlers
20 - Hydraulic circuit
20.1 - HYDRAULIC DIAGRAM-MAIN COMPONENTS
N.B.-:- See end of manual.
Nomenclature - HTL4010 - HTL3510

Marking Description
1 Attachment hydraulic oil
2 Drive hydraulic pump
3 Dual pump
4 Charge pump
5 Steering unit
6 Hydraulic oil tank assembly
7 Main proportional directional valve
8 Valve ON/OFF ( 3 sections) (HTL4010)
8 Valve ON/OFF ( 2 sections) (HTL3510)
9 Brake unit
10 Parking brake accumulator
11 Service brake valve
12 Steering selector valve
13 Pressure switch 90 b
15 Hydraulic drive engine
16 Hydraulic oil cooler fan motor - Hydraulic motor
17 Crowding valve
18 Telescoping valve
19 Outrigger valve (HTL4010)
20 Lifting valve
21 Boom lift cylinder
22 Boom telescopic cylinder
23 Level compensation cylinder
25 Stabiliser cylinder (HTL4010)
26 Load levelling cylinder (HTL3510)
27 Load levelling valve (HTL3510)
196 4000328140 E01.15 AUS

Telescopic handlers
Nomenclature - HTL3010 A
Marking Description
1 Attachment hydraulic oil
2 Drive hydraulic pump
3 Dual pump
4
5
6
Charge pump
Steering unit
Hydraulic oil tank assembly
B
7 Main proportional directional valve
8 Valve ON/OFF ( 2 sections)
9 Brake unit
10
11
12
Parking brake accumulator
Service brake valve
Steering selector valve
C
15 Hydraulic drive engine
16 Hydraulic oil cooler fan motor - Hydraulic motor
17
18
Crowding valve
Telescoping valve D
20 Lifting valve
21 Boom lift cylinder
22 Boom telescopic cylinder
24
26
27
Level compensation cylinder
Load levelling cylinder (HTL3010)
Load levelling valve
E
4000328140 E01.15 AUS 197

Telescopic handlers
21 - Troubleshooting
Stop the machine and contact HAULOTTE Services® if the following LEDs flash or remain lit :
• Parking brake defect LED P182 : Not enough pressure.
• Engine oil pressure fault LED P181 : Not enough pressure.
• Service brake fault LED P190 : Not enough pressure.
• Battery LED P180 : Wiring problem.
• LED P191.
The machine is equipped with an on-board defect detection system.

Default code, reported at the display tells to the user the nature of the faulty.
The machine switches to downgraded mode, depending on the type of fault : Certain movements can
be limited or forbidden to preserve the operator's safety.
(A) :The fault is only indicated on the display if it is active.
(D) : The fault is indicated on the display when it is detected after starting up the machine, whether it is
still active or not.
Diagnosis
Faults Description Solution
F02 : Contactor
Emergency pump fault relay (only platform
F02.02 (D) Check KM120
mode)
F02.03(D) Main contactor fault Check KMG
F02.05(D) Pre/post heating relay fault Check KM160
F03 : Relay
F03.08 (D) Start-up relay fault Check KA160
Engine power supply relay fault / Ignition
F03.09 (D) Check KA161
key
F03.12 (D) PWM supply relay fault Check KA122
F04 : Solenoid valves
Fork carriage compensation PWM
F04.02 (D) Check YV400 or YV420
solenoid valve fault
F04.05 (D) Boom lifting PWM solenoid valve fault Check YV300 or YV320
Boom telescoping PWM solenoid valve
F04.06 (D) Check YV340 or YV360
fault
F04.23 (D) Accessory control solenoid valve fault Check YV121, YV123 and YV124
F04.24 (D) Left-hand stabiliser solenoid valve fault Check YV122, YV700 and YV720
F04.25 (D) Right-hand stabiliser solenoid valve fault Check YV122, YV701 and YV721
F04.28 (D) Tilt correction solenoid valve fault Check YV122, YV740 and YV760
F04.30 (D) Floating lift TOR solenoid valve Check YV380
Hydraulic unlocking TOR solenoid valve
F04.32 (D) Check YV380
fault
F04.33 (D) Steering mode TOR solenoid valve fault Check YV680 or YV681
F05 : Joystick
Joystick operation defect (Boom
F05.03 (D) Check SJ120
telescoping)
F05.04 (D) Joystick operation defect (Lifting) Check SJ120
Joystick operation defect (Equipment
F05.07 (D) Check SJ120
carriage compensation)
F05.08 (D) Joystick operation defect (Attachments) Check SJ120
198 4000328140 E01.15 AUS

Telescopic handlers
Faults Description Solution A

Operating fault on the remote control
F05.09 (D) Check B402 (Radio-control)
joystick (Boom telescoping)
Operating fault on the remote control
F05.10 (D) Check B401 (Radio-control)
joystick (Lifting)
F05.11 (A)
Neutral position of the cab joystick not
detected since start-up
Neutral position of one of the joysticks on
Check SJ120
B
F05.12 (A) the remote control not detected since Check B401 or B402 (Radio-control)
start-up
Neutral position of one of the rollers on the
F05.13 (A) Check B302 or B303
cab joystick not detected since start-up
F07.03 (D)
F07.11 (D)
Boom angle sensor incoherence
Telescope length incoherence
F07 : Sensors
Check B403 or B404
Check SQ360 or SQ340
C
Inconsistency between pre-alarm and
F07.25 (D) Check B130 or B142
alarm LMI
F07.26 (D)1 Accelerator pedal position fault Check RP160
F07.28 (D)
F07.29 (D)
F07.30 (D)
Left outrigger sensor incoherence
Right outrigger sensor incoherence
Engine oil pressure sensor inconsistency
Check SP162
D
F07.31 (D) Alternator D+ signal inconsistency Check D+
F07.32 (D) LMI fault - For LMI529 only Check sensor LMI159
F08 : Electric circuit
F08.04 (D) ECU power supply fault Check the power supply
F08.05 (D) Voltage 5 V Check the 5 V power supply
F09 : Engine E
F09.01 (D) Engine overheating
F09.02 (D) Low engine oil pressure
F09.03 (D) Presence of water in diesel fuel
F09.04 (D) 1 Clogged air filter
F09.07 (D) 1
F09.08 (D) 1
Drive motor faulty
Engine shutdown
Check Engine
Engine shutdown F
F09.10 (D) Alternator fault Check D+
F10 : Functions
LMI529 calibration not performed or Check LMI529
F10.05 (A)
disabled - For LMI529 only Calibrate
F10.12 (A)
Communication problem with the display
LMI
Check the display
F11 : Security devices
G
F11.05 (A) LMI alarm shunted with the key Caution
F12 : Internal faults
F12.01 (D) ECU fault / CAN link Check the connections
F12.02 (D) ECU EEPROM fault Change the calculator
F12.04 (D) Machine parameter reset Check the parameters
F13 : Switchs
H
Inconsistency in the position of the
F13.03 (D) compensation selector (Radio-control Check B104 or B105
emitter)
F13.04 (D) accessory control selector (Radio-control
emitter)
Check B102 or B103
I
F13.05 (D) Check SA187
Platform/Fork/Winch selector (Cab)
Steering mode selector (Cab)
4000328140 E01.15 AUS 199

Telescopic handlers
Faults Description Solution

Inconsistency in the position of the drive
F13.07 (D) Check SA600 or SA620
selector (Cab)
Inconsistency in the position of the Left/
F13.08 (D) Check SA780 or SA781
Right stabiliser selector (Cab)
Inconsistency in the position of the tilt
correction selector (Cab)
Neutral position of one of the cab selectors
F13.10 (A) Check the switches in the cab
not detected since start-up
Neutral position of one of the remote
F13.11 (A) control selectors not detected since start- Check the remote control switches
up
F13.12 (A)1 Problem with control FAP Check SA161
F14 : Driving pump
F14.01 (D) H1 pump fault Check the drive pump
F14.02 (D) Fault on the H1 pump inputs Check the drive pump
F14.03 (D) Fault on the H1 pump outputs Check the drive pump
F14.04 (D) H1 pump in safety mode Check the drive pump
F14.05 (A) Inching pedal not calibrated or faulty Check the inching pedal
F14.06 (D) Engine rotation speed sensor fault Check sensor
F14.07 (D) Pump overheating H1
F15 : Protocol
F15.06 (A) CAN J1939 message not received Check CAN 2
1
: For machines fitted with engine PERKINS 854E-34TA only.
21.1 - PROCEDURE
• Note the fault codes
• Note any other LED's that may be lit and the situation of the machine when the defect appears.
• Stow the Telehandler.
• Stop the Telehandler.
Do not use the machine until the fault has been repaired.
• Service the machine as set out in this manual.
200 4000328140 E01.15 AUS

Telescopic handlers
) - Intervention register
Intervention register A
1 - Intervention register
The intervention register keeps a record of maintenance and repair work carried out inside or outside
the maintenance programme.
N.B.-:-In the case of a HAULOTTE Services® intervention, the qualified technician must indicate
B
the HAULOTTE Services® intervention number.
HAULOTTE
Number of
Date Type of intervention
hours
Intervenor Services®
intervention number C
4000328140 E01.15 AUS 201

Telescopic handlers
HAULOTTE
Number of
Date Type of intervention Intervenor Services®
hours
intervention number
202 4000328140 E01.15 AUS

Telescopic handlers
A
HAULOTTE
Number of
hours
intervention number
4000328140 E01.15 AUS 203

Telescopic handlers
HAULOTTE
Number of
hours
intervention number
204 4000328140 E01.15 AUS

Telescopic handlers
A
HAULOTTE
Number of
hours
intervention number
4000328140 E01.15 AUS 205

Telescopic handlers
HAULOTTE
Number of
hours
intervention number
206 4000328140 E01.15 AUS

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
(4, (4, (4,

&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
Option Nacelle/basket
1.
05-2
Coupe circuit
QS100
1A
1A
C 05-2

FU122
250A
160
12-17
D
03-8 if T4 interim
FU160.
161
80A 05-19
E
MA 31 16-14
04-9 if T4 final
KA161
12-18
1B
F Option kit
100C
2001.
27A
raffinerie 08-13.
160
KA160
12-14 SA1 Option
TI 2.
26.
refinery kit 2002.
G GB100. 08-13..
27
B106 TI 9. TI 8.
05-19
TI 13->16 MA 1 03
16-15
160
KM120
B106
B106
27
H 10-9 10-9 PERKINS ONLY

5
DEUTZ ONLY TI 6
KM160.
TI 3. RES_CAN
KM160.
TI 17
02-9 120 ohm 1/4W
I
B+ D+
120
5
27
27
28.
161
YA160.
J
B-
~
ST161
YA161 YV160. YA162.
M120
M160.
K
R160
0.
L
Pompe de secours Alternateur 04-1
Batterie de Préchauffage Démarreur Gavage moteur Stop moteur Pompe à surcal
démarrage Emergency pump Alternator Starter booster pump Engine stop carburant dem froid
Preaheat
Batteriy Fuel pump cold start
?!53?%
%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Option Nacelle/ Basket 1 04-2..

A
Coupe-batterie
QS100..
Battery switch
1A.. 04-2.
B
FU21 FU19
50A composants coté moteur 60A
C engine side components

79

FU122.
250A KM3
KM3 03-10
D
73 75
FU12
to_BT sensor
5A
E
FU22 FU18 FU15
3A 20A 7.5A
1
76
F 161
31
02-18

CALCULATEUR EIC2 61A
PRECHAUFFE EIC2 60A
28
GCU EIC2 58A
1B.
G EIC2 57A
KA160
GB100.. KA161
12-14 12-18
32
K52
K41
K21
27.

H MA "# " ! $

12V
5.
1.
CALCULATEUR MOTEUR
I TI ENGINE ECU
TI 13-->16 6.
B106
KM120. 05-19
key swich # #
5.
J B106
10-9 27. 27.

K45
K23
K68
YA160
TI 9 2001
TI 3 09-13
K gnd TI 8 2002
120.
B+ D+ 09-13
M120. M160 CN01
~
L B H J C F G A
B-
0 0
M Pompe de secours
Batterie Alternateur Démarreur 05-1
Battery Emerg. pump Alternator Starter

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Option Nacelle/ Basket 1. 1.

A
05-2
Coupe-batterie
QS100.
1.
Battery switch
1A
B
05-2
.27.
04-15 04-10
FU407 FU406
50A 15A
FU403 FU402 FU401
C 5A 5A 20A FU400 FU405
60A 3A
401
F1
406
411
250A

420
KM5
D KM5 04-8 KM4
KM4 04-13
415
415
+B400
FU404 04-8
414
E 5A
KM7
KM7 04-7
415
KM6
KM6
1.
04-15
composants coté moteur
412
416
404
F engine side components
+B400
417
419
413
419
1#3
418
1#3
414
#
G
B106 1#3 1#3 1#3 1#3 1#3 1#3 1#3
GB100... " 4 # #& 1
05-19.
04-12
! !& "% " "% "% !&

H
405
12V B106
"#
'*$'
,(+(
($

'()*''
10-9 1#3
09-13
421
4
-.
2002

)+,
# "
)($/(
*'*
MA 18 CALCULATEUR MOTEUR 2001
# "&
I ENGINE ECU
1#3 09-13
.TI. 3 4
# "
0)(($(
2(*
04-12

KA1 " "% "% 1& # "
04-12
J 5
0
422
1#3 161 1#3 1#3 1#3 1#3 1#3

4 .YA160. ! ! 1& 4 4
02-18
K KA160 KA161
.SQ163.
4002
12-14 12-18
B+ D+
.R160. 0 1#3 5# 0
M1 .M160. M2
4001
MA .1. 1
4001
.5.
~ 04-17 2 # 12 34 5 6 7 8
L TI .6. 3
B- 1#3 404
# TI .13. 04-14 4002 46()*''
EGR Valve
9 10111213141516
04-17 5 #
.27.
04-10 6 DIAG+
0 0 0
M Pompe de secours
Batterie Alternateur Démarreur Préchauffage Pompe
Emerg. pump Alternator Preheat 05-1
Battery Starter Lift Pump

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
104
FU115 5A 05-2
1. 104 VBAT_PERM perm_supply
A 02-18 10-9
04-19
100A APRES KM100 After KM100
04-19 07-1
1A 1A
02-18
102 ALIM H1 H1 supply
B 12-1
1A
0
05-19 FU102 7.5A
FU100 102 ALIM NOEUD B NodeB supply
KM100 Contacteur 09-3
104 20A principal
05-19 05-7 FU114 30A
114 ALIM E.V EV supply
(REV E) Main relay 13-2
C
SUPPLY
FU140 10A

LMI supply
100A
100A 140 ALIM LMI
10-6
CLE DE CONTACT: 100A R_ALT B106
Key switch 02-7
100 47 ohm, 2W ALIM CMDS+ Sensor +
ALIMENTATIONS
D 0=key off FU113 7.5A CAPTEURS cmd supply

113
1= key on 10-9
SA100
2= start FU161 20A
161 ALIM MOTEUR Engine supply
02-18
3
10
FU109 10A stop lamp
E 109 FEUX STOP
08-3
FU620 10A backw lamp
622 FEUX RECUL
LAMPS
07-1
FEUX
(-) Bat.
(+) A/C
(+) Bat.
FU106 10A
F 106 CLIGNOS G & D flash lamp L&R
C3 C2 C1 07-15
Option Anti Demarrage
FU189 30A A/C fan
Option Anti Startup 186 VENTIL DISSIP CLIM
06-14
(Modcod ou Modclé)
D2
D1
FU180 30A heating
180 CHAUFFAGE
G 06-14
A/C
10A
CLIM
FU181 5A A/C
181 CLIMATISATION
06-19
100A
3A
Option Radiocommande FU195 30A 195 PRISE 12V 12V plug
H 06-1
ALLUME CIG/ PLAFONNIER cigar lighter
SA188 FU182 20A
182 AUTORADIO dome light
car radio
06-1
ALIM PESAGE
FU184 10A front ws.w
187B 184 ESSUIE GLACE AR.
06-1
I ESSUIE GLACE AV
14-14 FU490 1A Weight supply rear ws.w
SWITCH RADIO: ALIM RADIO
FU183 10A LAVE GLACE ws. washer
187A 183
06-1
0: radio Radio supply
14-1 FU187 15A rotating light
FU103 10A
ACCESSOIRIES
1: cabine/ cab 103 GYRO/ KLAXON horn

07-1
SHUNT3-->2 (connector) or SHUNT 3A > 2 if option Anti Startup
SHUNT 10-->11 (connector) or SHUNT 10A >11 if option Anti Startup

ACCESSOIRES
J
AU nacelle SB141
103 KLAXON RADIO Radio horn
ES basket 14-1
SHUNT 187-->141
101 PRISE DIAG Diag plug
141
12-5
K AU radio KA187
2
100
FU101 15A 101 Warnings
ES radio WARNINGS
14-10 07-15
11 100 ALIM AUTORADIO car adio supply

06-11
L
2 DEMARRAGE Start up
10-5
BEFORE KEY ON
11
AVANT CONTACT
11
0 11 +12V APC 12V After keyon

04-19 KM100 10-8
M 16-15 05-2
0 0 0 0
03-19 06-1

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
commutateur chauffage heating switch
1 45
B 2 46
3
SA180
180
C
05-19

D
M180
E
42
Chauffage
182
Heating
05-19 07-11
183 183 210 51
F
SA181
05-19
186 43 181
SA183
G 05-19 05-19
184
05-19 - SP181
182
195 Options D
+ P
05-19
H
-
210
188
43
51
Options
48
183
2 1 +
43
D-
G-
D+
G+
182
110.
I
SA195
181
100
M SA182
41
SA184 U182
05-19
M183
54
KA189 KA181
196
282
KA189 KA181
J M186 06-16 06-18
6 3
183
50
49
XP195 EL182 XP183

M184 HL181
K M189
M181
0 0 0
Rétro ecl Ventil dissip. SA181 P Fréon Compresseur
L 05-19 backlighting A/C fan P Freon Compressor 07-1
PRISE 12V ESSUIE-GLACE AR ESSUIE-GLACE AV LAVE-GLACE PLAFONNIER ALLUME-CIGARE AUTO RADIO CLIMATISATION / CHAUFFAGE
12V PLUG REAR W.WIPPER FRONT W. WIPPER W.WASHER DOME LIGHT CIGAR LIGHTER CAR RADIO A/C / HEATING

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
100A 100A
A
05-19
103 103 08-2
100A
05-19
90
B Comodo droit
Right comodo
C SA104
D E

SA185 SB105 SA101
622
D 63
05-19
08-8
62
08-6
E
63
62
622
100B 100B
F
185
105
101
11-7 05-19
106
05-19
KA620 FU112 FU111 FU110
G
12-15 7.5A 7.5A 7.5A
0 90
31 49
110
KA104
92
06-15 R +
112
111
H
623 185 105 112 111 110
14-1 08-3 08-3 08-15

SA106
I 90
92
112
111
110
EL116 HL185 HA185 101 103 EL100 EL102 EL104
HA620 KA110
K
HA105
0 0 0 0 0 0
06-20 Buzzer Feu SA185 Gyrophare AV FT AR RR AV FT AR RR 08-2

L Buzzer Lamp Rotating light COTE DROIT COTE GAUCHE
RIGHT SIDE LEFT SIDE
RECUL KLAXON FEUX DE POSITION PLAQUE IMMAT. CLIGNOTANTS/WARNING

GYROPHARE
M SIDE MARKER LIGHT LICENCE PLATE TURN SIGNAL/HAZARD WARNING
REVERSE ROTATING LIGHT HORN

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
100A 100A 100A

A 10-6
07-20
KA110
07-12
B Comodo droit
Right comodo
191 191
FU191 FU117
C SA103 SA102 20A 7.5A
197
118
59A
64A

D KA107 KA108 SA191 SA117
KA107 KA108
08-4 08-7
110 110
59
64
07-13
E FU107 FU108
192
193
117
15A 15A
60 66
11-6
F EL111 EL112 EL109 EL110 EL191 EL192 EL117 HL117 HL106 HL191 HL183 HL180 HL195 HL161
EL193 EL194
0 0 0
G 10-9
07-20 Gauche Droit Afficheur Gauche Droit FeuX SA117 SA106 SA191 SA183 SA180 SA195 SA161
Left Right Display Left Right Lamps
FEUX ROUTE FEUX CROISEMENT PHARES DE TRAVAIL FEUX ANTI BROUILLARD VOYANTS SUR BOUTON
HIGH BEAM LOW BEAM WORKING LIGHT FOG LIGHTS BUTTON LIGHTS
H
111
1
I
07-11
112
4
07-9
0
109 61 61
2
J 05-19
62 62
P
61
5
SP114 07-19
63 63
3
62
07-19
63
EL113 EL114 EL106 EL108 EL105 EL107
L
11-6
11-5
0 0
Mano-contact Gauche Droit Droit Afficheur Gauche Afficheur Clignotant G et D Feu stop G et D Veilleuses G et D
Left Right Right Display Left Display Turn light L and R Stop lamp L and R Side-marker light L and R
FEUX STOP CLIGNOTANTS REMORQUE

M TRAILER
STOP LAMP TURN SIGNAL LAMP

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
vert jaune
B 4 green yellow
SV685 SV162 R681 121
M12 0S R682
2
(REV E) 3 (REV E)
rouge
5
red
C

102
D 05-19
7
603
606
685
165
123
122
604
605
124
# / # / # / # / # / # / # / # / # / # / # /
ALIM signal Sensor - Sens Sensor + signal Sensor - Sensor + Sensor - signal Sensor +
12V
E
VITESSE MOT. VITESSE POMPE U 600
102
PEDALE INCHING
HYDRO HYDRO C1=CC1
INCHING PEDAL
HYDROLIC ENGINE SPEED HYDROLIC PUMP SPEED C2=CAN
C3= PPC
F
C4= PSC
H1 - AC ECU C5= PPU
C6=CC2
OV CAN CAN CAN
S_PWM S_PWM S_PWM S_PWM S_PWM S_PWM S_TOR S_TOR ALIM CAN_High CAN_Low CAN_Gnd
G # / # / & # / # / # / # / # / # / # / # / # / # /
REV
MAV
MAR
0
FWD
4
6
600
620
683
2001
601
602
Park break
2nd speed
Frein de park
H
2eme vitesse
Drive direction
sens de marche
B605
2002
04-19
I 2001
04-19
B605
YV682 YV600 YV620 YV684 YV683
2002
HL685
10-1
J 2001
0 2002
10-2
SB685 E.V 14-20 03-19
2001
K FREIN DE PARK ELECTROS TRANSLATION 03-19

PARK BREAK STEERING E.V
12-1
12-1

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0
A
0 0 0 0
option sel treuil/nacelle

08-20 option TI4
113 option sel winch/basket 113 113
B
140
05-19 11-7
FAP
DPF
05-19
0
Park break
1 2
0
2 1 B106 0
Accessoires
Accessoiries
Frein de Park
C T4 final
SP100
113
Shunt lim. portée
Shunt reach limit
LMI CAN 04-5

B106
Cab emergency stop
REV
FWD
Arret d'urgence cabine
T4 interim
4 3 3 4

GV Trans
03-5
Neutre
MAV Trans
Neutral
MAR0Trans
HS steering
(L) B106
D T3 5 2 SB685 SA140 SB801
02-7 SA161 SA187
1 RP160
2002
3 4
SA600 SA620 SA684 SA680
E 2001 100A 11
Treuil
Winch
Basket
Nacelle
IVS
05-19 08-20 11-3 05-19 05-19
Signal
Regen forcée
Forced regen
Regen inhibée
F 100A 11 Inhibited regen
2
104
B106
400
684
167
168
B180
B181
B109
B110
B113
B114
B112
B107
B108
B101
0
! / ! / " / "/ "/& "/ "/ ! / !/ !/ " / ! / & ! / !/ " / " / ! / " / ! / ! / ! / " / & " / " / ! /
UN _ 04 UN_ 03 UN _11 12 _ VC 12_ VC 12 _ VD 12 _ VD Wake_ up 12 _ VB 12 _ VP UN _ 18 5V _ OUT UN_ 01 UN _ 09 UN _ 15 UN_ 14 UN _ 06 UN _ 12 UN_ 02 UN _ 08 UN _ 07 UN _ 20 UN _ 16 UN _ 10 UN _ 05
E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR
DEM ALIMENTATIONS COMODO GAUCHE
START SUPPLY D+ 5V PEDALE SWITCHS LEFT COMODO
H
D+ 5V PEDAL SWITCHS
2001
SPU- can gateway
I HTL36-14 HTL4014
options HTL36-17 HTL4017
CAN_J1939 S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR
CAN_HG
canH _ 1939 canL _ 1939 R _ 120 GND
_ GND
_ GND
_ GND
_ GND
_ HSD _ 06 HSD _ 09 HSD _ 05 HSD_ 04 HSD_ 07 HSD _ 08 HSD _ 11 canH _ HG canL_ HG R _ 120
J " / " / " / " / ! / ! / " / " / "/ " / " / & "/ ! / !/ " / "/ "/ " /
Crab
Float
Crabe
680
681
380
Synchro
B513
B650
B651
B653
K 0
Safety pump
2002
locking left axle
locking right axle
blocage essieu D
blocage essieu G
amort. unlock axle
Pompe de secours
2001
amort. déblocage essieu
1002
09-16 11-3 YV780 YV781 YV783 YV680 YV681 YV380

1001
L 0
KM120
2002
09-16 11-3 12-1

0 0 0 0
M
11-7 12-1

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TIER 3
B 0 0
Perkins only
12-1
00C
10-16
11-19
113 113
12-1
C
10-20

fule level
Masse moteur
jauge gasoil
Water in fuel
Engine ground
T huile hydro
def frein park
park break fualt
filtre hydro colm
Hydrolic oil temp

Pres huile moteur
Sealed hydro filter

Engine overheat
Eau dans le gasoil
08-10
08-7
08-7
07-13
D
Engnie oil pressure
Surchauffe moteur
00C
SQ189
100A
16-13 11-18
10-7 SQ126 SP162 ST160
E
cligno droit
High beam
ST125 SP691 SQ163
feux de route
Turn lamp left

Cligno gauche
Turn lamp right
feux de position
ST160/C
Side marker lamp

F
Engine temp
Temp moteur
63
62
60
125
126
691
162
164
100B
189A
189
166
164B
G
7#/ 7# / 7# / & 7# / 7# / 7# / 7# / 7# / 7# / 7# / 7# / 7# / 7# / 7# /
12V _ APC PD _ 4 PD _ 5 PD _ 6 PD _ 7 PU _ 2 PD _ 1 PD _ 3 0 _ 500 PU _ 5 PU _ 1 PU _ 4 0- 10000
_ PU _ 3
I Res CAN dans

AFFICHEUR - Display
l'afficheur/ in display
can _ L can _ H cligno_ GD feux _ Rte feux _ Pos T _ huile Filtre _ colm def _ freinP level _ fuel Eng _ T GND _
J 7# / 7# / 14 / 14 / 14 / & 14 / 14 / 14 / 81 / 81 / 7# /
00C
K 11-16 11-12
2001
L
10-4
2002
10-4
M

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0 0
A
11-20 12-1
113 113 113
11-20 13-2
B400
B
Left stab
Stab Droit
Right stab
14-1
0
Mode route
Road mode
B400
Stab gauche
Steeringmode
Mode direction
Frame levelling
JM3,6 JM5,8 JM2
JC1,2 JC4,10 JC5
Correction d'assiette
C

D J120
C6 C12 C9 JM7 JM9 SA681 SA780 SA781 SA782 SA692

JM4 JM1
up
Up
Left
Crab
Right
mort
Down
Down
Float
Droite
Crabe
Montée
Montée
Gauche
Synchro
Synchro
Y- lifting
Descente
Descente
E
X- cavage
Dead man
Off neutral
Y- relevage
Roller - aux
Hors neutre
102 102
roller - telesco
X- Forks tilting
05-19
B143
B144
B131
B118
B300
B301
B302roller - telesco
B303
B120
B124 Homme
B780A
B780B
B781A
B781B
B782A
B782B
B400
B400
F
/ / / / / / / / / / / / / & / / / / / / &
ALIM ALIM E_ANA E_TOR E_ANA E_ANA E_ANA E_ANA E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR
12V 5V Out
0-5V 0-5V 0-5V 0-5V 0-5V
HEAD - Noeud B - NBB02
102
H
Res can HG
RS _ RX RS _ TX RS _ GND CAN_ R120CANL _ HG CANH _ HG GND _ GND _ GND _ GND _ GND _ GND _ GND_ GND _ S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR S_TOR
/ / / / / / / / / & / / / / / / / / / / / / / /
I 101
09-15 05-19
1001 1002
0
0
0
0
09-15 0
3001
3002
3000
B132
160
B507
B501
B502
B509
B505
B505
B508
J H C D E B A F G
J
CN06
101
2002
2001
Road mode
mode route
Left stab
Right stab
frame levelling
Stab gauche
Stab droit
assiette
Feux recul
reverse lights
Relais EV PWM
relay EV
relay engine stop
relay stop moteur
Start relay
cmde relais dem
Preheat relay
relay préchauffage
K
0
C_SAUER D_ACTIA B_HG
HL692 HL780 HL781 HL782 KA160 KA620 KA122 KA161
1001
L 10-19
02-18
1002
10-19
0 0 0 0 0
M 12-20 SA692 SA780 SA781 SA782 13-2

VOYANTS SUR BOUTON CMDS RELAIS
BUTTON LIGHTS RELAYS CMD


I
L
F
K
E
B
A
H
D
C
M
1
05-19
12-20
12-20
2
4ELESCOPIC(ANDLERS
%LECTRICAL$IAGRAM
&/,)/
114
stab gauche descente B607

4
/
S_TOR
SP690
left stab down 690 Défaut frein de service

E_TOR
/
Service break fault

YV720
stab droit descente B600

S_TOR
/
Right stab down

SQ141
B121 présence siège

5
YV721
E_TOR
/
STABS
stab gauche montée B601 seat present

/ &
S_TOR
left stab up
YV700
SQ720.
stab droit montée B606 stab G baissé

/
S_TOR
Right stab up satb left down

6
YV701
114
B602 capteur pression /pressure sensor
Auxliaire A
S_TOR
/
SQ721.
Auxliary A stab D baissé

113
HTL3614/3617/4014/4017
stab right down

YV123
AUX
7
Auxliaire B B603
/
S_TOR
Auxliary B
YV124
Correc. assiette gacuhe B740 B115 stab G baissé

/

S_TOR
E_TOR
/
Frame levelling left satb left down

SQ720

8
YV740 0
HTL3210/4010
capteur position / position sensor

Correc. assiette droite B760
ASSIETTE
/
S_TOR
Frame levelling right B116 stab D baissé

/
FRAME LEVELLING

E_TOR
stab right down

SQ721
YV760

9
114
682 Essieu AV axé
/

E_TOR
Front axle in line

SQ682

0
10
KA122
695 Essieu AR axé
12-16
/

E_TOR
Rear axle in line

SQ683

113
115
11
B127 Telescope rentré

/

E_TOR
0
teslesco in
YV300
montée B608

SQ360

/ &
S_PWM
Up 0
LIFTING
YV320
B609 B403
LEVAGE
descente
12
0-5V
E_ANA
/
/
S_PWM
Down
B404 Angle flèche
0-5V
E_ANA
/ Boom angle
YV340
sortie B610
SR381
/
S_PWM
Out
113

13
YV360
rentrée B611
TELESCO
/
S_PWM
In
SQ340
B128 teles mi-course
/
E_TOR
half way telesco
14
YV400
montée B612
115
/
S_PWM
Up
SQ700
B125 stab G monté
/
E_TOR
stab left up
YV420
B613
CAVAGE
descente
/
S_PWM
Down
FORKS TILTING
15
SQ701
YV121
Valid. aux B614 B126 stab D monté
/
/
E_TOR
stab right up
S_PWM
aux validation
HTL/3617/4017 HTL3614/3617/4014/4017
YV122
Valid. stab+ assiette B615
16
/
S_PWM
Valid. stab+ frame levelling
VALIDATION
SP301
113
B264 Filtre air colmaté
Option
E_TOR
/
Sealed air filter
17
0
18
113
14-13
14-13
19
20
%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
187B
A
05-6
0 0
B400 SQ490
14-11
14-12
14-10
B
12-6
187A
SP490 SP491 SP492 SP493
490
05-6
103
C SQ491
05-19
187B
B512
B510
B511

RA 1 RA14 RA 13 RA 6 RA 3 RA 5
492
493
494
495
491
D +12V +12V +5V LMI D+ DEF

capteur pesage panier capteurs
klaxon basket weighting sensors verrouillage panier
Horn basket lock
sensors
E Recepteur Radiocommande
Radio receiver Emetteur Radiocommande
Radio transmitter
F
AU radio
pesage /load 4-20mA GND Radio ES
0
RA2 RA22 RA17 RA4 RA9 RA10 RA11 RA12 RA7 RA8 RA18 RA19 RA 20 RA21 RA15 RA16
Tilt
G
Up
Klaxon
105
Left
Devers
Horn
Start
Right
droite
Down
Lifting
gauche
Montée
113
Descente
Relevage
194
07-7
Radio OK
Telescoping
safety pump
Telescopage
KA187 13-19
SQ142
pompe de secours
H Option Nacelle/ Basket
0
B100
B129
B111
B102
B103
B104
B105
B401
B402
B310
B311
B312
B313
B140
I
/ / / / / / & / / / / / / / /
E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_TOR E_ANA E_ANA E_ANA E_ANA E_ANA E_ANA E_TOR
0-5V 0-5V 0-20mA 0-20mA 0-20mA 0-20mA
COMP. ROT. PANIER FLECHE

J COMP. BASKET ROT. BOOM
0
K
DEF LMI D+
S_TOR S_TOR S_TOR
/ / / 0 0
L
13-19 09-10
B511
B512
B510
M
14-12
14-10
14-11

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

D CAN HG
NOEUD B SPU
E
MOTEUR TIER3 RES CAN DS
FAISCEAU MOTEUR
CN DIAG
F
CAB
CN TI
G
CAN 2.0 CAN 2.0
AFFICHEUR
MOTEUR TIER4
H res term J1939
POMPE H1 DISPLAY LMI

CN DIAG <5m
J MOTEUR
RES INTERNE CALCULO MOTEUR
GAUGE

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS
&/,)/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
100A
11-5
FU23

40A
D
1 2 3 4 5 6 POSITION 0
0
E 05-8
Mat'n'lock 6 voies 1--480704-0+ sockets (male) 1 BATTERIE (-)
BATERY (-)
Mat'n'lock 6 voies 1-480707-0+ pin (fem) 02

2 MAINTIEN
F SA188. HOLD
I 0 II
1 2 3 4 5 6 03
SA187. 02-15 3 IGNITION
G
04
3 1 2 4 5 6 7 8 9 1 4 2 3 6 5 4 APPEL
ENERGIZE
Mat'n'lock 6 voies 1--480704-0+ sockets (male) 100C
H 5 BATTERIE (+)
Mat'n'lock 9 voies 1-480706-0+sockets (male) BATERY (+)
RADIO SELECTOR OPTION

WINCH/BASKET SELECTOR OPTION
I
02-14
K
YA3
Option kit raffinerie

M Option refinery kit

%LECTRICAL$IAGRAM
4ELESCOPIC(ANDLERS


(YDRAULIC$IAGRAM
4ELESCOPIC(ANDLERS
(4, (4, (4,

&/,)/

107P315160 D

(YDRAULIC$IAGRAM
4ELESCOPIC(ANDLERS

Operator's Manual: HTL 4010 - HTL 3510 (HTL 7732) - HTL 3010

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Operator's manual

4000328140 E01.15 AUS

Downloaded from www.Manualslib.com manuals search engine

2 4000328140 E01.15 AUS

5 - Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . 26

3.6 - Radio-control emitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5 - Telehandler vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7 - General points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

14 - Every 1500 h hours of operation . . . . . . . . . . . . . . . . . 182

You have just purchased a HAULOTTE® product

and we would like to thank you for your business.

The operator manual is a translation of the original instructions.

We would particularly like to draw your attention to 2 essential points :

2 - After Sales Service

4000328140 E01.15 AUS 9

Otherwise, it is essential to follow the manufacturer's recommendations below :

10 4000328140 E01.15 AUS

4- HAULOTTE Services® contact details

HAULOTTE HUBARBEITSBÜHNEN GmbH HAULOTTE VOSTOK HAULOTTE DO BRASIL

HAULOTTE IBERICA HAULOTTE MÉXICO, Sa de Cv

HAULOTTE MIDDLE EAST FZE

HAULOTTE NETHERLANDS BV HAULOTTE AUSTRALIA PTY Ltd HAULOTTE CHILE

4000328140 E01.15 AUS 11

12 4000328140 E01.15 AUS

Danger : Risk of injury or death (work safety)

Caution : Risk of material damage (work quality) E

Cross-reference to another part of the manual (see section or sheet)

Cross-reference to repairs (contact HAULOTTE Services®)

4000328140 E01.15 AUS 13

1.3 - LABEL COLORS

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

Red Prohibitions - Danger

Yellow Warning : Risk of material damage and/or minor injury

Other Additional technical information

14 4000328140 E01.15 AUS

2.2 - POTENTIAL RISKS

2.2.1 - Tip-over hazards

When driving at high speed, use only front-wheel

4000328140 E01.15 AUS 15

Do not raise the boom unless the chassis is level (0 °).

Do not level the machine with the boom or the accessory

• Transport the load as low as possible. Attach the

• Keep the heaviest part of the load closest to the

16 4000328140 E01.15 AUS

• Maintain proper tire pressure at all times. Otherwise, the

• Always wear the seat belt. C

If the telehandler starts to tip over :

4000328140 E01.15 AUS 17

2.2.2 - Electrical hazards

• The machine is not electrically insulated and does not offer

• Maintain a minimum safe distance with regard to power

Minimum safety distance

18 4000328140 E01.15 AUS