Humbaur 10000, HTK 195024 Operating Instructions Manual
OPERATING INSTRUCTIONS
MACHT’S MÖGLICH
HTK
Three way tipper (195024)
10000 SERIES EN
xx
humbaur.com
Humbaur GmbH
Mercedesring 1
86368 Gersthofen
Germany
Tel. + 49 821 24929-0 l info@humbaur.com
Fax + 49 821 249-100 l www.humbaur.com
Your trailer:
Model __________________________________________________
Type (abbreviation) _______________________________________________
Registration number ______________________________________________
►►
WHD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
VIN number
Trailer data:
Date of first registration ______________________
Gross weight ________________________________
Load capacity ________________________________
Keep this instruction manual readily available in the towing vehicle!
Pass on the complete documentation to the new owner if you sell the trailer.
Trailer components
Axle(s)
(Type / manufacturer) ____________________________________________
Brake system
(Type / manufacturer) ____________________________________________
Support device ___________________________________________________
(Type / manufacturer)
Electronic system __________________________________________________
(installed components)
This operating instruction manual must
be carefully read, understood and
complied with in full by anyone who is
responsible for the Humbaur GmbH
vehicle and its modules.
Humbaur GmbH accepts no liability for
damage or failures which arise through
disregard of this manual!
Read and observe the operating
instruction manual with all the
instructions, warnings and notes
before driving for the first time!
Please note that all illustrations are
representative and may differ from the
actual appearance / equipment.
Also read and observe the
instruction manuals for
components such as axles,
support devices, etc.!
The complete technical documentation is
part of the product and should be kept in
the driver's cab of the traction unit for
reference at all times.
Key details for the handling, operation
and the requisite care and maintenance
work of the trailer are referred to in this
operating instruction manual, and errors
can only be avoided and trouble-free
operation guaranteed if you are familiar
with them.
Errors excepted. The manufacturer:
Humbaur GmbH
Mercedesring 1
89368 Gersthofen (Germany)
reserves the right make technical
changes to the design, equipment and
accessories with respect to the
information and illustrations in the
operating instruction manual.
As a result, no claims whatsoever can be
derived from the information, illustrations
and descriptions.
Obligations of the operator
The trailer may only be operated in
perfect condition.
Ensure that the operating instruction
manual is included with the trailer e.g. if it
is sold.
Only utilise trained or instructed
personnel.
Ensure that the operating
instruction manual is complied
with in all life cycle phases of the
trailer and that the prescribed
personal protective equipment
(see “Personal protective
equipment / rules prohibitions”
on page 24) is worn.
Provide the requisite operating and
auxiliary materials.
1
Contents
Identification
Dimensions, weights and performance
data can be found in the approval documents of the respective trailer.
Vehicle type: Model
Three-way tipper, tandem (gross weight 19 t) HTK 195024
The applicable trailer should be marked with a cross upon delivery.
2
Keyword index
Use the keyword index from page 5 to
search for specific topics.
1 Safety
You will find safety information for the
correct handling of the trailer in the
"Safety" chapter from page 9.
Read this chapter before driving for the
first time.
2 General information
You will find details on vehicle
identification in the "General information"
chapter from page 27.
3 Operation
You will find information on loading and
unloading, correct load distribution and
coupling and uncoupling the trailer in the
chapter on "Operation" from page 37.
4 Operating the chassis
You will find valuable information on the
operating elements of the chassis, such
as the lifting / lowering system, support
devices and information on the safe
loading and unloading, in the chapter on
"Operating the chassis" from page 59.
5 Body
You will find information on how to
operate the body correctly, e.g. folding
down the drop sides, securing loading
ramps, and also on the equipment you
can use to secure the load in the chapter
on the "Body" from page 101.
6 Electrical system
You will find information on the lights,
plug connections and connector
assignments in the chapter on the
"Electrical system" from page 143.
Contents
7 Testing, care and maintenance
You will find out more about the work
required to maintain operational safety
and the value of your vehicle in the
chapter on "Testing, care and
maintenance" from page 157.
8 Troubleshooting
You will find information on
troubleshooting and important service
addresses in the "Troubleshooting
guide" from page 217.
3
Contents
4
Keywords
A
Accumulator parking brake . . . . . 66
Action
in the event of faults. . . . . . . . 218
in the event of fire . . . . . . . . . 218
Address
Manufacturer. . . . . . . . . . . . . . 1
Adjusting the central locking mecha-
. . . . . . . . . . . . . . . . . . . 182
nism
Adjusting the tubular drawbar . . 180
Aluminium surfaces. . . . . . . . . 212
Automatic lowering system . . . . . 72
Inductive sensor . . . . . . . . . . 153
Axle lifting system . . . . . . . . . . . 96
B
Body . . . . . . . . . . . . . . . . . . 101
Brake name plate . . . . . . . . . . 191
C
Care. . . . . . . . . . . . . . . . . . . 157
CE conformity statement . . . . . . 36
Centre of gravity. . . . . . . . . . . . 46
Changing the wheels. . . . . . . . 187
Chapter
Electrical system. . . . . . . . . . 143
General information
Operating the body . . . . . . . . 101
. . . . . . . . . 27
Operating the chassis
Operation
Safety. . . . . . . . . . . . . . . . . . 9
Testing, care and maintenance . . 157
Troubleshooting guide
Chassis
Operating. . . . . . . . . . . . . . . 59
Check when parking . . . . . . . . . 57
Cleaning
Aluminium disc wheels . . . . . . . 209
Cleaning the Duo-Matic coupling . 196
Climbing aids. . . . . . . . . . . . . . 126
Climbing the tipping box. . . . . . . 129
Compressed air container . . . . . 67
Connecting element . . . . . . . . . 48
Connecting the electric system . . 146
Coupling. . . . . . . . . . . . . . . . . 51
Hydraulic line . . . . . . . . . . . . 75
Coupling / uncoupling of the supply
. . . . . . . . . . . . . . . . . . . . 63
lines
. . . . . . . . . . . . . . . 37
. . . . . . . 59
. . . . . . . 217
D
Danger area . . . . . . . . . . . . . . 40
Departure check. . . . . . . . . . . . 57
Disposal
Batteries . . . . . . . . . . . . . . . 215
. . . . . . . . . . . . . . . . . 215
Tyres
Waste oil / lubricants . . . . . . . . 215
Disposing of operating materials . 215
Documentation
Maintenance of axles / wheels . . 159
Maintenance of support device
Proof of the HU/SP . . . . . . . . . 159
Draining the compressed air container
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
. . 159
E
EBS plug connection
7-pin (ISO 7638) . . . . . . . . . . 148
Electrical system . . . . . . . . . . . 143
maintenance. . . . . . . . . . . . . 199
Emergency release device
Brake. . . . . . . . . . . . . . . . . 197
Environmental pollution
Poisonous substances . . . . . . . 215
Environmental protection measures. .
208
Exchanging lights. . . . . . . . . . . 201
F
Fasteners, cable clamps . . . . . . 190
Fastening torque values
for screw connections . . . . . . . 163
for wheel nuts . . . . . . . . . . . . 163
Faulty wheel . . . . . . . . . . . . . . 189
Friction coefficients for material pairs .
123
5
Keywords
G
Galvanised steel surfaces. . . . . 211
General information. . . . . . . . . . 27
H
High-pressure cleaner . . . . . . . 209
Hydraulic connections . . . . . . . 175
Hydraulic pump
- switch off . . . . . . . . . . . . . 119
- switch on . . . . . . . . . . . . . 118
I
Identification . . . . . . . . . . . . . . . 2
Intelligent trailer access point (iTAP) .
155
L
Lettering work . . . . . . . . . . . . 206
Lifting axle. . . . . . . . . . . . . . . . 96
Lighting system . . . . . . . . . . . 144
Lights
Allocation plan . . . . . . . . . . . 199
Light bulbs . . . . . . . . . . . . . 200
Marker light
Position lamp. . . . . . . . . . . . 200
Power / type . . . . . . . . . . . . 200
Side light
Load securing . . . . . . . . . . . . 122
. . . . . . . . . . . . . 200
. . . . . . . . . . . . . . 200
Basic principles
Tie-down points
Loading . . . . . . . . . . . . . . . . . 42
Lubrication
Aluminium disc wheels . . . . . . . 190
Central locking for drop sides . . . 170
Central locking mechanism, front
Drop side mounting . . . . . . . . . 168
Implementation instructions . . . . 164
Spindle support
Tailgate mounting . . . . . . . . . . 171
Telescopic cylinder . . . . . . . . . 176
Tilting bearing
Towing ring. . . . . . . . . . . . . . 165
Underride protection lock. . . . . . 174
. . . . . . . . . . . 122
. . . . . . . . . . . 125
. 182
. . . . . . . . . . . 167
. . . . . . . . . . . . 173
M
Maintenance . . . . . . . . . . . . . . 157
Adjusting / maintaining the brake linings
. . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Brake lining exchange . . . . . . . 193
Cleaning the compressed air filter
Cleaning the coupling heads . . . 195
Compressed air system . . . . . . 194
Drop side lifting spring
Electric systems. . . . . . . . . . . 199
Greases
Hydraulic system . . . . . . . . . . 175
Licence plate light "LED". . . . . . 204
Licence plate light "Standard
Operating brake system . . . . . . 191
. . . . . . . . . . . . . . . 164
. . . . . . . 181
193
. . . 204
Position / marker lights. . . . . . . 205
Side light standard 24 V
Side marker lights. . . . . . . . . . 205
Tail light "24 V - standard". . . . . 201
Tail light "LED"
Tailgate locking / unlocking mechanics
184
Tailgate tension spring
Underride protection lock . . . . . 174
Maintenance brace. . . . . . . . . . 176
Maintenance intervals
Once-off maintenance work . . . . 160
Regular maintenance work
Marker lights . . . . . . . . . . . . . . 151
. . . . . . . . . . . 203
. . . . . . 202
. . . . . . . 183
. . . . 161
N
Number plate light . . . . . . . . . . 152
O
Operating
Body . . . . . . . . . . . . . . . . . 101
Chassis
Operating brake
use . . . . . . . . . . . . . . . . . . . 65
Operation. . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . 59
P
Painted and powder-coated steel sur-
. . . . . . . . . . . . . . . . . . . 211
faces
Parking warning signs. . . . . . . . 100
6
Keywords
Permitted weights / load distribution .
46
Personal protective equipment. . . 24
Physical foundations
Friction force . . . . . . . . . . . . 123
Plug connection
15-pin (ISO 12098-24V) . . . . . 147
7-pin (ISO 7638 - EBS) . . . . . . 148
ABS/EBS . . . . . . . . . . . . . . . 61
Plug connections (standard) . . . 145
Plug socket terminals
15-pin (ISO 12098-24V) . . . . . 147
7-pin (ISO 7638 - EBS) . . . . . . 148
Position lamps . . . . . . . . . . . . 151
Positioning the lifting device . . . 188
Product description
Three-way tipper HTK 19 t . . . . . 28
Versions / accessories
Prohibitory signs / symbols . . . . . 25
. . . . . . . 31
Q
Quick coupling
Duo-Matic. . . . . . . . . . . . . . . 64
R
Rear drop side
- lock . . . . . . . . . . . . . . . . 120
unlocked . . . . . . . . . . . . . . 117
Reversing / operating lights. . . . 152
Roll-up tarpaulin . . . . . . . . . . . 131
CRAMARO
Horizontal version
Rubber hoses . . . . . . . . . . . . . 212
. . . . . . . . . . . . . . 138
. . . . . . . . . . 132
S
Safety . . . . . . . . . . . . . . . . . . . 9
Safety during tipping . . . . . . . . . 39
Safety instructions . . . . . . . . . . 22
Securing the cargo bed
Tilting bearings . . . . . . . . . . . 78
Securing the trailer . . . . . . . . . . 66
Service addresses . . . . . . . . . . 219
Side light . . . . . . . . . . . . . . . . 202
Signal words . . . . . . . . . . . . . . 22
Sources of danger . . . . . . . . 16, 17
Spare wheel . . . . . . . . . . . . . . 189
Specifications for HTK 19 t - three-way
. . . . . . . . . . . . . . . . . . . 30
tipper
Spindle support identification . . . 35
Staff qualification . . . . . . . . . . . 16
Start of the journey . . . . . . . . . . 17
Steam jet . . . . . . . . . . . . . . . . 209
Steps
Pedestal with banister and folding lad-
. . . . . . . . . . . . . . . . . . . 128
der
Pedestal with climbing steps. . . . 127
Stichwörter . . . . . . . . . . . . . . . . 5
Switch-off / securing mechanisms
Lift limitation . . . . . . . . . . . . . 179
T
Tail light
LED with side light . . . . . . . . . 150
Standard with side light 24 V . . . 149
Testing . . . . . . . . . . . . . . . . . 157
Tilting positional stability . . . . . . . 39
Toolbox . . . . . . . . . . . . . . . . . . 99
Traffic signs regarding height . . . . 25
Trailer
decommissioning . . . . . . . . . . 216
disposal
securing . . . . . . . . . . . . . . . 188
Trailer information module (TIM) . 154
Trailer materials. . . . . . . . . . . . 210
Troubleshooting. . . . . . . . . . . . 217
Axles
Braking system
Electrical system . . . . . . . . . . 224
Loading / road handling . . . . . . 220
Rear drop side / side drop sides
Troubleshooting guide. . . . . . . . 217
Tyre pressure / wheel profile. . . . 186
Tyre types . . . . . . . . . . . . . . . 185
. . . . . . . . . . . . . . . 216
. . . . . . . . . . . . . . . . . 225
. . . . . . . . . . . 222
. 227
U
Uncoupling . . . . . . . . . . . . . . . . 55
Unloading. . . . . . . . . . . . . . . . . 42
Use
Foreseeable misuse . . . . . . . . . 11
7
Keywords
Intended use . . . . . . . . . . . . . 10
V
Vehicle combination brake balancing
12
Vehicle identification number. . . . 34
VIN . . . . . . . . . . . . . . . . . . . . 34
W
Warning signs . . . . . . . . . . . . . 23
Warranty. . . . . . . . . . . . . . . . . 14
Waste plate (A-plate). . . . . . . . . 98
Wheel chocks
in front. . . . . . . . . . . . . . . . . 93
Retaining pin . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . 92
Use
Wheel nuts . . . . . . . . . . . . . . 186
Zugösen-Verbindung 235
8
1
Safety
9
Use
1
Intended use
HUMBAUR vehicles and bodies are built
according to the acknowledged rules of
technology and safety engineering.
However, inappropriate use may result in
risks for life and limb of the user or third
parties and damage to the HUMBAUR
vehicles and other goods.
HUMBAUR vehicles and bodies are
exclusively made for appropriate
transportation according to the transport
regulations.
Appropriate use also includes adherence
to the regulations, descriptions and
recommendations in these instructions
and the operating and maintenance
instructions of the sub-suppliers.
Inquire at Humbaur GmbH or at a
HUMBAUR contract workshop if you are
planning additional changes to your
HUMBAUR vehicle or body.
Only have accessories attached to your
HUMBAUR vehicle or body after
discussion with Humbaur GmbH or a
HUMBAUR contract workshop.
The following are permitted:
– Transport of bulk goods
– Operation only within the framework
of the permissible gross weight
– Only operate with appropriate towing
vehicle
– Only operate in a technically flawless
condition
– Ensure an even weight distribution for
the goods
– Only drive with appropriately secured
goods
– Adhere to the legally prescribed and
permitted max. driving speed and
adapt the speed when driving on bad
roads or in bad weather conditions
– Loading and unloading is only
permitted in secured areas or on
public roads after additional securing
measures
– Use additional safeguards against
rolling off when switching off / parking
the trailer
The regular presentation of the trailer for
the main inspection and the safety tests
by the specialist staff as well as its
documentation is a requirement for
participating in road traffic.
The operator / user of the trailer is
responsible for regular servicing /
cleaning and maintenance.
HUMBAUR vehicle bodies are
provided with a VIN (Vehicle
Identification Number) - see
Page 34.
It is essential to specify the VIN when
making enquiries and ordering
spare parts!
10
Safety
Reasonably foreseeable misuse
Any use extending beyond the
prescribed transport applications is
regarded as other than intended.
In particular, this includes:
– Person / animal transports
– Transports of goods for which special
regulations apply and / or special
vehicle versions are required (e.g.
chemical substances, food stuff,
dangerous goods)
– Exceeding the load capacity
– Exceeding the max. permitted axle /
support / trailer load
– Transporting hot / liquid materials
(e.g. tar)
– Driving with badly secured or
unsecured goods
– Driving with a tipped cargo bed
– Driving with bad load distribution
(load one-sided or in one point)
– Structural changes to the trailer that
were not approved by the
manufacturer or were arbitrary
– Use of unapproved spare parts or
accessories
– Driving with a faulty light or electric
system
– Driving with a dirty trailer on which the
number plate, lights, markings are
unrecognisable or hard to recognise
– Driving when the underride protection
is not in driving position
– Driving with support devices not
moved up
– Arbitrary performance of
maintenance / repair of safety-related
components that may only be
maintained or repaired by specialist
personnel
– Driving at an excessive /
inappropriate speed in bad weather
conditions or on a bad road
– Parking the trailer without sufficient
safety precautions against rolling off
– Operating the trailer in a damaged
state and when parts are visibly worn
or safety-related components are
broken
Use
– Operating a trailer without
appropriate brake adjustment
involving the towing machine or with
the wrong oil pressure
– Tilting / lowering the loading bridge
while persons remain within the
danger zone
– Remaining on the cargo bed when
bulk goods are being tipped or when
the loading bridge is lowered
– Tilting the loading bridge on steep
slopes and soft ground
– Tilting the loading bridge with uneven
tyre pressure
The manufacturer:
Humbaur GmbH
Mercedesring 1
86368 Gersthofen (Germany)
rejects any damage which arises through
disregard of this manual – the risks are
borne solely by the user.
1
Safety
11
Use
WARNUNG
WARNING
nach
Überlastung der Bremsen!
Verminderte Bremswirkung durch überhitzte Bremsen / starker Bremsenverschleiß.
XBremskraft-Zugabstimmung
2000 - 5000 km und nach jedem
Zugmaschinenwechsel durchführen.
after 2000 - 5000 km and
Overloading of the brakes!
Reduced braking effect caused by overheated brakes / strong brake wear.
X
Perform Tractor / Trailer synchro-
nisation
after each exchange of tractor.
620.00127
1
Vehicle combination brake balancing
Vehicle combination brake balancing is
part of appropriate use.
Even when there is only 1 vehicle without
EBS in a vehicle combination, the
combination has to be balanced after
approx. 5,000 km.
When different brake systems, i.e. disk
brakes and drum brakes, are present in a
vehicle combination, the brakes of the
entire vehicle combination must be
balanced.
Towing vehicles without EBS always
require vehicle combination brake
balancing.
Unlike drum brakes, disk brakes do not
indicate overload to the driver by
noticeable deterioration of the braking
effect.
This overload may cause the brakes of
the towing vehicle or the trailer to
overheat. Overloaded brakes may result
in decreasing brake force, higher brake
lining and / or brake disk wear as well as
damage to the wheel bearings or axles.
Optimal distribution of the brake force in
the entire vehicle combination requires
the brakes of the vehicle combination to
be balanced with loaded vehicles
according to 71/320/EC or ECE R13 by a
neutral brake service after a short run-in
time of 2000-5000 km or within 14 days
after acceptance of the vehicle and after
every exchange of the towing vehicle.
When the towing vehicle and the trailer
are equipped with EBS, optimal brake
force distribution requires a balancing
examination and possible correction of
the EBS parameters of the towing
vehicle and possibly also the trailer.
Checks, settings and corrections of EBS
parameters may only be performed by
vehicle manufacturers!
Abb. 1 Warning sign on the trailer
Warranty claims against
Humbaur GmbH become void
when this instruction is not
adhered to or documentation of
the result of the vehicle
combination brake balancing is
missing.
12
Safety
Disclaimer
Any liability of the manufacturer
becomes null and void if:
Any risks and liability exclusions
resulting from this also exist if:
Use
1
– the trailer and its components were
altered without authorisation.
– The original parts or conversion parts
/ accessories approved by Humbaur
GmbH are replaced by other
components.
– subsequent changes were made to
the trailer
(e.g. new drill holes in the frame,
tubular drawbar or widening of
existing drill holes in the frame). This
is considered by Humbaur GmbH to
be a structural change, and the type
approval therefore becomes null and
void.
– Non-approved accessories or third-
party spare / component parts which
are not original HUMBAUR parts are
attached or installed. The type
approval of the trailer, possibly even
the insurance cover, becomes null
and void.
– care and maintenance intervals
prescribed by the manufacturer are
not complied with.
– Acceptance inspections have been
carried out by inspectors / authorised
experts of the technical inspection
authorities or officially recognised
organisations.
– Official approvals are available.
Safety
13
Service and warranty claims
1
The warranty includes the following:
Defects that occur during proper use of the trailer
as specified, or which are design-related or can
be attributed to material faults.
Repairs carried out during the guarantee period
do not extend it.
As the contracting party, the dealer is responsible for the warranty.
Requirements
Original replacement parts must be used for
repairs.
Repairs must be carried out by a specialist
workshop.
The maintenance instructions and regulations of
the manufacturer as listed in this operating
manual must be observed.
Defects must not be attributable to
Non-compliance with the technical and legal
regulations listed in this operating manual.
Improper use of the trailer or lack of experience
on the part of the user.
Unauthorised alterations to the trailer and the
use of fittings not approved by Humbaur GmbH
invalidate the warranty. Non-compliance with the
relevant statutory regulations.
The following are not defects
Each trailer is a hand-made product. Despite the
greatest of care, minor superficial scratches
which have no effect on the intended use can
occur during assembly.
Tension cracks in the surface (hair cracks) are
inherent in the production method and cannot be
avoided. These hair cracks have no impact on
the stability or use of the trailer.
Gaps between the drop side and the loading
bridge.
Furthermore, polyester components are not
100% colour-fast. Here, too, UV and weather
effects can cause fading.
It should also be noted that rubber parts generally age as a result of UV exposure and the
formation of cracks and fading of the surface is
possible.
Parts coated with the cathodic dip-painting
process (KTL) are not colour-fast. They can fade
as a result of UV irradiation.
Galvanised parts are not normally shiny, as they
lose their bright finish after a short time. This is
not a defect but rather a desired effect, as full
protection against rusting of the metal is only
guaranteed after oxidation. Wood is a natural
material. Despite the most diverse types of
processing and coating, it is therefore subject to
natural, weather-dependent expansion and
shrinkage, which can result in warping. Natural
wood grain and irregularities are normal for this
natural material and can appear on the surface.
Fading is also possible as a result of UV irradiation and weathering effects. A manufacturing
tolerance is specified for the thickness of the
wooden components used. Claims will not be
accepted for deviations within the tolerance.
As the trailers are not generally insulated,
temperature fluctuations can result in the formation of condensation under tarpaulins and polyester covers. In this case, adequate ventilation
should be provided to prevent mould growth.
Furthermore, the trailers are not 100% watertight. Water ingress at the doors, flaps and
windows is still possible, even with extremely
careful workmanship and the use of rubber
seals.
14
Safety
Service and warranty claims
1
The warranty will expire
If the regulations for operation, maintenance,
cleaning and inspection are not observed.
In the event of engineering alterations to the
trailer.
In the event of independently added fittings and
superstructures which have not been approved
by Humbaur.
In the event of the overloading and improper use
of the trailer.
If non-original Humbaur replacement parts are
used.
If the safety instructions provided on the trailer
are not observed.
If the service intervals are not adhered to, even
when the parts concerned, e.g. axle, brake,
drawbar, hydraulic systems etc. were fitted by
Humbaur.
In the event of incorrect surface treatment of the
materials used.
In the event of continued use of the trailer even
though defects have already been detected and
reported and the use has been prohibited by the
manufacturer until repairs have been carried out.
In the event of continued use of the trailer with
known defects where repair is not possible or is
time-consuming or is only possible with significant additional expense and reduced function.
The warranty does not include
Expenditure for ongoing maintenance.
Costs that can be attributed to normal wear or
even because the trailer has not been used for a
long time.
Faults that can be attributed to not treating the
trailer as specified.
Defects that can be attributed to the use of nonoriginal Humbaur replacement parts.
Defects that can be attributed as a consequence
of a repair not carried out by a specialist workshop.
Defects that can be attributed to structural alterations or assembly work on the vehicle.
Damage which can be traced back to snow and
water loads on tarpaulin, plywood or polyester
bodies.
The manufacturer reserves the right to make
design changes.
Safety
15
Staff qualification
1
HUMBAUR vehicles and bodies as well
as their operating components may only
be used and maintained by personnel
who are aware of:
– this operating instruction manual.
– the trailer and the associated traction
unit.
– the operating and maintenance
instructions of the suppliers.
– the German Road Traffic Act (StVO)
and German Road Traffic Licensing
Regulations (StVZO).
– All the respective health and safety /
accident prevention regulations as
well as other safety, occupational
health and road traffic regulations.
– the basic requirements of goods
transport.
– the risks of handling dump trucks
(see Brochure BGI -5064 "AVOID
TIPPING OVER")
16
Safety
Sources of danger
Take note of the following points without
fail:
– Coupling and uncoupling a trailer:
Standing in the danger area is
prohibited.
– Driving with unsecured support
devices.
– Driving with an unlocked tailgate.
– Driving when the underride protection
is not in the driving position.
– Inappropriate operation of the drop
sides.
– Clearance heights on the route, while
loading and unloading.
– Driving with a tipped loading bridge -
not permitted by law.
– Exceeding the permissible gross
weight or one-sided overloading
through incorrect loading.
– Poorly secured or unsecured goods
and / or body components.
– Reversing - keep an eye on the rear
area.
– Excessive twisting while
manoeuvring.
Check, adjust and secure before each journey
– Overloading of the trailer, axles and
brakes.
– Overstressing caused by fitting
incorrect wheel and tyre sizes.
– Use of wheels with incorrect offsets,
one-sided run-out or centrifugal
imbalance.
– Overstressing as a result of reckless
and inappropriate driving or handling.
– Impact and shock stress of the axles.
– Speed inappropriate for the road
conditions and the loading status of
the trailer, especially in bends.
– The parked trailer can tilt or sink in on
soft uneven ground.
– Tilting the loading bridge too close to
a slope or excavation.
– Driving on severe inclines.
– Loading / unloading of the trailer in an
area with a steep gradient.
– Standing on a tipped / moving loading
bridge.
– Driving under a raised loading bridge.
– Tilting the loading bridge on uneven
and soft ground.
1
– Jerky braking during tipping.
– Tipping with an engaged parking
brake.
– Failure to clean the cargo bed after
every use.
– Tipping viscous load materials e.g.
asphalt, soil, loamy sand.
– Tipping large rocks.
– Tipping with an inclined combination.
– Tipping under high-voltage
transmission lines (open power
lines).
Safety
17
Check, adjust and secure before each journey
1
In the chassis area
Note the following in general:
– Connect the supply lines
– Establish the electrical connections
– Retract the support devices and lock
them
– Check the tyres and rims for damage
– Check the tyre pressure, including
the spare wheel
– Check the tightening torque of the
wheel nuts
– In the case of a new trailer, retighten
the wheel nuts after 50 km and after
the first journey with a load
– Secure the:
spare wheel / spare wheel holder,
wheel chock
– Check the trailer lights, repair
defective lights
– Adhere to the permissible gross
weight
– Release the brakes and only start
driving when the brake operating
pressure has been reached
– Drain the compressed air tank
– Check the number plate and signs
– Check the attachment of the tubular
drawbar
– Check that the coupling (eyelet) is in
perfect condition
– Appropriately lock the trailer coupling
– Ensure that the loading bridge is
secured in the tilting bearings
– Check the number plate and signs
– Ensure that the telescopic cylinder
has been appropriately retracted
In the body area
Close and secure all body components,
such as:
– Tailgate
– Drop sides, side
– Toolbox
– Climbing aids
– Ensure that the load distribution is
balanced
– Use roll-up tarpaulin as required
18
Safety
Basic safety instructions regarding the tilting process
Tippers have a high risk of falling over.
They may fall over while tilting the load
and cause major injuries and serious
damage to goods.
Tipper accidents have varied causes and
usually result when a combination of
several issues was neglected during the
tipping process.
We are listing the most important issues
below, so that the risk of falling over can
be minimised.
Clean cargo bed
The inside surfaces of the cargo
bed must be kept clean to
prevent bulk goods from sliding
off!
Thoroughly clean the cargo bed after
each transport.
Total mass / weight
Higher loads increase the risk of
falling over!
Exceeding the max. permitted
total mass strongly increases the
risk of falling over.
Adhere to the permitted total mass
and the max. load capacity as well as
the max. axle loads.
Do not overload the cargo bed - as this
has a negative effect on this vehicle
component and the tilting moment.
Safe handling of tippers
Uneven / soft ground
Tilting on a soft / uneven ground
significantly reduces the stability
of the vehicle during the tilting
process!
Check before tilting that the vehicle
stands on firm and even ground which can usually be seen with the
naked eye.
Tyre pressure / load distribution
Uneven tyre pressure (different
on the right and left side) as well
as uneven load distribution
increase the risk of falling over!
Regularly check the tyre pressure -
establish the same tyre pressure in all
tyres.
Evenly distribute the goods across the
whole lengths / width of the cargo bed.
1
Safety
19
Safe handling of tippers
1
Unfavourable wind conditions
The risk of falling over increases
with the height to which the
loading bridge is raised at winds
above a strength of 5 Bft
(Beaufort scale = 35 km/h - small
deciduous trees start to sway)!
Check from which side the wind is
blowing before the tilting process and
tilt against the wind where possible.
Avoid lifting the lowing bridge fully up
when the side wind is strong.
Perform the tilting at fair speed.
Tipping at building sites
Sufficient distance must be kept
when tipping at fortified
excavation pits!
Maintain a distance of at least 1 m
from the excavation pit when tipping.
Tipping on slopes
A sufficient distance must be
maintained when tipping on
slopes!
Maintain a distance of at least 2 m
from the slope when tipping.
Ensure that the slope angle does not
exceed the following values:
- 45° on soft ground
- 60° on firm ground
- 80° on rock / rocky ground
Maintain a larger distance if you are
not sure.
Braking during tilting
The chassis must be able to
compensate fo the forces during
the tipping process.
The parking brake may not be activated
during the tipping process!
The operating brake may not be
continuously activated!
Check that the parking brake has
been released before the tipping
process.
Release the operating brake gently
and repeatedly - not suddenly - during
the tipping process.
Dragging bulk goods
Bulk goods that are difficult to
move from the cargo bed can be
dragged by a controlled
movement of the vehicle.
This process must be carried out
slowly and very carefully!
Very slowly drive forwards and gently
activate the operating brake - do not
stop suddenly.
Jacking up the air-suspension
A lowered chassis - supported
by a jack - provides more
stability for the vehicle.
The air-suspension should
always be lowered completely
where possible!
Use the lifting / lowering system to
lower the air-suspension completely
or switch on the automatic lowering
facility.
20
Safety
Safe handling of tippers
1
Total vehicle combination extended
During the tilting process, the
total vehicle combination must:
be arranged with the towing
vehicle and the trailer aligned /
stretched out.
This ensures stability!
Check that the total vehicle
combination is arranged as straight as
possible before tipping.
Height of the loading bridge
Tipping under power lines poses
the risk of an electric shock!
Remain seated in the driver's
cab in the event of an electric shock!
Check before tipping that no exposed
power lines are nearby or maintain a
safety distance of at least 5 m.
Tipping pieces of rock
Tipping pieces of rock poses a
high risk.
Pieces of rock may fall down
during the tipping process and
knock against the tailgate / drop
sides, vehicle body or tailgate
suspension, which may in turn
cause the vehicle to fall over!
Check before transporting pieces of
rock that your version of the vehicle is
suitable for that purpose.
Safety
21
Safety instructions
1
Signal words
DANGER
Describes an immediate risk
Death or major injuries will result when
this risk is not avoided.
WARNING
Describes a possibly dangerous
situation
Death or major injuries may result when
this risk is not avoided.
CAUTION
Describes a possibly dangerous
situation
Light or minor injuries may result when
this risk is not avoided.
NOTICE
Describes a possibly dangerous
situation
Damage to goods may result when this
risk is not avoided.
General mandatory signs.
Refers to information that must
be considered and adhered to in
order to ensure safe use.
Also forward all warnings and
instructions to other users or to auxiliary
staff!
Text highlighting
The following symbols in front of text are
used in these instructions:
(Arrow) Request for action
- (Dash) List
1. (Number) List of components
22
Safety
Warning signs used
The following warning signs may be used
in these operating instructions and on the
product.
Take note of these warning signs and
behave very carefully in such cases.
Warning of hazard point!
Be careful - several factors could
put persons at risk here.
Risk of crushing!
For limbs such as:
Hands / fingers / feet.
Risk of crushing!
For body / body parts.
Falling hazard!
Risk of electric shock!
Dangerous voltage.
Risk of impact!
Dropping objects.
Safety instructions
Risk of chemical burns!
Leaking battery acid.
Risk of poisoning!
Poisonous substances.
Risk of injury!
Obstacles in the head area.
Risk of slipping!
Risk of tripping!
1
Burn hazard!
Hot surfaces.
Risk of explosion!
Explosive operating materials.
Risk of impact!
Keep distance.
Safety
23
Personal protective equipment / rules prohibitions
1
Personal protective equipment
Wear the prescribed personal protective
equipment (PPE) during all work
described in these instructions.
This includes the following:
Safety shoes,
Sturdy footwear
Protective clothes
Protective helmet
Protective goggles
High-visibility clothing,
High-visibility vest
Protective mask,
Breathing protection
Hearing protection
Mandatory signs
Adhere to the following directives /
requests for action during all work
described in these instructions.
Important note!
To be considered and adhered
to
Read the operating instructions
before performing a task
Thoroughly wash your hands
Pull out the mains connector
before working on live
components
Ensure good ventilation
Perform tasks as a 2-person
team.
Instructions by support person
required
Protective clothing
24
Safety
Personal protective equipment / rules prohibitions
1
Prohibitory signs
Adhere to these prohibitions.
Do not climb up.
Do not reach in.
Do not touch.
Do not step onto the surface.
Open fire prohibited,
e.g. cigar, lighter.
Do not splash with water,
e.g. high-pressure cleaner.
Access prohibited,
Keep unauthorised persons out.
Stepping behind swivel arm /
moving parts prohibited.
Stepping between towing
machine and the trailer is.
Other important symbols
Take note of the following symbols for
professional disposal as well as first aid
in emergencies.
Problem waste!
Disposal in domestic waste not
allowed.
Risk of
environmental pollution.
Professional waste oil disposal,
Do not dispose of oil into the
environment.
Professional waste tyre
disposal,
Do not dispose of old tyres into
the environment.
Immediately rinse eyes with lots
of water.
Visit a doctor.
Traffic signs regarding height
Please take note of the following,
important traffic signs regarding height
information in public transport.
Maximum vehicle height!
This height may not be
exceeded.
Caution - height limitation at
m
bridges / underpasses!
Tunnel - limited height!
Take note of the maximum
height information.
Letting the trailer run against the
towing vehicle is prohibited.
Safety
25
Personal protective equipment / rules prohibitions
1
26
Safety
2
General information
27
HTK product description
I - 001
14
11
12
13
1
16
10
19
21
15
20
17
18
2
HTK 19 t
3 4
2
1
Pic. 1 Side view
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5 7
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9
10
I - 001
Pic. 2 Rear / front view
28
General information
I - 002
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