Vdocuments - MX Combilift LTD Operators Service Manual

5/20/2018 Combilif t Ltd. Ope ra tors & se r vic e Ma nua l. - slide pdf.c om
Combilift Ltd.
Operators & service
Manual
Models:
C3500kg / C4000kg / C4500kg / C4800kg / C5000kg / C5000XL
C6000lbs / C8000lbs / C9000lbs / C10,000lbs / C10,000XL
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Serial Number:

Dear Customer,
Thank you for choosing us and showing your faith in the

Combilift range of products. With this Combilift Product
you now own a machine designed by our team of
experienced engineers using the most up to date design
techniques and technology with the sole aim of
producing a machine that is efficient, reliable, safe and
the right tool for your businesses material handling
needs. The Combilift product possesses a vast range of
multi functional application possibilities that makes it one
of the leading products in the material handling industry.
Combilift Ltd
The Purpose of this operators Manual
This Manual contains all of the information you will

require to operate your Combilift product safely and
efficiently. It is essential that this manual remain with the
machine at all times. It is essential that the operator read
this manual before attempting to operate the Combilift.
Always follow all safety instructions laid out in this

manual

Combilift Ltd. C4000-C5000XL O&S Manual
Preface:
This operator’s manual has been written to provide the operator of this
Combilift product with regard to providing information to the operator in order
to ensure that this Combilift is operated in a safe and efficient manner. It does
not take precedence over any local or nationally applicable laws or regulations
with regard to the operation of lift trucks. If you are unsure, contact your local
authorities in order to determine what tests and training courses must be
completed in order to be fully qualified in the operation of this type of material
handling equipment.
The information found has been arranged in a manner to ensure the safe
operation of the machine. As can be seen the general principles of safe
operation are presented before how the machine actual operates. It is
essential that the operators spend time familiarising themselves not only with
the machine, but with the information contained in this manual also.
Throughout this manual there are a number of instructions that have been
highlighted in a number of ways. These instructions must be followed at all
times as they indicate warnings and advice which if not heeded can result in
damage to the truck, product, or property. In the worst case failure to adhere
to the warnings and advice can result in serious injury and even death.
The table of contents on the following pages show the structure of the
information contained in this manual and make for easier location of
information.

Contents
Section 1: Operating Instructions & Conditions ...................................... 1-1

1.1: Understand the Capacity of your Lift-Truck ............................................. 1-1
1.2: Centre of Gravity (CG) .............................................................................. 1-1
1.3: Load Chart ................................................................................................. 1-3
1.4: Serial Plate ................................................................................................. 1-3
1.5: Operator Qualification ............................................................................... 1-3
1.6: Operating Conditions ................................................................................. 1-4
Section 2: Machine Layout & Operator Controls ..................................... 2-1
Section 3: Safe Operation .......................................................................... 3-1

3.1: Entering and Exiting the Operator Cabin ................................................... 3-1
3.2: Starting the Engine..................................................................................... 3-1
3.3: Moving....................................................................................................... 3-2
3.4: Parking ....................................................................................................... 3-4
3.5: Loading & Unloading The Truck .............................................................. 3-5
3.6: Travelling Safely with a Load.................................................................... 3-7

3.7: Fuel Handling & Storage ........................................................................... 3-8
Section 4: Maintenance & Service Information ........................................ 4-1

4.1: Maintenance Schedule ............................................................................... 4-1
4.2: Initial Service – Conducted at 100 hours of Operation.............................. 4-7
4.3: Engine Oil And Engine Oil Filter (service Interval = 250Hours) .............. 4-7
4.4: Engine Coolant (Service interval = 2000Hours)........................................ 4-9
4.5: Hydraulic Oil and Filters ......................................................................... 4-10
4.6: Mast Maintenance (Service Interval = 250Hours) ................................... 4-12
4.7: Greasing Mast Carriage Channels ........................................................... 4-13
4.8: Water Pump V- Belt................................................................................. 4-13

4 9: Fuel Filter – Diesel Trucks (Service interval = 500 Hours) 4-14
Section 5: Technical Information & Circuit Diagrams ............................. 5-1

5.1: Towing the Combilift ................................................................................. 5-1
5.2: Mechanical Brake Release ......................................................................... 5-2
5.3: Checking The Charge Pressure .................................................................. 5-3
5.4: Fuse Box .................................................................................................... 5-4
5.5: Dash Relay Layout (Relay Loom) ............................................................. 5-5
5.6: Dash Relay Layout (PLC Loom) ............................................................... 5-6
5.7: Steering & Hydraulic Functions Circuit .................................................... 5-7
5.8: Hydraulic Drive Circuit: ............................................................................ 5-8
5.9: Standard Diesel Electric Circuit: ............................................................... 5-9
5.10: Standard LPG Electric Circuit: ................................................................ 5-12
5.11: Tier IV LPG Electric Circuit: .................................................................. 5-15
5.12: Diesel Electric Circuit (PLC): .................................................................. 5-18
5.13: LPG Electric Circuit (PLC): .................................................................... 5-20
5.14: Tier IV LPG Electric Circuit (PLC)......................................................... 5-22
5.15: Colour Codes for Electric Circuits: .......................................................... 5-24
5.16: PLC Details .............................................................................................. 5-25
5.17: PLC Diagnostics ...................................................................................... 5-28

Section 1: Operating Instructions & Conditions
1.1: Understand the Capacity of your Lift-Truck
The basic function of a lift truck is to lift, move and place materials. It operates
on the seesaw principle - two weights on opposite sides of a fulcrum. In this
case, the load on the forks must be balanced by the weight of the Combilift.
The location of the centre of gravity of both the Combilift and the load is a
major factor.
1.2: Centre of Gravity (CG)
The centre of gravity of any object is the single point

about which the object is balanced in all directions. Every
object has a centre of gravity. When the lift truck picks up
a load, the truck and load have a new, combined centre
of gravity.
The Combilift has moving parts that change its centre of gravity. The centre of
gravity moves forward and back as the mast is extended and retracted and
also as the mast is tilted backwards and forwards. The centre of gravity also
moves up and down as the mast moves up and down.
Combilift
and load
combined
Centre of
Gravity
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Combilift 6/72
C t f
The centre of gravity and therefore stability is also affected by the size,
weight, shape and position of the load; the height to which it is raised;
extension of mast forward and backward; tilt and side shift. Truck movement
such as acceleration, braking, turning and uneven surfaces will also affect
truck stability.
Combilift and load

combined Centre
of Gravity
Load Centre
of Gravity
Combilift Centre
Fulcrum of Gravity
To keep the lift truck stable, the centre of gravity must stay within the area of
the lift truck represented by a triangle drawn between the three wheels. If the
centre of gravity moves forward of the triangle front, the lift truck will tip
forwards. If it moves outside the right or left of the triangle the truck will tip to
the side.
Combilift and load combined

Centre of Gravity

1.3: Load Chart
The rated capacity of the truck is illustrated MAXIMUM STACKING CAPACITY ON A FIRM LEVEL SURFACE
COMPLYING WITH 89/392/EEC
on a load chart located inside the cabin. 5.5

?Kg
The load centre is determined by its centre )

m 4.5
?Kg
(
of gravity and is measured from the front

T
H
G
I
?Kg
E
face of the forks to the centre of gravity of H

T
F
2.5
?Kg ?Kg
?Kg
I
the load. It is assumed that the centre of L ?Kg
?Kg
gravity
than theinspecified
the vertical direction
horizontal is no
load greater
centre.
?Kg
600 700 800 900 1000

LOAD CENTRE (mm)
It is the responsibility of the operator to determine that the weight of the load
to be handled is not greater than the capacity shown on the load chart. The
operator must not handle any load that is greater than the capacity shown.
1.4: Serial Plate
The Serial Plate is the Metal Disc that is fixed to the Combilift in the cabin of
every machine. It is engraved with a number of details, which are required by
law. These are:
 The Trucks serial Number
 Its rated Capacity
 It’s unladen weight
 It’s date of manufacture
 The manufacturers name and address.
This plate should not be removed by anyone. If lost order a replacement from
Combilift immediately.
15 O Q lifi i
1.6: Operating Conditions
The Combilift can operate on a variety of different surfaces and in various

conditions but the following should be noted:
Ground Surface:
Floor and road surfaces should be of adequate load capacity, firm, smooth
and level. Approaches to kerbs, railway crossings etc. should also be firm,
smooth and adequately ramped to prevent possible displacement.
Aisle Dimensions:
Aisles should be arranged to eliminate corners, angles, inclines, steep ramps,
narrow passages and low ceilings. When Operating in guided aisles ensure
that the mast is retracted fully before entering the aisle. Enter the aisle slowly
to reduce impact on the rollers and guide rails.
Headroom:
Structures over aisles, which may be potential obstacles should be defined
and marked with a conspicuous colour. Low doorways should be marked with
their clearance limits.
Warning
Always be aware of overhead electrical power cables. Always remain a
minimum of 5M from overhead power lines as an electric arc can occur
even when approaching an electric line. This poses a high risk for not only
the o erator but for other ersonnel nearb .
Operating in Hazardous Areas:

Standard trucks are not equipped to operate in cold stores, flammable or
explosive areas, corrosive atmospheres or areas containing a high degree of
dust contamination.

Adverse Weather Conditions:

There are a number of weather conditions for which extra care must be taken.
 High Winds: Do not operate the truck in winds that are greater in speed
than 50km/hr as this can have serious effects on the stability of the
machine.
 Electrical Storms: Always discontinue operation of the truck in the event of

an approaching electrical storm due to the associated risks of lightning.
 Extreme Temperatures: The Combilift is rated to operate between -30°C

and +50°C. If the temperature falls below or rises above this range
discontinue operation of the machine in order to prevent damage to various
components

Section 2: Machine Layout & Operator Controls
It is essential before you start operating the Combilift to be familiar with the
main components and controls of the machine. The picture below indicates all
of the major components of the Combilift.
8
9
Component Layout
7
1. Forks
6
2. Front Swivels
5
3. Platforms
4
3
2 4. Hydraulic Oil level Gauge
5. Hydraulic Tank
6. Hydraulic Return Filter

1 10
1 7. Mast
3
2
8. Strobe Beacon
9. Overhead Guard /Operator
14 14
Cabin
10. LPG Tank / Diesel Tank
11. Rear Swivel

14
16
12. Access Panel
14
13. Bonnet
15

14 Worklights
Ignition Switch:

This is a three-position key switch located on the dash,
which isolates the electrical system when in the off
position.
Parking Brake Switch

 The park brake switch is the red button located on the
dash
 To APPLY the brake, depress the button. The button will
lock in the depressed position.
 To RELEASE the brake, rotate the button clockwise. It
should pop up into its normal position
 The Machine will NOT drive with the parking brake on
Direction Control Lever

 The directional control lever is the 5-postion lever
located on the dash. It can be set to forward, reverse,
left, right, or neutral.
 In order to select a direction of travel, push the lever in
 the desired
Always direction.
return the lever to the neutral position when the
truck is not moving
Note
The truck will NOT start unless the directional control lever is in the neutral
position.
Horn Button
 The horn Button is the push button located on the dash

next to the parking brake

Water Temperature gauge

This gauge Monitors the temperature of the engine

cooling system
 The truck must not be operated if the gauge pointer
moves to the red area as this indicates a fault in the
cooling system
Hour Meter

been
The hour meterfor
operating records how
in hours many
and hours
tenths of anthe truck has
hour.
 Use meter to determine maintenance intervals
Oil Pressure Indicator Light

 When the key switch is in the ‘ON’ position, with the
engine at rest, the oil pressure indicator is illuminated.

If the indicator is illuminated when the engine is ‘running’
then this indicates low engine oil pressure and/or
insufficient oil in the sump.
Note
Do NOT run engine if oil pressure indicator is illuminated.
Battery Charge Indicator Light

 This charging lamp indicates whether the alternator is
charging the system or not. With the key switch turned
ON and the engine not running, this red charge lamp
should illuminate.

If the charging lamp remains illuminated with the engine
running, it indicates a malfunction of the charging
system or associated components.
Pre-Heat Indicator Light (diesel engines)

 Whenever the light illuminates the truck should be

refuelled immediately.
Note
ALWAYS adhere to all safety precautions for refuelling the truck.
(See Section 3.7:)
Parking Brake Indicator Light

 The Parking Break indicator light indicate whether the
brake is “ON” or “OFF” P
Mode Indicator Lights

 The Mode indicator lights indicate which mode of travel
the machine is in. Sideward

If the machine is in normal mode, then the normal mode Mode
indicator light will illuminate
 If the machine is in sideward mode, then the sideward
mode indicator light will illuminate Normal
 Note: Modes of travel are covered in more detail in Mode
section 3 of this manual
Carousel Indicator Light

 The carousel indicator light is only used when the
machine is in sideward mode.
 When the front wheels are steered in to a certain
position, the carousel indicator light will illuminate. It is at
this point that the carousel mode is activated and the
machine can turn on its own axis.
 To deactivate the carousel the operator simply steers
the wheels out of the carousel position
Lift Control Lever

 The lift control lever controls the lift function of the Mast.

 To raise the forks PUSH the lever FORWARD

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Combilif t Ltd. Ope ra tors & se r vic e Ma nua l. - slide pdf.c om
Tilt Control Lever


The lift control lever controls the lift function of the Mast.
 To tilt the mast forward, PUSH the lever FORWARD
 To tilt the mast backward, PULL the lever BACKWARDS
Auxiliary Function Lever

 This lever controls the flow of oil to an attachment when
 fitted.
On trucks fitted with attachments providing more than
one function, the truck may be fitted with a button on the
fourth function lever. The operators must acquaint
themselves with the operation of these special
provisions before using the truck.
 Combilift have a number of standard functions which
can be fitted to the truck and operate off the auxiliary
function lever. These include:
 Fork Positioner
 Side shift
 Telescopic forks
 Lift Drop Forks

Take time to familiarise yourself with the auxiliary
functions on the Combilift and how they are operated by
the auxiliary lever
Warning
Adding an attachment to a Combilift will alter the rated capacity of the
machine. A load chart must be obtained from Combilift Ltd for any
attachment that is fitted to indicate this change in capacity

Warning 15/72
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Brake / Inching Pedal

 The Brake/ inching pedal is the pedal on the floor on the
left hand side of the steering Column as shown in the
diagram opposite
 The combined Brake/Inching Pedal has two functions:
Stop drive to slow the machine down.

It may be used to permit slow speed, for


precise manoeuvring of the truck in confined

spaces.
Accelerator Pedal
 The accelerator pedal is located on the floor on the right
hand side of the steering column.
 The accelerator pedal provides the operator
control of the truck speed.
 To INCREASE truck speed, DEPRESS pedal.
Steering Wheel / Column

 All models have both front and rear-end steering.
 When in forward mode the front wheels are fixed and
the rear wheel steers the truck.
 Rear-end steering allows sharper turns in confined
areas but demands greater driver care when turning.

When in sideward mode, the rear wheel is fixed and the
front wheels steer the truck.
 When driving forwards, turn steering wheel clockwise to
turn truck clockwise, turn steering wheel anti clockwise
to turn truck anti clockwise.
 When driving in reverse, turn steering wheel clockwise
to turn truck anti clockwise, turn steering anti clockwise
to turn truck clockwise.
 When driving in sideward mode, turning the steering
wheel clockwise will turn truck clockwise. Turning the
steering wheel anti clockwise to turn truck anti
clockwise.

 The same is true for travel in either direction when in
5/20/2018 Combilift Ltd. C4000-C5000XL O&S Manual
Seat Adjustment

It is the responsibility of the Operator to ensure that
the seat is adjusted according to operator weight,
height etc before operating the truck.
 ALWAYS report any malfunctioning of the seat
adjustments immediately.
 ALWAYS wear the seat belt provided.
 DO NOT adjust the seat when vehicle is in operation.


Keep clear of
Authorised & moving parts.
competent personnel should carry out
Installation & Maintenance only
A Upstop Adjustment
B Height Adjustment – Depending on operator

weight, rotate knob clockwise, to increase, and
anti-clockwise to reduce suspension stiffness.
C Using the height adjustment knob ‘B’, adjust

the yellow ride indicator ‘C’ to the middle of the
green area when seated.
D Backrest angle adjustment
E Seat belt Red
F Horizontal Adjustment (Slide rails) Green
H Backrest Extension Red
I Lumbar Support adjustment (5 positions)
Mast Height Cutout Override Button

http://slide pdf.c om/re This optional feature uses a push button switch which is
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5/20/2018 Combilift Ltd. C4000-C5000XL O&S Manual
Heater Switch (Optional)

 A four position rotary switch, located which selects
off, low, medium or high fan speeds.
Heater Temperature Control Switch (Optional)

 To increase cabin temperature, turn anti-clockwise.
 To decrease cabin temperature, turn clockwise.
Battery Isolator Key Switch

 This switch is used to disconnect power from the
battery in the event of an emergency.
On Off
 The switch is located inside the access panel on the
right hand side of the Combilift. (See diagram below)

It can be accessed without removing the panel
through the access hole provided
 When the Combilift is not in use turn switch to ‘OFF’
position, by turning switch ANTI-CLOCKWISE.
 The Combilift will not start unless the switch is
returned to the ‘ON’ position, by turning the switch
CLOCKWISE
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Section 3: Safe Operation
Many people are under the impression that driving a lift truck is like driving any
other vehicle. This is not the case. Lift trucks are designed for the purpose of
lifting, and moving heavy loads in confined spaces. For this reason it is
essential that operators are trained to operate the machines correctly and
ensure that they always operate the machine in a safe and controlled manner.
This section looks at how the machine should be operated.
3.1: Entering and Exiting the Operator Cabin

When entering or exiting the cabin of the Combilift, the three point contact
method should always be used. The three point contact method is when an
operator has three of their four limbs (hands & feet) in contact with the truck.
There are a number of handgrips as well as a footstep available to allow easy
and safe access to the operator cabin. DO NOT use the steering wheel as a
handgrip. When in the cabin of the Combilift, ALWAYS wear the seat belt
provided.
3.2: Starting the Engine
Diesel Engine
Ensure that the parking brake is applied and that the directional control

lever is in the neutral position

Insert the key into the ignition switch and turn clockwise to the preheat

position. The charge indicator lamp must light up.

Depress the accelerator.

Turn the ignition key further clockwise to the “Start” position. After the

engine
the ON starts, release the ignition key which will return automatically to
position.
 Check that all the indicator lamps are extinguished and that all gauges
are registering correctly.
LP Gas System
5/20/2018
Note
The truck will NOT start unless the directional control lever is in the neutral
position.
Note
The starter must not be operated continuously for more than 30 seconds. If
the engine does not start, return the key to the ‘OFF’ position and wait 10
seconds before trying again.
Note
When the machine is started the wheels will remain in whatever position
they were in when the machine was stopped until the operator selects a
direction of travel on the directional control lever
3.3: Moving
Because the Combilift is capable of multi directional travel it is important to be
aware of how the truck moves and how to drive it in a safe manner.
Important
The Combilift has two different modes of travel. These are:
Normal Mode: The front wheels are parallel to the platforms.

Steering is performed by the Rear Swivel.
Sideward Mode: The front wheels are at 90° to the platforms.

Steering is performed by the Front Swivels.

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Moving Backward
Select reverse on the directional control lever.


Depress the brake/inching pedal fully
 Look around to make sure your way is clear
 Release the parking brake and sound the horn
 Slowly release the brake/ inching pedal
 As the truck starts to move, depress the accelerator pedal to increase
speed
 To stop depress the inching pedal fully
Changing Mode
The Combilift will automatically realign the wheels when a direction of travel is
selected that requires the machine to change from one mode to the other. In
order to change mode:

Bring the machine to a complete stop.
 Apply the Parking Brake
 Select the direction you wish to travel in that is requires the machine to
be in the other mode of travel.
 As the wheels start to realign depress the accelerator pedal lightly to
speed up the operation.
 Once the mode change operation has finished and the light has
illuminated in the dash follow the normal driving instructions for that
mode of travel
Moving Left (Sideward Mode)

Select left on the directional control lever.

Depress the brake/inching pedal fully


Look around to make sure your way is clear


Release the parking brake and sound the horn


Slowly release the brake/ inching pedal


As the truck starts to move, depress the accelerator pedal to increase


speed

To stop depress the inching pedal fully

3.4: Parking
When parking the Combilift always ensure that one of the two recommended
parking methods are used to ensure the safety of the operator and others.
There are two recommended methods for parking your Combilift. One is called
the Attended parking method, for cases where the operator needs to exit the
machine but will be no more than 25 feet (7 metres) away. The other is the
Unattended parking method, for cases where the operator must exit the
machine but will be further than 25 feet away
The Attended Parking Procedure

Bring machine to a complete stop.

Once stopped, apply the parking brake and set the directional control

lever to the neutral position.

Lower the forks till they are on the ground and tilt the mast forward.

If loaded, retract the mast and rest the load on the platforms of the

machine.
Leave the engine running

Remove the seatbelt from its retainer and exit the Combilift by using the

three – point contact method

Stay within 25 feet (7 metres) of the machine at all times.

The Unattended Parking method

Bring machine to a complete stop.

Once stopped, apply the parking brake and set the directional control

lever to the neutral position.

Lower the forks till they are on the ground and tilt the mast forward.

If loaded, retract the mast and rest the load on the platforms of the

machine.
Turn off the machine.

Remove the seatbelt from its fastener and exit the Combilift by using the

three – point contact method as discussed earlier.

Chock wheels if on an incline

Turn off LP supply on LP gas machines


3.5: Loading & Unloading The Truck

This section provides information on the correct way to pick up a load and set
down a load. There are a number of safety guidelines that should be adhered
to at all times when lifting or placing loads.
 NEVER try to lift a load that the weight of which is not known
 ALWAYS consult the capacity chary for your truck before lifting a load.
 Avoid sudden and jerky movements
Adjusting the Load Forks

Forks should be spaced as far apart as the load being moved will allow. Both
forks should always be the same distance from the centre of the fork carriage.
To adjust:
Raise forks approximately 25mm (1”) off the floor.

Apply parking brake and switch off engine.


Lift up the keeper pin and slide the forks along the carriage.

When the forks are set to the desired position ensure that the keeper pin

is engaged in a slot on the top of the fork carriage bar.
Loading in Normal Mode

Lower/raise forks to the required height.


Enter the centre of the load.
 Drive as close to the load as possible.
 Extend mast to secure load if not already extended
 Apply parking brake.
 Lift load.
 Tilt rearward to secure load.
 Raise load above platform height.


Retract mastload
Double fork fullyif necessary until load is tight against face of forks.
 Lower forks until load is just above platform height. Rest the load on the
platforms where possible
Loading in Sideward Mode


Retract the mast fully.
 Drive the front of the machine as close to the load as possible.
 Drive until the machine is at the centre of the load.
 Apply parking brake.
 Lower/raise the forks to the required height.
 Extend mast.
 Lift load.

Double fork“double
section on load if necessary
forking”) until load is tight against face of forks. (See
 Tilt rearward to secure the load.
 Raise load above platform height.
 Retract mast fully.
 Lower forks until load is just above platform height. Rest the load on the
platforms where possible.
Placing a Load in Sideward Mode

Drive the front of the machine as close to the

placing area as possible.

Apply parking brake.

Lower/raise the forks to the required height.


Extend mast.


Lower load.
 Tilt forward.
 Retract mast fully.
 Release parking brake.
 Continue to drive in the sideward direction.
Stacking
Slowly approach stack with load

retracted and tilted backwards.

Stop at face of stack, select neutral and

apply parking brake.

Elevate load until clear of stack top


De Stacking
Approach stack with mast retracted and in

vertical position.
 Stop at face of stack, select neutral and apply
parking brake.
 Elevate forks to permit entry into pallet.
 Extend mast and enter the pallet with the forks.
 Elevate load until clear of stack and tilt mast backwards to stabilise load.
Operate accelerator pedal to ensure that the engine speed is sufficient to
prevent stalling.
 Retract mast fully and lower load to 150mm (6”) above ground, or where
possible on to the platforms
Double Forking a Load

If it is not possible to engage forks fully when lifting a load it will be necessary
to move the load closer to the front of the machine before lifting.
Note
The lift capacity of the Combilift is reduced if the forks are not fully engaged
To Double Fork a Load:

Raise the load slightly and retract the mast sufficiently to bring the load

closer to the machine.

Lower the load ensuring that it is still properly supported

Extend the mast again until the load is against the fork face.

The load is now ready to be lifted.


3.6: Travelling Safely with a Load
 When travelling with a load always keep the load as low as possible.

 Have the load resting on the platforms of the Combilift whenever
3.7: Fuel Handling & Storage

3.7.1 General

The facilities for storing and handling liquid fuels of all kinds MUST
be strictly in accordance with all current regulations.
WARNING
Adequate fire fighting equipment must be readily available in the refuelling
area at all times.
SAFETY RULES
No smoking, naked lights or other sources of ignition should be permitted in
the vicinity of the refuelling area and signs to this effect should be clearly
posted and free from obstructions at all times. Litter and other readily ignitable
materials should not be permitted to accumulate or be stored in the area.
3.7.2 Refuelling - Diesel

Trained and authorised personnel should carry out refuelling at

designated points only.

Before refuelling the truck, switch off the engine, apply brakes and

vacate truck.
If a pump appliance is not available, fuel MUST be stored and

transported in clean, uncontaminated and approved containers.

Containers MUST comply with current regulations and be clearly
labelled.
 When refuelling the truck, always ensure that the hose nozzle or the
can pourer is making good electrical contact with the tank filler tube
to prevent the accumulation of a hazardous charge of static
electricity. Exercise adequate care to prevent fuel spillage or over-
filling.
 After refuelling the truck, replace the tank filler cap and ensure that it
is securely fitted and leak free. Clean up any spillage using non-
combustible absorbent material before restarting the engine.

Note
 Trucks equipped with exchangeable fuel containers should ALWAYS

ensure that the service valve on the container is closed and all gas
in the connecting
release coupling. hoses used BEFORE disconnecting the quick
 All reserve containers should be stored with the service valves
closed and on racks arranged such that the container is in the same
relative position as when installed on the truck.
 Careless handling of gas containers can result in serious accidents.
Extreme care should be exercised at all times when transporting
containers to ensure that they are not dropped or damaged.
 Containers should always be transported in the vertical position to
ensure that the pressure within the container is in the form of vapour,
not liquid.
 Damage such as dents, scrapes or gouges in the container may
materially weaken the structure of the container and render it unsafe
for use.
 All containers should be checked regularly for dents, scrapes and
gouges in the pressure vessel section.
 Also Check for:
Damage to the various valves and the liquid level gauge.

Debris in the relief valve.


Deterioration, damage or loss of flexible seals in the filling or


Servicing connections.
Indications of leakage at valves or threaded connections i.e.

 Signs of frost on
Any defective orfittings
damagedand hoses usually
container signify
should be aremoved
leak. from
service immediately.
 Any leaking container should be moved immediately to a safe
distance from the truck, free from all ignition leaks.
Section 4: Maintenance & Service Information

4.1: Maintenance Schedule
In order to keep the Combilift in optimum working condition it is necessary to
service the truck at regular intervals. The Chart below details the intervals (in
hours of machine operation) at which maintenance tasks should be performed.
Service Interval (Hrs)
Item
Daily 250 500 2000
Check Engine Oil ●
Change Oil Filter Cartridge ●
Change Engine Oil ●
Check Air Filter Cartridge ●

Change Air Filter Cartridge ●
Change Diesel Engine Glow plugs ●

Change LPG engine Spark Plugs ●
Check Engine Mounts ●
Check Engine Mount Bolts ●
Check Engine Idling Speed ●
Change Both Diesel Fuel Filters ●
Check for Wear ●

Engine Belts
Check Tension ●
Check Cooling Fan ●
Check Radiator ●

Check Engine Coolant Level ●
Change Coolant in Cooling System ●
Check Oil Cooler ●
Check Hydraulic Oil Level ●
Change Hydraulic Oil ●
Change Hydraulic Suction Filter Cartridge ●
Change Hydraulic Return Filter Cartridge ●

Change Hydraulic In-Tank Strainer Filter ●
Check Battery Electrolyte levels ●
Check Swivel Bearings (Slew Rings) ●
Check Mast Carriage Bearings ●

There are a number of items indicated on the maintenance chart that must be
performed on a daily
optimum working basis. These
condition. These checks are essential
and a number in checks
of other keepingform
the truck in
what is
known as the daily inspection of the lift truck.
In most countries, it is required by law for the operator to perform the daily
inspection and for the company to have a written record of these checks.
Contact your local authorities in order to find out what regulations are in place
regarding daily inspections of industrial equipment of this nature.
The daily inspection must be carried out at the start of the working day before
the machine commences operation. Alternatively if your company operates a
multi shift system the checks should be carried out by operators at the
beginning of each shift. The inspection can be broken into 3 sections:
 The Visual Checks



The Engine Checks
The Operational Checks
The details of the Inspection should be recorded on a Checklist like the one
provided (page 4-6) and a record of these inspections should be kept on file
within your company’s records.
The Visual Checks

These checks are performed by doing a “walk around” inspection of the
machine. The checks are performed by checking the following items as
detailed below.
Warning
Before attempting any checks ensure that you are wearing the correct safety
equipment, i.e. gloves, safety boots, eye protection in form of safety glasses
or a full-face shield.

 Forks – Check that the Forks have no signs of excessive wear or

cracking. Check that both locating pins are in place and operational.
 Mast – Check for twisting and distortion in the channels. Look for signs of
cracking and check that there are no missing or loose bolts. Check the
mast chains for wear, missing links and pins. Make sure that the chains
are of equal tension and are adequately lubricated. DO NOT place your
hands inside the mast at any stage to check the chains tension.
Press on the chains with a long stick or screwdriver. Check around the lift
and tilt cylinders for signs of leakage. Also check all the hoses attached
to the mast for signs of leaking oil.
 Overhead Guard – look for signs of damage and cracking to the

overhead guard. Report any signs of damage immediately to your
supervisor.
The Engine Checks (service interval = Daily)

These are a series of checks that ensure that the engine of the truck is in good
working order.
 Check All the Fluid levels – i.e. the engine oil, the engine coolant, and
the hydraulic oil level. Do not operate the truck if any of these fluid levels
are below the min value reading.
 Check the radiator and oil cooler – Make sure that no leaves, dust or
other debris have built up on, or between, the radiator and oil cooler.
 Check all the belts and hoses – Check that all of the belts and hoses
are in good condition. Look for visible signs of wear and fray.

On diesel
Ensure thatmachines –
the filler capcheck the tank for signs of leakage or corrosion.
is on correctly
 On LPG machines, the fuel tank needs to be checked regularly.
Check the tank for scrapes dents and other damage

The Operational Checks (service Interval = Daily)
These checks
Combilift are performed
functions in order
correctly and in a tosafe
ensure that every
manner. part of are
The checks the
performed as follows:
 Check the seat belt – Enter the cabin using the three point contact
method. Make sure that the seat belt functions correctly. Check for any
cuts or fraying along the belt and that it secures correctly into the
retainer. Always wear the seat belt provided when you are driving
the Combilift.
 Check the seat – All Combilift machines come with adjustable air
suspension seats. The operator must ensure that the seat is correctly
adjusted for their individual height and weight. Instructions on how to set
the seat are in the operators’ manual.
Turn on the
the “On” Machine
position. This– Insert the key
will allow into to
power theflow
ignition and turn
through the the key to
electrical
system. Several lights should illuminate in the dash.
 Test the horn – the horn button is on the dash to the right hand side of
the operator. The Truck should not be operated if the horn is not
functioning. Depress the button to test the horn.

Starting the engine - Ensure that the Parking brake is applied by
depressing the large red button on the dash. Also ensure that the
directional control lever is in the Neutral position. Turn the key to the start
position to start the engine and then release the key. It will return to the
on position.
 Listen – Listen to the engine for a few seconds before driving off. Be
alert for any

look out strange
for any sounds
strange or noises
odours from
that may the engine.
indicate Also such
a problem be onasthe
a
very strong smell of gas or burning. If you detect anything, which is not
normal, stop the machine immediately and investigate the problem.
 Check the Dash look at the dash and make sure that the warning
Combilift Ltd. C4000 C5000XL O&S Manual
 Check the Brakes – With the parking brake still applied, select forward
on the the
sound directional control
horn, and lever.
release theKeeping both feet
parking brake. Theaway from should
machine the pedals,
start
to move slowly forward. Depress the inching pedal fully. The machine
will stop. Release the pedal and the machine will move off again. Then
reapply the parking brake and the machine will stop. If either brake is not
working do not operate the machine and report the fault to your
supervisor. In the highly unlikely event of neither brake working, the
machine can be stopped by switching off the engine. Make sure that you
have adequate space to perform this test and that it is performed on a
level surface.
 Check the Directional Control Lever – With the engine running and the
parking brake applied, select forward mode. Sound the horn and release
the parking brake. The machine should move forward. Depress the
inching pedal to stop the machine. Sound the horn, select reverse on the
directional
should nowcontrol
travel stick and release
backwards. thethe
Depress inching pedal.
inching pedalThe machine
to stop the
machine and apply the parking brake. Select left travel on the directional
control lever. The wheels will start to realign for sideward mode. When
the wheels are fully in position, sound the horn and release the parking
brake. The machine should now travel to the left. Depress the inching
pedal to stop the machine, select right travel on the directional control
lever, sound the horn and release the inching pedal. The machine should
now travel to the right.
 Check the steering – Set the steering wheel to the most comfortable
position for driving by use of the adjustment lever on the right hand side
of the column. With the engine running and the parking brake applied,
turn the steering wheel fully clockwise and counter-clockwise. The
steering should move easily in either direction, and not seem excessively
stiff or loose. Perform this check in both normal mode and sideward
mode.
On completion of the inspection the operator should:

Report any defect immediately to the supervisor / appropriate person


Never operate a lift truck that is in need of repair


O erators Dail Ins ection Sheet

Model: ______ Serial No: ______
Date: ________ Shift No: _______

Inspect the Combilift before each shift. Should the Combilift be found to require servicing or if during the
operation the Combilift malfunctions or becomes unsafe, stop the truck and report the situation
immediately to the designated authority. DO NOT operate the Combilift or attempt to service it. Servicing
is only to be conducted by a qualified technician.

Mark the Appropriate Box with X OK Machine OK Service Required
Mon Tues Wed Thurs Fri Sat Sun
Damage
Bent, Dented or Broken Parts
OK OK OK OK OK OK OK
Leaks
Tank, Valves, Fittings, Hoses
Tires
Chunks missing, Loose wheel nuts OK OK OK OK OK OK OK
Forks
Bent, Damaged or Worn
s Mast (inc. Chains)
k Damage, Signs of bending, loose chains OK OK OK OK OK OK OK
c Overhead Guard
e OK OK OK OK OK OK OK
h Damage, Crack ing
C Smell,
Engine
l Belts tight and in good condition
a Engine Oil level OK OK OK OK OK OK OK
u Signs of damage or leak ing
i
s Acceptable
V
Coolant Level
Range
Hydraulic Oil Level
Acceptable Range
Radiator & Oil Cooler
Build up of leaves, dust or debris
Hoses
Good Condition, No signs of wear
Fuel Tank / LPG Cy linder
Signs of damage or leak ing
Safety Equipment
k
s Engine
Horn, Operator Restraint, Reversing Bleeper
c Starts and runs OK, no unusual noise OK OK OK OK OK OK OK
e Mode change
h Wheels OK OK OK OK OK OK OK
C Travel
realign smoothly, no sticking
l No unusual Noise, Smooth changes OK OK OK OK OK OK OK

a

n Steering OK OK OK OK OK OK OK

4.2: Initial Service – Conducted at 100 hours of Operation

The initial service is conducted at this interval to ensure that the truck is
optimum working condition upon leaving the factory. In order to complete the
initial service the following task must be completed.
 Change engine oil & oil filter.

 Replace fuel filter.
 Check fan belt tension and adjust if required.
 Replace hydraulic suction filter (located at rear of hydraulic tank)
 Replace return filter (located on top of the hydraulic tank)
 Check hydraulic oil level.
 Check coolant level.
 Check the machine for hydraulic, coolant and fuel
leaks.
 Check air cleaner and replace if necessary.
 Check all mast carriage-bearing lock nuts are tight.
 Check all bolts and fittings are tight.
 Check radiator, and if necessary, clean fins
 Grease all points indicated on grease point chart
 Check all wheel nuts for tightness.
 Check mast chains; lubricate and adjust if required.
Note
All grease points indicated on the grease point chart MUST be greased
weekl usin an a ro riate EP2 Grease
Note
All wheel nuts should be checked daily and torqued every 250 hours:
Front Wheel nuts (210Nm or 155ft/lbs)
Back Wheel nuts (300Nm or 220ft/lbs)

Recommended Engine Oil Specification:
Diesel: API – CF (See notes at 4.12: if diesel particulate filter is fitted)

SAE 15W40 – All Temperatures
LPG: API – SJ/CF

SAE 15W40 – Above -18°C (0°F)
In order to change the Oil and oil filter, the following steps should be taken,
 Extend the mast carriage forward

in order to gain access to the
engine oil filter and oil drain plug.
Oil Filter
 Position a suitable container
beneath the Oil drain plug as Drain
indicated by the diagram opposite. Plug
(Container must be capable of
holding 10.5 litres) Bucket/
Container
 Remove the drain plug and allow
the system time to drain
completely
 Once the system has drained

completely, dispose of the used oil
in a safe and responsible manner
Note
Do not pour fluids into the ground, down a drain or into a stream, pond or

lake. Observe relevant environmental protection regulations when disposing

 Fill the engine with the appropriate volume of oil ensuring that the oil with
the correct temperature range is used. The Volume of oil required is:
 Kubota Diesel Engine: 9.5 Litres / 2.5 US Gallons

 GM LPG engine: 4.7Litres / 1.24 US Gallons
 Check the oil level on the dipstick. Ensure that the oil level is at the upper
notch on the dipstick.
4.4: Engine Coolant (Service interval = 2000Hours)

The coolant must consist of a mixture of 50% water to 50% coolant additive
(glycol based with anti-corrosion additives). This will give frost protection down
to -25°C and also protect the alloy parts in the cooling system against
corrosion. Therefore, the concentration of coolant additive must not fall below
40%. If greater frost protection is required, the coolant additive can be
increased but only up to 60% (frost protection to -40°C approx.). Any greater
proportion of coolant will decrease the frost protection and also the anti
corrosive properties.
The coolant level is monitored via the coolant reservoir located on the left
hand side of the cabin as shown in the diagram below. The coolant level
should always be kept between the upper and lower levels indicated on the
reservoir and topped up as is deemed necessary.
Operator Cabin
Coolant Reservoir /
Radiator
Expansion Tank
To drain system, remove the

pipe/bung from this position

depending on the type of

4.5: Hydraulic Oil and Filters

The hydraulic
Standard. oil used
I.S.O. G344inHVthe Combilift
grade should
oils with conform
improved to the/ International
viscosity temperature
characteristics. It should also have the correct temperature range for the
ambient temperature in which the machine is being operated. If the operating
temperature is outside the standard range, the standard oil should be
replaced with the correct grade.
Ensure that the correct type is used in the relevant ambient temperature. The
table below indicates a number of commercially available oils and the
temperature ranges that they are suitable for
AMBIENT Low Range Standard Range High Range

OPERATING -20°C to25°C -10°C to35°C 0°C to45°C
TEMPERATURE -4°F to 77°F 14°F to 77°F 32°F to 113°F
Castrol: Hyspin
B.P. Bartran AWH
HV 3232 AWH
HV 4646 AWH
HV 6868
Esso: Univis N 32 N 46 N 68
Mobil 13 M 15 M 16 M
Shell: Tellus oil T32 T46 T68
Texaco HDZ 32 HDZ 46 HDZ 68
Note
The Sequence in which the brand names are listed does not signify any
grading as to their quality or preference.
Note
The machine is supplied with an AWH46 hydraulic fluid when leaving the
factory. Please check if this is suitable for the ambient temperature in which
the machine is to be operated

Note

Filler Cap
Return Filter housing
Hydraulic Oil Level Suction Filter Housing

Gauge
Suction Filter
Access panel Cartridge
In Tank Strainer filter

Cartrid e
Suction Filter: (service Interval = 500Hours)

The suction filter, located on the back of the tank as shown in the diagram
below, must be replaced initially after 100 hours and then at intervals of every
500 hours (or 8 months depending on which occurs first)
To replace the Suction Filter:

1. Raise mast before removing suction filter.
2. Loosen and remove the old filter cartridge.
3. Fill the new filter cartridge with hydraulic oil of the same grade as that
already in the tank.
4. Smear some of the oil on the O-ring seal on the top of the filter cartridge
5. Install the new filter cartridge onto the filter housing. Hand tighten the
cartridge into position.
6. Only use a genuine Combilift component

Return Filter: (service Interval = 500 Hours)

5/20/2018
In-Tank Strainer Filter: (Service Interval = 2000 Hours) Combilif t Ltd. Ope ra tors & se r vic e Ma nua l. - slide pdf.c om
The In-Tank Strainer Filter, located in the bottom left hand corner of the tank,
must be replaced at intervals of every 2000 hours (or 24 months depending on
which occurs first). The strainer filter can only be accessed when the hydraulic
tank has been drained.
To replace the In-Tank Strainer Filter:

1. Drain the hydraulic oil tank through the drain plug in the bottom of the
tank
2. Remove the access panel on the side of the tank
3. Insert your hand into the tank and remove the filter by rotating it anti-
clockwise.
4. Fit the new strainer filter. Only use a genuine Combilift component.
5. Replace the access panel in the side of the tank, remembering to
correctly fit the access panel O-ring seal.
Change Hydraulic Oil (service interval = 2000Hours)

Drain Hydraulic system including tank. Once completed fill

system to the appropriate level with Hydraulic oil of the same

grade as that, which was already in the tank.
Capacity of Hydraulic oil in the Hydraulic system = 80 litres

approx
4.6: Mast Maintenance (Service Interval = 250Hours)

Mast chains should be checked for elongation periodically and adjusted as
required. The chains must be adjusted so that the upper mast stops never
come into contact with each other and the lower mast stops never come into
contact with each other. Adjust all chains evenly. An interval of 250 hours can
be taken as a typical value, under normal working conditions.
Periodic lubrication of the mast chains is required to ensure maximum life span
is achieved. Use SAE 20 oil in cold conditions and SAE 40 oil in warm
conditions. Frequency of lubrication depends largely on operating conditions.
A lubrication interval of 250 hours can be taken as a typical value, under

normal working conditions
5/20/2018
Additional Mast Maintenance (Contact Combilift for further information)
 Replacement of hydraulic cylinder seals.

 Replacement of chains.
 Replacement of bearings.
4.7: Greasing Mast Carriage Channels
The mast carriage channels must be greased periodically only on the vertical
(side) surfaces where the wear pads run. The frequency of this operation is at
the discretion of the user and essentially depends upon the working conditions
and the workplace. A lubrication interval of about 250 hours can be taken as a
typical value, under normal working conditions. For this purpose use EP2
grease.
4.8: Water Pump V- Belt

The engine is kept cool via the coolant that is pumped round the cooling
system. The water pump is powered by the Water pump V-belt. This is located
on the engine as shown and checked as follows:
Check the belt tension. Perform this when the engine IS NOT running. Press
on the belt with a stick or rod. Ensure that the deflection is no more that 10mm
to 12mm. If it is adjust the belt via the pulley adjusting bolts
Check the belt condition: Inspect the condition of the belt. Be on the look out
for signs of damage and wear. If the belt is damaged replace it immediately.
Also check if the belt has sunk deeply into the pulley as this indicates
excessive wear. Again replace the belt immediately if this is the case.
5/20/2018
4.9: Fuel Filter – Diesel Trucks (Service interval = 500 Hours) Combilif t Ltd. Ope ra tors & se r vic e Ma nua l. - slide pdf.c om
On all diesel engine Combilifts, there are two fuel filters located on the rear of
the fuel tank. The first filter, the small plastic filter, is to prevent particles
entering the electric fuel pump. The second larger filter is to prevent any
remaining particles entering the engine. These must be replaced in
accordance with the maintenance chart. They are both accessed by extending
the carriage forward and entering the frame of the machine.
Engine Fuel Filter
Electric Pump Fuel

Filter
4.10: Air Filter Element (Service Interval = 500 Hours)

The air filter housing is located under the bonnet on the right hand side of the
machine as shown in the diagram below. In order to access the filter housing,
remove the side access panel. The air filter cartridge must be replaced at
intervals of every 500 hours (or 8 months depending on which occurs first).
Always ensure that the Dust Valve is pointing down.
Rain Cap

Filter Housing
Combilift Ltd.
C4000-C5000XL O&S Manual 41/72
5/20/2018 In order to change the air filter Cartridge, take the following steps:
1. Open the access panel from the side of the machine

2. Remove the end cap from the filter housing
3. Remove the existing air filter cartridge and replace with the new
cartridge. Only use a genuine Combilift component.
4. Replace the End cap of the housing ensuring that the Dust valve is
pointing downwards as shown.
5. Close the access panel on the side of the machine
4.11: Grease Point Chart

The diagram below indicates all of the points on the Combilift that must be
greased regularly. A copy of this diagram is located in the operator
compartment in the form of a decal / Information sticker. All Points should be
greased weekly with an appropriate EP2 grease.
Combilift Ltd.
4.12: Diesel Particulate Filter (DPF)
The diesel particulate filter requires high temperature exhaust gases to burn
off any soot that may accumulate there. If the exhaust gas temperatures do
not regularly reach the required level to burn off the soot it may lead to a
blockage. Reduced engine performance and increased fuel consumption may
result from a blockage.
In most cases it is possible to clear a blockage by working the engine hard

(e.g. driving the truck with a full load up an incline) for a period of at least 5
minutes so that the exhaust gases reach the temperature required to burn off
the soot. However in some cases the DPF may need to be removed and
cleaned.
Avoid prolonged periods of idling to prevent any blockages from occurring i.e.
switch off the engine when not in use.
Note
Where Diesel Particulate Filters (DPF) are fitted Diesel Fuels with a maximum
sulphur content of 15ppm (parts per million) MUST be used.
Diesel Fuels specified to EN 590 or ASTM D975 S15 are Strongly Recommended.
Note
If a diesel particulate filter (DPF) is fitted to the truck then API CJ-4 engine oil
MUST be used.
Combilift Ltd.
http://slide pdf.c om/re a de r/full/c ombilif t-ltd-ope ra tors-se r vic e -ma nua l C4000-C5000XL O&S Manual 43/72
Section 5: Technical Information & Circuit Diagrams
5.1: Towing the Combilift

Should the need arise to Tow the Combilift it is necessary to first apply the
bypass condition on the hydrostatic pump in order to prevent It from being
damaged. It will then be necessary to mechanically release the brakes on the
motors.
Hydrostatic transmission / Bypass condition.

In this case the travel drive is switched on the free wheel position. For this
purpose the high-pressure valves of the variable displacement pump have a
so-called bypass function. By turning the relevant screw (item 1) the valve is
so released that free oil circulation is made possible. In order to bypass the
motor, screw in item 1 until it is level with the nut.
Towing Speed
The maximum permissible towing speed of 2 km/h should not be exceeded.
Towing distance

Combilift Ltd.
5.2: Mechanical Brake Release
In order to release the brake, follow the

steps laid out below.
1. Extract the plug from the rear

cover of the motor. (Labelled
142 in the diagram opposite)
2. Insert a socket head bolt as

shown in the diagram with a
nut fully inserted onto the bolt.
3. Using a spacer similar to the

one shown on the diagram
tighten the bolt into the Brake
assembly at the rear of the
motor
4. When the bolt is in tight, loosen

the nut off the bolt by turning it
anticlockwise as shown. This
action will release the brake
and allow the motor to turn
freely
5. To reapply the brake, repeat

the steps above in reverse
order.
Combilift Ltd.
5.3: Checking The Charge Pressure
In order to check the charge Pressure, the following steps should be taken.
When the reading is taken the charge pressure should measure between 16
bar and 22 bar (230PSI and 320PSI
Remove hose connecting Attach pressure gauge to

Port G on the pump and
seal with a 9/16“ JIC port G on
charge pump and read
pressure
Combilift Ltd.
5/20/2018
5.4: Fuse Box Combilif t Ltd. Ope ra tors & se r vic e Ma nua l. - slide pdf.c om
The diagram below shows the layout of the fuse box & the rating for each
fuse.
Relay Loom Fuse Table

Fuse Amps Function
1-Diesel 7.5 Mast Height Override, Dash Display Lights, Glow Plug Light, Glow Plug Relay, Alternator
1 – LPG 7.5 Mast Height Override, Dash Display Lights, Alternator Plug
2 7.5 Forward/Reverse Supply, Joystick Supply, Neutral Relay, Reverse Bleeper
33––Diesel
LPG 7.5
7.5 Pull HoldCoil,
Ignition Solenoid, Fuel Pump
Fuel Commander
4 20 Steering Solenoid Supply
5 7.5 Push Button Brake Switch, Inch Pedal Brake Switch, Brake Light, Brake Solenoid Supply
6 10 Wipers
7 15 Front Work Lights
8 15 Side Work Lights, Optional Cabin Interior Light
9 7.5 Cabin Heater Fan, Cabin Cooling Fan, Optional Radio
10 7.5 Horn
11 7.5 Optional Extra Solenoid (e.g. Independent Fork Positioner)
12 7.5 4-Way Switching Supply
13 7.5 Flashing Beacon
14 7.5 Optional Road Lights
PLC Loom Fuse Table

Fuse Amps Function
1-Diesel 7.5 Mast Height Override, Dash Display Lights, Glow Plug Light, Glow Plug Relay, PLC Supply
1 – LPG 7.5 Mast Height Override, Dash Display Lights, PLC Supply
2 7.5 Joystick Supply, Neutral Relay, Reverse Bleeper

3 – Diesel 7.5 Pull Hold Solenoid, Fuel Pump
Combilift Ltd.
5.5: Dash Relay Layout (Relay Loom)
Below is a diagram of the layout of the relays inside the dash in the cabin of
the Combilift truck with a relay loom.

5.6: Dash Relay Layout (PLC Loom)
Below is a diagram of the layout of the relays inside the dash in the cabin of
the Combilift truck with a PLC loom.
Relay Function
1 Starter
1a Glow Plug Timer
9 Steering Solenoid Supply
15 Neutral Cut-Off
22 Work Lights (Spot Lights)
1a

5.7: Steering & Hydraulic Functions Circuit
LH CARRIAGE CYLINDER RH CARRIAGE CYLINDER
INTEGRATED INTEGRATED
ONE WAY ONE WAY
RESTRICTOR RESTRICTOR
TILT CYLINDER TILT CYLINDER
HOSE BURST
CHECK VALVE
ON MAST & IN ALL
MAST CYLINDERS
LIFT CYLINDER
PRESSURE
TEST POINT
STEERING MOTOR
EF
L
P
R
INLET LIFT REACH TILT AUXILIARY MODE OUTLET
A's Represent Back Of Valve

B's Represent Front Of Valve
6-PORT DIVERTER
VALVE - STEERING
P1 P2
A B D C
4-PORT CHANGEOVER
VALVE - REFLEX STEERING
A B
LH STEERING CYLINDER RH STEERING CYLINDER
P T Legend
Feed From Pump

Return To Tank (Bleed)


5.8: Hydraulic Drive Circuit:
LH WHEEL MOTOR RH WHEEL MOTOR
P P
L L
B A B A
A B
Rotary Inch Valve
Drive 4-Port P T
Changeover Valve
b a
R Ps TRANSMISSION PUMP Fe MB
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350 BAR
A
18 BAR
T1 T2 X1 X2 G S MA
1 3
NON-RETURN 2
VALVE - 0.5 BAR BRAKE VALVE

OIL COOLER

5.9: Standard Diesel Electric Circuit:
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5.15: Colour Codes for Electric Circuits:

CODE - COLOUR
BK - BLACK
BN - BROWN
BL - BLUE
R - RED
O - ORANGE
Y - YELLOW
GR - GREEN
V - VIOLET
P - PINK
GY - GREY
W - WHITE
G/Y - GREEN / YELLOW
R/Y - RED / YELLOW
O/W - ORANGE / WHITE
NEGATIVE WIRES ARE NORMALLY BLUE

OR BLACK, DEPENDING ON WHAT UNIT
IS BEING INVESTIGATED.

TAKE ALL NEGATIVES TO BE BLACK
5.16: PLC Details

The diagram below shows the layout of the major components of the PLC
board that need to be known in order to correctly find and repair faults.
PLUG X4 PLUG X3 PLUG X5.1
System LED
LED
1 2 3 4 5 6 7 8 9 10
PLUG X5.2
1 2 3 4 5 6 7 8
Dip Switches
The pins in each of the plugs on the board are laid out as follows.
1 3 5 7 9 11 13 15 17
2 4 6 8 10 12 14 16 18
The System LED tells the operator what the PLC is doing. The following table
i l ti f h t th S t LED i i di ti

INPUTS
Plug Pin Function Wire Colour

X4 01 Rear Wheel @ Zero Degree Proximity Switch Black
X4 02 Front Wheel @ Zero Degree Proximity Switch Black
X4 03 Rear Wheel @ Ninety Degree Proximity Switch Black
X4 04 Front Wheel @ Ninety Degree Proximity Switch Black
X4 05 Carousel Steering Proximity Switch (DB Proxy) Black
X4 06 Park Brake Switch Signal Orange
X4 07 Inching Pedal Brake Switch Signal (Optional) Purple
X4 08 Forward Signal Fron Direction Lever White
X4 09 Power Supply to Board (Supplied From Fuse 1) Red
X4 10 Negative for Board power Supply Blue / Black
X4 11 Reverse Signal From Direction Lever Brown
X4 12 Left Signal From Direction Lever Green
X4 13 Right Signal From Direction Lever Grey
X4 14 Mast Height Proximity Switch Signal Black
X4 15 Mast Height Over Ride Button ??
X4 16 Optional Extra ??
OUTPUTS

X3 01 Forward Solenoid 01 White
X3 02 Forward Solenoid 02 White
X3 03 Reverse Solenoid 01 Brown
X3 04 Reverse Solenoid 02 Brown
X3 05 Common Supply for Pins 01‐04 (From Fuse 2 ) Red
X3 06 Drive Solenoid 01 Red
X3 07 Drive Solenoid 02 Red
X3 08 Ninety degree Indicator Light Green
X3 09 Zero Degree Indicator Light White
X3 10 Common Supply to pins 06‐09 (From Fuse 4 ) Red

Outputs (continued)
X5.1 01 Not Used n/a
X5.1 02 Common Supply for Output 08 (From fuse 4) Brown
X5.1 03 Steering Solenoid (Six Port) Brown
X5.1 07 Reflex Solenoid Red
X5.1 10 Common Supply for Output 10 (From fuse 5) Orange
X5.1 11 Brake Solenoid Orange
X5.1 15 Zero Degree Solenoid 01 Grey
X5.1 18 Zero Degree Solenoid 02 Grey

X5.2 03 Ninety Degree Solenoid 01 Green
X5.2 07 Ninety Degree Solenoid 02 Green
X5.2 11 Optional Extra (not assigned) ???

X5 2 14 C S l f O t t 16 (F f 4) B
Mode 2 – Proximity Sensor Function

5.17: PLC Diagnostics
Move Switch ‘2’ to the ‘ON’ Position

The diagnostics function can be used to make sure all components are
working correctly.
Front Wheel 0 Degree Sensor – LED 1
Mode 1 – Joystick Function

Rear Wheel 0 Degree Sensor – LED 2
Move Switch ‘1’ to the ‘ON’ position
 Neutral Position – No LED

 Forward Position – LED 1 Carousel Sensor – LED 3
 Reverse Position – LED 2
 Left Position – LED 3
 Right Position – LED 4
Front Wheel 90 Degree Sensor – LED 4
FORWARD
Rear Wheel 90 Degree Sensor – LED 5

LEFT NEUTRAL RIGHT
REVERSE
 Proximity Sensors can be energised by switching from Forward Mode to
Sideward mode.
 If the joystick is working correctly each LED will only light with the
joystick in the corresponding position.  If a LED does not light it should be energised manually to rule out the
failure of the corresponding proximity sensor.
 If the joystick is malfunctioning the LED corresponding to the position
will not light up.  Once activated the LEDs will remain lit until the switch is reset to the OFF
position.
5-28
C4000-OM-EN-08
Mode 4 – Solenoid Mode

Mode 3 – Switch Mode
NOTE: This mode must only be used with the key turned on, NOT with the
engine running.
Move Switch 3 to the ON Position

5/20/2018
Forward, Reverse, 0 and 90 Solenoids
Move Switch ‘4’ to the ‘ON’ Position to test.
Use the directional joystick to energise the solenoids as below

Park Brake – LED 1
FWD Solenoid
Mast Height Override Switch – LED 2

0 Solenoid
90 Solenoid
REV Solenoid
Steering, Reflex, Carousel and Drive Solenoids

Mast Height Proximity Sensor – LED 3 Move Switch ‘5’ to the ‘ON’ Position to test.
Steering Solenoid
Carousel Solenoid Drive Solenoid
 The Park Brake will only remain lit while the park brake is engaged.
 LED 2 will be ON constantly on all machines that do not have the Mast
Height Override Function. Reflex Solenoid
 To energise the mast height proximity sensor lift the forks to the height
of the proximity sensor.  The LED on each solenoid should be lit along with the LED on the board.
 If the solenoid LED does not light, a wiring problem may be present.
 If the solenoid LED is lit but a problem remains the solenoid and/or the valve
should be checked for malfunction.
5-29
C4000-OM-EN-08

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Thank you for choosing us and showing your faith in the

The Purpose of this operators Manual

This Manual contains all of the information you will

Always follow all safety instructions laid out in this

Combilift Ltd. C4000-C5000XL O&S Manual

Combilift Ltd. C4000-C5000XL O&S Manual

Section 1: Operating Instructions & Conditions ...................................... 1-1

Section 2: Machine Layout & Operator Controls ..................................... 2-1

Section 3: Safe Operation .......................................................................... 3-1

Section 4: Maintenance & Service Information ........................................ 4-1

Combilift Ltd. C4000-C5000XL O&S Manual

Section 5: Technical Information & Circuit Diagrams ............................. 5-1

Combilift Ltd. C4000-C5000XL O&S Manual

Section 1: Operating Instructions & Conditions

1.1: Understand the Capacity of your Lift-Truck

1.2: Centre of Gravity (CG)

The centre of gravity of any object is the single point

Combilift Ltd. C4000-C5000XL O&S Manual

Combilift and load

Combilift and load combined

Combilift Ltd. C4000-C5000XL O&S Manual

1.3: Load Chart

on a load chart located inside the cabin. 5.5

The load centre is determined by its centre )

of gravity and is measured from the front

face of the forks to the centre of gravity of H

the load. It is assumed that the centre of L ?Kg

600 700 800 900 1000

1.4: Serial Plate

Combilift Ltd. C4000-C5000XL O&S Manual

1.6: Operating Conditions

The Combilift can operate on a variety of different surfaces and in various

Operating in Hazardous Areas:

Combilift Ltd. C4000-C5000XL O&S Manual

Adverse Weather Conditions:

 Electrical Storms: Always discontinue operation of the truck in the event of

 Extreme Temperatures: The Combilift is rated to operate between -30°C

Combilift Ltd. C4000-C5000XL O&S Manual

Section 2: Machine Layout & Operator Controls

6. Hydraulic Return Filter

10. LPG Tank / Diesel Tank

11. Rear Swivel

Combilift Ltd. C4000-C5000XL O&S Manual

Parking Brake Switch

Direction Control Lever

next to the parking brake

Water Temperature gauge

Oil Pressure Indicator Light

Battery Charge Indicator Light

Pre-Heat Indicator Light (diesel engines)

 Whenever the light illuminates the truck should be

Parking Brake Indicator Light

Mode Indicator Lights

Carousel Indicator Light

Lift Control Lever

 To raise the forks PUSH the lever FORWARD

Tilt Control Lever

Auxiliary Function Lever

Brake / Inching Pedal