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Manuals and User Guides for CombiLift C5000. We have 1 CombiLift C5000 manual available for free PDF download: Manual

• C4000-OM-EN-08 (c)

  Serial Number: ___________

  Combilift ltd.

  Gallinagh Co. Monaghan

  Ireland

  Tel: + 353 47 80500 Fax: + 353 47 80501

  E-Mail: [email protected]

  Combilift Ltd.

  Operators & service Manual

  Models:

  C3500kg / C4000kg / C4500kg / C4800kg / C5000kg / C5000XL

  C6000lbs / C8000lbs / C9000lbs / C10,000lbs / C10,000XL

• C4000-OM-EN-08

  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 All instructions,
  prohibitive or otherwise, found in this manual should be adhered to
  at all times. They are there to protect your life and the lives of
  others. Always perform the Daily Inspection as indicated in this
  manual and follow the guidelines on service intervals.

• Combilift Ltd. C4000-C5000XL O&S Manual

  iC4000-OM-EN-08

  Preface: This operators 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.

• Combilift Ltd. C4000-C5000XL O&S Manual

  iiC4000-OM-EN-08

  Contents

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

  1.1: Understand the Capacity of your Lift-Truck
  ……………………………………… 1-11.2: Centre of
  Gravity (CG)
  ……………………………………………………………………
  1-11.3: Load Chart
  …………………………………………………………………………………….
  1-31.4: Serial Plate
  …………………………………………………………………………………….
  1-31.5: Operator Qualification
  …………………………………………………………………….
  1-31.6: 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
  …………………………………………… 3-13.2:
  Starting the Engine
  ………………………………………………………………………….
  3-13.3: Moving
  ………………………………………………………………………………………….
  3-23.4: Parking
  ………………………………………………………………………………………….
  3-43.5: Loading & Unloading The Truck
  ……………………………………………………..
  3-53.6: Travelling Safely with a Load
  …………………………………………………………..
  3-73.7: Fuel Handling & Storage
  …………………………………………………………………
  3-8

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

  4.1: Maintenance Schedule
  …………………………………………………………………….
  4-14.2: Initial Service Conducted at 100 hours of Operation
  ………………………… 4-74.3: Engine Oil And Engine Oil
  Filter (service Interval = 250Hours) ………….. 4-74.4: Engine
  Coolant (Service interval = 2000Hours)
  …………………………………. 4-94.5: Hydraulic Oil and
  Filters
  ……………………………………………………………….
  4-104.6: Mast Maintenance (Service Interval = 250Hours)
  …………………………….. 4-124.7: Greasing Mast Carriage
  Channels
  …………………………………………………..
  4-134.8: Water Pump V- Belt
  ………………………………………………………………………
  4-134.9: Fuel Filter Diesel Trucks (Service interval = 500 Hours)
  ………………… 4-144.10: Air Filter Element (Service
  Interval = 500 Hours) ………………………….. 4-144.11:
  Grease Point Chart
  ………………………………………………………………………..
  4-154.12: Diesel Particulate Filter (DPF)
  ………………………………………………………..
  4-15

• Combilift Ltd. C4000-C5000XL O&S Manual

  iiiC4000-OM-EN-08

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

  5.1: Towing the Combilift
  ………………………………………………………………………
  5-15.2: Mechanical Brake Release
  ……………………………………………………………….
  5-25.3: Checking The Charge Pressure
  …………………………………………………………
  5-35.4: Fuse Box
  ……………………………………………………………………………………….
  5-45.5: Dash Relay Layout (Relay Loom)
  …………………………………………………….
  5-55.6: Dash Relay Layout (PLC Loom)
  ………………………………………………………
  5-65.7: Steering & Hydraulic Functions Circuit
  ……………………………………………. 5-75.8:
  Hydraulic Drive Circuit:
  ………………………………………………………………….
  5-85.9: Standard Diesel Electric Circuit:
  ………………………………………………………
  5-95.10: Standard LPG Electric Circuit:
  ……………………………………………………….
  5-125.11: Tier IV LPG Electric Circuit:
  …………………………………………………………
  5-155.12: Diesel Electric Circuit (PLC):
  …………………………………………………………
  5-185.13: LPG Electric Circuit (PLC):
  …………………………………………………………..
  5-205.14: Tier IV LPG Electric Circuit (PLC)
  ………………………………………………… 5-225.15:
  Colour Codes for Electric Circuits:
  ………………………………………………….
  5-245.16: PLC Details
  ………………………………………………………………………………….
  5-255.17: PLC Diagnostics
  …………………………………………………………………………..
  5-28

• Combilift Ltd. C4000-C5000XL O&S Manual

  1-1C4000-OM-EN-08

  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

  Combilift Centre of Gravity

  Fulcrum

  Load Centre of Gravity

• Combilift Ltd. C4000-C5000XL O&S Manual

  1-2C4000-OM-EN-08

  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.

  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 Centre of Gravity

  Combilift and load combined Centre of Gravity

  Load Centre of Gravity

  Fulcrum

  Load Centre of Gravity

  Combilift and load combined Centre of Gravity

  Combilift Centre of Gravity

• Combilift Ltd. C4000-C5000XL O&S Manual

  1-3C4000-OM-EN-08

  1.3: Load Chart The rated capacity of the truck is illustrated
  on a load chart located inside the cabin. 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 the load. It is
  assumed that the centre of gravity in the vertical direction is no
  greater than the specified horizontal load centre. 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 Its unladen weight
  Its date of manufacture The manufacturers name and address.

  This plate should not be removed by anyone. If lost order a
  replacement from Combilift immediately.

  1.5: Operator Qualification The Combilift must NOT be operated
  by any other individual other than those who have been trained to
  do so. Training should be carried out either by Combilift Driver
  training personnel or a Combilift authorised training organisation.
  Details of these organisations can be acquired from Combilift Ltd.
  Drivers should be aware of all local authority regulations and laws
  regarding qualification of drivers for material handling
  equipment.

  COMPLYING WITH 89/392/EECMAXIMUM STACKING CAPACITY ON A FIRM
  LEVEL SURFACE

  600 700

  LIFT HEIGHT (m)

  2.5

  4.5

  LOAD CENTRE (mm)800 900

  ?Kg5.5

  1000

  ?Kg

  ?Kg

  ?Kg

  ?Kg

  ?Kg

  ?Kg

  ?Kg

  ?Kg

• Combilift Ltd. C4000-C5000XL O&S Manual

  1-4C4000-OM-EN-08

  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.

  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. Gradients: When differences in levels exist, low
  gradient ramps should be provided, having smooth, gradual level
  changes at top and bottom to prevent shocks to the load or fouling
  of the forks. Except in emergencies, do not turn the truck on
  gradients. Correct gradient procedure should be followed at all
  times (see Safe Operation in section 3) Do not park on a gradient.
  In an emergency apply parking brake and chock wheels, but do not
  leave the truck unattended.

  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 operator but for other personnel nearby.

• Combilift Ltd. C4000-C5000XL O&S Manual

  1-5C4000-OM-EN-08

  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 -30C

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

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-1C4000-OM-EN-08

  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.

  1 1

  23

  4

  5

  6

  78 9

  10

  23

  1112

  13

  14

  14

  14

  15

  14

  16

  Now that the main components of the truck have been identified,
  the next step is to identify the operator controls and how they
  function.

  Component Layout

  1. Forks 2. Front Swivels

  3. Platforms

  4. Hydraulic Oil level Gauge

  5. Hydraulic Tank 6. Hydraulic Return Filter

  7. Mast 8. Strobe Beacon 9. Overhead Guard /Operator

  Cabin 10. LPG Tank / Diesel Tank 11. Rear Swivel 12. Access
  Panel 13. Bonnet 14. Worklights 15. Hydraulic Tank Filler Cap 16.
  Exhaust

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-2C4000-OM-EN-08

  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 direction.

  Always return the lever to the neutral position when the truck
  is not moving

  Horn Button The horn Button is the push button located on the
  dash

  next to the parking brake. To operate the horn, depress the
  button. Light Switch: This is a two- position switch located on the
  dash Position 1 Lights on Position 2 Lights off

  Note The truck will NOT start unless the directional control
  lever is in the neutral

  position.

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-3C4000-OM-EN-08

  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 The hour meter records how many hours the truck
  has

  been operating for in hours and tenths of an 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.

  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) The Pre-heat indicator
  is a lamp connected to the glow

  plugs on the diesel engine. When operating in cold conditions,
  wait until the pre-

  heat indicator extinguishes before attempting to start
  engine

  Low fuel level indicator light The low-level indicator light
  illuminates whenever the

  fuel level on the truck reaches a certain level. On LPG engines
  a buzzer will also sound.

  Note Do NOT run engine if oil pressure indicator is
  illuminated.

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-4C4000-OM-EN-08

  Whenever the light illuminates the truck should be refuelled
  immediately.

  Parking Brake Indicator Light The Parking Break indicator light
  indicate whether the

  brake is ON or OFF Mode Indicator Lights The Mode indicator
  lights indicate which mode of travel

  the machine is in. If the machine is in normal mode, then the
  normal mode

  indicator light will illuminate If the machine is in sideward
  mode, then the sideward

  mode indicator light will illuminate Note: Modes of travel are
  covered in more detail in

  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 To
  lower the forks, PULL the lever BACKWARDS Reach Control Lever The
  reach control lever controls the movement function

  of the mast carriage. To extend the mast carriage forward, PUSH
  the lever

  FORWARD To retract the mast carriage backwards, PULL the
  lever

  BACKWARDS

  Note ALWAYS adhere to all safety precautions for refuelling the
  truck.

  (See Section 3.7:)

  P

  Normal Mode

  Sideward Mode

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-5C4000-OM-EN-08

  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

  Wipers The wipers are located on the front windows. They are
  activated by the switching on the wiper motor.

  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 ONLY attachments that have been approved by Combilift
  engineers may be

  fitted to Combilift Trucks

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-6C4000-OM-EN-08

  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 sideward
  mode.

  The steering wheel is also equipped with a spinner knob for
  easier steering

  The angle of the steering column is adjustable to increase
  driver comfort.

  To adjust the angle of the steering column, loosen the locking
  handle on the side of the column by turning the handle
  clockwise.

  Adjust the steering column to the desired angle Lock the column
  in position by retightening the locking

  handle by turning it anticlockwise

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-7C4000-OM-EN-08

  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 moving parts. Authorised
  & 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 F Horizontal Adjustment (Slide rails)
  H Backrest Extension I Lumbar Support adjustment (5 positions) Mast
  Height Cutout Override Button This optional feature uses a push
  button switch, which is

  connected to a sensor on high-lift Triplex masts. When the mast
  is above 3.5m (138) high, the machine

  will not drive. To re-commence driving the operator must
  either:

  Lower the forks of the machine using the lift control lever

  OR Press the mast drive enable button located on

  the dash.

  Red

  Red

  Green

• Combilift Ltd. C4000-C5000XL O&S Manual

  2-8C4000-OM-EN-08

  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. 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

  Engine Management Light (Yellow Light On Dash) If this light
  comes on it means the engine control unit

  (ECU) has detected a problem with the engine. If the light is on
  and the engine is running smoothly you can

  drive the truck. However, it should be checked at the earliest
  convenience. If the engine is running poorly the truck should not
  be driven.

  The ECU will store the fault information that will allow the
  fault to be diagnosed when the ECU is connected to a PC.

  On Off

• Combilift Ltd. C4000-C5000XL O&S Manual

  3-1C4000-OM-EN-08

  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 starts, release the ignition key which will return
  automatically to the ON position.

  Check that all the indicator lamps are extinguished and that all
  gauges are registering correctly.

  LP Gas System

  Open the valve on the LPG tank. 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 ON

  position. The charge indicator lamp must light up. Turn the
  ignition key further clockwise to the start position. As soon as
  the engine starts, release the ignition key, which will

  automatically return to the ON position. Check that all warning
  lamps are extinguished and that all gauges are

  registering correctly

• Combilift Ltd. C4000-C5000XL O&S Manual

  3-2C4000-OM-EN-08

  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.

  Moving Forward

  Select forward 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.

  (Note: If the machine is already in sideward mode, wait for the
  wheels to realign. Once the wheels are in position continuer as per
  the instructions)

  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

  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

  Moving Right (Sideward Mode)

  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

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  3-4C4000-OM-EN-08

  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

• Combilift Ltd. C4000-C5000XL O&S Manual

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  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 mast fully Double fork load if 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 Placing a Load in Normal 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 if operating in confined spaces. Drive rearward until machine
  is clear of load

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  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 load if
  necessary until load is tight against face of forks. (See

  section on double forking) 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. Operate accelerator pedal
  to ensure that engine speed is sufficient to prevent stalling and
  to give the required lifting speed.

  Extend mast until load is above the stack.

  Tilt mast to vertical position and lower load onto stack.

  Retract mast fully and lower forks to 150mm (6) above ground
  before moving off.

• Combilift Ltd. C4000-C5000XL O&S Manual

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  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.

  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

  possible. Try to avoid sudden and erratic movements with the
  machine. Accelerate

  and brake as smoothly as possible. When approaching a junction
  or corner, slow down, sound the horn and

  proceed only when you are sure that your path is unobstructed.
  Remember to turn slowly.

  Note The lift capacity of the Combilift is reduced if the forks
  are not fully engaged

• Combilift Ltd. C4000-C5000XL O&S Manual

  3-8C4000-OM-EN-08

  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.

  3.7.3 Refuelling — L.P. Gas

  Trained and authorised personnel should carry out recharging and
  changing L.P. Gas containers at designated points only.

  LP Gas trucks should not be refuelled or stored near underground
  entrances, lift shafts or any other place where leakage could
  collect in a potentially dangerous gas pocket.

  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.

• Combilift Ltd. C4000-C5000XL O&S Manual

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  Trucks equipped with exchangeable fuel containers should ALWAYS
  ensure that the service valve on the container is closed and all
  gas in the connecting hoses used BEFORE disconnecting the quick
  release coupling.

  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 fittings and hoses usually signify a leak. Any
  defective or damaged container should be removed from

  service immediately. Any leaking container should be moved
  immediately to a safe

  distance from the truck, free from all ignition leaks.

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-1C4000-OM-EN-08

  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.

  Grease All Points Indicated on the Grease Point Chart Weekly

  Item Service Interval (Hrs) 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 Engine Belts

  Check for Wear 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 Check
  Mast Carriage Wear Pads & Alignment Check Mast Bearings Check
  Mast Chains Lubricate & Adjust Mast Chains Grease Mast Channels
  Grease Mast Carriage Channels Check Wheel Nuts Torque Wheel Nuts
  Check Hydraulic Hoses for Leaks Check Hydraulic Hoses for Signs of
  Wear

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  There are a number of items indicated on the maintenance chart
  that must be performed on a daily basis. These checks are essential
  in keeping the truck in optimum working condition. These and a
  number of other checks form 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 companys 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.

  Overall condition Look for scrapes, dents, and other signs of
  damage.

  Watch for missing or loose nuts and bolts. Check underneath the
  machine for signs of leaking fuel, engine coolant, or oil.

  Tyres and wheels Check that all the wheel nuts are present and
  tight.

  Look for cuts in the tyres or foreign objects in the rubber.
  Also look for Plastic straps, wire, and other debris caught between
  the wheel and the wheel motor. Note: Always wear gloves when
  checking the tyres to avoid injury on sharp pieces of debris.

  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.

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  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 machines check the tank for signs of leakage or
  corrosion.

  Ensure that the filler cap is on correctly

  On LPG machines, the fuel tank needs to be checked
  regularly.

  Check the tank for scrapes, dents and other damage. Check that
  the tank is located on the locator pin. Check the restraining
  straps Check hose and connections for leaks Use a soapy water

  solution. NOT your hands. LP Gas can cause severe burns. Check
  that the tank fits inside the profile of the machine.

  Warning Always wear appropriate protective clothing such as
  gloves and face shield when checking LP tanks and fittings. LP can
  cause frostbite when released,

  due to its very low temperature.

• Combilift Ltd. C4000-C5000XL O&S Manual

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  The Operational Checks (service Interval = Daily) These checks
  are performed in order to ensure that every part of the Combilift
  functions correctly and in a safe manner. The checks are 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 Machine Insert the key into the ignition and turn
  the key to

  the On position. This will allow power to flow through the
  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 strange sounds or noises from the engine. Also be
  on the look out for any strange odours that may indicate a problem
  such as 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

  lights are all extinguished. The only light that should be on
  after the engine is started should be the parking brake. Should any
  other lights be illuminated, stop the machine and report the fault
  to your supervisor. A full list of all the gauges, indicators and
  controls along with each function can be found in section 2 of the
  this manual.

  Check the mast functions After checking that there is
  adequate

  space and headroom perform the checks on the mast functions.
  Raise and lower the mast making sure that the operation is smooth
  and controlled. Extend the mast forward and then retract it. Again
  watch for any signs of sticking. Tilt the mast fully forwards and
  backwards. Then test any auxiliary function that may be fitted to
  Your Combilift.

• Combilift Ltd. C4000-C5000XL O&S Manual

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  Check the Brakes With the parking brake still applied, select
  forward

  on the directional control lever. Keeping both feet away from
  the pedals, sound the horn, and release the parking brake. The
  machine should 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 control stick and release the inching
  pedal. The machine should now travel backwards. Depress the inching
  pedal 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 Repairs
  should only be performed by authorised personnel

  In order to keep a record of these daily inspections it is
  advised that a daily inspection checklist like the one provided on
  the next page should be used when performing the checks. A copy of
  this checklist should be kept on file at all times in order to keep
  track of the machines service history as well as any faults that
  occur.

  Note Remember, in most countries, it is against the law NOT to
  perform these

  checks or keep a record of the inspections.

• Combilift Ltd. C4000-C5000XL O&S Manual

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  DamageBent, Dented or Broken Parts

  LeaksTank, Valves, Fittings, Hoses

  TiresChunks missing, Loose wheel nuts

  ForksBent, Damaged or Worn

  Mast (inc. Chains)Damage, Signs of bending, loose chains

  Overhead GuardDamage, Crack ing

  EngineSmell, Belts tight and in good condition

  Engine Oil levelSigns of damage or leak ing

  Coolant LevelAcceptable Range

  Hydraulic Oil LevelAcceptable Range

  Radiator & Oil CoolerBuild up of leaves, dust or debris

  HosesGood Condition, No signs of wear

  Fuel Tank / LPG CylinderSigns of damage or leak ing

  Safety EquipmentHorn, Operator Restraint, Reversing Bleeper

  EngineStarts and runs OK, no unusual noise

  Mode changeWheels realign smoothly, no stick ing

  TravelNo unusual Noise, Smooth changes

  SteeringNo excessive play or restriction in either mode

  Inching PedalStops travel, smooth deceleration

  Parking BrakeFunctions and releases

  Hydraulic ControlsForks-Lift/lower, mast-in/out, tilt, Aux
  functions

  Hour Meter ReadingOperator InitialsSupervisors Initials

  OK OK

  OKOK

  OKOK OK OK OK

  OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OKOK OKOK OK

  OK OKOK OK

  OK

  Ope

  ratio

  nal C

  heck

  s OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OK

  OK

  OK OK OK OK

  OK OKFri Sat Sun

  OK OK OK OKMon Tues Wed Thurs

  OK OK

  Visu

  al C

  heck

  s

  OK OK OKOK OK

  Operators Daily Inspection 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

  Notes (regarding repair, etc):
  ______________________________

  ______________________________________________________

  ______________________________________________________

  Service Required

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-7C4000-OM-EN-08

  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.

  4.3: Engine Oil And Engine Oil Filter (service Interval =
  250Hours) The engine oil used in the Combilift should have the
  correct temperature range for the ambient temperature in which the
  machine is to be operating. Temperature affects the viscosity of
  the oil and therefore its lubricating properties. All Combilift
  trucks leave the factory with a special, high multi-grade oil in
  the engine and this can be used all year round except in very cold
  climates.

  Note All grease points indicated on the grease point chart MUST
  be greased

  weekly using an appropriate 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)

• Combilift Ltd. C4000-C5000XL O&S Manual

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  Recommended Engine Oil Specification: Diesel: API CF (See notes
  at 4.12: if diesel particulate filter is fitted) SAE 15W40 All
  Temperatures SAE 10W30 All Temperatures LPG: API SJ/CF

  SAE 10W30 All Temperatures SAE 15W40 Above -18C (0F) 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.

  Position a suitable container

  beneath the Oil drain plug as indicated by the diagram opposite.
  (Container must be capable of holding 10.5 litres)

  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

  Remove the engine oil filter located on the front of the engine
  as indicated

  by the diagram above Apply some engine oil to the new oil filter
  cartridge before fitting Install the new engine oil filter
  cartridge, ensuring that the O-ring seal is

  correctly placed. Only use a genuine Combilift component
  Reinstall the drain plug and tighten appropriately

  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 of oil, coolant, fuel, electrolyte and other harmful
  waste

  Oil Filter Drain Plug Bucket/ Container

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-9C4000-OM-EN-08

  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 -25C 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 -40C 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.

  To drain the cooling system, remove the filler cap from the top
  of the radiator and the pipe / bung from t bottom right hand corner
  of the radiator (as shown).

  Coolant Reservoir / Expansion Tank

  Operator Cabin

  Radiator

  To drain system, remove the pipe/bung from this position
  depending on the type of machine (i.e. LPG/Diesel)

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-10C4000-OM-EN-08

  4.5: Hydraulic Oil and Filters The hydraulic oil used in the
  Combilift should conform to the International Standard. I.S.O. G344
  HV grade oils with improved 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 OPERATING TEMPERATURE

  Low Range -20C to25C -4F to 77F

  Standard Range -10C to35C 14F to 77F

  High Range 0C to45C

  32F to 113F Castrol: Hyspin AWH 32 AWH 46 AWH 68 B.P. Bartran HV
  32 HV 46 HV 68 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

  There are a total of 3 filters on or in the hydraulic oil tank
  that must be replaced at certain intervals. These filters are:

  1. The Suction Filter 2. The Return Filter 3. The In-Tank
  Strainer Filter

  The locations of these filters are shown in the diagram on the
  next page.

  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 Before adding hydraulic oil, ensure that all cylinders are
  retracted and fill to

  upper level on the hydraulic oil level gauge

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-11C4000-OM-EN-08

  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) The return filter,
  located on the top of the tank, must be replaced at intervals of
  every 500 hours (or 8 months depending on which occurs first). To
  replace the Return Filter:

  1. Remove the four bolts from the lid of the filter housing in
  order to gain access to the filter element.

  2. Remove the retaining spring from the top of the filter
  element 3. Remove the old filter element and replace with the new
  filter element.

  Only use a genuine Combilift component. 4. Fit the retaining
  spring into the top of the filter element and refit the

  housing lid.

  Filler Cap Suction Filter Housing Suction Filter Cartridge

  Return Filter housing Hydraulic Oil Level Gauge Access panel In
  Tank Strainer filter Cartridge

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-12C4000-OM-EN-08

  In-Tank Strainer Filter: (Service Interval = 2000 Hours) 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. Periodic lubrication of the mast channels is
  required to ensure maximum life span is achieved. All roller
  surfaces must be greased periodically where the fork carriage
  bearings and mast section bearings run. The frequency of this
  operation is at the discretion of the user and essentially depends
  upon the working conditions. A lubrication interval of 250 hours
  can be taken as a typical value, under normal working conditions.
  For this purpose use graphite grease, avoid spray greases.

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-13C4000-OM-EN-08

  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.

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-14C4000-OM-EN-08

  4.9: Fuel Filter Diesel Trucks (Service interval = 500 Hours) 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.

  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 Dust Valve

  Engine Fuel Filter

  Electric Pump Fuel Filter

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-15C4000-OM-EN-08

  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.

  1. Steering Front 2. Swivel back 3. Steering back 4. Rear
  Steering 5. Rear Steering 6. Swivel Front 7. Swivel back 8.
  Steering back

  9. Swivel front 10. Steering front 11. Front Bearing 12.
  Carriage Bearing 13. Front tilt 14. Front tilt 15. Carriage Bearing
  16. Swivel Front

  17. Carriage Bearing 18. Rear Tilt 19. Mast bushing 20. Mast
  Bushing 21. Rear Tilt 22. Carriage Bearing

• Combilift Ltd. C4000-C5000XL O&S Manual

  4-15C4000-OM-EN-08

  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. C4000-C5000XL O&S Manual

  5-1C4000-OM-EN-08

  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 The towing distance should
  not exceed 1 km. (With no boost available to the hydraulic circuit
  drains, the heat generation in he hydraulic motor rotary group has
  to be taken into account.) Termination of the towing operation
  After termination of the towing operation turn back item 1t its
  original position. The original set pressure valve is thereby
  available. Screw item 1 up to stop. Tighten the nut

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-2C4000-OM-EN-08

  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. C4000-C5000XL O&S Manual

  5-3C4000-OM-EN-08

  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

  Warning Ensure that the Machine is switched off until the
  pressure gauge has been

  attached before trying to read the charge pressure.

  Remove hose connecting Port G on the pump and seal with a 9/16
  JIC

  Attach pressure gauge to port G on pump and read charge
  pressure

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-4C4000-OM-EN-08

  5.4: Fuse Box 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 3 Diesel 7.5 Pull Hold Solenoid, Fuel Pump 3 LPG
  7.5 Ignition Coil, Fuel Commander

  4 20 Steering Solenoid Supply 5 7.5 Push Button Brake Switch,
  Inch Pedal Brake Switch, Brake Light, Brake Solenoid Supply6 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 3 LPG 7.5 Ignition Coil, Fuel
  Commander

  4 20 Steering Solenoid Supply, PLC Output Supply 5 7.5 Push
  Button Brake Switch, Inch Pedal Brake Switch, Brake Light, Brake
  Solenoid Supply6 10 Wipers 7 15 Front Work Lights 8 15 Side Work
  Lights, Cabin Interior Light 9 7.5 Cabin Heater Fan, Cabin Cooling
  Fan, Optional Radio 10 7.5 Horn 11 7.5 Proximity Switch Supply,
  Guide Roller Light 12 7.5 Spare 13 7.5 Flashing Beacon 14 7.5
  Spare

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-5C4000-OM-EN-08

  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.

  OPT

  IONA

  L RE

  LAYS

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-6C4000-OM-EN-08

  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

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-7C4000-OM-EN-08

  D C

  TILT CYLINDER

  RH CARRIAGE CYLINDER

  HOSE BURSTCHECK VALVE

  ON MAST & IN ALLMAST CYLINDERS

  PRESSURETEST POINT

  INTEGRATEDONE WAY

  RESTRICTOR

  INTEGRATEDONE WAY

  RESTRICTOR

  PRIMING VALVEIN PISTON HEAD

  T

  BA4-PORT CHANGEOVER

  VALVE — REFLEX STEERING

  6-PORT DIVERTERVALVE — STEERING

  Return Filter25 Micron

  90 Micron (In-Tank)Strainer Filter

  STEERING MOTOREF

  T

  P

  L

  R

  GEA

  R P

  UM

  P

  REAR STEERING CYLINDER

  RH STEERING CYLINDERLH STEERING CYLINDER

  TILT CYLINDER

  LIFT CYLINDER

  LH CARRIAGE CYLINDER

  A’s Represent Back Of ValveB’s Represent Front Of Valve

  Legend

  Feed From PumpReturn To Tank (Bleed)Steering LinesHydraulic
  Functions

  OUTLETMODEAUXILIARYTILTREACHLIFTINLET

  P

  P1 P2

  A B

  5.7: Steering & Hydraulic Functions Circuit

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-8C4000-OM-EN-08

  5.8: Hydraulic Drive Circuit:

  P

  LB A

  T1

  350 BAR

  T2

  A

  18 BAR

  G S

  350 BAR

  Ps

  B

  P

  AB

  AB

  P

  A B

  TP

  X1 X2

  R

  L

  1 3

  2

  L

  MA

  MBFeTRANSMISSION PUMP

  Rotary Inch Valve

  Rear Wheel Motor

  LH WHEEL MOTOR RH WHEEL MOTOR

  Drive 4-PortChangeover Valve

  Legend

  Pump Suction LinePump Drain LinesBrake Release LinesMotor Drive
  LinesMotor Drain LinesControl Pressure

  b a

  OIL COOLER

  BRAKE VALVENON-RETURNVALVE — 0.5 BAR

  SHUT-OFFVALVE

  SUCTION FILTER10 MICRON NOMINAL

  Pur

  ge V

  alve

  ABT

  P

  OPTIONALAuto Carousel (Dead Band) 4-Port Changeover Valve

• Combilift Ltd. C4000-C5000XL O&S Manual

  5-9C4000-OM-EN-08

  5.9: Standard Diesel Electric Circuit:

  CO

  MB

  ILIF

  T LT

  DTi

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• Combilift Ltd. C4000-C5000XL O&S Manual

  5-10C4000-OM-EN-08

  CO

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• Combilift Ltd. C4000-C5000XL O&S Manual

  5-11C4000-OM-EN-08

  CO

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• Combilift Ltd. C4000-C5000XL O&S Manual

  5-12C4000-OM-EN-08

  5.10: Standard LPG Electric Circuit: 58

  BN

  65

  34

  21

  FUE

  L C

  OM

  MA

  ND

  ER

  GAS IGNITION COIL

  DASH PANEL

  SGO SENSOR

  LOW FUEL GUAGE

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  TEMPERATURE GUAGESen

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  CAB HEATER

  CAB FAN

  EXTRA SPOTLIGHT IF FITTED

  V

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  WIPER

  WIPER

  FLASHING BEACON

  mm

  VR

  SU

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  STARTER MOTOR

  BATTERY

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  STARTER SOLENOID

  KG

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  AM

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• Combilift Ltd. C4000-C5000XL O&S Manual

  5-13C4000-OM-EN-08

  BN

  87A

  3087

  REL

  AY

  9R

  BN

  FRONT WHEEL AT

  REAR WHEEL AT

  REL

  AY 1

  0

  R

  8787

  A

  304

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  8586

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  90 PROXIMITY

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  87

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  3086

  RBN

  87A

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  14

  GG

  8587

  8630

  FRONT WHEELS BACK

  MAST HEIGHT DRIVE

  R3/

  85 &

  R4/

  85

  BRAKE SOL.

  BRAKE LIGHT

  REVERSING BLEEPER

  REVERSING BLEEPER

  CUT-OUT RELAY

  FIT

  PUS

  H B

  UTT

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  IF M

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  R15

  /87A

  R14

  /86

  & R

  4/87 R/Y

  R20

  /87

  WHEELS TO 0 SOLENOID

  REAR WHEEL TO 0 PROX

  CUT-OUT

  BRAKE DRIVE CUT-OUT

  FRONT WHEELS 0 PROX

  0 LIGHTS ON DASH

  WHEELS TO 0ALLOW

  BN

  BK

  STEERING SOLENIOD

  TO 0 ALLOW

  TURN TO 90 SOLENIOD

  FRONT WHEEL 90 ALLOW

  FRONT WHEEL 90 PROX

  REAR WHEEL AT 90

  BN

  R9/

  87R

  7/30

  & R

  8/30

  R16

  /87

  BN

  REFLEX STEERING

  SOLENOID

  FRONT WHEELS AT

  90 LIGHTS ON DASH

  90 ALLOW

  PR

  OX

  5

  G

  PR

  OX

  5R

  16/8

  7R

  17/8

  7

  R6/

  87A

  R1/

  86R

  6/87

  R13

  /87

  R

  MAST HEIGHT PROX

  REMOVE RELAY 13 IF NO

  Title

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  uit

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