CombiLift C3500kg Operators & Service Manual
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CombiLift C3500kg Operators & Service Manual

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Combilift Ltd.
Operators & service
Manual
Models:
C3500kg / C4000kg / C4500kg / C4800kg / C5000kg / C5000XL
C6000lbs / C8000lbs / C9000lbs / C10,000lbs / C10,000XL
Serial Number: ___________
Combilift ltd.
Gallinagh
Co. Monaghan
Ireland
Tel: + 353 47 80500
Fax: + 353 47 80501
E-Mail: info@combilift.com
C4000-OM-EN-08 (c)
https://www.forkliftpdfmanuals.com/

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Summary of Contents for CombiLift C3500kg

  • Page 1 Combilift Ltd. Operators & service Manual Models: C3500kg / C4000kg / C4500kg / C4800kg / C5000kg / C5000XL C6000lbs / C8000lbs / C9000lbs / C10,000lbs / C10,000XL Serial Number: ___________ Combilift ltd. Gallinagh Co. Monaghan Ireland Tel: + 353 47 80500 Fax: + 353 47 80501 E-Mail: info@combilift.com...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    Combilift Ltd. C4000-C5000XL O&S Manual 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:...
  • Page 5 Combilift Ltd. C4000-C5000XL O&S Manual 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  ...

  • Page 6: Section 1: Operating Instructions & Conditions

    - 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.
  • Page 7 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 Combilift...

  • Page 8: Load Chart

    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: ...

  • Page 9: Operating Conditions

    C4000-C5000XL O&S Manual 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.
  • Page 10  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...

  • Page 11: Section 2: Machine Layout & Operator Controls

    C4000-C5000XL O&S Manual 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.
  • Page 12 Combilift Ltd. C4000-C5000XL O&S Manual 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 ...
  • Page 13 Combilift Ltd. C4000-C5000XL O&S Manual 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...
  • Page 14 Combilift Ltd. C4000-C5000XL O&S Manual  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”...
  • Page 15 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...
  • Page 16 Combilift Ltd. C4000-C5000XL O&S Manual 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: ...
  • Page 17 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.
  • Page 18  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’...

  • Page 19: Section 3: Safe Operation

    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.

  • Page 20: Moving

    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.
  • Page 21  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: ...

  • Page 22: Parking

     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.

  • Page 23: Loading & Unloading The Truck

    Combilift Ltd. C4000-C5000XL O&S Manual 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.
  • Page 24 Combilift Ltd. C4000-C5000XL O&S Manual 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.

  • Page 25: Travelling Safely With A Load

    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.

  • Page 26: Fuel Handling & Storage

    Combilift Ltd. C4000-C5000XL O&S Manual 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.
  • Page 27 Combilift Ltd. C4000-C5000XL O&S Manual  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.

  • Page 28: Section 4: Maintenance & Service Information

    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.
  • Page 29 Combilift Ltd. C4000-C5000XL O&S Manual 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.
  • Page 30 Combilift Ltd. C4000-C5000XL O&S Manual  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.
  • Page 31 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’...
  • Page 32 Combilift Ltd. C4000-C5000XL O&S Manual  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.
  • Page 33 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.

  • Page 34: Initial Service - Conducted At 100 Hours Of Operation

    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.
  • Page 35  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 https://www.forkliftpdfmanuals.com/...

  • Page 36: Engine Coolant (Service Interval = 2000Hours)

    Combilift Ltd. C4000-C5000XL O&S Manual  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 ...

  • Page 37: Hydraulic Oil And Filters

    Combilift Ltd. C4000-C5000XL O&S Manual 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.
  • Page 38 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).

  • Page 39: Mast Maintenance (Service Interval = 250Hours)

    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.

  • Page 40: Greasing Mast Carriage Channels

    Combilift Ltd. C4000-C5000XL O&S Manual 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.

  • Page 41: Fuel Filter - Diesel Trucks (Service Interval = 500 Hours)

    Combilift Ltd. C4000-C5000XL O&S Manual 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.

  • Page 42: Grease Point Chart

    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.

  • Page 43: Diesel Particulate Filter (Dpf)

    Combilift Ltd. C4000-C5000XL O&S Manual 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.

  • Page 44: 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.

  • Page 45: Mechanical Brake Release

    Combilift Ltd. C4000-C5000XL O&S Manual 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.

  • Page 46: Checking The Charge Pressure

    Combilift Ltd. C4000-C5000XL O&S Manual 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...

  • Page 47: Fuse Box

    Combilift Ltd. C4000-C5000XL O&S Manual 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 Mast Height Override, Dash Display Lights, Glow Plug Light, Glow Plug Relay, Alternator 1 –...

  • Page 48: Dash Relay Layout (Relay Loom)

    Combilift Ltd. C4000-C5000XL O&S Manual 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. https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 49: Dash Relay Layout (Plc Loom)

    Combilift Ltd. C4000-C5000XL O&S Manual 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 Starter Glow Plug Timer...

  • Page 50: Steering & Hydraulic Functions Circuit

    Combilift Ltd. C4000-C5000XL O&S Manual 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...

  • Page 51: Hydraulic Drive Circuit

    Combilift Ltd. C4000-C5000XL O&S Manual 5.8: Hydraulic Drive Circuit: RH WHEEL MOTOR LH WHEEL MOTOR Rotary Inch Valve Drive 4-Port Changeover Valve TRANSMISSION PUMP 350 BAR 350 BAR 18 BAR NON-RETURN VALVE - 0.5 BAR BRAKE VALVE OIL COOLER SUCTION FILTER...

  • Page 52: Standard Diesel Electric Circuit

    Combilift Ltd. C4000-C5000XL O&S Manual 5.9: Standard Diesel Electric Circuit: https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 53 Combilift Ltd. C4000-C5000XL O&S Manual 5-10 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 54 Combilift Ltd. C4000-C5000XL O&S Manual 5-11 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 55: Standard Lpg Electric Circuit

    Combilift Ltd. C4000-C5000XL O&S Manual 5.10: Standard LPG Electric Circuit: 5-12 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 56 Combilift Ltd. C4000-C5000XL O&S Manual 5-13 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 57 Combilift Ltd. C4000-C5000XL O&S Manual 5-14 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 58: Tier Iv Lpg Electric Circuit

    Combilift Ltd. C4000-C5000XL O&S Manual 5.11: Tier IV LPG Electric Circuit: 5-15 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 59 Combilift Ltd. C4000-C5000XL O&S Manual 5-16 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 60 Combilift Ltd. C4000-C5000XL O&S Manual 5-17 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 61: Diesel Electric Circuit (Plc)

    Combilift Ltd. C4000-C5000XL O&S Manual 5.12: Diesel Electric Circuit (PLC): 5-18 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 62 Combilift Ltd. C4000-C5000XL O&S Manual 5-19 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 63: Lpg Electric Circuit (Plc)

    Combilift Ltd. C4000-C5000XL O&S Manual 5.13: LPG Electric Circuit (PLC): 5-20 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 64 Combilift Ltd. C4000-C5000XL O&S Manual 5-21 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 65: Tier Iv Lpg Electric Circuit (Plc)

    Combilift Ltd. C4000-C5000XL O&S Manual 5.14: Tier IV LPG Electric Circuit (PLC) 5-22 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...
  • Page 66 Combilift Ltd. C4000-C5000XL O&S Manual 5-23 https://www.forkliftpdfmanuals.com/ C4000-OM-EN-08...

  • Page 67: Colour Codes For Electric Circuits

    Combilift Ltd. C4000-C5000XL O&S Manual 5.15: Colour Codes for Electric Circuits: CODE - COLOUR BK - BLACK BN - BROWN BL - BLUE ORANGE YELLOW GR - GREEN VIOLET PINK GY - GREY W - WHITE G/Y - GREEN YELLOW...

  • Page 68: Plc Details

    Combilift Ltd. C4000-C5000XL O&S Manual 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 1 2 3 4 5 6 7 8 9 10...
  • Page 69 Combilift Ltd. C4000-C5000XL O&S Manual 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 ...
  • Page 70 Combilift Ltd. C4000-C5000XL O&S Manual Outputs (continued) Plug  Pin  Function  Wire Colour  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  04  Not Used  n/a  X5.1  05  Not Used  n/a  X5.1  06  Common Supply for Output 09 (From fuse 4)  Brown  X5.1  07  Reflex Solenoid  Red  X5.1 ...
  • Page 71 Combilift Ltd. C4000-C5000XL O&S Manual 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 –...
  • Page 72 Combilift Ltd. C4000-C5000XL O&S Manual 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 Forward, Reverse, 0 and 90 Solenoids Move Switch ‘4’...

This manual is also suitable for:

C4000kgC4500kgC4800kgC5000kgC5000xlC6000lbs ... Show all

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