CombiLift C25000 User manual

www.combilift.com
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 make it one
of the leading products in the material handling industry.
Combilift Ltd
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.

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Contents
Section 1:Machine layout and Operator Controls ................. 3
1.1:Machine Overview and Components ............................................................. 3
1.2:Operator Controls & Display Layout ............................................................. 3
1.3:Operator Controls & Display Descriptions .................................................... 5
1.4:Fork Control Joystick ................................................................................... 12
Section 2:Operating instructions and Conditions .............. 14
2.1:Understand the Capacity of your Lift-Truck ............................................... 14
2.2:Centre of Gravity (COG) ............................................................................. 14
2.3:Load Chart ................................................................................................... 16
2.4:Operator Qualification and Responsibilities ................................................ 16
2.5:Entering and exiting the operator Cabin ...................................................... 18
2.6:Starting Procedure ........................................................................................ 18
2.7:Moving Off .................................................................................................. 19
2.8:Changing Direction without Changing Mode .............................................. 19
2.9:Changing Into Sideward Mode .................................................................... 19
2.10:To Change Back to Forward Mode .............................................................. 19
2.11:Stopping ....................................................................................................... 20
2.12:Loading ........................................................................................................ 20
2.13:When Loading in Sideward Mode ............................................................... 20
2.14:When Loading in Forward Mode ................................................................. 21
2.15:Placing a Load When In Sideward Mode .................................................... 21
2.16:Placing a Load When In Forward Mode ...................................................... 21
2.17:Double Forking ............................................................................................ 22
2.18: Stacking ....................................................................................................... 22
2.19:De-Stacking .................................................................................................. 22
2.20:Adjusting Load Forks (Optional Fork Positioning) ..................................... 23
2.21:Work Place Operating Conditions ............................................................... 23
Section 3:Daily Checks .......................................................... 28
3.1:Wheels and Tyres ......................................................................................... 28
3.2:Battery .......................................................................................................... 28
3.3:Engine Oil Level .......................................................................................... 28
3.4:Coolant Level ............................................................................................... 29
3.5:Hydraulic Tank ............................................................................................ 29
3.6:Fuel Tank ..................................................................................................... 30
3.7:Automatic Fan Belt Tensioner ..................................................................... 30
3.8:Load Forks ................................................................................................... 30
3.9:Controls ........................................................................................................ 30

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Section 4:Safe Operation ...................................................... 31
4.1:Safe Operation ............................................................................................. 31
4.2:Safe Driving ................................................................................................. 32
4.3:Fuel Handling & Storage ............................................................................. 34
4.4:Battery Charging .......................................................................................... 35
4.5:Operating in Hazardous Areas ..................................................................... 35
4.6:Safe Driving on Gradients ........................................................................... 35
4.7:Driving Position ........................................................................................... 35
4.8:Parking ......................................................................................................... 36
4.9:Wear Personal Protective Equipment (PPE) ................................................ 36
Section 5:Service information .............................................. 37
5.1:Initial service at 100 Hours .......................................................................... 37
5.2:Engine Oil .................................................................................................... 38
5.3:Changing Hydraulic Oil & Filters ................................................................ 39
5.4:Engine Cooling System ................................................................................ 43
5.5:Hydraulic Oil ............................................................................................... 45
5.6:Chain Maintenance ...................................................................................... 45
5.7:Fuel Filter Element ...................................................................................... 46
5.8:Air Filter Elements ....................................................................................... 46
5.9:Checking Belt Tensioner Spring Tension .................................................... 47
5.10:Greasing Mast Channels .............................................................................. 47
5.11:Greasing Mast Carriage Channels ............................................................... 47
5.12:Grease Point Chart ....................................................................................... 48
5.13:Diesel Particulate Filter (DPF) ..................................................................... 49
5.14:Diesel Fuel ................................................................................................... 49
5.15:Maintenance Chart ....................................................................................... 50
5.16:Operators Daily Inspection Sheet ................................................................ 51
Section 6:Technical Information & Circuit Diagrams ......... 52
6.1:Engine Wiring Diagram ............................................................................... 52
6.2:Checking the Charge Pressure ..................................................................... 55
6.3:Checking the Drive Pressure ........................................................................ 55
6.4:Hydraulic Functions Pressure Settings ........................................................ 56
6.5:Fuses ............................................................................................................ 57
6.6:Relay Layout ................................................................................................ 58
6.7:Combilift Electric Circuit ............................................................................ 60
6.8:Hydraulic Functions Circuit ......................................................................... 65
6.9:Hydraulic Drive Circuit ............................................................................... 66
6.10:PLC Details .................................................................................................. 67
6.11:John Deere Engine Plug ............................................................................... 70
Section 7:Appendices ............................................................ 71
7.1:Appendix A: Warranty Registration ............................................................ 71

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Section 1: Machine layout and Operator Controls
It is essential before you start operating the Combilift to be familiar with the
main components and controls of the machine, their function and where they
are located. Figure 1.1 below indicates all of the major components of the
Combilift and figure 1.2 on the following page indicates all of the operator
controls.
1.1: Machine Overview and Components
Figure 1.1: Machine Components Layout
1.2: Operator Controls & Display Layout
Component List
1. Forks
2. Front Swivels
3. Platforms
4. Hydraulic Tank
5. Mast
6. Flashing Beacon
7. Operator Cabin
8. Diesel Tank
9. Work Lights
10. Bonnet
11. Rear Swivel/Arm
12. Engine Access Panel

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Figure 1.2: Machine Controls Layout
Control Layout
1. Fuse Box
2. Engine Temperature Gauge
3. Hour Meter
4. Windscreen Wiper Switch
5. Cabin Fan Switch (Optional)
6. Heater Fan Switch (Optional)
7. Joystick On/Off Switch (If Fitted)
8. Fuel Gauge
9. Work Lights Switch
10. Engine Malfunction Indicator
11. Ignition Switch
12. Drive Speed Switch
13. Accelerator Pedal
14. Brake / Inch Pedal
15. Adjustable Suspension Seat
16. Direction Control Joystick
17. Temperature Control Knob (Optional)
18. Side Window Wiper Switch
19. Cooling Fan (Optional)
20. Horn Button
21. Parking Brake / Stop Switch
22. Fork Control Joystick
23. Interior Light
24. Adjustable Steering Wheel / Column
25. Camera Monitor
26. Windscreen Wiper
27. Air Vent
28. Hand Grip

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Note
The park brake is applied automatically if the operator vacates the operator’s
seat for more than 3 seconds.
To release the parking brake the operator must sit on the seat and depress
then release the parking brake switch.
1.3: Operator Controls & Display Descriptions
Now that the layout of the operator controls has been identified, the next step
is to detail how the controls function.
Ignition Switch:
 This is a three-position key switch located on the dash,
which isolates the electrical system when in the off
position.
Park Brake Switch
 The park brake switch is the red button located on the
dash to the right hand side of the joystick.
 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 park brake on.
Direction Control Joystick
 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, press the button.
Note
The truck will NOT start unless the direction control lever is in the neutral
position.

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Work Lights Switch:
 This is a three position rotary switch located on the dash
 Position 0 – Lights Off
 Position 1 – Front Lights On
 Position 2 – Front & Side Work Lights On
Joystick On/Off Switch (If Fitted):
 This is a two position rotary switch located on the dash
 Position ‘0’ or ‘OFF’ – The Joystick is inactive, the forks
and mast cannot be moved.
 Position ‘I’ or ‘ON’ – The Joystick is active, all fork and
mast functions are active.
Engine 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.
Note
Do NOT run engine if oil pressure indicator is illuminated.
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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.
 Whenever the light illuminates the truck should be
refuelled immediately.
Parking Brake Indicator Light
 The Parking Break indicator light indicates 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.
Note
ALWAYS adhere to all safety precautions for refuelling the truck.
P
Normal
Mode
Sideward
Mode

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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.
Fuel Gauge
 The fuel gauge displays how much diesel is in the
diesel tank.
 This gauge located on the dash (see figure 1.2 item
number 8)
Drive Cutout Override Button (Optional)
 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 drive cutout override button located
on the dash.
Window Wiper Switches
 There are 2 window wiper switches on the machine.
 The right hand side window wiper switch shown opposite is
located in the top right hand corner of the cabin. This rocker
switch activates the wiper by flipping it to the on position.
See Item 18 in figure 1.2 on page 5.
 The front window wiper switch shown opposite is located on
the dash. See Item 4 in figure 1.2 on page 5.
 The 2 position rotary switch activates the wiper by turning it
to the on or ‘I’ position.
90° Light – Optional (Green Light On Dash)
 This light illuminates when the swivels are in the 90°
position (sideward mode) indicating that it can be
driven in a guided aisle.
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Cabin Fan (Optional) Switch
 This is a 2 position rotary switch located on the dash.
 Turning it to the on position activates the cooling fan located
in the top right hand corner of the cabin. See Item 5 in figure
1.2 on page 5.
Drive Speed Switch
 This is a 2 position rotary switch located on the dash. Item
12 in figure 1.2 on page 5.
 Turning the switch to the ‘Tortoise’ symbol selects low drive
speed.
 Turning the switch to the ‘Hare’ symbol selects high drive
speed.
Heater Fan Switch (Optional)
 This four position rotary switch located on the dash allows
the operator to select between off, low, medium or high fan
speeds. Item 6 in figure 1.2 on page 5.
Temperature Control Knob (Optional)
 This knob is located to the right of the armrest see item 17
in figure 1.2 on page 5.
 To increase cabin temperature, turn anti-clockwise.
 To decrease cabin temperature, turn clockwise.
Brake / Inch Pedal
 The Brake / Inch pedal is the pedal on the floor to the
left hand side of the steering Column as shown in the
diagram opposite.
 The combined Brake / Inch Pedal has two functions:
 Permits slow speed, for precise manoeuvring of the
truck in confined spaces.
 Brings the machine to a complete stop when
pressure on the pedal is increased.
Note
When the Inch / brake pedal is fully depressed for a fixed time period the
parking brake will be engaged and the machine brought to a complete stop.
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Cold