CombiLift C3500kg User 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
https://www.forkliftpdfmanuals.com/

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.
CombiliftLtd
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.
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
i
C4000-OM-EN-08
Preface:
This operator’s manual has been written to provide the operator of this
Combilift product with regard to providing information to the operator in order
to ensure that this Combilift is operated in a safe and efficient manner. It does
not take precedence over any local or nationally applicable laws or regulations
with regard to the operation of lift trucks. If you are unsure, contact your local
authorities in order to determine what tests and training courses must be
completed in order to be fully qualified in the operation of this type of material
handling equipment.
The information found has been arranged in a manner to ensure the safe
operation of the machine. As can be seen the general principles of safe
operation are presented before how the machine actual operates. It is
essential that the operators spend time familiarising themselves not only with
the machine, but with the information contained in this manual also.
Throughout this manual there are a number of instructions that have been
highlighted in a number of ways. These instructions must be followed at all
times as they indicate warnings and advice which if not heeded can result in
damage to the truck, product, or property. In the worst case failure to adhere
to the warnings and advice can result in serious injury and even death.
The table of contents on the following pages show the structure of the
information contained in this manual and make for easier location of
information.
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
ii
C4000-OM-EN-08
Contents
Section 1: Operating Instructions & Conditions......................................1-1
1.1:Understand the Capacity of your Lift-Truck ............................................. 1-1
1.2:Centre of Gravity (CG).............................................................................. 1-1
1.3:Load Chart ................................................................................................. 1-3
1.4:Serial Plate................................................................................................. 1-3
1.5:Operator Qualification............................................................................... 1-3
1.6:Operating Conditions................................................................................. 1-4
Section 2: Machine Layout & Operator Controls .....................................2-1
Section 3: Safe Operation ..........................................................................3-1
3.1:Entering and Exiting the Operator Cabin................................................... 3-1
3.2:Starting the Engine..................................................................................... 3-1
3.3:Moving....................................................................................................... 3-2
3.4:Parking....................................................................................................... 3-4
3.5:Loading & Unloading The Truck .............................................................. 3-5
3.6:Travelling Safely with a Load.................................................................... 3-7
3.7:Fuel Handling & Storage........................................................................... 3-8
Section 4: Maintenance & Service Information........................................4-1
4.1:Maintenance Schedule............................................................................... 4-1
4.2:Initial Service – Conducted at 100 hours of Operation.............................. 4-7
4.3:Engine Oil And Engine Oil Filter (service Interval = 250Hours).............. 4-7
4.4:Engine Coolant (Service interval = 2000Hours)........................................ 4-9
4.5:Hydraulic Oil and Filters ......................................................................... 4-10
4.6:Mast Maintenance (Service Interval = 250Hours)................................... 4-12
4.7:Greasing Mast Carriage Channels ........................................................... 4-13
4.8:Water Pump V- Belt................................................................................. 4-13
4.9:Fuel Filter – Diesel Trucks (Service interval = 500 Hours)..................... 4-14
4.10:Air Filter Element (Service Interval = 500 Hours)................................ 4-14
4.11:Grease Point Chart................................................................................... 4-15
4.12:Diesel Particulate Filter (DPF)................................................................. 4-15
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
iii
C4000-OM-EN-08
Section 5: Technical Information & Circuit Diagrams .............................5-1
5.1:Towing the Combilift................................................................................. 5-1
5.2:Mechanical Brake Release......................................................................... 5-2
5.3:Checking The Charge Pressure.................................................................. 5-3
5.4:Fuse Box .................................................................................................... 5-4
5.5:Dash Relay Layout (Relay Loom)............................................................. 5-5
5.6:Dash Relay Layout (PLC Loom)............................................................... 5-6
5.7:Steering & Hydraulic Functions Circuit.................................................... 5-7
5.8:Hydraulic Drive Circuit:............................................................................ 5-8
5.9:Standard Diesel Electric Circuit: ............................................................... 5-9
5.10:Standard LPG Electric Circuit:................................................................ 5-12
5.11:Tier IV LPG Electric Circuit: .................................................................. 5-15
5.12:Diesel Electric Circuit (PLC):.................................................................. 5-18
5.13:LPG Electric Circuit (PLC): .................................................................... 5-20
5.14:Tier IV LPG Electric Circuit (PLC)......................................................... 5-22
5.15:Colour Codes for Electric Circuits:.......................................................... 5-24
5.16:PLC Details.............................................................................................. 5-25
5.17:PLC Diagnostics ...................................................................................... 5-28
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
1-1
C4000-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
Gravit
y
Combilift
Centre of
Gravity
Fulcrum
Load Centre
of Gravity
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
1-2
C4000-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 Gravit
y
Combilift and load
combined Centre
of Gravity
Load Centre
of Gravit
y
Fulcrum
Load
Centre of
Gravity
Combilift and load combined
Centre of Gravit
y
Combilift
Centre of
Gravit
y
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
1-3
C4000-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
It’s unladen weight
It’s date of manufacture
The manufacturers name and address.
This plate should not be removed by anyone. If lost order a replacement from
Combilift immediately.
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/EEC
MAXIMUM STACKING CAPACITY ON A FIRM LEVEL SURFACE
600 700
LIFT HEIGHT (m)
2.5
4.5
LOAD CENTRE (mm)
800 900
?Kg
5.5
1000
?Kg
?Kg
?Kg
?Kg
?Kg
?Kg
?Kg
?Kg
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
1-4
C4000-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 o
p
erator but for other
p
ersonnel nearb
y
.
https://www.forkliftpdfmanuals.com/

Combilift Ltd. C4000-C5000XL O&S Manual
1-5
C4000-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 -30°C
and +50°C. If the temperature falls below or rises above this range
discontinue operation of the machine in order to prevent damage to various
components
https://www.forkliftpdfmanuals.com/