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
Combilift Ltd.
Operators & service
Manual
Models:
C3500kg / C4000kg / C4500kg / C4800kg / C5000kg / C5000XL
C6000lbs / C8000lbs / C9000lbs / C10,000lbs / C10,000XL
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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.
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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.
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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
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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
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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
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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
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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
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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
.
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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
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C4000-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.
11
234
5
6
789
10
23
11 12
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
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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.
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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.
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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
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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
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Brake / Inching Pedal
The Brake/ inching pedal is the pedal on the floor on the
left hand side of the steering Column as shown in the
diagram opposite
The combined Brake/Inching Pedal has two functions:
Stop drive to slow the machine down.
It may be used to permit slow speed, for
precise manoeuvring of the truck in confined
spaces.
Accelerator Pedal
The accelerator pedal is located on the floor on the right
hand side of the steering column.
The accelerator pedal provides the operator
control of the truck speed.
To INCREASE truck speed, DEPRESS pedal.
Steering Wheel / Column
All models have both front and rear-end steering.
When in forward mode the front wheels are fixed and
the rear wheel steers the truck.
Rear-end steering allows sharper turns in confined
areas but demands greater driver care when turning.
When in sideward mode, the rear wheel is fixed and the
front wheels steer the truck.
When driving forwards, turn steering wheel clockwise to
turn truck clockwise, turn steering wheel anti clockwise
to turn truck anti clockwise.
When driving in reverse, turn steering wheel clockwise
to turn truck anti clockwise, turn steering anti clockwise
to turn truck clockwise.
When driving in sideward mode, turning the steering
wheel clockwise will turn truck clockwise. Turning the
steering wheel anti clockwise to turn truck anti
clockwise.
The same is true for travel in either direction when in
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
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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
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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
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Section 3: Safe Operation
Many people are under the impression that driving a lift truck is like driving any
other vehicle. This is not the case. Lift trucks are designed for the purpose of
lifting, and moving heavy loads in confined spaces. For this reason it is
essential that operators are trained to operate the machines correctly and
ensure that they always operate the machine in a safe and controlled manner.
This section looks at how the machine should be operated.
3.1: Entering and Exiting the Operator Cabin
When entering or exiting the cabin of the Combilift, the three point contact
method should always be used. The three point contact method is when an
operator has three of their four limbs (hands & feet) in contact with the truck.
There are a number of handgrips as well as a footstep available to allow easy
and safe access to the operator cabin. DO NOT use the steering wheel as a
handgrip. When in the cabin of the Combilift, ALWAYS wear the seat belt
provided.
3.2: Starting the Engine
Diesel Engine
Ensure that the parking brake is applied and that the directional control
lever is in the neutral position
Insert the key into the ignition switch and turn clockwise to the preheat
position. The charge indicator lamp must light up.
Depress the accelerator.
Turn the ignition key further clockwise to the “Start” position. After the
engine 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
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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 tr
y
in
g
a
g
ain.
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 leve
r
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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