CombiLift C-Series User manual
C3M2-OM-EN-02
www.combilift.com
Dear Customer,
Thank you for choosing Combilift and showing your faith
in our range of material handling products. By choosing
Combilift you now own a high-quality 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 fulfils your material
handling requirements in a safe, reliable and efficient
manner. 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.
In order to familiarise yourself with your truck in a quick
comprehensive manner please read this manual
attentively. In addition to the information regarding safety
and operation, this manual also contains important
maintenance checks and instructions for ensuring
continuous safe and reliable operation of your truck.
Should you have any questions or problems relating to
your truck, please contact your local Combilift partner who
will be happy to respond to your questions, suggestions
and/or comments. We are confident that you will be wholly
satisfied with your Combilift truck.
1
C3M2-OM-EN-02
Warning
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of California to cause
cancer and birth defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except as necessary, service
your vehicle in a well-ventilated area and wear gloves or wash your hands
frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
Preface
This manual describes how to operate and maintain the Combilift C-Series truck safely
and efficiently. It is essential that this manual remain with the truck at all times. It is
essential that the operator and all persons involved in work with the truck read this
manual before attempting to operate or service the truck.
Follow all local laws and regulations with regard to the operation of lift trucks where
they apply at the place of use.
Follow all instructions, prohibitive or otherwise, found in this manual. They are there
to protect the life of the operator and the lives of others working in the vicinity of the
truck.
Always perform the Pre-Use Inspection as indicated in this manual and follow the
guidelines on service intervals. Ensure that the truck is in good mechanical condition
at all times. Report any fault and have it corrected immediately otherwise even minor
faults may result in major failures and dangerous operating conditions.
About This Manual
The descriptions and illustrations contained in this manual are not in any way binding.
Combilift must reserve the right to make changes without prior notice in the interest of
the enhancement of the product.
Some trucks may be customised to suit the needs of individual customers. Therefore
these trucks may deviate slightly from the descriptions contained within this manual.
Every effort has been made to ensure that the information contained herein is accurate
at the time of writing. However it cannot be guaranteed that all of the statements in
this manual are completely correct.
Whenever the terms front, rear, right and left are used throughout this manual, it is
from the point of view of the operator sitting on the seat in the operating enclosure
looking forward.
This manual is not designed for the purpose of extensive maintenance work. Such
work must be performed by approved professionals.
The table of contents on the following pages outlines the structure of the information
contained within this manual and makes for easier location of information.
2
C3M2-OM-EN-02
Warranty Registration
The warranty registration form should be filled in and submitted online at:
www.combilift.com – Service – Warranty Registration
Please complete the warranty registration online within 30 days of receipt of the truck.
Contents
3
C3M2-OM-EN-02
Contents
Section 1:
Safety Information ........................................................................... 6
1.1
Safety Statements ................................................................................................... 6
1.2
Operator Safety ...................................................................................................... 6
1.3
Safety Decals ......................................................................................................... 7
1.4
Safety Equipment ................................................................................................... 8
1.5
Warning Devices .................................................................................................... 9
1.6
Operator Qualification and Responsibilities ........................................................ 10
1.7
Work Place Operating Conditions ....................................................................... 12
1.8
Diesel Particulate Filter (DPF) Regeneration ...................................................... 15
1.9
Decommissioning Recycling and Disposal ......................................................... 16
Section 2:
Basic Information .......................................................................... 17
2.1
Intended Use ........................................................................................................ 17
2.2
General ................................................................................................................. 17
2.3
Vehicle Description ............................................................................................. 18
2.4
Principle of Operation .......................................................................................... 19
2.5
Serial Number and Serial Plate ............................................................................ 20
2.6
Rated Capacity, Centre of Gravity and Stability ................................................. 21
2.7
Load Centre & Load Chart .................................................................................. 24
2.8
Attachments ......................................................................................................... 25
2.9
Tilting ................................................................................................................... 26
Section 3:
Components & Controls ................................................................ 27
3.1
Machine Overview and Components ................................................................... 27
3.2
Operating Components & Controls ..................................................................... 28
3.2.1
Steering Wheel / Column ................................................................................. 29
3.2.2
Inch Brake Pedal .............................................................................................. 30
3.2.3
Accelerator Pedal ............................................................................................. 30
3.2.4
Operator’s Seat ................................................................................................. 30
3.2.4.1
Kab 100 Series Seat Adjustments........................................................................................................ 32
3.2.4.2
Grammer Seat Adjustments................................................................................................................. 34
3.2.5
Switches/Buttons.............................................................................................. 36
3.2.6
Switches/Buttons for Optional Extras .............................................................. 37
3.2.1
Multifunction Display Console (MDC) ........................................................... 39
3.2.7
Battery Isolator Key Switch ............................................................................. 40
3.3
Hydraulic Function Lever Operation ................................................................... 41
3.4
Hydraulic Joystick Operation (If Fitted) .............................................................. 42
Section 4:
Operation Monitoring .................................................................... 43
4.1
Daily Pre-Shift Inspection Screen ........................................................................ 43
4.2
MDC Home Screen .............................................................................................. 44
4.3
MDC Pop Up Icons .............................................................................................. 52
4.4
Miscellaneous Dash Panel Indicator Lights ......................................................... 55
4.5
MDC Engine Fault Codes .................................................................................... 56
Section 5:
Operation ........................................................................................ 57
5.1
Pre-Use Checks .................................................................................................... 57
5.2
Fuel Handling & Storage ..................................................................................... 62
Contents
4
C3M2-OM-EN-02
5.2.1
Refuelling - Diesel ........................................................................................... 63
5.2.2
Refuelling - LP Gas ......................................................................................... 64
5.3
Checking Engine Oil Level .................................................................................. 66
5.4
Diesel Particulate Filter (DPF) Regeneration * ................................................... 67
5.4.1
Automatic DPF Regeneration .......................................................................... 68
5.4.2
Standstill DPF Regeneration ............................................................................ 68
5.5
Checking Coolant Level ...................................................................................... 70
5.6
Checking Hydraulic Oil Level ............................................................................. 72
5.7
Front Wheel Alignment ....................................................................................... 73
5.8
Entering and Exiting the Operator’s Cabin .......................................................... 74
5.9
Starting the Engine ............................................................................................... 74
5.9.1
Diesel engine starting procedure: ..................................................................... 75
5.9.2
LPG engine starting procedure: ....................................................................... 76
5.10
Stopping the Engine ............................................................................................. 76
5.10.1
Diesel engine stopping procedure: ............................................................... 76
5.10.2
LPG engine stopping procedure: ................................................................. 77
5.11
Moving Off .......................................................................................................... 77
5.12
Turning ................................................................................................................. 78
5.13
Stopping ............................................................................................................... 78
5.14
Changing Travel Direction .................................................................................. 79
5.15
Parking ................................................................................................................. 80
5.16
Picking Up, Placing, Stacking & De-stacking Loads .......................................... 81
5.16.1
Undercutting a Load .................................................................................... 83
5.16.2
Picking up a Load ........................................................................................ 84
5.16.3
Placing a Load.............................................................................................. 84
5.16.4
Stacking Long & Palletised Loads ............................................................... 85
5.16.5
De-stacking Long & Palletised Loads ......................................................... 86
5.17
Adjusting the Forks .............................................................................................. 87
5.18
Travelling Safely with a Load .............................................................................. 88
5.19
Driving on Slopes ................................................................................................ 89
5.20
Towing ................................................................................................................. 90
5.20.1
Hydrostatic Drive Bypass Function ............................................................. 90
5.20.2
Mechanical Release of Park Brake ............................................................. 91]
Section 6:
Maintenance ................................................................................... 93
6.1
Basic Safety Instructions for Servicing and Inspection ....................................... 94
6.2
Initial Service – Conducted at 100 hours of Operation........................................ 96
6.3
General Truck Maintenance Schedule ................................................................. 97
6.4
Diesel Engine Maintenance Schedule .................................................................. 98
6.5
LPG Engine Maintenance Schedule .................................................................... 99
6.6
Wheel Nut Torque.............................................................................................. 100
6.7
Grease Point Chart ............................................................................................. 101
6.8
Engine Oil System ............................................................................................. 102
6.8.1
Recommended Engine Oil Specification ....................................................... 102
6.8.2
Lubricating oil change intervals ..................................................................... 102
6.8.3
Engine Oil Viscosity Class ............................................................................ 103
6.8.4
Changing Engine Oil & Filter ........................................................................ 103
6.9
Diesel Fuel System (If Applicable) .................................................................... 105
6.9.1
Draining Water Separator .............................................................................. 106
6.9.2
Changing Filter Elements .............................................................................. 106
Contents
5
C3M2-OM-EN-02
6.9.3
Priming The Diesel Fuel System ................................................................... 107
6.10
LP Gas System (If Applicable) .......................................................................... 108
6.10.1
LP Gas Lock Off Valve Filter .................................................................... 109
6.10.2
LP Gas In-line Cannister Filter .................................................................. 109
6.10.3
LP Gas Pressure Regulator ........................................................................ 110
6.11
Engine Cooling System ...................................................................................... 111
6.12
Belt Drive System .............................................................................................. 115
6.13
Air Filter System ................................................................................................ 116
6.14
Battery Maintenance .......................................................................................... 119
6.14.1
Checking the Battery Electrolyte Level ..................................................... 119
6.14.2
Removing the Battery ................................................................................ 120
6.14.3
Installing a new Battery ............................................................................. 120
6.14.4
Battery Charging ........................................................................................ 121
6.14.5
Jumpstarting ............................................................................................... 121
6.15
Hydraulic Oil System ......................................................................................... 122
6.15.1
Hydraulic Oil Selection .............................................................................. 122
6.15.2
Hydraulic Oil Filters .................................................................................. 123
6.15.3
Hydraulic Oil & Strainer Filter .................................................................. 125
6.16
Mast Maintenance .............................................................................................. 128
6.16.1
Mast Channel Maintenance........................................................................ 128
6.16.2
Fork Carriage With Hydraulic Fork Positioning Maintenance .................. 128
6.16.3
Mast Chain Maintenance ........................................................................... 128
6.16.4
Mast Bearings ............................................................................................ 133
6.17
Cleaning & Greasing The Mast Carriage Channels ........................................... 134
6.18
Mast Carriage Alignment / Wear Pad Adjustment Procedure ........................... 135
6.19
Fork Maintenance .............................................................................................. 136
6.20
Air Conditioning (AC) System Maintenance (If Fitted) .................................... 138
Section 7:
Technical ...................................................................................... 139
7.1
Checking the Charge Pressure ........................................................................... 139
7.2
Valve Chest Pressure Settings ........................................................................... 140
7.3
Steering & Hydraulic Functions Circuit ............................................................ 143
7.4
Hydraulic Drive Circuit ..................................................................................... 144
7.5
Fuses .................................................................................................................. 145
7.5.1
14-Way Fuse Box .......................................................................................... 145
7.5.2
Power Distribution Module (PDM) Fuses ..................................................... 146
7.5.3
Inline Fuses .................................................................................................... 147
7.6
Relays ................................................................................................................. 147
Section 8:
Appendices .................................................................................. 148
8.1 Pre-Use Check Sheet ................................................................................................ 149
Safety Information
6
C3M2-OM-EN-02
Warning
Warning indicates a hazardous situation which if not avoided could result in
serious injury or death.
Caution
Caution indicates an unsafe practice which if not avoided could result in
serious injury or property damage.
Note
Used without the safety symbol indicates a situation that if not avoided
could result in damage to the equipment and/or property.
Also indicates important information regarding the operation and servicing
of the truck.
Section 1: Safety Information
1.1 Safety Statements
To ensure safe operation and maintenance of the truck, it is necessary to follow all the
instructions in this manual.
The following symbols and signal words WARNING, CAUTION and NOTE, and the
adjacent text, indicate hazards and instructions.
This is the Environmental Hazard Symbol. It is used to alert the reader to
potential damage to the environment.
This is the Safety Alert Symbol. It is used to alert the reader to potential
safety hazards.
1.2 Operator Safety
Before commencing use of the Combilift, operators must thoroughly read and
understand the material contained within this manual to become familiar with:
The trucks capabilities.
The meanings of the various machine signs (decals) found on the truck.
Whether you are a new operator or have used forklift trucks for many years, read
through this manual thoroughly. It provides instructions to help operate the Combilift
in a safe and efficient manner.
Safety Information
7
C3M2-OM-EN-02
1.3 Safety Decals
Maintain all safety decals on the machine in a legible manner. If a safety
decal becomes damaged or illegible, replace it with a new decal - available
from your local Combilift partner.
The machine safety decals are illustrated below and are accompanied by a
description of the meaning of each decal. The part number of each decal is also
shown for reordering.
Warning
Personal injury hazard.
Always wear the seat belt
while sitting in the truck.
Part No. CPD00009
Warning
Read the operators manual
before operating or working
with the truck.
Part No. CPD00009
Warning
Shearing hazard from rotating
fan. Stop the engine before
approaching.
Part No. CPD00004
Warning
Crushing hazard from moving
parts. Stop the truck and
isolate the battery before
approaching.
Part No. CPD00006
Warning
Personal injury hazard. Do
not stand on the forks.
Part No. CPD00003
Warning
Personal injury hazard. Do
not stand under the forks.
Part No. CPD00003
Warning
Scalding hazard. Only remove
the cap from the radiator
when cool.
Part No. CPD00005
Safety Information
8
C3M2-OM-EN-02
Warning
Never use the truck without the cabin properly installed.
Do NOT drill, weld, straighten or bend the cabin overhead guard.
Allow only trained authorised personnel to install a new cabin.
Caution
The safety devices are installed to protect the life of the operator and those
working in the vicinity of the truck. Do not remove or bypass any of the
safety devices.
Combilift will not assume liability for injuries or damages arising from or
caused by the removal or bypassing of any of the trucks safety devices.
Note
After turning the ignition key switch to the off ‘0’ position to stop the engine,
the engine control unit (ECU) remains active to save system data before it
switches off. For this reason, the power supply to the engine must not be
interrupted at the battery isolator switch or by removing the battery leads
until the ECU has switched off.
1.4 Safety Equipment
Safety equipment is provided to protect the operator from potential danger while
using the truck. The safety equipment must be checked frequently as part of the pre-
use inspection and maintained in good working condition at all times.
Cabin Overhead Guard
The cabin overhead guard is not designed for roll over protection. It is only intended
to offer protection from the impact of falling objects.
DO NOT operate the truck if the cabin overhead guard is damaged, corroded or has
been modified in any way.
Battery Isolator Key Switch
The battery isolator key switch allows the battery to be disconnected from the
electrical system.
Seat Belt
The purpose of the seat belt is to retain the operator in the seat and so prevent or
reduce injuries suffered in a crash. The seat belt ensures that as little contact is
made between the operator and cabin as possible. It also significantly reduces the
risk of being thrown from the cabin.
Park Brake
The park brake prevents inadvertent movement of the truck when it is parked or
stopped.
Safety Information
9
C3M2-OM-EN-02
Caution
The warning devices are installed to protect the life of the operator and
those working in the vicinity of the truck. Do not remove or bypass any of
the warning devices.
Combilift will not assume liability for injuries or damages arising from or
caused by the removal or bypassing of any the trucks warning devices.
Seat Switch
The purpose of the seat switch is to prevent the truck from being operated from an
incorrect position. When the seat is unoccupied the drive is disabled and the
hydraulic function levers are locked (the hydraulic joystick – if fitted – is blocked).
The following safety devices may be fitted as optional extras:
Seat Belt Switch
The purpose of the optional seat belt switch is to encourage the operator to wear the
seatbelt. The seatbelt should always be fastened across the top of the lap when
driving the truck. If fitted, the truck will not drive unless the seat belt is buckled.
Mast Above Height Drive Cut-out
This optional safety feature disables the drive when the forks are raised above a
predetermined height. This helps to avoid collisions between the mast and potential
overhead obstructions. To enable the drive, lower the mast below the cut-out height
or press and hold the cut-out override button.
Mast Lift Cut-out
This optional safety feature cuts out the lift function when the forks reach a
predetermined height. This helps to avoid collisions between the mast and potential
overhead obstructions. To continue raising the mast press and hold the lift cut-out
override button whilst operating the control lever.
Mast Not Fully Retracted Drive Cut-out (If Fitted)
This optional safety feature disables the drive if the mast reach function is not fully
retracted. This helps to avoid collisions between the forks and potential obstructions.
To enable the drive, retract the mast reach fully.
Inch Brake Pedal Brake Switch
The inch brake pedal brake switch applies the park brake when the inch brake pedal
is depressed and held in for 3 seconds or more. This safety feature brings the truck
to a complete stop.
1.5 Warning Devices
Warning devices are installed to make individuals in the vicinity of the truck aware of
its presence while it is being operated. The warning devices must be checked
frequently as part of the pre-use inspection and maintained in good working
condition at all times.
This manual suits for next models
4
Table of contents
Other CombiLift Forklift manuals
