C4 C5MK4 Om en 06

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 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.
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.
www.combilift.com
C4-C5MK4-OM-EN-06
Preface
This manual describes how to operate and maintain the Combilift - C-Series truck fitted
with a Deutz 2.9L stage IV/ tier 4 diesel engine - 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 cabin 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.
Warning
Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive
harm.
 Always start and operate the engine in a well-ventilated area.

 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
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Contents
Contents
Section 1: Safety Information ....................................................................... 4
1.1 Safety Statements ........................................................................................... 4
1.2 Operator Safety .............................................................................................. 4
1.3 Safety Decals ................................................................................................. 5
1.4 Safety Devices ............................................................................................... 6
1.5 Warning Devices ............................................................................................ 7
1.6 Operator Qualification and Responsibilities .................................................. 8
1.7 Work Place Operating Conditions ................................................................. 9
1.8 Decommissioning Recycling and Disposal ................................................. 14
1.9 Exhaust Filter Cleaning................................................................................ 14
Section 2: Basic Information .......................................................................15

2.1 Intended Use ................................................................................................ 15
2.2 General ......................................................................................................... 16
2.3 Vehicle Description ..................................................................................... 16
2.4 Principle of Operation .................................................................................. 17
2.5 Serial Number and Serial Plate .................................................................... 18
2.6 Rated Capacity, Centre of Gravity and Stability ......................................... 19
2.7 Load Centre & Load Chart .......................................................................... 22
2.8 Attachments ................................................................................................. 23
2.9 Tilting........................................................................................................... 24
Section 3: Components & Controls ............................................................25

3.1 Machine Overview and Components ........................................................... 25
3.2 Cabin/Dash Components & Controls........................................................... 26
3.3 Hydraulic Lever Operation .......................................................................... 33
3.4 Hydraulic Joystick Operation (If Fitted) ...................................................... 35
Section 4: Operation Monitoring .................................................................36

4.1 Display Console Buttons.............................................................................. 36
4.2 Display Home Screen .................................................................................. 37
4.2.1. Home Screen Instruments and Icons.................................................... 37
4.2.2. Pop Up Icons ........................................................................................ 44
4.3 Optional Dash Indicator Lights .................................................................... 45
Section 5: Operation ....................................................................................46

5.1 Pre-Use Checks ............................................................................................ 46
5.2 Fuel Handling & Storage ............................................................................. 51
5.3 Checking Engine Oil Level .......................................................................... 52
5.4 Exhaust Filter Cleaning................................................................................ 53
5.5 Checking Coolant Level .............................................................................. 56
5.6 Checking Hydraulic Oil Level ..................................................................... 58
5.7 Front Wheel Alignment ............................................................................... 59
5.8 Entering and Exiting the Operator Cabin..................................................... 59
5.9 Starting the Engine ....................................................................................... 60
5.10 Switching Off the Engine............................................................................. 61
5.11 Moving Off .................................................................................................. 62
5.12 Turning......................................................................................................... 63
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Contents
5.13 Stopping ....................................................................................................... 63

5.14 Changing Direction ...................................................................................... 64
5.15 Parking ......................................................................................................... 65
5.16 Loading & Unloading the Truck .................................................................. 66
5.17 Adjusting the Load Forks............................................................................. 71
5.18 Travelling Safely with a Load...................................................................... 72
5.19 Driving on Slopes ........................................................................................ 73
5.20 Towing ......................................................................................................... 75
5.20.1 Hydrostatic Drive Bypass Function ..................................................... 75
5.20.2 Mechanical Release of Park Brake ...................................................... 76
Section 6: Maintenance ...............................................................................77

6.1 Basic Safety Instructions for Servicing and Inspection ............................... 77
6.2 First Inspection After 100 Operating Hours ................................................ 80
6.3 Maintenance Schedule ................................................................................. 81
6.4 Wheel Nut Torque........................................................................................ 82
6.5 Engine Oil System ....................................................................................... 82
6.6 Diesel Fuel System ...................................................................................... 85
6.7 Engine Cooling System................................................................................ 88
6.8 Belt Drive System ........................................................................................ 91
6.9 Air Filter System .......................................................................................... 92
6.10 Battery Maintenance .................................................................................... 94
6.11 Hydraulic Oil System................................................................................... 98
6.12 Mast Maintenance ...................................................................................... 103
6.13 Cleaning & Greasing Mast Carriage .......................................................... 109
6.14 Mast Carriage Alignment / Wear Pad Adjustment Procedure ................... 109
6.15 Fork Maintenance ...................................................................................... 111
6.16 Air Conditioning (AC) System Maintenance (If Fitted) ............................ 112
6.17 Grease Point Chart ..................................................................................... 113
Section 7: Technical...................................................................................114
7.1 Checking the Charge Pressure ................................................................... 114
7.2 Valve Chest Pressure Settings ................................................................... 116
7.3 Steering & Hydraulic Functions Circuit .................................................... 118
7.4 Hydraulic Drive Circuit ............................................................................. 119
7.5 Fuses .......................................................................................................... 120
7.6 Relays ......................................................................................................... 122
Section 8: Appendices ...............................................................................123

8.1 Warranty Registration ................................................................................ 123
8.2 Operator’s Pre-Use Check Sheet ............................................................... 125
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Safety Information
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.
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.
1.2 Operator Safety

Before commencing use of the Combilift forklift operators must become familiar with
its capabilities and thoroughly read and understand the material contained in this
Manual along with 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
forklift in a safe and efficient manner.
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Safety Information
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 Warning
Personal injury hazard. Crushing hazard from moving

Always wear the seat belt parts. Stop the truck and
while sitting in the truck. isolate the battery before
Part No. CPD00009
approaching.
Part No. CPD00006
Warning Warning
Read the operators manual Personal injury hazard. Do

before operating or working not stand on the forks.
with the truck. Part No. CPD00003
Part No. CPD00009
Warning Warning
Shearing hazard from rotating Personal injury hazard. Do

fan. Stop the engine before not stand under the forks.
approaching. Part No. CPD00003
Part No. CPD00004
Warning
Scalding hazard. Only remove

the cap from the radiator
when cool.
Part No. CPD00005
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Safety Information
1.4 Safety Devices
The following safety devices are fitted to the truck as standard:
Overhead Guard/Cabin
 Replace the Overhead Guard/Cabin in any of the following instances:
 If it has permanently deflected.
 If a member is deformed.
 If it has become corroded.
 If it has been modified.
 If the mounting structure, base, or mounting hardware is damaged.
 Do not attempt to repair, straighten or reuse a damaged Overhead
Guard/Cabin
Warning
Never use the truck without the Overhead Guard/Cabin properly installed.
Do NOT drill, weld, straighten or bend the Overhead Guard/Cabin.
Allow only trained authorised personnel to install a new Overhead
Guard/Cabin.
Seat Belt
 Adjust the seat belt to contact the body firmly when fastened.
 Inspect the seat belt webbing for damage and replace if necessary.
 Test the buckle and retractor and repair or replace if necessary.
Seat Belt Switch (If Fitted)

 The truck will not drive unless the seat belt is buckled. When the belt is
unbuckled the drive is disabled.
Seat Switch
 The truck will not operate unless the seat is occupied. When the seat is
unoccupied the drive is disabled and the hydraulic function levers are locked
(the hydraulic joystick – if fitted – is blocked)..
Battery Isolator Key Switch

 The battery isolator key switch allows the battery to be disconnected from the
electrical system.
Note
The control unit remains active for up to 50 seconds after switching off the
engine to save the system data (lag) and then switches off automatically.
For this reason, the power supply to the engine must not be suddenly
interrupted by the isolator.
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Safety Information
The following safety devices may be fitted as optional extras:

Mast Up Drive Cut-out (If Fitted)
 When the mast is raised above a predetermined height the drive is disabled.
 To enable the drive, lower the mast below the drive cut-out height or press the
drive cut-out override button.
Mast Lift Cut-out (If Fitted)
 When the mast is raised to a predetermined height it will stop automatically.
 To continue raising the mast press the lift cut-out override button.
Mast Not Fully Retracted Drive Cut-out (If Fitted)

 The drive is disabled if the mast is not fully retracted.
 To enable the drive retract the mast fully.
Caution
The warning and 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 Ltd will not assume liability for injuries or damages arising from or
caused by the removal or bypassing of any the trucks safety or warning
devices.
1.5 Warning Devices
The following warning devices are fitted to the truck as standard:
Horn
 The horn is activated by pressing in the horn push button.
 Sound the horn at intersections.
 Stop and look for pedestrians or other traffic and proceed with caution.
Reversing Alarm
 The reversing alarm is activated when the engine is running and reverse drive
is selected.
 The reversing alarm may be wired as a motion alarm if required, in this
instance the alarm is activated in more than one direction.
Flashing Beacon
 The flashing beacon is activated when the key switch is turned to the ON
position.
The following optional warning devices may be fitted to the truck if required:
Blue Safety Lights (if fitted)

 Blue safety lights may be fitted that activate when a direction of travel is
selected.
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Safety Information
1.6 Operator Qualification and Responsibilities

 The operator of the Combilift must be qualified to operate the truck through
successful completion of a training program delivered by Combilift Driver
training personnel or a Combilift authorised training organisation.
 Operators shall be aware of all local authority regulations and laws regarding
the qualification of material handling equipment operators.
 No one shall operate the truck if impaired due to intoxication or drug reaction.
 Always ensure that the truck is in good working order before commencing work.
This is achieved by performing the pre-use inspection. The inspection is to be
carried out at the beginning of the working day or at the start of each shift.
 It is the operators responsibility to perform the pre-use inspection before each
shift. The Inspection and how it should be conducted is covered later in this
publication.
 Operation of the truck controls is only permitted when the operator is sitting on
the operators seat in the cabin with the seatbelt buckled and the cabin door
closed and latched securely.
 Never place any part of the body outside the confines of the cabin when
operating the truck.
 Diagnosis and repair of the truck shall be performed by trained competent
technicians unimpaired by intoxication or drug reaction.
 Unless authorised and trained to do so, the operator must not attempt any
repairs, but report defects immediately. When authorised to perform
maintenance work and/or repairs, ALWAYS ensure that the appropriate Health
and Safety regulations are strictly adhered to.
 Report any operational problems that may develop, (damaged pallets, ground
surface breaking up etc.) which could not only reduce safety but also cause
damage to the truck.
 Never attempt to exceed your truck’s handling capacity and take all precautions
to ensure the safety of others as well as yourself. In no circumstances should
counterweights be added to increase capacity.
 Stop working and switch off if for any reason, the truck becomes unsafe or
defective. Remove the key and place an ‘out of order’ sign in a prominent place
on the truck.
 Prohibit unauthorised and untrained people from accessing the starting key
and operating of the truck.
 The operator is responsible for visually monitoring the work area of the truck
and preventing anyone from entering the area without permission. If a person
enters the area while the truck is in operation, the operator shall stop the truck
and instruct the person to leave the work area until the truck has been
stopped. The person may then approach the machine in full view of the
operator.
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Safety Information
 Personnel being trained, educated, instructed or participating in a general

training program may only work on or with the machine under constant
supervision of an experienced supervisor.
 Work on the machine‘s electrical equipment may only be carried out by an
electrician or by trained persons under the direction and supervision of an
electrician.
 Work on the chassis, brakes and steering system may only be performed by
trained, specialised personnel.
 Only trained, specialised personnel with specific knowledge of and experience
in hydraulics may work on hydraulic units.
 If the mast mechanism malfunctions or becomes stuck in a raised position,
operate the mast control lever to eliminate any slack in the chains. DO NOT
go under the elevated parts of the truck to attempt to carry out repairs.
Warning
Every forklift operator must be trained in accordance with the rules provided
by the relevant local Health and Safety Authority (HSA).
Employers must ensure that each powered industrial truck operator is
competent to operate a powered industrial truck safely, as demonstrated by
the successful completion of the relevant training as specified by the
relevant local authority. Operating a powered industrial truck without the
proper training can cause serious injury or death.
1.7 Work Place Operating Conditions
Warning
Workplace situations are constantly changing. Check the work area before
beginning each shift. If in doubt, consult with the relevant supervisor.
Failure to observe new workplace conditions can lead to serious injury or
death.
Operators must be aware of special situations in their workplace in order to avoid

forklift accidents. Even if an operator works in the same area every day, there could
be changes that affect safety, such as:
 Contractors doing maintenance

 Wet areas
 Overhead repair work
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Safety Information
Be on the lookout for anything that might present a hazard such as:
 Potholes
 Pedestrian traffic
 Very narrow aisle ways
 Overhead obstructions
 Poor lighting making it hard to see hazards
 Wet, oily, or rough terrain
 Other equipment or vehicles operating in the area
Remember: Do not block any of the following safety critical items/areas with the
truck or the materials being handled:
 Electrical panels
 Fire exits
 Emergency stop buttons
 Aisle ways
 Fire extinguishers/hoses
Ground Surface:
Floor, road and yard 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 the impact on
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.
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Safety Information
Power Lines:
Warning
Always be aware of overhead electrical power cables. Always remain a safe
distance from overhead power lines as an electric arc can occur even when
approaching an electric line. This poses a high risk, not only for the
operator but for other personnel nearby.
If contact with a live electric source occurs:
 Do not leave the truck until the electricity has been disconnected and a
qualified technician directs the operator to leave the machine.
 If possible, drive the truck away from the danger area.
 Warn any people around the truck not to get any closer and not to touch the
truck.
 Arrange to have the power turned off.
The following table outlines the minimum clearance distance that must be observed
when working in the vicinity of power lines.
Nominal Voltage Clearance Distance

Up to 1000 V 1 metre (1.1 yards)
Over 1 kV up to 110 kV 3 metres (3.3 yards)
Unknown nominal voltage 5 metres (5.5 yards)
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.
Sparks from the exhaust or electrical system or hot parts can ignite explosions and
fires.
 Do not attempt to lift or place a load in a poorly lit area where vision is obscured
or reduced.
 Do not work in enclosed spaces where flammable materials, explosive vapours,
or combustible dust are found.
 Stay clear of flammable materials such as hay, straw, paper and cardboard.
 Park the truck only in areas free of flammable materials.
 Diesel engine exhaust emissions are toxic in concentrated amounts. Do not
operate the truck in enclosed spaces or inadequately ventilated spaces.
 Wear appropriate personal protective equipment (breathing filter, protective
suit) for protection against specific dangers, e.g. poisonous gases, corrosive
steam, poisonous surroundings, etc.
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Safety Information
Gradients:
When differences in levels exist, low gradient ramps should be provided, having
smooth, gradual level changes at the 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 – covered in section 5.19 on page 73 - should be followed at all
times. Do not park on a gradient. In an emergency apply the park brake and chock the
wheels, but do not leave the truck unattended.
Adverse Weather Conditions:

There are a number of weather conditions for which extra care must be taken.
 High Winds: Do not raise the mast 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: These forklift trucks are designed for use in ambient
temperatures ranging from -40°C (-40°F) to +40°C (+104°F) if the correct
hydraulic oils and greases are used. If the temperature falls below or rises
above this range discontinue operation of the machine in order to prevent
damage to various components. For operation outside these temperatures,
please consult your Combilift partner as special modifications and lubricants
are required.
Oil, Fuel and Coolant:
Any leaking or spilled oil, fuel or coolant must be cleaned up immediately and the
source of the leak repaired to avoid:
 Environmental hazards
 Fire hazards
 Slip hazards
 Personal injury hazards
Do not attempt to perform repairs to the hydraulic system until any residual hydraulic
pressure has been relieved.
Observe the valid safety and environmental regulations for the respective product
when handling oil, grease and other chemical substances. Do not service the truck
immediately after operation. Wait until hot surfaces have cooled and can be touched
comfortably. Smoking and open flames are prohibited during fuelling.
Noise/Hearing Protection:
Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect
against objectionable or uncomfortably loud noises.
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Safety Information
Exhaust Emissions:
Never allow the truck to remain stationary in confined spaces with the engine
running. Diesel engine exhaust fumes are harmful. Do not inhale exhaust. When
performing service and inspection work in an enclosed space, vent the exhaust out
of the area.
Warning
Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive
harm.
 Always start and operate the engine in a well-ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
Dock Boards (Bridge Plates)

Dock boards are designed and maintained so that one end contacts the dock (or
loading platform) and the other end contacts the transport vessel. When you load or
unload the transport vessel the dock board must be locked in place to prevent it from
rocking or sliding. Dock boards must have a high friction surface designed to reduce
the possibility of people or trucks slipping.
If using dock boards on loading docks:

 Never exceed the carrying capacity marked on portable or powered dock
boards.
 Portable dock boards must be secured in position, using anchors or other
devices that prevent slipping.
Trailers and Rail Cars

1. Before you load or unload a trailer, or rail car, make sure it does not move
unintentionally:
 Set the brakes
 Chock the wheels
2. In addition to setting the brakes and chocking the wheels, if a semi-trailer is
not coupled to a tractor, make sure that all four corners are supported to
prevent upending or corner dipping.
3. Maintain a safe distance from the edge of ramps, platforms, or other similar
working surfaces.
4. Never attempt to move a trailer with the Combilift truck.
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Safety Information
1.8 Exhaust Filter Cleaning

During auto or manual/stationary exhaust filter cleaning operations, the engine will
run at elevated idle and hot temperatures for an extended period of time. Exhaust
gases and exhaust filter components reach temperatures hot enough to burn people,
or ignite, or melt common materials. Avoid exposure and skin contact with hot
exhaust gases and components.
1.9 Decommissioning Recycling and Disposal

Safety and environmental stewardship measures must be taken into account when
decommissioning a machine and/or component. These measures include the
following:
 Use appropriate tools and personal protective equipment such as clothing,
gloves, face shields or glasses, during the removal or handling of objects and
materials.
 Follow instructions for specialised components.
 Release stored energy by lowering suspended machine elements,
disconnecting the battery, and releasing pressure in hydraulic components,
accumulators, and other similar systems.
 Minimize exposure to components which may have residue from chemicals.
Handle and dispose of these components appropriately.
 Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs,
and lines before recycling components. Use leak-proof containers when
draining fluids. Do not use food or beverage containers.
 Do not pour waste fluids onto the ground, down a drain, or into any water
source.
 Observe all national, state, and local laws and regulations governing the
handling or disposal of waste fluids (example: oil, fuel, coolant); filters; batteries;
and, other substances or parts.
 Burning of flammable fluids or components in other than specially designed
incinerators may be prohibited by law and could result in exposure to harmful
fumes or ashes.
 Service and dispose of air conditioning systems appropriately. Government
regulations may require a certified service centre to recover and recycle air
 conditioning refrigerants which could damage the atmosphere if allowed to
escape.
 Evaluate recycling options for tyres, metal, plastic, glass, rubber, and electronic
components which may be recyclable, in part or completely.
 Contact your local recycling centre for information on the appropriate way to
recycle or dispose of waste.
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Basic Information
Section 2: Basic Information

2.1 Intended Use
Warning
Unintended use can endanger the lives of operating personnel or other
persons in the vicinity of the truck.
Unintended use can cause extensive damage to the truck and/or to property
or materials being handled.
Operation by inexperienced persons, or in an unintended manner, can result in

hazards that can lead to personal risk and subsequent harm to the operator and
persons in the operating area of the truck. Improper use can damage the truck as
well as the product being handled and property in the vicinity of operation.
Read and understand the operating instructions in this Manual before operating the
truck. Before performing production work, the operator should find a remote, open
site to become familiar with the controls and trucks response. The truck must be in
serviceable condition before attempting to use it as described in the operating
instructions. If it is determined that the truck is not in a fit condition for operating,
notify the site or machine supervisor to have it repaired before use.
The Combilift forklift has been designed to lift loads, transport them and place them
in another location, taking into account the safety instructions listed in this manual
and any other local laws and regulations where applicable. One work cycle consists
of lifting, transporting and placing a load. Similar uses of the truck with alternative
attachments which do not change the safety requirements for the truck but modify
the way in which it is used are only acceptable when attachments that have been
approved by Combilift are used. The intended operation is described in this Manual.
The instructions describe how to operate, inspect and maintain the truck.
The truck must not be used for any of the following activities:
 lifting people without an approved work platform securely fitted
 transporting people
 pushing or pulling loads
The truck must not be used if:

 it has received unauthorised repairs
 it has received unauthorised modifications
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Basic Information
2.2 General
This truck is designed for use in ambient temperatures ranging from -40°C (-40°F) to
+40°C (+104°F) if the correct hydraulic oils and greases are used. For operation
outside these temperatures, please consult the manufacturer as special modifications
and lubricants are required.
Standard trucks must not be operated in flammable areas, corrosive atmospheres, or

in areas containing a high degree of dust contamination. Only trucks specifically
designed or modified to suit these conditions can enter such areas.
The safe maximum load capacities of the truck with relation to the load centre and fork
height, which MUST NOT BE EXCEEDED, are stated on the capacity plate.
The truck must be operated strictly in accordance with the operating instructions
provided in this manual in conjunction with the safety regulations of the country in
which the forklift truck is being operated.
2.3 Vehicle Description

The Combilift is a multifunctional, multidirectional forklift with four directions of travel
– Forward, Reverse, Left & Right. In order for these travel directions to be possible
the Combilift has 2 modes of travel, standard mode and sideward mode.
Standard Mode – In Standard Mode all wheels

are aligned parallel to the forks. In this mode the
rear wheel steers the truck. It is in this mode that
forward travel and reverse travel can take place.
Forward Travel is traveling with the forks
leading. Reverse Travel is traveling with the
forks trailing.
Forward Travel Reverse Travel
Sideward Mode – In sideward mode all wheels

are aligned perpendicular to the forks. Steering
is accomplished by the two front wheels. In this
mode Left Travel and Right Travel can take
place. Left Travel refers to travel with the
operators compartment leading. Right Travel
refers to travel with operators compartment Right Travel Left Travel
trailing.
Having the ability to drive forward, back, left and right makes the Combilift truck
capable of performing like a standard counterbalance forklift truck, a reach truck and
a side loading truck. Thus it is ideal for handling palletised loads and also long loads
such as pipes or timber.
The principle of this type of truck is that the weight of the load, which is lifted on the
forks in front of the load wheels, is offset by the combined weight of the truck chassis
and components.
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Basic Information
The mast can be moved in and out so that a palletised or long load can be lifted and
moved back within the wheelbase of the truck. This makes the Combilift truck more
stable when travelling with a load and also allows it to work in confined areas such
as narrow aisles.
2.4 Principle of Operation

Drive is achieved by means of a hydrostatic drive pump coupled to an internal
combustion (IC) engine. The drive pump pumps hydraulic oil through hydraulic hoses
to wheels motors on which each of the three wheels are mounted. The wheel motors
turn the wheels to drive the truck. The speed of the drive is controlled by a throttle
pedal located in the operating enclosure.
Steering is achieved by means of a hydraulic gear pump coupled to an internal

combustion (IC) engine. The gear pump pumps hydraulic oil through a steering
orbital unit. When the steering wheel is turned pressurised oil is fed via the steering
orbital to hydraulic steering cylinders to steer the truck. Hydraulic valves in the
steering system allow the wheels to be aligned parallel to the truck or perpendicular
to the truck as desired.
Lift, reach and tilt along with other optional auxiliary mast functions are achieved by
means of a hydraulic gear pump coupled to an internal combustion (IC) engine. The
gear pump pumps hydraulic oil through a block of valves. The valves can be
operated by levers (or a joystick if fitted) to direct the pressurised oil to hydraulic
cylinders to operate each of the mast functions. The operating speed of the mast
functions may be controlled by a throttle pedal located in the operating enclosure.
Forward, reverse, left or right travel may be selected by a direction control lever
mounted inside the operating enclosure. Selecting a direction of travel sends
electrical signals to a set of solenoid actuated hydraulic valves. The steering valves
direct the flow of hydraulic oil in the steering circuit to the steering cylinders to steer
the wheels to the appropriate position to achieve the desired direction of travel. The
direction control valve directs the flow of oil in the drive circuit to achieve the desired
direction of travel.
The truck is equipped with digital display console that display information regarding
the trucks operating condition such as the engine coolant temperature, the engine oil
pressure, low fuel, steering mode etc.
A brake/inch pedal slows the truck down when partially pressed and brings the truck
to a complete stop when fully pressed and held down. The park brake is applied by a
push button located to the right of the operator.
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Basic Information
2.5 Serial Number and Serial Plate

The truck serial number is stamped on the chassis on the cross member as indicated
in figure 2.5 below and the serial plate is affixed inside the cabin as indicated.
Serial Number
e.g. 23456
a
b
c
d
e
f
Figure 2.5
The Serial Plate is engraved with the following details:
a. Model: The model type of the truck is engraved in this box.

b. Serial No: The trucks serial number is engraved in this box.
c. Rated Capacity: The trucks maximum rated capacity in kilograms (kg)
or pounds (lbs) is engraved in this box and is given for the load centre
engraved in the following box.
d. Load Centre: The distance from the front face of the forks to the centre
of gravity of the load for which the maximum rated capacity is given is
engraved in this box.
e. Unladen Weight: The weight of the truck only is engraved in this box
f. Manufactured On: The date the truck was manufactured on is
engraved in this box
g. The manufacturers name, address and contact details are
displayed on the bottom of serial plate
The serial plate must not be removed. If lost order a replacement from Combilift
immediately.
Note
Ensure that the serial number on the chassis corresponds with the serial
number on the serial plate before putting the truck into operation.
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Basic Information
2.6 Rated Capacity, Centre of Gravity and Stability
The rated capacity is the maximum weight that a truck is designed to lift at a
specified load height to a specific load centre distance under safe operating
conditions. To understand the rated capacity it is necessary to be familiar with the
term centre of gravity.
The centre of gravity is an imaginary point in a body where the

total weight of the body may be considered to be concentrated.
Every object has a centre of gravity. When a load is supported
on the forks the truck and load may be considered as a single
entity with a 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 back and forth. The centre of gravity also moves up and down as the mast is
raised and lowered.
The position of the combined centre of gravity is affected by the size, weight, shape
and position of the load; the height to which the forks are raised; the position of the
reach; the tilt angle and side shift position.
To understand the stability of the truck it is useful to use the analogy of a see saw
where two objects are placed on opposite sides of a beam and the beam is
supported at a single point halfway along its length. For the see saw to balance, the
two objects must be equal in mass and placed at an equal and opposite distance
from the support point, also known as the fulcrum. If the mass on one side is
increased the see saw will tip to the side of the heavier mass. This can be corrected
by moving the heavier mass in towards the centre or fulcrum. This principle is the
most important factor that must be taken into account when considering the
stability of the truck.
If we look at the diagram below what this translates to is that as long as F1 is equal
to F2 then the system will balance.
D1
D2
M2
M1
F2 = M2xD2
M1 = M2 Fulcrum
D1 = D2 F1 = M1xD1
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Basic Information
The very same principle applies to the Combilift truck where the front wheels act as
the fulcrum, M1 represents the mass of the trucks heavy chassis and components on
one side of the fulcrum and D1 represents the distance from the fulcrum to the
centre of gravity of the truck. M2 represents the mass of the load on the forks on the
opposite side of the fulcrum and D2 represents the distance from the fulcrum to the
centre of gravity of the load. In the case of the truck F2 must always be less than F1
otherwise the truck will become unstable.
Combilift & Load

Combined
Centre of Gravity
Load
Centre of Gravity
Fulcrum Combilift
Centre of Gravity
D2 D1
F2 = M2xD2 M2 M1 F1 = M1xD1
If the mass of the load (M2) is increased or the distance from the fulcrum to the
centre of gravity of the load (D2) is increased such that F1 becomes greater than F2
then the truck will tip forward about the fulcrum.
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Basic Information
For the truck to remain stable both laterally and longitudinally, the combined centre of
gravity of the truck and the load must stay within an area known as the stability triangle.
To visualise the stability triangle, imagine three lines connecting each of the trucks
three wheels. The area inside these three lines forms the stability triangle. If the
combined centre of gravity moves outside the boundary of the stability triangle the
truck will tip over.
The diagram below illustrates the truck with the stability triangle represented by the
hatched area and a uniform load weighing less than the maximum rated capacity
resting on the forks. In this case the combined centre of gravity lies inside the boundary
of the stability triangle, therefore the truck and load will remain stable.
Truck and Load combined

Centre of Gravity
Truck Centre
Of Gravity
Load
Centre of
Gravity
If a balanced uniform load greater than the maximum rated capacity is lifted on the
forks the combined centre of gravity will move outside the front boundary of the stability
triangle. In this case the truck and load will be unstable and a frontal tip-over is likely
to occur.
If an unbalanced load is lifted on the forks such that the combined centre of gravity
moves outside the left or right boundary of the stability triangle, the truck and load will
be unstable and a tip-over to the left or right hand side is likely to occur.
Other factors that influence the stability of the truck to a lesser degree include
sudden acceleration, harsh braking, driving on sloped or uneven terrain, or turning
with elevated loads. Any of these factors alone or in combination can result in the
combined centre of gravity moving outside the boundary of the stability triangle thus
causing the truck to tip over.
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Basic Information
2.7 Load Centre & Load Chart
Warning
The capacity rating of the truck decreases as the load centre of the load
increases and as the load is raised.
Refer to the rated capacity at various heights listed on the load chart.
Failure to heed these guidelines can cause damage to the truck and
property or lead to a tip over causing serious injury or death.
Warning
Make sure that the load is centred and the forks are fully engaged. Failure to
do so can cause the load to fall or the truck to tip over, resulting in serious
injury or death.
The term “Load Centre” is used to describe the distance from the face of the forks to
the Centre of Gravity of the load when the forks are fully engaged with the load. The
maximum rated capacity of the Combilift is based on a load in the form of a cube
measuring 1200mm (48”) in length, depth and height where the centre of gravity lies
exactly in the centre of the cube i.e. 600mm (24″) from all sides.
If the size or shape of the load changes such that the position of its centre of gravity
moves away from the forks the truck will have less capacity to lift the load.
Raising a load also causes the truck to loose capacity due to mast tilt and deflection.
Therefore as the load centre and/or lift height increases the weight that can be safely
lifted reduces.
The trucks capacities at various heights and load centres are displayed on a load chart
located inside the operating enclosure. A sample load chart is shown below.
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Basic Information
To read the load chart the weight of the load (in kilograms or pounds) and the load
centre (in millimetres or inches) must be ascertained. These values can then be
compared to the values on the load chart to determine if it is safe to lift the load and to
what height it can be lifted.
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 on trucks the load chart.
Methods of determining the weight of the load:

 Weight is listed on pallet wrapper
 Weight is listed on bill of lading
 Weight is determined by multiplying the weight of each small container/bag by
the number of small containers/bags on a pallet. Each small container should
be marked with its weight.
 Ask your supervisor when in doubt.
Always make sure the load is flush against the front vertical face of the forks and that
loads that are unbalanced horizontally are loaded with the heaviest side of the load
nearest to the truck.
Always make sure that loads that are unbalanced vertically are loaded with the
heaviest side of the load nearest to the ground where possible.
2.8 Attachments
Warning
Never make any modifications to the truck that may affect the capacity
rating. Only options and attachments approved by Combilift Ltd. may be
installed on the truck. Other modifications will void the warranty and can
cause situations to arise that may lead to serious injury or death.
Fixed attachments to the forks or fork carriage affect the trucks capacity rating.
When the factory, dealer, or distributor installs a fixed attachment approved by
Combilift a modified load chart shall be attached inside the cabin of the truck. The
modified load chart identifies the type of attachment and the capacity ratings on the
load chart will be modified accordingly.
Removable attachments to the forks or fork carriage affect the trucks capacity
rating. When the factory, dealer, or distributor supplies a removable attachment
approved by Combilift an additional load chart shall be attached inside the cabin of
the truck. The additional load chart identifies the type of attachment and the changes
to the rated capacity when the attachment is in use.
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Basic Information
2.9 Tilting
Warning
DO NOT tilt the forks forward past horizontal with a load on the forks.
Use tilt with caution when the mast is in a raised position.
DO NOT use forward and backward tilt in quick succession.
The degree of forward and backward tilt that may be used is governed by the
application.
Tilting Guidelines
 When travelling with the truck loaded tilt the mast back and keep the load low.
This will help stabilize loads with an uneven weight distribution.
 When loading at high elevations, only tilt the load back far enough to seat it
against the front vertical face of the forks.
 When unloading at high elevations, make sure to only use enough tilt to level
the load for placing onto the rack or stack.
 Forward tilt past horizontal is only provided to assist the operator in withdrawing
the forks from a load after the load has been placed.
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Components & Controls
Section 3: Components & Controls

All operators must be familiar with the Combilift trucks main components and controls,
their function and where they are located before commencing operation of the truck.
The major components are labelled in figure 3.1 below.
3.1 Machine Overview and Components
Components
1. Operator Cabin
2. Mast
3. Forks
4. Front Left Hand Swivel
5. Front Right Hand Swivel
6. Rear Swivel
7. Diesel Tank
8. Diesel Tank Cap
9. Platforms
10. Exhaust
11. Air Filter Access Panel
12. Hydraulic Tank
13. Hydraulic Oil Level Gauge
14. Battery Isolator Key Switch
15. Cabin Access Handle
16. Window Wiper
17. Work Lights
18. Flashing Beacon
19. Side Access Panel
20. Cabin Access Step
21. Bonnet
Figure 3.1 Machine Components Layout
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3.2 Cabin/Dash Components & Controls
All controls and user adjustable components located inside the cabin of the Combilift
truck are labelled in figure 3.2 below.
Controls List
1. Steering Wheel
2. Adjustable Air Vent
3. Adjustable Steering Column
4. Accelerator Pedal
5. Brake/Inch Pedal
6. Operator Seat
7. Wiper Switches
8. Cabin Interior Light
9. Operator Cooling Fan
10. Lift Control Lever
11. Reach Control Lever
12. Tilt Control Lever
13. Aux Lever – e.g. Fork Positioning
14. Aux Lever – e.g. Side Shift
15. Ignition Key Switch
16. 4-Way Direction Lever
17. Horn Button
18. Park Brake Switch
19. Arm Rest
20. Fuse Box
21. Cup Holder
22. Engine Diagnostics Plug
2
1 0
23. Programming Port
3
24. Optional USB 12V Port

25. Optional Extra Switch Location
26. Optional Extra Push Button
27. Heater Fan Switch (If Fitted)
28. Optional Extra Push Button
29. Cooling Fan Switch
30. 90° Light (If Fitted)
31. Display Console
32. Work Lights Button
33. Cabin Access Handle
Figure 3.2 Machine Controls Layout
Note
The layout of the controls displayed above applies only to a standard truck.
The actual layout may vary depending on individual customer requirements.
Refer to the decals in the cabin of the individual truck if the layout is not
standard.
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Steering Wheel / Column

 The Combilift truck has both front and rear-end steering.
 When in standard mode the front wheels are fixed and the rear wheel steers
the truck.
 When in sideward mode, the rear wheel is fixed and the front wheels steer the
truck.
 The steering wheel is equipped with a spinner knob for easier steering.
 The angle of the steering column is adjustable to increase driver comfort.
Steering In Standard (0°) Mode

 When the truck is in standard mode the front wheels are fixed and the rear wheel
steers the truck.
 When driving forwards, turn the steering wheel clockwise to turn the truck
clockwise, turn the steering wheel anti clockwise to turn the truck anticlockwise.
 When driving in reverse, turn the steering wheel clockwise to turn the truck
anticlockwise, turn the steering anticlockwise to turn the truck clockwise.
Steering In Sideward (90°) Mode

 When in sideward mode, the rear wheel is fixed and the front wheels steer the
truck.
 When driving in sideward mode, turn the steering wheel clockwise to turn the
truck clockwise. Turn the steering wheel anticlockwise to turn the truck
anticlockwise.
 The same holds true for either left or right travel in sideward mode.
Adjusting the Steering Column

 To adjust the angle of the steering column, loosen the angle adjustment handle
on the right hand side of the column by turning the handle anticlockwise.
 Adjust the steering column so that the wheel can be reached comfortably when
sitting in the seat with your back against the seat backrest. See the description
for the ‘Operators Seat’ on the following page.
 Lock the steering column in position by turning the handle clockwise until tight.
Steering Knob
Angle Adjustment
Handle
Warning
Do not adjust the angle of the steering column when the truck is in
operation.
Stop the truck and apply the park brake before adjusting.
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Accelerator Pedal
 The accelerator pedal is located on the cabin floor to
the right hand side of the steering column as shown
highlighted in green in the diagram opposite.
 The accelerator pedal allows the operator to control the
speed of the truck.
 To INCREASE truck speed PRESS down on the pedal.
Brake / Inch Pedal

 The Brake / Inch pedal is located on the cabin floor to
the left hand side of the steering column as shown
highlighted in red in the diagram opposite.
 The combined Brake/Inch Pedal has two functions:
 It stops the hydraulic drive to bring the truck to a
smooth controlled halt.
 It also permits slow drive speed, for precise
manoeuvring of the truck in confined spaces.
Operators Seat
A correctly functioning seat that has been adjusted to suit the individual operator of the
truck is essential to the health of the trucks operator.
In order to reduce the risk of personal injury, the seat must be adjusted for the individual
operator before use and before every change of operator. The optimum suspension
setting is achieved when the ride indicator at the front of the seat is in the green zone.
The seat has a switch in the base that senses when an operator is in the seat. If the
operators weight is removed from the seat the truck will stop automatically after a time
delay.
 It is the responsibility of the operator to ensure that the seat is adjusted

according to their height and posture so that the steering wheel, pedals and
levers can be comfortably reached while the operator has their back resting
against the seat backrest before commencing operation of the truck.
 The angle of the steering column can also be adjusted to achieve optimum
comfort. Adjust the steering column angle when adjusting the seat.
 DO NOT place or allow any objects to fall within the moving area of the seat.
 Check that all setting stops are correctly engaged before starting the truck.
 ALWAYS report any malfunction of the seat immediately.
 ALWAYS wear the seat belt provided.
 DO NOT adjust the seat when vehicle is in operation.
 Keep clear of moving parts.
 Only authorised & competent personnel should carry out installation &
maintenance of the seat.
 Loads – other than the operators weight – must not be placed on the seat as
the truck may start to move if the park brake is not applied.
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A. Upstop Adjustment
B. Height Adjustment
C. Ride Indicator
D. Backrest Angle Adjustment
E. Seat Belt
F. Horizontal Adjustment (Slide rails)
H. Backrest Extension
I. Lumbar Support Adjustment (5 positions)
Up-stop Adjustment (A):

The Upstop adjustment lever A allows the upward travel of the seat suspension to be
limited.
 Slide lever A fully to the right to allow maximum travel.
 Slide lever A fully to the left to limit the stroke to the minimum.
Height Adjustment (B):

Tip: Bring the backrest forward and slide the seat back fully before adjusting the height.
To adjust the seat height for any individual operator the operator must be sitting on the
seat.
Fold out the height adjustment handle B fully and hold the knob on the end of the
handle.
 Turn handle B clockwise to rise the height of the seat.
 Turn handle B anticlockwise to lower the height of the seat.
 When the height has been set fold handle B back in.
Ride Indicator (C):

When adjusting the height of the seat it is important to check the ride indicator. To
protect the operator from shocks and vibrations the yellow ride indicator C should be
in the green area when the operator is seated. The suspension automatically
compensates for the weight of the operator.
Backrest Angle Adjustment (D):

To set the angle of the backrest the operator must sit on the seat with their back
touching lightly against the backrest.
 Pull lever D up to release the backrest catch.
 Lean forward/back at the waist to move the backrest to the desired angle.
 Release lever D to lock the backrest in position.
 Lean back and forward on the seat to ensure it is locked in position.
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Seatbelt (E):
The truck will not operate unless the seatbelt tongue is properly fastened in the seatbelt
buckle. To fasten the seatbelt:
 Sit back in the operator seat.
 Pull the seatbelt out of its retractor and place it across the lap.
 The belt must not be twisted.
 Place the seatbelt tongue into the buckle.
 To release the seatbelt press the red button.
Warning
Not wearing the seatbelt or operating with a damaged seatbelt can result in
injury to the operator.
DO NOT operate the truck unless the seatbelt is fastened across the top of
the lap.
Note
If the truck has the seat belt switch option fitted the drive is disabled if the
seatbelt tongue is not properly fastened in the seatbelt buckle.
Horizontal Adjustment (F):

The seat can be moved forward or back as required by the operator. Only touch the
horizontal adjustment lever at the grip provided.
 Pull lever F up to release the horizontal adjustment catch.
 Slide the seat forward or back to the desired position.
 Release lever F to lock the seat in position.
 Push the seat forward and back to ensure it is locked in position.
Backrest Extension (H):

The backrest extension is not adjustable.
Lumbar Support Adjustment (I):

The lumbar support adjustment knob I allows the support on the lower backrest to be
adjust to suit the individual operator. There are five setting positions.
 Turn knob I clockwise to increase the lumbar support.
 Turn knob I anticlockwise to reduce the lumbar support.
Warning
Do not adjust the seat when the truck is in operation. Stop the truck and
apply the park brake before making any adjustments to the seat.
Keep clear of moving parts. Maintenance should be carried out by
competent authorised persons only.
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Wiper Switches
 There are 2 wiper switches on the machine; both are
located in the front of the cabin.
 One is in the top left hand corner.
 The other is in the top right hand corner.
 The wipers are activated by flipping each of the switches to
the ‘ON’ position.
Cabin Interior LED Light

 This light illuminates the interior of the cabin.
 Press on the small circular recess on the bottom face of the
light housing to illuminate the light.
 Press in the same place a second time to extinguish the
light.
Ignition Key Switch:

 This is a three-position key switch located on the left hand
side of the dash.
4-Way Direction Lever

 The 4-way direction control lever is the 5-position lever
located on the left hand side of 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
Note
The truck will NOT start unless the direction control lever is in the neutral
position.
Park Brake Switch

 The park brake switch is the red button located on dash to
the right hand side of the operators seat.
 To APPLY the park brake, press the button. The button will
lock in the pressed position and the park brake icon will
appear on the display screen to alert the operator that the
park brake is applied.
 To RELEASE the park brake, rotate the button clockwise. It
should pop up into its normal position
 The Machine will NOT drive with the park brake on.
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Work Lights Button

 The work lights are controlled by pressing the button on the display 0
console directly below the work light icon on the bottom of the screen.
 Press the button once to activate the forward and backward facing
work lights only. The number 1 appears beside the work light icon.
 Press the button a second time to activate the left and right facing B
 Press the button a third time to activate all the work lights. The
number 3 appears beside the work light icon.
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.
Mast Height Drive cut-out Override Button (If Fitted)

 The drive cut-out feature prevents the truck from driving if
the mast is raised above a set height.
 To re-commence driving the operator must either:
 Lower the forks below the set cut-out height using the
lift control lever.
OR
 Press the drive cut-out override button located on the
right hand side of the dash (if fitted).
Operator Cooling Fan Switch

 This is a 2 position rotary switch located on the right hand
side of the dash.
 Turning it to the on position activates the cooling fan located
in the top rear right hand side of the cabin.
Cabin Heating Switch (If Fitted)

 This is a two position rotary switch located on the right hand
side of the dash (if fitted).
 It is used in conjunction with the cabin air blower fan switch.
 Turn the switch to hot, to activate the cabin heating.
 Turn the switch to cold, to deactivate the cabin heating.
Cabin Air Blower Fan Switch (If Fitted)

 This is a four position rotary switch located on the right hand
side of the dash (if fitted).
 It is used to switch on the cab air blower fan and to select 1
low, 2 medium or 3 high fan speed.
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Battery Isolator Key Switch

 This switch is used to disconnect power from the
battery.
 The switch is located behind the side access panel on
the right hand side of the Combilift (See diagram
opposite).
 It can be accessed through the hole provided in the
panel.
 When the Combilift is not in use turn the switch to the
‘OFF’ position, by turning it ANTI-CLOCKWISE.
On Off
 The Combilift will not start unless the switch is returned
to the ‘ON’ position, by turning the switch CLOCKWISE
3.3 Hydraulic Lever Operation
Lift Control Lever (Lever Closest To Operator)

 The lift control lever controls the raising and lowering of the
forks.
 To raise the forks, PULL the lever BACK
 To lower the forks, PUSH the lever FORWARD
Reach Control Lever (2nd Lever from Operator)

 The reach control lever controls the forward and backward
movement of the mast carriage.
 To extend the mast carriage forward, PUSH the lever
FORWARD
 To retract the mast carriage backwards, PULL the lever
BACKWARDS
Mast Tilt Lever (3rd Lever from Operator)

 The mast tilt lever controls the adjustment of the mast tilt
angle.
 To tilt the mast forward, PUSH the lever FORWARD
 To tilt the mast backward, PULL the lever BACKWARDS
Optional Auxiliary Function Levers (4th / 5th Lever from Operator)

 Extra levers control auxiliary hydraulic functions.
 Trucks with more than one auxiliary function may have a
5th lever or a button may be fitted on the fourth lever.
 Operators must acquaint themselves with the operation of
any extra functions before using the truck.
 The most common auxiliary functions fitted to Combilift
trucks are:
 Fork Positioning  Telescopic forks

 Side shift  Lift Drop Forks
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Refer to the lever decal inside the trucks cabin for the operation of any auxiliary
functions that have been fitted.
Operators MUST take time to familiarise themselves with the auxiliary functions
on the Combilift and how they are operated.
Note
When the truck is in neutral pressing the accelerator pedal will increase
the working speed of the hydraulic functions.
Note
The layout of the valve chest levers and positioning of controls and
switches may be subject to change due to individual customer
requirements. Please refer to the decals on the individual truck.
Operators must acquaint themselves with the layout of all controls before
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3.4 Hydraulic Joystick Operation (If Fitted)
This is a four-way joystick with three push buttons on the handle. It is used to control
the mast functions.
Joystick Functions (Standard Setup)
Lift
 To raise the forks, pull the joystick back.
 To lower the forks, push the joystick forward.
Reach
 To extend the mast, push the joystick right.
 To retract the mast, pull the joystick left.
Tilt
 To tilt the mast forward, push the joystick right while pressing the left hand button
on the handle.
 To tilt the mast back, pull joystick left while pressing the left hand button on the
handle.
Auxiliary
 Auxiliary hydraulic functions are controlled by moving the joystick while pressing
the right hand button on the handle.
 The middle button on the joystick may also be used on trucks fitted with more
than one auxiliary function.
 The most common auxiliary functions fitted to Combilift trucks are:
 Fork Positioning  Telescopic forks

 Side shift  Lift Drop Forks
Refer to the joystick decal inside the trucks cabin for the operation of any
auxiliary functions that have been fitted.
Operators MUST Take time to familiarise themselves with the operation of
any auxiliary functions on the truck.
Note
When the truck is in neutral pressing the accelerator pedal will increase the
working speed of the hydraulic functions.
Note
The layout of the joystick functions and positioning of controls and
switches may be subject to change due to individual customer
requirements. Please refer to the decals on the individual truck.
Operators must acquaint themselves with the layout of all controls before
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Operation Monitoring
Section 4: Operation Monitoring

In order to show measured values, indicators, warnings and messages, a digital
display console is provided which has been integrated into the dashboard.
4.1 Display Console Buttons
A B C D
ok
E F G
A. Home Screen/Previous Screen

B. Work Lights On/Off
C. Hydraulic Functions Lock/Unlock
D. Options Menu/Next Screen
E. Not Used
F. Options Menu Navigation
G. Options Menu Selection Confirmation
When the key switch is turned to the ‘ON’ position the display console screen powers
up and displays the daily pre-shift inspection screen illustrated below.
This screen is displayed in order to ensure that operators remember to perform the
pre-use checks before commencing operation of the truck. The pre-use checks are
described in section 5.1 Pre-Use Checks on page 46.
DAILY PRE-SHIFT INSPECTION

Are all safety and operational checks
performed
The screen above is displayed until button ‘D’ on the display console is pressed to
accept that the message on the screen has been acknowledged.
After button ‘D’ has been pressed, the home screen on the following page is displayed.
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4.2 Display Home Screen
The home screen conveys information regarding the trucks operating condition in the
form of graphical symbols. Press button ‘A’ at any time to return to the home screen.
Figure 4.2 below shows every instrument and icon that can possibly be displayed on
the home screen. Some of these instruments and icons are always visible while others
are only displayed under certain circumstances.
D E F G H I J K L M
AUX1 !
AUX2
A N AA W X B
0000.0 Hrs
C P O Q BB Z Y
Figure 4.2
V S R T U
4.2.1. Home Screen Instruments and Icons
A. Coolant Temperature Gauge

 This gauge monitors the temperature of the engine cooling system. It
should be watched closely during engine operation.
 As the engine coolant temperature increases the bars fill in solid white.
 The normal engine coolant operating temperature range is within the
Normal
Range {
upper three white bars on the gauge; 85–97°C (185–207°F).
 If the red bar at the top fills in solid the engine coolant temperature has
reached 100°C (212°F).
 At 100°C (212°F) the high temperature warning will pop up on the
screen. (See Pop Up Icons 4.2.2 on page 44).
 If operation is continued and the coolant temperature is allowed to
rise further - at a critical temperature above 100°C (212°F) - engine
performance may be automatically reduced to protect the engine
against the effects of overheating.
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B. Fuel Gauge
 This gauge displays how much diesel remains in the diesel tank.
 When the tank is full all bars are filled in solid white.
 As the fuel is consumed the bars turn black and only the outline
remains visible on the screen.
C. Hour Meter
 The hour meter displays the total number of hours the truck has
been operating for.
D. Left Indicator Icon (If Used)

 This icon is only used on trucks fitted with optional road lights.
 The left indicator icon is displayed when the left hand indicator light is
activated.
E. Auxiliary Hydraulic Function Icon

 The auxiliary hydraulic function icons illuminate to signal when one of
the optional auxiliary hydraulic functions has been selected. AUX1
 Optional auxiliary functions may be selected by various methods such AUX2
as pressing a button on a hydraulic joystick or lever or by pressing a
switch.
F. Glow Heater Icon

 The glow heater icon is displayed when the key switch is turned to
the on position and the engine is cold.
 Wait until the glow heater icon is no longer displayed before turning
the key to the start position.
G. Engine Warning Icon

 The engine warning icon lights up when a fault has been detected by
!
the ECU.
 If this icon is lit up while the engine is running, use the buttons on the
screen to navigate to the engine fault page.
 When the fault has been remedied press button D (ACK) to signal that the fault has
been acknowledged.
 The icon lights up amber if a minor fault is detected, and red if a more serious fault
that requires immediate attention is detected.
 Some serious faults cause the system to react by reducing the engine performance
to protect the engine.
 Depending on the fault, the engine power may be reduced to protect the engine.
 If a serious fault is detected the engine must be switched off immediately. If
the truck is in a danger zone or it is causing an obstruction or hazard it may be
driven a short distance to a safe area.
Note
In the event of a serious error being detected failure to switch off the engine
promptly will lead to a loss of guarantee.
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 The engine may shutdown automatically if necessary.

 There may be a start lock after the engine has stopped. The start lock is
deactivated by switching off the ignition key switch for approximately 30 seconds.
 Indicators such as the oil pressure icon or the coolant temperature icon may be
displayed on the screen if applicable.
 The ECU will store the information that will allow the error to be diagnosed when
the ECU is connected to a PC.
Note
Refer to the Deutz engine operating manual for further information on
engine faults.
H. Sidelights Icon (If Used)

 The sidelights icon is display when the sidelights are switched on.
I. Headlights Icon (If Used)

 The headlights icon is display when the headlights are switched on.
J. Engine Oil Pressure Icon

 When the key switch is in the ‘ON’ position, with the engine at rest,
the engine oil pressure icon is illuminated.
 If this icon is illuminated when the engine is ‘running’ it indicates low
engine oil pressure and/or insufficient oil in the sump.
 See 5.3 Checking Engine Oil Level on page 52.
Note
Do NOT run the engine if the oil pressure icon is illuminated. Check the oil
level on the dipstick. Check for oil leaks.
K. Battery Icon
 When the key switch is in the ‘ON’ position, with the engine at rest,
the battery icon is displayed.
 If the battery icon is displayed when the engine is ‘running’ it indicates
that the alternator is not providing enough voltage to power the
electrics and charge the battery.
L. Park Brake Icon

 The park brake icon is displayed when the park brake is applied.
M. Right Indicator Icon (If Used)

 This icon is only used on truck fitted with optional road lights.
 The right indicator icon is displayed when the right hand indicator light
is activated.
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N. Forward Drive Icon

 The forward drive icon changes colour from orange to green when
forward drive is selected with the 4-Way direction lever.
O. Reverse Drive Icon

 The reverse drive icon changes colour from orange to green when
reverse drive is selected with the 4-Way direction lever.
P. Left Drive Icon

 The left drive icon changes colour from orange to green when left
drive is selected with the 4-Way direction lever.
Q. Right Drive Icon

 The right drive icon changes colour from orange to green when right
drive is selected with the 4-Way direction lever.
Carousel Mode Icon

 The carousel mode icon can only be seen when left or right drive is
selected.
 When the front wheels are steered to a certain position, all four arrows
on the screen change from orange to green. It is at this point that
carousel mode is activated and the machine can turn on its own axis.
 To deactivate carousel mode steer the front wheels out of the
carousel position.
R. Seat Icon
 The seat icon is displayed when the operator is not sitting on the seat.
The truck will not operate if this icon is displayed.
S. Seat Belt icon (If used)

 The seat belt icon only applies on trucks fitted with an optional
seatbelt switch.
 The icon is displayed when the operator is sitting on the seat but does
not have the seat belt fastened.
 It appears in the same position on the screen as the seat icon.
 The truck will not operate if this icon is displayed.
T. Hydraulic Function Lock Icon

 The hydraulic function lock prevents the use of any of the mast
functions i.e. lift, tilt, reach etc.
 The lock the hydraulic functions press the button (C) below the icon.
 To unlock the hydraulic function press the button a second time.
U. Next Page Icon

 To skip to the next page of options on the screen press the button (D)
below the next page icon.
40
C4-C5MK4-OM-EN-06
V. Work Light Icon

 The work light icon is displayed along the bottom left hand side of the 0
screen.
 The work lights are controlled by pressing the console button (B)
directly below the work light icon.
 Press the button once to activate the forward and backward facing B
 Press the button a second time to activate the left and right facing
 Press the button a third time to activate all the work lights. The
number 3 appears beside the work light icon.
W. Exhaust Filter Icon *

* (only if optional diesel particle filter (DPF) is fitted)
 This icon is displayed when exhaust filter cleaning is in progress or

the after-treatment system has a fault, or the exhaust filter is in need
of cleaning and the operator has disabled auto exhaust filter cleaning.
 If conditions are safe, auto exhaust filter cleaning should be enabled.
(See 5.4 Exhaust Filter on page 53).
 When the exhaust filter indicator is combined with the warning
indicator, engine performance is reduced by the ECU because there
is an after-treatment system fault or the soot level of the exhaust filter !
is moderately high.
If conditions are safe, the operator should enable the auto exhaust
filter cleaning function. If conditions are not safe, the operator should
move the machine to a safe location and engage the auto exhaust
filter cleaning mode then activate the standstill exhaust filter cleaning
(See 5.4 Exhaust Filter on page 53).
 When the exhaust filter indicator is combined with the engine stop
indicator engine performance is further reduced by the ECU because
there is an after-treatment system fault or the soot level in the exhaust
filter is extremely high. If this combination is present, contact your
local Combilift partner.
Note
Very short intervals between two exhaust filter faults (<10h) can be an
indication of an engine fault. Contact your local Combilift partner.
Caution
Temperatures of approx. 600 °C occur on the exhaust pipe during exhaust
filter cleaning. Danger of burns!
A special engine operating state becomes active during standstill exhaust
filter cleaning and the machine must not be used.
Only activate standstill exhaust filter cleaning when the truck is parked in a
clear open area free of combustible materials.
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X. Engine Emission System Fault/Malfunction Icon *

 This icon is displayed when the engine emissions system has failed
or falls outside specified operating parameters.
Note
The engine must be switched off if the engine emission system failure icon
is displayed. On notification, immediately place the machine in a safe state
and or move it to a safe location. A mandated machine stop can only be
removed by a service technician. Contact your local Combilift partner if this
icon is displayed on the screen.
 In some situations, machine engine power is reduced.

 When a fault occurs in the emission system the following series of
escalating warnings can be expected:
 Within 2 hours of the fault occurring the Engine Emissions System
Malfunction and Warning icons are displayed in combination to
warn the operator of the presence of an emissions-related fault. !
Engine performance is reduced.
 After 2 hours, the Engine Emissions System Malfunction and Stop
icons are displayed in combination to warn the operator of the
presence of an emissions-related fault. Engine performance is
further reduced. Full engine performance can be restored by
switching the key switch ignition off and back on.
 After 3 hours and 50 minutes, the Engine Emissions System
Malfunction and Stop icons are displayed in combination and
engine performance is reduced to warn the operator of the
presence of an emissions-related fault that has not been
corrected.
 When a second fault occurs in the emission system within 40 hours
of a previous fault, the following series of escalating warnings can be
expected:
 Within 10 minutes, the Engine Emissions System Malfunction and
Stop icons are displayed in combination and engine performance
is reduced to warn the operator of the presence of an emissions-
related fault. Full engine performance can be restored by
switching the key switch ignition off and back on.
 After 30 minutes, the Engine Emissions System Malfunction and
Stop icons are displayed in combination and engine performance
is reduced to warn the operator of the presence of an emissions-
related fault that has not been corrected.
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Y. Engine Emission System Temperature Warning Icon *

 This icon is displayed when the exhaust gas temperature is high,

elevated idle is active, or exhaust filter cleaning is in progress.
The machine can be operated as normal unless the operator
determines that it is not in a safe location for high exhaust
temperatures. If the truck is not in a safe location for high exhaust
temperatures, auto cleaning must be disabled. (See 5.4 Exhaust !
Filter on page 53).
 When the engine emissions system temperature icon is combined
with the aftertreatment system warning icon or aftertreatment system
stop icon the engine performance is reduced by the ECU because the
exhaust gas temperature is higher than expected. Contact your local
Combilift partner if this fault occurs.
Z. Auto Exhaust Filter Cleaning Disable(d) Icon *

The auto cleaning disabled icon is displayed when the operator has
engaged the request to disable the auto exhaust filter cleaning
function. (See 5.4 Exhaust Filter on page 53).
 This icon remains on the screen until the operator re-engages
automatic exhaust filter cleaning from the display console.
 Disabling auto mode is not recommended for any situation unless it
is safety-related or if the fuel tank lacks he required fuel to complete
the cleaning process.
AA. Aftertreatment System Stop Icon *

 The aftertreatment system stop icon is displayed when a condition

exists that requires immediate operator action and service.
 It is displayed in combination with other exhaust after treatment
system icons to signify a reduction in engine power and speed.
BB. Aftertreatment System Warning Icon *

The aftertreatment system warning icon is displayed when a condition

!
exists that requires operator action.
 It is displayed in combination with other after treatment system icons
to signify a reduction in engine power.
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4.2.2. Pop Up Icons

There are a number of icons that may pop up on the screen accompanied by a
message. If any of these icons are displayed, the relevant action must be taken. Button
D may then be pressed to acknowledge the message and return to the home screen.
If button D is pressed without taking the relevant action the display will return to the
home screen however the message will reappear after 10 seconds.
Routine Maintenance Icon

 The routine maintenance icon is displayed on the screen when
routine maintenance is due. Initially it will be displayed after 100
hours.
 After the first 100-hour service the symbol should be set to activate
after every 250 hours in accordance with the maintenance schedule.
Low Engine Oil Pressure Pop Up Icon

 This icon pops up on the screen along with the message “Low Engine
Oil Pressure!” when the ECU has detected that the engine oil
pressure is below the expected range.
 Switch off the engine immediately as it can be severely damaged if
oil pressure is lost.
 Investigate the cause of the low oil pressure warning.
 The low pressure may be due to low oil level (See 5.3 Checking
Engine Oil Level on page 52).
High Engine Temperature Pop Up Icon

 This icon pops up on the screen along with the message “High Engine
Temperature!” when the ECU has detected that the engine coolant
temperature is 100°C (235°F) or higher.
 If the temperature does not drop after a short time, switch off the
engine and investigate the cause of the overheating before resuming
operation.
 If operation is continued and the coolant temperature is allowed to
rise further - at a critical temperature above 100°C (212°F) - engine
performance is automatically reduced to protect the engine against
the effects of overheating.
Drain Water Separator Pop Up Icon

 This icon pops up on the screen along with the message “Drain Water
Separator!” when water is detected in the water trap of the primary
fuel filter element.
 Stop the engine immediately and drain all water from the water trap.
 See 6.6 Diesel Fuel System on page 85.
Engine Power Limited Pop Up Icon

 This icon pops up on the screen along with the message “Engine
Power Limited!” when the ECU has detected a fault that requires the
engine power or speed to be reduced to protect the engine.
44
C4-C5MK4-OM-EN-06
 Stop the engine immediately and investigate the cause of the

problem. Contact your local Combilift partner.
Low Fuel Icon

 The low fuel icon is displayed when the fuel in the tank falls below a
certain level.
 Whenever the low fuel icon is displayed the truck should be refuelled
immediately.
 See 5.2 Fuel Handling & Storage on page 51.
Note
ALWAYS adhere to all safety precautions for refuelling the truck.
Engine Air Filter Dust Load Icon

 This icon is displayed when the air filter has become clogged with
dust.
 When the dust load icon is displayed the air filter must be serviced.
 See 6.9 Air Filter System on page 92.
4.3 Optional Dash Indicator Lights

Hydraulic Oil Overheating LED (If Fitted)
 The red - hydraulic oil overheating – LED located on the dash
illuminates if the hydraulic system temperature rises above a specified
allowable limit.
 If this light illuminates discontinue use of the truck, switch off the
engine and investigate the cause of the overheating.
 Continued use the truck with the hydraulic oil overheating LED
illuminated will degrade the hydraulic oil and cause damage to
hydraulic system parts. This may result in voidance of the warranty.
HYDRAULIC
 The Hydraulic Oil Overheating LED is identified by a decal (shown OIL
OVERHEATING
adjacent).
Neutral LED (If Fitted)

 The green neutral LED located on the dash illuminates when the
direction control lever is in the neutral position.
 The Neutral LED is identified by a decal (shown adjacent). NEUTRAL
90° LED (If Fitted)

 The green 90° LED located on the dash illuminates when the wheels
are all aligned in Sideward mode.
 It is normally only fitted on trucks with optional guide rollers.
 The 90° LED signals to the operator that the wheels are aligned in
Sideward mode and the truck can be driven in aisles with guide rails.
 The 90° LED is identified by a decal (shown adjacent).
45
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Operation
Section 5: 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:
 Thoroughly inspect the machine to confirm it is safe to use before commencing

each shift.
 Operate the machine correctly.
 Always operate the machine in a safe and controlled manner.
Warning
Check all systems before operating the truck. Report unsafe conditions and
have them corrected before commencing operation.
5.1 Pre-Use Checks
The truck must be maintained in a condition that is safe and without risk to safety and
health. Pre-Use checks play a vital role in ensuring the truck is in safe working
condition. Contact the local authorities in order to find out what regulations are in place
regarding Pre-Use checks of industrial equipment of this nature.
Warning
Before performing the pre-use checks:
 Park in a suitable area on level ground with adequate space and

headroom around the truck to perform all tests and checks
safely.
 Release any residual pressure in the hydraulic system i.e. lower
the mast fully and tilt the mast fully forward.
 Isolate the battery and remove the isolator key – unless
performing operational checks.
 Smoking and naked lights are prohibited.
 Ensure the relevant personal protective equipment (PPE) is worn
i.e. gloves, safety boots, eye protection, clothing.
46
C4-C5MK4-OM-EN-06
Operation
Caution
Escaping fluid under pressure can penetrate the skin causing serious
injury. Avoid hazards by relieving pressure before disconnecting hydraulic
or other lines. Tighten all connections before applying pressure. Search for
leaks with a piece of cardboard. Protect hands and body from high pressure
fluids. In the event of fluid penetrating the skin, seek medical attention
immediately.
 Employers must ensure that the Pre-Use checks are performed and that records
are kept.
 Operators must perform the checks and report any defects to their supervisor.
 Never operate a truck that has not been checked or that has failed on any of the
checks.
 If a truck becomes unsafe during a shift, stop operating the truck and report the
problem immediately.
 If a truck has failed on any of the checks place an ‘out of order’ notice on the
windscreen or steering wheel until the problem has been resolved.
The pre-use checks must be carried out at the start of the working day before the
machine commences operation. Alternatively if a multi shift system is being operated
the checks should be carried out at the beginning of each shift.
The following visual checks must be performed prior to using the truck:
 Overall Condition – Look for scrapes, dents, and other signs of damage. Watch
for missing or loose nuts and bolts. Check underneath the machine for signs of
leaking fuel, engine coolant, engine oil, hydraulic oil and battery electrolyte.
 Mast – Check for twisting and distortion in the channels. Look for signs of
cracking and check that there are no missing or loose bolts. Check the mast
chains for wear, missing links and pins. Make sure that the chains are of equal
tension and are adequately lubricated. DO NOT place your hands inside the
mast at any stage to check the chains tension. Press on the chains with a long
stick or screwdriver. Check around the lift and tilt cylinders for signs of leakage.
Also check all the hoses attached to the mast for signs of leaking oil.
 Fork Carriage – Check for excessive wear, damage, deformation and cracks.
 Forks – Check the forks for excessive wear, cracks, fractures and deformation.
Check that both locating pins are in place and operational.
 Tyres and Wheels – Check that all the wheel nuts are present and secure. Look
for cuts in the tyres or foreign objects in the rubber. Also look for plastic straps,
wire, and other debris caught between the wheel and the wheel motor. Always
wear gloves when checking the tyres to avoid injury on sharp pieces of
debris.
47
C4-C5MK4-OM-EN-06
Operation
 Access – Check that all steps and grab handles are secure, clean and in good
condition.
 Load Backrest (if fitted) – Check for deformation or cracks. Ensure it is fixed
securely.
 Hydraulics - Inspect the hydraulic hoses for kinks, routing and wear. Check all
seals and couplings for damage, wear and leaks. Use a piece of card when
checking for pinhole leaks.
 Hydraulic Oil Cooler – Look for a build-up or dust or debris on or around the
hydraulic oil cooler. Check around the fan and in the fins.
 Operators Cabin – Look for signs of damage and cracking to the overhead
guard. Ensure it is securely fixed. Report any signs of damage immediately to
your supervisor.
 Front Wheel Alignment – Check that the front wheels are aligned parallel to the
platforms and to each other when standard mode is selected. See section 5.7
page 59 if the front wheels are out of alignment.
 Safety Sign Decals – Check that all safety decals are present and legible.
 Hydraulic Tank – Check for damage or leaks. Check the hydraulic oil level with
the mast fully lowered.
 Battery - Check the battery connections are secure. Check the cells for
damage and leaks. Check the terminals for corrosion.
 Serial Plate and Capacity Chart – Check they are present and securely
attached and check the rated capacity.
 Electrical Connections/Terminals – Check they are securely connected and
undamaged. Check leads for loose or bare wires.
 Rear View Mirror (If Fitted) – Check it is clean and in good condition.
The following engine related checks must be performed prior to using the truck:
 Oil Level – Check the engine oil level on the dipstick. It must be between the
upper and lower level marks. Top up oil if necessary.
 Coolant Level – Check the coolant level in the coolant header tank by looking
through the sight glass
 Radiator – Check for build-up of leaves, dust or other debris on or around the
radiator.
 Check all the Belts and Hoses – Check that all of the belts and hoses are in
good condition. Look for visible signs of wear and fraying.
 Fuel Tank and Hoses – Check the tank for damage or corrosion. Check for
signs of leaking fuel. Check the fuel cap is present and secure. Check the
hoses for damage or deterioration.
 Fuel Pre-Filter Water Trap – check the contents of the water trap and empty if
required. Empty immediately if the water level warning system is activated.
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C4-C5MK4-OM-EN-06
Operation
 Exhaust - Check for excessive noise or smoke.

 Engine Compartment – Check the engine compartment for a build-up of
combustible fluids and materials.
The following operational checks must be performed prior to using the truck:
 Check the Seat Belt – Enter the cabin using the three point contact method.
Make sure that the seat belt functions correctly. Check for any cuts or fraying
along the belt and that it buckles securely. Always wear the seat belt provided
when you are driving the Combilift.
 Check the Seat – Check it is anchored securely and that the runners and sliders
operate freely. Check for objects under the seat that may interfere with the seat
switch. The operator must ensure that the seat is correctly adjusted to suit their
individual height and weight. Instructions on how to adjust the seat are presented
in an earlier section.
 Turn on the Machine – Insert the key into the ignition and turn the key to the
‘ON’ position. This will allow power to flow through the electrical system. The
screen on the dash display console should power up.
 Test the Horn – the horn button is located on the dash to the right hand side of
the operator. The Truck should not be operated if the horn is not functioning.
Press the button to test the horn.
 Test the Reversing Alarm – Select reverse drive. The reverse alarm should
sound continuously while in reverse. The truck should not be operated if the
reverse alarm is not functioning.
 Start the Engine - Ensure that the park brake is applied by pressing the large
red button on the dash. Also ensure that the directional control lever is in the
neutral position. Turn the key to the start position to start the engine and then
release the key. It will return to the on position.
 Sounds – Listen to the engine for a few seconds before driving off. If any strange
sounds are heard stop the machine immediately and investigate the problem.
 Smells - Check for any strange odours that may indicate a problem such as a
very strong smell of fumes or burning. If anything abnormal is detected, stop the
machine immediately and investigate the problem.
 Check the Dash – look at the dash display console to see if any warning icons
are displayed, or if the diagnostic lamp is illuminated. Should any warning icons
be displayed, stop the machine and report the fault to your supervisor. A full list
of all the warning icons can be found in Section 4: Operation Monitoring.
 Check the Work Lights – Turn the work lights switch to position 2 and check
that all work lights are working properly.
 Check the Mast Functions – After checking that there is adequate space and
headroom perform the checks on the mast functions. Raise and lower the mast
making sure that the operation is smooth and controlled. Extend the mast forward
fully and then retract it fully. Watch for any signs of sticking. Tilt the mast fully
forwards and backwards. Then test any auxiliary function(s) that may be fitted.
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C4-C5MK4-OM-EN-06
Operation
 Check the Brakes – With the park brake applied, select forward on the 4-way
direction control lever. Keeping both feet away from the pedals, sound the horn,
and release the park brake. The machine should start to move slowly forward.
Press the inch pedal. The machine will stop. Release the pedal and the machine
will move off again. Re-apply the park brake and the machine will stop. If either
brake is not working do not operate the machine and report the fault to your
supervisor. In the highly unlikely event of neither brake working, the machine can
be stopped by switching off the engine. Make sure there is adequate space
around the truck to perform this test. Only perform the brake test on a level
surface.
 Check the 4-Way Direction Control Lever – With the engine running and the
park brake applied, select forward mode. Release the park brake. The machine
should move forward. Press the inch pedal to stop the machine. Select reverse
and release the inch pedal. The machine should now travel backwards. Press the
inch pedal to stop the machine and apply the parking brake. Select left, the
wheels will start to realign for sideward (90°) mode. When the wheels have
finished realigning, sound the horn and release the park brake. The machine
should now travel to the left. Press the inch pedal to stop the machine, select right
travel with the direction control lever, sound the horn and release the inch pedal.
The machine should now travel to the right.
 Check the Steering – Set the steering wheel to the most comfortable position for
driving by use of the adjustment lever on the right hand side of the column. With
the engine running and the park brake applied, turn the steering wheel fully
clockwise and counter-clockwise. The steering should move easily in either
direction, and not seem excessively stiff or loose. Perform this check in both
standard (0°) mode and sideward (90°) mode.
On completion of the inspection the operator should report any defects immediately to
the supervisor / appropriate person.
 Never operate a lift truck that is in need of repair

 Repairs should only be performed by authorised personnel
The details of the checks should be recorded on a copy of the Pre-Use check sheet
provided at the back of this manual (see 8.2 Operator’s Pre-Use Check Sheet on
page 125). A record of the checks and any defects or repairs should be kept on file in
order to keep track of the trucks service history.
Note
Remember in many countries it is a legal requirement to perform these
checks and to keep a record of the findings.
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5.2 Fuel Handling & Storage
Use only diesel fuel. The facilities for storing and handling diesel MUST be strictly in
accordance with all current regulations.
Diesel fuel is hazardous to the environment. Do not allow diesel to leak into the
environment. Clean up any spillage using binding material and dispose of it in
accordance with environmental regulations.
Diesel fuel is hazardous to health. Wear gloves when handling.
Warning
No smoking, naked flames or other sources of ignition should be permitted
in the vicinity of the refuelling area and signs to this effect should be clearly
posted and free from obstructions at all times. Litter and other readily
ignitable materials should not be permitted to accumulate or be stored in
the refuelling area.
Warning
Adequate firefighting equipment must be readily available in the refuelling
area at all times.
The diesel tank is located on the left hand side of the truck near the rear, under the
cabin.
To Refuel:
 Park the truck according to the proper
parking procedure.
 Remove the cap (A) from the diesel tank by
turning anticlockwise.
 Add diesel fuel that meets the specifications
on the following page. A
 Replace the cap, ensuring that it is securely
fitted.
DIESEL
 Clean up any spilled fuel immediately. TANK
Diesel tank capacity: 75 litres / 79 quarts
Note
In order to satisfy the exhaust gas legislation, diesel engines that are
equipped with an exhaust after treatment system may only be operated with
ultra-low sulphur diesel fuel.
The operational reliability and durability of the individual exhaust after
treatment
The following technologies
fuel cannot
specifications be assured
/ standards upon failure to comply.
are approved:
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Diesel Fuels - EN 590 (Sulphur 10 ppm maximum)

- ASTM D 975 Grade 1-D S15 (Sulphur 15 ppm maximum)
- ASTM D 975 Grade 2-D S15 (Sulphur 15 ppm maximum)
Light Heating Oils - EN 590 quality (Sulphur 10 ppm maximum)
If other fuels are used that do not meet the requirements above the engine
warranty will be voided.
Below 0°C (32°F) ambient temperature use winter diesel (down to -20°C (-4°F)
Refer to the operating manual for the Deutz engine for further information.
5.3 Checking Engine Oil Level

The engine oil level is monitored via the dipstick (A) on the front of the engine.
Caution
Switch off the engine before checking the oil level.
The engine will be hot after operation. Wear protective gloves and avoid
contact with the engine.
Note
Oil level below the Min mark or above the Max mark leads to engine damage.
Mixing of engine oils should be avoided because the worst properties of the
mixture are always dominant.
1. Stop the truck on level ground and apply

the park brake.
2. Extend the reach to give access to the
front of the engine.
3. Switch off the engine and wait until the
dipstick (A) is cool enough to touch.
4. Pull out the dipstick and wipe the oil off
the gauge on the bottom of the dipstick A
with a clean lint free cloth.
5. Reinsert the dipstick as far as it will go
then pull it out again.
6. Check that the oil level lies between the
Min and Max marks on the gauge.
7. If the oil level is below the Min mark, add oil (see changing engine oil on page
84) of the permissible class and suitable viscosity (on page 82) but do not
exceed the Max level.
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5.4 Exhaust Filter Cleaning *
* This section only applies if the optional diesel particle filter has been fitted.
Caution
During auto or manual/stationary exhaust filter cleaning operations, the
engine will run at elevated idle and hot temperatures for approximately 20—
50 minutes. Exhaust gases and exhaust filter components reach
temperatures hot enough to burn people, ignite, or melt common materials.
If the machine is not in a safe location for elevated exhaust temperatures,
move the machine to a safe location and check for adequate fuel level before
beginning the exhaust filter cleaning process.
The Exhaust Filter, which includes the Diesel Oxidation Catalyst (DOC) and Diesel
Particulate Filter (DPF), is a critical component in the engine’s emissions control
system, that is required to meet governmental emissions regulations. The Exhaust
Filter captures diesel particulate matter or “soot” to prevent its release into the
atmosphere. This soot must be eliminated from the DPF to keep it functioning properly.
The process of eliminating collected soot is carefully controlled by the Engine Control
Unit (ECU) and is called “exhaust filter cleaning” or “regeneration”. During this process,
a rise in exhaust temperature occurs and allows the soot to be oxidized within the DPF.
Under normal machine operation and with the system in AUTO mode, the exhaust filter
system requires minimal operator interaction.
To avoid unnecessary build-up of diesel particulates or soot in the exhaust filter

system:
1. Utilize the Automatic (AUTO) Exhaust Filter Cleaning mode.
2. Work the engine at high load conditions where possible and keep idling to a
minimum.
3. Use only specified engine oil (See 6.5 Engine Oil System on page 82).
4. Use only ultra-low sulphur fuel (See 5.2 Fuel Handling & Storage on page 51).
In addition to soot, ash deposits also slowly build up in the DPF. Ash cannot be
removed by the engine exhaust filter cleaning process. Specialist cleaning is required
to remove ash deposits from the DPF. Contact your local Combilift partner if the DPF
becomes overloaded with ash.
Caution
Do not power wash the exhaust filter assembly when the external skin
temperature of the assembly exceeds 50 °C (120 °F).
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Automatic (AUTO) Exhaust Filter Cleaning

Operating the engine in AUTO Mode allows the ECU to perform intelligent exhaust
filter cleaning as required. The Exhaust Filter Cleaning icon will be displayed when the
system is actively performing an exhaust filter cleaning.
During this process, the injector will inject small amounts of fuel into the exhaust stream
to assist in cleaning the exhaust filter. When the exhaust filter cleaning process has
completed its cycle, the cleaning icon will automatically turn off.
Caution
If the truck is being operated in a location that is not safe for elevated
exhaust temperatures the auto exhaust filter cleaning function must be
temporarily disabled.
To Disable Auto Exhaust Filter Cleaning:

 With the Home screen displayed, press button (D) to display the options
screen.
 Navigate to the engine icon using button (F), then press button (G) to
display the engine information screen.
A B C D
ok
E F G
AUTO
 With the Engine Information screen displayed, press button (B) to
disable Auto Exhaust Filter cleaning.
AUTO
 The icon will change from to and the auto exhaust filter
cleaning will be disabled until button (B) is pressed a second time or
until the ignition is switch off and back on.
Caution
Auto Exhaust Filter Cleaning is enabled by default every time the ignition is
switched on.
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Standstill Exhaust Filter Cleaning

Standstill Exhaust Filter Cleaning is an automated process initiated at the request of
the operator. This process allows the system to clean the exhaust filter when the
operator previously needed to disable auto exhaust filter cleaning because of specific
conditions.
During the process the engine speed will be controlled by the ECU and the machine
must remain parked to complete the procedure.
The exhaust filter cleaning process is dependent upon the level of exhaust filter
restriction, ambient temperatures and current exhaust gas temperature.
Complete cleaning times will vary depending on several criteria including fuel type, oil
type, duty cycle, and the number of previously aborted exhaust filter cleaning requests.
Average time for a Standstill Exhaust Filter clean can range from 35-40 minutes.
After performing a Standstill Exhaust Filter clean allow the engine and the exhaust filter
time to return to normal operating temperature before stopping engine. At any time
during the parked procedure, the process can be cancelled.
Avoid cancelling the cleaning procedure unless absolutely necessary. Repeated
cancellations or ignoring of prompts to perform a standstill cleaning procedure will
cause engine power reductions and can eventually lead to dealer required service.
Caution
The truck must be parked in a safe location away from any combustible
materials or materials that may be damaged by heat before initiating a
Standstill Exhaust Filter clean.
To Initiate a Standstill Exhaust Filter Clean:

 Drive the truck to an open area well away from any flammable materials.
 Allow the engine to run at idle speed.
 Place the direction control lever in the neutral position and apply the
park brake.
Note
The engine must be warm before the standstill regeneration can be initiated.
The engine coolant must be at a minimum temperature of 75°C/167°F.
 Lock the hydraulic functions by pressing button (B) with the home
screen displayed.
 With the Home screen displayed, press button (D) to display the options
screen.
 Navigate to the engine icon using button (F), then press button (G) to
display the engine information screen.
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A B C D
ok
E F G
 With the Engine Information screen displayed, press button (C) and hold
for 5 seconds. The Standstill Exhaust Filter clean will commence and
the exhaust filter icon will be displayed until the process is complete.
 Avoid using any of the trucks controls during the Standstill Exhaust Filter
clean as this will cancel the procedure.
5.5 Checking Coolant Level
Caution
Switch off the engine before working on the cooling system.
Explosive release of fluids from pressurised cooling system can cause
serious burns.
The engine and cooling system must be cool to the touch before working on
the cooling system.
Only remove the filler cap when cool enough to touch with bare hands.
Slowly loosen the cap to relieve pressure before removing completely.
Coolant is harmful if swallowed. Seek immediate medical attention if
swallowed.
Avoid contact with skin and eyes. Wear protective gloves and goggles when
handling coolant.
The coolant level is monitored via the sight glass on the coolant header tank. The
coolant header tank is mounted on top of the radiator located at the rear right hand
corner of the truck.
Coolant is hazardous to the environment. Do not allow coolant to leak into the
environment. Clean up any spillage using binding material and dispose of it in
accordance with environmental regulations.
Note
It is advised not to mix different coolant products.
See www.combilift.com/coolant for a list of approved coolant products.
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To Check/Top Up The Coolant Level:

1. Park the truck in accordance with the C A B
recommended parking procedure.
2. Open the bonnet from the rear of the
truck using the bonnet handle (A).
3. Look through the sight glass (B). The
correct coolant level is half way up the
sight glass - when the system is cool.
4. If the coolant is low top up the system.
5. The header tank cap (C) must be cool
to the touch before removing the cap.
6. Turn the cap anticlockwise gradually
to release any pressure before
removing completely.
7. Top up the coolant to half way up the
sight glass. Replace the cap securely.
(See section 6.7 on page 88 for coolant
specification details)
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5.6 Checking Hydraulic Oil Level

The hydraulic oil level is monitored via the sight glass on the left hand side of the
hydraulic tank. The hydraulic tank is mounted on the right hand side of the truck in front
of the engine.
Caution
Switch off the engine before working on the hydraulic system.
Protective gloves and goggles must be worn when handling hydraulic oil.
Do not swallow. Ensure sufficient ventilation. Ensure cleanliness.
Note
Hydraulic oil is harmful to the environment. Do not allow hydraulic oil to be
released into the ground, down a drain or into a stream, pond or lake.
To Check the Hydraulic Oil Level:

1. Park the truck in accordance with the
2. Extend the reach, lower the forks fully,
tilt the mast forward fully and retract all
cylinders on any attachments.
3. Check the oil level on the sight glass A
(A) on the left hand side of the
hydraulic tank.
4. The oil level should be approximately
half way between the top and bottom of
the window.
5. If necessary top up with oil of the same grade and quality as that in the tank.
See section 6.11 on page 98.
To Add Hydraulic Oil:

1. Remove cover plate (B) from the front B C
of the lower bonnet panel (C) by
unscrewing the two socket button
head screws with a 4mm Allen key.
2. Unscrew the filler cap (D).
3. Add hydraulic oil through the filler
neck until the oil level is half way D
between the top and bottom of the
sight glass (A).
4. Refit the filler cap securely.
5. Refit the cover plate (B).
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5.7 Front Wheel Alignment
Note
Do not attempt to correct the wheel alignment by adjusting the front master
steering cylinder rod end before trying the procedure outlined below.
Wheels At Standard (0°) Mode Wheels At Sideward (90°) Mode
 Drive the truck in standard mode (i.e. forward or reverse) to an open area where
the ground is firm and level.
 Stop and apply the park brake.
 Check the alignment of the front wheels. Both front wheels should be aligned
parallel to each other and to the sides of the truck.
 If the wheels are out of alignment, select sideward mode for right travel by
moving the direction control joystick to the right.
 Wait for the wheels to finish repositioning.
 Press the accelerator pedal to increase the engine speed and turn the steering
wheel anticlockwise to fully extend both front steering cylinders.
 When the cylinders are fully extended continue to turn the steering wheel against
the resistance for 5-10 seconds (keep the engine speed up throughout).
 Turn the steering wheel clockwise to fully retract both front steering cylinders.
When the cylinders are fully retracted continue to turn the steering wheel against
the resistance for 5-10 seconds (keep the engine speed up throughout).
 Select standard mode for forward travel by moving the direction control joystick
forward.
 Wait for the wheels to finish repositioning.
 Release the park brake and drive the truck forward at least 1 metre.
 Stop and apply the park brake.
 Check the alignment of the front wheels.
 Both front wheels should now be aligned parallel to each other and to the sides
of the truck.
5.8 Entering and Exiting the Operator Cabin
Warning
The ‘Basic Information’ section of this manual contains crucial information
on topics such as ‘centre of gravity’ and ‘rated capacity’ that must be read
and understood prior to operating the truck.
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When mounting or dismounting the truck three points must be kept in constant contact
with the truck. That means one hand and two feet, or two hands and one foot – at all
times. Anything less and the risk of a fall is increased. Handgrips and footsteps have
been provided to allow easy and safe access to the operator cabin. DO NOT use the
steering wheel as a handgrip.
Remember:
 Check that the handgrips and footsteps are clean and in
good condition before using.
 Always face in towards the machine and use the handgrips
and footsteps provided.
 Mount and dismount only when the truck is stopped.
 Break three-point contact only when you reach the ground
or cab.
 Take extra care in wet, snowy or icy weather.
 Avoid wearing loose or torn clothing that can catch on the
truck.
 NEVER JUMP!
5.9 Starting the Engine

 Ensure the park brake is applied and the 4-way direction control lever is in the
neutral position.
 Ensure the accelerator pedal is not being pressed.
 Insert the key into the ignition switch and turn clockwise to position 1 – operating
voltage. The display console powers up. In cold weather if the coolant is below a
certain temperature the glow plugs are activated. Wait 15 seconds before
attempting to start the engine.
 Turn the ignition key further clockwise against spring pressure to position 2 - start.
Release the ignition key as soon as the engine starts. The key which will return
automatically to position 1.
Note
The truck will NOT start unless:
 The 4-way direction control lever is in the neutral position
 The battery isolator switch is in the ‘ON’ position
 The operator is sitting on the seat
 The seat belt is fastened *
* only if optional seat belt switch is fitted
Warning
Before starting the engine ensure that there are no bystanders in the
immediate vicinity of the truck.
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Note
The starter must not be operated continuously for more than 20 seconds. If
the engine does not start, return the key to the ‘OFF’ position and wait 60
seconds then repeat the starting process.
If the engine fails to start and the error lamp lights, the electronic engine
control has activated the start lock to protect the engine.
The start lock is cancelled by switching off the system with the ignition key
for approximately 30 seconds.
If the engine does not start up after two attempts determine the cause using
the fault table in the engine manual.
Do not run up the engine immediately to high idling speed / full load
operation from cold.
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 4-way direction control lever.
5.10 Switching Off the Engine

 Ensure the park brake is applied and the 4-way direction control lever is in the
neutral position.
 Ensure the accelerator pedal is not being pressed.
 Turn the key anticlockwise to position 0.
Note
Avoid switching the engine off from full load (coking/blockage of the
remaining lubricating oil in the turbocharger bearing housing). The
lubricating oil supply of the turbocharger is then no longer guaranteed!
This shortens the life of the turbocharger.
Run the engine in low idling speed for approximately one minute after
relieving the load.
engine to save the system data (lag) and then switches off automatically.
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5.11 Moving Off

It is important to be aware of how the Combilift truck moves and how to drive it in a
safe and efficient manner. The Combilift can be driven forward, backward, left or right
by selecting the desired direction of travel with the 4-way direction control lever.
Warning
Only operate the truck from the operator’s seat with the seat belt buckled
and the cabin door
closed and latched securely. Do not place any part of your body outside the
operating enclosure. Do not carry passengers. Failure to follow these
guidelines can result in serious injury or death.
Warning
Remain in the seat with the seat belt fastened while the truck is moving. The
seatbelt will help you remain inside the cabin should the truck tip over.
Never jump from the truck if it begins to tip over. Keep all body parts inside
the operating enclosure.
Caution
Moving the 4-way direction control lever when the truck is moving may
cause the truck to change direction abruptly and carries a risk of personal
injury and machine damage.
Do not move the 4-way direction lever when the truck is moving.
After changing direction with the truck stopped, confirm that the direction
indicator icon on the display screen is in agreement with the intended
direction selected.
If the direction control does not respond or the indicator icon does not
change colour park the truck in a safe location and inform the supervisor.
To Move Off:
 Start the engine as described in section 5.9
 Raise the forks to approximately 100mm (4˝) off the ground and tilt the mast back.
This is the recommended travelling position.
 Select the desired direction with the 4-way direction control lever.
 Wait for the wheels to realign if necessary.
 Make sure the way is clear.
 Press the brake/inch pedal fully.
 Look around to make sure your way is clear.
 Release the park brake and hold the steering knob with the left hand.
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 Sound the horn.

 Look in the intended direction of travel.
 Press the accelerator pedal lightly to increase the engine speed a little.
 Slowly release the brake/inch pedal.
 As the truck starts to move, gradually press the accelerator pedal until the truck
is moving at the desired speed.
 Release the accelerator pedal fully then press the brake/inch pedal fully to stop
travelling.
 Apply the park brake when the truck has stopped.
Note
Always adhere to all speed limits for the area in which the truck is
operating.
5.12 Turning
Warning
A lateral tip-over can occur if the truck is improperly operated. Slow down
before turning! Failure to slow down can cause serious injury or death.
 Slow down. Even if the forklift is not carrying a load it can tip-over if you turn at
high speed.
 Sound the horn as you reach an intersection to warn pedestrians and other
equipment operators you are approaching the intersection.
 Always follow the rules of the road and yield to other equipment operators and
pedestrians as required.
5.13 Stopping
Warning
When stopping, stay inside the cab until the truck comes to a complete
stop. Failure to stay inside the cab can result in serious injury or death.
Warning
Do not apply brakes abruptly. If you stop abruptly the load may dislodge
from the forks causing serious injury or death.
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Release the accelerator pedal to slow the truck down then gradually apply pressure to
the brake/inch pedal to bring the truck to a smooth controlled stop.
To perform an emergency stop release the accelerator pedal then press the
brake/inch pedal down fully. Keep the brake/inch pedal fully depressed until the truck
comes to a halt.
Stopping distances change depending on operating conditions such as inclines and

the quality of the ground surface.
To make sure the truck can be brought to a stop within an acceptable safe distance it
is important to operate in a manner that is appropriate for the current conditions. It
may be necessary to:
 Reduce speed
 Reduce load size
 Allow adequate distance between the truck and any other vehicle, object or
person.
Note
Be careful when traveling in snowy and icy conditions.
Reduce travel speed considerably in the event of bad weather.
5.14 Changing Direction

The procedure for changing drive direction differs depending on whether the wheels
have to realign from standard (0°) mode to sideward (90°) mode - or vice versa – or
not.
Changing Direction Without Changing Mode

This procedure applies when a change of direction is required that does not require
the mode to change i.e. when changing from forward to reverse or from right to left.
 Bring the machine to a complete stop by pressing the brake/inch pedal

 Select the desired change of direction with the 4-way direction control lever
 Wait until the direction arrow for the selected direction has changed colour on the
display.
 Follow the instructions under ‘moving off’.
Wheels At Standard (0°) Mode Wheels At Sideward (90°) Mode
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Changing Direction With Mode Change

This procedure applies when a change of direction is required that also requires the
mode to change e.g. when changing from forward to right or from reverse to left.
 Bring the machine to a complete stop by pressing the brake/inch pedal.

 Apply the park brake.
 Select the desired change of direction with the 4-way direction control lever.
 As the wheels start to realign press the accelerator pedal lightly to speed up the
operation.
 Wait until the wheels have finished realigning and the direction arrow for the
selected direction has changed colour on the display.
 Follow the instructions under ‘moving off’.
5.15 Parking
When parking the Combilift always ensure that one of the two recommended parking
methods are used to ensure the safety of the operator and others. There are two
recommended methods for parking your Combilift. One is called the Attended parking
method, for cases where the operator needs to exit the machine but will be no more
than 25 feet (7 metres) away. The other is the Unattended parking method, for cases
where the operator must exit the machine but will be further than 25 feet away.
Caution
Before exiting the vehicle, place controls in neutral and apply the park
brake.
If the truck is to be left unattended, fully lower the mast, tilt the mast fully
forward, turn the key to the ‘Off’ position and remove the key.
Park in a safe area on level ground. Never park on an incline/slope.
Ensure the parked truck will not cause an obstruction or safety hazard.
The Attended Parking Procedure

 Bring the truck to a complete stop.
 Once stopped, apply the park brake and set the 4-way direction lever to the
neutral position.
 Lower the forks fully and tilt the mast fully forward.
 If loaded, retract the mast and rest the load on the platforms of the machine.
 Leave the engine running.
 Remove the seatbelt from its buckle and exit the Combilift using the three point
contact method as discussed earlier.
 Stay within 25 feet (7 metres) of the machine at all times.
The Unattended parking method

 Bring the truck to a complete stop.
 Once stopped, apply the park brake and set the 4-way direction lever to the
neutral position.
 Lower the forks fully and tilt the mast fully forward.
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 If loaded, retract the mast and rest the load on the platforms of the machine.
 Turn the key switch to the ‘OFF’ position and remove the key to prevent
unauthorised use of the truck.
 Remove the seatbelt from its buckle and exit the Combilift using the three point
contact method as discussed earlier.
Warning
Never leave the seat without applying the park brake.
If the truck breaks down on an incline, securely chock the wheels remove
the key and place an ‘out of order sign’ on the windscreen.
5.16 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.
 Read and understand the ‘Basic Information’ and ‘Safety Information’ sections of
this manual before commencing operation.
 Assess the load before lifting. Check the weight, size, load centre and security.
NEVER try to lift a load if its weight is unknown.
 Do not handle unstable or loosely stacked loads.
 Before picking up a load adjust the forks to ensure that they are equally spaced
about the centre line of the fork carriage and as widely spaced as possible to
take the weight of the load evenly.
 Make sure the forks are fully inserted into the pallet or under the load.
 Check that the forks are of sufficient length. The length should be at least two
thirds of the depth (front to back) of the load.
 Forks must not protrude beyond the pallet/load.
 Use suitable attachments for lifting unusual loads.
 Make sure that pallets are in good condition.
 Observe floor loading limits.
 Check safe working load (SWL) of racking before placing a load onto it.
 ALWAYS consult the capacity chart in the cabin of the truck before lifting a load
and never exceed the rated capacity and load centre of the truck.
 When manoeuvring to pick up a load, avoid erratic movements that could result
in damage to the load and/or truck.
 Use caution when handling long, high or deep loads.
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 If the load obstructs view, drive in reverse or left or right and always looking in
the direction of travel.
 Make sure there is adequate clearance for the truck and load including overhead.
 Do not allow anyone to stand beneath or pass under the mast or forks.
 Never use the forklift to elevate anyone without the use of an approved man up
cage.
 Be aware of rear end swing when turning.
 Never carry passengers on the truck.
 Obey site rules and take particular care when there are pedestrians who should
be given priority.
 Use banks men if operating in congested or busy areas.
 Operate controls smoothly.
 Stop the truck, apply the park brake and select neutral before lifting a load.
4-Way Drive Loading/Unloading Advantages

 The 4-way travel capability of the Combilift truck allows for much easier alignment
of the forks/load with the picking/placing area than with any other conventional
type of forklift truck such as a counterbalance, reach or side loader.
 To position the forks/load precisely with the placing/picking location select the
required drive direction with the 4-Way direction lever.
 Fully press the brake/inch pedal, look all around to make sure the way is clear,
then release the park brake.
 Press the accelerator pedal to increase the engine speed then gradually release
the brake/inch pedal until the truck starts to move slowly.
 Make small steering corrections as necessary to align and position the forks/load
precisely.
 When aligned centrally with, parallel to and the correct distance from the desired
location fully press the brake/inch pedal, apply the park brake and select neutral.
Picking up a Palletised Load

 Manoeuvre the truck so that the forks are aligned centrally with the pallet and
approximately 50mm (2˝) from the front of the pallet.
 Use the 4-Way drive to get the truck into position if necessary.
 Apply the park brake and select neutral.
 Level the forks then adjust the space between the forks (see section 5.17 on
page 71) to suit the pallet.
 Use the tilt to level the forks then adjust the height of the forks to enable them to
enter the pallet without fouling.
 Extend the reach to insert the forks into the pallet until the front face of the forks
gently touch the pallet.
 Lift the load 100mm (4˝) off the ground and tilt the mast back to secure the load.
 Retract the mast fully.
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Operation
Picking up a Long Load

 Manoeuvre the truck so that the forks are aligned centrally with the load and
approximately 50mm (2˝) from the front of the load.
 Apply the park brake and select neutral.
 Level the forks then adjust the space between the forks (see section 5.17 on
page 71) to suit the load.
 Use the tilt to level the forks then adjust the height of the forks to enable them to
pass under the load without fouling anything.
 Extend the reach to insert the forks under the load until the front face of the forks
gently touch the load.
 Lift the load 100mm (4˝) off the ground and tilt the mast back to secure the load.
 Raise the load 100mm (4˝) above platform height.
 Retract the reach fully.
 Gently lower the forks until the load is resting on the platforms and then ensure
the truck is evenly balanced.
 Continue to lower the forks to 100mm (4˝) off the ground and keep the mast tilted
back.
Placing a Palletised Load

 Manoeuvre the truck so that the pallet is as close to the placing area as possible.
 Extend the reach.
 Level the load using the tilt function.
 Gently lower the load onto the placing surface.
 Retract the reach fully, tilt the mast back and raise/lower the forks to 100mm (4˝)
off the ground.
Placing a Long Load

 Manoeuvre the truck so that the load is as close to the placing area as possible.
 Raise the load 100mm (4˝) off the trucks platforms.
 Extend the reach.
 Level the load using the tilt function.
 Gently lower the load onto the placing surface.
 Retract the reach fully, tilt the mast back and raise/lower the forks to 100mm (4˝)
off the ground.
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Operation
Stacking Long & Palletised Loads

 Slowly approach the placing location with the load in the safe travel position.
 Select neutral and apply the park brake.
 Raise the load 100mm (4˝) off the trucks platforms if handling a long load.
 Level the load using the tilt function – or if the load is not secure keep it in the
tilted back position.
 Check overhead to make sure there is adequate headroom before lifting. Pay
attention to the highest point.
1 2 3 4
 Lift the load until the bottom of the pallet/load is 50-75mm (2-3˝) clear of the
racking (or the top of the load beneath if bulk stacking).
 Gradually operate the accelerator pedal to ensure that the engine speed is
sufficient to prevent stalling and to give the required lifting speed.
 Ensure the load is not going to foul the racking or adjacent loads before
traversing it out.
 Extend the reach until the load is directly above the desired location.
 If placing in racking, position the load with a 50-75mm (2-3˝) gap each side and
allow pallets to overhang the front of the racking by 25-50mm (1-2˝).
 If bulk stacking, position the load exactly on top of the load beneath, keeping the
stack perfectly upright and level.
 Use the tilt to level the load then lower the load gently onto the racking or stack.
 Position the forks at a height to clear the pallet/load without fouling on withdrawal.
 Retract the reach fully, checking to make sure that the forks do not foul on the
pallet or load on withdrawal. Make any necessary adjustments to prevent the
forks from fouling.
 If appropriate reverse away from the load.
 When the forks are clear of the load/stack, lower the forks to 100mm (4˝) above
the ground and tilt the mast back before moving off.
Warning
Avoid any travel with the mast raised and/or the reach extended.
Extreme care must be taken to avoid jerky movement when using the tilt
function, especially when the load is raised.
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Operation
De-stacking Long & Palletised Loads

 Slowly approach the placing location with the mast in the safe travel position.
 Select neutral and apply the park brake.
 Level the forks using the tilt function.
 Check overhead to make sure there is adequate headroom before lifting.
 Lift the forks to the required height to enter the pallet/load cleanly.
 Extend the reach until the fork heels gently touch the pallet/load.
 Check overhead to make sure there is adequate headroom before lifting. Pay
attention to the highest point.
1 2 3 4
 Lift the pallet/load approximately 50-75mm (2-3˝). If the load dips use the tilt
function to level the load before withdrawal.
 If the load is unstable use backward tilt to secure it if appropriate.
 Retract the reach fully, checking to make sure that the pallet/load does not foul
on the racking or adjacent loads on withdrawal. Make any necessary adjustments
to prevent the load from fouling.
 Lower the load smoothly under control (onto the platforms if the load is long) and
ensue the load is evenly balanced.
 Position the forks in the safe travel position.
 If appropriate reverse away from the racking/stack.
Undercutting a Load
This is when the forks are not fully inserted into the pallet or under a load. It may be
necessary to do this when it is not possible to get close enough to the pallet/load to
insert the forks fully.
Warning
The load centre is increased and therefore the lifting capacity is reduced
when the front face of the forks is not touching the load.
Ensure the truck has sufficient capacity to cope with the increase in load
centre.
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Operation
To Undercut a Load:
 Fully extend the reach to insert the forks as far as possible into the pallet or under
the load.
 Gradually lift the load just enough to ensure it is stable.
 If the load is unstable lower it back to its original position and report the problem
to the site supervisor.
 If the load is stable, retract the mast fully to bring the load closer to the truck.
 Reverse slowly just enough to clear the racking/stack.
 Lower a long load onto the trucks platforms ensuring that it is properly supported
and stable on the platforms.
 Lower a palletised load onto the ground.
 Extend the mast again until the load is against the front face of the forks
 The load is now ready to be lifted.
 Position the load in the safe travel position.
5.17 Adjusting the Load Forks
Adjusting the Forks for Palletised Loads:

 Measure the opening between the end stringers on the pallet.
 Raise the forks approximately 25mm (1˝) off the ground.
 Apply the park brake and switch off engine.
 Release the fork keeper pins *.
 Move the forks until the spacing between them is equal to one-half the opening
between the end stringers on the pallet.
 Position the forks equidistant from the ends of the fork carriage and engage the
fork keeper pins in one of the notches in the top fork bar *.
 If the truck has hydraulic fork positioning fitted, use the fork positioning lever to
adjust the forks.
Adjusting the Forks for Long Loads
Factors such as the length and rigidity of the load must be considered when positioning
the forks. Forks on opposite sides of the truck must always be positioned equidistant
from the centre of the fork carriage.
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Operation
To adjust:
 Raise the forks approximately 25mm (1˝) off the ground.
 Apply the park brake and switch off engine.
 Release the fork keeper pins. *
 Move the forks to the desired position.
 If a wide fork positioner or spreader bar is fitted, position the outer forks to best
suit the load. Factors such as the length and rigidity of the load must be
considered when positioning the outer forks.
 Position the forks equidistant from the ends of the fork carriage and engage the
fork keeper pins in one of the notches in the top fork bar. *
 If the truck has hydraulic fork positioning fitted, use the fork positioning lever to
adjust the forks.
* Trucks fitted with hydraulic fork positioning do not have keeper pins in the forks or notches in the top fork bar.
5.18 Travelling Safely with a Load

 When travelling with a load always keep the load as low as possible.
 With palletised loads ensure the load is tilted back and resting against the front
face of the forks.
 With long loads have the load resting on the platforms of the truck whenever
possible and secure the load if necessary to prevent movement during travel.
 Try to avoid sudden and erratic movements with the machine. Accelerate and
brake as smoothly as possible.
 When approaching a junction or corner, slow down, sound the horn and proceed
only when you are sure that your path is unobstructed.
 When approaching crossings and areas where driving vision is restricted or
obscured, reduce speed to a minimum and sound the horn - a series of short
blasts is more effective than one long blast.
 Cross railway lines slowly, only at authorised points and diagonally whenever
possible. Avoid bumps and kerbs.
 Be conscious of height and width restrictions and watch for the sudden
appearance of pedestrians from behind obstacles.
 Do not carry unsafe or insecure loads. Never carry loads stacked higher than the
top of the fork or load backrest (if fitted).
 Operators’ arms, hands, head or legs must not overhang the running lines when
the truck is in motion. Take care when indicating a turn or other manoeuvre.
 Follow the correct procedure when travelling on sloped ground. See section 5.19
on page 73.
 Take great care when travelling with a swinging load. If the load swings the centre
of gravity of the truck is also moving.
 Ensure the load is spread evenly on the forks.
 Always look in the direction of travel and avoid obstacles such as sudden dips or
potholes.
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Operation
 If the view forward is blocked by the load travel in reverse, left or right.
 Turn slowly and in the event of a tip over follow the procedure below.
 Warn anyone in the vicinity of the truck to stay clear if the trucks starts to become
unstable or to tip over.
HOLD ON TIGHT LEAN AWAY

TO STEERING WHEEL BRACE FEET FROM IMPACT LEAN FORWARD
5.19 Driving on Slopes
Always take great care when driving on a slope as the risk of an accident is increased.
If a slope is greater than 5% the following guidelines must be followed.
Do:
 Drive slowly and use the brakes gently.
 Drive directly up or down the slope in standard mode.
 Ensure the forks face uphill when driving up or down a slope with a load.
 Ideally the forks should face downhill when driving up or down a slope
without a load.
 Keep the mast tilted back and the forks approximately 100mm (4˝) off the
ground.
Long Load Palletised Load No Load
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Operation
Driving in this way aids stability, traction and adhesion (meaning the truck is less likely
to tip over or skid). If it is not possible to drive up and down the incline with the forks
positioned as above then take great care.
Don’t:
 Drive diagonally on a slope.
 Turn the truck around on or travel across a ramp or a slope.
 Leave the truck on a slope, except in an emergency. In case of emergency
always chock the wheels.
If it is necessary to drive in sideward mode on a slope with a long load the situation
must be fully assessed and a safe work procedure determined before proceeding.
It may be necessary to secure the load to prevent it from sliding on the platforms.
Rubber sheeting or other nonslip coatings may be fixed to the platforms to prevent the
load from sliding.
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Operation
5.20 Towing
Should the need arise to Tow the truck it is necessary to first apply the bypass condition
on the hydrostatic pump in order to prevent it from being damaged. It is also necessary
to mechanically release the park brake on each of the wheel motors. The truck should
only be towed if it has broken down in a location where it is deemed to be a safety
hazard.
Caution
Only tow the truck out of the immediate danger zone. Longer towing
distances and high towing speeds will damage the drive pump.
The maximum permissible towing speed of 2 km/h should not be exceeded.
During and after towing the drive pump will be hot. Wear protective clothing.
5.20.1 Hydrostatic Drive Bypass Function
A
1
2
B
To activate the bypass function:

1. Switch off the engine.
2. Remove the RH side access panel (A) (pull out firmly at the top then lift up and
out) to gain access to the drive pump (B).
3. Loosen the lock nut (2) by turning counter-clockwise one half rotation with a
13mm spanner.
4. Use a 4mm Allen key to screw in the screw (1) clockwise until it is against the
spring disc. This is apparent by the increased resistance. Then screw the screw
(1) one half turn into the spring disc.
5. Tighten the lock nut (2) clockwise with a torque of 22 Nm.
6. Repeat steps 3 to 5 on the opposite side.
Note
Switch off the bypass function immediately after towing.
To deactivate the bypass function:

1. Loosen the lock nut (2) with a 13mm spanner, then turn the screw (1)
counter-clockwise with a 4mm Allen key to the stop.
2. Retighten the lock nut (2), turning clockwise with a torque of 22 Nm.
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Operation
5.20.2 Mechanical Release of Park Brake
Caution
The truck must be secured to prevent it from rolling off before releasing the
park brake.
Re-engage the park brake as soon as the towing operation is complete.
To release the park brake:

A
1. Remove the rubber plug (A) from the centre of the
brake protector plate.
2. Take a fully threaded M12x80mm socket head bolt
and screw on an M12 hex nut (B) up to the bolt
head.
3. Take an M12 flat washer and oil both sides, then
C
insert the bolt into the washer.
4. Take a spacer (C) and insert the M12 bolt with the
nut and washer into the hole.
5. Place the spacer against the brake housing (D) with
the M12 bolt inserted into the hole left by the rubber D
plug.
6. Screw the bolt up to the end of the thread in the
brake piston. Do not over tighten the bolt!
7. Hold the bolt in place with an Allen key and screw
the nut up to the spacer so that the spacer is held
B
firmly against the brake housing.
8. Hold the bolt in place and turn the nut clockwise
approximately 1 full revolution.
9. This action will release the brake and allow the
motor to turn freely.
10. The procedure must be performed on all 3 wheel
motors.
To re-engage the park brake:
1. Re-engage the park brake as soon as the towing operation is complete.

2. Hold the bolt in place and unscrew the nut until the spacer comes loose.
3. Unscrew the bolt from the brake piston.
4. Insert a new rubber plug into the brake cover.
5. The procedure must be performed on all 3 wheel motors.
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Maintenance
Section 6: Maintenance
Combilift trucks are thoroughly examined, tested and lubricated before leaving the
factory; however, regular maintenance and lubrication are necessary to ensure smooth
running and maximum life of components.
The recommended maintenance periods in the maintenance schedule are for trucks
operating in normal, clean conditions when the specified fluids are used. For abnormal
temperatures, dust contamination areas or moist conditions, etc., more frequent
maintenance will be required. Maintenance periods should be halved when the truck
is operating in a harsh environment.
When carrying out maintenance work, the use of original parts is highly recommended.
These are specially designed for the truck and engine and ensure optimum
performance. Non-compliance may result in voidance of the warranty!
Caution
The information contained in this section is provided for trained and
authorised service personnel only. The specialist skills and knowledge can
be obtained through training with Combilift Service.
Some maintenance tasks could result in serious injury or property damage
if performed incorrectly
Warning
Servicing and maintaining a diesel engine powered truck 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 the truck in a
well-ventilated area and wear gloves or wash your hands frequently when
servicing the truck.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
6.1 Basic Safety Instructions for Servicing and Inspection
 Perform servicing and inspection work only if you have read and understood the
operator’s manual for the truck and the operator’s manual for the engine.
 Observe the basic safety instructions and all the warning signs attached to the
truck.
 The descriptions of work processes contained within this manual are provided
only for fully trained and competent maintenance staff with the necessary skills,
knowledge and experience to carry out the work safely.
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Maintenance
 Keep the operator’s manual with the truck at all times.

 Perform servicing and inspection work only with suitable work clothing and
personal protective equipment.
 Always wear safety glasses when performing servicing and inspection work.
 Always wear appropriate protective clothing, hats, gloves and safety shoes as
warranted by the circumstances.
 Wear hearing protection should there be noise exceeding 90 dbA.
 All work must be carried out in a pre-designated safe working area on firm level
ground with adequate space and headroom to perform all maintenance tasks
safely.
 Take the necessary precautions to ensure the safety of others who may be
affected by the work, e.g. other employees working nearby.
 Fire protection equipment must be present in the work area.
 Extend the reach at least half way to give access to the front of the engine and
filters.
 Lower the forks fully and tilt the mast forward fully before commencing
maintenance tasks.
 Confirm that the hydraulic system pressure has been relieved before working on
the hydraulic system.
 Pressurised jets of fluid can penetrate the skin causing serious injury. Use a
piece of cardboard or paper to check for leaks. In the event that oil penetrates
the skin, seek medical attention immediately.
 Remove the key and lock the cabin door to prevent anyone from starting the
engine while maintenance is underway.
 Ensure there is no residual load in the system by supporting hung weights etc.
 Always isolate the power source from the drive or equipment.
 Hot surfaces and fluids can cause severe burns. Wait until surfaces and fluids
have cooled and are comfortable to touch.
 Avoid skin and eye contact with oils and greases.
 Do not allow any fluids from the truck to spill on the ground or get into bodies of
water. Clean up any spills immediately.
 Always ensure tools are in good working condition and used in the proper
manner.
 Extract exhaust fumes using an extraction system and ensure the area is well
ventilated.
 Perform a functional test after any maintenance work.
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Maintenance
Cleaning
 Clean the truck thoroughly before performing any diagnosis or maintenance
tasks. Pay particular attention to the areas of the truck where work is to be carried
out e.g. around the filters.
 Do not use flammable solvents or cleaning agents that create harmful vapours.
 Do not pressure wash near electrical components or inside the cabin.
 Wear appropriate protective clothing such as goggles and gloves.
 Blow dirt off or out. Always blow out the oil cooler and radiator cooling fins from
the exhaust air side to the fresh air side.
 When using a high pressure water or steam jet observe the following rules:
 Maximum spray pressure 60 bar
 Maximum steam temperature 90°C
 Minimum distance 1metre
 Warm up the engine
Caution
Only carry out cleaning work on the engine when it is not running!
Cover all electrical/electronic parts and connections. (e.g. control units,
generator, solenoid valves etc.).
Do not aim the water/steam jet directly at electrical components.
Allow the engine to warm up.
Battery
 Wear protective clothing and safety glasses when working on the battery.
 If acid contacts the skin wash immediately with clean water.
 If acid contacts the eyes wash immediately with clean water and seek immediate
medical attention.
 Keep sources of ignition away from batteries.
 Do not place metal objects on or near the battery terminals.
 Disconnect the battery when working on the electrical system.
 Always disconnect the battery before welding.
 Follow the correct procedure when connecting and disconnecting the battery.
 Disconnecting: First negative and then positive

 Connecting: First positive and then negative
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Maintenance
6.2 First Inspection After 100 Operating Hours

The descriptions of work processes contained within this manual are provided only for
fully trained and competent maintenance staff with the necessary skills, knowledge and
experience to carry out the work safely. Follow the operator’s manual for the engine
for more details regarding engine servicing procedures.
To assure proper functioning of the truck, it is required that the first inspection be
performed after 100 operating hours or 3 months (depending on which comes first),
after initial start-up.
Tasks to be performed after 100 operating hours or 3 months

 Check tension and condition of the v-belt(s).
 Change hydraulic suction filter elements.
 Change the hydraulic return filter element.
 Check the engine oil level.
 Check the hydraulic oil level.
 Check the coolant level.
 Check the machine for hydraulic, coolant and fuel leaks.
 Check the engine air intake filter and clean or replace if necessary.
 Check all mast carriage-bearing lock nuts are tight.
 Check all bolts and fittings are tight.
 Check the routing of hydraulic hoses, pipes and wires.
 Check all chrome rods on the hydraulic cylinders are clean and undamaged.
 Check the cleanliness of the radiator and hydraulic oil cooler.
 Check instruments and warning devices.
 Check the electrical system, ensure all connections are secure.
 Check the brakes, steering and operation of hydraulic functions
 Check all lights.
 Check the cabin and door.
 Check the engine idle speed.
 Check the condition of the tyres.
 Check all wheel nuts for tightness (see note below).
 Check mast chains; lubricate and adjust if required.
Note
All grease points indicated on the grease point chart MUST be greased
every 100 operating hours / 2 months using EP2 Grease.
Note
All wheel nuts should be visually checked daily and torqued every 250
hours
See section 6.4 - Wheel Nut Torque on page 82
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Maintenance
6.3 Maintenance Schedule
Perform the tasks in the table below after the period of operating hours or the calendar
period as they first arise to keep the truck in optimum working condition.
The maintenance intervals shown are for trucks operating in normal conditions. For
trucks operating in harsh conditions more frequent maintenance will be required.
Maintenance Task Interval - Every ✔ Page

Check All Electrical Connections/Terminals
Check All Nuts And Bolts Are Present & Secure
250 Operating Hours (OH)

Check All Instruments & Warning Devices
Check Operation of Brakes, Steering & Hydraulic Functions 6 Months
Check the Lights 6 Months
Check the Tyres 6 Months
Check all Hydraulic Cylinder Chrome Rods for Dirt & Damage
Check the Routing of all Hoses, Pipes & Wires
Lubricate Mast Chains, Measure Mast Chain Stretch & Adjust 6 Months 105
Grease Mast Channels 6 Months 103
Grease Mast Carriage Channels 6 Months 109
Torque All Wheel Nuts 82
Check V-belt(s) For Wear & Tension 91
Check Engine Coolant Level and Concentration 88
Check Air Intake Hoses & Connections 92
Check Dry Air Filter – Clean or Replace Element 2 Years 92
Check Engine Idle Speed
500 Operating Hours (OH)
Check Hydraulic Pump Mounting Bolts

Check Radiator & Fan – Clean Fins If Necessary 1 Year
Check Hydraulic Oil Cooler & Fan – Clean Fins If Necessary 1 Year
Check Mast Bearings 108
Check Mast Carriage Bearings, Ensure Locknuts are Tight 109
Check Swivel Slew Ring Bearings
Check the Cabin & Door 1 Year
Change Fuel Filter (0.6L Filter) 1 Year 85
Change Engine Oil & Filter 1 Year 52
Change Hydraulic Suction Filter Cartridges 2 Years 99
Change Hydraulic Return Filter Insert 1 Year 100
Grease the bearings on the mast (only if applicable) 2 Years
Check Cold Starting Device(s)
1000 Operating
Check Engine Mounts and Mounting Bolts (tighten or replace)

Hours
Check Hydraulic System for Damage, Wear and Leaks

Replace V-belt(s) 2 Years 91
Change Fuel Filter (0.9L Filter) 1 Year 85
Change Fuel Pre-filter 1 Year 85
Change Hydraulic Oil & Strainer Filter (In-Tank) 2000 OH 3-4 Years 101
Change the Coolant 2 Years 88
Perform All Operator Pre-Use Checks In Conjunction With This Chart (Page 125)
Grease All Points Marked on the Grease Point Chart (Page 113) Every 100 Hours / 2 Months
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Maintenance
6.4 Wheel Nut Torque
Note
The wheel nut torque settings in the table below are for clean dry threads. If
the threads are lubricated the settings must be reduced.
All wheel nuts must be torqued every 250 hours. Park the truck in accordance with the
recommended parking procedure. Torque the wheel nuts according to the settings in
the wheel nut torque table below using a suitable torque wrench.
Wheel Nut Torque Table
Position Torque Setting
Front Wheel 210Nm / 155ft.lbs
Rear Wheel 300Nm / 220ft.lbs
6.5 Engine Oil System
Permissible Engine Oil Class
The lubricating oil quality has a considerable influence on the life, performance and
thus also on the cost effectiveness of the engine. The oil used in the engine must be
approved for use by the engine manufacturer.
A list of engine oils that have been approved for use with the Deutz engine in the
truck can be viewed by clicking on the following link:
www.deutz.com/en/service/maintenance/operating-liquids/oils/deutz-quality-class/
After clicking on the link scroll to the bottom of the web-page and click on:
DQC Release List Issue XX/20XX
Only select from the lists of oils that have been approved for one of the following
classes:
DQC III-10 LA / DQC IV-10LA
Lubricating oil change intervals:
 The intervals depend on:

 lubricating oil quality
 sulphur content in the fuel
 type of application of engine
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Maintenance
 The lubricating oil change interval must be halved if at least one of the following
conditions applies:
 Constant ambient temperature below -10 °C (14 °F) or lube oil
temperature below 60 °C (84 °F).
 Sulphur content in diesel fuel of >0.5 weight %.
 If the lubricating oil change intervals are not reached within a year, the oil
should be changed at least once a year.
Engine Oil Viscosity
The oil used in the engine must be suitable for the ambient temperature range where
the truck is operating as temperature affects the viscosity of the oil and therefore it’s
lubricating properties.
Too high a viscosity can lead to starting difficulties, too low a viscosity can endanger
the lubrication effect and cause a high lubricating oil consumption. At ambient
temperatures below -40 °C, the lubricating oil must be pre-heated.
The viscosity is classified according to SAE. Oils suitable for multiple ranges must
always be used. See the viscosity chart on the following page for the recommended
viscosity classes based on the ambient temperature.
ENGINE OIL VISCOSITY CHART
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 °C
-22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 °F
Caution
Switch off the engine before working on the lubricating system.
Wait until the engine and exhaust system are cool enough to touch before
commencing work.
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Maintenance
Changing Engine Oil & Filter
The engine oil and filter must be replaced at regular interval in accordance with the
maintenance schedule.
Note
Clean and dry the area around all components concerned thoroughly.
Observe safety regulations when handling oils and avoid skin contact.
Do not pour fluids into the ground, down a drain or into a stream, pond or
lake. Observe relevant environmental protection regulations when disposing
of used oil and filters.
1. Run the engine until it reaches its stable

C B
operating temperature.
2. Park the truck in a designated service
area (ground must be level) with the
reach extended to allow access to the
engine oil filter and drain plug.
3. Lower the mast fully and tilt fully forward.
drain plug (A) is cool enough to touch.
5. Position a suitable container (see point
13 for the volume of oil in the engine)
below the oil drain plug to collect the
used oil.
6. Unscrew the drain plug and allow the
system time to drain completely.
A Figure 6.4.1
7. Refit the oil drain plug with a new sealing
ring and tighten.
 Torque to 55 Nm (40.5 ft. lbs)
8. Unscrew and remove the used engine oil filter (B) (dispose of the used filter in
accordance with local environmental regulations).
9. Collect the draining oil from the filter.
10. Clean the sealing surface of the filter support with a clean lint free cloth.
11. Lightly coat the seal on a new Deutz original filter cartridge with clean engine
oil.
12. Screw on the new engine oil filter cartridge by hand - ensuring that the seal is
correctly placed – until the gasket is touching the sealing surface then tighten.
 Torque to 10-12 Nm (7.5-9 ft. lbs)
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13. Unscrew and remove the oil filler cap (C) (See figure 6.4.1) from the engine and
pour in clean, new engine oil of the permissible class and suitable viscosity (on
page 82).
Volume of oil required is: 8.2 litres / 8.65 quarts
14. Refit the oil filler cap and run the engine to warm the oil above 80°C (176°F).
Stop the engine wait for approximately 5 minutes until the oil has drained back
into the sump.
15. Check the oil level (see 5.3 on page 52) and top-up if necessary.
6.6 Diesel Fuel System
Warning
Switch off the engine before working on the fuel system.
Smoking and naked flames are prohibited when working on the fuel system.
Wait 5 minutes for the pressure to be relieved after the engine has shut
down as the system is under high pressure.
Note
Work on the fuel system may only be performed in a clean environment.
Contamination must be avoided.
Observe safety regulations when handling fuels and avoid skin contact.
Observe relevant environmental protection regulations when disposing of
waste fuel and used filter elements. DO NOT allow fuel to leak on the
ground.
The fuel passes from the tank through a pre-filter with a water separator and is then
conveyed by an electric feed pump through the main filter to the fuel injection
pump.
The filters and the feed pump are located on the back of the diesel tank (see figure
6.6 on the following page) and can be accessed by extending the reach and entering
area between the platforms. Replace the filters in accordance with the maintenance
schedule.
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A A. Fuel Pre-Filter With

Water Trap
B. Electric Fuel Pump
C C. Fuel Filter
Figure 6.6
Emptying the pre-filter water trap:

1. Place a suitable container underneath. 3 1
2. Disconnect the electrical connection (6). 2
3. Loosen the drain plug (5).
4. Drain until clean diesel runs out. 4
5. Tighten the drain plug – Torque 1.6 Nm
6. Reconnect the electrical connection. 5
6
Changing the pre-filter cartridge: 1. Fuel Inlet
2. Fuel Outlet
1. Place a suitable container underneath. 3. Venting Screw
4. Filter Element
2. Disconnect the electrical connection (6). 5. Drain Plug
3. Loosen the drain plug (5) and drain. 6. Electrical Connection
4. Unscrew and remove the used filter element.
5. Clean the sealing surfaces of the new cartridge and
filter head.
6. Apply a thin film of diesel to the sealing surfaces of
the new filter cartridge and screw onto the filter
head. (Torque to: 17-18Nm).
7. Refit the drain plug and electrical connection.
8. Vent the fuel system.
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Changing the fuel filter cartridge:

1. Place a suitable container underneath.
2. Unscrew and remove the used cartridge.
3. Clean the sealing surfaces of the new
cartridge and filter head.
4. Apply a thin film of diesel to the gasket on
the new filter cartridge and screw onto the
filter head. (Torque to: 10-12Nm).
5. Vent the fuel system.
Venting the Fuel System
The fuel system is vented via the electric fuel supply pump. In order to ensure that no
error messages are generated and that no damage to the high pressure pump may
occur, no attempt to start the system may be made during the entire venting process.
The venting process must be carried out as described below.
Venting Procedure:
1) Turn the ignition key switch to the “ON” position to activate the electric fuel
pump. Do not turn the ignition to the start position as damage to the fuel
pump may occur.
2) The electric fuel supply pump switches on for 20 seconds in order to vent the
fuel system and build up the required fuel pressure.
3) Wait until the fuel supply pump cuts out.
4) Turn the ignition key switch to the "OFF" position.
5) Repeat steps 1-4 above 2 more times to fully vent the fuel system.
6) The engine may only be started following this.
Note
Do not attempt to start the engine until the venting procedure has been
completed.
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6.7 Engine Cooling System
Caution
Switch off the engine before working on the cooling system.
Never operate the engine without coolant.
Explosive release of hot fluids from the pressurised cooling system can
cause serious burns.
The engine and cooling system must be cool to the touch before working on
the cooling system.
Only remove the filler cap when cool enough to touch with bare hands.
Slowly loosen the cap to relieve pressure before removing completely.
Coolant is harmful if ingested. Seek immediate medical attention if ingested.
Avoid contact with skin and eyes. Wear protective gloves and goggles when
handling coolant.
Note
Do not pour coolant into the ground, down a drain or into a stream, pond or
lake. Observe relevant local environmental protection regulations when
disposing of used coolant.
Note
It is advised not to mix different coolant products.
See www.combilift.com/coolant for a list of approved coolant products.
The coolant must be changed at regular intervals in accordance with the maintenance
schedule.
All Combilift IC engine powered trucks leave factory with a mixture of 50% water to
50% coolant concentrate (Glysantin® G64®) in the engines cooling system. This protects
the engine against:
 Freezing down to -37°C (-34.6°F)
 Corrosion
 Cavitation
 Overheating
If greater protection against freezing is required, the proportion of coolant concentrate

can be increased up to 60% (protection against freezing down to -52°C (-61.6°F)). Any
greater proportion of coolant will decrease the protection against freezing and also
impair the anti-corrosive properties.
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Coolant must be completely replaced when repairs are performed on the cooling
system. Rinse out the cooling system before filling with new coolant. A mixture of clean
water with 15% of the new coolant is recommended for rinsing.
The cooling system must be monitored regularly. This includes checking the
concentration of coolant concentrate to water. The concentration of coolant
concentrate to water must never be allowed to fall below 40% as the protective effects
fall away rapidly below this concentration.
Checking the Coolant Level

The coolant level is monitored via the sight glass on the coolant header tank. The
coolant header tank is mounted on top of the radiator located at the rear right hand
corner of the truck. See section 5.5 for details on how to check the coolant level.
Coolant Water Quality:

The water used to dilute the coolant concentrate must be clean and clear and must
conform to the values in the table below:
Analysis Values Minimum Maximum ASTM
pH 6.5 8.5 D 1293
D 512
Chlorine (Cl) mg/l - 100
D 4327
Sulphate (SO4) mg/l - 100 D 516
mmol/l 3.56
D 1126
mg/l 356
Total Hardness
°dGH 20.0
(CaCO3)
°e 25.0
°fH 35.6
Water that deviates from the values in the table above must be conditioned before it
can be used.
Draining the Cooling System:
1. Stop the truck in a designated service

area and extend the reach to allow
accesses to the radiator.
2. Lower the forks fully, tilt the mast
forward fully then switch off the engine. A
3. Open the bonnet from the rear of the
truck.
4. Remove the cap from the top of the
coolant header tank. The cap (A) must C
be cool to the touch before removing.
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5. Turn the cap anticlockwise gradually to

release any residual pressure before
removing completely.
6. Enter the area behind the mast. B
7. Place a suitable container under the
drain plug (B) on the bottom left corner
of the radiator.
8. Unscrew the drain plug and allow time
for the coolant to drain completely.
9. Refit the drain plug.
Flushing the Cooling System

1. Drain the system as described under ‘Draining the Cooling System’.
2. Fill the radiator with clean clear water then refit the radiator cap securely.
3. Run the engine for 5 minutes.
4. Wait until the radiator is cool enough to touch.
5. Remove the radiator cap, top the radiator up to full again then refit the radiator
cap securely.
6. If the truck has a cabin heater fitted, switch it on.
7. Run the engine for 15 minutes.
8. Watch the temperature gauge while the engine is running. If the temperature
gauge moves into the red area, switch the engine off immediately.
9. Wait until the radiator is cool enough to touch then drain the system as
described under ‘Draining the Cooling System’.
10. Repeat steps 2-9 using a solution of clean clear water (85%) mixed with the
new coolant concentrate (15%) that is going to be used.
A coolant system flushing solution may be used to remove scale and other
deposits if required.
Filling and Venting the Cooling System:

1. Park the truck in accordance with the recommended parking procedure.
2. Open the bonnet from the rear of the truck.
3. Remove the cap from the top of the coolant header tank. The cap (A) must be
comfortable to touch before removing.
4. Turn the cap anticlockwise gradually to release any pressure before removing.
5. Fill with the specified coolant up to the bottom of the header tank filler neck.
6. Switch on any available heating and set to the highest level so that the heating
circuit is filled and vented.
7. Fit the header tank cap securely.
8. Run the engine up to operating temperature (opening temperature of the
thermostat).
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9. Switch off the engine and allow to cool.

10. Check the coolant level in the header tank and top up to the top of the sight
glass (C) if necessary.
Total Coolant System Volume = 14 litres/14.8 quarts
6.8 Belt Drive System
Caution
Switch off the engine before working on the belt drives.
When work on the belt drives has been completed, check that all guards
have been replaced and that all tools have been removed from the engine.
Checking the Belt Drive:

 Check the entire belt drive i.e. the belt(s) associated pulleys, bearings etc.
visually for signs of damage and wear and replace any damaged parts.
 Check the tension on the belt(s) using a belt tension gauge - follow the
instructions provided with the device.
 Tension loose belts and replace belts showing signs of damage or wear.
 Do Not over tension the belt(s) as this will shorten the life of pulleys and
bearings.
Belt Replacement Procedure:

1. Insert the head of a socket wrench
into the square hole (A) on the belt
tensioner and press in the direction of
the arrow until a retaining pin can be C
inserted through the round hole (B) to A
hold the tensioner pulley off.
2. The v-rib belt (C) will then be tension
free.
3. Pull the belt off the smallest roller or
the tensioning roller first, then remove
the belt and mount a new belt.
4. Hold the tensioner off using the socket B
wrench and remove the holding pin.
5. Slowly release the tensioning roller
onto the new belt. Check that the belt
is correctly in its guides.
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6.9 Air Filter System
Caution
Switch off the engine before working on the air filter system.
Do not touch the engine, exhaust system, or cooling system immediately
after stopping the engine.
Wait until the stopped engine has cooled to the point that the exhaust
system, engine, and cooling system are comfortable to touch.
The truck is equipped with a dry air filter for filtering the engine intake air. The dry air
filter consists of a single main filter element. An optional safety filter element may be
fitted if required.
The dry air filter should be maintained in accordance with the maintenance schedule,
however more frequent maintenance will be required if the truck is operating in high
dust applications.
Note
Clean and dry the area around the filter housing thoroughly. Contamination
must be avoided. Block off the engine air intake if necessary.
Air contaminated with dust entering the engine will cause damage and
reduce performance.
Never run the engine if parts of the air intake system are removed. Replace
damaged air filter system parts immediately.
A
To Service the Air filter
B
2. Remove the cover plate (A) from the

front right hand side of the lower
bonnet panel (B) by unscrewing the
four socket button head screws with a
4mm Allen key.
C
3. Inspect the air intake hose (C) for
cracks or other damage and repair or
replace as necessary. Inspect all
connections and clamps and ensure
they are tightly sealed. Any leaks here
will admit dust directly to the engine.
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4. Check the outlet slot on the dust valve (D) for dust build up. Remove dust by
pinching the valve. Make sure the dust valve is flexible and not inverted,
damaged or plugged.
F H
5. Unlatch the filter cover (E) and remove from the filter housing (F).
6. Remove the primary filter element (G) – gently move the end of the filter back
and forth to break the seal, then rotate while pulling it straight out. Avoid
knocking it off the housing while removing.
7. If an optional safety filter element (H) has been fitted, visually check it in place
for damage and check that it is properly seated.
 Do not remove the safety filter unless it is due for replacement.
 Change the safety filter every three primary filter changes.
 DO NOT attempt to clean or reuse the safety filter.
 When changing the safety filter use a clean damp cloth to wipe the filter sealing
surface and the inside of the outlet tube.
8. Avoid leaving the outlet to the engine exposed for any period of time. Keep the
outlet covered to avoid admitting dust to the engine.
9. Inspect the primary filter element. Clean if lightly soiled or replace if heavily
soiled. If there is a streak of dust on the clean side of the filter it must be
replaced.
To clean the filter :
 Lightly knock off as much dust as possible.
 Blow out with dry compressed air (maximum 5 bar pressure) from the inside to
the outside.
10. If fitting a the new primary filter element inspect the new element for damage.
Never install a damaged filter. Do not wipe the sealing area on the filter.
11. Insert the new filter. If changing the safety filter at this service, seat it properly
before installing the primary filter. Insert new filters carefully. Make sure filters
are inserted completely into the housing. Press in by hand along the rim of the
filter, not the flexible centre..
12. Reinstall the filter housing cover ensuring that the dust valve is pointing down
towards the ground. The cover should not come into contact with the filter
element before it is fully in place. If there is contact before the cover is fully in
place the filter must be pushed in further before latching the cover.
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6.10 Battery Maintenance
The battery is located to the rear of the right hand side platform and can be
accessed by removing the right hand side access panel.
The truck is supplied with a 12V 105Ah 735A battery.
Caution
Protective clothing and goggles should be worn and particular care taken
not to come into contact with or spill battery electrolyte.
Batteries contain sulphuric acid which may leak for various reasons.
Sulphuric acid is a corrosive and poisonous liquid that will cause burns and
irritation to the skin and eyes.
Batteries generate explosive gases when being charged. Charge in a well-
ventilated area and follow the instructions for the charger being used.
Never connect the positive terminal to the negative terminal on the same
battery with a conductive object such as a metal tool.
The temperature of the battery must not exceed of 50° C (122° F) during
charging.
Smoking and the use of naked flames in the charging area is prohibited.
Clean the battery and terminals with a damp cloth. Using a dry cloth can
lead to a build-up of static electricity that may discharge and cause an
explosion.
Checking the Battery Electrolyte Level

recommended parking procedure and
switch off the engine and all electrical C
components.
2. Remove the RH side access panel (A)
(pull out firmly at the top then lift up and
out) to gain access to the battery (B).
3. Check the electrolyte level in each cell B
by removing each of the caps and
inspecting inside.
4. The electrolyte should be just above
the tops of the separators. A
5. If required top up each cell with
distilled or deionised water and refit
the cap
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Removing the Battery

recommended parking procedure and
switch off the engine and all electrical C
components. D
2. Remove the RH side access panel (A)
(pull out firmly at the top then lift up and
out) to gain access to the battery (B).
3. Isolate the electrical system by turning B
the isolator key (C) anticlockwise.
4. Remove the connector from the
negative black (-) battery terminal (C)
first, then remove the connector from
the positive red (+) battery terminal.
A
5. Remove the battery bar (D) by first
unscrewing the two M8 locknuts from
the battery rods. Ensure it does not
come into contact with the battery
terminals.
6. Use the handles on top of the battery to remove the old battery. CAUTION the
battery weights 27.6kg. Get assistance or use suitable equipment.
Note
engine to save the system data (lag) then switches off automatically.
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Installing a new Battery
1. Compare the new battery with the used battery and ensure the new battery
has the same polarity and performance characteristics as the old battery
2. Check that the new battery is clean and dry and that the caps are secure.
3. Check that the new battery has a voltage above 12.40V. If not, charge the
battery or use another that has a voltage above 12.40V.
4. Ensure the 2 terminal caps are still fitted at this stage.
5. Ensure the battery tray is clean and dry, then insert the new battery
6. Ensure the connectors are clean and corrosion free. Remove corrosion with
fine emery paper if required. Coat lightly with acid free grease.
7. Refit the battery bar then remove the terminal caps and place them on the
spent battery
8. Connect the positive (+) red battery terminal first then connect the negative (-)
black terminal.
9. Turn the battery isolator key clockwise, then start the engine.
Note
DO NOT over tighten the battery bar or terminal clamps.
Dispose of used batteries at a battery collection point.
Battery Charging
Charging the battery on the vehicle is not recommended. Follow steps 1 - 4 under
‘Removing the Battery’ on the previous page for instructions on how to remove the
battery from the truck. Follow the instructions for the battery charger being used.
Charging of the battery is required when the:

 Storage period is more than 6 months without charging.
 Colour of the state of charge (SOC) indicator turns black.
 Battery operating current voltage (OCV) is less than 12.4V.
Steps Prior to Charging:

 Wear protective glasses whilst handling the battery.
 Do not carry out charging near any source of ignition e.g. flames or sparks.
 Do not charge a damaged or frozen battery.
 Boost charging is not recommended.
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Jumpstarting:
When performing a jump start using jumper cables, there can be bursts of high
voltage of hundreds of volts when connecting the cables. Isolate the battery when
connecting the jumper cables. Only use standardised battery jumper cables. Only
connect batteries of the same nominal voltage. Before giving starting aid, try to figure
out the reason for the battery weakness. If the reason is a failure in the vehicle
electrical system, starting aid should not be given. The battery or the electric system
of the vehicle giving starting aid might become damaged. Always protect your eyes
and hands from the battery.
Performing a Jumpstart:
1. Switch off the ignition in both vehicles.

2. Connect the red jumper cable to the
positive pole of the weak battery.
3. Connect the red jumper cable to the
positive pole of the donor battery.
4. Connect the black jumper to the
negative pole of the donor battery.
5. Connect the black jumper cable to a
bare metal earth point (away from the
battery) on the vehicle with the weak
battery.
6. Start the engine in the vehicle providing assistance, followed by the vehicle
requiring assistance.
7. If the engine does not start after a maximum of 15 seconds, wait one minute
before trying again.
8. Once the engine has started, let both engines idle for approximately 2 minutes
then remove the cables.
9. Reverse the sequence of steps 1 to 5 sequence when disconnecting the
cables.
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6.11 Hydraulic Oil System
Note
Use of hydraulic oil that does not meet the required grade or temperature
range may cause poor operation, reduced efficiency and/or damage to
hydraulic components.
The machine is supplied with ISO 46 hydraulic fluid when leaving the
factory unless otherwise stated. Refer to the decal on the hydraulic tank.
Please check if this is suitable for the trucks operating temperature range.
Caution
Switch off the engine before working on the hydraulic system.
Wait until the hydraulic tank is cool enough to touch before commencing
work.
Clean up any oil spills immediately.
Note
Observe safety regulations when handling oils and avoid skin contact.
Do not pour fluids into the ground, down a drain or into a stream, pond or
lake. Observe relevant environmental protection regulations when disposing
of used oil and filters.
Hydraulic Oil
The hydraulic oil used in the trucks hydraulic system must conform to ISO 3448
viscosity classification grade and include additives for improved:
 Viscosity index
 Wear prevention
 Corrosion protection
 Stability against oxidation
 Deaerating and foam suppressing
 Compatibility with seals and gaskets
 Low pour point
The oil must also have the correct temperature range for the operating temperature of
the truck. If the operating temperature is outside the range of the standard grade 46
oil, the standard oil should be replaced with the appropriate grade of oil.
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The correct grade of oil for the relevant operating temperature range can be
determined using the following table:
HYDRAULIC OIL TABLE

FLUID OPERATING -11°C to 66°C -4°C to 74°C 4°C to 89°C
TEMPERATURE RANGE 12°F to 150°F 24°F to 166°F 39°F to 193°F
Maxol Multivis
RECOMMENDED FLUIDS
ISO GRADE
ISO GRADE
ISO GRADE
Castrol Hyspin AWH
BP Bartran HV
32
46
68
Mobil Univis N
Mobil DTE 10 Excel
Shell Tellus Oil T
Chevron Rando HDZ
Hydraulic Oil Filters

There are three oil filters in the hydraulic system. These are the:
 Suction Filter
 Return Filter
 Strainer Filter
The hydraulic oil filters must be changed at regular intervals in accordance with the
maintenance schedule.
Suction Filter
The hydraulic oil suction filter is mounted at the rear right hand corner of the truck
inside the RH side access panel.
The cartridge must be replaced after the first 100 hours of operation and then at regular
intervals in accordance with the maintenance schedule.
To change the suction filter cartridge:
1. Park the truck in accordance with the recommended parking procedure, switch
off the engine and and wait until the suction filter is cool enough to touch.
2. Release any residual pressure in the hydraulic system i.e. lower the mast fully
and tilt the mast fully forward.
3. Remove the RH side access panel (A) (pull out firmly at the top then lift up and
out) to gain access to the suction filter (B).
4. Reach in and close the shut-off valve on the back of the hydraulic tank to prevent
the oil in the tank from escaping when the suction filter element is removed.
5. Clean the area around the suction filter thoroughly before removing the used
cartridge to prevent any contamination from entering the hydraulic system.
6. Position a suitable container under the used filter element to collect any
escaping oil.
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7. Loosen and remove the filter cartridge.

Use a filter wrench if required.
8. Check the sealing surfaces and threads
on the filter mount and the new filter
element and clean if necessary.
9. Apply a thin film of clean hydraulic oil to
the o-ring on a new filter cartridge.
10. Screw the new filter cartridge on to the
filter mount until it is hand tight only. DO
NOT over tighten the filter. Only use a
genuine Combilift component.
11. Open the shut-off valve on the back of
the hydraulic tank before starting the
truck.
12. Dispose of waste oil and used filter
cartridges in compliance with local
regulations.
13. Start the truck and check around the
A B
filter for leaks. Repeat the check when
the hydraulic oil has reached operating
temperature.
14. Top up the hydraulic oil if necessary (see section 5.6 Checking Hydraulic Oil
Level on page 58).
Return Filter
The hydraulic oil return filter is mounted on the top of the hydraulic tank and filters the
oil as it is returned from the valve chest to the tank.
The filter cartridge must be replaced after the first 100 hours of operation and then at
regular intervals in accordance with the maintenance schedule.
To change the return filter element:

1. Park the truck in a designated service
area. Reach the mast out fully forward,
lower the mast fully and tilt the mast fully
forward.
return filter housing (A) is cool enough
to touch.
3. Open the bonnet using the handle
provided at the rear of the truck.
B
4. Clean and dry the filter housing and
surrounding area thoroughly before
removing the cover to prevent any
contamination from entering the
hydraulic system.
A
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5. Loosen the four bolts on the return filter housing cover (B) but do not remove
the bolts.
6. Remove the cover (B) by pressing down, turning clockwise and lifting off.
7. Remove the filter cartridge and bowl.
8. Remove the used filter cartridge from the bowl. Collect the used cartridge and
any escaping oil in a suitable container and dispose of them in compliance with
local regulations.
9. Apply a thin film of clean hydraulic oil to the O-ring on the bottom of the new
filter cartridge and fit the filter into the bowl.
10. Check the condition of the bowl seal and replace if necessary (apply a thin film
of clean hydraulic oil to a new seal before fitting). Insert the bowl into the
housing.
11. Check the condition of the cover seal and replace if necessary (apply a thin film
of clean hydraulic oil to a new seal before fitting).
12. Clean the filter cover if necessary the refit by reversing steps 5 & 6 above.
Ensure that the spring is in place between the lid and the cartridge.
13. Start the truck and check the filter for leaks. Repeat the check when the truck
has reached operating temperature.
14. Top up the hydraulic oil if necessary (see section 5.6 Checking Hydraulic Oil
Level on page 58).
Hydraulic Oil & Strainer Filter

The hydraulic oil should be analysed regularly to determine its condition. If analysis of
the hydraulic oil is not an option then it must be changed in accordance with the
maintenance schedule. Only use oil of the correct specification and suitable grade for
the ambient temperature range. The hydraulic oil and the strainer filter - located inside
the hydraulic tank - must be changed simultaneously.
Note
To achieve the correct hydraulic oil level, ensure that all cylinders are fully
retracted where possible, then fill to half way up the sight glass on the
hydraulic oil gauge. Otherwise the tank may be overfilled.
To change the hydraulic oil and strainer filter:

1. Operate the truck for a period of time long enough for the oil in the system to
become warm. This will help the oil to flow.
2. Park the truck in a designated service area (ground must be level). Extend the
reach to allow access to the drain plug on the bottom left hand side of the
hydraulic tank.
3. Lower the mast fully and tilt the mast fully forward.
4. Switch off the engine and wait until the hydraulic tank is cool enough to touch
before proceeding.
5. Remove the oil filler cover plate (A) from the front of the lower bonnet panel
(B).
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6. Unscrew and remove the filler cap (C) A B

and place on a clean dry surface.
7. Position suitable containers for catching
the used oil beneath the oil drain plug.
Hydraulic Tank Capacity: 60L / 63.5qt
8. Unscrew the oil drain plug (D) and allow
the system time to drain completely. C
9. Refit the oil drain plug and tighten (fit a
new seal if required).
10. Unbolt and remove the access panel (E)
from the left hand side of the hydraulic
tank and place on a clean dry surface.
11. Reach inside the tank and unscrew and
remove the used strainer filter (F)
F
(dispose of the used filter in accordance
with local environmental regulations).
12. Clean the bottom of the hydraulic tank
with hydraulic oil through the opening.
13. Apply a little hydraulic sealant to the
thread of a new strainer filter and fit the
new filter to the tank in the place of the
filter that was removed. Use a genuine
OEM component.
14. Check the condition of the tank access
panel O-ring seal and replace with a new E
seal if necessary.
15. Refit the access panel (E) securely
remembering to correctly fit the O-ring
seal.
16. Dispose of waste oil and used filter
elements in compliance with local
regulations. D
17. Clear the work area between the platforms, behind the mast.
18. Half fill the tank with fresh, clean hydraulic oil then refit the filler cap securely.
19. Start the engine, raise the forks off the ground, retract the reach fully then lower
the forks fully.
20. Switch off the engine.
21. Top up the hydraulic oil to half way up the sight glass on the left hand side of
the hydraulic tank.
22. Clean up any oil spills immediately.
23. Refit the oil filler cover plate (A) to the front of the lower bonnet panel (B).
24. Operate the truck until the oil becomes warm then check the oil level.
25. Check around the drain plug (D) and the access panel (E) for oil leaks.
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6.12 Mast Maintenance
Perform checks on the mast as required by the Pre-Use checks and maintenance as
required by the first 100 operating hours service and in accordance with the
maintenance schedule. Details on how to perform the checks and maintenance on the
mast are provided in this section.
Warning
Never work on the mast with the forks in a raised position unless adequate
supports are in place.
Block access to the lift truck control handles when working on the mast.
Mast Channel Maintenance

Periodic lubrication of the mast channels is required to
ensure maximum life span is achieved. All roller
surfaces must be greased periodically where the fork
carriage bearings and mast section bearings run. The
frequency of this operation is at the discretion of the
user and essentially depends upon the working
conditions. A lubrication interval of 250 hours can be
taken as a typical value under normal working
conditions. For this purpose use graphite grease, avoid
spray greases.
Fork Carriage With Wide Hydraulic Fork Positioning Maintenance

Periodic lubrication of the fork carriage bars is required to ensure maximum life span
is achieved. All surfaces where contact occurs between the forks and the fork bars
must be greased periodically where the forks run. The frequency of this operation is at
the discretion of the user and essentially depends upon the working conditions. A
lubrication interval of 250 hours can be taken as a typical value under normal working
conditions. For this purpose use graphite grease, avoid spray greases.
Mast Chain Maintenance

Regular inspection and lubrication of the chains will vastly increase their service life
and reduce downtime. When performing chain maintenance, make sure to follow the
guidelines in ‘Chain Inspection’, ‘Measuring Chain Stretch’, ‘Chain Lubrication’ and
‘Chain Adjustment’.
It is recommended that trucks used in arduous, harsh or aggressive environments such

as cold stores, marine, corrosive chemical, metal manufacturing or processing,
cement/aggregate processing and brine processes (this list is not exhaustive) should
have their mast chains and mast chain anchor pins replaced after a period not
exceeding 4000 operating hours or two years, whichever is the shorter. Additionally
where the lifting mechanism uses a single leaf chain (e.g. free lift section), the leaf
chain anchor bolts should also be replaced at the same time.
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Chain Inspection
Inspect the chains for the following damage and defects:
Symptom Appearance Probable cause Correction

Normal wear on sheave Replace leaf chain when 5% worn
Worn contour
Abnormal wear rubbing on Check Leaf chain alignment or increase
guides clearance
Worn surfaces on
Misalignment, rubbing on side Check leaf chain alignment and correct
outer plates or pin
flanges clearance as necessary
heads
Dirt or foreign substance

Clean & re-lubricate leaf chain
packed in joints
or
Tight joints Replace leaf chain
corrosion or rust
or
Replace leaf chain
bent pins
Missing parts Missing at original assembly Replace leaf chain
Abnormal Excessive internal friction Replace leaf chain, improve

protrusion or turned caused by high loading and lubrication and eliminate
pins inadequate lubrication overload conditions
Replace chain with leaf chain

of larger dynamic
Loading beyond chain's
Cracked capacity or eliminate
dynamic capacity (above
plates (fatigue) Crack from aperture high load condition or
fatigue endurance limit)
towards edge of link plate at dynamic (impulse)
90º to line of pull. Note there overloading
is no link plate distortion.
Fractured plates Replace leaf chain and correct cause of

High overload
(tension mode) overload
Note material distortion
Severe rusting or exposure to

acidic or caustic medium, plus
Arc like cracked
static pressure at press fit Replace leaf chain and protect from
plates
(between pin and pin link plate). hostile environment.
(stress corrosion)
No cyclic stress is necessary
for this phenomenon to occur.
Replace leaf chain and correct cause of

Enlarged holes High overload
overload
Exposure to corrosive Replace leaf chain and protect from

Corrosion pitting
environment hostile environment.
Worn leaf chain

Replace worn leaf chain components
anchor bolt Normal wear
and always when fitting new leaf chains
connecting pin
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Maintenance
Chain Lubrication
Caution
The chains must be kept lubricated at all times.
Running the chain dry will substantially shorten its life. Oil must be reapplied on a
regular basis to ensure the chains maximum life is achieved.
The frequency of this operation is at the discretion of the user and essentially depends
upon the working conditions and the workplace environment.
Ensure that the chain is slack during the lubrication process so that the lubricant
can flow between the chain link plates and pins.
It is recommended that the lubricant used on the chains has the following properties:
 Satisfactory corrosion protection and lubrication

 Ability to penetrate through / under water
 Continuously viscous after application
 Good adhesion properties
 Layer thickness and protective film able to withstand later aggression (rain / hail
etc.)
The following lubricants (available in an aerosol can) are recommended:
Fuchs anticorit bw366

Molykote mkl-n
Kluber structovis bhd 75s
Where chains are encased in dirt and dust the lubricant will be prevented from flowing
to the vital load bearing contact areas of the chain between the link plates and pins.
It is essential with leaf chains that all dirt and debris is removed prior to lubrication.
Recommended jet equipment cleaning method for leaf chain:
The following method is recommended when the use of jet cleaning equipment cannot
be avoided in leaf chain maintenance:
1. Cleaning - Clean the leaf chain using steam or hot water only. Absolutely no
additives should be used.
2. Compressed Air - Immediately after cleaning the leaf chain, all water should
be removed both from the surface and from inside the chain joints using high
pressure compressed air. The articulating links of the chain should be moved
several times during this process.
3. Re-lubricating – Make sure that the chain is slack and then spray with a
preservative and lubricant. Articulate the chain several times so that the
lubricant penetrates the chain joints.
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Measuring Chain Stretch

Leaf chain failure is usually a result of gradual elongation as the chain wears. Measure
the chain elongation with a chain wear gauge that displays the elongation of the chain
as a percentage value. Follow the instructions provided the chain wear gauge.
Chains should ideally be cleaned and measured in situ while placed under load. It is
acceptable for the chain to be tensioned by the weight of the carriage and forks.
When checking a chain for wear it is vital that the section that passes over the pulley
is measured as this section experiences the most wear during normal operation.
Warning
If a chain has reached a level of 2% elongation, a safe time limit must be set
for the chains to be replaced. If a chain has reached 3% elongation, it must
be taken out of service immediately.
Chains operating in hostile, aggressive or cold store environments are more

susceptible to premature failure and it is, therefore, particularly critical that any sign of
deterioration and pitch elongation is carefully inspected. Irrespective of the results of
the inspection chains operating in hostile and aggressive environments should be
replaced after a period not exceeding 4000 hours or two years, whichever is the
shorter. Those operating in cold stores should be replaced after a period not exceeding
6000 hours or three years, whichever is the shorter.
To check the free lift chains, raise the carriage 1ft (30 cm) off the ground to put tension
on the chains.
To check the main lift chains, raise the mast until the inner upright starts to rise putting
tension on the chains.
Adjusting for Chain Stretch

Chain elongation due to stretch (see ‘Measuring Chain Stretch’ above) can be
compensated for by adjusting the chain anchors (A). However if the full length of the
chain anchor is used up it will be necessary to remove a link.
The chain anchors are located on the fork carriage and also on the mast stages.
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Mast Chain Adjustment

The chains connecting the mast stages must be adjusted in such a way as that the
vertical mast channels are approximately flush with each other at the bottom and not
in contact with the bottom plate when the mast is unloaded and fully lowered.
To adjust a mast stage, tighten or loosen the adjusting nut on one of the chain anchors
to achieve the desired dimension. Adjust the opposite chain of the pair to achieve equal
tension in the chains.
Raise the mast fully and check that a clearance of at least 1mm exists between the
end of run stops ([A] and [B] in figure 6.12 1 and figure 6.12 2) on each of the mast
stages.
Fork Carriage Chain Adjustment

The chains connecting the fork carriage to the mast stages must be adjusted so that
the upper and lower end of run stops never make contact.
To set the clearance between the lower stop on

the fork carriage (A) and the corresponding
lower stop on the mast (B), remove the forks
and lower the fork carriage fully. Adjust the A
chain anchors so that there is a clearance of
approximately 5mm between the stops. B
Figure 6.12 1
To set the clearance between the upper stop

on the fork carriage (A) and the corresponding A
stop on the mast (B), remove the forks and
raise the fork carriage fully. Adjust the chain
anchors so that there is a clearance of B
approximately 1mm between the stops. When
the forks and a load are present the clearance Figure 6.12 2
will increase to a desired value of
approximately 5mm.
Caution
If the lower stops are allowed to collide they will warp and the lower
bearings on the mast carriage will come out of the mast channel.
If the upper stops are allowed to collide excessive forces will be placed on
the chains and the free lift cylinder resulting in premature failure.
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Chain Tension Adjustment

The chains on the mast must be adjusted so that each chain acting as one of a pair is
under equal tension to the opposite chain in the pair for proper load distribution and
mast operation.
Checking and Setting the Chain Tension

1. With the mast unloaded raise the sections to put the chains under tension.
2. Press the centre of a strand of chain with a suitable rod and then press at the
same place on the opposite chain of the pair.
3. Each chain in a pair should have equal “give”.
4. If the tension is not equal, tighten the bolt on the anchor of the slack chain.
5. Test the tension again. Adjust until the tension is equal.
Caution
Never place hands inside the mast to check chain tension.
Mast Bearings
Check for cracks or flat areas on the surface of the bearings and also check for
restrictions to rolling. Replace if any of these are detected and try to eliminate the
cause(s) of the failure.
Principle Causes of Bearing Failure
Insufficient Lubrication
The rollers stop rolling and the external surfaces rub on the adjacent
mast channel and start to wear causing flats on the surface.
Shocks
Violent frontal collisions during loading can cause bearings to fail.
The external surface will show cracks that cut the surface parallel to the
rolling axis.
Large Load Centre

Another possible cause of breakage is the mounting of special equipment
to handle loads with a very large load centre e.g. carpets, even if their
weight is lower than the rated capacity.
This condition creates oscillations that cause the detachment of the
external hardened surface of the bearing. In this case circumferential
cracks will appear and will run completely around the roller.
Note
The majority of bearings used on masts fitted to Combilift trucks are
maintenance free, however a small number of masts utilise bearings that
must be greased every 500 hours. Check the mast bearings for lubrication
passages and grease with EP2 grease if applicable.
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6.13 Cleaning & Greasing Mast Carriage
The mast carriage channels must be cleaned (if necessary) and greased (only on the
vertical (side) surfaces) periodically where the wear pads run. The frequency of this
operation is at the discretion of the user and essentially depends upon the working
conditions and the workplace. A lubrication interval of about 250 hours can be taken
as a typical value, under normal working conditions. For this purpose use EP2 grease.
6.14 Mast Carriage Alignment / Wear Pad Adjustment Procedure
1. Check that the mast carriage cylinders are securely fastened. Check that the
M24 castle nuts on the carriage cylinders are tight before commencing the mast
carriage alignment/wear pad adjustment procedure.
2. Fully extend the mast carriage then bring it back in by approximately 50mm.
Raise the mast until the bottoms of the forks are approximately 0.5m above
head height. This allows access to the mast carriage wear pad locking nuts and
adjustment bolts. Prop up the fork carriage using a suitable support to prevent
it from dropping. Do not allow access to the machine controls while working
under on the mast.
Warning
Failure to support the fork carriage and block access to the fork
controls while working under the mast could result in serious injury or
death.
Channel Mast Carriage
Fork
Carriage
Support
Locking Adjustment
Nut Bolt
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Maintenance
3. Loosen the locking nuts a couple of turns, then loosen the adjustment bolts a
couple of turns. There are 4 wear pads on the mast carriage, 2 at the front and
2 at the back. Ensure that the nuts and bolts are loosened off at all 4 wear pads.
Wear
Pads
4. Measure the distance (x) between the mast carriage side plate and the channel
at the front of the machine on both sides of the truck. The distance (x) must be
equal on both sides. Turn the front wear pad adjustment bolts clockwise to push
the wear pads up against the channels. Adjust the wear pads until the distance
(x) is equal on both sides.
X X
Note
The wear pads must only be in light contact with the channels to allow the
carriage to travel freely. Do not over tighten the adjustment bolts as the
force between the wear pads and the channel will cause the carriage to
stick. Maximum torque of the bolts should not exceed 25Nm (18.5ft.lb).
5. Adjust the wear pads on the rear as described in point 4.
6. Check that the vertical faces of the channels where the wear pads run are clean
and adequately lubricated. Operate the reach function to move the mast in and
out several times through the full extent of its travel.
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7. Check the torque of all the adjustment bolts. The torque must not exceed 25Nm
(18.5ft.lb).
8. Tighten all the locking nuts up against the mast carriage side plates to lock the
adjustment bolts in place. Use a spanner to prevent the adjustment bolts from
turning while the locking nuts are being tightened.
6.15 Fork Maintenance
Warning
Never operate the truck if the forks are damaged. If a defect is found in the
forks or mounting components take the truck out of service until the fork is
repaired or replaced. Report any fork damage to the relevant authority
immediately. Failure to follow this warning can cause serious injury or
death.
Inspect the forks as required by the pre-use checks. This section provides details on
how to perform a complete fork inspection.
!
Cracks
Visually examine the forks for surface cracks. Pay special attention to:
 Fork heel
 Welds that attach mounting components to the fork blank
Forks with surface cracks should not be returned to service.
Straightness of Blade and Shank

Check the straightness of the upper face of each blade and the front face of each
shank. If the deviation from straightness exceeds 0.5% of the length of the blade and/or
the height of the shank, respectively withdraw the fork from service.
Fork Angle
Check the angle between the front vertical face of each fork and the load face of each
shank. If the deviation exceeds 3° from the original specification withdraw the fork from
service.
Difference in Height between Fork Tips

Check the difference in height between tips of the forks with the forks mounted on the
fork carriage. If the difference in tip heights exceeds 3% of the length of the blade, the
forks should be removed from service.
Positioning Lock
Check the positioning lock on each fork to make sure it functions properly. If any
problems are noted, repair or replace the fork.
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Wear
Two different areas of the fork and fork attachment should be checked for wear.
 Fork Blade and Shank – Check each fork blade and shank for wear, pay
special attention to the area surrounding the heel of the fork. If the thickness is
reduced to 90% of the original thickness, remove the fork from service.
 Fork Hooks – Check the support face of the top hook and the retaining faces
of both hooks for wear, crushing, and other local deformations. If any of these
deficiencies cause excessive clearance between the fork and the fork carriage,
remove the fork from service.
Fork Marking
If the fork marking is not clearly legible, the fork manufacturer, or their representative
should remark it.
Repairing Forks
If a fork needs to be repaired or replaced, return it to the manufacturer or other expert
of equal competence who shall decide if it may be repaired or if it must be replaced
with a new fork. Never try to repair surface cracks or wear by welding the fork. If you
need to reset a fork, make sure it is subjected to an appropriate heat-treatment before
it is returned to service.
Load Testing Forks

A fork that has undergone repairs - other than repair or replacement of the positioning
lock or marking - must be load tested before it is returned to service. The test load must
correspond to 2.5 times the rated capacity marked on the fork.
6.16 Air Conditioning (AC) System Maintenance (If Fitted)

Combilift charge the AC system with approximately 1.85kg (4.1lbs) of R-134a
refrigerant.
Use suitable equipment for recovery and recharging of the air conditioning system.
Only trained HVAC engineers may perform maintenance work on the AC system.
Warning
Un-safe handling of refrigerant can result in frostbite when in contact with
the skin or eyes.
Ensure the relevant personal protective equipment (PPE) is worn i.e. gloves,
eye protection, clothing.
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6.17 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. All Points must be greased every 100 HOURS / 2 months
with EP2 grease.
1. RH Swivel Slew 1 9. LH Steering Cylinder Head 17. Carriage Front RH Bearing

2. Steering Link Pin Front RH 10. Steering Link Pin Rear LH 18. RH Tilt Cylinder Back
3. RH Swivel Slew 2 11. LH Swivel Slew 1 19. RH Mast Tilt Bushing
4. Steering Link Pin Rear RH 12. Steering Link Pin Front LH 20. LH Mast Tilt Bushing
5. RH Steering Cylinder Head 13. LH Swivel Slew 2 21. LH Tilt Cylinder Back
6. Rear Steering Cylinder Back 14. Carriage Front LH Bearing 22. Carriage Rear LH Bearing
7. Rear Swivel Slew 1 15. LH Tilt Cylinder Front 23. Carriage Rear RH Bearing
8. Rear Swivel Slew 2 16. RH Tilt Cylinder Front 24. Rear Steering Cylinder Front
25. Mast Side Shift Cylinder Back (If Fitted)

26. Mast Side Shift Cylinder Front (If Fitted)
Note
Optional attachments with moving parts may have additional grease points
that have not been indicated on the above chart.
Grease points on attachments must be located and greased every 100

HOURS using EP2 grease.
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Section 7: Technical
7.1 Checking the Charge Pressure
Warning
Ensure that the engine is switched off until the pressure gauge has been
attached securely.
To check the charge pressure:

1. Park the truck in accordance with the recommended parking procedure.
2. Release any residual pressure in the hydraulic system i.e. lower the mast fully
and tilt the mast fully forward.
3. Switch off the engine and remove the key from the ignition.
4. Remove the right hand side access panel (A) (pull out firmly at the top then lift
up and out) to gain access to port ‘G’ (B) on the top of the hydraulic drive pump.
5. Ensure the hydraulic pump is cool enough to touch before proceeding.
A B
Figure 7.1
6. Clean and dry the area around port ‘G’ thoroughly to prevent any contamination
from entering the hydraulic system.
7. Unscrew and remove the hose end from port “G” and seal the open end of the
hose with a 9/16“ JIC male plug. DO NOT permit any contamination to enter the
hydraulic system.
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8. Collect any draining oil in a suitable container and dispose of in compliance with
local regulations.
9. Unscrew and remove the hydraulic adapter from port ‘G’.
10. Screw an M14 pressure gauge test point adapter in to port ‘G’ securely.
11. Attach a pressure gauge - capable of reading pressure up to 40 bar (580 PSI)
– to the pressure gauge adapter.
12. Start the engine and read the charge pressure from the gauge.
13. The pressure should read approximately 25 bar (363 PSI) when the engine is
idling.
14. Contact your local service representative or Combilift service if the charge
pressure is outside the specified range.
15. Remove the gauge and refit the hydraulic adapter and hose securely. Apply a
suitable thread sealant to the threads on the adapter before refitting.
16. Clean up any oil spills immediately.
Note
Port ‘G’ Thread Specification - M14x1.5
Max tightening torque 80Nm / 60ft.lb
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Technical
7.2 Valve Chest Pressure Settings
Warning
Ensure that the engine is switched off until the pressure gauge has been
attached.
In order to check the valve chest pressure settings, the following steps should be taken:
 Park the truck in accordance with the recommended parking procedure.

 Extend the reach then switch off the engine.
 Thoroughly clean and dry the area around where the work is to be performed.
 Unscrew the cap from the test point adapter on the valve chest under the right
hand side of the cabin and attach a pressure gauge - capable of reading
pressure up to 300 bar (4400 PSI) - to the test point adapter on the valve
chest (see figure 7.2 below).
 Fully extend or retract the cylinder(s) of the function to be tested. For example
when checking the tilt-back pressure the mast must be tilted back as far as it
will go.
 Fully depress the accelerator pedal and push/pull the lever on the section to be
tested (in the example of testing the tilt back pressure the lever will be pulled
back).
 The reading on the gauge indicates the pressure setting on one particular port
on the valve chest.
Example: To check the reach pressure extend the reach out as far as it will go.
Fully depress the accelerator pedal and push the reach lever forward. The pressure
gauge will display the setting on the reach forward port.
Note
The main relief pressure is set at: 242 Bar / 3800 PSI
Figure 7.2
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Technical
Metric (SI Units) Settings Table
MODELS
C4000 C4500 C4800 C5000 C5000XL
Main Relief 242 Bar 242 Bar 242 Bar 248 Bar 248 Bar
Lift (Duplex) 220 Bar 228 Bar 235 Bar 234 Bar 234 Bar
Lift (Triplex) 221 Bar 221 Bar 228 Bar N/A N/A
Lift (Cascade) 221 Bar 221 Bar 221 Bar 228 Bar 228 Bar
Tilt Forward 111 Bar 111 Bar 111 Bar 179 Bar 179 Bar
(Standard) Back 242 Bar 242 Bar 242 Bar 248 Bar 248 Bar
Tilt Forward 111 Bar 111 Bar 111 Bar 111 Bar 111 Bar
(Cascade) Back 180 Bar 193 Bar 193 Bar 193 Bar 193 Bar
Reach 180 Bar 180 Bar 180 Bar 180 Bar 180 Bar
Side Shift 180 Bar 180 Bar 180 Bar 180 Bar 180 Bar
Fork Positioner 111 Bar 111 Bar 111 Bar 124 Bar 124 Bar
Side Shift & Fork Posn’r 221 Bar 221 Bar 221 Bar 207 Bar 207 Bar
Reach Forks 180 Bar 180 Bar 180 Bar 179 Bar 179 Bar
Lift/Drop Forks Up 180 Bar 180 Bar 180 Bar 180 Bar 180 Bar
Down 111 Bar 111 Bar 111 Bar 111 Bar 111 Bar
Imperial Settings Table
MODELS
C8000 C9000 C10000 C10000XL
Main Relief 3500 PSI 3500 PSI 3600 PSI 3600 PSI
Lift (Duplex) 3200 PSI 3300 PSI 3400 PSI 3400 PSI
Lift (Triplex) 3100 PSI 3200 PSI N/A N/A
Lift (Cascade) 3200 PSI 3200 PSI 3300 PSI 3300 PSI
Tilt Forward 1600 PSI 1600 PSI 2600 PSI 2600 PSI
(Standard) Back 3500 PSI 3500 PSI 3600 PSI 3600 PSI
Tilt Forward 1600 PSI 1600 PSI 1600 PSI N/A
(Cascade) Back 2600 PSI 2800 PSI 2800 PSI N/A
Reach 2600 PSI 2600 PSI 2600 PSI 2600 PSI
Side Shift 2600 PSI 2600 PSI 2600 PSI 2600 PSI
Fork Positioner 1600 PSI 1600 PSI 1800 PSI 1800 PSI
Side Shift & Fork Posn’r 3200 PSI 3200 PSI 3000 PSI 3000 PSI
Reach Forks 2600 PSI 2600 PSI 2600 PSI 2600 PSI
Lift/Drop Forks Up 2600 PSI 2600 PSI 2600 PSI 2600 PSI
Down 1600 PSI 1600 PSI 1600 PSI 1600 PSI
Note
The pressure values given in the tables above are to be used as a guideline
only. The pressures may be set differently in the factory on occasion to suit
different equipment and attachments.
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7.3 Steering & Hydraulic Functions Circuit

LH CARRIAGE CYLINDER RH CARRIAGE CYLINDER
ONE WAY ONE WAY

RESTRICTOR RESTRICTOR
TILT CYLINDER TILT CYLINDER
HOSE BURST
CHECK VALVE
LIFT CYLINDER
PRESSURE
TEST POINT
STEERING MOTOR P A1 A2 B2 A3 B3 A4 B4 A5 B5 T
P
EF
L
1 1 1 1 1
T E
0 0 0 0 0
2 2 2 2 2
242Bar
P
R 180Bar 180Bar
221Bar
180Bar
T 111Bar 111Bar T
INLET LIFT REACH TILT AUXILIARY MODE OUTLET
STEERING VALVE
A's Represent Back Of Valve
Y
B's Represent Front Of Valve
T P
C1 P1 P1
C2
B A P2
C4
C3
P2
Y1 C2 C3 Y2
C1 C2
LH STEERING CYLINDER RH STEERING CYLINDER
Legend
Feed From Pump

Return To Tank (Bleed)
Steering Lines
GEAR PUMP
Hydraulic Functions
PRIMING VALVE PRIMING VALVE

IN PISTON IN PISTON
REAR STEERING CYLINDER
Return Filter
25 Micron
90 Micron (In-Tank)
Strainer Filter
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Technical
7.4 Hydraulic Drive Circuit

LH WHEEL MOTOR RH WHEEL MOTOR
X X
1 1
L R L R
Rotary Inch Valve
b a
R Ps TRANSMISSION PUMP Fe MB
Purge Valve
A
A
P
B
B
P3
P4
350 BAR B P1
X
A P2
350 BAR
B
A
A
P
T
B
25 BAR
T1 T2 X1 X2 G S MA
1 3
NON-RETURN 2
VALVE - 0.5 BAR BRAKE VALVE
OIL COOLER
SUCTION FILTER
SHUT-OFF 10 MICRON NOMINAL
VALVE
Legend
Pump Suction Line B A

Pump Drain Lines
Brake Release Lines
Motor Drive Lines
L
Motor Drain Lines Rear Wheel Motor
Control Pressure
Z
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7.5 Fuses
Fuse 5 Fuse 10
The midi blade fuses in the 14-way midi blade fuse Fuse 14
box mounted on the dash inside the cabin of the Fuse 4 Fuse 9
truck are arranged in the order shown in the table to Fuse 13
the right. Fuse 3 Fuse 8
Fuse 12
The rating of each fuse and the function relating to Fuse 2 Fuse 7
each fuse is given in the table below. Fuse 11
Fuse 1 Fuse 6
14-Way Midi Blade Fuse Box Table

Fuse Amps Circuit
Mast Above Set Height Drive Cut-Out Override, Low Fuel
1 7.5
Warning System, Deutz Diagnostic Plug, Display Screen
4-Way Direction Joystick, Neutral Relay, PLC Board
2 7.5
Supplies
3 7.5 Spare
4 20 6-Port Valve Solenoid (Relay 9)
5 7.5 Brake Switch, Foot Brake Switch (If Fitted)
6 15 Wiper Motors
7 7.5 Road Lights (If Fitted)
8 15 Auxiliary Hydraulic Function Solenoids
9 10 Cabin Heater, Cabin Cooling Fan, Optional Radio
10 7.5 Horn
11 7.5 Proximity Switch Supply, Guide Roller Light (If Fitted)
Seat Switch, Seat Belt Switch, Auxiliary Function Joystick

12 7.5
Buttons
13 7.5 Flashing Beacon
Optional Extras - 12v Power Socket, Air Seat, Extra Oil

14 10
Cooler
120
C4-C5MK4-OM-EN-06
Technical
The following table gives the rating and function related to each of the midi link fuses
located inside the fuse box mounted on the inside of the backplate at the right hand
side of the truck. Remove the RH side access panel to gain access to the fuse box.
Midi Link Fuse Table

Fuse Amps Circuit
1 100 Glow Heater Relay
2 80 Main Fuse - Ignition Key Switch Supply
3 30 Deutz ECU Supply
4 30 Extra Oil Cooler With Electric Fan (If Fitted)
The following table gives the rating and function related to each of the midi blade
fuses located inside the fuse box mounted on the inside of the backplate at the right
hand side of the truck. Remove the RH side access panel to gain access to the fuse
box.
6-Way Midi Blade Fuse Box Table

Fuse Amps Circuit
Supply To PLC ST 1 – Steering Solenoids, Brake Solenoid,
A 15
Reversing Bleeper
Supply To PLC ST 19 – Drive Solenoid, Forward Solenoid, Reverse
B 15
Solenoid, Deadband Solenoid
Supply To PLC EX 1 – Work Lights, Reach Retract Slowdown (If
C 15
Fitted)
Supply To PLC EX 19 – Auxiliary Hydraulic Function Solenoids (If
D 15
Fitted), Valve Chest Lock Valve Solenoids
E 20 Supply To Fuel Pump Relay
F 15 Supply Air Seat Relay (If Fitted)
The following table gives the rating and function related to each of the inline midi
blade fuses.
The inline midi blade fuses are located inside the dash box and can be accessed by
removing the panel that the arm rest is mounted on.
Inline Midi Blade Fuse Table

Fuse Amps Function
CF1 7.5 Radio Memory Supply
121
C4-C5MK4-OM-EN-06
Technical
7.6 Relays
The 30/40A relays are mounted inside the dash box and can be accessed by
removing the panel that the arm rest is mounted on.
The glow relay is mounted on the inside of the backplate at the right hand side of the
truck. Remove the RH side access panel to gain access to the glow relay.
The following table gives the function related to each of the relays fitted as standard.
Relay Function
9 6-Port Steering Valve Solenoid
15 Neutral
FPR Fuel Pump Relay
GLOW Glow Plug Relay
The following table gives the function related to relays fitted for optional extras.
Relays For Optional Extras Function

23 Indicators - Road Lights
26 Brake Lights
32 Auxiliary Hydraulic Function Solenoid 1
32A Auxiliary Hydraulic Function Solenoid 2
32B Auxiliary Hydraulic Function Solenoid 3
37 Mast Retract Slowdown
45 Air Seat
OC Oil Cooler
Note
Some trucks may have additional relays that are not listed above. These
relays are for non-standard optional extras. Please Contact Combilift and
quote the truck serial number for information on the function related to
these relays.
122
C4-C5MK4-OM-EN-06
Appendices
Section 8: Appendices
8.1 Warranty Registration
The warranty registration form should be filled in and submitted online at:
www.combilift.com/warranty
Please complete the warranty registration online within 30 days of receipt of the truck.
Alternatively the warranty registration form on the following page can be filled in and
posted to the following address:
Combilift
Annahagh
Monaghan
Co. Monaghan
Ireland
123
C4-C5MK4-OM-EN-06
WARRANTY REGISTRATION FORM
Please complete the form below and return this to us within 30 days of delivery to Customer.
Form can be submitted online @ www.combilift.com/warranty
DEALER DETAILS: (Supplier)
Dealer Name: ___________________________________ Tel: _______________________
First Name: ________________________ Last Name: ____________________________
E-mail: ____________________________ Position/Role: __________________________
Street: ____________________________ Address Line 2: ________________________
City: ______________________________ Zip/Postal Code: ________________________
County/State:_______________________ Country: ______________________________
MACHINE DETAILS
MODEL: ___________________ SERIAL NO.
Delivery / installation date: _ _ / _ _ _ / _ _ _ _
CUSTOMER DETAILS (please state address where truck is located)
Customer Business Name: ________________________ Tel: _______________________
First Name: ________________________ Last Name: ____________________________
E-mail: ____________________________ Position/Role: __________________________
Street: ____________________________ Address Line 2: ________________________
City: ______________________________ Zip/Postal Code: ________________________
County/State:_______________________ Country: ______________________________
I have received my Aisle-Master/Combilift forklift and read the Operators Manual and am satisfied with both.
*Customer’s Signature: ________________________________ Date: __________________
WHEN COMPLETED PLEASE RETURN TO:
BY POST TO: Combilift, Annahagh, Monaghan, County Monaghan, Ireland.
BY EMAIL TO: warranty@combilift.com
Failure to complete Warranty Registration Form may impact the Warranty Claim Process.
8.2 Operator’s Pre-Use Check Sheet
Model:_______________ Serial Number:_______________
CHECK ITEMS ✔ OK X DEFECTIVE
Visual Checks
General: No damage, loose or missing nuts or bolts, leaking fluids, excessive dirt or rust. Previous defects repaired. 
Channels: No damage or distortion. No excessive wear, scoring, dirt or foreign bodies in the channels. End stops secure. 
Mast Chains: No damage, excessive wear or stretching. All links and pins in place. Equal tension, adequate lubrication. 
Rollers: No uneven wear or incorrect tracking. 
Fork Carriage: No damage, excessive wear, deformation or cracks. Square to mast and lubricated. End stop bolts present and secure. 
Forks: Correctly positioned. Not damaged, cracked, bent or excessively worn. Pins secure, not worn, loose or bent. 
Tyres: No damage, no excessive wear, cracks or cuts. No embedded foreign objects. No separation from rims. 
Wheels: No damage, excessive rust, cracks or debris. All nuts present and secure. 
Access: Steps and grab handles secure, clean and in good condition. 
Hydraulic Hoses: Routed correctly. No kinks or wear. Check all seals and couplings for damage, wear and leaks. 
Oil Cooler: No build-up of dust or debris around the fan or on the fins. 
Hydraulic Tank: No damage or leaks. Oil level (lower forks fully before checking). 
Operators Cabin: Secure, clean, undamaged, no loose items. 
Battery: All connections secure, no damage, leaks or corrosion. 
Front Wheel Alignment: In standard drive mode check the front wheels are aligned parallel to the platforms and to each other. 
Lights, Windows, Mirrors: Clean and in good condition. 
Fire Extinguisher (if fitted): Secure and charged. 
Electrical Connections/Terminals: All connections secure and undamaged, no melting or blackening, no loose or bare wires. 
Serial Plate, Capacity Chart & Safety Decals: Present, secure and easily legible. 
Engine Related Checks
Fluids: Oil, fuel and coolant levels within normal range. 
Radiator: No build-up of dust or debris around the fan or on the fins. 
Belts: In good condition, no damage, wear or fraying. 
Exhaust: No damage or corrosion. No excessive smoke or noise. No sparks or flames. 
Engine Compartment: No build-up of debris or fluids, no combustible materials near engine. 
Fuel Tank & Hoses: No damage, wear, deterioration or corrosion, no leaking fuel. Tank cap present and secure. 
Operational Checks
Seat & Seat Belt: In good condition, secure, properly adjusted, in good working order. 
Ignition & Electrical System: All buttons and controls working correctly. All warning lights working. Display screen working. 
Horn & Reversing Alarm: Working properly. Sufficiently audible. 
Work Lights: In good working order. 
Engine: Starts easily and runs smoothly. No unusual sounds or smells. 
Hydraulic Functions: Working smoothly through the full range of movement. 
Brakes (Inch & Park): Working correctly. 
Mode Change: Wheels align correctly and change direction smoothly. 
Steering: Working correctly with no excessive play or restriction in either travel mode. 
Defect Details:
Operator’s Signature: _________________________________________________________ Date: ________________________
Manager’s / Supervisor’s Signature: _____________________________________________ Date: ________________________

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Dear Customer,

Thank you for choosing Combilift and showing your faith

In order to familiarise yourself with your truck in a quick

About This Manual

 Always start and operate the engine in a well-ventilated area.

For more information go to www.P65warnings.ca.gov/diesel.

Section 2: Basic Information .......................................................................15

Section 3: Components & Controls ............................................................25

Section 4: Operation Monitoring .................................................................36

Section 5: Operation ....................................................................................46

5.13 Stopping ....................................................................................................... 63

Section 6: Maintenance ...............................................................................77

Section 8: Appendices ...............................................................................123

Section 1: Safety Information

This is the Environmental Hazard Symbol. It is used to alert the reader to

Also indicates important information regarding the operation and servicing

1.2 Operator Safety

1.3 Safety Decals

Maintain all safety decals on the machine in a legible manner. If a safety

Personal injury hazard. Crushing hazard from moving

Read the operators manual Personal injury hazard. Do

Shearing hazard from rotating Personal injury hazard. Do

Scalding hazard. Only remove

1.4 Safety Devices

The following safety devices are fitted to the truck as standard:

Seat Belt Switch (If Fitted)

Battery Isolator Key Switch

The following safety devices may be fitted as optional extras:

Mast Not Fully Retracted Drive Cut-out (If Fitted)

1.5 Warning Devices

The following warning devices are fitted to the truck as standard:

Blue Safety Lights (if fitted)

1.6 Operator Qualification and Responsibilities

 Personnel being trained, educated, instructed or participating in a general

1.7 Work Place Operating Conditions

Operators must be aware of special situations in their workplace in order to avoid

 Contractors doing maintenance

If contact with a live electric source occurs:

Nominal Voltage Clearance Distance

Operating in Hazardous Areas:

Adverse Weather Conditions:

 Electrical Storms: Always discontinue operation of the truck in the event of an

Oil, Fuel and Coolant:

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Dock Boards (Bridge Plates)

If using dock boards on loading docks:

Trailers and Rail Cars

1.8 Exhaust Filter Cleaning

1.9 Decommissioning Recycling and Disposal

Section 2: Basic Information

Operation by inexperienced persons, or in an unintended manner, can result in

The truck must not be used if:

Standard trucks must not be operated in flammable areas, corrosive atmospheres, or

2.3 Vehicle Description

Standard Mode – In Standard Mode all wheels

Sideward Mode – In sideward mode all wheels

2.4 Principle of Operation

Steering is achieved by means of a hydraulic gear pump coupled to an internal