CombiLift C3000CB Bedienungsanleitung
C2500CB-OM-EN-11
Dear Customer,
Thank you for choosing us and showing your faith in
the Combilift range of products. With this Combilift
Product you now own a machine designed by our
team of experienced engineers using the most up to
date design techniques and technology with the sole
aim of producing a machine that is efficient, reliable,
safe and the right tool for your businesses material
handling needs. The Combilift product possesses a
vast range of multi functional application possibilities
that makes it one of the leading products in the
material handling industry.
Combilift Ltd
The Purpose of this Operators Manual
This Manual contains all of the information you will
require to operate your Combilift product safely and
efficiently. It is essential that this manual remain with
the machine at all times. It is essential that the
operator read this manual before attempting to operate
the Combilift.
Always follow all safety instructions laid out in this
manual
All instructions, prohibitive or otherwise, found in
this manual should be adhered to at all times. They
are there to protect your life and the lives of others.
Always perform the Daily Inspection as indicated in
this manual and follow the guidelines on service
intervals.
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Contents
Section 1:Machine layout and Operator Controls..............1-1
1.1:Machine Overview and Components......................................................... 1-1
Section 2:Operating instructions and Conditions .............2-1
2.1:Understand the Capacity of your Lift-Truck ............................................. 2-1
2.2:Centre of Gravity (CG).............................................................................. 2-1
2.3:Load Chart ................................................................................................. 2-2
2.4:Serial Plate................................................................................................. 2-3
2.5:Operator Qualification............................................................................... 2-3
2.6:Operator Responsibilities........................................................................... 2-3
2.7:Entering and Exiting the Operator Cabin................................................... 2-4
2.8:Starting Procedure...................................................................................... 2-4
2.9:Moving Off ................................................................................................ 2-5
2.10:Changing Direction without Changing Mode............................................ 2-5
2.11:Changing Into Sideward Mode.................................................................. 2-5
2.12:To Change Back to Forward Mode............................................................ 2-5
2.13:Stopping..................................................................................................... 2-6
2.14:Loading...................................................................................................... 2-6
2.15:When Loading in Sideward Mode............................................................. 2-6
2.16:When Loading in Forward Mode............................................................... 2-6
2.17:Placing a Load When In Sideward Mode.................................................. 2-7
2.18:Placing a Load When In Forward Mode.................................................... 2-7
2.19:Double Forking.......................................................................................... 2-7
2.20:Stacking...................................................................................................... 2-8
2.21:De-Stacking................................................................................................ 2-8
2.22:Adjusting Load Forks ................................................................................ 2-8
2.23:Operating Conditions................................................................................. 2-9
Section 3:Safe operation......................................................3-1
3.1:Safe Operation ........................................................................................... 3-1
3.2:Operating in Hazardous Areas................................................................... 3-1
3.3:Safe Driving on Gradients ......................................................................... 3-1
3.4:Driving Position......................................................................................... 3-2
3.5:Parking....................................................................................................... 3-2
3.6:Bridge Plates and Dock Boards ................................................................. 3-2
3.7:Lifting the Machine.................................................................................... 3-2
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Section 4:Maintenance & Service Information...................4-1
4.1:Maintenance Schedule............................................................................... 4-1
4.2:Operators Daily Inspection Sheet .............................................................. 4-6
4.3:Initial Service – Conducted at 100 hours of Operation.............................. 4-7
4.4:Engine Oil & Engine Oil Filter (Service Interval = 250Hours)................. 4-7
4.5:Engine Coolant (Service interval = 2000Hours)........................................ 4-9
4.6:Mast Maintenance (Service Interval = 250Hours)..................................... 4-9
4.7:Hydraulic Oil & Filters............................................................................ 4-10
4.9:Water Pump V- Belt................................................................................. 4-12
4.10:Fuel Filter – diesel engine trucks (Service interval = 500 Hours)........... 4-12
4.11:Air Filter Element (Service Interval = 500 Hours).................................. 4-12
4.12:Grease Point Chart................................................................................... 4-13
4.13:Diesel Particulate Filter (DPF)................................................................. 4-14
Section 5:Technical Information & Circuit Diagrams ........5-1
5.1Hydraulic Functions Circuit....................................................................... 5-1
5.2Hydraulic Drive Circuit ............................................................................. 5-2
5.3Towing the Combilift................................................................................. 5-3
5.4Mechanical Brake Release......................................................................... 5-4
5.5Checking the Charge Pressure................................................................... 5-5
5.6Fuse Box Layout........................................................................................ 5-6
5.7Relay Layout.............................................................................................. 5-6
5.8Standard GM LPG PLC Electric Circuit: .................................................. 5-7
5.9Standard Kubota Diesel PLC Electric Circuit: .......................................... 5-9
5.10Standard Toyota 4Y LPG PLC Electric Circuit:...................................... 5-11
5.11Tier IV GM LPG PLC Electric Circuit:................................................... 5-14
5.12Colour Codes for Electric Circuits:.......................................................... 5-16
5.13PLC Details.............................................................................................. 5-17
5.14PLC Diagnostics ...................................................................................... 5-20
Section 6:Appendices...........................................................6-1
6.1:Appendix A: Certified LPG Engine Emission Control Warranty ............. 6-1
6.2:Appendix B: General Engine Warranty..................................................... 6-2
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Section 1: Machine layout and Operator Controls
1.1: Machine Overview and Components
It is essential before you start operating the Combilift to be familiar with the
main components and controls of the machine, their function and where they
are located. Figure 1 below and Figure 2 on the following page indicate the
major components of the machine and all of the operator controls.
Figure 1: Machine Component Layout – Front View
Component Layout
1. Forks
2. Front Swivels
3. Mast
4. Bonnet
5. Access Panels
6. Worklights
7. Strobe Beacon
8. Overhead Guard
9. Air Filter
10.LPG Tank / Diesel Tank
11.Rear Swivel
12. Exhaust
1
3
5
12
11
10
6
2
6
4
5
9
6
7
8
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6
7
1
2
3
4810
9
5
1314151617
18
19
20
11
12
21
22
23
24
Figure 2: Machine Control Layout – Rear View
Control Layout
1. Ignition 2. Light Switch
3. Parking Brake 4. Fuse Box
5. Horn Button 6. Direction Control lever
7. Lift Control Lever 8. Tilt Control Lever
9. Sideshift Control Lever 10. Fork positioner Control Lever
11. Pre Heat indicator 12. Low Level Fuel Indicator
13. Battery Charge Indicator 14. Oil Pressure Indicator
15. Sideward Mode Indicator 16. Parking Brake Indicator
17. Normal Mode Indicator 18. Carousel Indicator
19. Hour Meter 20. Water Temperature Gauge
21. Engine Management Light 22. Steering Wheel
23. Inching Pedal 24. Accelerator Pedal
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Ignition/Starter Switch
This is a two-position key switch that
isolates the electrical system when in the
‘OFF’ position.
Light Switch
Illuminates all work lights, dash light and cabin light.
To illuminate all lights, turn the switch clockwise.
To extinguish all lights, turn the switch anti-clockwise.
Horn Button
The horn button is located on the dash beside the
Directional control lever. Press to operate.
Direction control switch
A four-position switch which will engage any of the four
directions of travel.
To operate push lever in the desired direction of travel.
Always ensure that the Direction Control Switch to the
neutral position after bringing the truck to a halt.
Parking Brake
To APPLY brakes, PUSH button.
To RELEASE brakes, TURN BUTTON CLOCKWISE.
The machine will not drive with Parking Brake ON.
Water Temperature gauge
This gauge Monitors the temperature of the engine
cooling system
The truck must not be operated if the gauge pointer
moves to the red area as this indicates a fault in the
cooling system
Hour Meter
The hour meter records how many hours the truck has
been operating for in hours and tenths of an hour.
Use meter to determine maintenance intervals
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Engine Management Light (Yellow Light On Dash)
If this light comes on it means the engine control unit
(ECU) has detected a problem with the engine.
If the light is on and the engine is running ok you can
drive the truck. However, it should be checked at the
earliest convenience. If the engine is running poorly
the truck should not be driven.
The ECU will store the fault information that will allow
the fault to be diagnosed when the ECU is connected to
a PC.
Oil Pressure Indicator Light
When the key switch is in the ‘ON’ position, with the
engine at rest, the oil pressure indicator is illuminated.
If the indicator is illuminated when the engine is ‘running’
then this indicates low engine oil pressure and/or
insufficient oil in the sump.
Battery Charge Indicator Light
This charging lamp indicates whether the alternator is
charging the system or not. With the key switch turned
ON and the engine not running, this red charge lamp
should illuminate.
If the charging lamp remains illuminated with the engine
running, it indicates a malfunction of the charging
system or associated components.
Pre-Heat Indicator Light – (diesel engines)
The Pre-heat indicator is a lamp connected to the glow
plugs on the diesel engine.
When operating in cold conditions, wait until the pre-
heat indicator extinguishes before attempting to start
engine
Low fuel level indicator light
The low-level indicator light illuminates whenever the
fuel level on the truck reaches a certain level.
On LPG engines a buzzer will also sound.
Whenever the light illuminates the truck should be
refuelled immediately.
Note
Do NOT run engine if oil pressure indicator is illuminated.
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Parking Brake Indicator Light
The Parking Break indicator light indicate whether the
brake is “ON” or “OFF”
Mode Indicator Lights
The Mode indicator lights indicate which mode of travel
the machine is in.
If the machine is in normal mode, then the normal mode
indicator light will illuminate
If the machine is in sideward mode, then the sideward
mode indicator light will illuminate
Note: Modes of travel are covered in more detail in
section 3 of this manual
Carousel Indicator Light
The carousel indicator light is only used when the
machine is in sideward mode.
When the front wheels are steered in to a certain
position, the carousel indicator light will illuminate. It is at
this point that the carousel mode is activated and the
machine can turn on its own axis.
To deactivate the carousel the operator simply steers
the wheels out of the carousel position
Lift Control Lever
The lift control lever controls the lift function of the Mast.
To raise the forks, PULL the lever BACK
To lower the forks, PUSH the lever FORWARD
Tilt Control Lever
The tilt control lever controls the tilt function of the Mast.
To tilt the mast forward, PUSH the lever FORWARD
To tilt the mast backward, PULL the lever BACKWARDS
Sideshift Control Lever
The Sideshift control lever controls the sideshift
function of the forks.
To shift the forks left, PUSH the lever FORWARD.
To shift the forks, right, PULL the lever
BACKWARDS.
P
Sideward
Mode
Normal
Mode
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Fork Positioning Control Lever
This lever controls the position of the forks on the mast
carriage. The forks can be controlled simultaneously or
individually by use of this lever.
Push lever forward to position both forks outward, pull
lever back to position forks inward.
Depress left button on top of lever to control left fork.
Push lever forward to position left fork outward. Pull
lever back to position left fork inward.
Depress right button on top of lever to control right fork.
Push lever forward to position right fork outward. Pull
lever back to position right fork inward.
IMPORTANT
A new truck capacity plate MUST be obtained from Combilift Ltd to reflect
the new maximum load capacity when ANY attachment is fitted. Only
attachments approved by Combilift Ltd personnel should be fitted.
Steering
All models have both front and rear-end steering.
When in forward mode the front wheels are fixed and the
rear wheel steers the truck.
Rear-end steering allows sharper turns in confined areas but
demands greater driver care when turning.
When in sideward mode, the rear wheel is fixed and the
front wheels steer the truck.
When driving forwards, turn steering wheel clockwise to turn
truck clockwise, turn steering wheel anticlockwise to turn
truck anti clockwise.
When driving in reverse, turn steering wheel clockwise to
turn truck anticlockwise, turn steering anti clockwise to turn
truck clockwise.
When driving sideward to the right, turn steering wheel
clockwise to turn truck clockwise, turn steering wheel
anticlockwise to turn truck anticlockwise.
When driving sideward to the left, turn steering wheel
clockwise to turn truck clockwise, turn steering wheel
anticlockwise to turn truck anticlockwise.
The steering wheel is also equipped with a spinner knob for
easier steering.
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Brake/Inching Pedal
The combined Brake/Inching Pedal has two functions:
Stops drive to slow the machine down.
Permits slow speed, for precise manoeuvring of the
truck in confined spaces - See Section 2 for Operating
Instructions and Conditions.
Accelerator Pedal
The accelerator pedal is located on the floor on the right
hand side of the steering column.
It is used to increase the speed of the engine, therefore
increasing travel speed and / or hydraulic function
speed.
Battery Isolator Switch
This switch is used to disconnect power from the battery
in the event of an emergency.
The switch is located inside the cabin, beside the dash.
When the Combilift is not in use turn switch to ‘OFF’
by pressing switch until it clicks into the closed position.
The Combilift will not power-up unless the switch
is returned to the ‘ON’ position by pulling the switch up.
On
Off
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