Professional Documents
Culture Documents
C4000 Om en 17
C4000 Om en 17
C4000 Om en 17
www.combilift.com
C4000-OM-EN-17
C4-C5XL O&S
Preface
This manual describes how to operate and maintain the Combilift - C-Series
truck safely and efficiently. It is essential that this manual remain with the truck
at all times. It is essential that the operator and all persons involved in work
with the truck read this manual before attempting to operate or service the
truck.
Follow all local laws and regulations with regard to the operation of lift trucks
where they apply at the place of use.
Follow all instructions, prohibitive or otherwise, found in this manual. They are
there to protect the life of the operator and the lives of others working in the
vicinity of the truck.
Always perform the Pre-Use Inspection as indicated in this manual and follow
the guidelines on service intervals. Ensure that the truck is in good
mechanical condition at all times. Report any fault and have it corrected
immediately otherwise even minor faults may result in major failures and
dangerous operating conditions.
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 assumed that you are standing behind the vehicle looking toward the
forks.
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.
Note
This manual is not designed for the purpose of extensive
maintenance work. Such work must be performed by approved
professionals.
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Contents
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The basic function of a lift truck is to lift, move and place materials. It operates
on the seesaw principle - two weights on opposite sides of a fulcrum. In this
case, the load on the forks must be balanced by the weight of the Combilift.
The location of the centre of gravity of both the Combilift and the load is a
major factor.
The Combilift has moving parts that change its centre of gravity. The centre of
gravity moves forward and back as the mast is extended and retracted and
also as the mast is tilted backwards and forwards. The centre of gravity also
moves up and down as the mast moves up and down.
Combilift and
Load combined
Centre of Gravity
Load Centre
of Gravity
Combilift
Centre of
Gravity
Fulcrum
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The centre of gravity and therefore stability is also affected by the size,
weight, shape and position of the load; the height to which it is raised;
extension of mast forward and backward; tilt and side shift. Truck movement
such as acceleration, braking, turning and uneven surfaces will also affect
truck stability.
Combilift and
Load combined
Centre of Gravity
Load
Load Centre
Centre
of
of Gravity
Gravity
Combilift
Centre of
Gravity
Fulcrum
To keep the lift truck stable, the centre of gravity must stay within the area of
the lift truck represented by a triangle drawn between the three wheels. If the
centre of gravity moves forward of the triangle front, the lift truck will tip
forwards. If it moves outside the right or left of the triangle the truck will tip to
the side.
Load Combilift
Centre of Centre of
Gravity Gravity
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The rated capacity of the truck is illustrated MAXIMUM STACKING CAPACITY ON A FIRM LEVEL SURFACE
COMPLYING WITH 89/392/EEC
?Kg
than the specified horizontal load centre. 600 700 800 900 1000
LOAD CENTRE (mm)
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.
The Serial Plate is the Metal Disc that is fixed to the Combilift in the cabin of
every machine. It is engraved with a number of details, which are required by
law. These are:
This plate should not be removed by anyone. If lost order a replacement from
Combilift immediately.
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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.
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.
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
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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.
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.
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.
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The following table outlines the minimum clearance distance that must be
observed when working in the vicinity of power lines.
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 a gradient. Do not park on a gradient. In an emergency apply the park
brake and chock the wheels, but do not leave the truck unattended.
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.
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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.
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.
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5. Hydraulic Tank
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All controls and user adjustable components located inside the cabin of the
Combilift truck are labelled in figure 2.2 below.
Controls
1. Steering Wheel
2. Adjustable Steering Column
3. Accelerator Pedal
4. Brake/Inch Pedal
5. Operators Seat
6. Heater Temperature Control
7. Operator Cooling Fan
8. Window Wiper Switches
9. RH Side Window Opener
10. Lift Control Lever
11. Reach Control Lever
12. Tilt Control Lever
13. Auxiliary Control Lever
14. 4-Way Direction Control Lever
15. 90° Light (If Fitted)
16. Ignition Key Switch
17. Armrest
18. Adjustable Air Vent
19. Heater Fan Switch
P
°F
1 0
2
0 0 0 0 0 0
HOURS 1/10
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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Ignition Switch:
This is a three-position key switch located on the dash,
which isolates the electrical system when in the off
position.
Note
The truck will NOT start unless the directional control lever is in the neutral
position.
Horn Button
The horn Button is the push button located on the dash
next to the parking brake.
To operate the horn, depress the button.
Light Switch:
This is a two- position switch located on the dash
Position 1 – Lights on
Position 2 – Lights off
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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
Note
Do NOT run engine if oil pressure indicator is illuminated.
Note
ALWAYS adhere to all safety precautions for refuelling the truck.
(See Section 3.7:)
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Wipers
The wipers are located on the front windows.
They are activated by the switching on the wiper motor.
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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
operating the truck.
Warning
Adding an attachment to a Combilift will alter the rated capacity of the
machine. A load chart must be obtained from Combilift Ltd for any
attachment that is fitted to indicate this change in capacity.
Warning
ONLY attachments that have been approved by Combilift engineers may be
fitted to Combilift Trucks.
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This is a four-way joystick with three push buttons on the handle. It is used to
control the mast functions.
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.
Fork Positioning
To move the forks in/together, PULL the joystick
BACK while pressing the right hand button on the
handle.
To move the forks out/apart, push the joystick
FORWARD while pressing the right hand button
on the handle.
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
operating the truck.
Warning
Adding an attachment to a Combilift will alter the rated capacity of the
machine. A load chart must be obtained from Combilift Ltd for any
attachment that is fitted to indicate this change in capacity.
Warning
ONLY attachments that have been approved by Combilift engineers may be
fitted to Combilift Trucks.
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Accelerator Pedal
The accelerator pedal is located on the floor on the right
hand side of the steering column.
The accelerator pedal provides the operator control of
the truck speed.
To INCREASE truck speed, DEPRESS pedal.
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Seat Adjustment
It is the responsibility of the Operator to ensure that
the seat is adjusted according to operator weight,
height etc before operating the truck.
ALWAYS report any malfunctioning of the seat
adjustments immediately.
ALWAYS wear the seat belt provided.
DO NOT adjust the seat when vehicle is in operation.
Keep clear of moving parts.
Authorised & competent personnel should carry out
Installation & Maintenance only
A Upstop Adjustment
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On Off
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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.
Diesel Engine
Ensure that the parking brake is applied and that the directional control
lever is in the neutral position
Insert the key into the ignition switch and turn clockwise to the preheat
position. The charge indicator lamp must light up.
Depress the accelerator.
Turn the ignition key further clockwise to the “Start” position. After the
engine starts, release the ignition key which will return automatically to
the ON position.
Check that all the indicator lamps are extinguished and that all gauges
are registering correctly.
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LP Gas System
Open the valve on the LPG tank.
Ensure that the parking brake is applied and that the directional control
lever is in the neutral position
Insert the key into the ignition switch and turn clockwise to the ‘ON’
position. The charge indicator lamp must light up.
Turn the ignition key further clockwise to the ‘start’ position.
As soon as the engine starts, release the ignition key, which will
automatically return to the ‘ON’ position.
Check that all warning lamps are extinguished and that all gauges are
registering correctly
Note
The truck will NOT start unless the directional control lever is in the neutral
position.
Note
The starter must not be operated continuously for more than 30 seconds. If
the engine does not start, return the key to the ‘OFF’ position and wait 10
seconds before trying again.
Note
When the machine is started the wheels will remain in whatever position
they were in when the machine was stopped until the operator selects a
direction of travel on the directional control lever
3.3: Moving
Because the Combilift is capable of multi directional travel it is important to be
aware of how the truck moves and how to drive it in a safe manner.
Important
The Combilift has two different modes of travel. These are:
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Moving Forward
Select forward on the directional control lever.
Depress the brake/inching pedal fully
Look around to make sure your way is clear
Release the parking brake and sound the horn
Slowly release the brake/ inching pedal
As the truck starts to move, depress the accelerator pedal to increase
speed
To stop depress the inching pedal fully.
(Note: If the machine is already in sideward mode, wait for the wheels to
realign. Once the wheels are in position continue as per the instructions)
Moving Backward
Select reverse on the directional control lever.
Depress the brake/inching pedal fully
Look around to make sure your way is clear
Release the parking brake and sound the horn
Slowly release the brake/ inching pedal
As the truck starts to move, depress the accelerator pedal to increase
speed
To stop depress the inching pedal fully
Changing Mode
The Combilift will automatically realign the wheels when a direction of travel is
selected that requires the machine to change from one mode to the other. In
order to change mode:
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3.4: 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
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NEVER try to lift a load that the weight of which is not known
ALWAYS consult the capacity chary for your truck before lifting a load.
Avoid sudden and jerky movements
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Stacking
Slowly approach stack with load
retracted and tilted backwards.
Stop at face of stack, select neutral and
apply parking brake.
Elevate load until clear of stack top.
Operate accelerator pedal to ensure
that engine speed is sufficient to
prevent stalling and to give the required
lifting speed.
Extend mast until load is above the
stack.
Tilt mast to vertical position and lower
load onto stack.
Retract mast fully and lower forks to
150mm (6”) above ground before
moving off.
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De Stacking
Approach stack with mast retracted and in
vertical position.
Stop at face of stack, select neutral and apply
parking brake.
Elevate forks to permit entry into pallet.
Extend mast and enter the pallet with the forks.
Elevate load until clear of stack and tilt mast backwards to stabilise load.
Operate accelerator pedal to ensure that the engine speed is sufficient to
prevent stalling.
Retract mast fully and lower load to 150mm (6”) above ground, or where
possible on to the platforms
Note
The lift capacity of the Combilift is reduced if the forks are not fully engaged
When travelling with a load always keep the load as low as possible.
Have the load resting on the platforms of the Combilift whenever
possible.
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.
Remember to turn slowly.
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3.7.1 General
The facilities for storing and handling liquid fuels of all kinds MUST
be strictly in accordance with all current regulations.
Warning
Adequate fire fighting equipment must be readily available in the refuelling
area at all times.
Safety Rules
No smoking, naked lights 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
area.
Note
Where Diesel Particulate Filters (DPF) are fitted Diesel Fuels with a maximum
sulphur content of 15ppm (parts per million) MUST be used.
Diesel Fuels specified to EN 590 or ASTM D975 S15 are strongly recommended.
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Note
Do not attempt to correct the wheel alignment by adjusting the front master
steering cylinder rod end before trying the procedure outlined above.
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There are a number of items indicated on the maintenance chart that must be
performed on a daily basis. These checks are essential in keeping the truck in
optimum working condition. These and a number of other checks form what is
known as the daily inspection of the lift truck.
In most countries, it is required by law for the operator to perform the daily
inspection and for the company to have a written record of these checks.
Contact your local authorities in order to find out what regulations are in place
regarding daily inspections of industrial equipment of this nature.
The daily inspection must be carried out at the start of the working day before
the machine commences operation. Alternatively if your company operates a
multi shift system the checks should be carried out by operators at the
beginning of each shift. The inspection can be broken into 3 sections:
The details of the Inspection should be recorded on a Checklist like the one
provided (page 4-5) and a record of these inspections should be kept on file
within your company’s records.
Warning
Before attempting any checks ensure that you are wearing the correct safety
equipment, i.e. gloves, safety boots, eye protection in form of safety glasses
or a full-face shield.
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, or oil.
Tyres and wheels – Check that all the wheel nuts are present and tight.
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. Note: Always wear gloves when checking the tyres to
avoid injury on sharp pieces of debris.
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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.
Front Wheel Alignment – Check that the front wheels are aligned
parallel to the platforms and to each other when Forward/Reverse mode
is selected. See section 3.8:
Check All the Fluid levels – i.e. the engine oil, the engine coolant, and
the hydraulic oil level. Do not operate the truck if any of these fluid levels
are below the min value reading.
Check the radiator and oil cooler – Make sure that no leaves, dust or
other debris have built up on, or between, the radiator and oil cooler.
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 fray.
Warning
Always wear appropriate protective clothing such as gloves and face shield
when checking LP tanks and fittings. LP can cause frostbite when released,
due to its very low temperature.
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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 secures correctly into the
retainer. Always wear the seat belt provided when you are driving
the Combilift.
Check the seat – All Combilift machines come with adjustable air
suspension seats. The operator must ensure that the seat is correctly
adjusted for their individual height and weight. Instructions on how to set
the seat are in the operators’ manual.
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. Several lights should illuminate in the dash.
Test the horn – the horn button is on the dash to the right hand side of
the operator. The Truck should not be operated if the horn is not
functioning. Depress the button to test the horn.
Listen – Listen to the engine for a few seconds before driving off. Be
alert for any strange sounds or noises from the engine. Also be on the
lookout for any strange odours that may indicate a problem such as a
very strong smell of gas or burning. If you detect anything, which is not
normal, stop the machine immediately and investigate the problem.
Check the Dash – look at the dash and make sure that the warning
lights are all extinguished. The only light that should be on after the
engine is started should be the parking brake. Should any other lights be
illuminated, stop the machine and report the fault to your supervisor. A
full list of all the gauges, indicators and controls along with each function
can be found in section 2 of this manual.
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Check the Brakes – With the parking brake still applied, select forward
on the directional control lever. Keeping both feet away from the pedals,
sound the horn, and release the parking brake. The machine should start
to move slowly forward. Depress the inching pedal fully. The machine
will stop. Release the pedal and the machine will move off again. Then
reapply the parking 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 that you
have adequate space to perform this test and that it is performed on a
level surface.
Check the Directional Control Lever – With the engine running and the
parking brake applied, select forward mode. Sound the horn and release
the parking brake. The machine should move forward. Depress the
inching pedal to stop the machine. Sound the horn, select reverse on the
directional control stick and release the inching pedal. The machine
should now travel backwards. Depress the inching pedal to stop the
machine and apply the parking brake. Select left travel on the directional
control lever. The wheels will start to realign for sideward mode. When
the wheels are fully in position, sound the horn and release the parking
brake. The machine should now travel to the left. Depress the inching
pedal to stop the machine, select right travel on the directional control
lever, sound the horn and release the inching 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 parking 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 normal mode and sideward
mode.
Note
Remember, in most countries, it is against the law NOT to perform these
checks or keep a record of the inspections.
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Note
All grease points indicated on the grease point chart MUST be greased
weekly using an appropriate EP2 Grease
Note
All wheel nuts should be checked daily and torqued every 250 hours:
Front Wheel nuts (210Nm or 155ft/lbs)
Back Wheel nuts (300Nm or 220ft/lbs)
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Note
Maintenance, replacement, or repair of the emission control devices and systems
may be performed by any non-road engine repair establishment or individual.
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4.5: Engine Oil and Engine Oil Filter (Service Interval = 250Hours)
The engine oil used in the Combilift should have the correct temperature range
for the ambient temperature in which the machine is to be operating.
Temperature affects the viscosity of the oil and therefore it’s lubricating
properties. All Combilift trucks leave the factory with a special, high multi-grade
oil in the engine and this can be used all year round except in very cold
climates.
In order to change the Oil and oil filter, the following steps should be taken,
Note
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 oil, coolant, fuel, electrolyte and other harmful waste
Remove the engine oil filter located on the front of the engine as indicated
by the diagram above
Apply some engine oil to the new oil filter cartridge before fitting
Install the new engine oil filter cartridge, ensuring that the O-ring seal is
correctly placed. Only use a genuine Combilift component
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Fill the engine with the appropriate volume of oil ensuring that the oil with
the correct temperature range is used. The Volume of oil required is:
Check the oil level on the dipstick. Ensure that the oil level is at the upper
notch on the dipstick.
Note
It is advised not to mix different coolant additives.
See www.combilift.com/coolant for a list of approved coolant products.
If greater frost protection is required, the coolant additive concentration can be
increased up to 60% (frost protection to -52°C (-61.6°F)). Any greater
proportion of coolant will decrease the frost protection and also the anti-
corrosive properties.
The coolant level is monitored via the coolant reservoir located on the left
hand side of the cabin as shown in the diagram below. The coolant level
should always be kept between the upper and lower levels indicated on the
reservoir and topped up as is deemed necessary.
Operator Cabin
Coolant Reservoir /
Radiator Expansion Tank
To drain the cooling system, remove the filler cap from the top of the radiator
and the pipe / bung from t bottom right hand corner of the radiator (as shown).
4-9
C4000-OM-EN-17
C4-C5XL O&S
Ensure that the correct type is used in the relevant ambient temperature. The
table below indicates a number of commercially available oils and the
temperature ranges that they are suitable for
Note
The Sequence in which the brand names are listed does not signify any
grading as to their quality or preference.
Note
The machine is supplied with an AWH46 hydraulic fluid when leaving the
factory. Please check if this is suitable for the ambient temperature in which
the machine is to be operated
Note
Before adding hydraulic oil, ensure that all cylinders are retracted and fill to
upper level on the hydraulic oil level gauge
There are a total of 3 filters on or in the hydraulic oil tank that must be
replaced at certain intervals. These filters are:
The locations of these filters are shown in the diagram on the next page.
4-10
C4000-OM-EN-17
C4-C5XL O&S
Filler Cap
Breather
Return Filter housing
4-11
C4000-OM-EN-17
C4-C5XL O&S
Periodic lubrication of the mast chains is required to ensure maximum life span
is achieved. Use SAE 20 oil in cold conditions and SAE 40 oil in warm
conditions. Frequency of lubrication depends largely on operating conditions.
A lubrication interval of 250 hours can be taken as a typical value, under
normal working conditions.
4-12
C4000-OM-EN-17
C4-C5XL O&S
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.
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.
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.
4-13
C4000-OM-EN-17
C4-C5XL O&S
Fork
Carriage
Support
Locking Adjustment
Nut Bolt
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
4-14
C4000-OM-EN-17
C4-C5XL O&S
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).
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.
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.
Check the belt tension. Perform this when the engine IS NOT running. Press
on the belt with a stick or rod. Ensure that the deflection is no more that 10mm
to 12mm. If it is adjust the belt via the pulley adjusting bolts
Check the belt condition: Inspect the condition of the belt. Be on the lookout
for signs of damage and wear. If the belt is damaged replace it immediately.
Also check if the belt has sunk deeply into the pulley as this indicates
excessive wear. Again replace the belt immediately if this is the case.
4-15
C4000-OM-EN-17
C4-C5XL O&S
Rain Cap
Filter Housing
Dust Valve
4-16
C4000-OM-EN-17
C4-C5XL O&S
In order to change the air filter Cartridge, take the following steps:
4-17
C4000-OM-EN-17
C4-C5XL O&S
Note
See Appendix A for ‘California Engine Emission Control Warranty
Statement’ regarding owners ‘Warranty Rights and Obligations’.
4-18
C4000-OM-EN-17
C4-C5XL O&S
Towing Speed
Towing distance
The towing distance should not exceed 1 km. (With no boost available to the
hydraulic circuit drains, the heat generation in the hydraulic motor rotary group
has to be taken into account.)
After termination of the towing operation turn back item 1t its original position.
The original set pressure valve is thereby available. Screw item 1 up to stop.
Tighten the nut
5-1
C4000-OM-EN-17
C4-C5XL O&S
5-2
C4000-OM-EN-17
C4-C5XL O&S
In order to check the charge Pressure, the following steps should be taken.
When the reading is taken the charge pressure should measure between 16
bar and 22 bar (230PSI and 320PSI
Warning
Ensure that the Machine is switched off until the pressure gauge has been
attached before trying to read the charge pressure.
5-3
C4000-OM-EN-17
C4-C5XL O&S
3 – Diesel 7.5 Pull Hold Solenoid, Fuel Pump, High Temperature Engine Cut-out
3 – GM LPG 7.5 Ignition Coil, High Temperature Engine Cut-out, Anti-Backfire
3- Toyota LPG 10 High Temperature Engine Cut-out
4 20 Steering Solenoid Supply, PLC Output Supply
5 7.5 Push Button Brake Switch, Inch Pedal Brake Switch, Brake Light, Brake Solenoid Supply
6 20 Wipers
7 15 Front Work Lights, Dash Cluster Lights
8 15 Side Work Lights, Cabin Interior Light
9 7.5 Cabin Heater Fan, Cabin Cooling Fan, Optional Radio
10 7.5 Horn
11 7.5 Proximity Switch Supply, Guide Roller Light
12 7.5 Seat Switch, Seat Belt Switch
13 7.5 Flashing Beacon
14 10 Auxiliary Hydraulic Function
Inline Fuses
Fuse Amps Function
1 15 Valve Chest Lockout Valve Solenoids
2 15 Optional Air Seat
5-4
C4000-OM-EN-17
C4-C5XL O&S
Note
Some trucks may have additional relays that are not shown 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.
5-5
C4000-OM-EN-17
C4-C5XL O&S
Relay Function
1 Starter
1a Neutral Cut-Off
2 (Diesel Only) Glow Plug Timer Relay
9 Steering Solenoid Supply
22 Work Lights (Spot Lights)
32 Auxiliary Hydraulic Function Solenoid
LV Valve Bank Lock Valve Solenoids
CO High Engine Temperature Cut-out
LPG (Toyota Only) LP Gas System Relay (Not Shown)
Note
Some trucks may have additional relays that are not shown 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.
5-6
C4000-OM-EN-17
C4-C5XL O&S
INTEGRATED INTEGRATED
ONE WAY ONE WAY
RESTRICTOR RESTRICTOR
HOSE BURST
CHECK VALVE
ON MAST & IN ALL
MAST CYLINDERS
LIFT CYLINDER
PRESSURE
TEST POINT
STEERING MOTOR
EF
L
T
P
R
6-PORT DIVERTER
VALVE - STEERING
P1 P2
A B D C
4-PORT CHANGEOVER
VALVE - REFLEX STEERING
A B
P T Legend
PRIMING VALVE
IN PISTON HEAD
Return Filter
25 Micron
90 Micron (In-Tank)
Strainer Filter
5-7
C4000-OM-EN-17
C4-C5XL O&S
P P
L L
B A B A
A B
Drive 4-Port P T
Changeover Valve
b a
R Ps TRANSMISSION PUMP Fe MB
Purge Valve
350 BAR
350 BAR
A
18 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
OPTIONAL
Auto Carousel (Dead Band)
4-Port Changeover Valve
Legend T B
P A
Pump Suction Line B A
Pump Drain Lines
Brake Release Lines
Motor Drive Lines
L
Motor Drain Lines Rear Wheel Motor
Control Pressure
P
5-8
C4000-OM-EN-17
C4-C5XL O&S
5-9
C4000-OM-EN-17
C4-C5XL O&S
5-10
C4000-OM-EN-17
C4-C5XL O&S
5-11
C4000-OM-EN-17
C4-C5XL O&S
5-12
C4000-OM-EN-17
C4-C5XL O&S
5-13
C4000-OM-EN-17
C4-C5XL O&S
5-14
C4000-OM-EN-17
C4-C5XL O&S
5-15
C4000-OM-EN-17
C4-C5XL O&S
5-16
C4000-OM-EN-17
C4-C5XL O&S
5-17
C4000-OM-EN-17
C4-C5XL O&S
5-18
C4000-OM-EN-17
C4-C5XL O&S
5-19
C4000-OM-EN-17
C4-C5XL O&S
5-20
C4000-OM-EN-17
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: Kub Diesel Electric Circuit (PLC) Section: 1 of 3 Revision Date:22/05/15
Drawn By : David Murray
30 30 30
54 54 54
15 58 58 58
C4000-OM-EN-17
Amp
50A F1 F7 F8 F9
Fuse F3 F6 F10 F5
10 R 7.5 20 20 7.5 20 7.5 7.5
R O
30 IGNITION R R O
SWITCH R BN
R 0 SUPPLY FOR RADIO
O
+
RELAY CO CHARGE
BN Disconnected
T
86 S 1 3
(White Wire) 30 GLOW HR FUEL OIL
87 85
+
87A
0
PRKNG
2 BRAKE
4
3
R BN
P O
R
80
Amp R R
GY P
Main
Fuse RELAY 1 R
NEUTRAL
86
30
HOLD
87 85 BN
87A 2 4 3 RELAY
R R R Y V
R 30 86 L 2
R
GLOW PLUG TIMER RELAY
PULL
R
50 85 T 87
BN
7 6 8 RELAY 22
O V GR
R 86 V
30
30 MAST 87
m m
+ve B+ D+ 85
HEIGHT 87A
50A O/R
STRIP FUSE ON
STARTER V
SOLENOID
TIMER BASE.
SWITCH R
M
G R BN m
F P
GLOW PLUGS
M
-ve
5.12: Kubota Diesel Electric Circuit (PLC)
ISOLATOR
NEG
HORN
GLOW
WIPER
WIPER
CAB FAN
BATTERY
OIL GUAGE
FUEL PUMP
DASH PANEL
SPOTLIGHTS
CAB HEATER
ALTERNATOR
STARTER MOTOR
LOW FUEL GUAGE
SPARE SPOTLIGHT
STARTER SOLENOID
PULL/HOLD SOLENOID
CABIN INTERIOR LIGHT
TEMPERATURE GUAGE
TEMPERATURE SWITCH
R
R
5-21
C4-C5XL O&S
R
C4-C5XL O&S
5-22
C4000-OM-EN-17
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: Kub Diesel Electric Circuit (PLC) Section: 3 of 3 Revision Date:22/05/15
Drawn By : David Murray
30 30
54 54
58 58
C4000-OM-EN-17
F12 F14
7.5 10
BN R R
BN
BUTTON
SEATBELT SEAT On Top Of
SWITCH SWITCH LEVER
GY GY GY
Y R
5-23
C4-C5XL O&S
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: GM LPG Electric Circuit (PLC) Section: 1 of 3 Revision Date:22/05/15
Drawn By : David Murray
30 30 30 30
54 54 54 54
15 58 58 58 58
C4000-OM-EN-17
Amp
50A F1 F7 F8 F9
Fuse F3 F6 F10 F5 F13
7.5 7.5 15 20 7.5 20 7.5 7.5 7.5
R R O
30 IGNITION R R O
R/Y
SWITCH R BN
0
CHARGE FUEL OIL O SUPPLY FOR RADIO
RELAY CO +
BN T
86 S 1 3
30
87 85
87A 0
80 PRKNG
amp 2 BRAKE
4
Main 3
Fuse BN P O
R
R +
R
GY HR
NEUTRAL
R1
86
30
87 85
87A
BN R R R Y V
R
BN
R
+ve B+ TO F2 GR
R 22
O V
86 V
30
30 MAST 87
m m
D+ EXC 85
STARTER HEIGHT 87A
SOLENOID O/R O
SWITCH
ZD1
V
5.13: GM LPG Electric Circuit (PLC)
R
-ve
G BN m
P P
M
K
ISOLATOR
NEG
HORN
WIPER
WIPER
CAB FAN
BATTERY
OIL GUAGE
SPOTLIGHTS
DASH PANEL
CAB HEATER
ALTERNATOR
ANTI-BACKFIRE
STARTER MOTOR
LOW FUEL GUAGE
SPARE SPOTLIGHT
FLASHING BEACON
STARTER SOLENOID
TEMPERATURE SWITCH
TEMPERATURE GUAGE
R
R
5-24
C4-C5XL O&S
R
C4-C5XL O&S
5-25
C4000-OM-EN-17
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: GM LPG Electric Circuit (PLC) Section: 3 of 3 Revision Date:22/05/15
Drawn By : David Murray
30
54 54
58 58
C4000-OM-EN-17
F12 F14
7.5 10
BN R R
BN
BUTTON
SEATBELT SEAT On Top Of
SWITCH SWITCH LEVER
GY GY GY
Y R
5-26
C4-C5XL O&S
COMBILIFT LTD Model: C4000 - C5000 & C5000XL Title: GM LPG Tier IV (PLC) Section: 1 of 3 Revision Date:22/05/15
Drawn By : David Murray
30 30 30 30
54 54 54 54
15 58 58 58 58
C4000-OM-EN-17
Amp 50A
Fuse F1 F7 F8 F9 F6 F10 F5
R 7.5 15 15 7.5 20 7.5 7.5
R O
30 IGNITION R R O
SWITCH BN
CHARGE 0 SUPPLY FOR RADIO
O
LIGHT +
BN 80 T S 1 3
amp TEMP MIL OIL LIGHT FUEL
Main LIGHT 0
R G BN B V O
Fuse 1 3
2
P O
R
HOUR
METER
R R
BN HR
+
GY
R1 G/Y
86
+ve 30
87 85 BN
87A
R R R Y V
R CURTIS
R FOOT PEDAL R 22
86 V
30
-ve 1 2 3 4 5 6 MAST 87
30 85
HEIGHT 87A
STARTER
O/R
SOLENOID
SWITCH V m m
R
R R GY G B V BK R W G Y BN BN
P m
M
ISOLATER
5.14: GM LPG Tier IV Electric Circuit (PLC)
KEY SWITCH F A B C G E L M K J R S
NEG
HORN
WIPER
WIPER
CAB FAN
BATTERY
SPOTLIGHTS
CAB HEATER
STARTER MOTOR
SPARE SPOTLIGHT
R
R
5-27
C4-C5XL O&S
R
C4-C5XL O&S
5-28
C4000-OM-EN-17
COMBILIFT LTD Model: C4000 - C5000 & C5000XL Title: GM LPG Tier IV (PLC) Section: 3 of 3 Revision Date:22/05/15
Drawn By : David Murray
30
54 54
58 58
C4000-OM-EN-17
F12 F14
7.5 10
BN R R
BN
BUTTON
SEATBELT SEAT On Top Of
SWITCH SWITCH LEVER
GY GY GY
Y R
5-29
C4-C5XL O&S
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: Toyota 4Y Circuit (PLC) Section: 1 of 3 Revision Date:16/07/15
Drawn By : David Murray
30 30 30
54 54 54
C4000-OM-EN-17
58 58 58
50A F1 F1
F3 F2 F5
BN 7.5 10 7.5 7.5 7.5
R R
30 IGNITION O
80 SWITCH R
TEMP.
amp + GAUGE
Main FUEL OIL T
S
LIGHT LIGHT
Fuse RELAY LPG RELAY CO
PRKNG
BN 86 86
30 30 BRAKE
87 85 87 85 CHARGE
87A 87A LIGHT
15A O
Hr. METER
INLINE 1234567
R R
B/W R G/Y
GR V R
GY GY
R1
86
30
87 85
87A 2 1
TAC B
R
DISTRIBUTOR
+ve ASSEMBLY O V GR GY R BN
GR GR
30 OPTIONAL MAST
STARTER HEIGHT
SOLENOID SOCKET
O/R O
SWITCH IN CABIN 2 1 3
R
-ve 4
5 1 P P R
LPG
M
5.15: Toyota 4Y LPG PLC Electric Circuit
ISOLATOR
NEG
(MAIN) LPG ENGINE SPARK PLUGS ALTERNATOR
SOLENOID REGULATOR SWITCH PLUG J PLUG B
PLUG G (SLOW) PLUG F
PLUG H
1
BATTERY
4 5
1
1 2 1 2 3 3 2
(OPTIONAL)
1 2
POWER SUPPLY
IN CABIN
2
STARTER MOTOR
OIL PRESSURE SW
STARTER SOLENOID
ENGINE DISTRIBUTOR ALTERNATOR
SWITCH ASSEMBLY
TEMPERATURE SWITCH
ASSEMBLY
TEMPERATURE SENDER
5-30
C4-C5XL O&S
R
C4-C5XL O&S
5-31
C4000-OM-EN-17
COMBILIFT LTD Model: C3000 - C5000 & C5000XL Title: Toyota 4Y Circuit (PLC) Section: 3 of 3 Revision Date:16/07/15
Drawn By : David Murray
30 30
54 54
58 58
C4000-OM-EN-17
F10 F12 15A F13 F9 F6 F7 F8 15A F14
7.5 7.5 INLINE 7.5 7.5 20 15 20 INLINE 10
O R
R
R/Y
BN
0
R O SUPPLY FOR RADIO R
BN
BN
1 2
0 G
1 3 BUTTON
SEATBELT SEAT On Top Of
2 HYDRAULIC
SWITCH SWITCH
LEVER
P
R
GY GY GY
WIPER
SWITCH
R
R Y V BN R R
R
RELAY 45
RELAY 9 RELAY LV R 22 RELAY 32
86
86 V 86 86 30 86
30 30 30 30
m m 87 85
85 87 85 87 87 85 87A 85 87
87A
87A 87A 87A
ZD1
V
AIR
SEAT
m BN SWITCH
Y R
HORN
WIPER
WIPER
CAB FAN
LIGHTS
(OPTIONAL)
AIR SEAT
SPOTLIGHTS
CAB HEATER
DASH CLUSTER
SPARE SPOTLIGHT
FLASHING BEACON
AUXILIARY 6-PORT
SOLENOID (OPTIONAL)
5-32
C4-C5XL O&S
C4-C5XL O&S
CODE - COLOUR
BK - BLACK
BN - BROWN
BL - BLUE
R - RED
O - ORANGE
Y - YELLOW
GR - GREEN
V - VIOLET
P - PINK
GY - GREY
W - WHITE
G/Y - GREEN / YELLOW
R/Y - RED / YELLOW
O/W - ORANGE / WHITE
5-33
C4000-OM-EN-17
C4-C5XL O&S
The diagram below shows the layout of the major components of the PLC
board that need to be known in order to correctly find and repair faults.
System LED
LED
1 2 3 4 5 6 7 8 9 10
PLUG X5.2
1 2 3 4 5 6 7 8
Dip Switches
The pins in each of the plugs on the board are laid out as follows.
1 3 5 7 9 11 13 15 17
2 4 6 8 10 12 14 16 18
The System LED tells the operator what the PLC is doing. The following table
gives an explanation of what the System LED is indicating.
5-34
C4000-OM-EN-17
C4-C5XL O&S
Each of the plugs has a specific function as do the pins on each plug. The
tables on the following pages give details of the functions on each of the plugs
and the pin associated with each function.
INPUTS
OUTPUTS
5-35
C4000-OM-EN-17
C4-C5XL O&S
Outputs (continued)
5-36
C4000-OM-EN-17
C4-C5XL O&S
FORWARD
REVERSE
Proximity Sensors can be energised by switching from Forward Mode to
If the joystick is working correctly each LED will only light with the Sideward mode.
joystick in the corresponding position. If a LED does not light it should be energised manually to rule out the
If the joystick is malfunctioning the LED corresponding to the position failure of the corresponding proximity sensor.
will not light up. Once activated the LEDs will remain lit until the switch is reset to the OFF
position.
5-37
C4000-OM-EN-17
C4-C5XL O&S
Park Brake – LED 1 Use the directional joystick to energise the solenoids as below
FWD Solenoid
REV Solenoid
Steering Solenoid
The Park Brake will only remain lit while the park brake is engaged.
LED 2 will be ON constantly on all machines that do not have the Mast
Height Override Function. Reflex Solenoid
To energise the mast height proximity sensor lift the forks to the height
of the proximity sensor. The LED on each solenoid should be lit along with the LED on the board.
If the solenoid LED does not light, a wiring problem may be present.
If the solenoid LED is lit but a problem remains the solenoid and/or the valve
should be checked for malfunction.
5-38
C4000-OM-EN-17
C4-C5XL O&S
Section 6: Appendices
The California Air Resources Board and the Environmental Protection Agency are pleased to explain the
emission control system warranty on your Model Year (2013 - 2014)5 off-road Large Spark-Ignition (LSI)
engine. New off-road LSI engines must be designed, built and equipped to meet the State's stringent anti-
smog standards in all
50 states. Combilift must warrant the emission-control system on your engine for the periods of time
listed below provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel-injection system, regulator, ignition
system, engine computer unit (ECM), catalytic converter and air induction system. Also included may be
sensors, hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition
exists, Combilift will repair your LSI engine at no cost to you including diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE: The Model Year (2013-2014)5 off-road LSI engines are
warranted for 3 years or 2,500 hours, whichever occurs first, unless indicated otherwise. If any emission-
related part on your engine is defective, the part will be repaired or replaced by Combilift.
Miscellaneous Items Used In Above Systems: vacuum, temperature, and time-sensitive valves and
switches; sensors used for electronic controls; hoses, belts, connectors, assemblies, clamps, fittings,
tubing, wiring, sealing gaskets or devices, and mounting hardware; pulleys, belts and idlers
If you have any questions regarding your warranty rights and responsibilities, you should contact Combilift at
1-877-COMBI56
6-1
C4000-OM-EN-17
C4-C5XL O&S
Combilift warrants to the ultimate purchaser and each subsequent purchaser that
this engine is designed, built and equipped so as to conform at the time of sale with
the applicable regulations under section 213 of the Clean Air Act, and that this
engine is free from defects in materials and workmanship which may cause such
engine to fail to conform with the applicable regulations for the first two years from
the date of sale to the first ultimate purchaser.
As the engine owner, you are responsible for the proper maintenance of the engine
as stated in the maintenance instructions. Proper maintenance generally includes
replacement and service, at the owner's expense, of such items as spark plugs,
points, condensers, and any other part, item, or device related to emission control.
For engines located within 100 miles** of an authorized service center, warranty
repairs must be made only at authorized service centers. For engines located more
than 100 miles** from an authorized service center, Combilift will provide for a
service technician to come to the owner to make the warranty repair.
service.usa@combilift.com or 1-877-COMBI56
The warranty registration form can be filled 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 used.
6-2
C4000-OM-EN-17
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
MACHINE DETAILS
I have received my Aisle-Master/Combilift forklift and read the Operators Manual and am satisfied with both.
Failure to complete Warranty Registration Form may impact the Warranty Claim Process.