C4000

Steering
&
Lift
 C4000 Sensor Layout
Section 1

Fitted with Standard Carousel Mode

Page 1 Frontal Mode - Wheels At 0 Degrees

Page 2 Sideward Mode - Wheels At 90 Degrees
Page 3 Carousel Mode

Section 2

Fitted with Automatic Carousel Mode

Page 1 Frontal Mode - Wheels At 0 Degrees

Page 2 Sideward Mode - Wheels At 90 Degrees
Page 3 Auto Carousel Mode

Section 3

Synchronised Hydraulic Steering

Page 1 Turning Wheels Outwards
Page 2 Turning Wheels Inwards
(Section 1) Combilift Model C4000 Page 1
Fitted with Standard Carousel Mode

Frontal Mode - Wheels At 0 Degrees

5 Carousel Sensor

1 0 Degree Sensor

2 90 Degree Sensor

6 Port Valve
Steering Solenoid
4 Port Valve
Reflex Steering
Solenoid

T R
P L

Steering Motor

Valve Chest Wheels To

0 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN

0 Degree Sensor Carousel Sensor

NOTE:
Sensor
Orientation
90 Degree Sensor
(Section 1) Combilift Model C4000 Page 2
Fitted with Standard Carousel Mode

Sideward Mode - Wheels At 90 Degrees

5 Carousel Sensor

1 0 Degree Sensor

2 90 Degree Sensor

6 Port Valve
Steering Solenoid
(Energised)
4 Port Valve
Reflex Steering
Solenoid

T R
P L

Steering Motor

Valve Chest Wheels To

90 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN
(Section 1) Combilift Model C4000 Page 3
Fitted with Standard Carousel Mode

Carousel Mode
5 Carousel Sensor

1 0 Degree Sensor

2 90 Degree Sensor

6 Port Valve
Steering Solenoid
(Energised) 4 Port Valve
Reflex Steering
Solenoid
(Energised)

T R
P L

Steering Motor

Valve Chest Wheels To

90 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN
(Section 2) Combilift Model C4000 Page 1
Fitted with Automatic Carousel Mode

Frontal Mode - Wheels At 0 Degrees

1 0 Degree Sensor

Adjustable Quadrant
For Carousel

5 Carousel Sensor

2 90 Degree Sensor

6 Port Valve
Steering Solenoid
4 Port Valve
Reflex Steering
Solenoid

T R
P L

Steering Motor

Valve Chest Wheels To

0 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN

0 Degree Sensor

NOTE:
Sensor
Orientation

Carousel Sensor 90 Degree Sensor

(Section 2) Combilift Model C4000 Page 2
Fitted with Automatic Carousel Mode

Sideward Mode - Wheels At 90 Degrees

1 0 Degree Sensor

Adjustable Quadrant
For Carousel

5 Carousel Sensor

2 90 Degree Sensor
6 Port Valve
Steering Solenoid
(Energised) 4 Port Valve
NOTE: Reflex Steering
90 Degree Sensor Solenoid
Is looking for point on fixed
Quadrant

T R
P L

Steering Motor

Valve Chest Wheels To

90 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN
(Section 2) Combilift Model C4000 Page 3
Fitted with Automatic Carousel Mode

Auto Carousel Mode

1 0 Degree Sensor

Adjustable Quadrant
For Carousel

5 Carousel Sensor

2 90 Degree Sensor
6 Port Valve
Steering Solenoid
(Energised) 4 Port Valve
Reflex Steering
Solenoid
(Energised)

T R
P L

Steering Motor

Valve Chest Wheels To

90 Degrees

3 0 Degree Sensor 90 Degree Sensor 4

NOTE: Pressure Oil RED

Sensor Air Gap Return Oil BLUE
8 to 10 mm Locked Oil Pink
Synchronised Oil GREEN
(Section 3) Synchronised Hydraulic Steering Page 1
Turning Wheels
Out-wards

Pressure Oil RED

Return Oil BLUE
Synchronised Oil GREEN
Locked Oil Pink
Fixed Rod End Adjustable Rod End

4 Port Valve
Reflex Steering Solenoid
6 Port Valve
Steering Solenoid
(Energised)

T R
P L

Steering Motor

Priming Flow

The Priming (Purge) Valve is always built-in to the adjustable steer ram. This is fitted
to stop any leakage across the rams,
Priming Valve
Wheels out of alignment - Adjustment Unseated
Firstly make sure this is not a simple cure, by turning the steering wheel fully clockwise Cylinder Fully Open
& fully anticlockwise, (I.e. to full lock) this will open the Purge valves.
If the problem persists make sure the adjustable steer ram is closing fully.

Note: the Purge Valve is part of the ram and cannot be replaced without replacing the
ram itself

All new forklifts don’t have a stop bolt fitted to the swivel assembly on the adjustable
ram side; if this requires adjustment, with the forklift in normal mode I.e. (driving
forwards) the ram should be fully closed when the wheel is parallel with the load bed.
If you have an older unit with a stop bolt fitted you should first adjust the stop bolt so
that this stops the wheel at parallel then adjust the ram so it is shut at that point.
(Section 3) Synchronised Hydraulic Steering Page 2
Turning Wheels
In-wards

Pressure Oil RED

Return Oil BLUE
Synchronised Oil GREEN
Locked Oil Pink

4 Port Valve
Fixed Rod End Reflex Steering Solenoid Adjustable Rod End
6 Port Valve
Steering Solenoid
(Energised)

T R
P L

Steering Motor

Return Oil Flow

The Priming (Purge) Valve is always built-in to the adjustable steer ram. This is fitted
to stop any leakage across the rams,

Wheels out of alignment - Adjustment

Firstly make sure this is not a simple cure, by turning the steering wheel fully clockwise
& fully anticlockwise, (I.e. to full lock) this will open the Purge valves.
If the problem persists make sure the adjustable steer ram is closing fully.

Note: the Purge Valve is part of the ram and cannot be replaced without replacing the
Priming Valve
ram itself Unseated
Cylinder Fully Closed
All new forklifts don’t have a stop bolt fitted to the swivel assembly on the adjustable
ram side; if this requires adjustment, with the forklift in normal mode I.e. (driving
forwards) the ram should be fully closed when the wheel is parallel with the load bed.
If you have an older unit with a stop bolt fitted you should first adjust the stop bolt so
that this stops the wheel at parallel then adjust the ram so it is shut at that point.
 Hydraulic Schematic Steering and Lift Circuit

Section 4
Page 1 Brief description on the steering circuit
Page 2 Main Schematic For C4000
Page 3 Steering to the Right Normal Mode (Travelling to the Right)
Page 4 Steering to the Right in Sideward Mode
Page 5 Steering to the Right in Sideward Mode (Travelling to the Left)

Section 5
Page 1 Tilting Mast Backwards Whilst Reaching Out carriage rams
Page 2 Tilting Mast Forward Whilst Extending Lift Ram
Page 3 Steering to the Right Normal Mode (Whilst reaching out carriage rams)
(Section 4) Steering Pump Page 2

This particular Unit is a Sauer Danfoss Ospc 250 Ls

You have (5) ports marked L,R,T,P and EF. These are the five hydraulic fluid connection ports that make
the unit operate. They are as follows:

Ÿ P - Pump. The high pressure input from the pump

Ÿ T - Tank. The low-pressure return line to the reservoir (tank)

Ÿ L - Left. The high-pressure output line to the left steering cylinder port i.e. when you turn the
steering wheel to the left (counter-clockwise) this port carries fluid under pressure to the steering
cylinder(s)

Ÿ R - Right. The high-pressure output line to the right steering cylinder port i.e. when you turn the
steering wheel to the right (clockwise) this port carries fluid under pressure to the steering
cylinder(s)

Ÿ EF – The high-pressure output line to the five section valve bank i.e. when fluid is not required for
steering *the steering always takes precedence, this port carries fluid under pressure to the valve
bank

When not steering, the priority valve unit directs all inlet flow to the auxiliary circuit. However once
steering is initiated, part of the auxiliary flow is diverted to steering. Since steering has priority, all flow, if
required, will be diverted to steering. The tank port of the steering unit has flow only when steering is
operated. Thus, flow out of the auxiliary (“EF”) port and the tank port will fluctuate or stop depending on
steering input
(Section 4) Main Hydraulic Steering and Lift Schematic Page 2

For Combilift Model C4000

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor 2 Mode
EF 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode

5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump
P= Pressure
T= Tank
R= Right
L= Left
E.F = Extra Function
(Section 4) Combilift Model C4000 Page 3

Steering to the Right Normal Mode

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor 2 Mode
EF 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode

5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink
(Section 4) Combilift Model C4000 Page 4

Steering to the Right in Sideward Mode

(Travelling to the Right)

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor 2 Mode
EF 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode

5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering
(Energised ) Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink
(Section 4) Combilift Model C4000 Page 5

Steering to the Right in Sideward Mode

(Travelling to the Left)

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor 2 Mode
EF 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode

5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering
(Energised ) Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter Change-over
3 Tilt Relief Valve Pressure = 144 Bar
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
(Energised ) 5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink
(Section 5) Combilift Model C4000 Page 1

Tilting Mast back Whilst

Reaching Out carriage rams

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor Out
2 Mode
EF Back 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode
5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink
(Section 5) Combilift Model C4000 Page 2

Tilting Mast Foward

Whilst Extending Lift Ram

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor 2
Fwd Mode
EF Up 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode

5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink
(Section 5) Combilift Model C4000 Page 3

Steering to the Right Normal Mode

Whilst reaching out carriage rams

Priming (Purge)
Valve

Tilt Ram Tilt Ram

LH. Steering Ram RH. Steering Ram

Lift Ram
One Way One Way
Restrictor Restrictor
LH. Carriage Ram Velocity RH. Carriage Ram
Fuse

Restrictor
Sauer Danfoss Ospc 250 Ls Priority
Valve Normal
Steering Motor Out
2 Mode
EF 4
R
1 3
T

P
L
Lift Reach Tilt Aux
Sideward
Mode
5 Solenoid Operated
5 Section Valve Bank Electrical Section
Main Relief Valve

P2 D Test
A Point
P1 B
C

6 Port
Change-over
Valve
Steering Rear Steering Ram

Return Filter
25 Micron

1 Lift Relief Valve Pressure = 228 Bar

Hydraulic Tank
2 Reach Relief Valve Pressure = 114 Bar
In Tank 4 Port
Strainer Filter 3 Tilt Relief Valve Pressure = 144 Bar
Change-over
90 Micron Valve 4 Auxiliary Relief Valve Pressure = 114 Bar
(Reflex Steering)
5 Main Relief Valve Pressure = 250 Bar
Gear Pump

Steering Pump Oil flow

P= Pressure Pressure Red
T= Tank Return Blue
R= Right Metered Orange
L= Left Synchronised Oil Green
E.F = Extra Function Locked Oil Pink