Dear Customer,: Combilift LTD

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.
C14000J-OM-EN-07
Combilift Ltd Operators Manual: C14J/C16J
Contents
Section 1: Machine layout and Operator Controls ................. 4

1.1: Machine Overview and Components. ............................................ 4
Section 2: Operating instructions and Conditions .............. 11

2.1: Understand the Capacity of your Lift-Truck .................................. 11
2.2: Centre of Gravity (COG) .............................................................. 11
2.3: Load Chart ................................................................................... 13
2.4: Operator Qualification .................................................................. 13
2.5: Operator Responsibilities ............................................................. 13
2.6: Entering and exiting the operator Cabin ....................................... 14
2.7: Starting Procedure ....................................................................... 14
2.8: Moving Off .................................................................................... 14
2.9: Changing Direction without Changing Mode ................................ 15
2.10: Changing Into Sideward Mode ..................................................... 15
2.11: To Change Back to Forward Mode .............................................. 15
2.12: Stopping ....................................................................................... 16
2.13: Loading ........................................................................................ 16
2.14: When Loading in Sideward Mode ................................................ 16
2.15: When Loading in Forward Mode .................................................. 17
2.16: Placing A Load When In Sideward Mode ..................................... 17
2.17: Placing a Load When In Forward Mode ....................................... 17
2.18: Double Forking ............................................................................. 18
2.19: Stacking ....................................................................................... 18
2.20: De-Stacking ................................................................................. 18
2.21: Adjusting Load Forks ................................................................... 19
2.22: Operating Conditions ................................................................... 19
Section 3: Daily Checks.......................................................... 20

3.1: Wheels and Tyres ........................................................................ 20
3.2: Battery.......................................................................................... 20
3.3: Engine Oil Level ........................................................................... 20
3.4: Coolant Level ............................................................................... 21
3.5: Hydraulic Tank ............................................................................. 22
3.6: Fuel Tank ..................................................................................... 22
3.7: Automatic Fan Belt Tensioner ...................................................... 22
3.8: Load Forks ................................................................................... 22
3.9: Controls ........................................................................................ 23
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Section 4: Safe Operation ...................................................... 24

4.1: Safe Operation ............................................................................. 24
4.2: Safe Driving ................................................................................. 24
4.3: Fuel Handling & Storage .............................................................. 26
4.4: Battery Charging .......................................................................... 27
4.5: Operating in Hazardous Areas ..................................................... 27
4.6: Safe Driving on Gradients ............................................................ 28
4.7: Driving Position ............................................................................ 28
4.8: Parking ......................................................................................... 28
4.9: Bridge Plates and Dock Boards ................................................... 28
Section 5: Service information .............................................. 29

5.1: Initial service at 100 Hours ........................................................... 29
5.2: Engine Oil .................................................................................... 30
5.3: Filters ........................................................................................... 31
5.4: Engine Coolant (Service interval = 2000Hours) ........................... 33
5.5: Hydraulic Oil ................................................................................. 33
5.6: Mast Maintenance (Service Interval = 250Hours) ........................ 34
5.7: Greasing Mast Carriage Channels ............................................... 35
5.8: Fuel Filter Element ....................................................................... 35
5.9: Air Filter Element.......................................................................... 35
5.10: Checking Tensioner Spring Tension ............................................ 35
5.11: Grease Point Chart ...................................................................... 36
5.12: Diesel Particulate Filter (DPF) ...................................................... 37
5.13: Maintenance Chart ....................................................................... 38
5.14: Operators Daily Inspection Sheet ................................................ 39
Section 6: Circuit Diagrams ................................................... 40

6.1: Engine Wiring Diagram ................................................................ 40
6.2: Combilift Wiring Diagram (Diesel with PLC) ................................. 43
6.3: Hydraulic Steering & Functions Circuit ......................................... 48
6.4: Hydraulic Drive Circuit – Low Speed Setup ................................. 49
6.5: Hydraulic Drive Circuit – High Speed Setup ................................. 50
6.6: Hydraulic Drive Circuit – High/Low Speed Select ........................ 51
Section 7: Appendices............................................................ 52

7.1: Appendix A: Warranty Registration .............................................. 52
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C14000J-OM-EN-07
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.
Component Layout
1. Forks
2. Front Swivels
3. Platforms
4. Hydraulic Tank
5. Mast
6. Strobe Beacon
7. Overhead Guard
8. Diesel Tank
9. Work light
10. Bonnet
11. Rear Swivel
12. Access Panel
Figure 1: Machine Component Layout
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C14000J-OM-EN-07
Control Layout
1. Parking Brake
2. Hour Meter
3. Engine Temperature Gauge
4. Horn Button
5. Heater Vent
6. Cup Holder
7. Fuse Box
8. Heater Switch
9. Fuel Gauge
10. Wiper Switch
11. Cabin Heater Switch
12. Working Light switch
13. Ignition Switch
14. Wiper
15. Steering
16. Directional Control Lever
17. Accelerator Pedal
18. Brake/ Inching Pedal
19. Adjustable Seat
20. Auxiliary Function Lever
21. Auxiliary Function Lever
22. Tilt Control Lever
23. Reach Control Lever
24. Lift Control Lever
Figure 2: Machine Control Layout – Rear View
Ignition/Starter Switch
 This is a three-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.
Cabin Heater Switch (optional)

 A four position rotary switch, which selects off, low,
medium or high fan speeds.
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C14000J-OM-EN-07
Cabin Temperature Control (optional)

 To increase cabin temperature, turn anti-clockwise.
 To decrease cabin temperature, turn clockwise.
Horn Button
 The horn button is located on the dash below the
engine temperature gauge. 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.
Battery charge Indicator

 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.
Engine Oil Pressure Indicator

 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.
NOTE: Do NOT run engine if oil pressure indicator is illuminated.
Diesel Indicator
 This gauge registers the quantity of fuel in the tank, and
only operates when the ignition switch is turned to ‘ON.’
When the indicator is illuminated a quantity of
approximately 4.5 litres (1 gallon) remains in the tank and
indicates that the tank requires refilling.
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C14000J-OM-EN-07
Pre-Heat Indicator
 When operating in cold conditions, wait until the pre-
heat indicator extinguishes before attempting to start
engine.
Water Temperature Gauge

 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
 A digital meter that indicates, in hours and tenths of an
hour, the operating time of the truck. Use meter to
determine maintenance intervals.
Brake/Inching Pedal
The combined Brake/Inching Pedal has two functions:
-Stop drive to slow the machine down.
-May be used to permit slow speed, for precise
manoeuvring of the truck in confined spaces - See Section
2 for Operating Instructions and Conditions.
Accelerator Pedal
 The accelerator pedal provides the operator
control of the truck speed.
 To INCREASE truck speed, DEPRESS pedal.
Wipers
The wipers are located on the front windows.
The left hand wiper is activated by a switch on the wiper motor.
The right hand wiper is activated by a switch on the dash.
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C14000J-OM-EN-07
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 anti clockwise to turn truck anti clockwise.
 When driving in reverse, turn steering wheel clockwise to turn truck anti
clockwise, 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 anti clockwise to turn truck anti
clockwise.
 When driving sideward to the left, turn steering wheel clockwise to turn
truck clockwise, turn steering wheel anti clockwise to turn truck anti
clockwise.
 The steering wheel is also equipped with a spinner knob for easier
steering.
Lift Control Lever

 To RAISE forks, PULL lever.
 To LOWER forks, PUSH lever.
Mast Extension Lever

 To EXTEND the mast, PUSH lever.
 To RETRACT the mast, PULL lever.
Tilt Control Lever

 To tilt mast/forks FORWARD, PUSH lever.
 To tilt mast/forks BACKWARD, PULL lever.
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C14000J-OM-EN-07
Auxiliary Lever (Optional)

 This lever controls the flow of oil to an attachment
when fitted.
 On trucks fitted with attachments providing
more than one function, the truck may be fitted
with another auxiliary lever or a button on the fourth
function lever.
The operators must acquaint themselves with the operation

of these special provisions before using the truck.
NOTE
The lever position of functions may change on some Customised trucks.
Please refer to valve bank decal in truck Cab for accurate positionings.
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.
Battery Isolator Switch

 This switch is used to disconnect power from
the battery in the event of an emergency.
 The switch is located at the back of the
Combilift. ON OFF
 When the Combilift is not in use turn switch to

‘OFF’ position, by turning switch ANTI-
CLOCKWISE.
 The Combilift will not start unless the switch is
returned to the ‘ON’ position, by turning the switch CLOCKWISE.
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C14000J-OM-EN-07
Seat Adjustment: Diesel Machine

 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
B Height Adjustment – Depending on operator

weight, rotate knob clockwise, to increase, and
anti-clockwise to reduce suspension stiffness.
C Using the height adjustment knob ‘B’, adjust

the yellow ride indicator ‘C’ to the middle of the
green area when seated.
D Backrest angle adjustment
E Seat belt
F Horizontal Adjustment (Slide rails) Red
H Backrest Extension Green
Red
I Lumbar Support adjustment (5 positions)
Mast height Drive cut out

 This optional feature uses a push button switch, which
is connected to a sensor on high-lift Triplex masts.
When the mast is above 3.5m (138”) high, the machine
will not drive.
 To re-commence driving the operator must either:
 Lower the forks of the machine using the lift control lever
OR
 Press the mast drive enable button located on the dash.
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C14000J-OM-EN-07
Section 2: Operating instructions and Conditions
2.1: Understand the Capacity of your Lift-Truck
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.
2.2: Centre of Gravity (COG)
The centre of gravity of any object is the single

point about which the object is balanced in all
directions. Every object has a centre of gravity.
When the lift truck picks up a load, the truck and
load have a new, 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 backwards and forwards. The centre of gravity also
moves up and down as the mast moves up and down
Combilift
and load
combined
Load Centre Centre of
of Gravity Gravity Combilift
Centre of
Gravity
Fulcrum
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C14000J-OM-EN-07
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
Load Centre of Gravity
of 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.
Combilift and load combined

Centre of Gravity
Load Centre Combilift

of Gravity Centre of
Gravity
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C14000J-OM-EN-07
2.3: Load Chart

MAXIMUM STACKING CAPACITY ON A FIRM LEVEL SURFACE
The rated capacity of the truck is illustrated COMPLYING WITH 89/392/EEC
on a load chart located inside the cabin. The

?Kg
5.5
load centre is determined by its centre of ?Kg
LIFT HEIGHT (m)

4.5
?Kg
gravity and is measured from the front face ?Kg ?Kg

?Kg
of the forks to the centre of gravity of the 2.5

?Kg
load. It is assumed that the centre of gravity ?Kg
in the vertical direction is no greater than the ?Kg
specified horizontal load centre. 600 700 800 900

LOAD CENTRE (mm)
1000
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.
2.4: Operator Qualification
The Combilift must NOT be operated by any other individual other than those
who have been trained to do so. Training should be carried out either by
Combilift Driver training personnel or a Combilift authorised training
organisation. Details of these organisations can be acquired from Combilift
Ltd.
2.5: Operator Responsibilities
Always ensure that the truck is in good working order before commencing
work. This is achieved by performing the Daily inspection of the Combilift. The
daily 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 daily inspection before each

shift. The Inspection and how it should be conducted is covered later in this
publication.
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 safety of others as well as yourself. Stop working and
switch off if for any reason, in your opinion, the truck becomes unsafe or
defective.
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C14000J-OM-EN-07
2.6: Entering and exiting the operator Cabin

 When entering or exiting the Operator cabin of the Combilift, always use a
three point contact method to avoid slips and falls. The three point contact
method is applied by keeping 3 of the bodies 4 limbs (hands & feet) in
contact with the machine.
 Always use the handles and footsteps on the machine.
 NEVER use the steering wheel as a handle.
2.7: Starting Procedure
NOTE
Engine will not start if the direction control switch is not in the neutral position.
Diesel Engine
 Move the direction control switch to neutral
 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.
Cold Starting
 When the ambient temperature is cold, turn the key to the preheat
position and wait about 10 seconds until the glow plug indicator
lamp extinguishes before turning the engine.
WARNING
When the machine is started the wheels will remain in whatever position they
were in when the machine was stopped until the user selects a direction of
travel on the directional control switch
CAUTION
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.
2.8: Moving Off

 Ensure that the forks are as low as possible. If loaded, rest the load on the
platforms where possible.
 Select forward or reverse, or, right or left with Direction Control switch.
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C14000J-OM-EN-07
 Look around and when all is clear release parking brake and apply light
pressure to the accelerator pedal until the truck begins to move.
 Increase pressure on accelerator pedal to increase truck speed.
NOTE
The Combilift has a maximum ground speed of 10km/hr. Always adhere to all speed
limits in the area which the truck is operating
2.9: Changing Direction without Changing Mode

 Remove foot from the accelerator pedal.
 Gradually apply inching pedal to halt the truck.
 Select change of direction and gradually increase pressure on accelerator
until truck is travelling at desired speed.
2.10: Changing Into Sideward Mode

 Bring the truck slowly to a halt by depressing inching pedal fully.
 Ensure that all observers stand clear of the truck.
 Move the direction control switch from forward/reverse into the required
sideward direction. The wheels will automatically align themselves at right
angles to the forks.
 Wait until wheels are locked and dash light is illuminated before moving
NOTE
When in sideward mode the front wheels steer the truck while the back wheel
remains fixed
2.11: To Change Back to Forward Mode
NOTE
When in sideward mode, turn the steering completely anti-clockwise at least
once. This ensures correct alignment of the front wheels in forward
mode.
 Bring the truck slowly to a halt by depressing the inching pedal fully.
 Ensure all observers stand clear of truck.
 Move the direction control switch from left/right into the required forwards
direction.
 Wheels will automatically align themselves parallel with the forks.
 Wait until wheels are locked and dash light is illuminated before moving.
NOTE
When in forward mode the back wheel steers the truck, while the front wheels
remain fixed.
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C14000J-OM-EN-07
2.12: Stopping
 Always brake evenly and smoothly. Violent braking may cause the load to
slip from the forks.
 The forks must be lowered when the truck has stopped.
 After stopping the truck, return the direction control switch to neutral.
 When the operator leaves the forklift truck unattended, the parking brake
must be applied and the ignition key removed to prevent unauthorised use
NOTE
The brake/inching pedal permits slow drive speed for precise manoeuvring of
the truck in confined spaces. It operates independently of the accelerator
pedal, if fully depressed, stop the drive to slow the machine down
2.13: Loading
 Do not exceed rated capacity of truck. Overloading can cause truck
instability. If in doubt, check with the load chart, located inside the cabin.
 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.
 Check that the forks are of sufficient length. The length should be at least
three quarters the depth (front to back) of the load.
 When manoeuvring to pick up a load, avoid erratic movements that could
result in damage to the load and/or truck.
 Apply parking brake when loading
2.14: When Loading in Sideward Mode

 Retract the mast fully.
 Drive the front of the machine as close to the load as possible.
 Drive until the machine is at the centre of the load.
 Apply parking brake.
 Lower/raise the forks to the required height.
 Extend mast.
 Lift load.
 Double fork load if necessary until load is tight against face of forks. (See
section on “double forking”)
 Tilt rearward to secure the load.
 Raise load above platform height.
 Retract mast fully.
 Lower forks until load is just above platform height. Rest the load on the
platforms where possible
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C14000J-OM-EN-07
2.15: When Loading in Forward Mode

 Lower/raise forks to the required height.
 Enter the centre of the load.
 Drive as close to the load as possible.
 Extend mast to secure load if not already extended
 Lift load.
 Tilt rearward to secure load.
 Raise load above platform height.
 Retract mast fully
 Double fork load if necessary until load is tight against face of forks.
 Lower forks until load is just above platform height. Rest the load on the
platforms where possible.
2.16: Placing A Load When In Sideward Mode

 Drive the front of the machine as close to the placing area as possible.
 Extend mast.
 Lower load.
 Tilt forward.
 Retract mast fully.
 Release parking brake.
 Continue to drive in the sideward direction
NOTE
With a long length load, drive whenever possible in the sideward mode. Tilt
elevated loads forwards, only when directly over load destination
2.17: Placing a Load When In Forward Mode

 Drive the front of the machine as close to the placing area as possible.
 Extend mast.
 Lower load.
 Tilt forward.
 Retract mast if operating in confined spaces.
 Drive rearward until machine is clear of load
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2.18: Double Forking

If it is not possible to engage forks fully when lifting a load it will be necessary
to move the load closer to the front of the machine before lifting. This can be
achieved by double forking the load.
NOTE
The lift capacity of the Combilift is reduced if the forks are not fully engaged.
To Double Fork a Load:

 Raise the load slightly and retract the mast sufficiently to bring the load
closer to the machine.
 Lower the load and extend the mast again until the load is against the fork
face.
 The load is now ready to be lifted.
2.19: 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.
2.20: 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.
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2.21: Adjusting Load Forks

 Forks should be spaced as far apart as the load being moved will allow.
Both forks should always be the same distance from the centre of the fork
carriage.
 To adjust, raise forks approximately 25mm (1”) off the floor.
 Apply parking brake and switch off engine.
 Lift up the keeper pin and slide the forks along the carriage.
 When the forks are set to the desired position ensure that the keeper pin is
engaged in a slot on the top of the fork carriage bar.
2.22: Operating Conditions

The Combilift can operate on various surfaces but the following should be
noted
 Ground Surface: Floor and road 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.
 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.
 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.
 Gradients: When differences in levels exist, low gradient ramps should be

provided, having smooth, gradual level changes at 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 should be
followed at all times (see Safety Precautions) Do not park on a gradient. In
an emergency apply parking brake and chock wheels, but do not leave the
truck unattended.
NOTE
Always approach an incline straight on and keep forks and / or load facing
uphill at all times.
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Section 3: Daily Checks

Please refer to the John Deere engine manual that is supplied with
Combilift truck in relation to all Engine checks and activities.
INTRODUCTION
Before commencing the daily checks, ensure that the ignition switch is turned
to the ‘OFF’ position. Carefully examine the truck for evidence of damage.
Check all hydraulic components for leaks.
3.1: Wheels and Tyres

Inspect the tyres for wear or damage. Remove stones, swarf etc. from the tyre
tread.
NOTE
Torque wheel nuts every 250hrs - 600NM (442 ft/lbs) Front
- 695NM (512.6 ft/lbs) Rear
Special truck (All High Torque Motors)

Torque wheel nuts every 250hrs - 695NM (512.6 ft/lbs) (All wheels)
WARNING
Tyre changing can be dangerous, and should only be done by specially
trained personnel using proper tools and procedures.
WARNING
When lifting wheels and tyres, due allowance for the weight MUST be made.
Failure to do so could result in personal injury.
3.2: Battery
Under normal operating conditions the battery will require little or no
maintenance. If, however the battery requires re-charging, the guidelines
relating to battery charging in Section 3 should be noted and strictly adhered
to.
NOTE
Check level of electrolyte in each battery cell and top-up if necessary, using
only clean, distilled water. Bring level up to markers.
3.3: Engine Oil Level

Remove the dipstick from the engine and check the oil level. If necessary, top-
up to the correct level using the appropriate engine oil.
20
C14000J-OM-EN-07
3.4: Coolant Level
Adding Coolant
CAUTION: Explosive release of fluids

from pressurised cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
IMPORTANT: Never pour cold liquid into a hot

engine, as it may crack cylinder head or
block. DO NOT operate engine without
coolant for even a few minutes.
John Deere TY15161 Cooling System Sealer

may be added to the radiator to stop leaks.
DO NOT use any other stop-leak
Additives in the cooling system.
Air must be expelled from cooling system

when coolant is added.
Coolant level should be maintained to the bottom of the

radiator filler neck (A). If needed, as coolant as follows.
1. Loosen temperature sending unit fitting at rear of

cylinder head or plug in side of thermostat housing to
allow air to escape when filling system.
IMPORTANT: When adding coolant to the system,

use the appropriate coolant solution. (
See ENGINE COOLANT SPECIFICATIONS
in Fuels, Lubricants, and Coolant Section
for mixing of coolant ingredients before
adding to cooling system.)
Do not overfill cooling system. A pressurised

system needs space for heat expansion without
overflowing at top of radiator.
2. Fill radiator (B) until coolant level touches bottom of

radiator filler neck (A).
3. Tighten plugs and fittings when air has been expelled
from system.
4. Run engine until it reaches operating temperature.
21
C14000J-OM-EN-07
CAUTION
In normal circumstances the coolant reservoir cap should not be removed. If
however the cap must be removed then this should only be done when the
system has cooled and is not pressurised.
3.5: Hydraulic Tank

Fully lower the mast. Check the oil level on the sight gauge. If necessary top-
up to the correct level using clean hydraulic oil. (See Note 1.4 in Maintenance
Section)
The following checks should be made:

 Check the tank for leaks, damage, rust and other corrosion.
 Ensure that the drain plug is securely tightened.
Report all defects, leaks and damage immediately.
3.6: Fuel Tank

3.6.1 Diesel Tank
The following checks should be made:
 Check the tank for leaks, damage, rust and other corrosion.
 Check that the filler cap and sender unit are leak free, secure and
functioning correctly.
3.7: Automatic Fan Belt Tensioner
Belt drive systems equipped with automatic (spring) belt tensioners cannot be
adjusted or repaired. The automatic belt tensioner is designed to maintain
proper belt tension over the life of the belt. If tensioner spring is not within
specification, replace tensioner assembly.
3.8: Load Forks

Inspect the forks for signs of cracking, bending or distortion. DO NOT use the
truck if you suspect serious damage.
To determine the amount of wear of the fork blade use the fork shank as a
reference. If fork blade thickness has been reduced by more than 10%
anywhere, the ISO Safety Standard for used Forks requires that the fork
MUST be replaced.
22
C14000J-OM-EN-07
3.9: Controls
Check that all controls are in the NEUTRAL position.
With the engine running, check that all indicator lamps are off and that the
following function satisfactorily:
 Lift and lower function
 Reach function
 Tilt function
 Auxiliary function (where fitted)
 Horn function
 Work lights
 Brake/Inching function
 Accelerator pedal
 Parking Brake
 Forward / Reverse drive function
 Steering - Forward mode
- Sideward mode
23
C14000J-OM-EN-07
Section 4: Safe Operation

4.1: Safe Operation
 Combilift will not assume any liability for injuries or damage arising from or
caused by the removal of any safety devices from their vehicles by the
user.
 Fully trained, qualified and authorised drivers must only operate combi-Lift
forklift trucks.
 Ensure that the truck is suitable for the area in which it is to be operated.
 Before raising or lowering forks, give clear indication of your intentions to
other people and ask them to stand clear.
 Do not allow anyone to walk or stand beneath elevated forks.
 Do not exceed rated load capacity of the truck. In no circumstances should
counterweights be added to increase capacity.
 If the hoist mechanism malfunctions or becomes stuck in a raised position,
operate the hoist 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
Never lower the hoist mechanism with the load forks mechanically supported.
Failure to observe this rule will result in carriage plus load forks falling as they
are pulled clear of the support causing excess shock loading and possible
damage to the hoist components as the hoist chain slack is taken up.
4.2: Safe Driving

 Before moving off, look around and when clear, commence driving without
causing inconvenience to other aisle users. Remember that pedestrians
have right of way and must be safeguarded at all times.
 Operate truck smoothly without erratic movements avoiding fast turns.
 Regulate the speed of the truck to conform to prevailing conditions. Ensure
that the truck can be brought to a halt safely.
 Maintain a safe driving distance from other vehicles. Always give clear
indication of your intentions to other people.
 Do not carry passengers.
 Do not overtake at aisle intersections, in areas of limited visibility, or in
dangerous locations.
 Maintain a safe distance from railway lines, ramps, platforms, dock edges
etc
 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.
24
C14000J-OM-EN-07
 Be conscious of height and width restrictions and watch for 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 carriage or backrest.
 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.
 Always travel with forks as low as possible. If loaded, rest the load on
platforms where possible. (See fig. 4)
 Ensure load is tight against face of forks. (See fig. 4)
Caution
Take special care when travelling without a load, as the risk of tip-over may be
greater when cornering at high speed. In the event of a tip-over, hold tightly to
steering wheel. Do not leave overhead guard.
UNSAFE
UNSAFE
UNSAFE UNSAFE UNSAFE
Figure 3: Driving hazards
25
C14000J-OM-EN-07
SAFE SAFE
Figure 4: Correct Procedure
4.3: Fuel Handling & Storage

4.3.1 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.
4.3.2 Refuelling - Diesel

 Trained and authorised personnel should carry out refuelling at
designated points only.
 Before refuelling the truck, switch off the engine, apply brakes and
vacate truck.
 If a pump appliance is not available, fuel MUST be stored and
transported in clean, uncontaminated and approved containers.
Containers MUST comply with current regulations and be clearly
labelled.
 When refuelling the truck, always ensure that the hose nozzle or the
can pourer is making good electrical contact with the tank filler tube
to prevent the accumulation of a hazardous charge of static
electricity. Exercise adequate care to prevent fuel spillage or over-
filling.
26
C14000J-OM-EN-07
 After refuelling the truck, replace the tank filler cap and ensure that it
is securely fitted and leak free. Clean up any spillage using non-
combustible absorbent material before restarting the engine.
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.
4.4: Battery Charging

 Batteries contain sulphuric acid and generate explosive gases when
being charged. Trained and authorised personnel only must charge
them in designated, well-ventilated areas.
 In the event of an accident flush acid away from the eyes and/or skin
using plain water and obtain medical attention immediately.
 Check level of electrolyte in each battery cell and top-up if
necessary, using only clean distilled water. Bring level up to
markers.
WARNING
Protective clothing and goggles should be worn and particular care taken not
to come into contact with or spill electrolyte when checking its level.
Keep the battery clean and dry, and terminals free from corrosion. Check that
the ventilation holes in battery caps are clear.
Temperature must not exceed of 38° C (100° F) during charging.
Smoking and the use of naked lights in the charging area are strictly
prohibited.
NOTE
A smear of petroleum jelly applied to clean terminals will offer protection
against acid corrosion
4.5: Operating in Hazardous Areas

 No spark proofing is fitted to the truck as standard; consequently it
MUST NOT be used in flammable or explosive areas.
 The truck MUST NOT be used in corrosive atmospheres or in areas
containing a high degree of dust contamination.
27
C14000J-OM-EN-07
4.6: Safe Driving on Gradients

 When differences in levels exist, 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.
 Do not drive across, turn or stack on gradients.
 Correct gradient procedure should be followed at all times.
 Do not park on a gradient. In an emergency apply the parking brake and
chock the wheels - but do not leave the truck unattended.
 Always approach an incline straight on, and keep forks and /or load facing
uphill at all times.
4.7: Driving Position

 Only operate controls from the correct driving position and do not operate
any control until you are certain of its function.
4.8: Parking
 Apply parking brake by pressing the red button.
 Ensure that the direction control switch is set to neutral.
 Lower the forks fully.
 Park clear of aisles, doorways, stairways and fire points and ensure that
the truck will not obstruct other traffic.
4.9: Bridge Plates and Dock Boards

 Bridge plates and dock boards must have an adequate safety factor to
support a loaded truck and be secured when in use to prevent accidental
movement.
 Do not exceed the maximum permissible load, which must be clearly
marked on all bridge plates and dock boards.
 The sides of bridge plates, and where possible dock boards, must be
raised to minimise the possibility of the truck being driven over the edge.
 The surface of the above equipment must be of a slip resistant substance.
 Drive slowly when crossing bridge plates and dock boards.
28
C14000J-OM-EN-07
Section 5: Service information

INTRODUCTION
Routine maintenance may be carried out by the users/operators, but only if
the correct facilities and replacement parts, e.g. filters are used.
The service intervals are given in operating hours (recorded on the lift truck
meter) and in calendar time.
Service the machine at the interval that occurs first. These intervals are based
on normal operation of 8 hours per day. The time intervals must be decreased
from the recommendations in the maintenance schedule for the following
reasons: -
 If the lift truck is used more than 8 hours per day.
 If the lift truck must work in dusty operating conditions.
Combi-Lift trucks are built with quality components, the use of inferior spare
parts can result in inadequate safety and poor reliability. Only use genuine
approved parts.
5.1: Initial service at 100 Hours
 Change engine oil & oil filter.

 Replace fuel filter.
 Check automatic belt tensioner.
 Replace hydraulic suction filters.
 Replace return filter.
 Check hydraulic oil level.
 Check coolant level.
 Check the machine for hydraulic, coolant and fuel leaks.
 Check air cleaner and replace if necessary.
 Check all mast carriage-bearing lock nuts are tight.
 Check all bolts and fittings are tight.
 Check radiator, and if necessary, clean fins
 Grease all points indicated on grease point chart
 Check all wheel nuts for tightness.
 Check mast chains; lubricate and adjust if required.
Note
All grease points indicated on the grease point chart MUST be greased
weekly using an appropriate EP2 Grease
NOTE: Lubricate all grease points weekly. (See grease point chart).
29
C14000J-OM-EN-07
5.2: Engine Oil
The engine oil used in the Combi-Lift 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 its lubricity.
Engine Break in Service
The engine is ready for normal operation. However, extra care during the first
100 hours of operation will result in more satisfactory long-term engine
performance and life.
DO NOT exceed 100 hours of operation with break in oil.

This engine is factory filled with John Deere ENGINE BREAK IN OIL
(SAE10W30).
Operate the engine at heavy loads with minimal idling during the break in
period.
If the engine has significant operating time at idle, constant speeds, and/or
light load usage, or makeup oil is required in the first 100-hour period, a longer
break in period may be required. In these situations, an additional 100-hour
break in period is recommended using a new change of John Deere
ENGINE BREAK IN OIL and a new John Deere oil filter. For further details
please see the engine manual that was supplied with this truck.
Diesel Engine Oil

Use oil viscosity based on the expected air temperature range during the
period between oil changes.
John Deere PLUS50 ™ oil is preferred.

Oils meeting one of the following specifications are also recommended:
• ACEA Oil Sequence E7

Extended service intervals may apply when John Deere
PLUS50
™, ACEA E7, or ACEA E6 engine oils are used.
Consult your John Deere dealer for more information. Other oils may be used
if they meet one or more of the following:
• John Deere TORQGARD SUPREME™

• API Service Category CJ4
• API Service Category CI4 PLUS
• API Service Category CI4
See notes at 5.12: if a diesel particulate filter (DPF) is fitted.
Multi-viscosity diesel engine oils are preferred.
30
C14000J-OM-EN-07
The following illustration shows the grades of oil that should be used for
varying ambient air temperatures.
5.3: Filters
There are a total of 4 filters on or in the hydraulic oil tank that must be
replaced at certain intervals. These filters are:
1. The Suction Filters (2)

2. The Return Filter
3. The In-Tank Strainer Filter
Filler Cap Tank Breather
Hydraulic Oil Level Gauge

Suction Filters
Return Filter
In Tank Strainer Filter
31
C14000J-OM-EN-07
Suction Filters: (service Interval = 500Hours)

The suction filters, located on the side of the tank as shown in the diagram
above, must be replaced initially after 100 hours and then at intervals of every
500 hours (or 8 months depending on which occurs first)
To replace the Suction Filter:

1. Raise mast and then switch off engine before removing suction filter.
2. Loosen and remove the old filter cartridge.
3. Fill the new filter cartridge with new hydraulic oil of the same grade as
that already in the tank.
4. Smear some of the new oil on the O-ring seal before replacing filter.
5. Install the new filter cartridge onto the filter housing.
6. Hand tighten the cartridge into position.
7. Only use a genuine Combilift component
Return Filter: (service Interval = 500 Hours)

The return filter, located on the side of the tank, must be replaced at intervals
of every 500 hours (or 8 months depending on which occurs first).
To replace the Return Filter:
1. Raise mast and then switch off engine before removing return filter.
2. Loosen and remove the old filter cartridge.
3. Fill the new filter cartridge with new hydraulic oil of the same grade as
that already in the tank.
4. Smear some of the new oil on the O-ring seal before replacing filter.
5. Install the new filter cartridge onto the filter housing.
6. Hand tighten the cartridge into position.
7. Only use a genuine Combilift component.
In-Tank Strainer Filter: (Service Interval = 2000 Hours)

The In-Tank Strainer Filter, located in the bottom right hand corner of the tank,
must be replaced at intervals of every 2000 hours (or 24 months depending on
which occurs first). The strainer filter can only be accessed when the hydraulic
tank has been drained.
To replace the In-Tank Strainer Filter:
1. Drain the hydraulic oil tank through the drain plug in the bottom of the
tank.
2. Remove the access panel on the back of the tank.
3. Insert your hand into the tank and remove the filter by rotating it anti-
clockwise.
4. Fit the new strainer filter. Only use a genuine Combilift component.
5. Replace the access panel on the back of the truck, remember to
correctly fit the access panel O-ring seal.
32
C14000J-OM-EN-07
5.4: Engine Coolant (Service interval = 2000Hours)
CAUTION:
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Flushing and Refilling Cooling System

Shut off engine. Only remove filler cap when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve pressure before removing
completely.
Note:
When John Deere COOLGARD is used, the drain interval is 3000 hours or 36
months (whichever occurs first). The drain interval may be extended to 5000
hours or 60 months of operation (whichever occurs first), provided that the
coolant is tested annually & additives are replenished, as needed, by adding a
supplemental coolant additive (SCA). If COOLGARD is not used, the flushing
interval is 2000 hours or 24 months of operation.
Drain old coolant, flush the entire cooling system, test thermostats, and fill
with recommended clean coolant per the procedure set out in engine Manual
supplied with this truck.
5.5: Hydraulic Oil

The hydraulic oil used in the Combi-Lift should conform to the International
Standard I.S.O. G344 HV grade oils with improved viscosity / temperature
characteristics. It should also have the correct temperature range for the
ambient temperature in which the machine is being operated. If the operating
temperature is outside the standard range, the standard oil should be
replaced with the correct grade. The following table shows examples of
commercially available oils. Ensure that the correct type is used in the
relevant ambient temperature.
Low Range Standard Range High Range

AMBIENT -20ºC to 25ºC -10ºC to 35ºC 0ºC to 45ºC
TEMPERATURE -4ºC to 77ºF +14ºC to 95ºF 32ºF to 113ºF
Castrol: Hyspin AWH 32 AWH 46 AWH 68

B.P. Bartran HV 32 HV 46 HV 68
Esso: Univis N 32 N46 N 68
Mobil: 13 M 15 M 16 M
Shell: Tellus Oil T32 T46 T68
Texaco: HDZ 32 HDZ 46 HDZ 60
33
C14000J-OM-EN-07
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 upper level on the hydraulic oil level gauge.
5.6: Mast Maintenance (Service Interval = 250Hours)
Mast chains should be checked for elongation periodically and adjusted as

required. The chains must be adjusted so that the upper mast stops never
come into contact with each other and the lower mast stops never come into
contact with each other. Adjust all chains evenly. An interval of 250 hours can
be taken as a typical value, under normal working conditions.
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.
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.
Additional Mast Maintenance (Contact Combilift for further information)
 Replacement of hydraulic cylinder seals.

 Replacement of chains.
 Replacement of bearings.
34
C14000J-OM-EN-07
5.7: Greasing Mast Carriage Channels
The mast carriage channels must be greased periodically only on the vertical
(side) surfaces 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.
5.8: Fuel Filter Element
Engines are equipped with a primary fuel filter and a final fuel filter. Both filters
are replaced at the same 500hour interval. Please refer to engine manual for
full instructions on how to correctly replace fuel filter elements
5.9: Air Filter Element
Replacing Radial Seal Air Cleaner Filter Element
Please refer to the engine manual that was issued with this truck for full
guidelines and instructions on replacing air Filter
element.
IMPORTANT: ALWAYS REPLACE primary air

cleaner element when torn, or visibly dirty.
5.10: Checking Tensioner Spring Tension
A belt tension gauge will not give an accurate measure of the belt tension
when automatic spring tensioner is used. Measure tensioner spring tension
using a torque wrench and procedure outlined in the engine manual that was
issued with this truck. For full guidelines and instructions on working on
Automatic Fan Belt Tensioner please also refer to engine manual.
35
C14000J-OM-EN-07
C14000J-OM-EN-07
GREASE POINT GREASE POINT CHART
DESCRIPTIONS
C6000 - C12000 Kg
Combilift Ltd
1
1. Steering Front 3 C14000 - C26000 Lbs
2. Swivel Back 2
3. Steering Back
LUBRICATE ALL POINTS INDICATED,
4. Rear Steering 16
MAST, AND ATTACHMENTS WITH EP2
4
5. Rear Steering GREASE
5.11: Grease Point Chart
6. Swivel Front
7. Swivel Back
15 18 17 ENGRASE TODOS LOS PUNTOS
8. Steering Front 19
INDICADOS , EL MÀSTIL Y TODOS LOS
9. Swivel Front 14 5 ACCESORIOS CON GRASA EP2 CADA
6 SEMANA
10. Steering Front
on the mast, and attachments where fitted.
11. Swivel Back 7

12. Front Bearing 13
SCHMIEREN SIE ALLE PUNKTE: MAST,
13. Front Tilt 20
12 21 22
TRAVERSEN UND ANBAUGERÄTE
14. Front Tilt WÖCHENTLICH MIT EINEM EP2 - FETT.
15. Front Bearing
16. Swivel Back
17. Rear Bearing 11 GRAISSEZ TOUS LES POINTS INDIQUéS,
18. Rear Tilt LE MâT, LES éQUIPEMENTS, CHAQUE
19. Mast Bushing 9 SEMAINE EN UTILISANT UNE GRAISSE
EP2
20. Mast Bushing 8
10
21. Rear Tilt
22. Rear Bearing
Lubricate all points weekly using EP2 grease. Also lubricate all grease points
Operators Manual: C14J/C16J
36
5.12: Diesel Particulate Filter (DPF)
The diesel particulate filter requires high temperature exhaust gases to burn
off any soot that may accumulate there. If the exhaust gas temperatures do
not regularly reach the required level to burn off the soot it may lead to a
blockage. Reduced engine performance and increased fuel consumption may
result from a blockage.
In most cases it is possible to clear a blockage by working the engine hard

(e.g. driving the truck with a full load up an incline) for a period of at least 5
minutes so that the exhaust gases reach the temperature required to burn off
the soot. However in some cases the DPF may need to be removed and
cleaned.
Avoid prolonged periods of idling to prevent any blockages from occurring i.e.
switch off the engine when not in use.
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.
Note
If a diesel particulate filter (DPF) is fitted to the truck then API CJ-4 engine oil
MUST be used.
37
C14000J-OM-EN-07
5.13: Maintenance Chart
In order to keep the Combilift in optimum working condition it is necessary to

service the truck at regular intervals. The Chart on the following page details
the intervals (in hours of machine operation) at which maintenance tasks
should be performed.
Service Interval (Hrs)
Item Daily 250 500 2000
Check engine oil & coolant level ●
Check fuel filter / water bowl ●
Check air cleaner dust un-loader valve ●
Visual walk around inspection ●
Check engine mounts & bolts ●
Service battery ●
Change engine oil & replace oil-filter ●
Check crankcase vent system ●
Check air intake hoses, connections & systems ●
Replace fuel filter elements ●
Check automatic Belt tensioner ●
Check for belt wear ●
Check engine electrical ground connections ●
Check cooling fan ●
Check cooling system ●
Coolant solution analysis-Add SCAs as required ●
Pressure test cooling system ●
Check engine speeds ●
Check crankshaft & vibration damper ●
Flush & refill cooling system ●
Test thermostats ●
Check & adjust engine valve clearance ●
Change air filter element ●
Change diesel glow plugs ●
Check oil cooler ●
Check hydraulic oil level ●
Change hydraulic oil ●
Change hydraulic filter cartridges ●
Change hydraulic in tank strainer filter ●
Check swivel bearings (slew rings) ●
Check mast carriage bearings ●
Check mast carriage wear pads & alignment ●
Check mast bearings ●
Check mast chains ●
Lubricate & Adjust Mast Chains ●
Grease Mast Channels ●
Grease Mast Carriage Channels ●
Check wheel nuts ●
Torque wheel nuts ●
Check hydraulic hoses for wear & leaks ●
38
C14000J-OM-EN-07
Inspection Sheet Operators Daily Inspection Sheet
Model: ______ Serial No: ______

5.14: Operators Daily Inspection Sheet
Date: ________ Shift No: _______
Inspect the Combilift before each shift. Should the Combilift be found to require servicing or if during the operation
the Combilift malfunctions or becomes unsafe, stop the truck and report the situation immediately to the designated
authority. DO NOT operate the Combilift or attempt to service it. Servicing is only to be conducted by a qualified
technician.
Mark the Appropriate Box with X OK Machine OK Service Required

Mon Tues Wed Thurs Fri Sat Sun
Damage
Bent, Dented or Brok en Parts
OK OK OK OK OK OK OK
Leaks
Tank , Valves, Fittings, Hoses
Tires
Chunk s missing, Loose wheel nuts
Forks
Bent, Damaged or Worn
Visual Checks
Mast (inc. Chains)

Damage, Signs of bending, loose chains
Overhead Guard
Damage, Crack ing
Engine
Smell, Belts tight and in good condition
Engine Oil level
Signs of damage or leak ing
Coolant Level
Acceptable Range
Hydraulic Oil Level
Acceptable Range
Radiator & Oil Cooler
Build up of leaves, dust or debris
Hoses
Good Condition, No signs of wear
Fuel Tank / LPG Cylinder
Signs of damage or leak ing
Safety Equipment
Operational Checks
Horn, Operator Restraint, Reversing Bleeper

Engine
Starts and runs OK, no unusual noise
Mode change
Wheels realign smoothly, no stick ing
Travel
No unusual Noise, Smooth changes
Steering
No excessive play or restriction in either mode
Inching Pedal
Stops travel, smooth deceleration
Parking Brake
Functions and releases
Hydraulic Controls
Forks-Lift/lower, mast-in/out, tilt, Aux functions
Hour Meter Reading
Operator Initials
Supervisors Initials
Notes (regarding repair, etc): ____________________________________

____________________________________________________________
____________________________________________________________
39
C14000J-OM-EN-07
Section 6: Circuit Diagrams

6.1: Engine Wiring Diagram
A—Engine Coolant Temperature (ECT) Sensor

B—Electronic Injector Connector
C—Manifold Air Temperature (MAT) Sensor
D—(ECU) Connector
E—Optional Instrument Panel
F— Engine Wiring Harness
G—Engine Oil Pressure Sensor Connector
H—Power and Ground Battery Connections
I— Fuel Rail Pressure Sensor
J— Crankshaft Position Sensor
K—Pump Position Sensor
L— Pump Control Valve Solenoid
M—Fuel Temperature Sensor
N—Water in Fuel Sensor
40
C14000J-OM-EN-07
B1—Analog Throttle S2— Speed Select Switch

F1— Fuse (20 Amp) (Harness) (Momentary)
G1—Alternator S3— Bump Enable Switch
K1—Starter Relay (Momentary)
M1—Starter Motor S4— High Low Speed Select
N1—Transient Voltage Protector Switch
P1— Optional Gauge S5— Override Shutdown Switch
P2— Optional Gauge (Momentary)
P3— Oil Pressure Gauge V1— Diode
P4— Coolant Temperature Gauge X1— Vehicle Harness Connector
P5— Tachometer Display X2— Alternator Harness Connector
P6— Hour Meter/Diagnostic Gauge X3— Single Point Ground
S1— Ignition Key Switch X4— CAN Terminator
X5— Analog Throttle Connector
41
C14000J-OM-EN-07
Engine Wiring Diagram - Continued
B1—Analog Throttle S2— Speed Select Switch

F1— Fuse (20 Amp) (Harness) (Momentary)
G1—Alternator S3— Bump Enable Switch
K1—Starter Relay (Momentary)
M1—Starter Motor S4— High Low Speed Select
N1—Transient Voltage Protector Switch
P1— Optional Gauge S5— Override Shutdown Switch
P2— Optional Gauge (Momentary)
P3— Oil Pressure Gauge V1— Diode
P4— Coolant Temperature Gauge X1— Vehicle Harness Connector
P5— Tachometer Display X2— Alternator Harness Connector
P6— Hour Meter/Diagnostic Gauge X3— Single Point Ground
S1— Ignition Key Switch X4— CAN Terminator
X5— Analog Throttle Connector
42
C14000J-OM-EN-07
6.2: Combilift Wiring Diagram (Diesel with PLC)
COMBILIFT LTD Title: John Deere (Diesel) Electric Circuit Colour Codes
Model: C14000
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
NEGATIVE WIRES ARE NORMALLY BLUE

OR BLACK, DEPENDING ON WHAT UNIT
IS BEING INVESTIGATED.
TAKE ALL NEGATIVES TO BE BLACK
UNLESS STATED OTHERWISE.
43
C14000J-OM-EN-07
COMBILIFT LTD Model: C14000 Title: John Deere Diesel Electric Circuit ( PLC ) Section: 1 (of 4) Revision Date:05/01/16
Drawn By : Ciaran McKenna
C14000J-OM-EN-07
Combilift Ltd
44
C14000J-OM-EN-07
Combilift Ltd
45
C14000J-OM-EN-07
Combilift Ltd
46
C14000J-OM-EN-07
Combilift Ltd
47
6.3: Hydraulic Steering & Functions Circuit
48
C14000J-OM-EN-07
6.4: Hydraulic Drive Circuit – Low Speed Setup
X X
LH WHEEL MOTOR RH WHEEL MOTOR
1 1
L R R L
A B
Rotary Inch Valve

P T
R Ps Fa1 Fe MB B
FWD.
A
T1 T2 X1 X2 S MA REV.
PURGE VALVE B
NON-RETURN
VALVE - 2 BAR T
OIL COOLER DOUBLE SUCTION FILTER

10 MICRON NOMINAL
Y
Legend
Pump Suction Line L R

Pump Drain Lines
Brake Release Lines 1
Motor Drive Lines
Motor Drain Lines Rear Wheel Motor
Control Pressure Lines
Purge Lines X
49
C14000J-OM-EN-07
6.5: Hydraulic Drive Circuit – High Speed Setup
X X
LH WHEEL MOTOR RH WHEEL MOTOR
1 1
L R R L
A B
Rotary Inch Valve

P T
R Ps Fa1 Fe MB B
FWD.
A
T1 T2 X1 X2 S MA REV.
PURGE VALVE B
NON-RETURN
VALVE - 2 BAR T
OIL COOLER DOUBLE SUCTION FILTER

10 MICRON NOMINAL
Legend
Pump Suction Line L R

Pump Drain Lines
Brake Release Lines 1 Y
Motor Drive Lines
Motor Drain Lines Rear Wheel Motor
Control Pressure Lines
Purge Lines X
50
C14000J-OM-EN-07
6.6: Hydraulic Drive Circuit – High/Low Speed Select
51
C14000J-OM-EN-07
Section 7: Appendices
7.1: Appendix A: Warranty Registration
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.
52
C14000J-OM-EN-07
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, Gallinagh, Monaghan, County Monaghan, Ireland.
BY EMAIL TO: [email protected]
Failure to complete Warranty Registration Form may impact the Warranty Claim Process.

Dear Customer,: Combilift LTD

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Dear Customer,: Combilift LTD

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Dear Customer,

Thank you for choosing us and showing your faith in

The Purpose of this operators Manual

This Manual contains all of the information you will

 Always follow all safety instructions laid out in this

 All instructions, prohibitive or otherwise, found in

 Always perform the Daily Inspection as indicated in

Section 1: Machine layout and Operator Controls ................. 4

Section 2: Operating instructions and Conditions .............. 11

Section 3: Daily Checks.......................................................... 20

Section 4: Safe Operation ...................................................... 24

Section 5: Service information .............................................. 29

Section 6: Circuit Diagrams ................................................... 40

Section 7: Appendices............................................................ 52

Section 1: Machine layout and Operator Controls

1.1: Machine Overview and Components.

11. Rear Swivel

12. Access Panel

Figure 1: Machine Component Layout

Cabin Heater Switch (optional)

Cabin Temperature Control (optional)

Direction control switch

Battery charge Indicator

Engine Oil Pressure Indicator

NOTE: Do NOT run engine if oil pressure indicator is illuminated.

Water Temperature Gauge

Lift Control Lever

Mast Extension Lever

Tilt Control Lever

Auxiliary Lever (Optional)

The operators must acquaint themselves with the operation

Battery Isolator Switch

 When the Combilift is not in use turn switch to

Seat Adjustment: Diesel Machine

B Height Adjustment – Depending on operator

C Using the height adjustment knob ‘B’, adjust

D Backrest angle adjustment

F Horizontal Adjustment (Slide rails) Red

H Backrest Extension Green

Mast height Drive cut out

Section 2: Operating instructions and Conditions

2.1: Understand the Capacity of your Lift-Truck

2.2: Centre of Gravity (COG)

The centre of gravity of any object is the single

Combilift and load

Combilift and load combined

Load Centre Combilift

2.3: Load Chart

on a load chart located inside the cabin. The

load centre is determined by its centre of ?Kg

LIFT HEIGHT (m)

gravity and is measured from the front face ?Kg ?Kg

of the forks to the centre of gravity of the 2.5

load. It is assumed that the centre of gravity ?Kg

in the vertical direction is no greater than the ?Kg

specified horizontal load centre. 600 700 800 900

2.4: Operator Qualification

2.5: Operator Responsibilities

It is the operators’ responsibility to perform the daily inspection before each