TITLE .................................................................................................................

PAGE
1. INITIAL SERVICE AT 100 HOURS 2
1.1. TO CHANGE SUCTION FILTER 3
1.2. HYDRAULIC OIL 3
1.3. CHAIN MAINTENANCE 4

2. GREASE POINT CHART 4

3. MAINTENANCE CHART 5

4. BATTERY MAINTENANCE 5
4.1 RECCOMENDED CHARGING PROCEDURE 5
4.2 CHANGING BATTERIES 6

5. HYDRAULIC FUNCTIONS CIRCUIT 7

6. HYDROSTATIC DRIVE CIRCUIT 8

7. ELECTRICAL CIRCUIT (SECTION 1) 9

7.1 ELECTRICAL CIRCUIT (SECTION 2) 10
7.2 ELECTRICAL CIRCUIT (SECTION 3) 11
7.3 ELECTRICAL CIRCUIT (SECTION 4) 12

8. FRONTAL MODE 13

9. SIDEWARD MODE 14

10. CAROUSEL MODE 15

11. ELECTRIC CIRCUIT FOR DRIVING FORWARD 16

11.1 ELCTRIC CIRCUIT FOR DRIVING BACKWARD 17
11.2 ELECTRIC CIRCUIT FOR DRIVING SIDEWARD (RIGHT) 18
11.3 ELECTRIC CIRCUIT FOR DRIVING SIDEWARD (LEFT) 19
11.4 ELECTRIC CIRCUIT FOR DRIVING IN CAROUSEL(CLOCKWISE) 20
11.5 ELECTRIC CIRCUIT FOR DRIVING IN CAROUSEL(ANTICLOCKWISE) 21

12. SYNCHRONISED HYDRAULIC STEERING 22

12.1 SYNCHRONISED HYDRAULIC STEERING DIAGRAM 2 23

13. HYDROSTATIC TRANSMISSION / BYPASS CONDITION 24

14. MECHANICAL BRAKE RELEASE 25

15. CHECKING REAR MOTOR CHARGE PRESSURE 26

16. DASH LAYOUT (INTERNAL) 27

16.1 DASH LAYOUT PARTS LIST 28

17. FUSE BOX 29

18. AC4 80V INVERTER CONNECTORS 30
1. INITIAL SERVICE AT 100 HOURS

• Check Battery Electrolyte levels

• Replace hydraulic suction filter located at rear.
• Replace return filter located at front.
• Check all bolts and fittings are tight.
• Check all mast carriage-bearing lock nuts are tight.
• Check all wheel nuts for tightness (200 N/m)
• Grease all points. (See grease point chart)
• Check mast chains; lubricate and adjust.
• Check machine for hydraulic leaks.
• Check hydraulic oil level.

NOTE: Lubricate all grease points weekly. (See grease point chart).

NOTE: All wheel nuts must be checked weekly and torqued if necessary to the
correct level. (All three wheels: 210Nm or 155ft/lbs)

2
1.1 To Change Suction Filter
Unscrew the filter element. Lightly smear the sealing ring of the new filter with
hydraulic oil. Hand tighten.

IMPORTANT: Fill the replacement filter with oil before fitting. This prevents cavitation
to the pump during start up.

1.2 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
-4ºF to 77ºF +14ºF 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

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 upon 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.

3
1.3 Chain Maintenance
Mast chains should be checked for elongation and adjusted as required.

To lubricate the chains, use oil with a viscosity that will remain fluid at all occurring
ambient temperature conditions, lubricating oils with a viscosity from SAE20 to
SAE40 are suitable. The following are examples of commercially available chain-
lubricating products: -

1. Rexnord high performing chain spray

2. BP Energol Transmission Oil 80
3. ESSO Transmission Oil ST80
4. Shell Tonna Oil T200.

2. GREASE POINT CHART

1. Steering Front 9. Steering front 17. Rear tilt

2. Swivel back 10. Swivel front 18. Mast bushing
3. Steering back 11. Front Bearing 19. Mast bushing
4. Rear Steering 12. Front tilt 20. Rear tilt
5. Rear Steering 13. Front tilt 21. Rear bearing
6. Swivel back @0° 14. Front bearing 22. Swivel Back @90°
7. Steering back 15. Swivel front
8. Swivel back 16. Rear bearing

Lubricate all points weekly using an EP2 grease. Also lubricate all grease points on
the mast, and attachments where fitted.

4
3. MAINTENANCE CHART
Schedule: A = EVERY 250 HOURS / 4 MONTHS (OR WHICHEVER OCCURS FIRST).
B = EVERY 1000 HOURS
C = Every 2000 HOURS

Check Change
Hydraulic Oil Cooler A
Electric Motor mounting bolts B
Pump mounting bolts B
Hydraulic Oil A B
Tank internal filter B
Suction filter A
Return filter A
Back arm bearing & lock nuts A
Slew bearings (front wheels) A
Wheel Nuts (210 N/m) A
Mast bearings & lock nuts B
Carriage bearings and lock nuts B
Carriage wear pad adjustment A
Mast chain adjustment A

4.0 BATTERY MAINTENANCE

WARNING
• Batteries produce explosive gases during operation and
charging. Keep your Combilift in a designated area
while you are charging or changing the batteries. The
area must be properly ventilated to remove the gases
produced while it is charging. Keep all sparks, arcs,
and lighted tobacco away from the batteries. Failure to
do this can cause serious injury or death.

4.1 RECOMMENDED CHARGING PROCEDURE

• Park your Combilift in the battery bay

• Open the bonnet of the machine
• Latch the battery cover in the open position
• Disconnect the battery plug
• Check the charger cable and plug for frayed insulation and broken connectors
and connect it to the battery plug.
• When the batteries are fully charged disconnect the charger cable and
reconnect the battery cable to the truck cable.

5
 CAUTION
• Make sure top of batteries are clean and dry.

• Check the electrolyte levels and top off with distilled

water after the batteries are completely charged.
• Check the charger cable and plug for frayed insulation
• Make sure you do not accidentally connect the charger
to the Combilift machine cable or you will damage the
Combilift.

Never use a battery that weighs less or more than the weight range listed on the
identification plate. Since the battery is part of the counterweight, too much or little
battery weight can cause the truck to tip.

4.2 CHANGING BATTERIES:

CAUTION
Make sure you are using a hoist that has sufficient capacity to lift the battery.

Recommended Changing Procedure:

• Park your Combilift in the battery bay.

• Open the Bonnet of the Combiift
• Latch the battery cover to the open position.
• Disconnect the battery plug
• Lift the battery out of the Combilift.

Installation:

• Orient the new battery so the connector faces the right direction.
• Carefully lower it into place
• Connect the cable
• Latch the battery cover
• Close the bonnet of the Combilift.

6
7
8
SEAT SWITCH
BLUE

KEY
A4

B1 KSI
B12
MOTOR THERMAL
SW
B6

THROTTLE PEDAL
SW B8
A5 ENABLE

A6 1ST SPEED

A12 HYDRO

MAIN
B+

U
AC
V MOTOR

E1 +12V
E3 PHASE A SPEED
ENCODER
E5 PHASE B
D1 E2 I/O GnD
SAFETY
B-
D2

POT HIGH 1 A2

POT WIPER 1 A1 Side A Side B Adaptor 04-40089 MDI

BLUE X6 BLUE M1
F6

X5
GREEN GREEN M6
F5

X4
YELLOW YELLOW M5
F4

POT LOW A3 X3
VIOLET VIOLET M4
F3

X2
RED RED M2
F2

X1
BROWN BROWN M3
F1

SAFETY
A1 15

18 A2
13
14
15
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING FORWARD
POS 1
POS 3 This circuit only shows the parts of the electric circuit which
deal with driving the machine in normal mode.

POS 4 POS 2
NEUTRAL

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

NORMAL
FWD REV MODE

When the directional control lever is moved from the neutral position to
position 1, the following chain of events occur:

1. Relay 16 is energised allowing a supply to be fed to relays 7, 8, & 9.

2. Relay 3 is energised allowing a supply to the forward solenoid.

3. A supply is put to relay 7 position 30 and straight through 87a then to

wheels to 0º solenoid. This allows oil to flow.

4. Relay 9 is supplied via relay 8 which energises the steering solenoid

FWD
(six port valve) this allows oil flow through the six port valve which
brings the wheels back to the 0º position (Normal Mode)
REV
5. This in turn energises the front wheel proximity switch, which energises
relay 8. Relay 8 then de-energises relay 9, switching off the six port
valve so changing the flow of oil from the front wheels to the rear wheel
cylinder. The rear wheel then turns round to the 0º position which then
energises the 0º proximity switch for the rear wheel.

6. When the rear wheel 0º proximity switch is energised, this in turn

energises relay 7 which turns off the wheel to 0º solenoid and turns on
the normal mode light in the dash panel.The machine is in forward mode.
16

Wheels Steering
to 0° Solenoid
Solenoid (six port)
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING BACKWARD
POS 1
POS 3 This circuit only shows the parts of the electric circuit which
deal with driving the machine in normal mode.

POS 4 POS 2
NEUTRAL

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

NORMAL
FWD REV MODE

When the directional control lever is moved from the neutral position to
position 2, the following chain of events occur:

1. Relay 16 is energised allowing a supply to be fed to relays 7, 8, & 9.

2. Relay 4 is energised allowing a supply to the reverse solenoid and

activating the reversing bleeper.

3. A supply is put to relay 7 position 30 and straight through 87a then to

wheels to 0º solenoid. This allows oil to flow.

FWD
4. Relay 9 is supplied via relay 8 which energises the steering solenoid
(six port valve) this oil flow through the six port valve brings the wheels
REV
back to the 0º position (Normal Mode)

5. This in turn energises the front wheel proximity switch, which energises
relay 8. Relay 8 then de-energises relay 9, switching off the six port
valve so changing the flow of oil from the front wheels to the rear wheel
cylinder. The rear wheel then turns round to the 0º position which then
energises the 0º proximity switch for the rear wheel.

6. When the rear wheel 0º proximity switch is energised, this in turn

energises relay 7 which turns off the wheel to 0º solenoid and turns on
the normal mode light in the dash panel.The machine is in backward
mode.
17

Reversing Wheels to Steering

Bleeper 0° Solenoid Solenoid
(six port)
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING SIDEWARD (RIGHT)
POS 1
POS 3 This circuit only shows the parts of the electric circuit which
deal with driving the machine in sideward mode.

POS 4 POS 2
NEUTRAL

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

SIDEWARD
MODE FWD REV

When the directional control lever is moved from the neutral position to
position 3, the following chain of events occur:

1. Relay 17 energises supplying relays 6, 9, 10, & 11

2. Relay 3 energises, allowing a supply to the forward solenoid.

3. Relay 6 disables the reversing bleeper

FWD

4. Power is supplied to the wheels to 90º (sideward mode) solenoid via

REV relay 11. Oil flows to the rear wheel cylinder, turning the rear wheel to
the 90º position. When the rear wheel is in the 90º position, the 90º
proximity switch energises which in turn energises relay 10

5. Relay 10 energises the 6 port valve (steering solenoid) allowing oil to

flow to the front wheel cylinders. The front wheel turn out to the 90º
position and energise the front 90º proximity switch. When the front
90º poximity switch is energised, it in turn energises relay 11.

6. Relay 11 then switches off the wheels to 90º solenoid and turns on the
sideward mode (90º) dash indicator light. The machine is now in
Forward Sideward Mode and drives to the right.
18

90° dash light

90° Solenoid
Reversing

Rear wheel
@ 90° prox
Solenoid
(six port)
Steering
Bleeper

Wheels @
Wheels to
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING SIDEWARD (LEFT)
POS 1
POS 3 This circuit only shows the parts of the electric circuit which
deal with driving the machine in sideward mode.

POS 4 POS 2
NEUTRAL

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

SIDEWARD
MODE FWD REV

When the directional control lever is moved from the neutral position to
position 4, the following chain of events occur:

1. Relay 17 energises supplying relays 6, 9, 10, & 11

2. Relay 4 energises, allowing a supply to the reverse solenoid. Relay 14

also energises.

3. Relay 6 disables the reversing bleeper

FWD
4. Power is supplied to the wheels to 90º (sideward mode) solenoid via
relay 11. Oil flows to the rear wheel cylinder, turning the rear wheel to
REV the 90º position. When the rear wheel is in the 90º position, the 90º
proximity switch energises which in turn energises relay 10

5. Relay 10 energises the 6 port valve (steering solenoid) allowing oil to

flow to the front wheel cylinders. The front wheel turn out to the 90º
position and energise the front 90º proximity switch. When the front
90º poximity switch is energised, it in turn energises relay 11.

6. Relay 11 then switches off the wheels to 90º solenoid and turns on the
sideward mode (90º) dash indicator light and the reflex steering
solenoid. The machine is now in Forward Sideward Mode and drives to
the left.
19

90° dash light

90° Solenoid
Reversing

Rear wheel
@ 90° prox
Solenoid
(six port)
Steering
Bleeper

Wheels @
Wheels to
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING IN CAROUSEL.
POS 3 POS 1 (Clockwise)
POS 4 POS 2 This circuit only shows the parts of the electric circuit which
NEUTRAL deal with driving the machine in carousel mode. Also the
machine must be in sideward mode to operate the carousel
function.

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

SIDEWARD
MODE FWD REV

When the directional control lever is moved from the neutral

position to position 3, the following chain of events occur:

1. Relay 17 energises supplying relays 6, 9, 10, & 11

2. Relay 3 energises, allowing a supply to the forward

solenoid.

3. Relay 6 disables the reversing bleeper

4. Power is supplied to the wheels to 90º (sideward mode)

solenoid via
relay 11. Oil flows to the rear wheel cylinder, turning the
rear wheel to
the 90º position. When the rear wheel is in the 90º
FWD position, the 90º
proximity switch energises which in turn energises relay
10

REV 5. Relay 10 energises the 6 port valve (steering solenoid)

allowing oil to
flow to the front wheel cylinders. The front wheel turn out
to the 90º
position and energise the front 90º proximity switch.
When the front
90º poximity switch is energised, it in turn energises relay
11.

6. Relay 11 then switches off the wheels to 90º solenoid and

turns on the
sideward mode (90º) dash indicator light. The machine is
now in
20

Forward Sideward Mode and drives to the right.

90° dash light
90° Solenoid
Reversing

Rear wheel
@ 90° prox
Solenoid
(six port)
Steering
Bleeper

Wheels @
Wheels to
 ELECTRIC CIRCUIT FOR
Park Brake
Directional
Lever DRIVING IN CAROUSEL.
POS 3 POS 1 (Anti-Clockwise)
POS 4 POS 2 This circuit only shows the parts of the electric circuit which
NEUTRAL deal with driving the machine in carousel mode. Also the
machine must be in sideward mode to operate the carousel
function.

POS 1: FORWARD IN NORMAL MODE

POS 2: REVERSE IN NORMAL MODE
POS 3: FORWARD IN SIDEWARD MODE (RIGHT)
POS 4: REVERSE IN SIDEWARD MODE (LEFT)

SIDEWARD
MODE FWD REV

When the directional control lever is moved from the neutral position to
position 4, the following chain of events occur:

1. Relay 17 energises supplying relays 6, 9, 10, & 11

2. Relay 4 energises, allowing a supply to the reverse solenoid. Relay 14

also energises.

3. Relay 6 disables the reversing bleeper

FWD
4. Power is supplied to the wheels to 90º (sideward mode) solenoid via
relay 11. Oil flows to the rear wheel cylinder, turning the rear wheel to
REV the 90º position. When the rear wheel is in the 90º position, the 90º
proximity switch energises which in turn energises relay 10

5. Relay 10 energises the 6 port valve (steering solenoid) allowing oil to

flow to the front wheel cylinders. The front wheel turn out to the 90º
position and energise the front 90º proximity switch. When the front
90º poximity switch is energised, it in turn energises relay 11.

6. Relay 11 then switches off the wheels to 90º solenoid and turns on the
sideward mode (90º) dash indicator light and the reflex steering
21

solenoid. The machine is now in Forward Sideward Mode and drives to

the left.
90° dash light
90° Solenoid
Reversing

Rear wheel
@ 90° prox
Solenoid
(six port)
Steering
Bleeper

Wheels to

Wheels @
22
23
HYDROSTATIC TRANSMISSION / BYPASS CONDITION.

In this case the travel drive is switched on the free wheel position. For this purpose
the high-pressure valves of the variable displacement pump have a so-called bypass
function.

By turning the relevant screw (item 1) the valve is so released that free oil circulation
is made possible.

Bypass: Screw in item 1 until it is level with the nut.

Towing Speed

The max. towing speed of 2 km/h should not be exceeded.

• Higher permissible speeds are depended on the hydraulic motor speed or the
selected gear.

Towing distance

The towing distance should not exceed 1 km.

• With no boost available the hydraulic circuit drains.

The heat generation in he hydraulic motor rotary group has to be taken into
account.

Termination of the towing operation

After termination of the towing operation turn back item 1. The original set pressure
valve is thereby available.

VALVE FUNCTION: SCREW BACK ITEM 1 UP TO STOP. SCREW UP THE NUT.

24
 MECHANICAL BRAKE RELEASE

In certain service situations, it may be necessary to release the motor brake.

• Extract and release

the plug (142) from
the brake cover.

• Tighten the screw in

the piston

• And tighten the nut

until the motor shaft
turns freely.

After brake release, mount a

new plug (142).

25
26
 Ref No.
COMBILIFT DASH - INTERNAL LAYOUT SECTION 16
COMBILIFT DASH - INTERNAL LAYOUT
Ref No.
SECTION 16

OPTIONAL RELAYS
COMBILIFT WATER TIGHT FUSEBOX Ref No.
SECTION 17