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

PAGE
1. INITIAL SERVICE AT 100 HOURS 2
1.1. ENGINE OIL 3
1.2. TO CHANGE SUCTION FILTER 4
1.3. ENGINE COOLANT 4
1.4. HYDRAULIC OIL 4
1.5. CHAIN MAINTENANCE 5

2. GREASE POINT CHART 5

3. MAINTENANCE CHART 6
3.1 AIR CLEANER ELEMENT 6
3.2 WATER PUMP V-BELT 7
3.3. FUEL FILTER 7
3.4 COOLANT LEVEL 7

4. HYDRAULIC FUNCTIONS CIRCUIT 8

5. HYDROSTATIC DRIVE CIRCUIT 9

6. ELECTRICAL CIRCUIT (LPG GM ENGINE SECTION 1) 10

6.1 ELECTRICAL CIRCUIT (LPG GM ENGINE SECTION 2) 11
6.2 ELECTRICAL CIRCUIT (LPG GM ENGINE SECTION 3) 12
6.3 ELECTRICAL CIRCUIT (LPG GM ENGINE SECTION 4) 13
6.4 ELECTRICAL CIRCUIT (DIESEL KUBOTA ENGINE SECTION 1) 14
6.5 ELECTRICAL CIRCUIT (DIESEL KUBOTA ENGINE SECTION 2) 15
6.6 ELECTRICAL CIRCUIT (DIESEL KUBOTA ENGINE SECTION 3) 16
6.7 ELECTRICAL CIRCUIT (DIESEL KUBOTA ENGINE SECTION 4) 17

7. FRONTAL MODE 18

8. SIDEWARD MODE 19

9. CAROUSEL MODE 20

10. FOUR DIRECTION ELECTRICAL CIRCUIT 21

10.1 ELCTRIC CIRCUIT FOR DRIVING BACKWARD 22
10.2 ELECTRIC CIRCUIT FOR DRIVING SIDEWARD (RIGHT) 23
9.3 ELECTRIC CIRCUIT FOR DRIVING SIDEWARD (LEFT) 24

11. SYNCHRONISED HYDRAULIC STEERING 25

11.1 SYNCHRONISED HYDRAULIC STEERING DIAGRAM 2 26

12. HYDROSTATIC TRANSMISSION / BYPASS CONDITION 27

13. MECHANICAL BRAKE RELEASE 28

14. CHECKING REAR MOTOR CHARGE PRESSURE 29

15. DASH COMPONANTS 30

16. FUSE BOX 32

1. INITIAL SERVICE AT 100 HOURS
• Change engine oil & oil filter. (See Note 1.1)
• Check air cleaner and replace if necessary.
• Replace fuel filter.
• Check fan belt tension and adjust if required.
• Replace hydraulic suction filter located at rear. (See Note 1.2, See also Fig1)
• Replace return filter located at front. (See Fig 1)
• Check all bolts and fittings are tight.
• Check all mast carriage-bearing lock nuts are tight.
• Check all wheel nuts for tightness (210 N/m)
• Grease all points. (See grease point chart)
• Check radiator, and if necessary, clean fins.
• Check mast chains; lubricate and adjust. (See Note 1.5)
• Check machine for hydraulic, coolant and fuel leaks.
• Check hydraulic oil level. (See Note 1.4)
• Check coolant level. (See Note 1.3)

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)

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1.1 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.
All Combi-Lift trucks leave the factory with a special, high multigrade oil in the
engine and this can be used all year round except in very cold climates.

The following table illustrates the correct oil grades for the varying ambient
temperatures.

MULTIGRADE ENGINE OIL SUITABLE FOR ALL DIESEL ENGINES

°F °C

100 40
30

SAE 15W-40/15W-50
SAE 20W-40/20W-50
80
20
SAE 10W-50 / 10W-60

60

SAE 10W-30
SAE 10W-40
10
40
0
SAE 5W-50

SAE 5W-30
SAE 5W-40
20
-10
0 -20
-20 -30

For further notes, see Volkswagen manual.

The engine oil filter and drain plug

are accessible from the front of the
machine with the mast extended
fully. Lightly smear the sealing
ring of the new filter with oil
before fitting.
When the new oil is added, the
level should be checked. Run
engine for a short period. After
stopping engine, wait for approx 5
minutes until the oil has drained
back into the sump. Re-check level,
and if necessary top-up to the
maximum level on the dipstick.

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1.2 To Change Suction Filter
Unscrew the filter element.
Lightly smear the sealing
ring of the new filter with Suction Filter
hydraulic oil. Hand tighten.
IMPORTANT: Fill the
Return Filter
replacement filter with oil
before fitting. This prevents
Strainer Filter
cavitations to the pump
during start up. Drain Plug
Fig 1. Hydraulic Tank
1.3 Engine Coolant
The coolant must consist of a mixture of 50% water to 50% coolant additive (glycol
based with anti-corrosion additives). This will give frost protection down to -25°C
and also protect the alloy parts in the cooling system against corrosion. Therefore, the
concentration of coolant additive must not fall below 40%.

If greater frost protection is required, the coolant additive can be increased but only up
to 60% (frost protection to -40°C approx.). Any greater proportion of coolant will
decrease the frost protection and also the anti corrosive properties.

1.4 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.
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1.5 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 8. Steering front 15. Front bearing

2. Swivel back 9. Swivel front 16. Swivel Back
3. Steering back 10. Steering Front 17. Rear bearing
4. Rear Steering 11. Swivel Back 18. Rear tilt
5. Rear Steering 12. Front bearing 19. Mast bushing
6. Swivel Front 13. Front tilt 20. Mast bushing
7. Swivel back 14. Front tilt 21. Rear Tilt

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

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

Check Change
Engine Oil (See Note 1.1) A
Engine Oil Filter A
Air cleaner element A
Engine belts A
Idling speed A
Diesel Fuel Filter A
Engine coolant level A C
Radiator & Fans A
Hydraulic Oil Cooler A
Timing belt condition & Tension A C
LPG Spark plugs B
Diesel Glow plugs B
Engine mounting bolts B
Pump mounting bolts B
Hydraulic Oil A B
Tank internal filter (See fig 1) B
Suction filter (See Note 1.2) 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

3.1 Air Cleaner Element

The air cleaner is located beside the

battery under the bonnet and is
accessible from the rear of the
machine. When replacing the outer
cover, ensure that the dust valve is
towards the bottom.

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3.2 Water Pump V-Belt

The two-piece pulley on the pump

tensions the drive belt for the water
pump.
To tension the belt:
• Remove the outer half of the pulley
(three socket cap bolts).
• Tension belt by varying the number
of shims between the pulley halves.
• Place the shims taken out in front of
the outer pulley half.

3.3 Fuel filter

The fuel filter is located behind the
diesel tank and is accessed from the
front of the machine when the mast is
forward.

3.4 Coolant level

The coolant reservoir is built into the top
of the radiator and is accessible from the
front of the machine through the access
hole in the top of the bonnet.

To drain the cooling system:

• Extend mast fully forward.
• Remove filler cap from the top of
the radiator.
• Remove drain plug from bottom of
the radiator.
• Allow radiator to drain completely
before replacing the plug and
tightening.

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 A1 15

18 A2
13
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 A1 15

18 A2
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 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.
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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
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the normal mode light in the dash panel.The machine is in backward

mode.

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.
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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.
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
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sideward mode (90º) dash indicator light and the reflex steering
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 @
Wheels to
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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.

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 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).

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 Ref No.
COMBILIFT WATER TIGHT FUSEBOX CM25017-00 SECTION 17

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