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C25000 O&S Manual

17

C25000-OM-EN-05

Warning

Every forklift operator must be trained in accordance with the rules

provided by the relevant local Health and Safety Authority (HSA).

Employers must ensure that each powered industrial truck operator is

competent to operate a powered industrial truck safely, as demonstrated by

the successful completion of the relevant training as specified by the

relevant local authority. Operating a powered industrial truck without the

proper training can cause serious injury or death.



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 the safety of others as well as yourself. In no
circumstances should counterweights be added to increase capacity.



Stop working and switch off if for any reason, the truck becomes unsafe

or defective. Remove the key and place an ‘out of order’ sign in a
prominent place on the truck.



Prohibit unauthorised and untrained people from accessing the starting

key and operating of the truck.



The operator is responsible for visually monitoring the work area of the

truck and preventing anyone from entering the area without permission.
If a person enters the area while the truck is in operation, the operator
shall stop the truck and instruct the person to leave the work area until
the truck has been stopped. The person may then approach the
machine in full view of the operator.



Personnel being trained, educated, instructed or participating in a

general training program may only work on or with the machine under
constant supervision of an experienced supervisor.



Work on the machine‘s electrical equipment may only be carried out by

an electrician or by trained persons under the direction and supervision
of an electrician.



Work on the chassis, brakes and steering system may only be

performed by trained, specialised personnel.



Only trained, specialised personnel with specific knowledge of and

experience in hydraulics may work on hydraulic units.



If the mast mechanism malfunctions or becomes stuck in a raised

position, operate the mast 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.

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Summary of Contents for C25000

Page 1: ...that make it one of the leading products in the material handling industry Combilift Ltd 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 inst...

Page 2: ... 18 2 7 Moving Off 19 2 8 Changing Direction without Changing Mode 19 2 9 Changing Into Sideward Mode 19 2 10 To Change Back to Forward Mode 19 2 11 Stopping 20 2 12 Loading 20 2 13 When Loading in Sideward Mode 20 2 14 When Loading in Forward Mode 21 2 15 Placing a Load When In Sideward Mode 21 2 16 Placing a Load When In Forward Mode 21 2 17 Double Forking 22 2 18 Stacking 22 2 19 De Stacking 22...

Page 3: ... 5 8 Air Filter Elements 46 5 9 Checking Belt Tensioner Spring Tension 47 5 10 Greasing Mast Channels 47 5 11 Greasing Mast Carriage Channels 47 5 12 Grease Point Chart 48 5 13 Diesel Particulate Filter DPF 49 5 14 Diesel Fuel 49 5 15 Maintenance Chart 50 5 16 Operators Daily Inspection Sheet 51 Section 6 Technical Information Circuit Diagrams 52 6 1 Engine Wiring Diagram 52 6 2 Checking the Charg...

Page 4: ...d Figure 1 1 below indicates all of the major components of the Combilift and figure 1 2 on the following page indicates all of the operator controls 1 1 Machine Overview and Components Figure 1 1 Machine Components Layout 1 2 Operator Controls Display Layout Component List 1 Forks 2 Front Swivels 3 Platforms 4 Hydraulic Tank 5 Mast 6 Flashing Beacon 7 Operator Cabin 8 Diesel Tank 9 Work Lights 10...

Page 5: ...el Gauge 9 Work Lights Switch 10 Engine Malfunction Indicator 11 Ignition Switch 12 Drive Speed Switch 13 Accelerator Pedal 14 Brake Inch Pedal 15 Adjustable Suspension Seat 16 Direction Control Joystick 17 Temperature Control Knob Optional 18 Side Window Wiper Switch 19 Cooling Fan Optional 20 Horn Button 21 Parking Brake Stop Switch 22 Fork Control Joystick 23 Interior Light 24 Adjustable Steeri...

Page 6: ...ocated on the dash to the right hand side of the joystick To APPLY the brake depress the button The button will lock in the depressed position To RELEASE the brake rotate the button clockwise It should pop up into its normal position The Machine will NOT drive with the park brake on Direction Control Joystick The directional control lever is the 5 postion lever located on the dash It can be set to...

Page 7: ...ge monitors the temperature of the engine cooling system 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 The hour meter records how many hours the truck has been operating for in hours and tenths of an hour Use meter to determine maintenance intervals Oil Pressure Indicator Light When the key switch is in the ON p...

Page 8: ...start engine Low fuel level indicator light The low level indicator light illuminates whenever the fuel level on the truck reaches a certain level On LPG engines a buzzer will also sound Whenever the light illuminates the truck should be refuelled immediately Parking Brake Indicator Light The Parking Break indicator light indicates whether the brake is ON or OFF Mode Indicator Lights The Mode indi...

Page 9: ...riplex 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 drive cutout override button located on the dash Window Wiper Switches There are 2 window wiper switches on the machine The right hand side window wiper switch shown opposite is located in the top right...

Page 10: ...ect between off low medium or high fan speeds Item 6 in figure 1 2 on page 5 Temperature Control Knob Optional This knob is located to the right of the armrest see item 17 in figure 1 2 on page 5 To increase cabin temperature turn anti clockwise To decrease cabin temperature turn clockwise Brake Inch Pedal The Brake Inch pedal is the pedal on the floor to the left hand side of the steering Column ...

Page 11: ... sideward mode turning the steering wheel clockwise will turn truck clockwise Turning the steering wheel anti clockwise to turn truck anti clockwise The same is true for travel in either direction when in sideward mode The steering wheel is also equipped with a spinner knob for easier steering The angle of the steering column is adjustable to increase driver comfort To adjust the angle of the stee...

Page 12: ...ding 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 H Backrest Extension I Lumbar Support adjustment 5 positions Seat Switch The seat switch is a safety...

Page 13: ...he operator s seat 1 4 Fork Control Joystick Component Layout Lift Control To raise forks pull joystick back To lower forks push joystick forward Mast Extension Retraction To extend mast roll Reach scroll wheel forward To retract mast back roll Reach scroll wheel back Tilt Control To tilt forks forward roll Tilt scroll wheel forward To tilt forks back roll Tilt scroll wheel back Side shift Control...

Page 14: ...yourself with the auxiliary functions on the Combilift and how they are operated by the auxiliary lever Battery Isolator Key Switch This switch is used to disconnect power from the battery in the event of an emergency The switch is located above the access panel on the right hand side of the Combilift See diagram opposite When the Combilift is not in use turn switch to the OFF position by turning ...

Page 15: ...d 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 th...

Page 16: ...ability To keep the lift truck stable the centre of gravity must stay within the area of the lift truck represented by a triangle drawn between the three wheels If the centre of gravity moves forward of the triangle front the lift truck will tip forwards If it moves outside the right or left of the triangle the truck will tip to the side Load Centre of Gravity Combilift and load combined Centre of...

Page 17: ...ired due to intoxication or drug reaction Always ensure that the truck is in good working order before commencing work This is achieved by performing the pre use inspection The 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 pre use inspection before each shift The Inspection and how it should be co...

Page 18: ...thorised and untrained people from accessing the starting key and operating of the truck The operator is responsible for visually monitoring the work area of the truck and preventing anyone from entering the area without permission If a person enters the area while the truck is in operation the operator shall stop the truck and instruct the person to leave the work area until the truck has been st...

Page 19: ...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...

Page 20: ... pedal to halt the truck Select change of direction and gradually increase pressure on accelerator until truck is travelling at desired speed 2 9 Changing Into Sideward Mode Bring the truck slowly to a halt by depressing the brake inch pedal fully Ensure that all observers stand clear of the truck Parking brake must be applied before change in mode is selected Do not press brake pedal while a chan...

Page 21: ...ching pedal permits slow drive speed for precise manoeuvring of the truck in confined spaces It operates independently of the accelerator pedal if fully depressed it will bring the machine to a complete stop 2 12 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 fo...

Page 22: ...ouble 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 15 Placing a Load When In Sideward Mode Drive the front of the machine as close to the placing area as possible Apply parking brake Lower raise the forks to the required height Extend mast Lower load Tilt forward Retract mast fu...

Page 23: ...racted 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 a...

Page 24: ...e fork control joystick and moving the joystick left of right 2 21 Work Place Operating Conditions Operators must be aware of special situations in their workplace in order to avoid forklift accidents Even if an operator works in the same area every day there could be changes that affect safety such as Contractors doing maintenance Wet areas Overhead repair work Be on the lookout for anything that...

Page 25: ...e slowly to reduce the impact on rollers and guide rails Headroom Structures over aisles which may be potential obstacles should be defined and marked with a conspicuous colour Low doorways should be marked with their clearance limits Power Lines If contact with a live electric source occurs Do not leave the truck until the electricity has been disconnected and a qualified technician directs the o...

Page 26: ... 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 faci...

Page 27: ...ak repaired to avoid Environmental hazards Fire hazards Slip hazards Personal injury hazards Do not attempt to perform repairs to the hydraulic system until any residual hydraulic pressure has been relieved Observe the valid safety and environmental regulations for the respective product when handling oil grease and other chemical substances Do not service the truck immediately after operation Wai...

Page 28: ...cks Never exceed the carrying capacity marked on portable or powered dock boards Portable dock boards must be secured in position using anchors or other devices that prevent slipping Trailers and Rail Cars 1 Before you load or unload a trailer or rail car make sure it does not move unintentionally Set the brakes Chock the wheels 2 In addition to setting the brakes and chocking the wheels if a semi...

Page 29: ... 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 ...

Page 30: ... A should be maintained to approximately half full Do not overfill the cooling system A pressurised system needs space for heat expansion without overflowing IMPORTANT When adding coolant to the system use the appropriate coolant solution See section 5 4 on page 43 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 hy...

Page 31: ...s 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 3 9 Controls Check that all controls are in the NEUTRAL ...

Page 32: ...using excess shock loading and possible damage to the hoist components as the hoist chain slack is taken up 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 E...

Page 33: ...e 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 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 carr...

Page 34: ...C25000 O S Manual 33 C25000 OM EN 05 SAFE SAFE Figure 1 driving hazards Figure 2 Correct Procedure UNSAFE UNSAFE UNSAFE UNSAFE UNSAFE ...

Page 35: ...te 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...

Page 36: ...ing 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 4...

Page 37: ... not obstruct other traffic 4 9 Wear Personal Protective Equipment PPE Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against uncomfortably loud noises Operating equipment safely requires the full attention of the operat...

Page 38: ...ved parts 5 1 Initial service at 100 Hours Change engine oil oil filter Replace fuel filter Check automatic belt tensioner Replace element in high pressure hydraulic inline filter drive circuit Replace element in high pressure hydraulic inline filter steering hydraulic functions circuit Replace return filter Check hydraulic oil level Check coolant level Check the machine for hydraulic coolant and ...

Page 39: ... 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 BREAKIN OIL and a new John Deere oil filter For further details please see engine manual that was supplied with this truck Diesel Engine Oil Use oil viscosity based on the expected air temperature range ...

Page 40: ...0W30 All Temperatures 5 3 Changing Hydraulic Oil Filters There are five hydraulic oil filters used on the trucks hydraulic system that must be replaced at certain intervals These filters are as follows 1 One return filter located on top of the hydraulic tank 2 Two strainer filters located inside the hydraulic tank 3 One high pressure inline filter located inside the engine compartment 4 One high p...

Page 41: ...ing lid Hydraulic Oil In Tank Strainer Filters Service Interval 2000 Hours The hydraulic oil and strainer filters located inside the hydraulic tank must be replaced at intervals of every 2000 hours or 24 months depending on which occurs first The strainer filters can only be accessed when the hydraulic tank has been drained To replace the Hydraulic Oil In Tank Strainer Filters 1 Drain the hydrauli...

Page 42: ...lter element gets clogged The visual indicator must be inspected weekly If the colour inside the window changes from green to red the filter element must be replaced One of the hydraulic functions must be in use while inspecting the visual indicator as the indicator will return to green in the absence of hydraulic pressure Two people are required to inspect the visual indicator one to operate the ...

Page 43: ...screw the filter housing using the appropriate tools and extract the spent filter cartridge 3 Collect the spent oil and cartridge in a suitable container and dispose of them in accordance with environmental protection regulations 4 Check the thread on the filter housing and the thread and seal on the filter head for cleanliness and clean if necessary 5 Check the condition of all seals and change i...

Page 44: ...placed when repairs are performed on the cooling system Rinse out the cooling system before filling with new coolant A mixture of clean water with 15 of the new coolant is recommended for rinsing Caution Switch off the engine before working on the cooling system Never operate the engine without coolant Explosive release of hot fluids from the pressurised cooling system can cause serious burns The ...

Page 45: ... with the maintenance schedule The cooling system must be monitored regularly This includes checking the concentration of the antifreeze The concentration of antifreeze to water must never be allowed fall below 35 as the protective effects fall away rapidly below this concentration Water quality Water quality is important to the performance of the cooling system Distilled deionized or demineralize...

Page 46: ...able 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 Chain Maintenance Mast chains should be checked for elongation and adjusted as required The chains must be adjusted so that the upper and lower stops on the mast never collide Adjust all chains eve...

Page 47: ...the right hand side of the machine and locate the air filter unit to the right of the engine 2 Unlatch and remove the housing service cover 3 Remove the primary filter Push down on the filter using the handle this will tilt the filter to approximately 5 to loosen the filter gasket seal Use the handle to pull the filter out of the housing 4 Remove the safety filter Note The safety filter only needs...

Page 48: ...d with this truck For full guidelines and instructions on working on Automatic Fan Belt Tensioner please also refer to engine manual 5 10 Greasing Mast Channels All roller surfaces must be greased periodically where the fork carriage and mast sections run The frequency of this operation is at the discretion of the user and essentially depends upon the working conditions and the workplace A lubrica...

Page 49: ...ear Swivel Back 10 LH Carriage Back 11 LH Steering Back 12 LH Steering Front 13 LH Swivel Front 14 LH Swivel Back 15 LH Cradle Outer 16 LH Cradle Inner 17 Rear RH Steering Back 18 Rear RH Steering Front 19 Rear Cradle Front 20 Rear Swivel Front 21 Rear LH Steering Front 22 Rear LH Steering Back 23 RH Carriage Front 24 LH Carriage Front 25 Carriage Rear RH 26 Carriage Front RH 27 Carriage Rear LH 2...

Page 50: ...imum Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Cold Filter Plugging Point CFPP should be at least 5 C 9 F below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature Fuel lubricity should pass a maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 121561 Sulphur Conten...

Page 51: ...eck 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 Test glow plugs Check oil cooler Check hydraulic oil level Change hydraulic oil Cha...

Page 52: ...s Supervisors Initials Visual Checks OK OK OK OK OK OK OK Mon Tues Wed Thurs Fri Sat Sun OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK Operational Checks OK OK OK OK OK OK OK OK OK OK OK OK OK O...

Page 53: ...ic 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 ...

Page 54: ...e P2 Optional Gauge P3 Oil Pressure Gauge P4 Coolant Temperature Gauge P5 Tachometer Display P6 Hour Meter Diagnostic Gauge S1 Ignition Key Switch S2 Speed Select Switch Momentary S3 Bump Enable Switch Momentary S4 HighLow Speed Select Switch S5 Override Shutdown Switch Momentary V1 Diode X1 Vehicle Harness Connector X2 Alternator Harness Connector X4 CAN Terminator X5 Analog Throttle Connector ...

Page 55: ...tional Gauge P3 Oil Pressure Gauge P4 Coolant Temperature Gauge P5 Tachometer Display P6 Hour Meter Diagnostic Gauge S1 Ignition Key Switch S2 Speed Select Switch Momentary S3 Bump Enable Switch Momentary S4 High Low Speed Select Switch S5 Override Shutdown Switch Momentary V1 Diode X1 Vehicle Harness Connector X2 Alternator Harness Connector X3 Single Point Ground X4 CAN Terminator X5 Analog Thro...

Page 56: ...re should measure between 20 28 bar 290 406 PSI 6 3 Checking the Drive Pressure In order to check the drive main pressure the following steps should be taken Ensure that the engine is switched off and the park brake applied Attach a pressure gauge to port MB or port MA on the pump as indicated in the diagram on the following page Start the engine and fully depress the accelerator pedal Read the pr...

Page 57: ...ate the function being tested in the example of testing the tilt back pressure scroll the tilt scroll wheel back The reading on the gauge indicates the pressure setting on one particular port on the valve chest Example To check the tilt forward pressure tilt the mast forward as far as it will go Fully depress the accelerator pedal and scroll the tilt scroll wheel forward The pressure gauge will di...

Page 58: ...per Carousel Alarm Dash Light 0 90 Dash Lights 5 7 5 Brakes Park Brake Foot Brake Switch Rear Brake Relay Brake Solenoids Brake Light on Dash 6 10 Wipers 7 10 Front LED Work Lights Optional Mast LED Work Lights 8 7 5 Cabin Interior Light 9 10 Cabin Heater Optional 10 7 5 Horn 11 7 5 Proximity Switches 12 7 5 Fork Control Joystick Supply Optional Auxiliary Functions 13 7 5 Flashing Beacons 14 7 5 O...

Page 59: ...bers if ordering fuses from Combilift Fuse Rating Amps Functions 1 80 Main Fuse Ignition Switch 2 50 Auxiliary Fuse Box 3 30 Oil Cooler 4 30 Air Conditioning 6 6 Relay Layout There are a number of relays involved in the electrical control system of the truck Most are located in the electrical enclosure in the dash and the others are in the engine compartment To access the relays in the dash remove...

Page 60: ...usel Alarm Optional 22 Side Rear LED Work Lights Spot Lights 9 Steering Solenoid G Engine Plug G Power To ECU 1A Neutral Cut Off DB Dead Band Solenoid Carousel Valve DE Dead End Solenoid Optional Hi Hi Low Speed Solenoid Open the engine access panel to gain access to the relays located in the engine compartment The following table and diagram give details of the relays located in the engine compar...

Page 61: ...C25000 O S Manual 60 C25000 OM EN 05 6 7 Combilift Electric Circuit ...

Page 62: ... R THROTTLE PEDAL J G 87 30 85 86 RELAY 1 70A PRESSURE RELEASE SOLENOID IN LINE FUSE 10A FUEL SENDER DASH PANEL F P H R S T R R O V GR GY R R GY HOUR METER FUEL LIGHT TEMP GAUGE OIL LIGHT LIGHT GLOW OIL PRESSURE SENDER TEMPERATURE SENDER CHARGE LIGHT 58 15 54 AUX FUSEBOX 50 F1 7 5A IF HIGH MAST IS FITTED REMOVE LINK WIRE FIT BUTTON LINK R R R Y W FUEL PUMP AC SUPPLY PLUG MF4 30A IGNITION SWITCH 30...

Page 63: ...L CAROUSEL 35 PROXIMITY SW R AUX FUSEBOX AUX FUSEBOX AUX FUSEBOX Drawn By David Murray Title John Deere Diesel Electric Circuit PLC COMBILIFT LTD Model C25000 Section 2 of 4 CAROUSEL LIGHT BK W GR O GY BK 15 54 PIN 4 DRIVE SOLENOID 90 INDICATOR LAMP 0 INDICATOR LAMP BN PIN 3 PIN 8 PIN 10 PIN 9 GR PIN 4 PIN 6 PIN 7 PIN 5 BN R R PIN 17 PIN 18 PIN 12 PIN 13 PIN 14 PIN 16 PIN 15 PIN 9 PIN 10 PIN 8 PIN...

Page 64: ...ORT 2 1 0 FRONT WIPER CAB HEATER RH SIDE WIPER m 87 87A 85 m m 30 RELAY 22 86 1 2 3 10A F7 7 5A F9 7 5A F8 O R R BN R R R CAB FAN BN Y R V O HORN V 7 5A P F10 58 15 54 FLASHING BEACON ZD1 SPOTS OPTIONAL 2xFRONT LED SPOTS 2xMAST LED BN 0 FLASHING BEACON ZD1 R 87 87A 85 30 RELAY HI TORQ 86 SPEED SWITCH ON DASH BN HI TORQ SOLENOID SIDE REAR LED SPOTS AUX F3 10A AUX F1 10A AUX F2 7 5A AUX F4 15A 12V S...

Page 65: ... RELAY JS2 86 30 87A 87 85 RELAY JS3 86 30 LINK IF AUXILIARY VALVES ARE FITTED REMOVE LINK WIRE AND INSERT RELAY LINK TO OPTIONAL AUXILIARY FUNCTION VALVE TO OPTIONAL AUXILIARY FUNCTION VALVE AUX FUSEBOX 15 54 58 Drawn By David Murray Title John Deere Diesel Electric Circuit PLC COMBILIFT LTD Model C25000 Section 4 of 4 JOYSTICK SWITCH ON DASH OPTIONAL 58 15 54 AUX FUSEBOX Revision Date 18 09 14 5...

Page 66: ...P LS HT P L CL CR T EF R STEERING SOLENOID 6 PORT RH STEERING IN PISTON HEAD PRIMING VALVE LH STEERING IN TANK STRAINER FILTER 90 MICRON 25 MICRON RETURN FILTER SIDE SHIFT DIVERTER CUT OFF VALVE SHUTTLE VALVE SHUTTLE VALVE P T F S MA MF A LS ACCUMULATOR REAR STEERING C1 C2 C4 C3 P1 P2 225 225 B T A P To Port G On Drive Pump See Drive Circuit To Front Motors Port XD See Drive Circuit A B T 25 MICRO...

Page 67: ...ines Speed Select Lines Rotary Inch Valve T B PURGE VALVE T1 T2 S X1 X2 MA R Ps MB Fe Fa1 X R L 1 Y B FWD A REV B T A P X L R 1 Y 3 2 L R 1 HI LO SPEED SELECT VALVE 1 XD 10 MICRON HIGH PRESSURE FILTER REAR WHEEL MOTORS RH MOTOR CHANGEOVER VLAVE REAR DRIVE BLOCK P A T B CAROUSEL VALVE X 1 Y R L 90 MICRON SUCTION STRAINER A XD LH WHEEL MOTOR RH WHEEL MOTOR BRAKE CHARGING VALVE P T F S MA MF A LS ACC...

Page 68: ...ndicating System LED Status Meaning No LED No power Supply to PLC Flashing Green Fast PLC is not Programmed Flashing Green Slow PLC is Programmed Running Normally Static Green PLC is Programmed but not Running Static Red PLC has Failed Replace PLC Each of the plugs has a specific function as do the pins on each plug The tables on the following pages give details of the functions on each of the plu...

Page 69: ...e Black X4 11 Reverse Signal From Direction Lever Brown X4 12 Left Signal From Direction Lever Grey X4 13 Right Signal From Direction Lever Green X4 14 Mast Height Proximity Switch Signal Yellow X4 15 Mast Height Over Ride Button Red X4 16 Speed Control Optional White X4 17 Optional Extra X4 18 Seat Switch Grey OUTPUTS Plug Pin Function Wire Colour X3 01 Forward Solenoid 01 White X3 02 Forward Sol...

Page 70: ...15 0 Solenoid 1of2 Grey X5 1 16 Supply for 0 Solenoid 2of2 from fuse 4 Brown X5 1 17 Not Used n a X5 1 18 0 Solenoid 2of2 Grey Plug Pin Function Wire Colour X5 2 01 Not Used n a X5 2 02 Supply for 90 Solenoid 1of2 from fuse 4 Brown X5 2 03 90 Solenoid 1of2 Green X5 2 04 Not Used n a X5 2 05 Not Used n a X5 2 06 Supply for 90 Solenoid 2of2 from fuse 4 Brown X5 2 07 90 Solenoid 2of2 Green X5 2 08 No...

Page 71: ...Electronic Accelerator Pedal Low Pin A Black JD Main D Start Allow Relay Relay 1 Pin 87 Red JD Main E Negative Supply To B Blue JD Main G Ignition On Relay G Pin 87 Red JD Main H Malfunction Indicator Light MIL To Fuse 1 Blue JD Main J Alternator Excitor To Fuse 3 Red JD Main L Electronic Accelerator Pedal Analog Input Pin B White JD Main M Electronic Accelerator Pedal High Pin C Red ...

Page 72: ... 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 filled out and posted to the following address Combilift Ltd Annahagh Co Monaghan Ireland ...

Page 73: ...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 Post...

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