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CombiLift C2500CB Manual

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Dear Customer,
Thank you for choosing Combilift and showing your faith
in our range of material handling products. By choosing
Combilift you now own a high quality 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 make it one of
the leading products in the material handling industry.
In order to familiarise yourself with your truck in a quick
comprehensive
manner
please
read
this
manual
attentively. In addition to the information regarding safety
and operation, this manual also contains important
maintenance checks and instructions for ensuring
continuous safe and reliable operation of your truck.
Should you have any questions or problems relating to
your truck, please contact your local Combilift partner who
will be happy to respond to your questions, suggestions
and/or comments. We are confident that you will be wholly
satisfied with your Combilift truck.
www.combilift.com
C2500CB-OM-EN-16

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Summary of Contents for CombiLift C2500CB

  • Page 1 Dear Customer, Thank you for choosing Combilift and showing your faith in our range of material handling products. By choosing Combilift you now own a high quality machine designed by our team of experienced engineers using the most up to date design techniques and technology with the sole...
  • Page 2 About This Manual The descriptions and illustrations contained in this manual are not in any way binding. Combilift must reserve the right to make changes without prior notice in the interest of the enhancement of the product. Some trucks may be customised to suit the needs of individual customers. Therefore these trucks may deviate slightly from the descriptions contained within this manual.

  • Page 3: Table Of Contents

      Switching Off the Engine................53     5.10 Moving Off ....................53     5.11 Turning ......................54     5.12 Stopping ....................... 55     5.13 Changing Direction ..................56     5.14 Parking ......................57   C2500CB-OM-EN-16...
  • Page 4 PLC Diagnostics ..................120   Section 8: Appendices ................122   8.1: Certified LPG Engine Emission Control Warranty ........123     8.2: General Engine Warranty ................124     Warranty Registration Form ..............125     Pre-Use Check Sheet .................. 126   C2500CB-OM-EN-16...

  • Page 5: Section 1: Safety Information

    Operator Safety Before commencing use of the Combilift forklift operators must become familiar with its capabilities and thoroughly read and understand the material contained in this Manual along with the meanings of the various machine signs (decals) found on the truck.

  • Page 6: Safety Decals

    Maintain all safety decals on the machine in a legible manner. If a safety decal becomes damaged or illegible, replace it with a new decal - available from your local Combilift partner. The machine safety decals are illustrated below and are accompanied by a description of the meaning of each decal.

  • Page 7: Safety Devices

     The brake/inch pedal brake switch applies the park brake when the brake/inch pedal is depressed and held in for 3 seconds or more. Battery Isolator Key Switch  The battery isolator key switch allows the battery to be disconnected from the electrical system. C2500CB-OM-EN-16...

  • Page 8: Warning Devices

    Do not remove or bypass any of the safety devices. Combilift Ltd will not assume liability for injuries or damages arising from or caused by the removal or bypassing of any the trucks safety or warning devices.

  • Page 9: Operator Qualification And Responsibilities

    Safety Information Operator Qualification and Responsibilities  The operator of the Combilift must be qualified to operate the truck through successful completion of a training program delivered by Combilift Driver training personnel or a Combilift authorised training organisation.  Operators shall be aware of all local authority regulations and laws regarding the qualification of material handling equipment operators.

  • Page 10: 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 C2500CB-OM-EN-16...
  • Page 11 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. C2500CB-OM-EN-16...
  • Page 12  Engine exhaust emissions are toxic in concentrated amounts. Do not operate the truck in enclosed spaces or inadequately ventilated spaces.  Wear appropriate personal protective equipment (breathing filter, protective suit) for protection against specific dangers, e.g. poisonous gases, corrosive steam, poisonous surroundings, etc. C2500CB-OM-EN-16...
  • Page 13 If the temperature falls below or rises above this range discontinue operation of the machine in order to prevent damage to various components. For operation outside these temperatures, please consult your Combilift partner as special modifications and lubricants are required. Oil, Fuel and Coolant...
  • Page 14 3. Maintain a safe distance from the edge of ramps, platforms, or other similar working surfaces. 4. Never attempt to move a trailer with the Combilift truck. C2500CB-OM-EN-16...

  • Page 15: Section 2: Basic Information

    If it is determined that the truck is not in a fit condition for operating, notify the relevant supervisor to have it repaired before use. The Combilift forklift has been designed to lift loads, transport them and place them in another location, taking into account the safety instructions listed in this manual and any other local laws and regulations where applicable.

  • Page 16: General

    Having the ability to drive forward, back, left and right makes the Combilift truck capable of performing like a standard counterbalance forklift truck, a reach truck and a side loading truck safely and efficiently. Thus it is ideal for handling palletised loads and also long loads such as pipes or timber.

  • Page 17: Principle Of Operation

    A brake/inch pedal slows the truck down when partially pressed and brings the truck to a complete stop when fully pressed and held down. The park brake is applied by a push button located inside the operating enclosure. C2500CB-OM-EN-16...

  • Page 18: Serial Number And Serial Plate

    The manufacturers name, address and contact details are displayed on the bottom of serial plate The serial plate must not be removed. If lost order a replacement from Combilift immediately. Note Ensure that the serial number on the chassis corresponds with the serial number on the serial plate before putting the truck into operation.

  • Page 19: Rated Capacity, Centre Of Gravity And Stability

    If we look at the diagram below what this translates to is that as long as F1 is equal to F2 then the system will balance. F2 = M2xD2 M1 = M2 Fulcrum D1 = D2 F1 = M1xD1 C2500CB-OM-EN-16...
  • Page 20 To visualise the stability triangle, imagine three lines connecting each of the trucks three wheels. The area inside these three lines forms the stability triangle. If the combined centre of gravity moves outside the boundary of the stability triangle the truck will tip over. C2500CB-OM-EN-16...
  • Page 21 Combi-CB & Load Combined Combi-CB Centre of Gravity Centre of Gravity Load Centre of Gravity Stability Triangle Boundary C2500CB-OM-EN-16...

  • Page 22: Load Centre & Load Chart

    Therefore as the load centre and/or lift height increases the maximum weight that can be safely lifted reduces. The trucks capacities at various heights and load centres are displayed on a load chart located inside the operating enclosure. A sample load chart is shown below. C2500CB-OM-EN-16...

  • Page 23: Attachments

    Fixed attachments to the forks or fork carriage affect the trucks capacity rating. When the factory, dealer, or distributor installs a fixed attachment approved by Combilift a modified load chart shall be attached inside the operating enclosure. The modified load chart identifies the type of attachment and the capacity ratings on the load chart will be modified accordingly.

  • Page 24: Tilting

     When unloading at high elevations, make sure to only use enough tilt to level the load for placing onto the rack or stack.  Forward tilt past horizontal is only provided to assist the operator in withdrawing the forks from a load after the load has been placed. C2500CB-OM-EN-16...

  • Page 25: Section 3: Components & Controls

    Components & Controls Section 3: Components & Controls All operators must be familiar with the Combilift trucks main components and controls, their function and where they are located before commencing operation of the truck. The major components are labelled in figure 3.1 below.

  • Page 26: Operating Components & Controls

    The layout of the controls displayed above applies only to a standard truck. The actual layout may vary depending on individual customer requirements. Refer to the decals in the cabin of the individual truck if the layout is not standard. C2500CB-OM-EN-16...
  • Page 27 DO NOT operate the truck unless the seatbelt is fastened across the top of the lap. Note If the truck has the seat belt switch option fitted the drive is disabled if the seatbelt tongue is not properly fastened in the seatbelt buckle. C2500CB-OM-EN-16...
  • Page 28  The weight is adjusted correctly when the arrow is in the middle of the viewing window.  Within the viewing area, the individual height can be adjusted to a minimum spring movement.  When the minimum/maximum weight adjustment has been reached, you can hear it reaching the upper or lower end stop. C2500CB-OM-EN-16...
  • Page 29  When driving in sideward mode, turn the steering wheel clockwise to turn the truck clockwise. Turn the steering wheel anticlockwise to turn the truck anticlockwise.  The same holds true for either left or right travel in sideward mode. C2500CB-OM-EN-16...
  • Page 30  When partially pressed down it restricts the flow of oil through the hydrostatic drive system thus reducing the travel speed.  Press the pedal down gradually to reduce the travel speed gradually.  Release the pedal gradually to increase the travel speed gradually. C2500CB-OM-EN-16...
  • Page 31  In position 0 – All work lights are switched off.  Turn the switch clockwise to position 1 to illuminate the forward facing work lights only.  Turn the switch clockwise to position 2 to illuminate all work lights. C2500CB-OM-EN-16...
  • Page 32  The operating enclosure light illuminates the interior of the operating enclosure.  Press on the small circular recess on the bottom face of the light housing to illuminate the light.  Press in the same place a second time to extinguish the light. C2500CB-OM-EN-16...

  • Page 33: Hydraulic Lever Operation

     Trucks with more than one auxiliary function may have a push button fitted on the fourth lever.  Operators must acquaint themselves with the operation of any auxiliary functions before using the truck.  The most common auxiliary function fitted is hydraulic fork positioning. C2500CB-OM-EN-16...
  • Page 34 Note The layout of the hydraulic levers is subject to change due to individual customer requirements. Please refer to the decal on the individual truck. Operators must acquaint themselves with the layout of all controls before operating the truck. C2500CB-OM-EN-16...

  • Page 35: Hydraulic Joystick Operation (If Fitted)

    The layout of the joystick functions may be subject to change due to individual customer requirements. Please refer to the decal on the individual truck. Operators must acquaint themselves with the layout of all controls before operating the truck. C2500CB-OM-EN-16...

  • Page 36: Section 4: Operation Monitoring

    If the needle on the temperature gauge moves into the red area the engine must be switched off promptly to prevent damage due to overheating. The engine must be allowed to cool before recommencing operation. The cause of the overheating should be investigated and rectified. C2500CB-OM-EN-16...
  • Page 37  The glow indicator remains illuminated for 10 seconds after the key has been turned to the ‘ON’ position.  If the ambient temperature is below 10°C (50°F) wait for the glow indictor light to go off before turning the key to the start position. C2500CB-OM-EN-16...

  • Page 38: Control Panel Instruments And Indicators

    Fuel Gauge (Diesel Engines Only – If Fitted))  The fuel gauge displays how much diesel remains in the diesel tank.  When the tank is full the needle points to 1.  As the fuel is consumed the needle moves anticlockwise from 1 to 0. C2500CB-OM-EN-16...

  • Page 39: Section 5: Operation

     Isolate the battery and remove the key – unless performing operational checks.  Smoking and naked lights are prohibited.  Ensure the relevant personal protective equipment (PPE) is worn i.e. gloves, safety boots, eye protection, clothing. C2500CB-OM-EN-16...
  • Page 40 Check that both locating pins are in place and operational.  Tyres and Wheels – Check that all the wheel nuts are present and secure. Look for cuts in the tyres or foreign objects in the rubber. Also look for plastic straps, C2500CB-OM-EN-16...
  • Page 41 Top up oil if necessary.  Coolant Level – Check the coolant level in the coolant header tank by looking through the sight glass  Radiator – Check for build-up of leaves, dust or other debris on or around the radiator. C2500CB-OM-EN-16...
  • Page 42 Make sure that the seat belt functions correctly. Check for any cuts or fraying along the belt. Ensure that it buckles securely. Always wear the seat belt provided when driving the Combilift.  Check the Seat – Check it is anchored securely and that the runners and sliders operate freely.
  • Page 43  Check the 4-Way Direction Control Lever – With the engine running and the park brake applied, select forward mode. Release the park brake. The machine should move forward. Press the inch pedal to stop the machine. Select reverse and release the inch pedal. The machine should now travel backwards. Press the C2500CB-OM-EN-16...

  • Page 44: Fuel Handling & Storage

    LPG to come into contact with skin.  Refuel at a well ventilated and open place.  When fuel and/or lubricants are spilled, refuel after letting the engine cool down.  DO NOT mix gasoline or alcohol with diesel fuel. C2500CB-OM-EN-16...

  • Page 45: Refuelling - Diesel

     Add diesel fuel. (Use a strainer to prevent any contaminating particles from entering the tank)  Take care to avoid overfilling or spillage. DIESEL TANK  Replace the cap, ensuring that it is securely fitted. Diesel tank capacity: 46 litres / 48.5 quarts C2500CB-OM-EN-16...

  • Page 46: Refuelling - Lp Gas

     Evacuate all persons, except those necessary to deal with the emergency.  Whenever possible, and if it is safe to do so, turn off all isolation valves necessary to cut off or reduce the source or sources of escaping gas. C2500CB-OM-EN-16...
  • Page 47  Deterioration, damage or loss of flexible seals in the filling or servicing connections.  Indications of leakage at valves or threaded connections i.e. Signs of frost on fittings and hoses usually signify a leak.  Any defective or damaged container should be removed from service immediately. C2500CB-OM-EN-16...

  • Page 48: Checking Engine Oil Level

    6. Check that the oil level lies between the upper and lower level marks. 7. If the oil level is below the Min mark, add oil (see Engine Oil System on page 75) of the permissible class and suitable viscosity but do not exceed the Max level. C2500CB-OM-EN-16...

  • Page 49: Checking Coolant Level

    7. Turn the cap anticlockwise gradually to release any pressure before removing fully. 8. Top up the coolant and replace the cap(s) securely. (See section 6.9 on page 86 for coolant and water quality details) Note: When the coolant level drops due to evaporation, add water only. C2500CB-OM-EN-16...

  • Page 50: Checking Hydraulic Oil Level

    4. Unscrew the filler cap (C). 5. Add hydraulic oil through the filler until the oil level is half way between the top and bottom of the sight glass (A). 6. Refit the filler cap securely. 7. Close the bonnet (B). C2500CB-OM-EN-16...

  • Page 51: Front Wheel Alignment

     Release the park brake and drive the truck forward at least 1 metre.  Stop and apply the park brake.  Check the alignment of the front wheels.  Both front wheels should now be aligned parallel to each other and to the sides of the truck. C2500CB-OM-EN-16...

  • Page 52: Entering And Exiting The Operator Cabin

     The operator is sitting on the seat  The seat belt is fastened * * only if optional seat belt switch is fitted Warning Before starting the engine ensure that there are no bystanders in the immediate vicinity of the truck. C2500CB-OM-EN-16...
  • Page 53 If either of these indicators are illuminated stop the engine immediately and determine the cause.  If the engine fails to start after 10 seconds turn the key to the off position for 10 seconds then repeat the starting procedure. C2500CB-OM-EN-16...

  • Page 54: Switching Off The Engine

     Turn the key anticlockwise to position 0. 5.10 Moving Off It is important to be aware of how the Combilift truck moves and how to drive it in a safe and efficient manner. The Combilift can be driven forward, backward, left or right by selecting the desired direction of travel with the 4-way direction control lever.

  • Page 55: Turning

     Sound the horn as you reach an intersection to warn pedestrians and other equipment operators you are approaching the intersection.  Always follow the rules of the road and yield to other equipment operators and pedestrians as required. C2500CB-OM-EN-16...

  • Page 56: Stopping

     Reduce speed  Reduce load size  Allow adequate distance between the truck and any other vehicle, object or person. Note Be careful when traveling in snowy and icy conditions. Reduce travel speed considerably in the event of bad weather. C2500CB-OM-EN-16...

  • Page 57: Changing Direction

     As the wheels start to reposition press the accelerator pedal lightly to speed up the operation.  Wait until the wheels have finished repositioning and the appropriate mode indicator has illuminated on the dash cluster.  Follow the instructions for moving. C2500CB-OM-EN-16...

  • Page 58: Parking

     Lower the forks fully and tilt the mast fully forward.  Leave the engine running.  Remove the seatbelt from its buckle and exit the Combilift using the three point contact method as discussed earlier.  Stay within 25 feet (7 metres) of the truck at all times.

  • Page 59: Loading & Unloading The Truck

     Do not allow anyone to stand beneath or pass under the mast or forks.  Never use the forklift to elevate anyone without the use of an approved man up cage.  Be aware of rear end swing when turning. C2500CB-OM-EN-16...
  • Page 60  Stop the truck, apply the park brake and select neutral before lifting a load. 4-Way Drive Loading/Unloading Advantages  The 4-way travel capability of the Combilift truck allows for much easier alignment of the forks/load with the picking/placing area than with any other conventional type of forklift truck.
  • Page 61  Reverse the truck slowly whilst looking in the direction of travel. Make occasional checks and any necessary adjustments to prevent the forks from fouling on withdrawal.  Stop when the forks are clear of the load.  Tilt the mast back and raise/lower the forks to 100mm (4˝) off the ground. C2500CB-OM-EN-16...
  • Page 62 50-75mm (2-3˝) gap each side and allow pallets to overhang the front of the racking by 25-50mm (1-2˝).  If bulk stacking, position the load exactly on top of the load beneath, keeping the stack perfectly upright and level. C2500CB-OM-EN-16...
  • Page 63  Stop and apply the park brake when the fork tips are clear of the racking or stack.  Lower the forks to 100mm (4˝) above the ground and tilt the mast back before moving off. C2500CB-OM-EN-16...
  • Page 64  Apply the park brake and select neutral.  Check overhead to make sure there is adequate headroom before lifting the load. Pay attention to the highest point (this may be on a load backrest if fitted). C2500CB-OM-EN-16...
  • Page 65  Stop and apply the park brake when the load is clear of the racking or stack.  Lower the load under control until the forks are 100mm (4˝) above the ground.  Tilt the mast back before moving off. C2500CB-OM-EN-16...

  • Page 66: Adjusting The Forks

     If the truck has hydraulic fork positioning fitted, use the fork positioning lever to adjust the forks. * Trucks fitted with hydraulic fork positioning do not have keeper pins in the forks or notches in the top fork bar. C2500CB-OM-EN-16...

  • Page 67: Travelling Safely With A Load

     Warn anyone in the vicinity of the truck to stay clear if the trucks starts to become unstable or to tip over. HOLD ON TIGHT LEAN AWAY BRACE FEET LEAN FORWARD TO STEERING WHEEL FROM IMPACT Figure 5.17 C2500CB-OM-EN-16...

  • Page 68: Driving On Slopes

    If it is not possible to drive up and down the incline with the forks positioned as above then take great care and use additional means to secure the load such as ratchet straps if necessary. C2500CB-OM-EN-16...
  • Page 69 It may be necessary to secure the load to prevent it from sliding off the forks. Forks with non-slip surfaces or covers may be require to prevent the load from sliding or it may be necessary to secure the load with ratchet straps or chains. C2500CB-OM-EN-16...

  • Page 70: Towing

    1. Loosen the lock nut (2) with a 13mm spanner, then turn the screw (1) counter-clockwise with a 4mm Allen key to the stop. 2. Retighten the lock nut (2), turning clockwise with a torque of 22 Nm (16 ft.lb). 3. Repeat steps 1 and 2 on the opposite side. C2500CB-OM-EN-16...

  • Page 71: Mechanical Release Of Park Brake

    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. C2500CB-OM-EN-16...

  • Page 72: Section 6: Maintenance

    Maintenance Section 6: Maintenance Combilift trucks are thoroughly examined, tested and lubricated before leaving the factory; however, regular maintenance and lubrication are necessary to ensure smooth running and maximum life of components. The recommended maintenance periods in the maintenance schedule are for trucks operating in normal, clean conditions when the specified fluids are used.
  • Page 73  Always ensure tools are in good working condition and are used in the proper manner.  Extract exhaust fumes using an extraction system and ensure the area is well ventilated.  Perform a functional test after any maintenance work. C2500CB-OM-EN-16...
  • Page 74  Isolate the battery when working on the electrical system.  Always disconnect the battery before welding.  Follow the correct procedure when connecting and disconnecting the battery.  Disconnecting: First negative and then positive  Connecting: First positive and then negative C2500CB-OM-EN-16...

  • Page 75: First Inspection After 100 Operating Hours

    100 operating hours / 2 months using EP2 Grease. Note Torque all wheel nuts to 210Nm / 155 ft. lbs every 250 hours. The wheel nut torque setting is for clean dry threads. If the threads are lubricated the setting must be reduced. C2500CB-OM-EN-16...

  • Page 76: Maintenance Schedule

    Change the Hydraulic Tank Breather 2 Years Change the Coolant Perform the tasks in the maintenance schedule after the period of operating hours or the calendar period as they first arise to keep the truck in optimum working condition. C2500CB-OM-EN-16...

  • Page 77: Engine Oil System

    (see page 126). Note Perform additional maintenance on the engine and fuel system as described in the relevant engine maintenance manual. Contact your local Combilift partner for assistance if required. Note The recommended maintenance intervals in the maintenance schedule are for maintaining trucks operating in normal conditions.
  • Page 78 4. If the engine is cold run it for 5 minutes to warm the oil. This will help it to flow. 5. Open the bonnet from the right hand side of the truck. 6. Remove the access panel (A) from the right hand side of the truck. C2500CB-OM-EN-16...
  • Page 79 21. Stop the engine wait for approximately 5 minutes until the oil has drained back into the sump. 22. Check the oil level on the dipstick (see 5.3 on page 47) and top-up if necessary. 23. Refit the access panel (A) to the right hand side of the truck and close the bonnet. C2500CB-OM-EN-16...
  • Page 80 14. Unscrew and remove the used engine oil filter (D) (dispose of the used filter in accordance with local environmental regulations) from the left hand side of the engine. Use a filter wrench if required. Toyota LPG GM LPG C2500CB-OM-EN-16...

  • Page 81: Diesel Fuel System (If Applicable)

    Note Work on the fuel system may only be performed in a clean environment. Clean and dry the area around all components concerned thoroughly. Contamination must be avoided. Replace filter elements immediately if they get plugged. C2500CB-OM-EN-16...
  • Page 82 1. Place a suitable container underneath the main fuel filter (C) to collect any draining fuel. 2. Unscrew and remove the used element. 3. Clean the sealing surfaces of the new element and filter head with a clean lint free cloth. C2500CB-OM-EN-16...

  • Page 83: Lp Gas System (If Applicable)

    Due to the inherent danger of gaseous fuels, LP gas system maintenance should only be performed by persons knowledgeable of the hazards associated with the use of gaseous fuels. Any maintenance, service or repair should be performed by trained and experienced service technicians. C2500CB-OM-EN-16...

  • Page 84: Lp Gas Inline Filter (If Fitted)

    6.7 LP Gas Inline Filter (If Fitted) and 6.8 LP Gas Pressure Regulator. Contact your local Combilift partner for assistance if required. LP Gas Inline Filter (If Fitted) The LP gas inline filter is mounted on the sliding LP gas bottle carrier, which is located below the seat on the left hand side of the truck.

  • Page 85: Lp Gas Pressure Regulator

    9. Unbolt the regulator bracket (B) by removing the two bolts (C). 10. Turn the regulator and bracket assembly clockwise 90° about the x-axis. 11. Open the drain plug (E) which should be at the bottom of the regulator after performing the previous step. C2500CB-OM-EN-16...

  • Page 86: Gm Engine Lp Gas Pressure Regulator Oil Build-Up

    14. When all the oil has drained completely, remove the receptacle and refit the drain plug securely. 15. Remount the regulator securely using the bolts that were removed at step 10. 16. Reconnect the hose to the LP gas outlet. C2500CB-OM-EN-16...

  • Page 87: Engine Cooling System

    Observe relevant local environmental protection regulations when disposing of used coolant. Coolant All Combilift IC engine powered trucks leave the factory with a mixture of 50% water to 50% coolant concentrate ( in the cooling system. This protects the ®...
  • Page 88 <40mg/l Sulphates <100mg/l Total Solids <340mg/l Total Dissolved Solids <170mg/l Water that deviates from the values in the table must be conditioned. Note Do not use bottled drinking water because it often contains higher concentrations of total dissolved solids. C2500CB-OM-EN-16...
  • Page 89 (On the PSI GM LPG engine use a suitable high temperature thread sealant when refitting the drain plug) 14. Refit the radiator drain plug with a new seal (D) and tighten into the radiator.  Torque to 94-98 Nm (70-72 ft. lbs) Kubota Diesel Toyota LPG PSI GM LPG C2500CB-OM-EN-16...
  • Page 90 11. Check the coolant level in the radiator and top up to the bottom of the filler neck if necessary. Top up the coolant bottle also if required. Approximate Coolant System Capacity = 14 litres/14.8 quarts C2500CB-OM-EN-16...

  • Page 91: Belt Drive System

    GM LPG - Apply force half way between the alternator pulley and the water pump pulley. The belt should deflect by between 12mm and 14mm. If the belt deflects by more or less than the permissible amount the tension must be Belt Deflection x adjusted. C2500CB-OM-EN-16...

  • Page 92: Air Filter System

    3. Inspect the air intake hose (B) for cracks or other damage and repair or replace as necessary. Inspect all connections and clamps and ensure they are tightly sealed. Any leaks here will admit dust directly to the engine. C2500CB-OM-EN-16...
  • Page 93 The cover should not come into contact with the filter element before it is fully in place. If there is contact before the cover is fully in place the filter must be pushed in further before latching the cover. C2500CB-OM-EN-16...

  • Page 94: Battery Maintenance

    (clean the top of the battery before removing the caps). 5. The electrolyte should be just above the tops of the separators. 6. If required top up each cell with distilled or deionised water and refit the cap securely. C2500CB-OM-EN-16...
  • Page 95 8. Connect the positive (+) red battery terminal first then connect the negative (-) black terminal. 9. Turn the battery isolator key clockwise, then start the engine. Note DO NOT over tighten the battery bar or terminal clamps. Dispose of used batteries at a battery collection point. C2500CB-OM-EN-16...
  • Page 96 7. If the engine does not start after a maximum of 15 seconds, wait one minute before trying again. 8. Once the engine has started, let both engines idle for approximately 2 minutes then remove the cables. 9. Reverse the sequence of steps 1 to 5 sequence when disconnecting the cables. C2500CB-OM-EN-16...

  • Page 97: Hydraulic Oil System

    Combilift trucks are supplied with ISO Grade 46 hydraulic fluid unless otherwise stated. Refer to the decal on the hydraulic tank. Please check if the hydraulic fluid is suitable for the trucks operating temperature range.
  • Page 98 7. Position a suitable container under the used filter element to collect any escaping oil. 8. Unscrew and remove the used filter element. Use a filter wrench if required. C2500CB-OM-EN-16...
  • Page 99 9. Apply a thin film of clean hydraulic oil to the O-ring on the bottom of a new filter element and fit into the bowl. C2500CB-OM-EN-16...
  • Page 100 10. Reach inside the tank then unscrew and remove the used strainer filter (C) (dispose of the used filter in accordance with local environmental regulations). 11. Extract any remaining oil and clean the bottom of the hydraulic tank through the opening. C2500CB-OM-EN-16...
  • Page 101 (A). 5. Clean the used breather (A) and the surrounding area thoroughly before removing the used breather. 6. Unscrew and remove the used breather from the end of the breather hose (B). 7. Fit a new breather. C2500CB-OM-EN-16...

  • Page 102: Mast Maintenance

    4000 operating hours or two years, whichever is the shorter. Additionally where the lifting mechanism uses a single leaf chain (e.g. free lift section), the leaf chain anchor bolts should also be replaced at the same time. C2500CB-OM-EN-16...
  • Page 103 Enlarged holes High overload overload Exposure to corrosive Replace leaf chain and protect from Corrosion pitting environment hostile environment. Worn leaf chain Replace worn leaf chain components anchor bolt Normal wear and always when fitting new leaf chains connecting pin C2500CB-OM-EN-16...
  • Page 104 The articulating links of the chain should be moved several times during this process. 3. Re-lubricating – Make sure that the chain is slack and then spray with a preservative and lubricant. Articulate the chain several times so that the lubricant penetrates the chain joints. C2500CB-OM-EN-16...
  • Page 105 The chain anchors are located on the fork carriage and also on the mast stages. Note The truck must be parked on smooth level ground when adjusting the chains. C2500CB-OM-EN-16...
  • Page 106 4. If the tension is not equal, tighten the bolt on the anchor of the slack chain. 5. Test the tension again. Adjust until the tension is equal. Caution Never place hands inside the mast to check chain tension. C2500CB-OM-EN-16...
  • Page 107 4. Turn the adjusting screw ¼ turn anticlockwise then tighten the locking nut. 5. Repeat step 4 on the bearing directly opposite. 6. Repeat steps 1-5 until the wear pads have been adjusted on all mast bearings C2500CB-OM-EN-16...

  • Page 108: Fork Maintenance

    Check the straightness of the upper face of each blade and the front face of each shank. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively withdraw the fork from service. C2500CB-OM-EN-16...
  • Page 109 Never try to repair surface cracks or wear by welding the fork. If you need to reset a fork, make sure it is subjected to an appropriate heat-treatment before it is returned to service. C2500CB-OM-EN-16...

  • Page 110: Grease Point Chart

    2.5 times the rated capacity marked on the fork. 6.16 Grease Point Chart The diagram below indicates all of the points on the Combilift that must be greased regularly. A copy of this diagram is located in the operator compartment in the form of a decal / Information sticker.

  • Page 111: Section 7: Technical

    10. The pressure should read between 22 - 25 bar (320 - 362 PSI) when the engine is idling. 11. Contact your local service representative or Combilift service if the charge pressure is outside the specified range. 12. Remove the gauge and refit the hydraulic adapter and hose. Apply a suitable thread sealant to the threads on the adapter before refitting.

  • Page 112: Valve Chest Pressure Settings

    Example: To check the lift pressure raise the mast to full height. Press the accelerator pedal down fully and pull the lift lever (joystick if fitted) back. The pressure gauge will display the setting on the lift port. Note The main relief pressure is set at: 262 Bar / 3800 PSI C2500CB-OM-EN-16...
  • Page 113 2400 Lift/Drop Forks Down 2400 Note The pressure values given in the tables above are to be used as a guideline only. The pressures may be set differently in the factory on occasion to suit different equipment and attachments. C2500CB-OM-EN-16...

  • Page 114: Steering & Hydraulic Functions Circuit

    Technical Steering & Hydraulic Functions Circuit C2500CB-OM-EN-16...

  • Page 115: Hydraulic Drive Circuit

    Technical Hydraulic Drive Circuit C2500CB-OM-EN-16...

  • Page 116: Fuses

    Cabin Heater (If Fitted), Cabin Cooling Fan (If Fitted), Radio (If Fitted) Horn Independent Fork Positioning Solenoids (If Fitted) Proximity Switches Supply, Seat Switch, Seat Belt Switch (If Fitted) Flashing Beacon Optional Extras - 12v Power Socket, Air Seat, Extra Oil Cooler C2500CB-OM-EN-16...

  • Page 117: Relays

    Engine Cut-Off Relay Note Some trucks may have additional relays that are not listed above. These relays are for non-standard optional extras. Please Contact Combilift and quote the truck serial number for information on the function related to these relays.

  • Page 118: Plc Details

    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 plugs and the pin associated with each function. C2500CB-OM-EN-16...
  • Page 119 01  Forward Solenoid 01  White  X3  02  Forward Solenoid 02  White  X3  03  Reverse Solenoid 01  Brown  X3  04  Reverse Solenoid 02  Brown  X3  05  Common Supply for Pins 01‐04 (From Fuse 2 )  Red  X3  06  Drive Solenoid 01  Red  X3  07  Drive Solenoid 02  Red  X3  08  Ninety degree Indicator Light  Green  X3  09  Zero Degree Indicator Light  White  X3  10  Common Supply to pins 06‐09 (From Fuse 4 )  Brown  C2500CB-OM-EN-16...
  • Page 120 09  Not Used n/a  X5.2  10  Common Supply for Output 15 (From fuse 4)  Brown  X5.2  11  Carousel Indicator Light  Red  X5.2  12  Not Used  n/a  X5.2  13  Not Used  n/a  X5.2  14  Common Supply for Output 16 (From fuse 4)  Brown  X5.2  15  Dead Band (Carousel Steering) Solenoid 01  Grey  X5.2  16  Common Supply for Output 17 (From fuse 4)  Brown  X5.2  17  Not Used  n/a  X5.2  18  Dead Band (Carousel Steering) Solenoid 02  Grey  C2500CB-OM-EN-16...

  • Page 121: Plc Diagnostics

     If the joystick is malfunctioning the LED corresponding to the  Once activated the LEDs will remain lit until the switch is reset to the position will not light up. OFF position. _____________________________________________________________________________________________________________________ C2500CB-OM-EN-16...
  • Page 122 The LED on each solenoid should be lit along with the LED on the board.  If the solenoid LED does not light, a wiring problem may be present.  If the solenoid LED is lit but a problem remains the solenoid and/or the valve should be checked for malfunction. _____________________________________________________________________________________________________________________ C2500CB-OM-EN-16...

  • Page 123: Section 8: Appendices

    Appendices Section 8: Appendices 8.1 Certified LPG Engine Emission Control Warranty 8.2 General Engine Warranty 8.3 Warranty Registration Form 8.4 Operator’s Pre-Use Check Sheet C2500CB-OM-EN-16...

  • Page 124: Certified Lpg Engine Emission Control Warranty

    (ECM), catalytic converter and air induction system. Also included may be sensors, hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, Combilift will repair your LSI engine at no cost to you including diagnosis, parts and labor. MANUFACTURER'S WARRANTY COVERAGE: The Model Year (2013-2014) off-road LSI engines are warranted for 3 years or 2,500 hours, whichever occurs first, unless indicated otherwise.

  • Page 125: General Engine Warranty

    For engines located within 100 miles** of an authorized service center, warranty repairs must be made only at authorized service centers. For engines located more than 100 miles** from an authorized service center, Combilift will provide for a service technician to come to the owner to make the warranty repair.

  • Page 126: Warranty Registration Form

    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, Annahagh, Monaghan, County Monaghan, Ireland.

  • Page 127: Pre-Use Check Sheet

    Pre-Use Check Sheet Model:_______________ Serial Number:_______________ ✔ CHECK ITEMS DEFECTIVE Visual Checks   General: No damage, No loose or missing nuts or bolts, No leaking fluids, No excessive dirt or rust. Previous defects repaired.  Channels: No damage or distortion. No excessive wear, scoring, dirt or foreign bodies in the channels. End stops secure. ...

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