CombiLift C2500CB, Manual

Page 1: ...ulti 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 pl...

Page 2: ...Always perform the Pre Use Inspection as indicated in this manual and follow the guidelines on service intervals Ensure that the truck is in good mechanical condition at all times Report any fault and...

Page 3: ...24 3 1 Machine Overview and Components 24 3 2 Operating Components Controls 25 3 3 Hydraulic Lever Operation 32 3 4 Hydraulic Joystick Operation If Fitted 34 Section 4 Operation Monitoring 35 4 1 Disp...

Page 4: ...egulator 84 6 8 1 Toyota Engine LP Gas Pressure Regulator Oil Build Up 84 6 8 2 GM Engine LP Gas Pressure Regulator Oil Build Up 85 6 9 Engine Cooling System 86 6 10 Belt Drive System 90 6 11 Air Filt...

Page 5: ...structions in this manual The following symbols and signal words WARNING CAUTION and NOTE and the adjacent text indicate hazards and instructions This is the Environmental Hazard Symbol It is used to...

Page 6: ...njury hazard Always wear the seat belt while sitting in the truck Part No CPD00009 Warning Read the operators manual before operating or working with the truck Part No CPD00009 Warning Shearing hazard...

Page 7: ...maged Overhead Guard Cabin Seat Belt Adjust the seat belt to contact the body firmly when fastened Inspect the seat belt webbing for damage and replace if necessary Test the buckle and retractor and r...

Page 8: ...aised to a predetermined height it will stop automatically To continue raising the mast press the lift cut out override button 1 5 Warning Devices The following warning devices are fitted to the truck...

Page 9: ...uck Diagnosis and repair of the truck shall be performed by trained competent technicians unimpaired by intoxication or drug reaction Unless authorised and trained to do so the operator must not attem...

Page 10: ...al 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...

Page 11: ...Electrical panels Fire exits Emergency stop buttons Aisle ways Fire extinguishers hoses Ground Surface Floor road and yard surfaces should be of adequate load capacity firm smooth and level Approaches...

Page 12: ...lammable or explosive areas corrosive atmospheres or areas containing a high degree of dust contamination Sparks from the exhaust or electrical system or hot parts can ignite explosions and fires Do n...

Page 13: ...F to 40 C 104 F if the correct hydraulic oils and greases are used If the temperature falls below or rises above this range discontinue operation of the machine in order to prevent damage to various...

Page 14: ...dock or loading platform and the other end contacts the transport vessel When you load or unload the transport vessel the dock board must be locked in place to prevent it from rocking or sliding Dock...

Page 15: ...escribed in the operating instructions 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 h...

Page 16: ...Left Right In order for these travel directions to be possible the Combilift has 2 modes of travel standard mode and sideward mode Standard Mode In Standard Mode all wheels are aligned parallel to the...

Page 17: ...an internal combustion IC engine The gear pump pumps hydraulic oil through a block of valves The valves are operated by levers or a joystick if fitted and are used to direct the pressurised oil to hy...

Page 18: ...in this box b Serial No The trucks serial number is engraved in this box c Rated Capacity The trucks maximum rated capacity is engraved in this box and is given for the load centre engraved in the fo...

Page 19: ...ast is raised and lowered The position of the combined centre of gravity is affected by the size weight shape and position of the load the height to which the forks are raised the mast tilt angle and...

Page 20: ...out the fulcrum Other factors that influence the stability of the truck to a lesser degree include sudden acceleration harsh braking unbalanced loads driving on sloped or uneven terrain or turning wit...

Page 21: ...illustrates the truck with a uniform load greater than the maximum rated capacity resting on the forks In this case the combined centre of gravity lies outside the boundary of the stability triangle t...

Page 22: ...the face of the forks to the Centre of Gravity of the load when the forks are fully engaged with the load The maximum rated capacity of the Combi CB is based on a load in the form of a cube measuring...

Page 23: ...y the number of small containers bags on a pallet Each small container should be marked with its weight Ask the relevant supervisor when in doubt Always make sure the load is flush against the front v...

Page 24: ...ng Guidelines When travelling with the truck loaded tilt the mast back and keep the load low This will help stabilize loads with an uneven weight distribution When loading at high elevations only tilt...

Page 25: ...below 3 1 Machine Overview and Components Figure 3 1 Machine Components Layout Components 1 Overhead Guard 2 Mast 3 Side Shifting Fork Carriage 4 Forks 5 Front Left Hand Swivel 6 Front Right Hand Swiv...

Page 26: ...3 2 below Figure 3 2 Controls Layout Controls List 1 Adjustable Seat 2 Steering Wheel 3 Steering Column Angle Adjuster 4 Accelerator Pedal 5 Brake Inch Pedal 6 Battery Isolator Key Switch 7 Armrest 8...

Page 27: ...injury to the operator 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...

Page 28: ...tment the locking lever must latch into the desired position with an audible click It should not be possible to move the seat when it is locked Do not lift the locking lever with any part of the leg B...

Page 29: ...n The Combi CB truck has both front and rear end steering In standard mode the front wheels are fixed and the rear wheel steers the truck In sideward mode the rear wheel is fixed and the front wheels...

Page 30: ...agram The accelerator pedal provides control of the engine speed RPM and therefore of the trucks travel speed To increase travel speed press down on the pedal Inch Brake Pedal The inch brake pedal is...

Page 31: ...utral In order to select a direction of travel push the lever in the desired direction Always return the lever to the neutral position when the truck is not moving Park Brake Switch The park brake swi...

Page 32: ...ld the drive cut out override button if fitted located on the control panel Operating Enclosure Cooling Fan Switch If Fitted This is a 2 position rotary switch located on the control panel if fitted T...

Page 33: ...d movement of the mast and forks To raise the forks PULL the lever BACK To lower the forks PUSH the lever FORWARD Tilt Lever 2nd from left The mast tilt lever controls the tilt angle of the mast and f...

Page 34: ...lever with an integrated rocker switch will be fitted in this instance Press and hold the left side of the rocker switch on top of the lever to position the left fork only Push the lever forward to mo...

Page 35: ...to the LEFT To tilt the mast forward PUSH the joystick to the RIGHT Side Shift To move the forks to the left PULL the joystick to the LEFT whilst pressing and holding the left hand button on the handl...

Page 36: ...e illustrated in figure 4 1 below with all of the possible symbols visible Figure 4 1 4 2 1 Display Cluster Instruments and Indicators A Hour Meter The hour meter records the trucks total running time...

Page 37: ...eered in to the position where carousel mode is activated the carousel mode indicator will illuminate When this indicator is illuminated the truck turns in a very small arc G Battery Charge Indicator...

Page 38: ...ely See 5 2 Fuel Handling Storage on page 43 4 2 2 Control Panel Instruments and Indicators Malfunction Indicator MIL If Fitted The MIL light if fitted is an amber coloured light located on the contro...

Page 39: ...Checks The truck must be maintained in a condition that is safe and without risk to safety and health Pre Use checks play a vital role in ensuring the truck is in safe working condition Contact the l...

Page 40: ...erated the checks should be carried out at the beginning of each shift The following visual checks must be performed prior to using the truck Overall Condition Look for scrapes dents and other signs o...

Page 41: ...k and to each other when standard mode is selected See section 5 6 on page 50 if the front wheels are out of alignment Safety Sign Decals Check that all safety decals are present and legible Hydraulic...

Page 42: ...can cause severe burns Check that the tank fits inside the profile of the machine Exhaust Check for excessive noise or smoke Engine Compartment Check the engine compartment for a build up of combustib...

Page 43: ...switch to position 2 and check that all work lights are working properly Check the Mast Functions Before checking the mast functions ensure that there is adequate space and headroom to perform all of...

Page 44: ...levant supervisor Never operate a lift truck that is in need of repair Repairs should only be performed by authorised personnel The details of the checks should be recorded on a copy of the Pre Use ch...

Page 45: ...using non combustible absorbent material before restarting the engine To Refuel Park the truck in accordance with the recommended parking procedure in a well ventilated area Switch off the engine Remo...

Page 46: ...shorter intervals approximately half DO NOT USE Fuels that have sulphur content greater than 1 0 10000 ppm LPG Emergency Procedures Action in Case of LPG Fire Raise the alarm The Fire Brigade should...

Page 47: ...ontainer may materially weaken the structure of the container and render it unsafe for use All containers should be checked regularly for dents scrapes and gouges in the pressure vessel section Check...

Page 48: ...nough to touch before proceeding or wear appropriate heat protection gloves 4 Pull out the dipstick and wipe the oil off with a clean lint free cloth 5 Reinsert the dipstick as far as it will go then...

Page 49: ...and full level marks 5 If the coolant is not visible in the bottle the radiator must also be topped up 6 The radiator cap must be cool enough to touch before removing 7 Turn the cap anticlockwise grad...

Page 50: ...ween the top and bottom of the window 5 If necessary top up with oil of the same grade and quality as that in the tank See section 6 13 on page 96 To Add Hydraulic Oil 1 Park the truck in accordance w...

Page 51: ...ne speed and turn the steering wheel anticlockwise to fully extend both front steering cylinders When the cylinders are fully extended continue to turn the steering wheel against the resistance for 5...

Page 52: ...d footsteps have been provided to allow easy and safe access to the operating enclosure DO NOT use the steering wheel as a handgrip Remember Check that the handgrips and footsteps are clean and in goo...

Page 53: ...is applied and the 4 way direction control lever is in the neutral position Ensure the accelerator pedal is not being pressed Insert the key into the ignition switch and turn clockwise to position 1 o...

Page 54: ...rating enclosure Do not carry passengers Failure to follow these guidelines can result in serious injury or death Warning Remain in the seat with the seat belt fastened while the truck is moving The s...

Page 55: ...d direction of travel Press the accelerator pedal lightly to increase the engine speed a little Slowly release the brake inch pedal As the truck starts to move gradually press the accelerator pedal un...

Page 56: ...form an emergency stop release the accelerator pedal and press the brake inch pedal down fully Keep the brake inch pedal fully depressed until the truck comes to a halt Stopping distances change depen...

Page 57: ...the 4 way direction control lever Follow the instructions for moving Direction Change With Mode Change This procedure applies when a change of direction is required that necessitates a change to the a...

Page 58: ...Stay within 25 feet 7 metres of the truck at all times Unattended parking method Bring the truck to a complete stop on level ground Once stopped apply the park brake and set the 4 way direction lever...

Page 59: ...Forks must not protrude beyond the pallet load Use suitable attachments for lifting unusual loads Make sure that pallets are in good condition Observe floor loading limits Check safe working load SWL...

Page 60: ...teering corrections as necessary to position the forks load precisely When the desired position is achieved fully press the brake inch pedal apply the park brake release the accelerator pedal and sele...

Page 61: ...the space between the forks see section 5 16 on page 65 to suit the load Use tilt to level the forks then adjust the height of the forks to enable them to enter the load without fouling Select forward...

Page 62: ...bulk stacking Gradually operate the accelerator pedal to give the required lift speed Ensure that the load is perfectly aligned and it is not going to foul the racking or adjacent loads on entry Side...

Page 63: ...ehind the truck is clear Press the accelerator pedal lightly to increase the engine speed then gradually release the brake inch pedal until the truck begins to move slowly in reverse Reverse looking i...

Page 64: ...t forward and release the park brake Press the accelerator pedal lightly to increase the engine speed then gradually release the brake inch pedal until the truck begins to move forward slowly Make sma...

Page 65: ...o increase the engine speed then gradually release the brake inch pedal until the truck begins to move slowly in reverse Reverse looking in the direction of travel Make occasional checks to prevent th...

Page 66: ...gth and rigidity of the load must be considered when positioning the forks Forks on opposite sides of the truck must always be positioned equidistant from the centre of the fork carriage To adjust Rai...

Page 67: ...rians from behind obstacles Do not carry unsafe or insecure loads Never carry loads stacked higher than the top of the fork or load backrest if fitted Operators arms hands head or legs must not overha...

Page 68: ...deally the forks should face downhill when driving up or down a slope without a load Keep the mast tilted back and the forks approximately 100mm 4 off the ground Raise the forks at the bottom of a slo...

Page 69: ...he wheels If it is necessary to drive in sideward mode on a slope with a load the situation must be fully assessed and a safe work procedure determined before proceeding It may be necessary to secure...

Page 70: ...4 Use a 4mm Allen key to turn the screw 1 clockwise until it is against the spring disc This is apparent by the increased resistance Then turn the screw 1 one half turn into the spring disc 5 Tighten...

Page 71: ...ten the screws A on one of the front wheel motors ensure the screws are retightened in a diametrically opposite manner to the torque setting specified below 2 Repeat step 1 on the opposite front wheel...

Page 72: ...e optimum performance Non compliance may result in voidance of the warranty 6 1 Basic Safety Instructions for Servicing and Inspection Perform servicing and inspection work only if you have read and u...

Page 73: ...m Pressurised jets of fluid can penetrate the skin causing serious injury Use a piece of cardboard or paper to check for leaks In the event that oil penetrates the skin seek medical attention immediat...

Page 74: ...1 metre Warm up the engine Batteries Wear protective clothing and safety glasses when working on the battery If acid contacts the skin wash immediately with clean water If acid contacts the eyes wash...

Page 75: ...ting hours or 3 months Check tension and condition of the engine v belt s Change the hydraulic suction filter element Change the hydraulic return filter element Change the engine oil Change the engine...

Page 76: ...c Oil Level 500 Operating Hours OH 49 Check Engine Coolant Level and Concentration 86 Check Air Intake Hoses Connections 2 Years 91 Check Engine Idle Speed 2 Years Check Hydraulic Pump Mounting Bolts...

Page 77: ...ribed in the relevant engine maintenance manual Contact your local Combilift partner for assistance if required Perform all checks on the pre use check sheet in conjunction with the maintenance schedu...

Page 78: ...e below 10 C 14 F or lube oil temperature below 60 C 84 F Sulphur content in diesel fuel of 0 5 weight If the lubricating oil change intervals are not reached within a year the oil should be changed a...

Page 79: ...g oil from the filter 15 Clean the sealing surface of the filter support with a clean lint free cloth 16 Lightly coat the seal on a new original filter element with clean engine oil 17 Screw on the ne...

Page 80: ...ngine 8 Unclip the drain hose B from the right hand side of the radiator oil cooler 9 Unscrew the cap C from the oil drain fitting on the bottom of the engine and screw the threaded end of oil drain h...

Page 81: ...ine sump oil volume 4 litres 4 2 quarts GM engine sump oil volume 4 7 litres 5 quarts 20 Clean up any oil spills immediately 21 Refit the oil filler cap and run the engine to warm up the oil Check aro...

Page 82: ...dance with the maintenance schedule A Fuel Pre Filter B Electric Fuel Pump C Main Fuel Filter Changing the diesel fuel pre filter 1 Park the truck in a designated service area with the forks lowered f...

Page 83: ...pe to seal any LP gas fuel system fittings Failure to follow this warning may cause leaks possibly resulting in serious injury death and or property damage and may void any warranty coverage 4 Apply a...

Page 84: ...burn off any remaining fuel in the lines 5 Turn the ignition key switch to the 0 off position and remove the key 6 Isolate the battery by turning the battery isolator key switch anticlockwise 7 Open...

Page 85: ...ounted under the bonnet to the left hand side of the engine Draining Oil Build up from the Toyota Engine LP Gas Pressure Regulator 1 Park the truck in a well ventilated area and ensure no external ign...

Page 86: ...until it has reached its stable operating temperature This will help the oil to flow from the regulator 4 When the engine is warm close the valve on the LPG bottle fully The engine will continue to ru...

Page 87: ...legislation 6 9 Engine Cooling System Coolant All Combilift IC engine powered trucks leave the factory with a mixture of 50 water to 50 coolant concentrate Glysantin G64 in the cooling system This pro...

Page 88: ...the cooling system before filling with new coolant A mixture of clean water with 15 of the new coolant is recommended for rinsing The coolant must be changed at regular intervals in accordance with th...

Page 89: ...ner behind the truck under the drain plug C to collect the used coolant 9 Unscrew the drain plug and allow time for the coolant to drain completely from the radiator Use a funnel or hose to channel th...

Page 90: ...posits if required Filling the Cooling System 1 Drain and flush the system as described under Draining the Cooling System and Flushing the Cooling System 2 Remove the cap from the top of the radiator...

Page 91: ...th a genuine OEM belt To Check the Belt Tension Perform this check when the engine IS NOT running Open the bonnet from the right hand side of the truck and remove the access panel from the right hand...

Page 92: ...element An optional safety filter element may be fitted if required The dry air filter should be maintained in accordance with the maintenance schedule however more frequent maintenance will be requi...

Page 93: ...sed for any period of time Keep the outlet covered to avoid admitting dust to the engine 9 Inspect the primary filter element Clean if lightly soiled or replace if heavily soiled If there is a streak...

Page 94: ...equired top up each cell with distilled or deionised water and refit the cap securely Caution Protective clothing and goggles should be worn and particular care taken not to come into contact with or...

Page 95: ...new battery with the used battery and ensure the new battery has the same polarity and performance characteristics as the old battery 2 Check that the new battery is clean and dry and that the caps ar...

Page 96: ...nominal voltage Before giving starting aid try to figure out the reason for the battery weakness If the reason is a failure in the vehicle electrical system starting aid should not be given The batte...

Page 97: ...System Hydraulic Oil The hydraulic oil must be changed at regular intervals in accordance with the maintenance schedule The hydraulic oil used in the trucks hydraulic system must conform to ISO 3448...

Page 98: ...ard 3 Switch off the engine and remove the key from the ignition 4 Open the bonnet from the right hand side of the truck to gain access to the suction filter A 5 Wait until the suction filter hydrauli...

Page 99: ...s of operation and then at regular intervals in accordance with the maintenance schedule To change the return filter element 1 Park the truck in a designated service area in accordance with the recomm...

Page 100: ...ly to warm up the hydraulic oil This will help the oil to flow 2 Park the truck in a designated service area 3 Lower the mast fully and tilt the mast fully forward 4 Switch off the engine remove the k...

Page 101: ...hort period of operation Hydraulic Tank Capacity 35 litres 37 quarts 16 Dispose of waste oil and used filter elements in compliance with statutory legislation Hydraulic Tank Breather The hydraulic tan...

Page 102: ...the forks run The frequency of this operation is at the discretion of the user and essentially depends upon the working conditions A lubrication interval of 250 hours can be taken as a typical value...

Page 103: ...nditions Cracked plates fatigue Crack from aperture towards edge of linkplate at 90 to line of pull Note there is no linkplate distortion Loading beyond chain s dynamic capacity above fatigue enduranc...

Page 104: ...66 Molykote mkl n Kluber structovis bhd 75s Where chains are encased in dirt and dust the lubricant will be prevented from flowing to the vital load bearing contact areas of the chain between the link...

Page 105: ...pulley is measured as this section experiences the most wear during normal operation To check the free lift chains raise the carriage 1ft 30 cm off the ground to put tension on the chains To check th...

Page 106: ...n the truck is parked on a smooth level surface with the mast fully lowered and tilted forward fully To adjust the fork carriage height tighten or loosen the adjusting nut on one of the chain anchors...

Page 107: ...heir weight is lower than the rated capacity This condition creates oscillations that cause the detachment of the external hardened surface of the bearing In this case circumferential cracks will appe...

Page 108: ...that bears such a defect must be removed from service Straightness of Blade and Shank Check the straightness of the upper face of each blade and the front face of each shank If the deviation from str...

Page 109: ...rk positioning Wear Two different areas of the fork and fork attachment should be checked for wear Fork Blade and Shank Check each fork blade and shank for wear pay special attention to the area surro...

Page 110: ...art 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 stick...

Page 111: ...entering the hydraulic system 7 Unscrew and remove the hose end from port G on the bottom of the pump and seal the open end with a 9 16 JIC male plug DO NOT permit any contamination to enter the hydra...

Page 112: ...test point and attach a pressure gauge capable of reading pressure up to 300 bar 4400 PSI 8 Fully extend or retract the cylinder s of the function to be tested For example when checking the tilt back...

Page 113: ...n occasion to suit different equipment and attachments The valve chest pressure readings should be in line with those given in the following table Valve Chest Pressure Settings Table Bar PSI Main Reli...

Page 114: ...Technical 113 C2500CB OM EN 16 7 3 Steering Hydraulic Functions Circuit...

Page 115: ...Technical 114 C2500CB OM EN 16 7 4 Hydraulic Drive Circuit...

Page 116: ...pply Neutral Relay Reverse Bleeper PLC X3 Alternator Plug Pin 3 Toyota Only 3 Diesel 7 5 Pull Hold Solenoid Fuel Pump 3 Toyota LPG 10 Engine Cut Off Distributor Plug J Pin 1 3 GM LPG 7 5 Ignition Coil...

Page 117: ...unted in the engine compartment under the bonnet and can be accessed by opening the bonnet from the right hand side of the truck The fuse is located below the bonnet gas strut Engine Compartment Fuse...

Page 118: ...ting 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 Run...

Page 119: ...for Board power Supply Blue 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...

Page 120: ...01 Grey X5 1 16 Common Supply for Output 12 From fuse 4 Brown X5 1 17 Not Used n a X5 1 18 Zero Degree Solenoid 02 Grey Plug Pin Function Wire Colour X5 2 01 Not Used n a X5 2 02 Common Supply for Ou...

Page 121: ...g correctly each LED will only light with the joystick in the corresponding position If the joystick is malfunctioning the LED corresponding to the position will not light up Mode 2 Proximity Sensor F...

Page 122: ...of the proximity sensor Mode 4 Solenoid Mode NOTE This mode must only be used with the key turned on NOT with the engine running Forward Reverse 0 and 90 Solenoids Move Switch 4 to the ON Position to...

Page 123: ...Appendices 122 C2500CB OM EN 16 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...

Page 124: ...m Ignition Module s PCV Valve Oil Filler Cap Engine Control Module Miscellaneous Items Used In Above Systems vacuum temperature and time sensitive valves and switches sensors used for electronic contr...

Page 125: ...le for the proper maintenance of the engine as stated in the maintenance instructions Proper maintenance generally includes replacement and service at the owner s expense of such items as spark plugs...

Page 126: ...AILS please state address where truck is located Customer Business Name ________________________ Tel _______________________ First Name ________________________ Last Name ____________________________...

Page 127: ...latforms and to each other Lights Windows Mirrors Clean and in good condition Fire Extinguisher if fitted Secure and charged Electrical Connections Terminals All connections secure and undamaged no me...