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CombiLift C3000CB Manual

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C2500CB-OM-EN-11
Dear Customer,
Thank you for choosing us and showing your faith in
the Combilift range of products. With this Combilift
Product you now own a 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 makes it one of the leading products in the
material handling industry.
The Purpose of this Operators Manual
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 instructions laid out in this
manual
 All instructions, prohibitive or otherwise, found in
this manual should be adhered to at all times. They
are there to protect your life and the lives of others.
 Always perform the Daily Inspection as indicated in
this manual and follow the guidelines on service
intervals.
Combilift Ltd

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  • Page 1 Dear Customer, Thank you for choosing us and showing your faith in the Combilift range of products. With this Combilift Product you now own a machine designed by our team of experienced engineers using the most up to date design techniques and technology with the sole...

  • Page 2: Table Of Contents

    Combilift Ltd C2500-C3000CB O&S Manual Contents Section 1: Machine layout and Operator Controls ....1-1     1.1:   Machine Overview and Components ............1-1 Section 2: Operating instructions and Conditions ..... 2-1     2.1:   Understand the Capacity of your Lift-Truck ..........2-1  ...
  • Page 3       Hydraulic Functions Circuit ............... 5-1     Hydraulic Drive Circuit ................5-2     Towing the Combilift ................. 5-3     Mechanical Brake Release ................. 5-4     Checking the Charge Pressure ..............5-5     Fuse Box Layout ..................5-6  ...

  • Page 4: Machine Layout And Operator Controls

    Section 1: Machine layout and Operator Controls 1.1: Machine Overview and Components It is essential before you start operating the Combilift to be familiar with the main components and controls of the machine, their function and where they are located. Figure 1 below and Figure 2 on the following page indicate the major components of the machine and all of the operator controls.
  • Page 5 Combilift Ltd C2500-C3000CB O&S Manual Figure 2: Machine Control Layout – Rear View Control Layout 1. Ignition 2. Light Switch 3. Parking Brake 4. Fuse Box 5. Horn Button 6. Direction Control lever 7. Lift Control Lever 8. Tilt Control Lever 9.
  • Page 6 Combilift Ltd C2500-C3000CB O&S Manual Ignition/Starter Switch  This is a two-position key switch that isolates the electrical system when in the ‘OFF’ position. Light Switch Illuminates all work lights, dash light and cabin light.  To illuminate all lights, turn the switch clockwise.
  • Page 7 Combilift Ltd C2500-C3000CB O&S Manual Engine Management Light (Yellow Light On Dash)  If this light comes on it means the engine control unit (ECU) has detected a problem with the engine.  If the light is on and the engine is running ok you can drive the truck.
  • Page 8 Combilift Ltd C2500-C3000CB O&S Manual Parking Brake Indicator Light  The Parking Break indicator light indicate whether the brake is “ON” or “OFF” Mode Indicator Lights  The Mode indicator lights indicate which mode of travel the machine is in.
  • Page 9 IMPORTANT A new truck capacity plate MUST be obtained from Combilift Ltd to reflect the new maximum load capacity when ANY attachment is fitted. Only attachments approved by Combilift Ltd personnel should be fitted.
  • Page 10  The switch is located inside the cabin, beside the dash.  When the Combilift is not in use turn switch to ‘OFF’ by pressing switch until it clicks into the closed position.  The Combilift will not power-up unless the switch is returned to the ‘ON’...
  • Page 11 Combilift Ltd C2500-C3000CB O&S Manual Seat Adjustment  It is the responsibility of the Operator to ensure that the seat is adjusted according to operator weight, height etc before operating the truck.  ALWAYS report any malfunctioning of the seat adjustments immediately.

  • Page 12: Operating Instructions And Conditions

    - two weights on opposite sides of a fulcrum. In this case, the load on the forks must be balanced by the weight of the Combilift. The location of the centre of gravity of both the Combilift and the load is a major factor.

  • Page 13: Load Chart

    Combilift Ltd C2500-C3000CB O&S Manual 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.

  • Page 14: Serial Plate

    C2500-C3000CB O&S Manual 2.4: Serial Plate The Serial Plate is the Metal Disc that is fixed to the Combilift in the cabin of every machine. It is engraved with a number of details, which are required by law. These are: ...

  • Page 15: Entering And Exiting The Operator Cabin

    C2500-C3000CB O&S Manual 2.7: Entering and Exiting the Operator Cabin  When entering or exiting the Operator cabin of the Combilift, always use a three point contact method to avoid slips and falls. The three point contact method is applied by keeping 3 of the bodies 4 limbs (hands & feet) in contact with the machine.

  • Page 16: Moving Off

     Increase pressure on accelerator pedal to increase truck speed. NOTE The Combilift has a maximum ground speed of 10km/hr. Always adhere to all speed limits in the area which the truck is operating 2.10: Changing Direction without Changing Mode ...

  • Page 17: Stopping

    Combilift Ltd C2500-C3000CB O&S Manual 2.13: Stopping  Always brake evenly and smoothly. Violent braking may cause the load to slip from the forks.  The forks must be lowered when the truck has stopped.  After stopping the truck, return the direction control switch to neutral.

  • Page 18: Placing A Load When In Sideward Mode

    NOTE The lift capacity of the Combilift is reduced if the forks are not fully engaged . To Double Fork a Load:  Raise the load slightly and drive rearward sufficiently to bring the load closer to the machine.

  • Page 19: Stacking

    Combilift Ltd C2500-C3000CB O&S Manual 2.20: Stacking  Slowly approach stack with load 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.

  • Page 20: Operating Conditions

    Combilift Ltd C2500-C3000CB O&S Manual 2.23: Operating Conditions The Combilift can operate on various surfaces but the following should be noted  Ground Surface: Floor and road surfaces should be of adequate load capacity, firm, smooth and level. Approaches to kerbs, railway crossings etc.

  • Page 21: Safe Operation

    3.1: 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.

  • Page 22: Driving Position

    Combilift Ltd C2500-C3000CB O&S Manual 3.4: Driving Position  Only operate controls from the correct driving position and do not operate any control until you are certain of its function. 3.5: Parking  Apply parking brake by pressing the red button.

  • Page 23: Maintenance & Service Information

    4.1: Maintenance Schedule In order to keep the Combilift in optimum working condition it is necessary to service the truck at regular intervals. The Chart below details the intervals (in hours of machine operation) at which maintenance tasks should be performed.
  • Page 24 Combilift Ltd C2500-C3000CB O&S Manual Note Maintenance, replacement, or repair of the emission control devices and systems may be performed by any non-road engine repair establishment or individual. There are a number of items indicated on the maintenance chart that must be performed on a daily basis.
  • Page 25 Combilift Ltd C2500-C3000CB O&S Manual  Forks – Check that the Forks have no signs of excessive wear or cracking. Check that both locating pins are in place and operational.  Mast – Check for twisting and distortion in the channels. Look for signs of cracking and check that there are no missing or loose bolts.
  • Page 26 Always wear the seat belt provided when you are driving the Combilift.  Check the seat – All Combilift machines come with adjustable air suspension seats. The operator must ensure that the seat is correctly adjusted for their individual height and weight. Instructions on how to set the seat are in the operators’...
  • Page 27 Combilift Ltd C2500-C3000CB O&S Manual  Check the Brakes – With the parking brake still applied, select forward on the directional control lever. Keeping both feet away from the pedals, sound the horn, and release the parking brake. The machine should start to move slowly forward.

  • Page 28: Operators Daily Inspection Sheet

    Date: Shift No: Inspect the Combilift before each shift. Should the Combilift be found to require servicing or if during the operation the Combilift malfunctions or becomes unsafe, stop the truck and report the situation immediately to the designated authority.

  • Page 29: Initial Service - Conducted At 100 Hours Of Operation

    Engine Oil & Engine Oil Filter (Service Interval = 250Hours) 4.4: The engine oil used in the Combilift should have the correct temperature range for the ambient temperature in which the machine is to be operating. Temperature affects the viscosity of the oil and therefore it’s lubricating properties.
  • Page 30 Combilift Ltd C2500-C3000CB O&S Manual Recommended Engine Oil Specification: Diesel: API – CF (If a diesel particulate filter (DPF) is fitted See 4.13:) SAE 15W40 – All Temperatures SAE 10W30 – All Temperatures LPG: API – SJ/CF SAE 10W30 – All Temperatures SAE 15W40 –...

  • Page 31: Engine Coolant (Service Interval = 2000Hours)

    A lubrication interval of 250 hours can be taken as a typical value, under normal working conditions. For this purpose use graphite grease, avoid spray greases. Additional Mast Maintenance (Contact Combilift for further information)  Replacement of hydraulic cylinder seals.  Replacement of chains.

  • Page 32: Hydraulic Oil & Filters

    C2500-C3000CB O&S Manual 4.7: Hydraulic Oil & Filters The hydraulic oil used in the Combilift should conform to the International Standard. I.S.O. G344 HV grade oils with improved viscosity / temperature characteristics. It should also have the correct temperature range for the ambient temperature in which the machine is being operated.
  • Page 33 3. Insert your hand into the tank and remove the filter by rotating it anti- clockwise. 4. Fit the new strainer filter. Only use a genuine Combilift component. 5. Replace the access panel in the side of the tank, remembering to correctly fit the access panel O-ring seal.

  • Page 34: Water Pump V- Belt

    1. Remove the end cap from the filter housing 2. Remove the existing air filter cartridge and replace with the new cartridge. Only use a genuine Combilift component. 3. Replace the End cap of the housing ensuring that the Dust valve is pointing downwards as shown.

  • Page 35: Grease Point Chart

    Lubricate all of the points indicated on the chart below on a weekly basis using the appropriate EP2 Grease. Also lubricate all grease points on the mast and any attachments that may be fitted to the Combilift. 1. Swivel Front 2.

  • Page 36: Diesel Particulate Filter (Dpf)

    Combilift Ltd C2500-C3000CB O&S Manual 4.13: Diesel Particulate Filter (DPF) Refer to the accompanying diesel particulate filter manual (only supplied if a DPF has been fitted) for further details. Note Where Diesel Particulate Filters (DPF) are fitted Diesel Fuels with a maximum sulphur content of 15ppm (parts per million) MUST be used.

  • Page 37: Technical Information & Circuit Diagrams

    Combilift Ltd C2500-C3000CB O&S Manual Section 5: Technical Information & Circuit Diagrams 5.1 Hydraulic Functions Circuit Model: COMBILIFT LTD Title: Hyd. Functions Circuit Combi CB Revision Date:06/10/09 Pressure Settings LIFT Main = 3800PSI/262Bar Lift 3600PSI/248Bar Sideshift Tilt 3800PSI/262Bar Sideshift =...

  • Page 38: Hydraulic Drive Circuit

    Combilift Ltd C2500-C3000CB O&S Manual 5.2 Hydraulic Drive Circuit COMBILIFT LTD Model: Title: Hydraulic Drive Circuit Combi CB Revision Date:06/10/09 FRONT REAR RIGHT WHEEL WHEEL MOTOR MOTOR CHANGEOVER VALVE MANIFOLD BLOCK TRANSMISSION PUMP 350 BAR FWD. 350 BAR REV. 18 BAR...

  • Page 39: Towing The Combilift

    C2500-C3000CB O&S Manual 5.3 Towing the Combilift Should the need arise to Tow the Combilift it is necessary to first apply the bypass condition on the hydrostatic pump in order to prevent It from being damaged. It will then be necessary to mechanically release the brakes on the motors.

  • Page 40: Mechanical Brake Release

    Combilift Ltd C2500-C3000CB O&S Manual 5.4 Mechanical Brake Release In order to release the brake, follow the steps laid out below. 1. Extract the plug from the rear cover of the motor. (Labelled 142 in the diagram opposite) 2. Insert a socket head bolt as shown in the diagram with a nut fully inserted onto the bolt.

  • Page 41: Checking The Charge Pressure

    Combilift Ltd C2500-C3000CB O&S Manual 5.5 Checking the Charge Pressure In order to check the charge Pressure, the following steps should be taken. When the reading is taken the charge pressure should measure between 16 bar and 22 bar (230PSI and 320PSI)

  • Page 42: Fuse Box Layout

    Proximity Switches Supply, Seat Switch, Seat Belt Switch Flashing Beacon Spare Inline Valve Chest Lock Valve Solenoids 5.7 Relay Layout Below is a table of the relays inside the dash in the cabin of the Combilift. PLC Loom Relay Table Relay Function Starter Solenoid Glow Plug Timer...

  • Page 43: Standard Gm Lpg Plc Electric Circuit

    Combilift Ltd C2500-C3000CB O&S Manual 5.8 Standard GM LPG PLC Electric Circuit: C2500CB-OM-EN-11...
  • Page 44 Combilift Ltd C2500-C3000CB O&S Manual C2500CB-OM-EN-11...

  • Page 45: Standard Kubota Diesel Plc Electric Circuit

    Combilift Ltd C2500-C3000CB O&S Manual Standard Kubota Diesel PLC Electric Circuit: C2500CB-OM-EN-11...
  • Page 46 Combilift Ltd C2500-C3000CB O&S Manual 5-10 C2500CB-OM-EN-11...

  • Page 47: Standard Toyota 4Y Lpg Plc Electric Circuit

    Combilift Ltd C2500-C3000CB O&S Manual 5.10 Standard Toyota 4Y LPG PLC Electric Circuit: 5-11 C2500CB-OM-EN-11...
  • Page 48 Combilift Ltd C2500-C3000CB O&S Manual 5-12 C2500CB-OM-EN-11...
  • Page 49 Combilift Ltd C2500-C3000CB O&S Manual 5-13 C2500CB-OM-EN-11...

  • Page 50: Tier Iv Gm Lpg Plc Electric Circuit

    Combilift Ltd C2500-C3000CB O&S Manual 5.11 Tier IV GM LPG PLC Electric Circuit: 5-14 C2500CB-OM-EN-11...
  • Page 51 Combilift Ltd C2500-C3000CB O&S Manual 5-15 C2500CB-OM-EN-11...

  • Page 52: Colour Codes For Electric Circuits

    Combilift Ltd C2500-C3000CB O&S Manual 5.12 Colour Codes for Electric Circuits: CODE - COLOUR BK - BLACK BN - BROWN BL - BLUE ORANGE YELLOW GR - GREEN VIOLET PINK GY - GREY W - WHITE G/Y - GREEN YELLOW...

  • Page 53: Plc Details

    Combilift Ltd C2500-C3000CB O&S Manual 5.13 PLC Details The diagram below shows the layout of the major components of the PLC board that need to be known in order to correctly find and repair faults. PLUG X3 PLUG X5.1 PLUG X4 System LED 1 2 3 4 5 6 7 8 9 10...
  • Page 54 Combilift Ltd C2500-C3000CB O&S Manual INPUTS Plug  Pin  Function  Wire Colour  X4  01  Rear Wheel @ Zero Degree Proximity Switch   Black  X4  02  Front Wheel @ Zero Degree Proximity Switch   Black  X4  03  Rear Wheel @ Ninety Degree Proximity Switch   Black  X4  04  Front Wheel @ Ninety Degree Proximity Switch   Black  X4  05  Carousel Steering Proximity Switch (DB Proxy)  Black  X4  06  Park Brake Switch Signal  Orange  X4  07  Inching Pedal Brake Switch Signal (Optional)  Orange  X4  08 ...
  • Page 55 Combilift Ltd C2500-C3000CB O&S Manual Outputs (continued) Plug  Pin  Function  Wire Colour  X5.1  01  Not Used  n/a  X5.1  02  Common Supply for Output 08 (From fuse 4)  Brown  X5.1  03  Steering Solenoid (Six Port) Relay Switching  Brown  X5.1  04  Not Used  n/a  X5.1  05  Not Used  n/a  X5.1  06  Common Supply for Output 09 (From fuse 4)  Brown  X5.1  07  Reflex Steering Solenoid  Red  X5.1 ...

  • Page 56: Plc Diagnostics

    Combilift Ltd C2500-C3000CB O&S Manual Mode 2 – Proximity Sensor Function 5.14 PLC Diagnostics Move Switch ‘2’ to the ‘ON’ Position The diagnostics function can be used to make sure all components are working correctly. Front Wheel 0 Degree Sensor –...
  • Page 57 Combilift Ltd C2500-C3000CB O&S Manual Mode 3 – Switch Mode Mode 4 – Solenoid Mode NOTE: This mode must only be used with the key turned on, NOT with the engine running. Move Switch ‘3’ to the ‘ON’ Position Forward, Reverse, 0 and 90 Solenoids Move Switch ‘4’...

  • Page 58: Appendices

    (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.

  • Page 59: Appendix B: General Engine Warranty

    100 miles** from an authorized service center, Combilift will provide for a service technician to come to the owner to make the warranty repair. ** Under either circumstance for information on how to make arrangements for...

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