CombiLift C2500CB User manual

C2500CB-OM-EN-16
www.combilift.com
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.

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C2500CB-OM-EN-16
Warning
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of California to cause
cancer and birth defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except as necessary, service
your vehicle in a well-ventilated area and wear gloves or wash your hands
frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
Preface
This manual describes how to operate and maintain the Combilift - CB truck safely
and efficiently. It is essential that this manual remain with the truck at all times. It is
essential that the operator and all persons involved in work with the truck read this
manual before attempting to operate or service the truck.
Follow all local laws and regulations with regard to the operation of lift trucks where
they apply at the place of use.
Follow all instructions, prohibitive or otherwise, found in this manual. They are there
to protect the life of the operator and the lives of others working in the vicinity of the
truck.
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 have it corrected immediately otherwise even minor
faults may result in major failures and dangerous operating conditions.
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.
Every effort has been made to ensure that the information contained herein is accurate
at the time of writing. However it cannot be guaranteed that all of the statements in
this manual are completely correct.
Whenever the terms front, rear, right and left are used throughout this manual, it is
from the point of view of the operator sitting on the seat in the operating enclosure
looking forward.
This manual is not designed for the purpose of extensive maintenance work. Such
work must be performed by approved professionals.
The table of contents on the following pages outlines the structure of the information
contained within this manual and makes for easier location of information.

Contents
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C2500CB-OM-EN-16
Contents
Section 1: Safety Information ....................................................................... 4 
1.1  Safety Statements ........................................................................................... 4 
1.2  Operator Safety .............................................................................................. 4 
1.3  Safety Decals ................................................................................................. 5 
1.4  Safety Devices ............................................................................................... 6 
1.5  Warning Devices ............................................................................................ 7 
1.6  Operator Qualification and Responsibilities .................................................. 8 
1.7  Work Place Operating Conditions ................................................................. 9
Section 2: Basic Information .......................................................................14

2.1  Intended Use ................................................................................................ 14 
2.2  General ......................................................................................................... 15 
2.3  Vehicle Description ..................................................................................... 15 
2.4  Principle of Operation .................................................................................. 16 
2.5  Serial Number and Serial Plate .................................................................... 17 
2.6  Rated Capacity, Centre of Gravity and Stability ......................................... 18 
2.7  Load Centre & Load Chart .......................................................................... 21 
2.8  Attachments ................................................................................................. 22 
2.9  Tilting ........................................................................................................... 23
Section 3: Components & Controls ............................................................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  Display Clusters ........................................................................................... 35 
4.2.1.  Display Cluster Instruments and Indicators ......................................... 35 
4.2.2.  Control Panel Instruments and Indicators ............................................ 37
Section 5: Operation ....................................................................................38 
5.1  Pre-Use Checks ............................................................................................ 38 
5.2  Fuel Handling & Storage ............................................................................. 43 
5.2.1  Refuelling - Diesel ................................................................................... 44 
5.2.2  Refuelling - LP Gas ................................................................................. 45 
5.3  Checking Engine Oil Level .......................................................................... 47 
5.4  Checking Coolant Level .............................................................................. 48 
5.5  Checking Hydraulic Oil Level ..................................................................... 49 
5.6  Front Wheel Alignment ............................................................................... 50 
5.7  Entering and Exiting the Operator Cabin ..................................................... 51 
5.8  Starting the Engine ....................................................................................... 51 
5.9  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

Contents
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C2500CB-OM-EN-16
5.15  Loading & Unloading the Truck .................................................................. 58 
5.16  Adjusting the Forks ...................................................................................... 65 
5.17  Travelling Safely with a Load ...................................................................... 66 
5.18  Driving on Slopes ........................................................................................ 67 
5.19  Towing ......................................................................................................... 69 
5.20  Mechanical Release of Park Brake .............................................................. 70 
5.21  Diesel Particulate Filter (DPF)..................................................................... 70
Section 6: Maintenance ...............................................................................71 
6.1  Basic Safety Instructions for Servicing and Inspection ............................... 71 
6.2  First Inspection After 100 Operating Hours ................................................ 74 
6.3  Maintenance Schedule ................................................................................. 75 
6.4  Engine Oil System ....................................................................................... 76 
6.5  Diesel Fuel System (If Applicable) .............................................................. 80 
6.6  LP Gas System (If Applicable) .................................................................... 82 
6.7  LP Gas Inline Filter (If Fitted) ..................................................................... 83 
6.8  LP Gas Pressure Regulator .......................................................................... 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 Filter System .......................................................................................... 91 
6.12  Battery Maintenance .................................................................................... 93 
6.13  Hydraulic Oil System ................................................................................... 96 
6.14  Mast Maintenance ...................................................................................... 101 
6.15  Fork Maintenance ...................................................................................... 107 
6.16  Grease Point Chart ..................................................................................... 109
Section 7: Technical ...................................................................................110 
7.1  Checking the Charge Pressure ................................................................... 110 
7.2  Valve Chest Pressure Settings ................................................................... 111 
7.3  Steering & Hydraulic Functions Circuit .................................................... 113 
7.4  Hydraulic Drive Circuit ............................................................................. 114 
7.5  Fuses .......................................................................................................... 115 
7.6  Relays ......................................................................................................... 116 
7.7  PLC Details ................................................................................................ 117 
7.8  PLC Diagnostics ........................................................................................ 120
Section 8: Appendices ...............................................................................122 
8.1:  Certified LPG Engine Emission Control Warranty ................................... 123 
8.2:  General Engine Warranty .......................................................................... 124 
8.2  Warranty Registration Form ...................................................................... 125 
8.4 Pre-Use Check Sheet .................................................................................. 126 

Safety Information
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C2500CB-OM-EN-16
Warning
Warning indicates a hazardous situation which if not avoided could result in
serious injury or death.
Caution
Caution indicates an unsafe practice which if not avoided could result in
serious injury or property damage.
Note
Used without the safety symbol indicates a situation that if not avoided
could result in damage to the equipment and/or property.
Also indicates important information regarding the operation and servicing
of the truck.
Section 1: Safety Information
1.1 Safety Statements
To ensure safe operation and maintenance of the truck, it is necessary to follow all the
instructions 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 alert the reader to
potential damage to the environment.
This is the Safety Alert Symbol. It is used to alert the reader to potential
safety hazards.
1.2 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.
Whether you are a new operator or have used forklift trucks for many years, read
through this manual thoroughly. It provides instructions to help operate the Combilift
forklift in a safe and efficient manner.

Safety Information
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C2500CB-OM-EN-16
1.3 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. The part number of each decal is also
shown for reordering.
Warning
Personal injury 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 from rotating
fan. Stop the engine before
approaching.
Part No. CPD00004
Warning
Crushing hazard from moving
parts. Stop the truck and
isolate the battery before
approaching.
Part No. CPD00006
Warning
Personal injury hazard. Do
not stand on the forks.
Part No. CPD00003
Warning
Personal injury hazard. Do
not stand under the forks.
Part No. CPD00003
Warning
Scalding hazard. Only remove
the cap from the radiator
when cool.
Part No. CPD00005

Safety Information
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C2500CB-OM-EN-16
Warning
Never use the truck without the Overhead Guard/Cabin properly installed.
Do NOT drill, weld, straighten or bend the Overhead Guard/Cabin.
Allow only trained authorised personnel to install a new Overhead
Guard/Cabin.
1.4 Safety Devices
The following safety devices are fitted to the truck as standard:
Overhead Guard/Cabin
 Replace the Overhead Guard/Cabin in any of the following instances:
 If it has permanently deflected.
 If a member is deformed.
 If it has become corroded.
 If it has been modified.
 If the mounting structure, base, or mounting hardware is damaged.
 Do not attempt to repair, straighten or reuse a damaged 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 repair or replace if necessary.
Seat Switch
 The truck will not operate unless the seat is occupied. When the seat is
unoccupied the drive and the hydraulic functions are disabled.
Seat Belt Switch (If fitted)
 The optional seat belt switch disables the hydrostatic drive if the seat belt is
unbuckled.
Park Brake
 The park brake prevents inadvertent movement of the truck.
Brake/Inch Pedal Brake Switch
 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.

Safety Information
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C2500CB-OM-EN-16
Caution
The warning and safety devices are installed to protect the life of the
operator and those working in the vicinity of the truck. 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.
The following safety devices may be fitted as optional extras:
Mast Up Drive Cut-out (If Fitted)
 When the mast is raised above a predetermined height the drive is disabled.
 To enable the drive, lower the mast below the drive cut-out height or press the
drive cut-out override button.
Mast Lift Cut-out (If Fitted)
 When the mast is raised 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 as standard:
Horn
 The horn is activated by pressing in the horn push button.
 Sound the horn at intersections.
 Stop and look for pedestrians or other traffic and proceed with caution.
Reversing Alarm
 The reversing alarm is activated when the engine is running and reverse drive
is selected.
 The reversing alarm may be wired as a motion alarm if required, in this
instance the alarm is activated in more than one direction.
Flashing Beacon
 The flashing beacon is activated when the key switch is turned to the ON
position.
The following optional warning devices may be fitted to the truck if required:
Blue Safety Lights (if fitted)
 Blue safety lights may be fitted that activate when a direction of travel is
selected.

Safety Information
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C2500CB-OM-EN-16
1.6 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.
 No one shall operate the truck if impaired 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 conducted is covered later in this
publication.
 Operation of the truck controls is only permitted when the operator is sitting on
the operators seat in the cabin with the seatbelt buckled. If fitted, the cabin door
the cabin door must closed and latched securely.
 Never place any part of the body outside the confines of the cabin when
operating the truck.
 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 attempt any
repairs, but report defects immediately. When authorised to perform
maintenance work and/or repairs, ALWAYS ensure that the appropriate Health
and Safety regulations are strictly adhered to.
 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 the trucks 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 the ignition 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.

Safety Information
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C2500CB-OM-EN-16
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.
Warning
Workplace situations are constantly changing. Check the work area before
beginning each shift. If in doubt, consult with the relevant supervisor.
Failure to observe new workplace conditions can lead to serious injury or
death.
 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.
1.7 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

Safety Information
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C2500CB-OM-EN-16
Be on the lookout for anything that might present a hazard such as:
 Potholes
 Pedestrian traffic
 Very narrow aisle ways
 Overhead obstructions
 Poor lighting making it hard to see hazards
 Wet, oily, or rough terrain
 Other equipment or vehicles operating in the area
Remember: Do not block any of the following safety critical items/areas with the
truck or the materials being handled:
 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 to kerbs, railway crossings etc. should also be firm, smooth and
adequately ramped to prevent possible displacement.
Aisle Dimensions
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.

Safety Information
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C2500CB-OM-EN-16
Warning
Always be aware of overhead electrical power cables. Always remain a safe
distance from overhead power lines as an electric arc can occur even when
approaching an electric line. This poses a high risk, not only for the
operator but for other personnel nearby.
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 operator to leave the machine.
 If possible, drive the truck away from the danger area.
 Warn any people around the truck not to get any closer and not to touch the
truck.
 Arrange to have the power turned off.
The following table outlines the minimum clearance distance that must be observed
when working in the vicinity of power lines.
Operating in Hazardous Areas
Standard trucks are not equipped to operate in cold stores, flammable 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 not attempt to lift or place a load in a poorly lit area where vision is obscured
or reduced.
 Do not work in enclosed spaces where flammable materials, explosive vapours,
or combustible dust are found.
 Stay clear of flammable materials such as hay, straw, paper and cardboard.
 Park the truck only in areas free of flammable materials.
 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.
Nominal Voltage Clearance Distance
Up to 1000 V 1 metre (1.1 yards)
Over 1 kV up to 110 kV 3 metres (3.3 yards)
Over 110 kV up to 220 kV 4 metres (4.4 yards)
Over 220 kV up to 380 kV 5 metres (5.5 yards)
Unknown nominal voltage 5 metres (5.5 yards)

Safety Information
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C2500CB-OM-EN-16
Gradients
When differences in levels exist, low gradient ramps should be provided, having
smooth, gradual level changes at the top and bottom to prevent shocks to the load or
fouling of the forks. Except in emergencies, do not turn the truck on gradients. Correct
gradient procedure – covered in section 5.18 on page 67 - should be followed at all
times. Do not park on a gradient. In an emergency apply the park brake and chock the
wheels, but do not leave the truck unattended.
Adverse Weather Conditions
There are a number of weather conditions for which extra care must be taken.
 High Winds: Do not raise the mast in winds that are greater in speed than
50km/hr as this can have serious effects on the stability of the machine.
 Electrical Storms: Always discontinue operation of the truck in the event of an
approaching electrical storm due to the associated risks of lightning.
 Extreme Temperatures: These forklift trucks are designed for use in ambient
temperatures ranging from -40°C (-40°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 components. For operation outside these temperatures,
please consult your Combilift partner as special modifications and lubricants
are required.
Oil, Fuel and Coolant
Any leaking or spilled oil, fuel or coolant must be cleaned up immediately and the
source of the leak 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. Wait until hot surfaces have cooled and can be touched
comfortably. Smoking and open flames are prohibited during fuelling.
Noise/Hearing Protection
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 objectionable or uncomfortably loud noises.

Safety Information
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C2500CB-OM-EN-16
Warning
Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive
harm.
 Always start and operate the engine in a well-ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
Exhaust Emissions
Never allow the truck to remain stationary in confined spaces with the engine
running. Engine exhaust fumes are harmful. Do not inhale exhaust. When performing
service and inspection work in an enclosed space, vent the exhaust out of the area.
Dock Boards (Bridge Plates)
Dock boards are designed and maintained so that one end contacts the 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 boards must have a high friction surface designed to reduce
the possibility of people or trucks slipping.
If using dock boards on loading docks:
 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 loading or unloading 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-trailer is
not coupled to a tractor, make sure that all four corners are supported to
prevent upending or corner dipping.
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.

Basic Information
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C2500CB-OM-EN-16
Warning
Unintended use can endanger the lives of operating personnel or other
persons in the vicinity of the truck.
Unintended use can cause extensive damage to the truck and/or to property
or materials being handled.
Section 2: Basic Information
2.1 Intended Use
Operation by inexperienced persons, or in an unintended manner, can result in
hazards that can lead to personal risk and subsequent harm to the operator and
persons in the operating area of the truck. Improper use can damage the truck as
well as the product being handled and property in the vicinity of operation.
Read and understand the operating instructions in this manual before operating the
truck. Before performing production work, the operator should find a remote, open
site to become familiar with the controls and the trucks response. The truck must be
in serviceable condition before attempting to use it as described 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 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. One work cycle consists
of lifting, transporting and placing a load. Similar uses of the truck with alternative
attachments which do not change the safety requirements for the truck but modify
the way in which it is used are only acceptable when attachments that have been
approved by Combilift are used. The intended operation is described in this Manual.
The instructions describe how to operate, inspect and maintain the truck.
The truck must not be used for any of the following activities:
 lifting people without an approved work platform securely fitted
 transporting people
 pushing or pulling loads
The truck must not be used if:
 it has received unauthorised repairs
 it has received unauthorised modifications

Basic Information
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C2500CB-OM-EN-16
2.2 General
This truck is designed for use in ambient temperatures ranging from -40°C (-40°F) to
+40°C (+104°F) if the correct hydraulic oils and greases are used. For operation
outside these temperatures, please consult the manufacturer as special modifications
and lubricants are required.
Standard trucks must not be operated in flammable areas, corrosive atmospheres, or
in areas containing a high degree of dust contamination. Only trucks specifically
designed or modified to suit these conditions can enter such areas.
The safe maximum load capacities of the truck with relation to the load centre and fork
height, which MUST NOT BE EXCEEDED, are stated on the capacity plate.
The truck must be operated strictly in accordance with the operating instructions
provided in this manual in conjunction with the safety regulations of the country in
which the forklift truck is being operated.
2.3 Vehicle Description
The Combilift is a multifunctional, multidirectional forklift with four directions of travel
– Forward, Reverse, 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 forks. In this mode the
rear wheel steers the truck. It is in this mode that
forward travel and reverse travel can take place.
Forward Travel is traveling with the forks
leading. Reverse Travel is traveling with the
forks trailing.
Sideward Mode – In sideward mode all wheels
are aligned perpendicular to the forks. Steering
is accomplished by the two front wheels. In this
mode Left Travel and Right Travel can take
place. Left Travel refers to travel with the
operators compartment leading. Right Travel
refers to travel with operators compartment
trailing.
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.
The principle of this type of truck is that the weight of the load, which is lifted on the
forks in front of the load wheels, is offset by the combined weight of the truck chassis
and components.

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C2500CB-OM-EN-16
2.4 Principle of Operation
Drive is achieved by means of a hydrostatic drive pump coupled to an internal
combustion (IC) engine. The drive pump pumps hydraulic oil through hydraulic hoses
to wheels motors on which each of the three wheels are mounted. The wheel motors
turn the wheels to drive the truck. The speed of the drive is controlled by a throttle
pedal located in the operating enclosure.
Steering is achieved by means of a hydraulic gear pump coupled to an internal
combustion (IC) engine. The gear pump pumps hydraulic oil through a steering
orbital unit. When the steering wheel is turned pressurised oil is fed via the steering
orbital to hydraulic steering cylinders to steer the truck. Hydraulic valves in the
steering system allow the wheels to be aligned parallel to the truck or perpendicular
to the truck as desired.
Lift, tilt and side shift along with other optional auxiliary mast functions are achieved
by means of a hydraulic gear pump coupled to 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
hydraulic cylinders to operate each of the mast functions.
Forward, reverse, left or right travel may be selected by a direction control lever
mounted inside the operating enclosure. Selecting a direction of travel sends
electrical signals to a set of solenoid actuated hydraulic valves. The solenoid
actuated valves direct the flow of hydraulic oil to the steering cylinders to steer the
wheels to the appropriate position to achieve the desired mode of travel. The
direction control valve directs the flow of oil out of the drive pump to achieve the
desired direction of drive.
The truck is equipped with analogue dash clusters that display information regarding
the trucks operating condition such as the engine coolant temperature, the engine oil
pressure, low fuel, steering mode etc.
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.

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C2500CB-OM-EN-16
Note
Ensure that the serial number on the chassis corresponds with the serial
number on the serial plate before putting the truck into operation.
2.5 Serial Number and Serial Plate
The serial plate (A) is affixed inside the trucks operating enclosure and the serial
number (B) is stamped on the trucks chassis above the front right hand swivel. Open
the bonnet to view the serial number.
The Serial Plate is engraved with the following details:
a. Model: The model type of the truck is engraved 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 following box.
d. Load Centre: The distance from the front face of the forks to the centre
of gravity of the load for which the maximum rated capacity is given is
engraved in this box.
e. Unladen Weight: The weight of the truck only is engraved in this box
f. Manufactured On: The date the truck was manufactured on is
engraved in this box
g. 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.
B
A

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C2500CB-OM-EN-16
2.6 Rated Capacity, Centre of Gravity and Stability
The rated capacity is the maximum weight that a truck is designed to lift at a
specified load height to a specific load centre distance under safe operating
conditions. To understand the rated capacity it is necessary to be familiar with the
term centre of gravity.
The centre of gravity is an imaginary point in a body where the
total weight of the body may be considered to be concentrated.
Every object has a centre of gravity. When a load is supported
on the forks the truck and load may be considered as a single
entity with a combined centre of gravity.
The truck has moving parts that alter the position of the centre of gravity. The centre
of gravity moves back and forth as the mast is tilted backward and forward. The centre
of gravity also moves up and down as the mast 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 the side shift position.
To understand the stability of the truck it is useful to use the analogy of a see saw
where two objects are placed on opposite sides of a beam and the beam is
supported at a single point halfway along its length. For the see saw to balance, the
two objects must be equal in mass and placed at an equal and opposite distance
from the support point, also known as the fulcrum. If the mass on one side is
increased the see saw will tip to the side of the heavier mass. This can be corrected
by moving the heavier mass in towards the centre or fulcrum. This principle is the
most important factor that must be taken into account when considering the
stability of the truck.
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.
M1 = M2
D1 = D2
M2
M1
D1
D2
F2 = M2xD2
F1 = M1xD1
Fulcrum

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C2500CB-OM-EN-16
The very same principle applies to the Combi-CB truck where the front wheels act as
the fulcrum, M1 represents the mass of the trucks heavy chassis and components on
one side of the fulcrum and D1 represents the distance from the fulcrum to the
centre of gravity of the truck. M2 represents the mass of the load on the forks on the
opposite side of the fulcrum and D2 represents the distance from the fulcrum to the
centre of gravity of the load. In the case of the truck F2 must always be less than F1
otherwise the truck will become unstable.
If the mass of the load (M2) is increased or the distance from the fulcrum to the
centre of gravity of the load (D2) is increased such that F2 becomes greater than F1
then the truck will tip forward about 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 with elevated loads. Any of these factors alone or in combination
can result in the combined centre of gravity moving outside the boundary of the
stability triangle thus causing the truck to tip over.
For the truck to remain stable both laterally and longitudinally, the combined centre of
gravity of the truck and the load must stay within an area known as the stability triangle.
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.
Combi-CB & Load
Combined
Centre of Gravity
Combi-CB
Centre of Gravity
Load
Centre of Gravity
Fulcrum
M1
M2 D2 D1
F2 = M2xD2 F1 = M1xD1