Petersen TL-3 Owner's manual

TL-3
OWNER/OPERATOR
MANUAL

Petersen Industries, Inc.
TL Owner's Manual
TABLE OF CONTENTS
OPERATION:
Part 1: A Word to Owner, Operator and Service Personne
about Safety
Part 2: Dai y Inspections – Before Leaving the Storage Faci ity
Part 3: Safety Devices
Part 4: Contro s
Part 5: Training
Part 6: Setting Up at the Job Site
Part 7: Loading Procedures
Part 8: Dumping the Load
MAINTENANCE:
Part 1: Safety Procedures and Precautions for Service
and Repair
Part 2: Service
DIAGRAMS AND BILL OF MATERIALS:
Note: There are mu tip e drawings inc uded for
some of the components isted be ow. You wi
need to identify which drawing matches the
components on your oader. P ease ca our Parts
Department at 800-930-5623, Ext. 229, shou d you
need assistance. P ease have your oader Seria
Number avai ab e when ca ing our Parts
Department. See “How to Find the Seria Number”
in this section of the manua .

Petersen Industries, Inc.
TL Owner's Manual
How to Find the Seria Number
Load Capacity Chart
Lubrication Diagram
Wiring Co or & Number Chart
TL3 Loader Hydrau ic Circuit Diagrams
Head, Pedesta and Outrigger Diagrams
TL3 Main Boom Diagram
TL3 Tip Boom Diagram
TL3 Tip Boom Extended Fixed Tip Diagram
Main and Tip Lift Cy inder Diagrams
Tip Extension Cy inder Diagram
Hose Recoi Assemb y, Right Side Diagram
Hose Recoi Assemb y, Left Side Diagram
Sing e Cy inder Trash Bucket Assemb y Diagram
Sing e Cy inder Trash Bucket A-Frame Diagram
Sing e Cy inder Trash Bucket Sadd e Diagram
Sing e Cy inder Trash Bucket Rotator Diagram
Sing e Cy inder Bucket Manifo d Diagram
Sing e Cy inder Bucket Jaw Diagram
Big Bite Bucket Diagram
P. I. Se f-Winding Tarp Ro er Diagram
Misce aneous Parts Diagrams and Bi of Materia s
Notification of Transfer of Ownership

WARRANTY:
VENDOR INSERTS:
Hydraulic Pump Information
PTO Information
Hydraulic Hoist Information
OWNER/OPERATOR TRAINNG DVD
CLICK HERE!
Petersen Industries,
Inc. TL Owner's Manual

Petersen Industries, Inc.
TL Owner's Manual
Part 1: A Word to Owner, Operator, and Service
Personnel About Safety
FAILURE TO READ THIS BOOKLET IS A MISUSE OF THE
EQUIPMENT. ANYONE WHO WILL OPERATE, SERVICE OR
WORK AROUND THIS LOADER MUST FIRST READ THIS
BOOKLET. DEATH OR SERIOUS INJURY MAY RESULT
FROM IMPROPER USE OR MAINTENANCE OF THIS
LOADER.
Introduction
Anyone who will operate, service or work around the loader should first read this
manual. It is important that all workers understand the safety, operational, service, and
repair re uirements of the loader. Death or serious injury can result from improper use
or maintenance of the loader.
As an owner or employer, it is your responsibility to know the specific re uirements,
governmental regulations, precautions, and work hazards that exist. You should make
these known to all personnel working with the e uipment or in the area. It is your
responsibility to instruct the operator in the safe operation of the e uipment and to
provide the operator with properly maintained e uipment.
It is the operator's responsibility to operate the loader with skill, good judgment and
caution. Following recognized safety procedures helps to avoid accidents.
Do not allow untrained personnel, even on a temporary basis, to operate this
e uipment. Operators must be trained by an experienced trash loader operator who is
familiar with all aspects of operation, safety, and maintenance of this e uipment. Keep
children, visitors and untrained personnel away from the e uipment.

Petersen Industries, Inc.
TL Owner's Manual
Modifications to any part of this loader can create a safety hazard and therefore shall
not be made without the manufacturer's written approval. Use only factory approved
parts to repair or maintain this e uipment. If this e uipment is rebuilt or remounted,
mounting procedures and retesting is re uired in accordance with factory instructions.
DO NOT OPERATE THE LOADER UNDER ANY
CIRCUMSTANCE IF THERE IS REASON TO BELIEVE THE
UNIT IS BROKEN OR MALFUNCTIONING. DO NOT
ATTEMPT TO PLACE THE BOOM OF A BROKEN OR
MALFUNCTIONING UNIT IN THE BODY OF THE LOADER
UNIT WITHOUT ASSISTANCE FROM ANOTHER CRANE OR
LIFTING DEVICE. ANY ATTEMPT TO USE OR MOVE THE
BROKEN OR MALFUNCTIONING UNIT COULD RESULT IN
SERIOUS BODILY INJURY OR DEATH.
The lighting and reflective devices on the unit is in compliance with FMVSS 108,
however it is the responsibility of the end user to verify that the lighting specifically
complies with any additional local re uirements for the area that the truck is to be
operated within.
The mud flaps installed on the unit are positioned based on the method of locating the
mud flap a distance behind the rear tire in order for the bottom of the mud flap to be
mounted low enough to be below the line formed from a 22.5 degree tangent angle out
the rear tire. It is however the responsibility of the end user to verify that the mud flaps
comply with re uirements for the area that the truck is to be operated within.

Petersen Industries, Inc.
TL Owner's Manual
Part 2: Daily Inspections - efore Leaving
the Storage Facility
One of the most important factors in the prevention of accidents is a positive attitude
towards safety. The habit of anticipating possible problems normally prevents many
accidents from occurring.
Each morning, prior to leaving the storage facility or lot, the following inspections should
be made:
1. Check oil level and battery.
2. Check the brakes and backup alarm. The backup alarm must always be sounding
prior to backing up. If your unit is e uipped with any additional alarms or warning
lights, check these items also for proper operation.
3. Check rearview mirrors and adjust if necessary.
4. Check tires for proper inflation, cuts, and loose wheel nuts.
5. Check head and taillights, strobes, and flashers for proper operation.
6. Check the hydraulic system for any unusual conditions such as pools of hydraulic
fluid or lubricating oil under the chassis, any outrigger which may have crept down,
or any signs of damage or improper maintenance. The hydraulic hoses should be
free from cuts and abrasions and there should be no evidence of binding or leakage.
7. Ensure that outriggers are fully retracted and the bucket is open and resting on the
floor of the body. If the body contains debris, the bucket should be closed and at
rest on the load. Ensure that most of the bucket and boom tip are below top of body.
Consult the truck manufacturer's manual for vehicle checks recommended by them.
Any insufficiencies found during this inspection must be corrected prior to use of the
e uipment.

Petersen Industries, Inc.
TL Owner's Manual
Part 3: Safety Devices
We will now discuss some of the components designed into the loader system to ensure
that safe loader control is maintained. There are hydraulic system flow devices
designed into the loader system to control the flow of hydraulic fluid. Loader control and
speed are essential to the safe operation of, and longevity of the loader.
To maintain safe loader control you must ensure that proper engine speed is observed,
all oil flow restrictors are in place and have not been modified, and all valves are
operating properly. You must not remove, or tamper with the manufacturer's
recommended settings of oil flow devices.
Excessive operating speed causes erratic operation of the loader. Excessive operating
speed decreases operator control and increases the stresses on the loader's supporting
structures, which could cause unexpected component failure. The result of unexpected
component failure could be damage to the e uipment and/or serious bodily injury or
death.

Petersen Industries, Inc.
TL Owner's Manual
FLOW RESTRICTORS
Swing Actuator Restrictors: - The swing actuator flow restrictors control the swing speed
of the loader boom. These restrictors are located on the swing drive motor, one on
each port. These restrictors are factory preset and must not be removed or drilled out.
Hydrau ic Actuator, Restrictor Size = 0.056”
Gearbox Rotator, Restrictor Size = 0.110”
Some signs of restrictor removal or modification are:
1. Excessive boom swing speed. Full travel time should be 20 seconds, ±3 seconds,
from head stop to head stop.
2. Broken or bent head (swing) stops. Catastrophic actuator damage will result if head
stops are damaged or missing.
3. Excessive swing speed causes excessive wear on the main boom/tip boom
connecting bolt.
Swing Actuator Restrictors:
HA36 Actuator Restrictor Size = 0.056”
Dinamic Oil Restrictor Size = 0.110”

Petersen Industries, Inc.
TL Owner's Manual
Bucket Motor Restrictors: The bucket motor restrictors control the speed of the bucket
rotation. These restrictors are located on the motor ports. These restrictors are factory
preset and must not be removed or drilled out.
Sing e Cy inder Restrictor Size: 0.046”
Big Bite Bucket Restrictor Size: 0.046”
Some signs of restrictor removal or modification are:
1. Excessive bucket rotation speed. Bucket rotation must not exceed 15 RPM.
2. Broken bucket rotator motor mounting bolts.
3. Broken bucket motor shaft and/or housing.
Bucket
Restrictors

Petersen Industries, Inc.
TL Owner's Manual
LOAD CONTROL VALVES
The load control valves are either a part of or plumbed directly onto load holding
cylinders. These valves are found on the main boom lift cylinder, tip cylinder, tip
extension, and the outrigger cylinders.
Main Boom Lift, Tip, and Tip Extension Cy inders:
Counter-balance Valves: - The counter-balance valve is a cartridge type valve, mounted
directly into a housing that is welded to the lift, tip, and tip extension cylinders. These
valves hold the load until hydraulic pressure is applied to it causing the valve to open.
This ensures the load is held in case of hose rupture, or other hydraulic system failure.
Notice to Operators: If oad contro va ve(s)
ma function, do not attempt to adjust va ves,
and/or continue to use the oader. Return to
the maintenance faci ity for repair.
Counter-balance valve adjustment is not normally needed after initial installation.
However, if adjustment is needed, first release load from valve and rest bucket on
ground or floor of body. Turn valve screw far enough out so that valve will hold load
when control valve is opened and truck PTO is off. The PTO should be off when
adjusting the screw, back on to lift the boom, and off again to test load holding capability
of the valve.
If the cartridge valve is replaced, you must first release the load from the valve. This
means the boom must be at rest in the floor of the body or on the ground, prior to
removing the cartridge valve.
FAILURE TO FOLLOW THE PRECEDING INSTRUCTIONS
REGARDING COUNTER-BALANCE VALVE ADJUSTMENT
AND/OR REPLACEMENT, COULD RESULT IN THE BOOM
FALLING ONCE THE CARTRIDGE VALVE IS REMOVED,
WHICH COULD RESULT IN DAMAGE TO THE EQUIPMENT
OR SERIOUS PERSONAL INJURY OR DEATH.

Petersen Industries, Inc.
TL Owner's Manual
If the operator experiences hydraulic failure while on route, first try to get the hydraulic
system working again. If you cannot get the hydraulic system working, we recommend
that you call for the assistance of an auxiliary service vehicle that can provide a power
source for the loader hydraulic system. The connections from the auxiliary power source
should be made at the appropriate loader valve bank. Hydraulic pressure from the
power source should go to the “in” at the loader valve bank, and return to the power
source should come from the “out” at the loader valve bank. Using the auxiliary power
source to run the hydraulics, replace all loader components to the travel position, and
then return the loader to the shop for repair.
Outrigger Cy inders:
Pilot Operated Check Valve: - The outrigger cylinders use pilot operated check valves
which are part of the cylinders. In the event of hose failure, these valves hold the load
until hydraulic pressure is applied, causing the valve to open.
These valves are factory preset and are not serviceable.
If you need to remove this valve, make sure the load is released from the cylinder prior
to removing the valve.
LOCK COLLAR
The lock collar is an integral part of the trash loader that holds the head and spindle
assembly in the pedestal. The lock collar must be in place and the lock collar bolts
properly tor ued prior to use of the trash loader. The lock collar must be tight against
the bottom of the spindle bearing housing with a maximum gap of one- uarter inch
(1/4").
Under normal operating conditions, there is very little load applied to the lock collar.
However, the following improper operating practices could put excess stress on the lock
collar and therefore must be avoided.
• Excessively packing the load with the boom. Evidence of this may be the bulkhead
of the body may be bowed outward.
• Forcing the dump body down with the boom. Evidence of this may be the bulkhead
of the body is dented down.
• Improper positioning of the boom prior to raising the dump body. Evidence of this
may be the underside of the main boom will be dented and scarred.
Improper lock collar installation and/or the improper operating practices listed above,
could result in the head assembly being pulled up out of the pedestal assembly. The

Petersen Industries, Inc.
TL Owner's Manual
separation of these two loader components will result in e uipment damage, and could
result in serious personal injury or death.
Maintenance and shop personnel must continuously check for the above listed signs of
abuse, and must report their observations to the person responsible for the operation
practices of the trash loader operators. Corrective measures must be taken to stop
abusive loading practices.
BACK-UP ALARM
All truck mounted loaders have back-up alarms that must sound any time the gear shift
selector is in reverse “R”. The back-up alarm is on the daily checklist of items to be
checked prior to leaving the storage facility. If the back-up alarm is not working, it must
be repaired prior to putting the vehicle in service.
ALARM MUST SOUND WHEN BACKING UP. DO NOT
BACK UP WITHOUT HAVING SOMEONE CLEAR BEHIND
THIS VEHICLE.
It is the operator’s responsibility to make sure that the area behind the loader is clear
before backing up.
“BOOM-UP” ALARM
A warning system that alerts the loader operator when the boom is not stowed properly
for travel. A sensor is installed on the boom, and an audible alarm and red light in the
Lock Collar
(See Item No. 9 on the Head
and Pedestal Assembly
drawing found in the “Dia. &
Drawings” Section of this
manual).

Petersen Industries, Inc.
TL Owner's Manual
truck cab. When the operator enters the truck cab after using the loader, the warning
light and audible alarm will alert him if the boom travel height exceeds 13 feet.
Some trucks have a customizable red light and alarm already in the dash that can be
used as a boom up alarm. If the truck is e uipped with such a light and alarm, the
boom up sensor will be wired into this light and alarm to function as a boom up alarm.
This system should be viewed as a tool to help operators measure the height of their
boom, but more importantly, to warn the loader operators that their boom is above safe
height for travel. It is not intended to replace an operator’s good judgment on safe
travel height of their boom.
Operators should always be aware that some routes may have streets, roads, alleys,
etc., that do not comply with the legal height re uirement of 13’6”, and should conduct
their operations accordingly.
The PI factory boom sensors are set to 13’-0” so if you have a low height object you
need to travel under you will need to set the sensor to the desired boom height. It
therefore, may be necessary for the boom up sensor to be adjusted to a lower setting
than the factory setting.
To adjust the boom sensor:
1. Park the truck on a smooth and level paved surface.
2. Set the outriggers out and down to stabilize the truck (Do not lift the
truck). Swing the boom over to the side of the truck with the boom fully
extended. Lift the main boom to desired height (typically the highest
point is at the tip boom stop).
The boom up alarm
may have a round
dial attached to the
light that can be
turned to adjust the
volume of the
audible alarm.
The boom up
sensor will turn on
a light once the
sensor passes the
head side plate.

Petersen Industries, Inc.
TL Owner's Manual
3. Loosen the sensor and slide it up or down as necessary so that the in
dash alarm starts to go off at this boom height.
4. Tighten the sensor and put a visible mark at the center of the bracket so
that a visual inspection can confirm that the sensor position has not
changed. Note: This sensor must be within 1/8” of the head side plate
to function properly.
BEFORE MOVING TRUCK, BOOM MUST BE STOWED TO
LOWEST POSSIBLE HEIGHT; MAX. BOOM HEIGHT NOT TO
EXCEED 13’6”.
This boom-up warning system became a standard feature of our loader in April, 2002. If
you have an older model Lightning Loader that does not have this boom-up warning
system, you can contact our Parts Department and order a retro-fit kit to install this
system.
SAFETY SYMBOLS
Your loader has re uired safety decals (see following pages) that alert those operating,
working around, or performing maintenance on the loader of certain safety hazards.
The safety decals are used to show the conse uence of human interaction with a
hazard in terms of:
1. The degree of severity.
(minor injury, severe injury, death)
When adjusting or
checking boom
sensor, use a set
gage or measure to
desired height
(measure to from the
ground to the upper
most point of the tip
boom stop).
Once sensor is set to
re uired setting, mark
with paint marker.

Petersen Industries, Inc.
TL Owner's Manual
2. The probability of severity.
(WILL result in, COULD result in)
The following definitions for identifying hazard levels are provided with their respective
signal words.
DANGER Immediate hazards which WILL result in severe personal injury
or death.
WARNING Hazards or unsafe practices which COULD result in severe
personal injury or death.
CAUTION Hazards or unsafe practices which COULD result in minor personal
injury or product or property damage.

Petersen Industries, Inc.
TL Owner's Manual

Petersen Industries, Inc.
TL Owner's Manual

Petersen Industries, Inc.
TL Owner's Manual
Part 4: Controls
THROTTLE CONTROL
Throttle controls are installed for loaders mounted on a truck chassis. For loaders
mounted on trucks with mechanical engines, either a manual throttle or a Muncie
Hydrothrottle is installed. For loaders mounted on trucks with electronically controlled
engines, a manual switch is used to advance the engine speed. The engine speed is
advanced to the preset RPM, thus increasing the volume of oil available for loader
functions. The hydraulic system is designed for maximum oil flow of 18 gallons per
minute. This engine speed is based on the ratios of the transmission and the pto gear
and is noted below.
Exceeding preset RPM will cause excess oil flow, which may cause unsafe operating
speeds, excessive oil temperature, undue wear and tear on the loader and chassis.
Some signs of throttle control mal-adjustment or tampering are:
1. Leaking hydraulic seals caused by excess heat.
2. Prematurely worn loader components caused by excess operating speed.
3. Sticks, bricks, rocks, etc. found in the truck cab may indicate the loader operator has
purposely intended to exceed preset engine RPM by jamming the truck accelerator.
PTO OVER-SPEED CONTROL
The over-speed control is a device that disconnects the PTO or diverts the flow of oil
back to tank rather than to the loader valves.
The purpose of this control device is to prevent excess oil flow to the hydraulic system,
which could happen if the throttle control device is altered or over-ridden.
This over speed is set at 350 rpm higher than the preset rpm.
Power Take-Off Manual Transmission:
Manual Shift Control – The PTO is engaged when the knob on the dash or
floor is pulled out and disengaged when the knob is pushed in. The truck
gear shift lever must be in neutral and the clutch depressed whenever the
knob is moved.
Air Shift Control – The PTO is engaged when the switch is moved to apply
air to PTO, the “On” position. The PTO is disengaged when the switch is