PETTIBONE 6036 Owner's manual

OWNER/OPERATOR MANUAL
MODEL 6036/6044/8036/8044
10044/10056
ROUGH TERRAIN FORKLIFT
OM-4009

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
6036/6044/8036/8044 OWNER/OPERATOR MANUAL
Copyright December 1999
Pettibone Michigan, L.L.C.
Technical Publications
Baraga, MI
The information and illustrations in this manual have been approved as accurate at
the time of printing. However, the manual may contain information on options not
present on your machine. Pettibone Michigan L.L.C. reserves the right to make
changes and improvements in its products at anytime without notice or obligation.
This manual is to remain with the unit at all times. The storage compartment for this
manual is located in the operators cab behind the seat.
Contact Pettibone Michigan or an authorized dealer for replacement manuals.

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continued on next page
Table of Contents
INTRODUCTION .................................................................................................................................... 6
PREFACE................................................................................................................................................... 6
CALIFORNIA PROPOSITION 65 WARNING ................................................................................. 7
HYDRAULIC PRESSURE WARNING SHEET ...................................................................................... 8
SAFETY .................................................................................................................................................... 9
SAFETY RULES ....................................................................................................................................... 9
EXPLANATION OF  DANGER ................................................................................................ 9
EXPLANATION OF  WARNINGS ........................................................................................... 9
EXPLANATION OF  CAUTIONS ............................................................................................. 9
EXPLANATION OF NOTES  .............................................................................................................. 9
BEFORE OPERATION ........................................................................................................................... 10
MACHINE OPERATION ........................................................................................................................ 11
TRANSPORTING SAFELY ................................................................................................................... 12
PARKING THE MACHINE .................................................................................................................... 12
BURN PREVENTION ............................................................................................................................. 12
FIRE OR EXPLOSION PREVENTION ................................................................................................. 13
MAINTENANCE ..................................................................................................................................... 14
SAFETY WHILE SERVICING THE MACHINE .................................................................................. 14
MAINTENANCE PROCEDURES ..........................................................................................................14
SAFETY .................................................................................................................................................. 16
DECAL LOCATIONS ............................................................................................................................. 16
DECALS .................................................................................................................................................. 16
Left Side View of Machine Decals .................................................................................................... 17
Decals Located Behind Seat ............................................................................................................... 18
Hydraulic and Fuel Tank Decals ........................................................................................................ 21
MATERIAL SAFETY DATA SHEETS (MSDS)................................................................................... 40
IDENTIFICATION NUMBERS.............................................................................................................. 40
EQUIPMENT.......................................................................................................................................... 42
MACHINE INSPECTION AND DELIVERY REPORT ........................................................................ 42
SAFETY ................................................................................................................................................... 42
RIGHT, LEFT, FRONT AND REAR OF MACHINE ............................................................................ 43
EXPLANATION OF  DANGER .............................................................................................. 44
EXPLANATION OF  WARNINGS ......................................................................................... 44
EXPLANATION OF  CAUTIONS ........................................................................................... 44
EXPLANATION OF NOTES  ............................................................................................................ 44
SAFETY PRECAUTIONS ...................................................................................................................... 44

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
(Continued on next page)
continued from previous page
INTRODUCTION .............................................................................................................................. 46
IDENTIFICATION .................................................................................................................................. 46
FORKLIFT IDENTIFICATION PLATE ................................................................................................ 46
ENGINE IDENTIFICATION PLATE .................................................................................................... 46
TRANSMISSION IDENTIFICATION PLATE...................................................................................... 46
AXLE IDENTIFICATION PLATE LOCATION ................................................................................... 46
EQUIPMENT DESCRIPTION ............................................................................................................... 48
FORKLIFT DESCRIPTION .................................................................................................................... 48
STANDARD ENGINE DESCRIPTION ................................................................................................. 48
TRANSMISSION DESCRIPTION ........................................................................................................ 48
AXLE DESCRIPTION ............................................................................................................................ 48
OPTIONS ................................................................................................................................................. 48
OPERATION .......................................................................................................................................... 51
Operators Seat ................................................................................................................................... 51
Entering the Operators Compartment ............................................................................................... 51
Seat Suspension Adjustment (optional).............................................................................................. 51
Arm Rest ............................................................................................................................................. 51
Seat Belt.............................................................................................................................................. 52
Instrument Panel ................................................................................................................................. 53
Fuel Gauge.......................................................................................................................................... 53
Engine Coolant Temperature Gauge .................................................................................................. 53
Engine Coolant Temperature Warning Light (Optional) ................................................................... 53
Inclinometer........................................................................................................................................ 55
Parking Brake Switch ......................................................................................................................... 55
Clutch Cut-off Switch ........................................................................................................................ 55
Axle Lock Warning Light .................................................................................................................. 55
Brake Oil Pressure Warning Light .................................................................................................... 55
Park Brake Indicator Light ................................................................................................................. 55
Low Voltage Warning Light .............................................................................................................. 55
Engine Oil Pressure Warning Light ................................................................................................... 56
Ignition Switch ................................................................................................................................... 56
Steering Selector................................................................................................................................. 56
Hydraulic Controls ............................................................................................................................. 57
Throttle and Brake Controls ............................................................................................................... 58
Transmission Controls ........................................................................................................................ 59
CHECK TRANSMISSION OIL .............................................................................................................. 60
CHECK HYDRAULIC FLUID LEVEL ................................................................................................. 61
TIRES AND RIMS .................................................................................................................................. 61
INSPECTION FOR LEAKS .................................................................................................................... 62
GENERAL INSPECTION ....................................................................................................................... 62
GAUGES AND INDICATORS ............................................................................................................... 62
HYDRAULIC FLUID LEVEL ................................................................................................................ 62
CHANGES IN PERFORMANCE ........................................................................................................... 62
TABLE IV. TIRE PRESSURES ............................................................................................................. 62

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OPERATIONAL CHECKS & SERVICES ............................................................................................. 63
OPERATING INSTRUCTIONS ............................................................................................................. 63
STARTUP AND DRIVING..................................................................................................................... 63
RAISING THE LOAD ............................................................................................................................. 67
MAINTENANCE.................................................................................................................................... 69
INTRODUCTION .................................................................................................................................. 69
TABLE V. SCHEDULED MAINTENANCE ........................................................................................ 69
TABLE VI. FLUIDS AND LUBRICANTS ........................................................................................... 71
LUBRICATION ...................................................................................................................................... 73
TABLE VII. LUBRICATION POINTS ................................................................................................. 75
TROUBLESHOOTING ........................................................................................................................... 76
HOW TO USE TROUBLESHOOTING TABLES ................................................................................. 76
TABLE VIII. ENGINE TROUBLESHOOTING ................................................................................... 76
TABLE IX. ENGINE ELECTRICAL TROUBLESHOOTING ............................................................. 80
TABLE X. TRANSMISSION TROUBLESHOOTING......................................................................... 81
TABLE XI. HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................. 83
MAIN DIRECTIONAL VALVE TROUBLESHOOTING ............................................................... 85
REMOTE CONTROL (JOYSTICK) VALVE TROUBLESHOOTING .......................................... 87
ACCUMULATOR CHARGING VALVE TROUBLESHOOTING................................................. 88
FRAME TILT CYLINDER TROUBLESHOOTING ....................................................................... 89
FORK TILT CYLINDER TROUBLESHOOTING .......................................................................... 90
EXTENSION CYLINDER TROUBLESHOOTING ........................................................................ 91
REPLACE FUEL FILTER ELEMENT................................................................................................... 92
BLEEDING THE FUEL SYSTEM ......................................................................................................... 92
MAINTENANCE PROCEDURES ..........................................................................................................92
SERVICE AIR CLEANER ...................................................................................................................... 94
DRAIN AND REFILL COOLING SYSTEM ......................................................................................... 95
THERMOSTAT TEST ............................................................................................................................ 96
FUSE REPLACEMENT .......................................................................................................................... 98
ENGINE OIL CHANGE.......................................................................................................................... 98
TRANSMISSION OIL CHANGE ......................................................................................................... 99
TRANSMISSION FILTER ELEMENT REPLACEMENT .................................................................. 100
AXLE LUBRICANT CHANGE ............................................................................................................ 100
SUMMARY............................................................................................................................................ 101

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
NOTES
THIS PAGE
INTENTIONALLY
LEFT BLANK

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
PREFACE
This manual instructs the owner/operator in the correct operation of the Pettibone Michigan Extendo
forklift. The location and operation of all controls are explained in this manual. It also contains
lubrication tables, which indicate the recommended servicing intervals for all fluids and greased
components.
This manual should be considered a permanent part of your vehicle. It should stay with the vehicle, if
sold, to provide the next owner with required operating instructions.
All instructions, illustrations and specifications contained herein are based upon the latest product
information available at the time of printing. Pettibone Michigan reserves the right to change
specifications without prior notice in order to follow its policy of constantly striving to manufacture a
better product without incurring any liability to provide these new features on any units previously
manufactured.
Be sure your dealer has returned the Warranty Registration Form for your machine to Pettibone
Michigan. This form must be filled out properly in initiate warranty coverage on the machine. In
addition, your dealer will fill out a Machine Inspection Report, which the owner should sign. Also, a
30-day check up is recommended as defined in this manual. If a problem occurs with your machine
during the warranty period, contact your dealer immediately. Do not continue to operate the machine
until authorized.
INTRODUCTION

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
HYDRAULIC PRESSURE WARNING SHEET
OBSERVE ALL MAXIMUM HYDRAULIC SYSTEM PRESSURE WARN-
INGS AND DECAL FOR THIS MACHINE.
SETTINGS HIGHER THAN POSTED PRESSURES MAY RESULT IN
DEATH, SEVERE INJURY OR PROPERTY DAMAGE.
In many instances we have learned that the hydraulic relief valves of this equipment have been
reset, thereby increasing the maximum pressures and, with this, the load the unit will lift before
the relief valve opens. In some instances, the consequences of increasing this setting have been
serious. The function of the relief valve is to provide a fuse action to protect the machine and
the operator from overloading. When overloaded, different portions of the machine can become
stressed to a level at which parts fracture, possibly resulting in death, severe injury or property
damage. Resetting hydraulic pressures above factory settings is an extremely dangerous
practice.
Accordingly, you are advised that the settings of these valves are limited to the maximum listed
above. Pressure settings in excess of this level render each and all Pettibone Michigan
warranties null and void, and constitute an obvious misuse and abuse of our product.
Pettibone Michigan, L.L.C.
WARNING

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
SAFETY RULES
Most accidents involving machine operation and maintenance can be avoided by following basic rules
and precautions. Read and understand all the safety messages in this manual, and the safety signs on
the machine before operating or servicing the machine. See the dealer for any questions. Failure to
read and follow these instructions could result in death, serious injury or damage to the ma-
chine.
READ THIS MANUAL COMPLETELY and be sure to understand the characteristics of speed,
stability, and steering of this machine. Do not remove this manual from the machine. This manual
must remain with the machine at all times. The manual storage box is located inside the operators
compartment, behind the operators seat. See your dealer or contact Pettibone Michigan for additional
manuals.
The safety information given in this manual does not replace safety codes, insurance regulations, or
federal, state and local laws. Be sure the machine has the correct equipment according to these rules or
laws.
IMPORTANT: Safety messages in this section point out situations that can be encountered during
the normal operation and maintenance of your machine. These safety messages also give possible
ways of dealing with these conditions.
Additional safety messages are used in the text of the manual to show specific safety hazards.
EXPLANATION OF  DANGER
Denotes a hazard which WILL result in death or injury if proper precautions are not taken.
EXPLANATION OF  WARNINGS
A warning is a statement that informs the reader of a condition that is unsafe to personnel. Failure to
heed a warning may result in DEATH or INJURY to personnel.
EXPLANATION OF  CAUTIONS
Cautions are provided as statements, which identify conditions and/or practices that could result in
property damage or damage to the equipment.
EXPLANATION OF NOTES 
Notes are statements that simply provide additional information.
SAFETY