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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continued from previous page
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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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

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BEFORE OPERATION
·Avoid loose fitting clothing, loose or uncovered long hair, jewelry or loose personal articles.
·Different jobs will require different protective equipment. Items such as hard hats, protective
shoes, heavy gloves, reflector type vests, respirators, and ear protection may be required. Know
and use the equipment that is required before starting the job.
·Be prepared for emergencies. Always have a first aid kit and a good fire extinguisher. Know
how to use both.
·Know the hand signals used on the job. Follow the instructions of the flag man, signs, etc.
·Check that all guards and covers are installed correctly.
·Foreign material or grease on the step or hand rail can cause an accident. Keep the step and hand
rail clean.
·Before operating at night, check that all lamps illuminate.
·Know the rules, laws and safety equipment necessary for transporting this machine on road or
highway.
·Before starting the engine, walk around the machine and check for oil or fluid leaks. Replace all
broken or missing parts and do the required lubrication and maintenance as shown in this manual.
Clean all trash and debris from the machine.
·Always face the machine and use the hand rail and step when climbing aboard. Do not rush.
·Remove all loose objects from the operators compartment and from the machine. Loose objects
can jam controls and cause accidents.
·Before starting the engine, always properly fasten and securely tighten the seat belt, and always
keep the seat belt fastened while operating the machine. Failure to do so could result in death
or serious injury.
·Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, use good
ventilation to replace the exhaust fumes with fresh air.
·Make sure all persons are away from the machine and give a warning before starting the engine.

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
MACHINE OPERATION
·Check all controls in a clear area and make sure the machine is operating correctly.
·Do not allow other persons to ride on the machine. Other persons can fall or can cause an accident.
 Do not use the machine to lift personnel or to lift any type of personnel carrier, including platforms.
The machine operator may not have control over such a carrier device, which could result in
serious injury or death.
·Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or de-
crease the speed until everything can be seen.
·Contact with high voltage power lines, underground cables, etc., can cause serious injury or death
from electrocution.
NOTE
Before driving or operating in an area with high voltage lines or cables, HAVE THE
POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines or
cables. Know the safe working distance from the high voltage power equipment and
observe federal, state/provincial, or local safety codes or regulations that apply to the job
site.
·Electrical cables, gas pipes, water pipes, sewers, or other underground objects can cause death or
serious injury. Learn the location of underground hazards before operating the machine in a new
area.
·If this machine rolls over, death or serious injury may occur. Determine if weather, road, or earth
conditions will permit safe operation on a hill, ramp, or rough ground.
·Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before
starting the forklift and look for hazards.
·Be alert and always know the location of all workers in the area. Keep all other persons completely
away from the machine. Serious injury or death can result if these instructions are not followed.
·Operate the machine controls from the operators seat only.
·Keep the forks low when moving around the work area and be careful when raising the load.

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·Before operating the equipment where visibility is reduced, such as next to a building, install
safety markers to warn others of possible danger.
TRANSPORTING SAFELY
NOTE
When correctly loaded on the flatbed of a tractor-trailer, this machine is
designed to be transported between local work sites.
·Know which warnings must be placed on machine for highway travel and whether an escort is
needed.
·Flag attachment on furthest projection of machine for safety.
·Know measurements of machine when mounted on truck. Be sure machine is within proper
limits for highway transporting.
·Become familiar with public laws and ordinances affecting driving on public roads with a
mounted machine. Check route for clearance. Check bridges for weight limits.
·Always shut down machine engine when transporting, even over short distances, and never ride
on machine while transporting. Serious injury or death can result if these instructions are not
followed.
·Do not put chains over or against hydraulic lines or hoses.
·Always use tape or cap exhaust pipe to prevent air from spinning turbocharger while vehicle is
transported at highway speeds. The turbochargers depend upon engine oil pressure to lubricate
shaft bearings and may be damaged if spun dry. BE SURE TO REMOVE TAPE AFTER
TRANSPORTING OR BEFORE STARTING ENGINE.
PARKING THE MACHINE
·When parking the machine and before leaving the operators seat, engage the parking brake by
flipping the switch located on the right side of the dashboard.
·Always face the machine and use the hand rail and step when getting off. Do not rush and do not
jump from the machine.
BURN PREVENTION
·Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or
clothing. Antidote- EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water
continued on following page

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a doctor immediately.
EYE: Flush with water for 15 minutes and get prompt medical attention.
·If the battery electrolyte freezes, the battery may explode if, (1) battery charge is attempted, or
(2) trying to jump start the engine. To prevent the battery electrolyte from freezing, keep the
battery at full charge.
·Hot coolant can spray out when the radiator cap is removed. To remove the radiator cap, let the
cooling system cool, turn to the first notch, wait until the pressure is released, then remove the
radiator cap.
FIRE OR EXPLOSION PREVENTION
·Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion,
when disconnecting the battery cables, disconnect the negative (-) cable first. When connecting
battery cables, connect the negative (-) cable last. When connecting jumper cables to start the
engine, connect the negative (-) cable last and disconnect the negative (-) cable first after the
engine starts.
·Do not short circuit the battery posts with metal items.
·Do not weld, grind, or smoke near a battery.
·Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you
operate this machine in an area with flammable dust or vapors, use good ventilation to remove
the flammable dust or vapors.
·Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running or
near open flames or sparks.
·Use nonflammable cleaning solvent to clean parts.
·Fire can cause injury or death. Always have a fire extinguisher near or on the machine. Make
certain the fire extinguisher is serviced according to the manufacturers instructions.
·If a fire extinguisher has been used, always recharge or replace the fire extinguisher before
operating the machine.
·Remove all trash or debris from the machine each day. Especially check the engine area and
exhaust system.
·Starting fluid (ether) can cause death or serious injury. Do not inhale starting fluid vapors.
Wear face protection when removing or installing a starting fluid container or when using aerosol
spray starting fluid. Use starting fluid according to the instructions in this manual.

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·If the machine has an oil, fuel, or hydraulic leak, always repair the leak and clean the area before
operating.
·Keep the cooling system clean and maintain the correct coolant level.
·Check the electrical system for loose connections or frayed insulation. Repair or replace the loose or
damaged parts.
·Before welding or using a torch on the machine, clean the entire machine to reduce risk of fire
hazard.
WARNING
Do not weld on any structural member unless specifically authorized by
Pettibone Michigan. Any unauthorized welding will void the warranty and
may cause death, severe injury or damage to the equipment.
MAINTENANCE
SAFETY WHILE SERVICING THE MACHINE
The following section gives suggested guidelines for operational maintenance on your machine. It
is not intended for use as a service manual.
Check the Hour Meter regularly to determine when the machine needs periodic maintenance. In severe
conditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often.
Your experience may dictate a more severe servicing program.
Safety while servicing machine is the owners responsibility. Only qualified and authorized
personnel should be permitted to maintain, repair, adjust and inspect the machine.
Read and understand warnings and safety precautions in the SAFETY section and elsewhere in this
manual before doing any service on machine. The following precautions should be used as a reminder
to safe servicing.
WARNING
Improper service or repair can cause death, serious injury and/ or damage to
the equipment. Refer to the service manual for proper maintenance procedures,
including any supplied component manuals.
MAINTENANCE PROCEDURES
·Before servicing the machine, put a DO NOT OPERATE tag on the instrument panel.
·Lower boom to ground, shut down machine to a zero energy state, remove key from ignition and
allow machine to cool before beginning work. continued on following page

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
 Relieve all hydraulic pressure in the hydraulic reservoir before breaking any hydraulic connection or
before opening the reservoir access cover.
 Disconnect battery.
WARNING
If it is necessary to have the engine running while servicing the machine,
have another person assist with the procedure. Do not leave the operators
seat with the engine running. Failure to follow these precautions could result
in death, serious injury or damage to the equipment.
 Do not support the machine, the boom, or any attachments on cinder blocks, hollow tiles, or props
that may crumble under a load. Do not work under a machine that is supported solely by a jack.
 Remove, block or guard against body contact with all other sources of hazardous pressure,
temperature, electricity or machine motion.
 Make sure that boom and attachments are grounded to avoid electrical shock.
 Do not make any modifications to this machine or weld on any structural member unless
specifically authorized by Pettibone Michigan. Any unauthorized modifications made or welding
will void the warranty and may cause death, serious injury or damage to the equipment.
WARNING
Unauthorized modifications to this machine can cause injury or death.
Refer to your authorized dealer or Pettibone Michigan before modifying the
machine.
·Metal chips or debris can cause eye injury. Always wear eye or face protection when using a hammer
on this machine. Use a hammer with a soft face, such as brass, to drive hardened pins.
·Hydraulic fluid or grease injected into skin can cause severe injury or death. Keep hands and body
away from any pressurized leak. If fluid is injected into skin, see a doctor immediately.
·When servicing this machine, always wear safety protection, including but not limited to hard hat,
workshoes and safety glasses.
 Dont leave loose tools and rags on the machine. Make sure that all walking and climbing surfaces
are clean.
 Handle fuel carefully. Do not smoke while filling fuel tank or working near fuel. Refer to the
Lubricants table when replacing oils, fluids or filling fuel tank.

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
SAFETY
The decals pictured in this section were accurate at this publication was printed. Pettibone Michigan
reserves the right to add additional safety decals to the machine as necessary to ensure operator safety. It
is the operators responsibility to follow the instruction decals on the particular machine being operated.
WARNING
Injury or death can result if safety decals are not followed. Immedi-
ately replace any missing or damaged safety decal(s), and keep all
safety decals clean and legible. Contact an authorized dealer or
Pettibone Michigan for new safety decals.
·Be sure to read all safety decals and all instruction decals. Check these decals daily. Keep these decals
clean.
·To clean the decals, use only a cloth, water, and soap. Do not use solvents, gasoline, etc.
·Replace decals if damaged, missing, or unreadable. If a decal is on a part that is replaced, install a
new decal on the replacement part.
DECAL LOCATIONS
Table I., MACHINE DECALS consists of a list of decals located on the 6044 forklift. The table is
divided into five columns:
 ITEM#: gives the number by which the particular decal is identified in Figures 1a. and 1b., Decal
Locations.
 PART#: gives number of that decal the Pettibone Michigan part number for reordering purposes.
 DESCRIPTION: gives a description of the decal.
 SERIAL # / DATE OF CHANGE: references if the decal was added to or changed on a particular
machine.
 QTY. : lists the total number of that particular decal needed for the machine.
Full-size illustrations of these decals, along with expanded descriptions of each decals location, are
shown on pages 23-39 following Table I.
DECALS

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
Left Side View of Machine Decals
11
1418
9
5
10
12
4
15
8
19 123
16, 17 13
67

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Decals Located Behind Seat

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044